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Assignment 1

The assignment consists of six problems related to cutting forces, friction in orthogonal cutting, shear strain, tool life relationships, and the impact of varying cutting parameters on tool life. Students are required to prove relationships, evaluate parameters based on given data, and compare tool lives for different materials under specified conditions. The submission date for the assignment is February 10, 2025.

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2 views

Assignment 1

The assignment consists of six problems related to cutting forces, friction in orthogonal cutting, shear strain, tool life relationships, and the impact of varying cutting parameters on tool life. Students are required to prove relationships, evaluate parameters based on given data, and compare tool lives for different materials under specified conditions. The submission date for the assignment is February 10, 2025.

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no name
Copyright
© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
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Assignment

Date of Submission: February 10, 2025

1−𝑟 𝑠𝑖𝑛 𝛼 𝑟 𝑐𝑜𝑠 𝛼


1. 𝑃𝑟𝑜𝑣𝑒 that main cutting force: 𝑃𝑧 = 𝜏𝑠 . 𝑓. 𝑡 [( ) + 𝑡𝑎𝑛 {𝐶 − 𝑡𝑎𝑛 −1 (1−𝑟 𝑠𝑖𝑛 𝛼 )}],
𝑟 𝑐𝑜𝑠 𝛼

𝑤ℎ𝑒𝑛 2𝜑 + λ − 𝛼 = 𝐶.

2. Assume that in an orthogonal cutting operation the friction force ‘F’ on the tool face is given
by KτsA2 (where K is a constant). Show that the following relationship exists between the mean
k cos 2 ( −  )
co-efficient of friction, rake angle γ, and the shear angle β: =
1 + k sin ( −  ) cos( −  )

3. During an orthogonal machining, the following observations were made: Vc = 150 m/min, f
= 0.4 mm/rev, t2 = 0.8 mm, φ = 60o, α = 15o. Evaluate (i) shear strain during metal failure, (ii)
the rate of shear strain, if the thickness of the shear zone is measured as 9 μm.

4. During orthogonal cutting of a MS tube at 15 m/min, using a 15o rake HSS tool, the following
data were recorded: Chip thickness ratio = 0.35, Co-efficient of friction = 0.6. The friction force
on the tool chip interface was measured by means of a special set up as 48 kgf. Determine the
components of the cutting forces, shear angle, shear strain and work done in deformation.

5. The tool life relationship for HSS tool is VT 0.123= C1 and the same for carbide tool is CT 0.21
= C2. Assuming that at a cutting speed of 25 m/min the tool lives are same, compare their tool
lives at 35 m/min.

6. The following equation for tool life is given for a turning operation: VT 0.13f 0.77d 0.37 = C. A
‘60 min’ tool life was obtained while cutting at V = 30 m/min, f = 0.3 mm/rev and d = 2.5 mm.
Determine the change in tool life if the cutting speed, feed and depth of cut are increased by
20% at a time.

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