ME 338

Manufacturing Processes II
HW#1
Instructor: Ramesh Singh
Assigned Date: Sept 6, 2009
Due Date: Sept 11, 2009



1. Assume the tool-workpiece contact to be a parallel spring damper system as shown in Fig. 1.



Fig. 1. Tool-workpiece spring damper system

+ + =
Viscous damping ratio, =

a) For free vibrations (F(t)=0), solve the differential equation and plot solutions for
critically damped(=1) and underdamped(<1)
b) Machine tools encounter unit impulse, unit step and periodic force functions which may
excite vibration in the machine.
Assuming F(t) to be unit impulse function and unit step function, plot their responses for
the spring-damper system for a critically damped condition (=1) and make
observations on the differences.


2. You are grinding a steel, which has a specific grinding energy (u) of 25 W-s/mm
3
. The
grinding wheel rotates at 3000 rpm, has a diameter (D) of 120 mm, thickness (b) of 20 mm,
and (c) 5 grains per mm
2
(c). The motor has a power of 2 kW. The work piece moves (v) at
1.5 m/min. The chip thickness ratio (r) is 10.

a) Determine the grinding force and force per grain.
b) Determine the temperature (K
2
is 0.2
o
K-m/N). Room temperature is 20
o
C.

Let the grain be a SiC grain modeled as a continuously varying circular beam as shown in
Fig. 2. Assume the force/grain is acting at the tip and the bonding is perfect. Use cantilever
beam theory to find maximum stress. Will these stresses be sufficient to fail the grain? Look
up all the properties of SiC.






3. Machining Economics
a) Derive the optimal cutting v
b) Find optimal cutting velocity and tool life for maximum profit
rate for the following conditions.
Given:
Taylor tool life equation
Machining (turning) parameters
Depth of cut, d = 1.00 mm
Feed, f = 0.2 mm/rev
Workpiece geometry
Workpiece diameter,
Workpiece length,
Time parameters
Setup time,
Tool replacement time,
Cost parameters
Machine utilization rate,
Machining overhead,
Tool cost,




Fig. 2. SiC grain geometry.
Derive the optimal cutting velocity and tool life for lowest unit cost.
elocity and tool life for maximum profit and maximum production
rate for the following conditions.
Taylor tool life equation VT
0.3
= 400, V (m/min)
Machining (turning) parameters
= 1.00 mm
= 0.2 mm/rev
Workpiece geometry
Workpiece diameter, D = 50 mm
Workpiece length, L = 200 mm

Setup time, t
p
= 0.80 min/pt
Tool replacement time, t
c
= 1.5 min/edge
Machine utilization rate, k
o
= 0.50 $/min
Machining overhead, k
m
= 0.05 $/min
Tool cost, k
t
= 2.50 $/edge

and maximum production