Key Answers

1) Define the two ways of manufacturing. (5pt)

a) Technologically,
 Manufacturing is the application of physical and chemical processes to alter the
geometry, properties, and/or appearance of a given starting material to make parts
or products.
 Assembled of multiple parts to make products
 The processes to accomplish Manufacturing involve a combination of machinery,
tools, power, and manual labor, shown in figure 1.1

b) Economically
Manufacturing is the transformation of materials into items of greater value by means of
one or more processing and/or assembly operations. The key point is that Manufacturing
adds value to the material by changing its shape or properties or, by combining it with
other materials that have been similarly altered.
Examples:
 Converting iron ore to steel adds value
 Transforming sand into glass adds value
 Refining petroleum into plastic adds value
2) List and define the control parameters of machining. (4pt)

Depth of cut(d): The amount of diameter to be reduced

Feed (f): Amount of length reduced per revolution

Cutting speed(v): The measure of cutting tool how the quickly rotates.

3) List the main factors of chip forming. (3pt)

• Work piece material
• Tool geometry
• Cutting conditions
4) Define the Principal Angles of Single Point cutting tools with the diagram. (5pt)

Rake, shear and clearance angle of a cutting tool are the most important feature of cutting
tool

a) Rake angle (α):

  Inclination of rake surface from reference plane.
 Rake angle is provided for ease of chip flow and overall machining.
 Increase tool life and Improve surface finish

Rake angle depend up on the work tool it can be divide positive, or negative or even zero
rake as shown in the below Figure

Positive rake – helps reduce cutting force and thus cutting power requirement

Negative rake – to increase edge-strength and life of the tool

Zero rake – to simplify design and manufacture of the form tools

b) Clearance angle

 Inclination of clearance or flank surface from the finished surface.

 It is essentially provided to avoid rubbing of the tool (flank) with the machined
surface which causes loss of energy and damages of both the tool and the job
surface.
  Hence, clearance angle is must be positive (3 ~ 15° depending upon tool-work
materials and type of the machining operations like turning, drilling, boring etc.)
c) Shear angle

 It has been observed that during machining, particularly ductile materials.

 the chip sharply changes its direction of flow (relative to the tool) from the direction
of the cutting velocity to that along the tool rake surface after thickening by shear
deformation or slip or lamellar sliding along a plane.
5) Name and describe the three modes of tool failure in machining. (5pt)

During the operation, a cutting tool may fail due to one or more of the following
reasons:
1. Thermal cracking and softening
 Although the cutting tool is quit hard to withstand high temperature, still
every tool material has a certain limit to which it can withstand the elevated
temperature without losing its hardness. If that limit crossed, the tool
material starts deforming plastically at the tip and at the cutting edge under
the action of cutting pressure.
The main factors responsible for creating such condition of tool failure are
 Cutting speed,
 High feed rate
 Excessive depth of cut
 Smaller nose radius and improper selection of tool material
2. Mechanical chipping
Mechanical chipping of the nose and/or the cutting edge fail due to high cutting
pressure, mechanical impact, excessive wear, too high vibration and chatter, weak
tip and cutting edge, etc.
 3. Gradual wear
When a tool is in use for some time it is found to have lost some weight or mass, implying
that it has lost some material from it, which is due to wear

Types of wears −crater wear

−Flank wear

Crater wear

 Crater wear is created due to pressure of hot chip sliding up the face of the tool
 The metal from the tool is supposed to transferred sliding chip in the form of
diffusion
 Higher feed and lack of cutting fluids increase the rate of crate wear

Flank wear

It occurs due to abrasion between tool flank and work piece and excessive heat generation
The magnitude of these wear is depending on tool material hardness
When a tool is subjected to such type of wear:
 Work piece loses its dimensional accuracy
 Energy consumption/power requirement is increased
 Poor surface finish of work piece
 1) A turning operation has to be performed on an aluminum rod of diameter50 mm and
length 300mm. The Spindle speed of lathe is given to be 500 RPM. The feed and depth of
cut are 0.15mm/rev and 0.3 mm respectively from the below diagram. Find out the cutting
speed in mm/s and the volumetric material removal rate (MRRv). (5pt)

Given N 1 = 500RPM ƒ1 =0.15mm/rev D 1 =50mm

t 1=0.3mm L=300mm
π D1 N 1 π∗500∗50
Solution V c = = 1000 =¿78.54m/min=1308.9mm/sec
1000
MRR v =V c∗t∗ƒ 1 =78540*0.3*0.15=3534.3mm/min or 58.905mm/sec
1) The following data related to an orthogonal cutting process: Chip length obtained = 96mm,
Uncut chip length = 240mm, Rake angle used =200 and Depth of cut (uncut chip thickness) =
0.6mm respectively with Horizontal and vertical components of cutting force =2400N and
240N respectively. Determine the following: (8pt)
a) Shear plane angle
b) Chip thickness
c) Friction angle and
d) Resultant cutting force.
Given
l c =96 mm l u=240 mm α=200 t u=0.6 mm F c =2400 N F t=240 N

Required
a) Shear plane angle φ
tu l 96 r cos γ 0.4 cos 20
rc= : chip thicknessratio= c = =0.4 tan ∅=¿ c ¿= = ϕ=23.50
tc l u 240 1−r c sin γ 1−0.4 sin 20

b) Chip thickness
 l c t u 96 0.6 240∗0.6
r c =: chip thickness ratio= = = = =0.4=t c = =1.5 m
l u t c 240 t c 96

F α +¿ Fc sin α
c) Friction angle μ=tan β= N = F t cos
F c cos α −¿ Ft sin α ¿
¿=

240 cos 20+2400 sin 20 1046.37

= =¿ 25.70
2400 cos 20−240 sin 20 2173.177

d) Resultant cutting force.

R=√ F c + F t √ 24002 +2402 =2412N
2 2