Manufacturing Processes Home Work #5 Solutions Yr 102

Review Questions
19.7 (10%) Explain the difference between roughing and finishing operations in
machining.
Answer.
A roughing operation is used to remove large amounts of material rapidly and to
produce a part geometry close to the desired shape, and leave some materials (called
stock) on the workpiece for subsequent finish cut. Rough cut uses large MRR, f =
0.4~1.25 mm/rev, d = 2.5~20 mm.
A finishing operation follows roughing and is used to achieve the final geometry and
surface finish. f around 0.125~0.4 mm/rev, d =0.7 2 mm.

19.8 (10%) What is a machine tool?

Answer. A machine tool can be defined as a power-driven machine that positions and
moves a tool relative to the work to accomplish machining or other metal cutting process.

19.11 Name and briefly describe the four types of chips that occur in metal cutting.
Answer. The four types are (1) discontinuous, in which the chip is formed into separated
segments; (2) continuous, in which the chip does not segment and is formed from a
ductile metal; (3) continuous with built-up edge, which is the same as (2) except that
friction at the tool-chip interface causes adhesion of a small portion of work material to
the tool rake face, and (4) serrated, which are semi-continuous in the sense that they
possess a saw-tooth appearance that is produced by a cyclical chip formation of
alternating high shear strain followed by low shear strain

19.13 (10%) Identify the two forces that can be measured in the orthogonal metal cutting
model.
Answer. The two forces that can be measured in the orthogonal metal cutting model are
(1) cutting force and (2) thrust force (or feed force).

19.17 What is the specific energy in metal machining?

Answer. Specific energy is the amount of energy required to remove a unit volume of the
work material.

Problems
19.2 Solution:
(a) From Problem 21.1, = 15 and = 26.85.
= 45 + /2 - /2; rearranging, = 2(45) + - 2
= 2(45) + - 2() = 90 + 15 2(26.85) = 51.3
Now, with = 0 and remaining the same at 51.3,
Merchant Equation, Eq. (21.16) = 45 + 0/2 51.3/2 = 19.35
1
 (b) Chip thickness at = 0: tc = to/tan = 0.30/tan 19.35 = 0.854 mm

(c) Shear strain = cot 19.35 + tan (19.35 - 0) = 2.848 + 0.351 = 3.199

19.7 (20%) Solution:

(a) r = to/tc, tc = to/r = 0.003/0.55 = 0.054 cm
-1 -1
(b) = tan (0.55 cos 15/(1 - 0.55 sin 15)) = tan (0.6194) = 31.8
(c) = 2(45) + - 2() = 90 + 15 - 2(31.8) = 41.5
(d) = tan 41.5 = 0.88
(e) = cot 31.8 + tan(31.8 - 15) = 1.615 + 0.301 = 1.92

19.14 Solution:
1 1
(a) = tan (0.45 cos 5/(1 0.45 sin 5)) = tan (0.4666) = 25.0
2
(b) As = tow/sin = (0.2)(3.0)/sin 25.0 = 1.42 mm .
Fs = AsS = 1.42(220) = 312 N
(c) = 2(45) + - 2() = 90 + 5 2(25.0) = 45.0
Fc = Fscos ( )/cos ( + )
Fc = 312 cos(45 5)/cos(25.0 + 45.0 5) = 566 N
Ft = Fssin( )/cos( + )
Ft = 312 sin(45 5)/cos(25.0 + 45.0 5) = 474 N

19.21 (25%) Solution:

From Table 19.2, Pu = 0.7 N-m/mm3 for aluminum. For f = 0.05 cm/rev, correction

factor = 0.9 from Figure 19.14.

3 3
RMR = vfd = 270 1000(0.5)(6.2) = 837000 mm /min = 13950 mm /sec

Pc = 0.9(0.7)(13950) = 8788.5W=8.79kW

Pg = 8.79/0.87 = 10.1 kW

19.23 has statement corections

19.23 A turning operation is to be performed on a 15 kW lathe that has an 87% efficiency
rating. The roughing cut is made on alloy steel whose hardness is in the range 325 to 335
2
 HB. The cutting speed is 9380 cm/min, feed is 0.075 cm/rev, and depth of cut is 0.375 cm.
Based on these values, can the job be performed on the 15 kW lathe? Use Table 19.2 to
obtain the appropriate unit power value.
Solution:
From Table 19.2, Pu = 3.6 N-m/mm3
A correction factor must be applied. From Figure 19.14, the correction factor
is 0.75~0.8. Therefore, if the corrected Pu = 0.83.6 = 2.88 (N-m/mm3)
3
RMR = vfd = 9380 cm/min(0.075 cm)(0.375 cm) = 263.8125 cm /min
3 3
RMR =263812.5 mm /min = 4396.9 mm /sec
Required cutting power ,
3
Pc = (2.88N-m/mm3)( 4396.9 mm /sec) = 12663 N-m/sec = 12.663 kW
At efficiency E = 87%, the lathe available power = 0.87(15) = 13.05 kW
Since the lathe provides power (13.05kW) that is larger than machining
requirement (12.663 kW). Therefore, this operation can be accomplished on
the 15 kW lathe.

19.27 has statement corections

19.27 (25%) Solve Problem 19.26 except that the feed = 0.018 cm/rev and the work
material is stainless steel (Brinell Hardness = 240 HB).
Solution:
3
(a) From Table 19.2, Pu =2.8 N-m/mm for stainless steel. A correction factor
must be applied from Figure 19.14. For f = 0.018 cm/rev, correction factor
= 1.1~1.15.
Pc = Pu x RMR
3 3
RMR = (120 1000)(0.18) (1.8) = 38880 mm /min =648 mm /sec

HPc = 1.1(2.8)(648) = 2.05 kW =1995.8W =1.996 kW

(b) HPg = 1.996/0.85 = 2.35 kW