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HW 1

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hiloje7193
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ME 497 Special Topics in ME: Machining Dynamics and Machine

Tool Vibrations
FALL 2024
Assignment 1
Date: 18.10.2024
Due: 25.04.2021

Problem 1:

A set of orthogonal tests are conducted to identify the shear angle, average friction coefficient, and shear
stress of P20 mold steel that has a hardness of 34Rc. The cutting conditions and measured forces and chip
thicknesses are given below. The cutting tool was an S10 grade plunge turning tool with a zero rake angle.
The width of cut (i.e., the width of disk) was b =4 mm, and the cutting speed was V = 240 m/min.

Table: Orthogonal cutting test conditions and measurements in plunge turning of P20 mold steel
Feed rate Tangential Force Feed Force Measured Chip
c [mm/rev] Ft [N] Ff [N] Thickness hc [mm]
0.02 350 290 0.050
0.03 480 350 0.058
0.04 590 400 0.074
0.05 690 440 0.083
0.06 790 480 0.102
0.07 890 505 0.116
0.08 980 540 0.131

(a) Evaluate the cutting coefficients Ktc and Kfc [N/mm2] and edge force constants Kte and Kfe [N/mm]
by a linear regression of the measured forces.

(b) Evaluate the shear angle ( c ), shear stress (  s ), and average friction coefficient (  a ) for each test to
form an orthogonal cutting database.

(c) Predict the cutting force coefficients (Ktc, Kfc) using empirically expressed c ,  s , and  a and
compare them against the values identified from mechanistic linear regression of the forces.

(d) Using the orthogonal to oblique transformation, express the cutting constants for a helical end mill that
has 30o and 5o of helix and normal rake angles, respectively.

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