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Sheet

Uploaded by

sherifabdelbasset
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© © All Rights Reserved
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‫قسم تكنولوجيا االنتاج‬

‫بسم هللا الر حمن الرحيم‬

SHEET (1)

1. what is the cutting tools classifications?


2. what is the single-point cutting tool? Describe several types of single
point cutting tool?
3. What is a carbide tipped tool and inserted bit tool? Mention the
advantages of inserted bit tools?
4. Draw a clear sketch in space showing the elements of single point
cutting tools, and defined these elements?
5. Define the right-hand and left-hand cutting tools?
6. Define the following angles, and what is purpose for each one:
- back rake angle. - side rake angles
- side relief angle. - end relief angle.
7. Describe a tool with (10 8 5 4 6 20 1/16") signature in (ASA) system
Write down the angles for this tool in ORS system, and draw its
views.
8. The geometry of a cutting tool used for a turning operation is as
follows: (7 10 6 6 8 15 1/8") according to (ASA), calculate the
orthogonal rake angle and inclination angle.
9. In an orthogonal cutting operation, the orthogonal rake angle is 10
deg. calculate the back-rake angle and the side rake angle if the main
cutting-edge angle is 75, 90, and 0 deg.
10. Differentiate between orthogonal and oblique cutting methods.
11. Explain how the chips are formed in metal cutting operations and
classified these types.
12. Explain how the built-up edge is formed on tool face during
machining operations, suitable sketches are required.
13. Define the following terms: -specific cutting pressure.
- cutting coefficient k. -chip thickness ratio.
14. The following values related to a cutting test under orthogonal cutting
conditions: - cutting force Fc=3350 N
- feed force Fr=2185 N - tool geometry (10 0 5 5 15 0 1/32")
- chip thickness ratio r=0.35, determine : - the cutting
forces. - the coefficient of friction - draw the cutting
tool views.

15. A seamless tube 50 mm outer diameter is reduced in length on a lathe


using a single point tool. The cutting speed is 40 m/min, the cutting
feed is 0.2 mm, the length of continuous chip for one revolution of
tube is 88 mm, the cutting force 2500 N, the feed force 900 N and the
rake angle of the tool is 15 deg. Calculate:
- chip thickness ratio. - shear angle. - friction angle.
chip and shear velocities. - shear stress and shear strain if the
cutting width is 2.5 mm.

16. In an orthogonal cutting process, the following data are obtained: chip
thickness 0.45 mm width of cut 2.5 mm, feed 0.25 nm/rev, cutting
force 1150 N, thrust force 300 N, cutting speed 0.667m/sec and
cutting tool rake angle 10 deg. Calculate:
a- chip thickness ratio. b- shear angle. c- friction angle.
d-chip velocity. e-shear velocity. f- shear stress.
g-normal stress h-shear strain.
i-shear energy per unit volum.
j- total energy consumed per unit time in cutting
17. Determine graphically the values of the following:
a- shear angle. b- shear force. C- chip velocity.
d- shear velocity e- normal to shear plane force
if the following data are given:
chip thickness 0.35 mm, width of cut 3 mm, feed rate 0.25 mm/rev.
cutting force 1200 N, thrust force 300 N, rake angle of the tool 8 deg
and cutting speed 40 m/min.

18. During an orthogonal cutting of a tube at 15 m/min, using a 15 deg,


rake angle HSS tool, the following data were recorded: chip thickness
ratio 0.35, coefficient of friction 0.6. The friction force on the tool
chip interface was measured by means of a special set-up is 500 N.
Determine the components of the cutting forces, shear strain and work
done in deformation

19. In an orthogonal cutting test on an aluminum alloy, the following


values have been recorded: cutting tool rake angle 20 deg, length of
chip before and after cutting 150, 35 mm respectively, depth of cut
0.12mm, width of uncut chip 3.75 mm, chip width 4 mm, shear stress
200 N/cm2, coefficient of friction 0.77 and cutting speed 30 m/min.
Calculate: a-cutting force. b- feed force.
c- total energy consumed per unit volum of metal removal.
d-motor power if mechanical and electrical efficiencies are 0.75.
0.98 respectively.

20. Prove that the specific cutting pressure in an ideal orthogonal cutting
is 2𝜏 𝑚 𝑐𝑜𝑡∅ if 2∅ + 𝛽 − 𝛾 = 𝜋/2, where: 𝜏 𝑚 shear stress, ∅shear
angle, 𝛽friction angle, 𝛾 rake angle.
21. A seamless tube 40mm outher diameter and 2mm thickness is reduced
in length on a lathe by using a single point cutting tool. The following
data are available: length of continuous chip for one complete
revolution of the tube is 60 mm, cutting speed 30 m/min, feed rate 0.2
mm/rev. cutting force 2400 N. feed force 800 N and the tool
designation is (0 8 5 5 10 0 1/8) ASA. Calculate:
a- friction angle. b-shear angle
c- the energy consumed in friction / unit volum.
d- the energy consumed in shear / unit volum.
e- the total energy consumed /unit time in cutting
f- the power required to drive the m/c in hp.& in kw., if the mech. &
elec. efficiencies are 0.75 &0.9 respectively.

22. In an orthogonal turning operation for a tube, the following data are
available: tube thickness 2 mm, cutting speed 0.5 m/sec feed 0.2
mm/rev. chip thickness ratio 0.6, cutting force 3200 N, feed force 800
N, outher diameter of the tube 70 mm and total designation is (0 12 6
6 20 0 3/16) ASA system. Calculate the values of the following:
a- chip thickness. b-shear plane angle.
c- friction force & normal force at tool face.
d-coefficient of friction on the tool face.
e-chip velocity & shear velocity in m/min.
f-cutting energy per unit volume of chip removed.
g- friction energy per unit volum of chip removed.
h- average normal and average shear stress.

23. During the machining of steel flange, with 10° rake angle, the
following data were taken: feed rate 0.5 mm/rev cutting speed 40
m/min, width of cut 2 mm, the shear angle 20°, the machining power
consumed 3 kw, the power consumed while ruining idle 0.5 kw.
Calculate: the cutting force, chip thickness ratio, specific cutting
pressure, and chip thickness.

24. An orthogonal cutting test was carried out on a steel tube with
external and internal diameters of 100, 90 mm respectively, using a
cutting tool have 10°, and feed 0.3 mm/rev. the resultant cutting force
was found to be 3600 N making an angle of 40° with the direction of
cut if the chip thickness was 1:5 mm, calculate:
a- angle of friction. b- friction force. c- shear force.
d- shear stress. e-shear strain. f- shear energy.

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