Acropolis Technical Campus University Question Paper Solution June-2013 (Me-603, Metal Cutting & CNC M/C)

ACROPOLIS TECHNICAL CAMPUS
UNIVERSITY QUESTION PAPER SOLUTION

JUNE-2013 (ME-603, METAL CUTTING & CNC M/C)
ANS. 1 (a)
MACHINE TOOL DRIVES
To obtain a machined part by a machine tool, coordinated motions must be imparted to its
working members. These motions are either primary (cutting and feed) movements, which
remove the chips from the WP or auxiliary motions that are required to prepare for machining
and ensure the successive machining of several surfaces of one WP or a similar surface of
different WPs. Principal motions may be either rotating or straight reciprocating. In some
machine tools, this motion is a combination of rotating and reciprocating motions. Feed
movement may be continuous (lathes, milling machine, drilling machine) or intermittent
(shapers, planers). As shown in Figure1. Stepped motions are obtained using belting or gearing.
Stepless speeds are achieved by mechanical, hydraulic, and electrical methods.
STEPPED SPEED DRIVES:

Belting: The belting system, shown in Figure 2. is used to produce four running rotational speeds
n1, n2, n3,and n4. It is cheap and absorbs vibrations. It has the limitation of the low-speed
changing, slip, and the need for more space. Based on the driver speed n1, the following speed
can be obtained in a decreasing order:
This type is commonly used for grinding and bench-type drilling machines.

Pick-Off Gears
Pick-off gears are used for machine tools of mass and batch production (automatic and
semiautomatic machines, special-purpose machines, and so on) when the changeover from job to
job is comparatively rare. Pick-off gears may be used in speed or feed gearboxes. As shown in
Figure 3, the change of speed is achieved by setting gears A and B on the adjacent shafts. As the
center distance is constant, correct gear meshing occurs if the sum of teeth of gears A and B is
constant.
Gearboxes
Machine tools are characterized by their large number of spindle speeds and feeds to cope with
the requirements of machining parts of different materials and dimensions using different types
of cutting tool materials and geometries. The cutting speed is determined on the bases of the
cutting ability of the tool used, surface finish required, and economical considerations. A wide
variety of gearboxes utilize sliding gears or friction or jaw coupling. The selection of a particular
mechanism depends on the purpose of the machine tool, the frequency of speed change, and the
duration of the working movement. The advantage of a sliding gear transmission is that it is
capable of transmitting higher torque and is small in radial dimensions. Among the
disadvantages of these gearboxes is the impossibility of changing speeds during running. Clutch-

type gearboxes require small axial displacement needed for speed changing, less engagement
force compared with sliding gear mechanisms, and therefore can employ helical gears. The
extreme spindle speeds of a machine tool main gearbox nmax and nmin can be determined by
where
Vmax = maximum cutting speed (m/min) used for machining the most soft and machinable
material with a cutting tool of the best cutting property
Vmin = minimum cutting speed (m/min) used for machining the hardest material using a cutting
tool of the lowest cutting property or the necessary speed for thread cutting
dmax, dmin = maximum and minimum diameters (mm) of WP to be machined
The speed range Rn becomes
In case of machine tools having rectilinear main motion (planers and shapers), the speed range
Rn is dependent only on Rv. For other machine tools, Rn is a function of Rv and Rd, large
cutting speeds and diameter ranges are required. Generally, when selecting a machine tool, the
speed range Rn is increased by 25% for future developments in the cutting tool materials. Table
1 shows the maximum speed ranges in modern machine tools.


ANS. 2 (a)
Tool geometry is basically referred to some specific angles or slope of the salient faces and
edges of the tools at their cutting point.
Both material and geometry of the cutting tools play very important roles on their performances
in achieving effectiveness, efficiency and overall economy of machining. Cutting tools may be
classified according to the number of major cutting edges (points) involved as follows:
Single point cutting tools : Examples: turning tools, shaping, planning and
Slotting tools and boring tools
Double or Two point cutting tools : Example : drills
Multipoint (more than two) cutting tool: Example: Milling cutters, Broaching tools,
Hobs, Gear shaping cutters etc.
The geometry of a single point cutting tool is determined by the following features:
Face or rake surface, which is the surface of cutting tool along which the chips move
Flank surface that face the workpiece. There are two flank surfaces, namely principal and
auxiliary flank surfaces.
Cutting edge that remove material from the workpiece. There are two cutting edges.
The principal cutting edge performs the function of major material removal and is formed by the
intersection line of rake face with the principal flank surface. The auxiliary cutting edge, often
called as end cutting edge, is formed by intersection of rake face with the auxiliary flank surface.
Corner or cutting point, which is meeting point of the principal and auxiliary cutting edges.
Often a nose radius is provided to avoid a sharp corner. The above mentioned features are shown
in the figure.

CONCEPT OF RAKE AND CLEARANCE ANGLES OF CUTTING TOOLS.

Tool geometry is basically referred to some specific angles or slope of the salient faces and
edges of the tools at their cutting point. Rake angle and clearance angle are the most significant
for all the cutting tools. The rake angle and clearance angles are illustrated with figures below
Rake angle (): Angle of inclination of rake surface from reference plane
Clearance angle (): Angle of inclination of clearance or flank surface from the finished surface
The rake angle has the following function:
It allows the chip to flow in convenient direction
It reduces the cutting force required to shear the metal and consequently helps to increase
the tool life and reduce the power consumption. It provides keenness to the cutting edge.
It improves surface finish.
Rake angle may be positive, or negative or even zero as shown in Figure.

