King Fahd University of Petroleum & Minerals

Mechanical Engineering Department

ME 406: Manufacturing and Design

Semester (152) SOLUTION (Each question 6.25 points, Total 50 Points)
Homework # 5 (Grinding chapter 21 and Non Traditional Machining Processes
chapter 22

Q1-Problem 21.1
21.1 . Wheel speed = 1600 m/min, work speed = 0.30 m/s, and crossfeed = 5 mm. The number of
active grits per area of wheel surface = 50 grits/cm2. Determine (a) average length per chip, (b)
metal removal rate, and (c) number of chips formed per unit time for the portion of the
operation when the wheel is engaged in the work.
Solution: (a) lc = (Dd)0.5 = (150 x 0.06)0.5 = 3.0 mm

(b) RMR = vwwd = (0.30 m/s)(103 mm/m)(5.0 mm)(0.06 mm) = 90 mm3/s = 5400 mm3/min

(c) nc = vwC = (1600 m/min)(103)(5.0 mm)(50 grits/cm2)(10-2) = 4,000,000 chips/min

Q2-Problem 21.2
21.2 In an external cylindrical grinding operation on a hardened steel tube whose outside radius =
42.5 mm, the grinding wheel diameter = 100 mm and wheel width = 20 mm. The workpiece
rotates at a surface speed of 25 m/min, the wheel rotates at 1800 rev/min, infeed (depth of cut)
= 0.05 mm, and traverse feed = 0.50 mm/rev. There are 45 active grits/cm2 of wheel surface, and
the operation is performed dry. Determine (a) volume rate of metal removed. (b) number of
chips formed per unit time, and (c) average volume per chip. (d) If the tangential cutting force on
the work = 55 N, compute the specific energy in this operation.
Solution: (a) RMR = vwwd = (25 m/min)(103)(0.50 mm)(0.05 mm) = 625 mm3/min

(b) nc = vwC

v = NπD = (1800 rev/min)(100π mm/rev) = 565,487 mm/min

nc = (565,487 mm/min)(0.5 mm)(45 grits/cm2)(10-2) = 127,235 grits/min (chips/min)

(c) Average volume per chip = (625 mm3/min)/( 127,235 chips/min) = 0.0049 mm3/chip

(d) U = Fcv/RMR

v = 565,487 mm/min = 565.5 m/min

U = 55(565.5)/625 = 49.8 N-m/mm3

Q3-Problem 21.3
21.3 An internal cylindrical grinding operation is used to finish an internal bore from an initial
diameter of 250.00 mm to a final diameter of 252.5 mm. The bore is 125 mm long. A grinding
wheel with an initial diameter of 150.00 mm and a width of 20.00 mm is used. After the
operation, the diameter of the grinding wheel has been reduced to 149.75 mm. Determine the
grinding ratio in this operation.
Solution: GR = (volume of work material removed)/(volume of wheel removed)

Volume of work material removed = (π/4)(125)(252.52 – 250.02) = 123,332 mm3

Volume of wheel removed = (π/4)(20)(1502 – 149.752) = 1177 mm3

GR = 123,332/1177 = 104.8

Q4-Problem 21.4
21.4 In a centerless grinding operation, the grinding wheel diameter = 250 mm, and the regulating
wheel diameter = 150 mm. The grinding wheel rotates at 1800 rev/min, and the regulating
wheel rotates at 200 rev/min. The inclination angle of the regulating wheel = 2.0°. Determine the
production rate of cylindrical work parts that are 15.0 mm in diameter and 135 mm long.
Solution: From Eq. (21.11), fr = πDrNr sin I

fr = π(150)(200) sin 2.0° = 30,000π(0.0349) = 3289 mm/min

Parts production rate = (3289 mm/min)/(135 mm/pc) = 24.4 pc/min

Q5-Problem 22.8
22.7 A square hole is to be cut using ECM through a plate of low alloy steel that is 12 mm thick. The
specific removal rate for this steel is 3.7 x 10-2 mm3/A-s. The hole is 35 mm on each side, but the
electrode used to cut the hole is slightly less than 35 mm on its sides to allow for overcut, and its
shape includes a hole in its center to permit the flow of electrolyte and to reduce the area of the
cut. This tool design results in a frontal area of 245 mm2. The applied current = 1200 amps. (a)
Using an efficiency of 95%, how long will it take to cut the hole? (b) If the tool were designed
with a frontal area equal to the hole size, how long will it take to cut the hole?
Solution: (a) Given that C = 3.7 x 10-2 mm3/A-s

From Equation (22.6) fr = CI/A = (3.7 x 10-2 mm3/A-s)(1200 A)/(245 mm2) = 0.1812 mm/s

At 95% efficiency, fr = 0.95(0.1812 mm/s) = 0.172 mm/s

Time to machine = (12 mm)/(0.172 mm/s) = 69.7 s = 1.16 min

(b) The area of the square hole = 352 = 1225 mm2

 fr = CI/A = (3.7 x 10-2 mm3/A-s)(1200 A)/(1225 mm2) = 0.0362 mm/s

At 95% efficiency, fr = 0.95(0.0362 mm/s) = 0.0344 mm/s

Time to machine = (12 mm)/(0.0344 mm/s) = 348.5 s = 5.81 min

Comment: The electrode design with the hole in the center reduces the time to machine by a
factor of 5 because of the reduced frontal area.

Q6-Problem 22.9
22.9 (A) An electric discharge machining operation is performed on tungsten. Determine the amount
of metal removed in the operation after one hour at a discharge current of 20 amps for this
metal. Use metric units and express the answers in mm3/hr. Refer to Table 4.1 for the melting
temperature of tungsten.
Solution: For tungsten, the melting temperature given in Table 4.1 = 3410°C.

Using Equation (22.7), RMR = KI/Tm1.23 = 664(20)/(34101.23) = 0.5997 mm3/s = 2159 mm3/hr

Q7-Problem 22.10
22.10 In a wire EDM operation performed on 12-mm-thick C1080 steel using a tungsten wire electrode
whose diameter = 0.125 mm, past experience suggests that the overcut will be 0.02 mm, so that
the kerf width will be 0.165 mm. Using a discharge current = 15 amps, what is the feed rate that
can be used in the operation? Estimate the melting temperature of 0.80% carbon steel from the
phase diagram of Figure 6.4.
Solution: From Figure 6.4, Tm = 1500°C for 1080 steel

Using Equation (22.7), RMR = 664(15)/(15001.23) = 9960/8065 = 1.232 mm3/s = 73.92 mm3/min

Frontal area of kerf A = 0.165(12.0) = 1.98 mm2

fr = 73.92/1.98 = 37.33 mm/min

Q8 Problem 22.11
22.11 A wire EDM operation is used to cut out punch-and-die components from 25-mm-thick tool steel
plates. However, in preliminary cuts, the surface finish on the cut edge is poor. What changes in
discharge current and frequency of discharges should be made to improve the finish?
Solution: As indicated in Figure 22.8(a), surface finish in EDM could be improved by reducing
discharge current and increasing frequency of discharges.