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Tutorial-2: Manufacturing Science and Technology-II (ME - 322)

This document contains 12 problems related to various machining operations including turning, drilling, milling, grinding, and electric discharge machining. The problems involve calculating speeds, feeds, cutting times, material removal rates, and amounts of material removed given various cutting conditions and workpiece parameters. The overall document focuses on analyzing and optimizing different machining processes.

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Deepam Shyam
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68 views2 pages

Tutorial-2: Manufacturing Science and Technology-II (ME - 322)

This document contains 12 problems related to various machining operations including turning, drilling, milling, grinding, and electric discharge machining. The problems involve calculating speeds, feeds, cutting times, material removal rates, and amounts of material removed given various cutting conditions and workpiece parameters. The overall document focuses on analyzing and optimizing different machining processes.

Uploaded by

Deepam Shyam
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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Tutorial-2

Manufacturing Science and Technology-II (ME - 322)

1. In a production turning operation, the foreman has decreed that the single pass must
be completed on the cylindrical workpiece in 5.0 min. The piece is 400 mm long and
150 mm in diameter. Using a feed = 0.30 mm/rev and a depth of cut = 4.0 mm, what
cutting speed must be used to meet this machining time requirement?
2. Drilling operation is to be performed with a 25.4 mm diameter twist drill in a steel
workpart. The hole is a blind-hole at a depth = 50 mm, and the point angle = 118°.
Cutting conditions are: speed = 25 m/min, feed = 0.25 mm/rev. Determine: (a) the
cutting time to complete the drilling operation, and (b) metal removal rate during the
operation, after the drill bit reaches full diameter.
3. A gun drilling operation is used to drill a 7/16-in diameter hole to a certain depth. It
takes 4.5 minutes to perform the drilling operation using high pressure fluid delivery
of coolant to the drill point. The cutting conditions are: N = 3000 rev/min at a feed =
0.002 in/rev. In order to improve the surface finish in the hole, it has been decided to
increase the speed by 20% and decrease the feed by 25%. How long will it take to
perform the operation at the new cutting conditions?
4. A peripheral milling operation is performed on the top surface of a rectangular
workpart which is 300 mm long by 100 mm wide. The milling cutter, which is 75 mm
in diameter and has four teeth, overhangs the width of the part on both sides. Cutting
conditions are: v = 80 m/min, f = 0.2 mm/tooth, and d = 7.0 mm. Determine: (a) the
time to make one pass across the surface, and (b) the material removal rate during the
cut.
5. A face milling operation is used to machine 5 mm from the top surface of a
rectangular piece of aluminum 400 mm long by 100 mm wide. The cutter has four
teeth (cemented carbide inserts) and is 150 mm in diameter. Cutting conditions are: v
= 3 m/s, f = 0.27 mm/tooth, and d = 5.0 mm. Determine: (a) time to make one pass
across the surface, and (b) metal removal rate during cutting.
6. A slab milling operation is performed to finish the top surface of a steel rectangular
workpiece 10.0 mm long by 3.0 mm wide. The helical milling cutter, which has a 2.5
mm diameter and eight teeth, is set up to overhang the width of the part on both sides.
Cutting conditions are: v = 100 m/min, f = 0.009 mm/tooth, and d = 0.250 mm.
Determine: (a) the time to make one pass across the surface, and (b) the metal
removal rate during the cut.
7. Turning tests have resulted in 1-min tool life for a cutting speed v = 4.0 m/s and a 20-
min tool life at a speed v = 2.0 m/s. (a) Find the n and C values in the Taylor tool life
equation. (b) Project how long the tool would last at a speed v = 1.0 m/s.
8. In a surface grinding operation the wheel diameter = 150 mm and the infeed = 0.07
mm. The wheel speed = 1450 m/min, work speed = 0.25 m/s, and the cross-feed = 5
mm. The number of active grits per area of wheel surface C = 0.75 grits/mm2.
Determine: (a) average length per chip, (b) metal removal rate, and (c) number of
chips formed per unit time for the portion of the operation when the wheel is engaged
in the work.
9. An internal cylindrical grinding operation is used to finish an internal bore from an
initial diameter of 250.00 mm to a final diameter of 252.5 mm. The bore is 125 mm
long. A grinding wheel with an initial diameter of 150.00 mm and a width of 20.00
mm is used. After the operation, the diameter of the grinding wheel has been reduced
to 149.75 mm. Determine the grinding ratio in this operation.
10. An aluminum alloy is to be ground in an external cylindrical grinding operation to
obtain a good surface finish. Specify the appropriate grinding wheel parameters and
the grinding conditions for this job.
11. In an ECM process with a pure iron workpiece, a removal rate of 7 cm3/min is
desired. Determine the current required.
12. An electric discharge machining operation is being performed on tungsten. (a)
Determine the amount of metal removed in the operation after one hour at a discharge
amperage = 20 amps. (b) If the work material were tin, determine the amount of
material removed in the same time. Use metric units and express the answer in mm3.

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