TS-1/ 2024 (Theory of Metal Cutting)
1. A hollow pipe 38 mm outer diameter and 35 mm inner diameter is being orthogonally
turned on a lathe using HSS tool having rake angle of 35° and a feed of 0.15 mm/rev. The
length of the continuous chip over one revolution of the workpiece is 72 mm. The cutting
speed is 12.5 m/min. The measured tangential and thrust forces are 410 N and 170 N
respectively. Calculate:
(a) Friction angle and angle between N and R
(b) Thickness of chip and length of chip-tool contact
(c) Shear velocity and chip velocity
(d) Shear stress and normal stress on the shear plane
(e) Shear stress and normal stress on the rake face
(f) Shear strain and specific shear energy
2. Draw Merchant's circle diagram showing all forces and all the angles for the following
cases:
i. flank angle = 10o, wedge angle = 100o, and F = N
ii. α = 0o, µ = 0.6, β = 85o
iii. α = -45o, µ = 0, β = 130o
iv. α = -30o, µ = 0.15, δ = 6o
3. A steel block is orthogonally cut using HSS tool having rake angle 10o and wedge angle
70o at a depth of cut 3.5 mm and a feed of 0.26 mm/rev. If the shear strength of the work
material is 410 N/mm2 and during cutting shear stress varies linearly with normal stress
governed by equation 𝜏𝑠 = 𝜏𝑠0 + 0.2𝜎𝑠 .
Estimate the following:
(a) cutting and thrust forces (c) shear stress and frictional stresses
(b) frictional and shear forces (d) cutting ratio and chip reduction coefficient
4. The following observations were made during an orthogonal cutting of a steel tube on
lathe:
Width of cut = 0.5 cm, cutting speed = 8.2 m/s, rake angle = 20o, uncut thickness = 0.25
mm, cutting ratio = 0.351, 𝜙 + 𝜆 − 𝛼 = 35o. Find the magnitude of cutting and thrust
forces, if the tensile property of the material is given as 𝜎� = 784(𝜀̅)0.15 N/mm2.
5. In an orthogonal cutting test on an alloy of aluminium, the following values were from
experimental data
Rake angle = 20o; Thrust Force = 340 N; Uncut thickness = 0.125 mm; Width of cut =
3.75 mm; Cutting speed = 0.5 m/sec; Chip thickness = 0.51mm.
If the force in the cutting speed direction is three times that of thrust force, the average
shear stress, shear strain and the friction stress.
6. During orthogonal turning of a MS bar of 60 mm diameter, the observations made are:
𝑅𝑎𝑘𝑒 𝑎𝑛𝑔𝑙𝑒 = 150 , 𝐽𝑜𝑏 𝑟𝑝𝑚 = 450, 𝑑𝑒𝑝𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡 = 2.0 𝑚𝑚, 𝐹𝑒𝑒𝑑 = 0.15 𝑚𝑚/𝑟𝑒𝑣,
𝜇 = 0.8, 𝑆ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = 450 𝑁/𝑚𝑚2
Using Lee & Shafer relationship, estimate the following:
(a) shear velocity and chip velocity (b) cutting and thrust force
(c) specific energy of cutting and shearing (d) friction stress
7. Following observations were made during orthogonal cutting of steel workpiece with
carbide tool having zero rake angle:
𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑 = 60 𝑚/𝑚𝑖𝑛, 𝑐ℎ𝑖𝑝 𝑟𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 5
𝐹𝑒𝑒𝑑 = 0.1 𝑚𝑚/𝑟𝑒𝑣, 𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝐹𝑜𝑟𝑐𝑒 = 760 𝑁
𝐷𝑒𝑝𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡 = 2.0 𝑚𝑚, 𝑇ℎ𝑟𝑢𝑠𝑡 𝑓𝑜𝑟𝑐𝑒 = 390 𝑁
Workpiece material properties are as follows:
𝜌 = 7200 𝑘𝑔/𝑚3 , 𝐶 = 502 𝐽/𝑘𝑔0 𝐶, 𝑘 = 50 𝑊/𝑚𝑘
Find the following:
(a) Heat flux in shear plane and friction plane
(b) Average temperature rise in shear plane and friction plane
(c) Average temperature of shear plane and rake face
8. A steel workpiece having 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ = 200 𝑁/𝑚𝑚2 , 𝑘 = 50 𝑊/𝑚𝐾, 𝜌 =
6000 𝑘𝑔/𝑚3 , 𝐶 = 500 𝐽/𝑘𝑔0 𝐶 is orthogonally machined using 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑 =
60 𝑚/𝑚𝑖𝑛, 𝑓𝑒𝑒𝑑 = 0.1 𝑚𝑚/𝑟𝑒𝑣, 𝑑𝑒𝑝𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡 = 2.0 𝑚𝑚 𝑎𝑛𝑑 𝑟𝑎𝑘𝑒 𝑎𝑛𝑔𝑙𝑒 = 100 . If the
chip thickness ratio is 0.25 and coefficient of friction at rake face is 0.67, then
find the following:
(a) Heat flux in shear plane and rake face
(b) Total temperature rise of the chip
(c) Temperature of the rake face
9. Derive the following:
𝑐𝑜𝑠 2 (𝜑−𝛼)
a. 𝜇 = sin(𝜑−𝛼) cos(𝜑−𝛼)+1 𝑖𝑓 𝐹𝑓 = 𝐾𝑤𝑡2
b. 𝐾(1 + 𝑟 2 ) = 𝑈𝑐 (𝑟 − 𝜇𝑟 2 )
c. 𝐻𝑒𝑎𝑡 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛 𝑠ℎ𝑒𝑎𝑟 𝑝𝑙𝑎𝑛𝑒 = 𝐹𝑐 𝑉(1 − 𝜇𝑟) 𝑖𝑓 𝛼 = 0
d. 𝜇 = 1 𝑖𝑓 𝑙𝑓 = 𝑡2 , 𝜑 = 𝛼 𝑎𝑛𝑑 𝜏𝑠 = 𝜏𝑓
