PROBLEMS

1. Two thousand bars 80 mm in diameter and 300 mm long must be

turned
down to 65 mm diameter for 150 mm of their length. The surface
finish and accuracy requirements are such that a heavy
roughing cut
(removing most of the material) followed by a light-finishing
needed. The roughing cut is to be taken at maximum power. Thecut are
light
finishing cut is to be taken at a feed of 0.13 mm, a cutting speed
1.5 m/s, and at of
maximum power.
Ifthe lathe has a 2-kW motor and an
efficiency of
total production time in kiloseconds (ks) for the batch50%, calculate the
of work. Assume
that the specific cutting energy for the work
material is 2.73 GJ/m²,
Machine Tools and Machining Operations 65

the time taken to return the tool to the beginning of the cut is 15 s,
and the time taken to load and unload a workpiece is 120s.
2. A workpiece in the form of a bar 100 mm in diameter is to be turned
down to 70 mm diameter for 50mm of its length. Aroughing cutusing
maximum power and a depth of cut of 12 mm is to be followed by a
finishing cut using a feed of 0.1 mm and a cuttingspeed of 1.5m/s.
It takes 20 s to load and unload the workpiece and 30 s to set the
cutting conditions, set the tool at the beginning of the cut and engage
the feed.
The specific cutting energy for the material is 2.3 GJ/m', and the
lathe has a 3-kW motor and a 70% efficiency. Estimate:
a. The machining time for the rough cut
b. The machining time for the finish cut
c. The total production time for each workpiece
3. A 50 mm diameter bar is to be screw-threaded, for 250 mm of its
length, on a lathe. The included angle of the thread is 60 degrees, the
pitch is 2.5 mm, and the outside diameter of the threaded portion is to
be 50mnm.
a. If the undeformed chip thickness is limited to 0.13 mm, how many
passes of the tool will be required to complete the operation?
b. If the rotational frequency of the workpiece is 0.8 s and it takes
20 s to return the tool and engage the carriage with the lead screw
after each pass, what will be the total production time?
center is
AA 1.5 m diameter disc with a 600mm diameter hole in the
machine. The
to be faced, starting at the outside, on a vertical-boring
and
rotational frequency of the table is 0.5 s-, the feed is 0.25 mm,
the back engagement (depth of cut) is 6 mm. The specific cutting energy
is 3.5 GJ/m.
for the work material and the particular cutting conditions
Calculate:
a. The machining time, in kiloseconds
beginning of the operation
b. The power consumption (in kW)at the
c. The power consumption just before the end of
the operation
on a lathe, the depth of
5. In apipe flange facing operation carried out
diameters of the flange are
cut is 12 mm, and the inside and outside
energy of the
250 mm and 500 mm, respectively. The specific cuttingfrequency of the
work material is 2.6 GJ/m', the maximum rotational
be applied is
lathe spindle is 6 s-, and the maximum feed that can degrees. Find:
60
0.25 mm. The major cutting-edge angle of the tool is the machine is
a. The maximum power required for
machining when
operating at maximum capacity
b. The cutting force
c. The machining time
66 Fundamentals of Machining and Machine Tools
6. Fifty 1mdiameter discs having an 80 mm diameter hole in the center
are to be faced on a vertical-boring machine with a feed of 0.25 mm
and a back engagement (depth of cut) of 5 mm. The machine has an
automatic control device by which the cutting speed is continuously
adjusted to allow maximum power utilization at the cutting tool of
3 kW. However, the maximum rotational frequency of the spindle is
limited to 0.7 s-!.
If the specific cutting energy for the work material is 2.27 GJ/m:
and it takes 600 s to unload a machined disc, load an unmachined disc.
and return the tool to the beginning of the cut, calculate the total
production time for the batch, in kiloseconds (ks).
7. In a facing operation carried out on a lathe, the end of a
carbon steel
cylindrical workpiece 300 mm diameter is to be faced with a high
speed steel tool having a major cutting-edge angle of 60
depth of cut (back engagement) is 10 mm and the feed 0.1 degrees. The
a. What is the maximum rotational mm.
frequency for the lathe if the power
available for machining is 4 kW? (Find the specific
for the work material from Figure cutting energy
b. What is the machining 1.50.)
time?
8. In aparticular mechanical shaper
arm is 1.4 m, the rocker-arm pivot mechanism, the length of the rocker
is 1.4 m below the
between the link and the ram, the radius of the connection
the crank pivot is 700 mm crank is 150 mm, and
rotated at 0.3 s-', calculate:
above the rocker-arm pivot. If the
crank is
a. The time for a
b. The time for a
forward stroke of the ram
return stroke of the ram
c. The maximum
cutting speed, in meters per second
the forward stroke (rn/s). during
9. The cross-feed on a
per millimeter. A shaper consists of a lead screw having 0.2 threads
ratchet and pawl on the end of the
driven from the shaper crank such that the pawl indexes the lead screw is
one tooth during each ratchet by
at one stroke per return stroke of the ram. If the
second and the ratchet on the shaper is operating
has 20 teeth, calculate: cross-feed lead screw
a. The feed, in
millimeters (mm)
b. The shortest time to
130 mm long by 100machine the
mm wide surface
of a
rectangular workpiece
10. A shaper is
operated at
machine a workpiece 150twommcutting
in
strokes per second and is used to
using a feed of 0.4 mm and a length at a cutting speed of 0.5 m/s
Calculate: back engagement (depth of cut) of 6 mm.
Machine Tools and Machining Operations 67

