NUMERICAL SHEET

1. During machining on a shaper under orthogonal cutting condition, the specimen length
along the stroke is 100 mm and the chip length of 40 mm is obtained with a tool of 15°
rake angle. Determine the shear angle and chip thickness if uncut chip thickness is 1.5
mm?

2. In an orthogonal cutting operation on a material with shear yield strength of 250 N/mm 2,
the following data is obtained
rake angle of the tool: 15°
uncut chip thickness: 0.25 mm
width of chip: 2 mm
chip thickness ratio: 0.46
friction angle: 40°
Determine the shear angle, cutting force component and force on the tool.

3. In an orthogonal cutting operation on a material with shear yield strength of 200 N/mm 2,
the following data is observed,
length of cut chip obtained from uncut chip length of 100 mm is : 50 mm
rake angle of the tool: 10°
uncut chip thickness: 0.2 mm
width of cut: 1.5 mm
coefficient of friction: 0.8
Determine the shear plane angle, resultant force on the tool, cutting force component of
resultant force.

4. From the following data observed during an experiment on orthogonal cutting, determine
the shear plane angle and friction angle if the rake angle = 20°, uncut chip thickness =
0.125 mm, cutting force component = 1100 N, force component normal to it = 400 N,
cutting ratio = 0.42.

5. With the help of Merchant's model, determine the cutting force in machining an alloy
steel plate in condition of orthogonal cutting. The tool has a rake angle of 10°, friction
angle: 35°, uncut chip thickness = 1 mm and width of cut = 5 mm. The yield strength of
the alloy in shear is 240 N/mm2.