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TA202: Problems for Practice

1. In an orthogonal cutting operation, the tool has a rake angle = 15. The chip thickness
before the cut = 0.30 mm and the cut yields a deformed chip thickness = 0.65 mm.
Calculate (a) the shear plane angle and (b) the shear strain for the operation.

2. In Problem 1 above, suppose the rake angle were changed to a = 0. Assuming that
the friction angle remains the same, determine (a) the shear plane angle, (b) the chip
thickness, and (c) the shear strain for the operation.
3. The cutting conditions in a turning operation are: v = 2 m/s, f = 0.25 mm, and d = 3.0
mm. The tool rake angle = 10 which produces a deformed chip thickness tc = 0.54
mm. Determine: (a) shear plane angle, (b) shear strain, and (c) material removal rate.
Use the orthogonal cutting model as an approximation of the turning process.

4. The cutting force and thrust force in an orthogonal cutting operation are: Fc = 1470 N
and Ft = 1589 N. The rake angle = 5, the width of the cut = 5.0 mm, the chip thickness
before the cut = 0.6, and the chip thickness ratio = 0.38. Determine (a) the shear
strength of the work material and (b) the coefficient of friction in the operation.
5. Turning is performed on a work material with shear strength of 250 MPa. The
following conditions are used: v = 3.0 m/s, f = 0.20 mm/rev, d = 3.0 mm, and rake
angle = 7 in the direction of chip flow. The resulting chip ratio = 0.5. Using the
orthogonal model as an approximation of turning, determine: (a) the shear plane angle;
(b) the shear force; (c) cutting force and feed force.
6. During an orthogonal machining of mild steel with a tool of 00 rake angle, the following
data were obtained:
t1 = 0.25 mm; t2 = 0.75 mm; w = 2.5 mm; Fc = 950 N; FT 475 N
i) the coefficient of friction between the tool and the chip, and
ii) the ultimate shear stress of the work material

7. For the machining of a mild steel workpiece with a cutting speed of 200 m/min using a tool
of 100 rake angle, the width of cut and the uncut thickness are 2 mm and 0.2 mm
respectively. If the average value of the coefficient of friction between the tool and the chip
is 0.5 and the shear stress of the work material is 400 N/mm 2, determine, i) the shear plane
ssangle, and ii) the cutting and the thrust components of the machining force.5.7321,

8. Turning tests have resulted in 1-min tool life for a cutting speed v = 4.0 m/s and a 20-
min tool life at a speed v = 2.0 m/s. (a) Find the n and C values in the Taylor tool life
equation. (b) Determine how long the tool would last at a speed v = 1.0 m/s.