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Tutorial Sheet 3

The document contains 9 questions related to machining processes and calculations using Merchant's Circle Diagram (MCD). The questions provide details of machining conditions like tool geometry, cutting forces, and ask to determine values of shear angle, shear force, friction force, and other variables.

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Ajay yadav
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382 views

Tutorial Sheet 3

The document contains 9 questions related to machining processes and calculations using Merchant's Circle Diagram (MCD). The questions provide details of machining conditions like tool geometry, cutting forces, and ask to determine values of shear angle, shear force, friction force, and other variables.

Uploaded by

Ajay yadav
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY JAIPUR

Department of Mechanical Engineering

Course Code: MET225 (Machining Science & Machine Tools)

Tutorial Sheet -2

1. A mild steel rod was subjected to orthogonal turning at high speed , feed
of 0.20 mm/rev and 2.0 mm depth of cut by a carbide tool of geometry : 0 0,
100, 80 , 70 , 150 , 600, 0 (mm). Assuming co-efficient of friction at the chip-
tool interface equal to 0.50, determine the following for the above
machining: (a) Width of cut (b1); (b) thickness of chip before (α1) and after
cut (α2); (c) shear angle (βo).

2. If a mild steel rod is turned at feed of 0.32 mm/rev by tool of geometry :


00, 120, 60 , 60 , 200 , 450, 0 (mm) and chip thickness becomes 0.64 mm,
then determine the expected values of chip reduction coefficient and shear
angle.

3. During pure orthogonal turning of a metal rod by a tool of the following


geometry – inclination angle (λ) =0 , orthogonal rake (ϒo) = 0 and principal
cutting edge angle (φ) = 900 – it was noted that the magnitudes of the
tangential component (Pz) and the axial component (Px) of the cutting force
are 600 N and 200 N , respectively , and the value of chip-reduction
coefficient (ξ) is 1.732. Using MCD (Merchant’s circle diagram),
determine the magnitude of the shear force Ps and friction force F for the
above condition.

4. While turning a metal rod of diameter 100 mm at speed of 625 rpm , feed
of 0.4 mm/rev and 5 mm depth of cut by a carbide tool of geometry 00, -
120, 60 , 60 , 300 , 600, 0 (mm), the following observations were made :
Tangential force (Pz) =1200 N , axial force (Px) = 400 N and chip thickness
(α2) = 1.0 mm. Determine the yield shear strength (τs) of the work material
under the aforesaid condition.

5. In an orthogonal turning by a tool having ϒo = 00 and φ =900 , the


magnitude of the cutting force components Pz and Px were found to be 800
N and 400 N , respectively. Determine the value of the apparent coefficient
of friction (µa) that has occurred at the chip-tool interface under the above
– mentioned condition.

6. During turning of a steel rod of 150 mm diameter , at speed of 560 rpm,


feed of 0.32 mm/rev. and 4.0 mm depth of cut by a tool of geometry 00, -
120, 80 , 70 , 300 , 600, 0 (mm), it was observed that Pz = 1000 N , Py = 200
N and chip thickness α2 = 0.80 mm. Determine without using MCD, for the
above –mentioned condition, the values of F, N, µa , Ps , Pn , τs and cutting
power consumption.

7. A ductile metal rod of 120 mm diameter is turned at a speed of 320 rpm ,


feed of 0.24 mm/rev. and 3.00 mm depth of cut by a tool of the following
geometry 00, 100, 80 , 60 , 200 , 700, 0 (mm). The following observations
were made: Tangential force (P z) = 750 N; transverse force (P y) = 200 N ;
chip thickness (α2) = 0.70 mm. Using MCD , determine the approximate
values of
(a) Friction force (at rake face), F
(b) Normal force (at rake face), N
(c) Shear force, Ps
(d) Cutting power consumption, Pc
(e) Dynamic yield shear strength (τs) of the work.

8. During the orthogonal turning of a rod it was observed that P z = Pxy = Px =


F = N and Pn = 2Ps , Where Pz is the tangential force , Px is the axial force
, Pxy is the resultant force of Px and Py , Py is the radial or transverse force ,
F and N are the frictional force and normal force at the rake face , P s is the
shear force and Pn is the force normal to Ps. Draw the MCD and determine
the possible values of the tool orthogonal rake (ϒo), principal cutting edge
angle (φ) and shear angle (βo) for the above condition.

9. Determine, without using MCD, the values of the shear force Ps and the
force Pn normal to the shear plane under the following observed conditions:
Pz = 1000 N, Px = 400 N, Py = 200 N, ϒo = 150 , ξ = 2.0, Where ξ is the
chip reduction coefficient.

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