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The document discusses several examples of calculating values related to metal cutting operations using orthogonal cutting tools. It provides step-by-step workings to determine chip thickness ratio, shear angle, shear force, work done in shear, shear strain, cutting force, and power required for the tool. Values such as feed rate, chip thickness, rake angle, shear strength, width of cut, cutting speed, and coefficient of friction are used as inputs to calculate the various output parameters.

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haile mehari
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2K views

Solution

The document discusses several examples of calculating values related to metal cutting operations using orthogonal cutting tools. It provides step-by-step workings to determine chip thickness ratio, shear angle, shear force, work done in shear, shear strain, cutting force, and power required for the tool. Values such as feed rate, chip thickness, rake angle, shear strength, width of cut, cutting speed, and coefficient of friction are used as inputs to calculate the various output parameters.

Uploaded by

haile mehari
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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I.

MECHANICS OF METAL CUTTING – WORKED OUT OF PROBLEMS:

1. During turning a mild steel component with a single point orthogonal shaped cutting tool
with a back rake angle of 0°, If feed is 0.18 mm/rev and a chip thickness of 0.36 mm is
obtained determine the following:
(a) Chip Thickness Ratio
(b) Shear Angle

Solution:
1.1.To find Chip Thickness Ratio:
r = chip thickness ratio = t/tc
t = chip thickness before cutting = feed in mm = 0.18 mm
tc = chip thickness after cutting = 0.36 mm
0.18
r=  0 .5
0.36

1.2.To find shear angle:


Ø = shear angle, α = back rake angle = 0°
r cos  0.5  cos 0 0.5
tan    tan     0.5
[1  r sin  ] [1  0.5  sin 0] 1
 Ø = 27°
r = 0.5
2. During turning a mild steel component with an orthogonal tool a feed of 0.75 mm/rev
is used. The rotational frequency of the spindle is 50 rpm. If the chip thickness is 1.5
mm determine the chip thickness ratio. Also find the length of the chip removed in
one minute if the work diameter is 50 mm before the cut is taken. Assume a
continuous chip.
Solution:

2.1.To find Chip Thickness Ratio:


r = chip thickness ratio = t/tc
t = chip thickness before cutting = feed in mm = 0.75 mm
tc = chip thickness after cutting = 1.5 mm
0.75
r=  0. 5
1 .5
L1 = Length before cutting = πDnw = π x 50 x 50 = 7857 mm

2.2.To find length of chip removed per minute:


l l
We know that r = c  0.5 = c
l 7857
 lc = 3928.5 mm
r = 0.5
3. In an orthogonal cutting operation;
Cutting Speed = 80 m/min
Cutting force = 20 kg
Feed force = 8 kg
Back Rake Angle = 15°
feed = 0.2 mm/rev
Chip Thickness = 0.4 mm
Determine the following: a) Shear Angle, b) Work done in shear c) Shear Strain
r = chip thickness ratio = t/tc
t = chip thickness before cutting = feed in mm = 0.2 mm
tc = chip thickness after cutting = 0.4 mm
Solution:

3.1.To find chip thickness ratio:


0 .2
r=  0 .5
0 .4

3.2.To find shear angle:


Ø = shear angle, α = back rake angle = 15°
r cos  0.5  cos15 0.49
tan    tan     0.56
[1  r sin  ] [1  0.5  sin 15] 0.87
 Ø = 29°

3.3.To find shear force:


Fs  FP cos   FQ sin 
Where Fs = Shear Force
FP = Cutting Force = 20 kg
FQ = thrust force or feed force = 8 kg
 Fs  20  cos 29  8  sin 29 = 17.4 – 3.84 = 13.56 kg.

3.4.To find work done in shear:


VC = 80 m/min
VC cos  80 cos15
We know that shear velocity VS  =
cos    cos29  15

 VS = 77.6/0.97= 80 m /min

Work done in shear = Fs X VS = 13.56 x 80 = 1085 kg-m/min

3.5.To find shear strain:


We know that shear strain,   tan      cot 
  tan 29  15  cot 29 = 0.25+1.8 = 2.05.
4. Calculate the power consumed during cutting of a low carbon steel bar 40mm
diameter if cutting force is 150 kg at 200 rpm.
Solution:
4.1 To find power consumed:
FP = Cutting Force = 150 kg
d n   40  200
Cutting Speed = v  w w = = 25.14 m/min
1000 1000
F v
Power consumed = P HP = (25.14 x 150)/4500 = 0.84 HP
4500
5. (a) In an orthogonal cutting if the tool has a normal rake angle of 10°, the feed is 1.25
mm and the chip thickness is 2 mm determine the following;
(i) Chip thickness Ratio
(ii) Shear angle
(b) If shear strength is 6000kg/cm2, width of cut is 10mm, cutting speed is 30
m/min, and coefficient of friction is 0.9 determine the following;
(iii) Shearing force
(iv) Frictional Angle
(v) Cutting force
(vi) Horse power required at the cutting tool
Solution:
5.1.To find chip thickness ratio:
1.25
r=  0.625
2 .0
5.2.To find Shear Angle:

r cos  0.625  cos10


tan    tan    0.65
[1  r sin  ] [1  0.5  sin 10]
   330
5.3.To find Shearing force:
S A
FS= S (Note Ss = shear stress and A = cross sectional area of the chip = width
sin 
x depth of cut)
6000  (1  0.125) 6000  0.125
= = = 1376 kg
sin 33 0.545
5.4.To find Frictional Angle:
We know that tanβ =µ where β is the frictional angle and µ is the coefficient of
friction.
 tan β = 0.9,  β= 42°
5.5.To find power required at the tool:
F v
Power required = P HP
4500
F cos    1376 cos42  10
Where FP = S 
cos(     ) cos(33  42  10)
1169.76
 FP =  2785 kg
0.42
2785  30
Power required=  18.6 HP
4500

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