TUTORIAL (Individuals) Dateline : 15/12/2011 @ 5.

00 pm

1. In orthogonal operation, the 3 mm wide tool has a rake angle of 6.5 . The lathe is set so the chip thickness before the cut is 0.3 mm and produces a deformed thickness of 0.67 mm. Calculate (a) the shear plane angle and (b) the shear strain for the operation.

2. In a turning operation, spindle speed is set to provide a cutting speed of 1.8 m/s. The tool rake angle is 10 . The feed and depth of cut are 0.30 mm and 2.6 mm, respectively After the cut, the deformed chip thickness is measured to be 0.49 mm. Determine (a) shear plane angle, (b) shear strain, and (c) specific energy. Use the orthogonal cutting model as an approximation of the turning process 3. The cutting force has been measured in an orthogonal cutting operation to be 1334 N with cutting speed 2 m/s. The rake angle = 8 , width of cut = 5 mm, chip thickness before the cut = 0.38 mm, and chip thickness ratio = 0.4. Determine (a) the chip thickness after the cut, (b) shear plane angle, (c) shear strain, (d) cutting power and (e) specific energy required to perform the machining process.

4. An orthogonal cutting operation is performed using a rake angle of 13 , chip thickness before the cut = 0.31 mm and width of cut = 2.5 mm. The chip thickness ratio is measured after the cut to be 0.55. Determine (a) the chip thickness after the cut, (b) shear angle and (b) shear strain.

5. In orthogonal cutting operation, the rake angle = 20 at the following cutting conditions: cutting speed =100 m/min, chip thickness before the cut = 0.38 mm, and width of cut = 3.8 mm. The resulting chip thickness ratio = 0.50. The cutting force has been measured in an orthogonal cutting operation to be 1515 N. Determine (a) the shear plane angle, (c) shear strain, (d) cutting power and (e) specific energy required to perform the machining process. 6. Thirty pieces, each with a surface area = 11.4 mm2 are to be gold plated in a batch plating operation. (a) What average plating thickness will result if 10 amps are applied for 12 min in a cyanide bath? 7. A part made of sheet steel is to be nickel plated. The part is a rectangular flat plate that is 0.09 cm thick and whose face dimensions are 15 cm by 20 cm. The plating operation is carried out in an acid sulfate electrolyte, using a current = 22 amps for a duration = 35 min. Determine the average thickness of the plated metal resulting from this operation.

8. A steel metal part has total surface area = 900 mm2. How long will it take to deposit a copper plating (assume valence +1) of thickness = 0.015 mm onto the surface if 15 amps of current are applied?

9. Increasing current is applied to a workpart surface in an electroplating process according to the relation I= 12.0 + 0.2t, where I = current, amps; and t = time, min. The plating metal is chromium, and the part is submersed in the plating solution for a duration of 30 min. What volume of coating will be applied in the process?

10. A batch of 50 identical parts is to be nickel plated using racks. Total part have the surface area = 1135 cm2. If it is desired to plate an average thickness = 0.015 mm on the surface of each part, how long should the plating operation be allowed to run at a current = 100 amps?