Boothroyd Chapter-2 Problems 1-13, page 104-107:

1. In an orthogonal cutting test on mild steel, the following results were obtained:
Cutting force F
c
= 900 N
Thrust force F
t
= 40 N
!ncut chi" thic#ness a
c
= 0.$ mm
Chi" thic#ness a
0
= 0.% mm
&idth of cut a
w
= $.0 mm
'ength of contact between chi" and tool l
f
= 0. mm
&or#ing normal ra#e
ne
= 0 deg.

a. Calculate the mean angle of friction on the tool face .
b. Calculate the mean shear strength of the wor# material
s
.
c. Calculate the mean frictional stress
f
.
$. In an orthogonal cutting test the following conditions were noted:
&idth of chi" (width of cut) = $. mm
!ndeformed chi" thic#ness = 0.$ mm
Chi" thic#ness = 1.0 mm
&or#ing normal ra#e = * deg
Cutting force = 900 N
Thrust force = 900 N
a. Calculate the shear angle
b. Calculate the mean shear strength of the wor# material.
+. In an e,"erimental turning o"eration where low*carbon steel was being machined using a
carbide tool, the following data were obtained:
Cutting force F
c
= 1 #N
Thrust force F
t
= 0. #N
&or#ing normal ra#e
ne
= $0 deg.
-eed f = 0.141 mm
&or#ing ma.or cutting*edge angle
r
= 4 deg.
/e"th of cut (bac# engagement) a
p
= mm
Cutting s"eed v = $ m0s
Cutting ratio r
c
= 0.$
&or#"iece diameter d
w
= 100 mm
&or#"iece machined length l
w
= +00 mm.

1stimate from the abo2e date:

a. The s"ecific cutting energ3 of the wor# material p
s
.
b. The "ower re4uired for machining P
m
.
c. The undeformed chi" thic#ness a
c
.
d. The width of cut a
w
.
e. The shear angle .
f. The mean angle of friction on the tool face .
g. The time ta#en to com"lete the machining o"eration.
4. 5how that in metal cutting when the wor#ing normal ra#e is 6ero, the ratio of the shear
strength of the wor# material
s
to the s"ecific cutting energ3 p
s
is gi2en b3
$
1
1
s c
s c
r
p r

=
+
. In an orthogonal machining o"eration with a ra#e angle of deg. and an undeformed chi"
thic#ness of 1 mm, the chi" thic#ness is found to be + mm. &hat will the chi" thic#ness
be if the ra#e angle is increased to 1 deg assuming 1rnst and 7erchant8s first theor3
holds, that is, $9 : ; * <
ne
= =0$. >ssume the friction coefficient is not influenced b3
changes in ra#e angle.
?. /eri2e an e,"ression for the s"ecific cutting energ3 p
s
in terms of the shear angle 9 and
the mean shear strength of the wor# material
s
in orthogonal cutting. >ssume that the
shear*angle relationshi" of 1rnst and 7erchant a""lies, that is $9 : ; * <
ne
= =0$
%. >ssuming that the shear angle theor3 of 'ee and 5haffer a""lies, namel3 9 : ; * <
ne
=
=04, show that the s"ecific cutting energ3 p
s
will be gi2en b3
p
s
=
s
(1:cot 9 )
where
s
is the mean shear strength of the wor# material.
@. -or the orthogonal cutting of a "articular wor# material, it is found that the length of
chi"*tool contact is alwa3s e4ual to the chi" thic#ness a
c
and that the mean shear stress at
the chi"*tool interface is e4ual to the mean shear stress on the shear "lane. 5how that,
under these circumstances, the mean co*efficient of friction on the tool face A must be
e4ual to or less than 40+ and that when it is e4ual to unit3, the shear angle 9 is e4ual to
the wor#ing normal ra#e
ne
.
9. In the cutting e,"eriments using a shar" tool with 6ero ra#e, it was found that the chi"*
tool contact length was e4ual to the chi" thic#ness a
0
. It was also found that the shear
stress along the tool face was constant and was a constant "ro"ortion R of the shear
strength of the wor# material on the shear "lane.
a. /eri2e an e,"ression for the cutting force F
c
in terms of a
c
, a
w
,
s
, R and 9 .
b. /ifferentiate the e,"ression to obtain the 2alue of 9 to gi2e minimum F
c
.
10. >ssume that in an orthogonal cutting o"eration, the frictional force -f on the tool face is
gi2en b3 K
s
A
0
where K is a constant,
s
is the a""arent shear strength of the wor#
material, and A
0
is the cross*sectional area of the chi". 5how that the following
relationshi" e,ists between the mean coefficient of friction A on the tool face, the shear
angle 9, and the wor#ing normal ra#e
ne
$
cos ( )
sin( ) cos( ) 1
e
e e
n
n n
K
K

