Dey od Yadav. p wt B Tech Vi Semester h prothest oad Cutting Machini ree (Catieg Machining: Mechanism & Misha te Machining {a) Draw Merchant's Circk L rai inne z Ho a= 0 n= 06 and f= 5" sae (Dave he hibae ts pe rieren LUE achaan \ hollow pipe and gonally tamed on a lathe using a HSS too! having rake angle of 3 ict ounce Ship over oe revolution of workpiece is 72m The cutng ape Dri Merchant Cle Digram and calculate the flowing 2h ON epee ngle between N, and R and F, and R It. Length of uncut thickness and chip thickness Te, $hiB: Workpiece and Chip- Tool contact length TV. Shear velocity and Chip velocity V. Sear and Normal Stress on the shear plane Vt. Friction and normal force on the friction plane VIL. Specific energy in shear and ftietion plane A steel block is orthogonally cut using HSS tool in orthogonal cutin Uncut width = 0.5 om, Rake angle = 20°, Uncut Thickness Cutting Speed = 8.2 r/min Wedge angle = 65° Tensile propery ofthe workpiece material i given by: « (W/m?) = 784(e)°! ‘Shear strength variation of the workpiece material is given by". r+ 02.0, Draw Merchant Circle Diagram and find the following L ‘Shear angie and flank angle IL Cutting force and Thrust force TI, Length of work-chip contact and chip- tool contact TV. Shear velocity and Chip velocity V. Shear and Normal Stress on the shear plane VL. Friction and normal force on the frition plane VIL. Specific energy in shear and friction plane 1g condition using the following parameters: = 0.25 mm Coefficient of friction = 0.5, The following data were recorded during orthogonal cuting test by using a cutting tool of 65° wedge angle Rake angle = 20° Depth of cut = 6 mm, Feed =0.25 mnvrev, Cutting speed=0.6m's Uncut length before cutting = 29.4mm Chip length after cutting = 12.9 mm ‘Thrust force = 450 N [If cutting force is three times more than thrust force then calculate the following: 1. Shear plane angle and flank plane angle from cut plane 1. Length of shear plane and friction plane MM. Friction force and shear force IV. Dynamic coefficient of friction on rake face and friction angle V. Shear stress in shear plane and Shear strain VI. Shear Velocity and Chip Velocity Vil. Specific Cutting Energy and Shear Power Following observation were made during orthogonal cutting of steel workpiece with carbide tool having zero rake angle: Cutting speed = 60 m/min Chip reduction coefficient =$ Feed=0.l mnvrev Depthofcut_ = 2mm Cutting Force = 760 N Thrust force = 390 N Workpiece material properties are: p = 7200ke/m’, C-= 502 J/kg °C. k = SOW/mK Find: (i) Heat flux in shear plane and friction plane (ii) Average temperature rise in shear plane and ftiction plane (iii) Average temperature of shear plane and rake face 3000 kg/m’, C= $00 J/kg °C is orthogonally 10% Ifthe chip thickness ‘A steel workpiece having shear strength = 200 Nimm’, k = $0 WimK, p = machined wsing cing speed 60 mini, fed = 0.1 mney depth of eat = 20m and ake ang ratio is 0.25 and coefficient of friction at rake face is 0.67 then find the following: 1 “Heat flux in shear plane and friction planesure rise of friction plane s [7 [os [u [wo fis [mo “| Flank | V=122 (m/min) | 2 [028 Joss [oso |o [0% far [v=t224ovmin | 012 [020 [o2s [oss [oat [os [50 [oss ore [9% (mm) | 6 ] host | | (onimin) | 0.2 | »_ {023 }036 |oss [ass fon fost | io | | 1 sing 0.75 mm wt i Using 0.25 ram uniform flank wea 8 the citron of too flue. Detain the tol lives for both cutting speeds. 1 Determine the values of n and Cin the Taylors tool fe equation - Calculate the tool life for cutting speed of 183 m/min. ye eC von ed Tylor’ el sain ge ley Which are based on a feed of 0.25 mmvrev and a epth of cut =. etermine volume of steel that would be removed with each of the following toc ifa minutes life is used as basis for each case. i eee ae Tool Material 2 iS HSS D125 70 Cemented carbide 0.25 500 ! [Ceramic 06 750) ] 8. A workpiece made of low carbon steel has been machined using two different cutting tools A and B under identca} ‘pachining conditions. The n and C constants in the tool life equation fr two tools are given as: na= 0.32, ne = 0.42, Cx 4 sive C= 90 ans, Find: (a) Cutting speed at which both the tool have same tol life. Also caleulate the coresponding 1 Tife (© Which tool requires less ffequent tool change at cuting speed of 60 m/min. c) Cutting speed below which tool B tll give better tool life. Also find the corresponding ool life (2) Cutting speed above which tool A will ive beter tool life. [Also find the corresponding