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Practice set MT_1

The document outlines various machining scenarios involving different materials such as aluminum, stainless steel, titanium alloys, copper, and cast iron, detailing parameters like cutting force, thrust force, chip thickness, rake angles, and cutting speeds. It includes calculations for shear angles, friction angles, shear stress, chip velocity, and shear strain during orthogonal machining processes. Each scenario provides specific data points for analysis and requires the application of machining principles to derive the necessary mechanical properties.

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B.S.S. Vinayak
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© © All Rights Reserved
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3 views

Practice set MT_1

The document outlines various machining scenarios involving different materials such as aluminum, stainless steel, titanium alloys, copper, and cast iron, detailing parameters like cutting force, thrust force, chip thickness, rake angles, and cutting speeds. It includes calculations for shear angles, friction angles, shear stress, chip velocity, and shear strain during orthogonal machining processes. Each scenario provides specific data points for analysis and requires the application of machining principles to derive the necessary mechanical properties.

Uploaded by

B.S.S. Vinayak
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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1.

In orthogonal turning of aluminium bar of diameter 100 mm with uncoated carbide tool, the
cutting velocity is 90 m/min, the feed is 0.24 mm/rev and the depth of cut is 2mm. The chip
thickness obtained is 0.48. If the orthogonal rake is zero, and the principle cutting edge angle is
90 0. Find the shear angle.

2. Stainless steel is machined on lathe with a triple carbide tool having designation 0°-12°-6°-6°-
8°-75°-1mm ORS shape, a feed of 0.12 mm/rev have been employed. A chip thickness of 0.4 mm
has been obtained.

Find the chip reduction coefficient and shear angle and Designate the single point cutting to
according to ORS.

3. Side cutting edge angle (according to American System) of a single point tool is 30° and this
cutting edge lies in a plane parallel to the base of the tool. The effective rake angle measured in a
plane perpendicular to both the base and the cutting edge is 20°. Find the back rake and side rake
angles and analyse the significance of rake angles.

4. The cutting force and thrust force of 567N and 267N, respectively, were measured with
dynamometers during orthogonal machining of a Titanium alloys. The following data from an
orthogonal machining of haste alloy have been observed.
Rake angle of the tool α = 12º
Initial uncut chip thickness t = 0.127mm
Width of cut b = 6.35mm
Cutting speed V = 5 m/s
Chip thickness after cutting tc = 0.32mm
A. Determine the shear angle, the friction angle and shear stress along shear plane

B. Find the chip velocity and shear strain in chip during orthogonal machining of SS.

5. The following data from an orthogonal machining of Copper with HSS tool have been
observed.

Uncut chip thickness t = 0.127 mm

Width of cut b = 6.35 mm

Cutting speed V = 2 m/s

Rake angle α = 10o

Cutting force FC = 567 N

Thrust force FT = 227 N

Chip thickness tc = 0.228

A. Determine the shear angle, the friction angle and shear stress along shear plane

B. Find the chip velocity and shear strain in chip during orthogonal machining of copper alloys.
6. The following data from an orthogonal for machining of aluminium cylinder blocks and head
have been observed.

Chip thickness ratio tr = 0.383

Width of cut b = 3.00 mm

Cutting speed V = 2m/s

Rake angle α = 15o

Uncut chip thickness t = 0.5 mm

Shear stress of material = 140 N/mm2

Coefficient of friction on the tool face µ = 0.7

A. Determine the cutting force and thrust force in machining of aluminium cylinder blocks and
heads.

B. Estimate the normal and tangential forces on the tool face during orthogonal machining of
cast-iron material.

7. The dynamometer measures the cutting force to be 1800N and the nominal thrust force to be
1540N.

The following data has been used for orthogonal machining of SS:

Chip thickness ratio r = 0.51

Width of cut b = 3.83 mm

Cutting speed V = 0.223 m/s

Rake angle α = 20o

Uncut chip thickness t = 0.3 mm


A. Determine the shear angle, the friction angle and shear stress along shear plane

B. Find the chip velocity and shear strain in chip during orthogonal machining of SS.

8. The following data from an orthogonal for machining of Cast-iron cylinder blocks and head
have been observed.

Chip thickness ratio tr = 0.383

Width of cut b = 3.00 mm

Cutting speed V = 2m/s

Rake angle α = 15o

Uncut chip thickness t = 0.5 mm

Shear stress of material = 140 N/mm2

Coefficient of friction on the tool face µ = 0.7

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