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Cos Tan Here Is The Chip T 1 Si Hickness Ratio. N: R R R W

The document discusses chip formation geometry and shear plane angle calculations. It provides equations to calculate the shear plane angle based on the chip thickness ratio and tool rake angle. It then provides multiple examples applying these calculations to determine values like shear plane angle, cutting forces, friction angle, material removal rate, and power requirements for different turning operations using various materials, depths of cut, feeds, and cutting speeds. It also includes examples calculating tool life and determining the optimal cutting speed and tool choice to minimize costs based on tool life equations.

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pmagrawal
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35 views1 page

Cos Tan Here Is The Chip T 1 Si Hickness Ratio. N: R R R W

The document discusses chip formation geometry and shear plane angle calculations. It provides equations to calculate the shear plane angle based on the chip thickness ratio and tool rake angle. It then provides multiple examples applying these calculations to determine values like shear plane angle, cutting forces, friction angle, material removal rate, and power requirements for different turning operations using various materials, depths of cut, feeds, and cutting speeds. It also includes examples calculating tool life and determining the optimal cutting speed and tool choice to minimize costs based on tool life equations.

Uploaded by

pmagrawal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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From the geometry of chip formation for a continuous type chip without built-up

edge, show that the shear plane angle is given by


r cos
tan c
where rc is the chip thickness ratio.
1 rc sin
State the assumptions made.
During orthogonal turning of a ductile alloy bar by a tool of side rake angle 15,
depth of cut 4.0 mm, feed 0.25 mm/rev, it was found that cutting force is 800 N
and feed force is 500 N. If chip thickness ratio is 0.4, evaluate using Merchant
Circle Diagram (Graphical method):
i. Magnitude of the resultant force
ii. the shear plane angle
iii. the frictional force
iv. the friction angle
C-40 steel is turned with a HSS tool of side rake angle of 8 at a cutting speed of
0.6 m/sec. The depth of cut (chip width) is 1.5 mm whereas the uncut chip
thickness is 0.3 mm. One meter long chip weighs 5.7 g. Assume that the width
of the chip remains unchanged and the metal density is 7.9 g/cm3. Calculate
i. Chip thickness ratio and shear angle.
ii. MRR and power requirement.
It is required to reduce 50 mm dia MS bar to 40 mm dia for 150 mm of length by
means of single operation on a lathe. The conditions are as follows.
Operators hourly rate = Rs. 60
Machine hourly rate = Rs. 240
Time to remove, replace and reset the tool = 0.1 10 min
Cost of regrinding the tool = Rs. 20
Initial cost of tool = Rs. 200
No. of possible regrinds of the tool = 10
No. of parts to be turned = 12000
Feed rate f = 0.2 mm/rev
Taylors Tool life equation VT 0.2 = 300
Evaluate the economic spindle speed for the lathe for minimum cost.
The life of two tools, A and B, are governed by the equations VT 0.125 2.5 and
VT 0.25 7 respectively in certain machining operation where V is the cutting
speed in m/sec and T is tool life in seconds.
(i) Find out the speed at which both the tools will have the same life. Also
calculate the corresponding tool life.
(ii) If you have to machine at a cutting speed of 1 m/sec, then which one of
these tools will you choose in order to have less frequent tool changes?

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