too! life 9, Inassessing of machinability of three workpiece materials, the following data were obtained during turing with HSS tool (Workpiece Material Toot life (min Cutting speed (amin.) Steel P 40 100 10 175 Steel Q 65 200 20 300 Steel R 40 cy 20 90 Determine the machinability index considering stel Pas standard materil and {0 Von asthe eterion (i) Von a the criterion (i) Vio a the exiteron 10, in assessment of machinabilty of a test material onthe basis of 50 m/min ting speed criterion, the data obtained during machining are given in Table. Material Cuating peed Citing Tool fe (ani) temperature (ain) © Seandard 100, = 3 rial 150 - = 40 600 200 Test material t 20 500 250, Find: . «cutting temperature for the machinablity criterion I, Refatine machinabilty forte test material ee Ree aad for unit oo! Ke fr the standard material TV. Tool life for the unit cutting temperature rise forthe teDr Vinod Yadava, Professor MED, MNNIT Allahabad 3 5 @ @) @ (b) TS2/2019 MECHANICAL ENGINEERING DEPARTMENT B.Tech. VI Semester (Mechanical / Production and Industrial Engineering) MANUFACTURING SCIENCE AND TECHNOLOGY. II (Cutting Machining Processes: Turning, Shaping, Drilling and Milling) © A single point cutting tool with tool signature 6-10-7-7-10-30-0.5 mm (ASA) is used for tuming a MS workpiece At primary approach angle of 60° then find normal rake angle ofthe operation (Il) Calealate the beck rake angle and side rake angle ofa single point cutting tol which i usd for turing a MS workpiece with inclination angle 6° normal rake angle (10°) and approach angle of 75° (lf) Draw tree-view diagram for the ccuting too! having tool specification as: 40 mm x 40 mm, 20-15-3-12-3-15-20-30-0.5 mm (ASA), Rake angle when turi (ASA) of 40 mm Roughness Ra, ing tool is changed with another tool having tool signature 20-20-3-10-3-12-10-15-1.6 mm 40 mm shank cross-section (e) MRR and Production Rate () Feed Power and Cutting Power (e) (©) A casted pipe of length 185 mm, 548 mm OD and 200 mm ID isto be machined to 500 mm OD, 228 mum ID and 170 mm length. The rotational frequency is 6 per second, maximum permissible depth of cut and feed are 12 sam and 0.25 mm, respectively. The specific cuting energy of workpiece material is 2.6 GI/ mm’. Find (I the total ‘machining time for one piece (II) Average MRR (Ill) Average power required, ‘Write the possible process sequences and calculate the total machining time corresponding to each process plan to Produce 900 pieces of the dimensions (in mm) as given in figure below. Use data for MS workpiece and HSS tool as: V= 30-40 m/min, f= up to 0.5 mmvrev and d = up to 3 mm. 305 (All dim, in mm) | t Moos ze | eal wore | ‘A cuboid shape solid block of metal of dimension 100 mm x 60 mm x 30 mm is machined to dimension 100 mm = 60 mm x 17 mm using single point cutting tool of tool signature 10-15-8-6-15-30-0.5mm (ASA) on a shaper machine whose quick return ratio is 2/3. The specific energy of workpiece material is 1.6 /mm? and selected cutting parameters are V= 40 mvmin, f+ 0.2 mm / stroke and d= 2mm. The approach and over travel along with of workpiece is 2 mm each and along length is 5 mm each. Find (I) Normal rake angle and Inclination angle (II) MRR. and Production Rate (III) Cutting power and Feed power (IV) Percentage change in Ra if cutting edge angles are reduced by 50% and feed is reduced by 75%, Draw three view diagram of a twist drill showing all the drill elated angles. Also find normal rake angle and inclination angle of drilling operation performed using a twist rill having chisel edge angle=130°, point angle = 118°, helix angle=30%, lip clearance angle=10°, and chisel edge radius is one-tenth of drill radius at (I) Centre of rill 4 <—— » Se 9 So =e OS A steel solid block i drilled with a twist dill of 20 mm diameter at 300 RPM and 0.3 mvn/ev feed. The Twist a related angles are: helix angle=22°, point angle=118°, chisel angle =130°. The solid block has specific ee cid Jhnm!, The cutting force can be taken as three times of its thrust force. Find (1) maximum rake angle. (ID) Tit juired to drill a hole of 100 mm depth (IIT) Upward axial thrust acting on the drill w) Torque acting on the drill (V) Percent change in cutting power if drill RPM is changed to 400.10. ML. 2. 