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Solving session 5

The document contains solutions to problems related to orthogonal cutting operations, including calculations for shear plane angle, shear strain, shear strength, and coefficient of friction. It also covers cutting force and feed force calculations for different materials and conditions, along with power requirements for a lathe operation. Key equations and results are provided for each problem discussed.

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nashimounir
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3 views

Solving session 5

The document contains solutions to problems related to orthogonal cutting operations, including calculations for shear plane angle, shear strain, shear strength, and coefficient of friction. It also covers cutting force and feed force calculations for different materials and conditions, along with power requirements for a lathe operation. Key equations and results are provided for each problem discussed.

Uploaded by

nashimounir
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Solving session 5

Chapter 17
Equations used in chapters 17 and 18
Equations used in chapters 17 and 18 contd.
Problem 17.1
• The rake angle in an orthogonal cutting operation = 12. The chip
thickness before the cut = 0.30 mm, and the resulting chip thickness
after the cut = 0.70 mm.
• Calculate (a) the shear plane angle and (b) the shear strain for the
operation.
Problem 17.1 Solution
(a) r = to/tc = 0.30/0.70 = 0.4286
(b)  = tan-1(0. 4286 cos 12/(1 - 0. 4286 sin 12))
= tan-1(0.4602)
= 24.7
Problem 17.2
• The cutting force and thrust force in an orthogonal cutting operation
are 1470 N and 1589 N, respectively.
• Rake angle = 5, width of the cut = 5.0 mm, chip thickness before the
cut = 0.6, and chip thickness ratio = 0.38.
• Determine (a) the shear strength of the work material and (b) the
coefficient of friction in the operation.
Problem 17.2 Solution
(a)  = tan-1(0.38 cos 5/(1 - 0.38 sin 5)) = tan-1(0.3916) = 21.38
• Fs = 1470 cos 21.38 – 1589 sin 21.38 = 789.3 N
• As = (0.6)(5.0)/sin 21.38 = 3.0/.3646 = 8.23 mm2
• S = 789.3/8.23 = 95.9 N/mm2 = 95.9 MPa

(b)  = 45 + /2 - /2; rearranging,  = 2(45) +  - 2


•  = 2(45) + α - 2() = 90 + 5 – 2(21.38) = 52.24
•  = tan 52.24 = 1.291
Problem 17.3
• Low carbon steel having a tensile strength = 300 MPa and a shear
strength = 220 MPa is turned at a cutting speed = 2.5 m/s.
• Feed = 0.20 mm/rev and depth of cut = 3.0 mm. The rake angle = 5
in the direction of chip flow. The resulting chip ratio = 0.45.
• Using the orthogonal model to approximate turning, determine the
cutting force and feed force.
Problem 17.3 Solution
 = tan-1(0.45 cos 5/(1 - 0.45 sin 5)) = tan-1(0.4666) = 25.0
As = tow/sin  = (0.2)(3.0)/sin 25.0 = 1.42 mm2.
Fs = AsS = 1.42(220) = 312 N
 = 2(45) + α - 2() = 90 + 5 - 2(25.0) = 45.0
Cutting forces
Fc = Fscos (β – α)/cos ( + β – α)
Fc = 312 cos(45 - 5)/cos(25.0 + 45.0 - 5) = 566 N
Ft = Fssin(β – α)/cos( + β – α)
Ft = 312 sin(45 - 5)/cos(25.0 + 45.0 - 5) = 474 N
Problem 17.4
• In a turning operation on stainless steel, cutting speed = 150 m/min,
feed = 0.25 mm/rev, and depth of cut = 7.5 mm. How much power
will the lathe draw in performing this operation if its mechanical
efficiency = 90%. Use Table 17.2 to obtain the appropriate specific
energy value.
Table 17.2
Problem 17.4 Solution
• From Table 17.2, U = 2.8 N-m/mm3 = 2.8 J/mm3
• RMR = vfd = (150 m/min)(103 mm/m)(0.25 mm)(7.5 mm) = 281,250
mm3/min = 4688 mm3/s
• Pc = (4688 mm3/s)(2.8 J/mm3) = 13,125 J/s = 13,125 W = 13.125 kW

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