CUTTING FORCES IN METAL CUTTING OPERATION
1.0 Explain the significance of providing the rake and clearance angle on the metal cutting tool?
2.0 What is the essential criterion for a cutting tool to give maximum production with minimum maintenance and trouble?
3.0 How can you classify the cutting tools in metal cutting operation?
4.0 Explain between the right hand and left hand cutting tools.
5.0 (a) What do you understand by form tools?
(b) For what applications are used?
(c) Describe the common types of form tools.
6.0 (a) What is the most practical measure of machinability?
(b) Which factors affect machinability?
7.0 Explain the effects of cutting parameters versus the cutting forces on the cutting tools.
8.0 In an orthogonal cutting process, the following were observed: Chip length of 80 mm was obtained with an undercut chip length of 200 mm, the rake angle used was 20 degrees and depth of cut 0.5 mm. The horizontal and vertical components of cutting forces were 2000N and 200N respectively. Determine the shear plane angle, chip thickness, friction angle and the resultant cutting force.
9.0 A mild steel bar of 120 mm diameter is turned with HSS tool at a cutting speed of 0.2 m.p.m with feed of 0.2 mm/rev. and the depth of cut is 5 mm. It is found that the machine consumes 0.5 kW when running ideal and 2.5 kW when cutting. Determine the tangential force on the tool, the normal pressure on the chip, and the shear resistance assuming the shear angle to be 20 degrees.
10.0 The main cutting force in axial turning of a shaft can be split up into three components. Describe them and indicate approximate relationship between them.
11.0 During cutting of a metal at 15 m/min with HSS tool having the rake angle of 15 degrees, the chip thickness ratio was 0.35 and the friction force on the tool chip interface measured by means of a special set up was 48kgf with coefficient of friction of 0.6. Estimate the component of the cutting force’s shear angle, shear strain and the work done in deformation.
12.0 (a) Show with a neat sketch the forces acting on a chip in orthogonal machining.
(b) Derive an expression for calculating the coefficient of friction between the tool chip interface.
13.0 A surface 80 mm by 160 mm is rough machined using a face milling cutter of 150 mm diameter having 100 teeth. The cutting force is off-set by 15 mm from the line of symmetry of the surface. Estimate the time to rough machine the surface, if the feed per tooth is 0.25 mm and the cutting speed of 20 m/min is employed.
(a) With 5 mm approach and 5 mm over-run; What is the single pass feed time?
(b) If tool axis is symmetrical with the job, what happens to the machining time?
1.0 Explain the significance of providing the rake and clearance angle on the metal cutting tool?
2.0 What is the essential criterion for a cutting tool to give maximum production with minimum maintenance and trouble?
3.0 How can you classify the cutting tools in metal cutting operation?
4.0 Explain between the right hand and left hand cutting tools.
5.0 (a) What do you understand by form tools?
(b) For what applications are used?
(c) Describe the common types of form tools.
6.0 (a) What is the most practical measure of machinability?
(b) Which factors affect machinability?
7.0 Explain the effects of cutting parameters versus the cutting forces on the cutting tools.
8.0 In an orthogonal cutting process, the following were observed: Chip length of 80 mm was obtained with an undercut chip length of 200 mm, the rake angle used was 20 degrees and depth of cut 0.5 mm. The horizontal and vertical components of cutting forces were 2000N and 200N respectively. Determine the shear plane angle, chip thickness, friction angle and the resultant cutting force.
9.0 A mild steel bar of 120 mm diameter is turned with HSS tool at a cutting speed of 0.2 m.p.m with feed of 0.2 mm/rev. and the depth of cut is 5 mm. It is found that the machine consumes 0.5 kW when running ideal and 2.5 kW when cutting. Determine the tangential force on the tool, the normal pressure on the chip, and the shear resistance assuming the shear angle to be 20 degrees.
10.0 The main cutting force in axial turning of a shaft can be split up into three components. Describe them and indicate approximate relationship between them.
11.0 During cutting of a metal at 15 m/min with HSS tool having the rake angle of 15 degrees, the chip thickness ratio was 0.35 and the friction force on the tool chip interface measured by means of a special set up was 48kgf with coefficient of friction of 0.6. Estimate the component of the cutting force’s shear angle, shear strain and the work done in deformation.
12.0 (a) Show with a neat sketch the forces acting on a chip in orthogonal machining.
(b) Derive an expression for calculating the coefficient of friction between the tool chip interface.
13.0 A surface 80 mm by 160 mm is rough machined using a face milling cutter of 150 mm diameter having 100 teeth. The cutting force is off-set by 15 mm from the line of symmetry of the surface. Estimate the time to rough machine the surface, if the feed per tooth is 0.25 mm and the cutting speed of 20 m/min is employed.
(a) With 5 mm approach and 5 mm over-run; What is the single pass feed time?
(b) If tool axis is symmetrical with the job, what happens to the machining time?