a. The total machining timne to produce 800 components each 100 mm

in width
b. The percentage of this time during which the tool is not contacting
the workpiece
c. The metal removal rate during actual machining

11. A shaper is operated at a frequency of reciprocation of 1.5 s-! and is

used to machine a 4 mm layer of material from the top of a rectangular
low-carbon steel workpiece. The width of the workpiece is 150 mm
and its length is 200 mm. The tool has a major cutting-edge angle of
30 degrees and is contacting the workpiece for 72% of the time. The
feed is 0.25 mm. Find:
a. The undeformed chip thickness
b. The total time to complete the operation neglecting setup, loading,
and unloading
c. The metal removal rate during machining
d. The power required during machining (use Figure 1.50 to obtain
the specific cutting energy)
12. Ina drilling operation using a twist drill, the rotational frequency of a
drillis 5 s-l,the feed O.25mm, the major cutting-edge angle 60 degrees,
and the drill diameter 12 mm. Assuming that the specific cutting energy
for the work material is 2 GJ/m', calculate:
a. The maximum metal removal rate
b. The undeformed chip thickness
c. The drill torque, in Newton-meters (N-m)

13. In a slab-milling operation, the width of the medium carbon steel

workpiece is 75 mm, its length is 200 mm, and a 5-mm layer is to be
removed in one pass.
a. What feed speed (mm/s) could be used if the power available for
cutting is 3 kW and the specific cutting energy for the work material
is 3.6 GJ/m3?
b. If the cutter diameter is 100 mm and the ideal surface roughness is
1.5 micrometers (um), what should be the rotational frequency of
the cutter?
c. What is the cutting speed?
d. What is the machining time?
teeth and is 100 mm in
JA In a slab-milling operation, the cutter has 20
diameter. The rotational frequency of the cutter is 5 s, the workpiece
is
feed speed is 1.3 mm/s, the working engagement (depth of50cut) mm.
6 mm, and the back engagement (width of the
workpiece) is
The relationship between the maximum undeformed chip thickness
a
Cmax
and the specific cutting energY P, in gigajoules per cubic meter
(GJ/m), for the work material is:
68 Fundamentals of Machining and
Machine Tools
P.=141+(25x10°) /a.
Estimate:
a. The maximum metal removal rate
b. The maximum power, in kilowats (kW), required at the cutter
JS. In aslab-milling operation, the length of the workpiece is 150 mm, its
width is 50mm, and a layer 10mm in thickness is to be removed from
its upper surface. The diameter of the cutter is 40 mm, and it has
10 teeth. The workpiece is of medium carbon steel, the feed speed
selected is 2 mm/s, and the cutter speed is 2.5 rev/s. Estimate:
a. The power required (in kW)
b. The machining time for the operation
Note: Use Figure 1.52 to obtain the specific cutting energy.
16. In a face-milling operation the back engagement (depth of cut) is 5 mm,
the work feed speed is 0.65 mm/s, and the working engagement (width
of the workpiece) is 50 mm. The cutter has a diameter of 100 mm and
has 20 teeth. If the cutting speed is to be 1m/s, calculate:
a. The rotational frequency of the cutter
b. The maximum metal removal rate
c. The time taken to machine 1000 workpieces of length 150 mm if
it takes 180 s to load and unload a workpiece and return the cuter
to the beginning of the cut

17. In a finish-surface-grinding operation on a horizontal-spindle surface

grinder, the length of the workpiece is 100 mm and its width 50 mm.
The cross-feed is applied every stroke of the worktable and is set at
0.25 mm, the back engagement (depth of cut) is 0.1 mm, and the
maximum traverse speed is 250 mm/s. The frequency of worktable
reciprocation is ls-. Calculate:
a. The machining time
b. The maximum metal removal rate
C. The maximum power consumption in watts (W) if the specifhc
cutting energy for the conditions employed is 25 GJ/m³
d. The maximum tangential force on the grinding wheel if its diameter
is 150mm and has a rotational frequency of 60 s

REFERENCE