King Saud University College of Engineering Industrial
Engineering Dept.
IE-352
Section 1, CRN: 5022
Section 2, CRN: 32997
Second Semester 1432-33 H (Spring-2012) 4(4,1,1)
MANUFACTURING PROCESSES - 2
Sunday, Apr 29, 2012 (08/06/1433H)
Homework 3 Answers
Name:
Ahmed M. El-Sherbeeny, PhD
Student Number:
4
Section:
Su-8:00 / Su10:00
Answer ALL of the following questions [2 Points Each].
1. Let n=0.5 and C=90 in the Taylor equation for tool wear. What is
percent decrease in cutting speed is required to cause a (a) 2-fold
(i.e. 200%) and (b) 10-fold (i.e. 1000%) increase in tool life?
Solution:
Taylor Equation for tool life:
n
V T =C
n=0.5 ;
C=90
V T 0.5 =90 V 1 T 10.5=V 2 T 20.5
a)
T 2 =T 1 +200 T 1=3 T 1
V 1 T 10.5=V 2 (3 T 1)0.5
V 1= 3 V 2
V2
V = =0.577
3
1
V 1 V 2
V
=1 2 =10.577=0.423
V1
V1
decrease in cutting speed =
42.3
Note, less than half speed reduction is required for tool life to
triple
a)
T 3 =T 1 +1000 T 1=11 T 1
El-Sherbeeny, PhD
2012
Apr 29, 2012
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HW 3 Answers
IE 352 (01,02) - Spring
King Saud University College of Engineering Industrial
Engineering Dept.
V 1 T 10.5=V 3 (11 T 1)0.5
V 1= 11 V 3
V3
=0. 302
V =
11
1
V 1 V 3
V
=1 3 =10. 302=0.698
V1
V1
decrease in cutting speed =
69 . 8
2. In an orthogonal cutting operation, spindle speed is set to provide a
cutting speed of 1.8 m/s. The width and depth of cut are 2.6 mm and
0.30 mm, respectively. The tool rake angle is 8. After the cut, the
deformed chip thickness is measured to be 0.49 mm. Determine (a)
shear plane angle, (b) shear strain, and (c) material removal rate.
Given:
m
cutting speed: V =1.8 s
width: w=2.6 mm
thicknesses: t 0=0.30 mm , t c =0.49 mm
rake angle: 8
Required:
a)
b)
c)
R MR=?
Solution:
a) can be obtained from:
tan =
r cos
1r sin
t 0.30 mm
r= o =
=0. 612
t c 0. 49 mm
0.612 cos 8
1
1
tan 10.612 sin 8 =tan 0.663
El-Sherbeeny, PhD
2012
Apr 29, 2012
Page - 2
HW 3 Answers
IE 352 (01,02) - Spring
King Saud University College of Engineering Industrial
Engineering Dept.
33.5
b)
can be obtained from:
cot+tan
cot 33.5 + tan ( 33.5 8 )
1.987
c)
R MR
(material removal rate) is the volume of material removed
(i.e. cut) every second which can be obtained from:
[(
R MR=w t o V =( 2.6 mm )( 0.30 mm ) 1.8
m
mm
(1000
)
s
m
]
mm3
R MR=1404
s
El-Sherbeeny, PhD
2012
Apr 29, 2012
Page - 3
HW 3 Answers
IE 352 (01,02) - Spring
King Saud University College of Engineering Industrial
Engineering Dept.
3. Assume that, in orthogonal cutting, the rake angle is 25 and the
coefficient of friction is 0.2. Use the cutting ratio equation to determine
the percentage increase in chip thickness when the friction is
doubled.
Given:
rake angle: 25
coefficients of friction: 1=0.2 , 2=2 1=0.4
Required:
percentage increase in chip thickness
i.e.
t c t c
2
tc
tc
tc
1=?
Solution:
cutting ratio equation:
cos
t sin
r= o =
tc
Rearranging:
cos
t c =t o
Assuming rake angle (
constant
El-Sherbeeny, PhD
2012
) and depth of cut ( t o ) are kept
Apr 29, 2012
Page - 4
HW 3 Answers
IE 352 (01,02) - Spring
King Saud University College of Engineering Industrial
Engineering Dept.
2
sin2
sin1
sin1
cos
t o
tc
=
tc
2
We lack the values for the shear angles( 1 and
use:
2 ), so we
45 +
2 2
Note how we use this equation since 1 and 2< 0.5
Also, note:
1=tan 1 1=tan 1 0.2=11.31
2=tan 1 2=tan 1 0.4=21.80
25 11.31
1 =45 + 1 =45 +
=51.85
2 2
2
2
25 21.80
2=45 + 2 =45 +
=46.60
2 2
2
2
Substituting in chip thickness formula we generated
tc
tc
cos ( 46.60 25 ) sin51.85
=1.13
cos ( 51.8525 ) sin 46.60
El-Sherbeeny, PhD
2012
Apr 29, 2012
Page - 5
HW 3 Answers
IE 352 (01,02) - Spring
King Saud University College of Engineering Industrial
Engineering Dept.
t
c
increase in chip thickness t 1=1.131=13
c
2
El-Sherbeeny, PhD
2012
Apr 29, 2012
Page - 6
HW 3 Answers
IE 352 (01,02) - Spring
King Saud University College of Engineering Industrial
Engineering Dept.