RAKE ANGLE- TYPES AND THEIR SIGNIFICANCE.

Positive rake:
Positive rake or increased rake angle reduces compression, the forces , and the friction,
yielding a thinner ,less deformed and cooler chip
But increased rake angle reduces the strength of the tool section and heat conduction
capacity
Some areas of cutting where positive rake may prove more effective are , when cutting
tough, alloyed materials that tend to work harden, such as certain stainless steel, when
cutting soft or gummy material or when low rigidity of workpiece, tooling , machine
tool, or fixture allows chatter to occur.
Negative rake:
To provide greater strength at the cutting edge and better heat conductivity , zero or
negative rake angles employed on carbide, ceramic, polycrystalline diamond, and poly
crystalline cubic boron nitride cutting tools.
These materials tend to be brittle but their ability to hold their superior hardness at high
temperature results in their selection for high speed and continuous machining operation.
Negative rakes increases tool forces but it is necessary to provide added support to the
cutting edge. This is particularly important in making intermittent cuts and in absorbing
the impact during the initial engagement of the tool and work.
Negative rakes are recommended on tool which does not possess good toughness ( low
transverse rupture strength)

Negative rake causes high compression, tool forces and friction , resulting in highly
deformed , hot chip.
The rake angle for a tool depends on the following factors
1. Type of the material being cut: A harder material like cast iron may be machined by smaller
rake angle than that required by soft material like mild steel or aluminum.
2. Type of tool material. Tool material like cemented carbide permits turning at high speed. At
high speeds rake angle has little influence on cutting pressure. Under such condition the rake
angle can minimum or even negative rake angle is provided to increase the tool strength.
3. Depth of cut: In rough turning, high depth of cut is given to remove the maximum amount of
the material. This means that the tool has to withstand severe cutting pressure. So the rake angle
should be decreased to increase the lip angle that provides the strength of the cutting edge.
4. Rigidity of tool holder and machine: an importantly supported tool on old or worn out
machine cannot take up high cutting pressure. So while machining under above condition, the
tool used should have larger rake angle.
ANS 2 (b)
Tool wear is a time dependent process. As cutting proceeds, the amount of tool wear increases
gradually. But tool wear must not be allowed to go beyond a certain limit in order to avoid tool
failure. The most important wear type from the process point of view is the flank wear, therefore
the parameter which has to be controlled is the width of flank wear land, VB. This parameter
must not exceed an initially set safe limit, which is about 0.4 mm for carbide cutting tools. The
safe limit is referred to as allowable wear land (wear criterion), VBk
The cutting time required for the cutting tool to develop a flank wear land of width VBk is
called tool life, T, a fundamental parameter in machining. The general relationship of VB versus
cutting time is shown in the figure (so-called wear curve). Although the wear curve shown is for
flank wear, a similar relationship occurs for other wear types. The figure shows also how to
define the tool life T for a given wear criterion VBk

The slope of the wear curve (that is the intensity of tool wear) depends on the same parameters,
which affect the cutting temperature as the wear of cutting tool materials is a process extremely
temperature dependent. Parameters, which affect the rate of tool wear are v cutting conditions
(cutting speed V, feed f, depth of cut d) v cutting tool geometry (tool orthogonal rake angle) v
properties of work material From these parameters, cutting speed is the most important one. As
cutting speed is increased, wear rate increases, so the same wear criterion is reached in less time,
i.e., tool life decreases with cutting speed:
If the tool life values for the three wear curves are plotted on a natural log-log graph of cutting
speed versus tool life as shown in the right figure, the resulting relationship is a straight line
expressed in equation form called the Taylor tool life equation:
VTn= C
Where n and C are constants, whose values depend on cutting conditions, work and tool material
properties, and tool geometry. These constants are well tabulated and easily available.An
expanded version of Taylor equation can be formulated to include the effect of feed, depth of cut
and even work material properties.

Factors Affecting Tool Life
The life of tool is affected by many factors such as: cutting speed, depth of cut, chip thickness,
tool geometry, material or the cutting fluid and rigidity of machine. Physical and chemical
properties of work material influence tool life by affecting form stability and rate of wear of
tools. The nose radius tends to affect tool life.
1. Cutting speed: Cutting speed has the greatest influence on tool life. As the cutting speed
increases the temperature also rises. The heat is more concentrated on the tool than on the
work and the hardness of the tool matrix changes so the relative increase in the hardness
of the work accelerates the abrasive action. The criterion of the wear is dependent on the
cutting speed because the predominant wear may be wear for flank or crater if cutting
speed is increased.
2. Feed and depth of cut: The tool life is influenced by the feed rate also. With a fine feed
the area of chip passing over the tool face is greater than that of coarse feed for a given
volume of swarf removal, but to offset this chip will be greater hence the resultant
pressure will nullify the advantage.
3. Tool Geometry: The tool life is also affected by tool geometry. A tool with large rake
angle becomes weak as a large rake reduces the tool cross-section and the amount of
metal to absorb the heat.
4. Tool material: Physical and chemical properties of work material influence tool life by
affecting form stability and rate of wear of tool.
5. Cutting fluid: It reduces the coefficient of friction at the chip tool interface and increases
tool life.

Acropolis Technical Campus University Question Paper Solution June-2013 (Me-603, Metal Cutting & CNC M/C)

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ACROPOLIS TECHNICAL CAMPUS

UNIVERSITY QUESTION PAPER SOLUTION

STEPPED SPEED DRIVES: