King Fahd University of Petroleum & Minerals

Mechanical Engineering Department

ME 206: MANUFACTURING PROCESSES 1

Semester (092)

Homework # 5

Assigned on: 19/May/2010

Due date: 26/May/2010

Name: ________________________ ID #: _____________________

Section #: _________

Problems Marks Grades

1 1 10

2 2 10

3 3 10

4 4 10

5 5 10

Total 50
 1. During the orthogonal cutting test performed on mild steel the following data
were obtained
to = 0.25 mm Fc = 900 N = 10°
tc = 0.75 mm Ft= 450 N w = 2.5 mm

Using these data:

a. Calculate the mean frictional angle, 
b. Estimate the shear angle, 
c. Calculate the mean shear stress of the work material,s
d. Calculate the chip/tool friction force F and the normal the shear plan force Fn

Solution

a)
R = (Fc2 + Ft2 )1/2 = (9002 + 4502 )1/2 = 1006.2 N
Fc = R cos ( -  )
900 = 1006.2 cos ( -  );
( -  ) = 26.56°
 = 10° + 26.56° = 36.56°

b) using Merchant  = 45 + /2 - /2 = 45 + 5 - 18.28 = 31.72° = 0.5536 radian

c) Fs = R cos ( +  -  ) = 1006.2 cos (31.72 + 36.56 – 10) = 529.03 N

 s = Fs /As
As = wto/sin = 2.5  0.25 /sin 31.72 = 1.19 mm2
 s = 529.03 N /(1.19  10-6) = 444.56 MPa

d) F = R sin  = 1006..2 sin 36.56 = 599.36 N

Fn = R sin ( +  -  ) = 1006 sin 58.28 = 855.90 N
 2. A turning operation is to be performed on a 20 hp lathe with efficiency of 90%.
The work material is an alloy steel whose hardness is in the range of 360 to 380
HB. The cutting condition is V = 122 m/min, feed = 0.25 mm/rev, and depth of
cut = 3.8 mm. Based o these values, can the job be performed on this lathe? Use
the table below

Table: Values of specific energy for alloy steel

Brinell hardness specific energy
HB W-s/mm3
251-300 2.8
301-350 3.6
351-400 4.4

Solution
Cutting Power = MRR us =
MRR = Vfd = 122  103 mm/(min60s/min)  0.25 mm  3.8 mm = 1931.67 mm3/s
us from the table = 4.4 W-s/mm3
Cutting Power = 1931.67 mm3/s  4.4 W.s/mm3= 8499.35 W = 11.39 hp

The power needed for the lathe = Cutting Power/efficiency = 11.39/0.9 = 12.66 hp

Since the available power (20 hp) is higher than the needed power (12.66 hp), then
the lathe will be able to do the required job.
 3. A drilling operation is to be performed with a 25.4 mm diameter twist drill in a
steel workpiece. The hole is a blind hole at a depth = 50 mm. The cutting
conditions are; speed = 25 m/min, feed = 0.25 mm/rev. Determine
a. The cutting time to complete the drilling operation
b. Metal removal rate
(ignore effect of point angle in calculation)
Solution:
a)
t = L/fN
N = V/D = 25/( (25.5  10-3) = 313.3 rev/min
t = 50 mm / [(0.25 mm/rev)  (313.3 rev/min) = 0.64 min = 38.8 sec
b)
MRR = D2fN/4 = (25.4 mm)20.25 mm/rev 313.3 rev/min = 39687.86 mm3/min
Also MRR = volume / time

4. tool life test on a lathe have resulted in the following data: 1) V = 350 ft/min, T =
7 min; 2) V = 259 ft/min. T = 50 min.:
a. Determine exponent n and constant C of the Taylor tool life equation
b. Based on n and C, what is likely tool material used in this operation
c. Compute the tool life that corresponds to cutting speed V = 300 ft/min
d. Compute the cutting speed corresponding to a tool life T = 10 min.
Solution
a)
350  (7)n = C = 250  (50)n
350/250 = (50/7)n
n = ln (350/250)/ln(50/7) = 0.17
C = 350  (7)0.17 = 487.23 ft/min
b) from table 8.4 the tool used is a high-speed steels tool.
c) ln T = ln (C/V)/n = ln (487.23/300)/0.17 = 2.85
T = 17.29 min
d) V = C/Tn = 387.23/(100.17) = 329.4 ft/min
5. Name the different types of tool wear and the main reasons for the occurrence of
each type.

Solution
a. Flank wear: Due to: a) sliding of tool along the machined surface
causing adhesive and/or abrasive wear. b)Temperature rise

b. Crater wear: Due to: a) temperature rise of tool and b) chemical

affinity between the tool and the workpiece.

c. Chipping: due to a) mechanical shock and b) thermal fatigue