4. A turning operation is performed on stainless steel with hardness 200
HB (with specific energy of 2.8 J/mm 3), cutting speed = 200 m/min,
feed = 0.25 mm/rev, and depth of cut = 7.5 mm. How much power will
the lathe draw in performing this operation if its mechanical efficiency
is 90%?
Given:
J
total specific energy: ut =2.8
m
cutting speed: V =200 min
mm
mm
feed: f =0.25 rev
depth of cut: t 0=7.5 mm
mechanical efficiency: mech =90
Required:
Total power drawn from source: Power source=?
Solution:
cutting power is related to power from source through:
Powerc =Power sourcemech
or
Power source=
Powerc
mech
also, total specific energy:
ut =
Power c
total cutting power
=
material removal rate
R MR
o Since turning operation is involved
[(
)]
m
m m min
m m3
R MR=f t 0 V =( 0.25 m m) ( 7.5 mm ) 200
1000
=6250
min
m 60 sec
s
)(
)(
o Thus,
Power c =u tR MR = 2.8
J
m m3
J
6250
=17500 =17.5 kW
3
s
s
mm
)(
Substituting into the source power equation:
Power source=
El-Sherbeeny, PhD
2012
Powerc 17.5 kW
=
=19.44 k W
mech
0.9
Apr 29, 2012
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HW 3 Answers
IE 352 (01,02) - Spring
King Saud University College of Engineering Industrial
Engineering Dept.
5. With a carbide tool, the temperature in a cutting operation is
measured as 650C when the speed is 90 m/min and the feed is 0.05
mm/rev. What is the approximate temperature if the speed is
doubled? What speed is required to lower the maximum cutting
temperature to 480C?
Given:
first operation:
o cutting temperature: T 1 =650 C
m
o cutting speed: V 1=90 min
mm
o feed: f =0.05 rev
Required:
a) second operation:
o V 2=2 V 1
o T 2 =?
b) third operation:
o T 3 =480 C
o V 3=?
Solution:
equation for mean temperature in orthogonal cutting (note, it is
mentioned if it is turning on a lathe or not):
T=
0.000665Y f 3 V t 0
c
K
since, Y f , c , K are material dependent, and assuming constant
depth of cut ( t 0 ) and rearranging equation above:
0.000665 Y f
T
=
c
V
3
t0
=C
K
Thus,
T1
T2
=
3 V 1 3 V 2
El-Sherbeeny, PhD
2012
Apr 29, 2012
Page - 8
HW 3 Answers
IE 352 (01,02) - Spring
King Saud University College of Engineering Industrial
Engineering Dept.
El-Sherbeeny, PhD
2012
Apr 29, 2012
Page - 9
HW 3 Answers
IE 352 (01,02) - Spring
King Saud University College of Engineering Industrial
Engineering Dept.
a) second operation:
3 V 2 T = 3 2 V 1 T =3 2T =( 1. 26 ) (650 C )
1
1
V1 1
V 1
T2= 3
T 2 =819 C
b) third operation:
T
480 C
3 V 3= T 3 3 V 1= 650 C 90=3.309
1
V 3=3.3093
m
V 3=36.2 min
Alternative Solution:
assuming this was a turning operation, and using equation for
mean temperature in turning on a lathe
T mean V a f b
or: T mean=C V a f b
assuming constant feed ( f ), and using a=0.2 , b=0.125 (since
given that this is carbide tool)
T mean=C V a f b
T mean1
V
0.2
1
T mean2
V 0.2
2
a) second operation:
0.2
V
2V 1
T mean2 = 20.2 T mean1=
V1
V1
0.2
( )
T mean1= ( 20.2 ) ( T mean1 ) =( 1.1 5 ) ( 650 C )
T 2 =74 7 C
b) third operation:
V 0.2
3 =
T 3 0.2 480 C 0.2
V =
90 =1.816
T 1 1 650 C
El-Sherbeeny, PhD
2012
Apr 29, 2012
Page - 10
HW 3 Answers
IE 352 (01,02) - Spring
King Saud University College of Engineering Industrial
Engineering Dept.
1
V 3=1.816 0.2 =1.8165
m
V 3=19.8 min
Note that the second solution did not produce a significantly large
difference in final temperature, and yet a large difference in cutting
speeds.
El-Sherbeeny, PhD
2012
Apr 29, 2012
Page - 11
HW 3 Answers
IE 352 (01,02) - Spring
