REVIEW QUESTIONS:

21.9) An orthogonal cutting operation is a cutting operation where the cutting edge is perpendicular
to the direction of cutting speed.
21.10) Orthogonal cutting is useful in the analysis of metal machining because it simplifies the rather
complex three-dimensional machining situation to two dimensions. In addition, the tooling in the
orthogonal model has only two parameters (rake angle and relief angle), which is a simpler geometry
than a single-point tool.
21.11) 4 types of chips that occur in metal cutting : continuous ( long, continuous chips) ,
discontinuous(chips form into separate segments) , serrated (semi-continuous in the sense that they
possess a saw-tooth appearance) and built-up edge( same as continuous but there there is deformed
metal that adheres to the cutting edge of the tool).
21.12) The four forces that act upon the chip in the orthogonal metal cutting model but cannot be
measured directly in an operation are: friction force, normal force to friction , shear force and normal
force to shear.
PROBLEM
21.1
a)
The chip thickness ratio:
0
0, 3
0, 46
0, 65
c
t
r
t
= = ~
The shear plane angle :
0
cos 0, 46.cos15
cos 0, 506
1 sin 1 0, 46.sin15
26,84
r
r
o
|
o
|
= = =

=

b)
The shear strain is calculated by:
tan( ) cot 2,189 | o | = + =
*Calculating the friction angle:
0
45 51, 32
2 2
o |
| | = + =
21.2
With the friction angle remains the same as in question 21.1 , we can calculate the new shear plane
angle by the equation:
0
0 51, 32
45 45 19, 34
2 2 2 2
o |
| = + = + =
The chip thickness ratio:
0
cos
cos
1 sin
cos cos19, 34
0, 94
cos sin cos cos 0 sin0.cos19, 34
0, 3
0, 32
0, 94
c
r
r
r
t
t mm
r
o
|
o
|
o o |
=

= = =
+ +
= = ~

The shear strain for the operation:
tan( ) cot 3, 2 | o | = + =
21.19
From table 21.2 , we get U= 2,8 Nm/mm
3

The neccesary power to operate the lathe:
3
0
. . . . 2, 8.10 .200.0, 25.7, 5
19, 44
0, 9.60
c MR
g
P U v t w U R
P kW
E E E
= = = = =
21.21
From figure 21.14 ,The correction factors for t
0
=0,02 inch is 0,85
From table 21.2 , we get HPu = 0,25 , multiply it by the correction factor we get HPu=2,8.0,85=0,2125Hp/(in
3
/min)
The necessary horsepower to operate the lathe:
0
. . . . 0, 2125.900.12.0, 02.0, 25
13, 2
0,87
c MR
g
P HPu v t w HPu R
P HP
E E E
= = = = =

21.33
Mean temperature rise at the tool-chip interface:
0,333
0,333 0,333
3
0 0 0 0
3
0
1170
0, 4
0, 4
0, 4 4, 5.10 .0, 25
0, 25.2, 2
. . . 708, 5
2, 9.10 0, 8
728, 5
a
F
vt t w vt U
T C
C K C K
T T T C

| |
| | | |
A = = = =
| | |
\ . \ .
\ .
= A + =