In orthogonal cutting, __________ are independent variables. I. Surface finish of cutting tool;II. Temperature rise in workpiece;III. Depth of cut;IV. Tool holder;V. Cutting force;VI. Stiffness of cutting tool
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In orthogonal cutting, __________ are independent variables.
I. Surface finish of cutting tool;
II. Temperature rise in workpiece;
III. Depth of cut;
IV. Tool holder;
V. Cutting force;
VI. Stiffness of cutting tool
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- Question: Determine the optimum cutting speed for an operation on a Lathe machine using the following information: Tool change time: Tool regrinds time: 3 min Machine running cost Re.0.50 per min Depreciation of tool regrinds Rs. 5.0 The constants in the tool life equation are 60 and 0.2 3 min3) Turning: A turning operation is to be adopted under the following machining conditions: Cutting speed: V = 75 m/min Feed rate: f= 0.25 mm/rev Depth of cut: a = 1.75 mm External workpiece diameter: Do = 50 mm Determine: a. The final workpiece diameter b. The rotational speed of the workpiece c. The tool feed rate expressed in m/min d. The material removal rate mm³/min e. The specific energy of the material assuming that the measured cutting force is F= 750 N. Knowing the specific energy, which of materials from the table below could the workpiece be composed? Approximate Specific-Energy Requirements in Cutting Operations SPECIFIC ENERGY* MATERIAL Aluminum alloys Cast irons Copper alloys High-temperature alloys W-s/mm³ 0.4-1.1 1.6-5.5 1.4-3.3 3.3-8.5 0.4-0.6 4.9-6.8 3.8-9.6 3.0-5.2 2.7-9.3 3.0-4.1 hp-min/in³ 0.15-0.4 0.6-2.0 0.5-1.2 1.2-3.1 0.15-0.2 1.8-2.5 1.1-3.5 1.1-1.9 1.0-3.4 1.1-1.5 Magnesium alloys Nickel alloys Refractory alloys Stainless steels Steels Titanium alloys * At…2) State whether or not the following statements are true for orthogonal cutting, explaining your reasons: a. For the same shear angle, there are two rake angles that give the same cutting ratio. b. For the same depth of cut and rake angle, the type of cutting fluid used has no influence on chip thickness. c. If the cutting speed, shear angle, and rake angle are known, the chip velocity can be calculated. d. The chip becomes thinner as the rake angle increases. e. The function of a chip breaker is to decrease the curvature of the chip.
- Question 4. The following data are available from orthogonal cutting experiments. The depth of cut (feed) to = 0.13 mm, width of cut b = 2.5 mm, rake angle a = - 5°, and cutting speed V = 2 m/s. Chip thickness, t. (mm) = 0.23 Cutting force, F. (N) = 430 Thrust force, F; (N) = 280 Determine the shear angle ð, friction coefficient u , shear stress t, shear strain y on the shear plane, chip velocity Ve, and shear velocity Vs, as well as energies uf ,Ug, and uQUESTION 2 Tool life is the most important factor in the evaluation of machinability. Tool life can be defined as the period of time which the tool cuts effectively and efficiently. A cutting tool should have a long tool life. On the other hand, the cutting speed decreases the tool life due to the abrasive action that occurs between the cutting tool and materials. The increase in cutting speed will decrease the machining time, thus reduce the total machining cost. Justify what actions should be taken to increase the tool life and at the same time shorten the machining time.2. The following data was obtained from an orthogonal cutting test: Rake angle = 20° Cutting speed = 100 m/min Chip length before cutting = 29.4 mm Chip length after cutting = 12.9 mm Vertical cutting force 1050 N Horizontal cutting force = 630 N Using Merchant's analysis, calculate (a) resultant force (c) friction force and friction angle (b) shear plane angle (d) total work done
- Write TRUE is the statement/s is True. If the statement is false, identify the word/s that makes the sentence incorrect and write its corresponding correct answer. 7. In planning, the tool travels along the workpiece during the removal of the material on the workpiece. 8. The factors that can be manipulated in cutting process are cutting speed, feed and depth of cut. 9.In thermally assisted machining, the tool is heated which reduces the required cutting force.The following data was obtained from an orthogonal cutting test. Rake angle = 20° Depth of cut = 6 mm Feed rate = 0.25 mm/rev Cutting speed = 0.6 m/s Chip length before cutting = 29.4 mm Vertical cutting force = 1050 N Horizontal cutting force = 630 N Chip length after cutting = 12.9 mm Using Merchant's analysis, calculate (a) Magnitude of resultant force, (b) shear plane angle, (c) friction force and friction angle, and (d) various energies consumed.Question 3. State whether or not the following statements are true, explaining your reasons: 3.a. For the same shear angle, there are two rake angles that give the same cutting ratio, 3.b. For the same depth of cut and rake angle, the type of cutting fluid used has no influence on chip thickness, 3.c. If the cutting speed, shear angle, and rake angle are known, the chip velocity can be calculated, 3.d. The chip becomes thinner as the rake angle increases, 3.e. The function of a chip breaker is to decrease the curvature of the chip.
- Answer the following questions by circling True or False. 5. Tool layouts can be converted into a cam profile that is used for the control of the tool. .... () 6. Higher the rake angle, less the cutting forces. 7. A very large clearance angle increases the strength of the tool tip. 8. The continuous chip causes poor surface finish and low tool life. 9. Ceramics are the hardest tool materials in the world. 10. The smaller the cutting ratio, the larger the cutting deformation. 11. A shaper can be used for maching flat surfaces in horizontal and angular directions. 12. During the return stroke of the shaper, the cutting tool will simply be sliding... 13. The cutting speed of the hydraulic shaper changes throughout most of the cutting stroke. 14. Arbour-mounted cutters are used in vertical axis machines to generate flat surfaces... 15. Dividing head is an important attachment that is used to divide the periphery of the workpiece into a number of divisions to machine surfaces.. () () ()Determine the optimum cutting speed for an operation on a lathe machine using the following information: Tool change time 3 min Tool regrind time 3 min Machine running cost Re. 0.50 per min Depreciation of tool regrind Re. 0.50 The constants in the tool life equation are 60 and 0.2.QUESTION 2 Tool life can be defined as the actual machining time of successive surface sharpening between raw material and cutting tool. Tool life is commonly presented in the form of a curve in'which the log of the cutting speed is plotted against the log of the tool life measured in minutes. Justify the action that should be taken to remove maximum material per minute with the same tool life and at the same time keep the good surface finish.