0) @ © A.22 mm diameter hole is made using a 20 num diameter drill and vertical boring machine. Ite point angle of drill is 120° and plate thickness is 30 mm then find (a) Time required for machining required hole (b) MRR if the hole is (D) Through hole (1) Blind hole having 20 mm depth. The setting approach and over travel length can be taken as 2 rm and 3 mn respectively. Take cutting velocity and feed as 20 m/min and 0.1 mon/rey respectively. Draw three view diagram of a helical milling cutter. A helical milling cutter having tool angle as: helix angle=30°, radial rake angle=15°, clearance angle=8" is used for milling operation. Find (1) Axial rake angle (11) Normal rake angle (II) When normal rake angle=radial rake angle? Ina slab milling operation, a straight slab milling cutter of diameter 80mm and 20mm thickness is used having 15 teeth with each tooth of 10° radial rake angle. The cutter rotates at 200 RPM, table feed =75 mm/min and depth of ‘cut taken is $ mm. The work piece material is steel having specific energy 14 J/mm’. Find (1) Rake angle (2) Cutting Power (3) Motor power if the machine efficiency is 75% (4) Milling time for 100 mm length. ‘The raw stock of size 90 mmx 70 mmx 50 mm is used to make a slot as shown in the figure given below using shaper. Equal depth of material is removed from all the faces using data: Stroke length~200 mm, number of double strokes per minute=24,Cutting to return time=3:2, Maximum depth of cut for roughing 2 mm and for finishing 1 mm, Feed for roughing 2.5 mm/double stroke and for finishing 0.5 mm/double stroke. Find: ([) Time required for 500 parts (II)Time required for making three finished blocks without slot(II)Average MRR for making one piece (IV) Ram eyele of the shaper in terms of RPM. (All Dimensions are in mm) ft. y M a d San ss gPeaa {A peripheral up milling is performed using a slab milling cuter of 64 mm diameter having 16 teeth. The cutting conditions used are: feed = 0.025 mmv/tooth, cutting speed 100 m/min and depth of cut=5 mm, Find (I) table speed and machining time for one travel if the part length is 500 mm({Daverage uncut thickness and contact angle per tooth (III) MRR and Ra (IV) the power required in kW if specific energy of cutting is 8 Gi/m’. = {Alot of 30 mm width, 300 mm length and 10 mm depth is made in a solid block of rectangular cross-section using ‘vertical milling operation. For this purpose a milling cutter having side cutting edge angle 30° and end cutting edge angle 60° with &teth is required. The cutting condition selected are: depth of cut=4mm, feed per tooth-0.1 mm and cating speed=14 m/min, Find (D machining time for making the slot II) MRR and Ra (DA 125 mm diameter and 300 mm long steel bar is turned at 460 RPM using 0.125 mm/rev feed and HSS tool. The tool is required to be changed after every 5 workpiece. But, if the same bar is tumed at 306 RPM and previous feed the tool change is required after 25 workpieces. How many times the tool will fail if 1200 bars are turned at 420 RPMA(IDA hole of diameter 25 mm and depth 100 mm is drilled in steel workpiece with HSS drill. A tool life of 10min was obtained at 300 rpm and 52.5 min at 250 rpm. How many times the tool will fail if 100 holes are made at 275 rpm? AA piece of stainless steel bar of 150 mm length and 50 mm diameter is tumed in single pass. The too! life equation used is VT°%=250, The cost of the cutting tool is Rs.40.The operator rate is Rs.8 per min for cutting machine. Cutting machine overhead rate is 200 % of cutting machine operator rate, The grinding machine operator rete is Rs.20 per ground. Grinding machine overhead rate is 300 % of grinder operator rate, Operator of cutting machine takes 6 min to change the cutting tool. The feed used for generating acceptable surface finish is 0.3 mm/rev Considering 20 sec setting time, find (1) Minimum cost of machining (II) cutting speed for maximum profit rate (TI) the machining cost for maximum production (IV) the profit rate for maximum production. ‘Atri is used to drill 10 holes, each 12 mm diameter, in a plate of surface area 152 mm »200 mm and 20 ‘The average drill cost is Rs.200 per tool life, the labor cost is Rs.450 per hour and the overhead cost is Rs.300 per hour. The time to change the drill is 1 min, the time to move from hole to hole for the 10 holes and the time to load and unload the partis a total of 2 min, The total pre travel and over travel for each hole is 2.5 mm and the feed used is 0.15 mm/rev. Ifthe tool life equation used is V1? '=30 m/min and criteria of optimization is maximum production rate then determine(I) the cutting speed to be used (II) the unit cost per piece for drilling and (III) the production rate in terms of pieces per hour. ‘mm thick,