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Lecture 3 Exercise Problems With Solutions

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61 views8 pages

Lecture 3 Exercise Problems With Solutions

Uploaded by

pushkarkamble
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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ME G532: Machine Tool Engineering

Exercise Problems
EX.1
Q1) A 150 mm long 12 mm diameter stainless steel rod is to be
reduced in diameter to 10 mm by turning on a lathe in one pass. The
spindle rotates at 500 rpm, and the tool is traveling at an axial speed
of 200 mm/min. Calculate the cutting speed, material removal rate
and the time required for machining the steel rod.
Solution:

Given data: Lj = 150 mm, D1 = 12 mm, D2 = 10 mm, N = 500 rpm


Using Equation, v = 12500 / 1000 = 18.85 m / min.
Depth of cut = d = (12 – 10) /2 = 1 mm
Feed rate = 200 mm/min, we get the feed f in mm/rev by dividing
feed rate by spindle rpm. That is
f = 200/500 = 0.4 mm/rev
MRR = 3.142120.41500 = 7538.4 mm3/min
Machining time, t = 150/(0.4500) = 0.75 min
EX.2

Q2) A mild steel bar 100 mm long and 38 mm in diameter is turned


to 35 mm dia. And was again turned to a diameter of 32 mm over a
length of 40 mm as shown in the Fig. Calculate the machining time.
Assume cutting speed of 60 m/min and feed 0.4 mm/rev. The depth
of cut is not to exceed 3 mm in any operation.
EX. 3
Q3) Find the time required to drill 4 holes in a cast iron flange each of
2 cm depth, if the hole diameter is 2 cm. Assume cutting speed as
21.9 m/min and feed as 0.02 cm/rev.
Solution:
Approach Distance, 𝐴 = 𝐷 tan(90 − 𝜃Τ2ቇ
2
Commonly used twist drill will have a point angle of 118°
Therefore, 𝐴 = 𝐷 tan(90 − 59) = 0.3 × 𝐷
2
1000 × 𝑣 1000 × 21.9
𝑁= = = 348.7 ≈ 350 rpm
𝜋×𝐷 𝜋 × 20

Machining time, 𝑡 = 𝑑 𝑜𝑟 𝑡 + 𝐴 = 20 + 0.3 × 20 = 0.3714min


𝑓𝑟 0.2 × 350
Time for four holes = 4 × 0.3714 = 1.48min
EX. 4
Q4) A keyway has to be cut in spindle whose dimensions are 40 cm
long 4 cm diameter with a 1 cm width. The cutter diameter is 10 cm.
If the cutter is revolving at 120 rpm, what time will be required to cut
one cm deep keyway at a feed of 0.05 cm/rev of cutter.
Solution:

𝐴= 𝑑(𝐷 − 𝑑)

𝐴= 10(100 − 10) = 30 mm Side View

Machining time, 𝑡 = 𝐿 + 𝐴 = 400 + 30 = 7.17 min


𝑓𝑟 0.5 × 120
EX. 5
Q5) A 175 mm long workpiece is to be machined on a shaper which
has a cutting stroke to idle stroke velocity ratio of 0.84. Calculate the
strokes/min of the shaping tool if the cutting speed is 30 m min.
Assume an approach and overshoot of 5 mm.
EX. 6
Q6) A slab milling operation is performed to finish the top surface of a
steel rectangular workpiece 250 mm long by 75 mm wide. The helical
milling cutter, which has a 60 mm diameter and eight teeth, is set up to
overhang the width of the part on both sides. Cutting conditions are: v = 30
m/min, f = 0.23 mm/tooth, and t = 3 mm. Determine: (a) the time to make
one pass across the surface, and (b) the metal removal rate during the cut.
Thanks

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