Scribd
Upload
18 views

ME322-HW3-233

Uploaded by

rubyii1456
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
18 views

ME322-HW3-233

Uploaded by

rubyii1456
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
You are on page 1/ 3

King Fahd University of Petroleum & Minerals

Mechanical Engineering Department

ME 322: MANUFACTURING PROCESSES


Semester (233)

Homework # 3
Assigned on: 26/July/2024

Due date: 2/August/2024


Use this page as a cover page for your HW.

Warning: Copying any problem or part of a problem will


result in zero grade for the whole homework.

Name: _____________________________ ID #: _________________ Section #: _____

# Marks Grades

1 14

2 12

3 12

4 12

5 12

6 12

7 13

8 13

Total 100
Problem 1
The following data are available from orthogonal cutting experiment.
Depth of cut to = 0.13 mm, width of cut w = 2.5 mm, rake angle α = −5̊, cutting speed V = 2 m/s, Chip
thickness, tc, 0.23 mm, cutting force, Fc, 430 N, thrust force, Ft, 280 N. Determine the followings:
(a) The shear angle ,
(b) friction coefficient μ (using F= μ N),
(c) shear stress τ,
(d) shear strain γ on the shear plane,
(e) chip velocity Vc,
(f) shear velocity Vs,
(g) total specific energy, ut

Problem 2
In a turning operation on stainless steel, the cutting speed = 200 m/min, feed = 0.25 mm/rev, and depth of cut
= 7.5 mm. Is it possible to perform this operation on a 35 HP machine if it’s mechanical efficiency = 90%?
(Hint: 1Hp=746 Watts)

Problem 3
Orthogonal cutting is performed on a metal whose mass specific heat = 1.0 J/g-C, density = 2.9 g/cm3, and
thermal diffusivity = 0.8 cm2/s. Cutting speed = 3.5 m/s, uncut chip thickness = 0.25 mm, and width of cut = 2.2
mm. Cutting force = 950 N. Determine the cutting temperature if the ambient temperature = 22C.

Problem 4
Low carbon steel having a tensile strength = 300 MPa and a shear strength = 220 MPa is turned at a cutting
speed = 2.5 m/s, feed = 0.20 mm/rev and depth of cut = 3.0 mm. The rake angle = 5° in the direction of chip
flow. The resulting chip ratio = 0.45. Using the orthogonal model to approximate turning, determine the
cutting force and thrust force.

Problem 5
A face milling operation is performed on a rectangular cast iron workpiece that is 300 mm long by 30 mm
wide by 57 mm thick, using 4-teeth 50-mm diameter high-speed steel milling cutter. The milling operation
reduces the thickness of the piece to 50 mm in one pass. The cutting speed is 0.60 m/s and chip load is 0.22
mm per tooth. Calculate the following:
(a) The rotational speed (rpm) of the cutter
(b)The machining time (min)
(c) The metal removal rate (mm3/min)

Problem 6
A peripheral milling operation is performed on the top surface of a rectangular workpart which is 400 mm
long x 58 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 speed = 70 mm/min, chip load 0.25= mm/tooth, and depth of cut = 5.0 mm.
Determine:
(a) The rotational speed of the cutter (rpm)
(b) The feed rate (mm/min)
(c) Actual machining time to make one pass across the surface (min)
(d) The maximum material removal rate during the cut (mm3/min)
(e) Is this machining operation feasible? If not, how would you improve the machining operation?

Problem 7
In manufacturing a spare part product, several 10-mm-diameter through holes have been drilled through 30-
mm thick cast iron plates using feed rate 0.08 mm/rev and different cutting speeds. At a 25 m/min cutting
speed, the high-speed steel drill tool can be used to drill 30 holes. However, when using 35 m/min cutting
speed, the drill tool can be used for drilling only five holes. The twist drill tool has 118 point angle. Determine
the values of n and C in the Taylor tool life equation for the data.
Problem 8
In a machine shop, there is only one drill press available. Five holes (12 mm diameter) need to be drilled in a
50 mm thick steel plate. Three holes are blind and are 32 mm deep. The remaining two holes are through
holes. At the moment there is only one drill available in the machine shop with a diameter of 12 mm and point
angle of 118o. The drill can achieve a tool life of 1 minute at a cutting speed of 16 m/min (vT0.25 = C).
The used cutting speed is 15 m/min and feed of 0.2 mm/rev, the used drill press has a rated power of 450Watts
with an efficiency of 85%. If the specific energy of steel plate is 2.0 W-s/mm3, then provide detailed analysis
for the following question
(a) Find the feed rate (mm/min)
(b) Find the RMR
(c) Find the power required for the machining operation (W)
(d) Can this operation be performed using the available drill press?
(e) Find the total time taken to drill the five holes (min)
(f) Find the tool life at the cutting speed of the tool
(g) Can this tool drill all 5 holes?

You might also like