ME 331: Manufacturing Processes and systems

September 2, 2015

Tutorial sheet 1
Problem 1:-In an orthogonal cutting experiment, following data was generated,
Cutting speed 60m/min, Depth of cut 1 mm, chip thickness 2 mm. Rake
angle 12 degree, Cutting force 1000N (in the direction of tool movement) &
800N perpendicular to the direction of tool movement. Width of cut 3 mm.
Calculate shear angle
Find out work done in shearing and energy lost by friction
Calculate shear strain & strain rate
Sketch and show the Mohr circle on shear plane,
Give your remarks on the process based on results.
Problem 2:- In an orthogonal machining, rake angle is increased from 120 to 150,
what will be the effect on
shear angle chip thickness ratio
shear force Shear strain (in %)
State the effects on tool, work material and Mohr circle.
Problem 3:- In a turning operation, the constant in tool life equation are n=0.2 &
C=250.IF tool life is 100 min at 100m/min cutting speed, find out tool life at 150
m/min.If I want the tool to work for 300min,what should be the cutting speed?
Problem 4:-What are the common types of chips? What does each type indicate
about the process?