ME363 HW3 Due: 9/28/2011

1. Calculate the expected main cutting force in an orthogonal machining operation where the
shear stress is 35,000 psi (241 MPa). The rake angle is +10o, the feed is 0.015 inch (0.381
mm) and the depth of cut is 0.100 inch (25.4 mm). Assume that the Fn/Fs ratio is equal to 1
where Fn = force normal to the shear plane and Fs = shear plane force). The chip thickness
ratio is 0.6.

2. It is desired to determine the efficiency of a lathe. A cutting test was performed with
velocity of 165 ft/min (50 m/min), feed of 0.010 inch (0.254 mm), and depth of cut of 0.100
inch (2.54 mm). During the test, the dynamometer reading indicated 450 lbs (2000N) in the
cutting direction and 200 lbs (890 N) in the feed direction. The wattmeter reading for the
main spindle motor was 2.68 HP (2 KW).

(a) Determine the efficiency of this machine.

(b) What is the specific horsepower of this material?

3. An orthogonal cutting operation has been performed with the following conditions (textbook
21.45):

t=0.1 mm, width of cut = 5mm, tc =0.2 mm, Vc= 2 m/s, rake angle=10°, main cutting force=
500N, thrust cutting force= 200N.

Calculate the total percentage of the total energy dissipated in the shear zone.

4. Calculate the shear plane temperature rise during orthogonal machining of mild steel using
the following data gathered. Assume that the percentage of heat going to the work β=0.1.

Cutting data
cutting force = 890 N (200 lbf), thrust force = 667 N (150 lbf), cutting speed V= 2 m/s (394
fpm), undeformed chip thickness=0.25 mm (0.0098 in.), width of cut=2.5mm (0.098 in.),
cutting ratio = 0.3, rake angle=0°

material data for mild steel

density= 7200 kg/m3 (0.26 lb/in3), heat conductivity k= 43.6 W/m-K (320.6 Btu-in/hr-ft2-°F),
specific heat c= 502 J/Kg-K (0.12 Btu/lb-F)