UNIVERSITI MALAYSIA SARAWAK FACULTY OF ENGINEERING MECHANICAL AND MANUFACTURING ENGINEERING DEPARTMENT

KNP 2013-MANUFACTURING TECHNOLOGY ASSIGNMENT 2 - CHAPTER 10

NAME

: ABU BAKAR BIN UMAR SYARIFUDIN

MATRIX NO. : 29067 LECTURER DUE DATE : DR. ABDULLAH YASSIN : 8TH JUNE 2012

Question 1 The maximum temperature in orthogonal cutting is located at about the middle of the tool-chip interface, this can be prove by the action of shearing in the primary shear plane and friction at the tool-chip interface. High temperature will reach on the chip in the primary shear plane, and the temperature would decrease from then on. When there is no frictional heat was involved, we can expect the highest temperature will occur at the shear plane.The rake face of the toll will slides up when the chip is formed. The friction between the chip surface and the tool will cause temperature to increase.

Question 2 Tool life can be almost infinite at low cutting speeds. It depend on the product that we desire, if the manufacturing is mass production, it would be waste of time to having a low cutting speeds since low cutting speed will remove less material in a given time. Lower cutting speeds also often also lead to the formation of a built-up edge and discontinuous chips, thus affecting surface finish. In conclusion, the low cutting speed can be used depend on the situation, not recommended on mass production that need to be done in short time.

Question 4 At low cutting speed, the energy is dissipated in the shear plane and at chip-tool interface, it is conducted through the workpiece and tool and eventually to the environment. At the higher speeds, conduction cannot take place quickly enough to prevent temperatures rising significantly. At the high speed, the heat will be taken away by the chip and this will lead to cool workpieace. Question 5 There is solution to prevent the workpiece or the tool getting hot and may damage the tool and workpiece itself. By using cutting fluid, this overheated workpiece and cutting tool can be prevent. The purpose of the cutting fluid is Reduce friction and water, thus improving tool life and the surface finish of the workpiece. Cool the cutting zone, thus improvising tool life and reducing the temperature and thermal distortion of the workpiece.

Reduce forces and energy consumption Flush away the chips from the cutting zone, thus preventing the chips from the interfering with the cutting process, particularly in operations such as drilling and tapping. Protect the machined surface from environmental corrosion.

Question 6 Temperature definitely can effect on the life of cutting tool. The reason is all material will become weaker and less hard as they become hotter, therefore this will weaken the tool itself. The chemeical reactivity typically increases with increasing temperature, as does diffusion between the workpiece and the cutting tool. The high temperature also can affect the effectiveness of cutting fluids, the fluid cant reduce the friction very well in this lead to higher friction. Finally, in interruoted cutting, there can be excessive thermal shock if the temperatures are high.

Question 7 Cutting uids can have adverse eects on the freshly machined surfaces, as well as various components of the machine tool and the lubricants used on the machines themselves, such as altering their viscosity and lubricating capabilities. If a cutting uid is very eective as a coolant, it could lead to thermal shock in interrupted cutting operations. Cutting uids have to be replaced periodically because they degrade, adversely aecting their performance. This degradation can be due to intense shear in the cutting zone, contamination by other materials, or from bacteria attacking the oil.If the cutting is no longer eective because of this degradation, workpiece quality will be compromised, but then there is the additional environmental concern associated with uid disposal.

Question 8 The not desirable chip is the continuous chips because usually machine will operate at high speeds and this will generate rate is high, and this continuous chips will entangle on spindles and machine components, and this will interfere with the cutting operation. For this reason, discontinuous chips is desirable. To prevent the formation of continuous chips, chips breaker can be use. Somehow, chips breaker also can lead to vibration and chatter. Question 9 Diameter , V = (800(12))/1000 = 30.2 m/min D.O.C , d =( Do Df)/2 = (12.5-12)/2 = 0.25mm Feed, f = 200/800 = 0.25 mm/rev Davg = (12.5+12)/2 = 12.25mm MRR = (12.25)(0.25)(0.25)(800) = 1924 mm3/min

t = l/fN = 150/(0.25*800) = 0.75 min Unit power 5W.s / mm3 Power = 5(1924)/60 = 160 W T = 9600/(800*2*) =1.9N.m Fc=(1.9*1000)/(12.25/2) = 310 N

Question 10 Casting, forging, and powder metallurgy will end with not a precise dimension and surface finish, so to obtain better dimensional and surface finish, machining process is required. Machining process can remove unnecessary part such as those caused by defects or uneven deformation and warpinh upon cooling.

Question 11

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since D>>>>>d (d2 lc2 =

Question 12 N = V/(D) = 0.75/( 0.075m) = 3.18rev/s = 190rpm v = fNn = (0.0002mm)(190rpm)(10) = 0.38m/min iflc< l, t = l/v = 0.25/0.38 = 0.658min = 39.5s MRR = wdv= (0.05)(0.006)(0.38) = 1.14 x 10-4m3 / min

Question 13 V= DN, N = V/ D = 2.3/ (0.15) = 488rpm Feed speed, vf = fNn = 0.2 x 488 x10 = 976 mm/min = `16.3 mm/s Cutting time t=(l+2lc)/vf = (250 + 2(175))/16.3 =24.5s