Manufacturing Processes II

Academic year: 2015-16: Assignment 1: Weightage: 3 marks

SOLVE ON A4 SIZE PAPER ONLY
Last date of submission is 16th October 2015.
1. Show that in metal cutting when the working normal rake is zero, the ratio of the shear
strength of the work material s to the specific cutting energy ps is given by

ps

(1 rc ) rc
.
1 rc2

2. Derive an expression for the specific cutting energy ps in terms of the shear angle and
the mean shear strength of the work material s in orthogonal cutting. Assume that the
shear-angle relationship of Ernst and Merchant applies, that is 2 + - ne = /2
3. Assuming that the shear angle theory of Lee and Shaffer applies, namely + ne=/4, show that the specific cutting energy ps will be given by ps = s (1+cot ) where s
is the mean shear strength of the work material
4. For the orthogonal cutting of a particular work material, it is found that the length of
chip-tool contact is always equal to the chip thickness a0 and that the mean shear stress at
the chip-tool interface is equal to the mean shear stress on the shear plane. Show that,
under these circumstances, the mean coefficient of friction on the tool face must be
equal to or less than 4/3 and that when it is equal to unity, the shear angle is equal to the
working normal rake ne.
5. In the cutting experiments using a sharp tool with zero rake, it was found that the chiptool contact length was equal to the chip thickness a0. It was also found that the shear
stress along the tool face was constant and was a constant proportion R of the shear
strength of the work material on the shear plane.
a. Derive an expression for the cutting force Fc in terms of ac, aw, s, R and .
b. Differentiate the expression to obtain the value of to give minimum Fc.
6. Assume that in an orthogonal cutting operation, the frictional force F f on the tool face
is given by KsA0 where K is a constant, s is the apparent shear strength of the work
material, and A0 is the cross-sectional area of the chip. Show that the following
relationship exists between the mean coefficient of friction on the tool face, the shear
angle , and the working normal rake ne

K cos 2 ( n e )

K sin( n e ) cos( n e ) 1

Manufacturing Processes II
Academic year: 2015-16: Assignment 2: Weightage: 2 marks
SOLVE ON A4 SIZE PAPER ONLY
Last date of submission is 16th October 2015.
1) If, when machining at high cutting speeds, the heat conducted into the cutting tool
becomes negligible and the heat conducted into the work piece is 4 percent of the total
heat generated, derive an expression for the final chip temperature in terms of the
specific cutting energy ps , the specific heat capacity of the work material c and Density
of work material .
2 a) Show that when cutting metal orthogonally with a tool of zero rake angle, the rate of
heat generated ps in the shear zone is given by Ps Fc v(1 rc ) Where, Fc is the cutting
force, v is the cutting speed, is the mean coefficient of friction on the tool face and rc is
the cutting ratio.
2 b) For the same condition, calculate the mean shear-zone temperature rise s when the
metal has a specific cutting energy of 2.8 GN/m2, =1.0, rc=0.2 and 10 percent of the
shear-zone heat is conducted into the work piece. Assume for the work material that
7200 kg/m3 and c=500 J/kgK
2 c) What would be the value of s if the cutting speed were doubled and the proportion
of shear-zone heat conduction into the work piece remained the same time?
3) During some machining experiments, it was found that for the range of conditions
studied, the following assumptions could be made:
a. The heat conducted into the cutting tool was negligible.
b. The proportion of the heat generated in the shear zone conducted into the work piece
was 0.2.
c. The maximum temperature rise in the chip due to the frictional heat source m
followed the relation m f R where f is the mean temperature rise of the chip
due to the frictional heat source and R is the thermal number.
d. The heat generated due to friction was equal to 20 percent of the heat generated in the
shear zone.
Derive an expression for the maximum temperature in the chip above the initial work
piece temperature in terms of the specific cutting energy of the work piece ps , the specific
heat c, density of the work piece and the thermal number R .
4) It was found from experiments where the chips produced during shaping were caught
in a calorimeter that the mean chip temperature rise was 500 C. The cutting conditions
were as follows:
Cutting speed = 1 m/s, Undeformed chip thickness = 0.5mm, Width of chip = 5mm,
Working normal rake angle = 45 , Cutting force = 6000N, Thrust force = 0N, Chip
thickness = 1.2mm, Length of work piece = 300mm.
After 100 strokes of the shaper, the insulated work piece was immersed in a calorimeter
and its additional heat content found to be 30 kJ. Neglecting the heat conducted into the
cutting tool calculate the proportion of the shear-zone heat conducted into the work piece