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Assignment 1 2

The document contains 4 problems related to machining processes and mechanics. Problem 1 asks the student to calculate the maximum cutting speed that can be used for a turning operation based on given information about the workpiece material, feed rate, depth of cut, lathe power, and efficiency. Problem 2 asks the student to calculate the machining time for roughing and finishing cuts on a lathe given information about the workpiece dimensions, cutting speeds, feeds, depths of cut, and available spindle speeds. Problem 3 asks the student to calculate machining time, material removal rate, and power required for drilling a hole given information about the hole dimensions, cutting speed, feed rate, and approach distance. Problem 4 asks the student to calculate mach

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235 views2 pages

Assignment 1 2

The document contains 4 problems related to machining processes and mechanics. Problem 1 asks the student to calculate the maximum cutting speed that can be used for a turning operation based on given information about the workpiece material, feed rate, depth of cut, lathe power, and efficiency. Problem 2 asks the student to calculate the machining time for roughing and finishing cuts on a lathe given information about the workpiece dimensions, cutting speeds, feeds, depths of cut, and available spindle speeds. Problem 3 asks the student to calculate machining time, material removal rate, and power required for drilling a hole given information about the hole dimensions, cutting speed, feed rate, and approach distance. Problem 4 asks the student to calculate mach

Uploaded by

Jeevan G
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We take content rights seriously. If you suspect this is your content, claim it here.
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ME338 ASSIGNMENT NO.

MACHINING PROCESS

1. In a turning operation on an aluminum alloy workpiece, the feed = 0.5 mm/rev, and depth
of cut = 6.5 mm. The motor horsepower of the lathe is 20 hp and it has a mechanical
efficiency = 92%. The unit horsepower value = 0.225 hp/(in3/min) for this aluminum grade.
What is the maximum cutting speed that can be used on this job? [412 m/min].
2. A component of diameter 40 mm and length 120 mm is to be machined on lathe from a raw
material of 50 mm diameter. For roughing cut, the cutting speed of 30 m/min and feed 0.24
mm/rev, and for finishing cut, the cutting speed of 60 m/min and feed 0.1 mm/rev is to be
used. The maximum depth of cut for roughing is 2 mm. The finishing allowance is 0.75
mm. If the avaialable spindle speeds (rpm) are 70, 110, 176, 280, 440, 700, 1100. Calculate
machining time neglecting approach and overtravels. [Ans: 8.6 min]
3. A hole with 40 mm diameter and 50 mm depth is to be drilled in mild steel component. The
cutting speed can be taken as 65 m/min and the feed rate as 0.25 mm/rev. Calculate the
machining time, the MRR and power required. Assume approach of the drill to be 3 mm.
[Ans 164 cm3/min]
4. A steel flat surface of dimensions 100 mm x 250 mm is to be produced on a horizontal axis
milling machine. An HSS slab mill with a 100 mm diameter and 150 mm width is to be
used. The milling cutter has 8 teeth. If the surface is machined using depth of cut of 2 mm
calculate machining time and MRR. Note that cutting speed required is 20 m/min and feed
is 0.13 mm/tooth. [Ans.: 2.7 min]
ME338 ASSIGNMENT NO. 2

MACHINING MECHANICS

1. In an orthogonal cutting operation, the tool has a rake angle = 15°. The chip thickness
before the cut = 0.30 mm and the cut yields a deformed chip thickness = 0.65 mm. Calculate
(a) the shear plane angle and (b) the shear strain for the operation. [Ans: 26.85°, 2.19]
2. In a turning operation, spindle speed is set to provide a cutting speed of 1.8 m/s. The feed
and depth of cut of cut are 0.30 mm and 2.6 mm, respectively. The tool rake angle is 8°.
After the cut, the deformed chip thickness is measured to be 0.49 mm. Determine (a) shear
plane angle, (b) shear strain, and (c) material removal rate. [Ans: 33.6°, 2, 1400 mm3/s]
3. The orthogonal cutting of steel with 10o with a depth of cut of 2 mm and feed rate of 0.20
mm/rev. The cutting speed is 200 m/min. The chip thickness ratio is 0.31. The horizontal
and vertical components of forces measured using dynamometer are 1200N and 650N.
Calculate friction, shear forces, co-efficient of friction at tool-chip interface. Also estimate
the total power required. Note that total power is distributed in shear and friction domain.
[250N, 1300N, 3, 2.2kW]
4. During turning a steel rod of diameter, 160 mm at speed of 560 rpm, feed 0.32 mm/rev and
depth of cut 4 mm. The tool has following geometry
0o, -10o, 6o, 6o, 15o, 75o, 0 (mm)
The followings were observed: Fc =1600 N, Ft=800 N and chip thickness=1 mm.
Assuming orthogonal cutting, calculate all force components and co-efficient of friction.
Also, estimate cutting power and specific cutting energy (J/mm3), unit power (hp/cm3/min).
[Fs = 1200N, F=700N, 0.43, 8kW, 1.25 J/mm3]

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