King Saud University College of Engineering Industrial Engineering Dept.

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1 IE-352 Section 1, CRN: Section 2, CRN: First Semester H (Fall-2011) 4(4,1,1) MANUFACTURING PROCESSES - 2 Machining Exercises Name: Student Number: 42 Answer ALL of the following questions [2 Points Each]. 1. Let n = and C = 90 in the Taylor equation for tool wear. What is the percent increase in tool life if the cutting speed is reduced by (a) 50% and (b) 75%? 2. Taking carbide as an example and using the equation for mean temperature in turning on a lathe, determine how much the feed should be reduced in order to keep the mean temperature constant when the cutting speed is doubled. 3. An orthogonal cutting operation is being carried out under the following conditions: t o = 0.1 mm, t c = 0.2 mm, width of cut = 5 mm, V = 2 m/s, rake angle = 10º, F c = 500 N, and F t = 200 N. Calculate the percentage of the total energy that is dissipated in the shear plane. 4. For a turning operation using a ceramic cutting tool, if the speed is increased by 50%, by what factor must the feed rate be modified to obtain a constant tool life? Use n = and y = Using the equation for surface roughness to select an appropriate feed for R = 1 mm and a desired roughness o μm. How would you adjust this feed to allow for nose wear of the tool during extended cuts? Explain your reasoning. El-Sherbeeny, PhD Jan 16, 2012 IE 352 (01,02) - Fall 2011 Machining Exercises Page - 1

2 IE-352 Section 1, CRN: Section 2, CRN: First Semester H (Fall-2011) 4(4,1,1) MANUFACTURING PROCESSES - 2 Machining Exercises Answers Name: Student Number: 42 Answer ALL of the following questions [2 Points Each]. 1. Let n = and C = 90 in the Taylor equation for tool wear. What is the percent increase in tool life if the cutting speed is reduced by (a) 50% and (b) 75%? Taylor Equation for tool life: VT n = C n = ; C = 90 VT = 90 V 1 = V 2 T 2 a) V 2 = 0. 5V 1 V 1 = 0. 5V 1 T 2 = 0. 5T 2 T 2 = 2 T 2 = 2 T 2 = 4 increase in tool life = T 2 = T 2 1 = 3 i.e. increase in tool life is 300% b) V 2 = 0. 25V 1 (since speed decreases by 75%) = 0. 25T 2 T 2 = 4 El-Sherbeeny, PhD Jan 16, 2012 IE 352 (01,02) - Fall 2011 Mach Exer. Answers Page - 1

3 T 2 = 16 increase in tool life = T 2 = 16 1 = 15 i.e. increase in tool life is 1500% (i. e. 15 fold) 2. Taking carbide as an example and using the equation for mean temperature in turning on a lathe, determine how much the feed should be reduced in order to keep the mean temperature constant when the cutting speed is doubled. equation for mean temperature in turning on a lathe, T mean α V a f b Given: T mean = C 1 ; V 2 = 2V 1 ; for carbide: a = 0.2, b = C 1 = C 2 V 0.2 f V = (2V 1 ) 0.2 f f f = 1 f = =2 1.6 =0.330 reduction in feed = f 2 = = i.e. reduction in feed is 67% El-Sherbeeny, PhD Jan 16, 2012 IE 352 (01,02) - Fall 2011 Mach Exer. Answers Page - 2

4 3. An orthogonal cutting operation is being carried out under the following conditions: t o = 0.1 mm, t c = 0.2 mm, width of cut = 5 mm, V = 2 m/s, rake angle = 10º, F c = 500 N, and F t = 200 N. Calculate the percentage of the total energy that is dissipated in the shear plane. Note, for detailed solution, see similar exercise: cutting force exercise 2.PDF Givens: thicknesses: t o = 0.1 mm; t c = 0.2 mm angles: α = 10 velocities: V = 2 m/s forces: F c = 500 N; F t = 200 N; F s =? ; F n =? Required: %ge of total energy dissipated in primary shearing zone Power s = F sv s Power tot F c V i.e. U s U tot (100) = Power s Power tot (100) =? Strategy: we have F c and V, and we need to find F s and V s V s can be obtained if we have shear angle (φ), from, V s = V cos α cos(φ α) o and φ can be obtained from, tan φ = r cos α 1 r sin α o and r can be obtained from, r = t o 0.1 mm = t c 0.2 mm = o now, working back cos 10 φ = tan 1 = 1 sin 10 tan 1 39 = 28.3, and: El-Sherbeeny, PhD Jan 16, 2012 IE 352 (01,02) - Fall 2011 Mach Exer. Answers Page - 3

5 V s = 2 m/s cos 10 = (2 m/s) = 2.075m/s cos( ) Note how shear velocity is higher (4%) than cutting speed F s is now required and can be obtained force circle, by resolving component of F c along F s direction, and F t opposite to F s direction F s = F c cos φ F t sin φ = (500 N) cos 28.3 (200 N) sin 28.3 = 440 N 94.9 N = 345 N Substituting values of V s and F s into Power s Power tot = F sv s F c V Power s (345 N)(2.075 m/s) = = Power tot (500 N)(2 m/s) 1000 = %ge of total energy dissipated in shearing is approximately 72% Note, you can check your answer by calculating %ge of energy dissipated due to friction (which should 28%; see cutting force exercise 1.PDF ), and adding the two values, which should amount to exactly 100%. El-Sherbeeny, PhD Jan 16, 2012 IE 352 (01,02) - Fall 2011 Mach Exer. Answers Page - 4

6 4. For a turning operation using a ceramic cutting tool, if the speed is increased by 50%, by what factor must the feed rate be modified to obtain a constant tool life? Use n = and y = 0.6. Given: V 2 = V 1 + V 1 = 1.5V 1 T 2 = n = ; y = 0.6 Required: f 2 =? Taylor tool life equation for turning operation: VT n d x f y = C 1 V 1 n d 1 x y = V 2 T 2 n d 2 x f 2 y since T 2 =, and assuming constant depth of cut (d) V 1 y = 1.5V 1 f 2 y f f 2 = = = 09 feed must be modified by a factor of 50.9% El-Sherbeeny, PhD Jan 16, 2012 IE 352 (01,02) - Fall 2011 Mach Exer. Answers Page - 5

7 5. Using the equation for surface roughness to select an appropriate feed for R = 1 mm and a desired roughness o μm. How would you adjust this feed to allow for nose wear of the tool during extended cuts? Explain your reasoning. Given: R = 1 mm = m R t = 1 μm = m Required: f =? how to adjust feed to account for nose wear equation for surface roughness, R t = f2 8R f = (8R)R t = ( m)( m) = m 2 = = m/rev = m/rev appropriate feed is mm/rev when nose wear occurs radius (R) will increase to keep the surface roughness (R t ) the same the feed must also increase El-Sherbeeny, PhD Jan 16, 2012 IE 352 (01,02) - Fall 2011 Mach Exer. Answers Page - 6

MECHANICS OF METAL CUTTING

MECHANICS OF METAL CUTTING Radial force (feed force) Tool feed direction Main Cutting force Topics to be covered Tool terminologies and geometry Orthogonal Vs Oblique cutting Turning Forces Velocity diagram