=
+
11. -or the machining of a "articular wor# material, it is found that the shear angle 9 is
alwa3s e4ual to wor#ing normal ra#e
ne
. >ssuming that the shear strength of the wor#
material in the stic#ing friction region on the tool face is the same as the shear strength
s

of the material on the shear "lane and that the length of the stic#ing region is e4ual to the
chi" thic#ness a
0
, deri2e e,"ressions for the cutting force F
c
and the thrust force F
t
in
terms of
s
,
ne
and the cross*sectional area of the uncut chi" A
c
. >lso calculate the 2alue
of
ne
for which F
t
= 0. Neglect the forces in the sliding*region on the tool face.
1$. In machining test it was found that for a "articular material the following relation a""lied:
$9 : ; * <
ne
= =0$. >lso, when the rac# angle <
ne
was $0 deg, the coefficient of friction
was 1.$.
a. &hat would the chi" thic#ness be if in a turning o"eration, the feed was 0. mm and
the ma.or cutting angle was ?0 degB
b. If the cutting force is limited to + #N and the s"ecific cutting energ3 of the material $
CD0m
+
, what ma,imum de"th of cut can be ta#enB
1+. >ssuming the in an orthogonal machining the distribution along the normal stress is
along tool ra#e face is linear, becoming ma,imum at the cutting edge and reducing to
6ero at the end of chi" tool contact length, dri2e an e,"ression for the mean coefficient of
friction A between the tool and the chi" and tool in terms of: the ma,imum normal stress
E
m
, normal stress E
0
at which real and a""arent areas of contact become e4ual, and the
coefficient of friction region A
s
.
Solved Examples rom !hosh a"d #all$% (chapter 4; page no. 195 onwards)
1. /uring orthogonal machining with a cutting tool ha2ing a 10 ra#e angle, the chi"
thic#ness is measured to be 0.4mm, the uncut chi" thic#ness being 0.1mm. /etermine
the shear "lane angle and also the magnitude of the shear strain.
$. /uring an orthogonal machining o"eration on mild steel, the results obtained are t
1
=
0.$mm, t
2
= 0.%mm, w= $.mm, 0 = , F
C
= 90N, F
T
=4%N. (i)/etermine the
coefficient of friction between the tool and the chi". (ii)/etermine the ultimate shear
stress

5
of the wor# material.
+. 7ild steel is being machined at a cutting s"eed of $00 m0min with a tool of ra#e angle
10 . The width of cut and the uncut thic#ness are $mm and 0.$mm, res"ecti2el3. If the
a2erage 2alue of the coefficient of friction between the tool and the chi" is 0. and the
shear stress

5
of the wor# material is 400 N0mm
$
, determine (i) the shear angle and (ii)
the cutting and the thrust com"onents of the machining forces.
4. -ind out the order of magnitude of the cutting com"onent of the machining force during
orthogonal machining of machining of mild steel with an uncut thic#ness of 0.$mm, the
width of cut being $.mm.
&"solved Examples rom !hosh a"d #all$% (chapter 4; page no. 282
onwards)
1. The chi"s from an orthogonal cutting o"eration with an uncut thic#ness of 0.$mm for
2arious ra#e angles are

1 10 0
t
2
0.4 0. 0.?+ 1.1+
Calculate, for each chi", the corres"onding shear angle and shear strain and "lot them
against

.
$. The cutting and the thrust com"onents of the machining force during orthogonal
machining of aluminum with a ra#e angle of 10 are found to be +1$N and 1@N,
res"ecti2el3. (i) 1stimate the coefficient of friction between the tool and the chi" (ii) If
the ra#e angle is reduced to 0 , #ee"ing all the other "arameters the same, and if the
coefficient of friction also remains unchanged, estimate the new 2alues of -
C
and -
T
,
using 7erchant8s first solution.
+. /uring orthogonal machining with a ra#e angle 10 and an uncut thic#ness 0.1$mm, the
2alues of -
C
and -
T
are found to be 1%N and $1%N, res"ecti2el3. The a2erage is also
measure and found to be 0.4+mm. 12aluate the machining constant for the wor# material.
4. &hen the ra#e angle is 6ero during orthogonal cutting, show that
$
(1 )
1
s
c
r r
U r

=
+
. /uring an orthogonal cutting test, the obser2ations made are
t
1
= 0.$ mm t
2
= 1.$ mm w = $. mm F = 0 F
c
= 900 F
r
= @10
Calculate the mean shear strength of the wor# material.
?. 1stimate the cutting com"onent of the machining force during the orthogonal machining
of aluminum allo3 with an uncut thic#ness of 0.1mm, the width of cut being $.mm.
%. > metal is being cut orthogonall3 with a tool with 6ero ra#e angle. 5how that the rate of
heat generation in the shear "lane can be e,"ressed as
(1 )
C
F r
.