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2019 Mid Sem MCTD

this is model question paper for machine control and tool design

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15 views2 pages

2019 Mid Sem MCTD

this is model question paper for machine control and tool design

Uploaded by

v49608556
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
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NATIONAL INSTITUTE OF TECHNOLOGY, ROURKELA-8

MID SEMESTER EXAMINATION, 2020


Session: 2019-20 Semester: Spring
B.Tech, Sixth semester
Subject: Metal Cutting & Tool Design Deptt. Code: ME3202
Full Marks: 80
This question paper contains 02 page
Duration of examination: 2 hrs

Answer ANY FOUR questions.


Figures at the right are marks. All parts of a question should be answered in one place.
Q No. Marks
1. (a) Differentiate between shear plane and shear zone theory. Derive Merchant and Ernst’s 14
shear angle relationship based on upper bound theorem. Write down the assumptions made in
the theory.
(b) In an orthogonal turning operation, the tangential cutting force, feed force and radial force 06
are 650N, 125N and 60N respectively. The feed and depth of cut are 0.2mm/rev and 2mm
respectively. The chip-thickness is 0.23mm. The orthogonal rake angle and principal cutting
edge angle are 100 and 600 respectively. Determine dynamic shear strength of work-material.

2 (a) Determine tangential cutting force, feed force and radial force in turning operation. 15
The tool signature of the cutting tool is 00-150-80-80-100-600-1.5mm(ORS). Feed and
depth of cut are 0.3mm/rev. and 3mm respectively. Dynamic shear strength of work
material is 450N/mm2. Average chip-thickness is 0.34mm. Use Lee and Shaffer
theory. Calculate specific power due to cutting, specific power due to friction ,specific
power due to shear, normal and tangential component of stress at the chip/tool
interface.

(b) What do you mean by “restricted orthogonal cutting”? Derive an expression of chip-flow 05
deviation angle in restricted orthogonal cutting. Fs
3 (a) Prove FcVc = FVchip + FsVs where Fc, F, Fs are the tangential cutting force, friction 10
force, shear force and Vc, Vchip and Vs cutting velocity, chip-velocity, velocity of
shear respectively.
(b) During turning operation of AISI-304 with a carbide cutting tool having a tool 10
geometry given by 00-(-50)-60-60-80-750-1mm ORS, the following forces have been
recorded by a two-dimensional dynamometer: i) Tangential cutting force Fc = 1400N
ii) Feed forcer Fx = 850N. Chip reduction co-efficient is 3.
Determine i) the radial component of force Fy, ii) the friction force F and normal force
N iii) the shear force and normal force at the shear plane.
4 (a) Differentiate between orthogonal cutting and oblique cutting. State the advantages of 04
oblique cutting over orthogonal cutting. Give an example of a pure orthogonal cutting
operation.
(b) Sketch a cutting tool for turning operation and indicate its geometry in MRS and ORS 06

Signature of paper setter


system of nomenclature. Write the tool signature in each case.

(c ) Describe Pissipanen’card analogy model for orthogonal machining operation. Derive an (10)
expression of dynamic shear strain in terms of chip reduction co-efficient and orthogonal rake
angle. Show the variation of dynamic shear strain with respect to orthogonal rake angle and
chip reduction co-efficient.

5 (a) Define shut-height of the press. State the role of shut-height of the press in die design. (02)
(b) State the die design rule for blanking and piercing operation. (04)
(c) Design a simple conventional die to make a blank of 20mm diameter. The sheet
thickness is 2mm. The die block thickness is within 14 to 16 times sheet thickness.
The shut height of the press is 215mm. The thickness of bolster plate is 60mm. The
thickness of punch holder and die holder of die holder are 30mm each. Assume all 14
other data suitably. Design and sketch the following components with dimensions
along with simple conventional die: i) die block ii) punch iii) mechanical stripper iv)
die set. Give a sectional assembled front view and top view of die with dimension.

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