I.
MECHANICS OF METAL CUTTING – WORKED OUT OF PROBLEMS:
1. During turning a mild steel component with a single point orthogonal shaped cutting tool
with a back rake angle of 0°, If feed is 0.18 mm/rev and a chip thickness of 0.36 mm is
obtained determine the following:
(a) Chip Thickness Ratio
(b) Shear Angle
Solution:
1.1.To find Chip Thickness Ratio:
r = chip thickness ratio = t/tc
t = chip thickness before cutting = feed in mm = 0.18 mm
tc = chip thickness after cutting = 0.36 mm
0.18
r= 0 .5
0.36
1.2.To find shear angle:
Ø = shear angle, α = back rake angle = 0°
r cos 0.5 cos 0 0.5
tan tan 0.5
[1 r sin ] [1 0.5 sin 0] 1
Ø = 27°
r = 0.5
2. During turning a mild steel component with an orthogonal tool a feed of 0.75 mm/rev
is used. The rotational frequency of the spindle is 50 rpm. If the chip thickness is 1.5
mm determine the chip thickness ratio. Also find the length of the chip removed in
one minute if the work diameter is 50 mm before the cut is taken. Assume a
continuous chip.
Solution:
2.1.To find Chip Thickness Ratio:
r = chip thickness ratio = t/tc
t = chip thickness before cutting = feed in mm = 0.75 mm
tc = chip thickness after cutting = 1.5 mm
0.75
r= 0. 5
1 .5
L1 = Length before cutting = πDnw = π x 50 x 50 = 7857 mm
2.2.To find length of chip removed per minute:
l l
We know that r = c 0.5 = c
l 7857
lc = 3928.5 mm
r = 0.5
3. In an orthogonal cutting operation;
Cutting Speed = 80 m/min
Cutting force = 20 kg
Feed force = 8 kg
Back Rake Angle = 15°
feed = 0.2 mm/rev
Chip Thickness = 0.4 mm
Determine the following: a) Shear Angle, b) Work done in shear c) Shear Strain
r = chip thickness ratio = t/tc
t = chip thickness before cutting = feed in mm = 0.2 mm
tc = chip thickness after cutting = 0.4 mm
Solution:
3.1.To find chip thickness ratio:
0 .2
r= 0 .5
0 .4
3.2.To find shear angle:
Ø = shear angle, α = back rake angle = 15°
r cos 0.5 cos15 0.49
tan tan 0.56
[1 r sin ] [1 0.5 sin 15] 0.87
Ø = 29°
3.3.To find shear force:
Fs FP cos FQ sin
Where Fs = Shear Force
FP = Cutting Force = 20 kg
FQ = thrust force or feed force = 8 kg
Fs 20 cos 29 8 sin 29 = 17.4 – 3.84 = 13.56 kg.
3.4.To find work done in shear:
VC = 80 m/min
VC cos 80 cos15
We know that shear velocity VS =
cos cos29 15
VS = 77.6/0.97= 80 m /min
Work done in shear = Fs X VS = 13.56 x 80 = 1085 kg-m/min
3.5.To find shear strain:
We know that shear strain, tan cot
tan 29 15 cot 29 = 0.25+1.8 = 2.05.
4. Calculate the power consumed during cutting of a low carbon steel bar 40mm
diameter if cutting force is 150 kg at 200 rpm.
Solution:
4.1 To find power consumed:
FP = Cutting Force = 150 kg
d n 40 200
Cutting Speed = v w w = = 25.14 m/min
1000 1000
F v
Power consumed = P HP = (25.14 x 150)/4500 = 0.84 HP
4500
5. (a) In an orthogonal cutting if the tool has a normal rake angle of 10°, the feed is 1.25
mm and the chip thickness is 2 mm determine the following;
(i) Chip thickness Ratio
(ii) Shear angle
(b) If shear strength is 6000kg/cm2, width of cut is 10mm, cutting speed is 30
m/min, and coefficient of friction is 0.9 determine the following;
(iii) Shearing force
(iv) Frictional Angle
(v) Cutting force
(vi) Horse power required at the cutting tool
Solution:
5.1.To find chip thickness ratio:
1.25
r= 0.625
2 .0
5.2.To find Shear Angle:
r cos 0.625 cos10
tan tan 0.65
[1 r sin ] [1 0.5 sin 10]
330
5.3.To find Shearing force:
S A
FS= S (Note Ss = shear stress and A = cross sectional area of the chip = width
sin
x depth of cut)
6000 (1 0.125) 6000 0.125
= = = 1376 kg
sin 33 0.545
5.4.To find Frictional Angle:
We know that tanβ =µ where β is the frictional angle and µ is the coefficient of
friction.
tan β = 0.9, β= 42°
5.5.To find power required at the tool:
F v
Power required = P HP
4500
F cos 1376 cos42 10
Where FP = S
cos( ) cos(33 42 10)
1169.76
FP = 2785 kg
0.42
2785 30
Power required= 18.6 HP
4500
