Manufacturing

Processes &
Engineering 2019 /2020
Metrology
Code: DME 121

Level 1 – Semester 1

Sheet 1 - Introduction to Machining

Prepared by:

Dr. - Mohamed Abdelhalim Mansour

THEORY OF METAL MACHINING
1) What distinguishes machining from other manufacturing processes?
2) Identify some of the reasons why machining is commercially and
technologically important.
3) Name the three most common machining processes.
4) What are the three categories of cutting tools in machining? Give an
example of a machining operation that uses each of the tooling types.
5) Identify the parameters of a machining operation that are included within the
scope of cutting conditions.
6) Define the difference between roughing and finishing operations in
machining.
7) What is a machine tool?
8) What is an orthogonal cutting operation?
9) Name and briefly describe the three types of chips that occur in metal
cutting.
10) Describe in words what the Merchant equation tells us.
11) What is the specific energy in metal machining?
12) What does the term size effect mean in metal cutting?

2
Multiple Choice Quiz
1) A lathe is used to perform which of the following machining operations (one
best answer)?
(a) broaching, (b) drilling, (c) milling, or (d) turning.
2) With which one of the following geometric forms is the drilling operation
most closely associated?
(a) external cylinder, (b) flat plane, (c) round hole, (d) screw threads.
3) If the cutting conditions in a turning operation are v = 300 ft/min, f = 0.010
in/rev, and d = 0.100 inch, which one of the following is the material emoval
rate?
(a) 0.3 in3/min, (b) 0.025 in3/min, (c)3.0 in3/min, or (d) 3.6 in3/min.
4) A roughing operation generally involves which one of the following
combinations of cutting conditions?
(a) high v, f, and d; (b) high v, low f and d;
(c) low v, high f and d; or (d) low v, f, and d.
5) The chip thickness ratio is which one of the following?
(a) tc/to, (b) to/tc, (c) f/d, or (d) to/w.
6) Which of the three types of chip would be expected in a turning operation
conducted at low cutting speeds on a brittle work material (one answer)?
(a) continuous, (b) continuous with built-up edge, or (c) discontinuous.

3
7) According to the Merchant equation, an increase in rake angle would have
which of the following results, all other factors remaining the same (more
than one)?
(a) decrease in friction angle, (b) decrease in power requirements,
(c) increase in shear plane angle. (d) (b) and (c).
8) Which of the following metals would usually have the lowest unit
horsepower?
(a) aluminum, (b) brass, (c) cast iron, or (d) steel.
9) For which one of the following values of chip thickness before the cut to
would you expect the specific energy to be the greatest?
(a) 0.010 inch, (b) 0.025 inch, or (c) 0.12 mm.
10) Which of the following cutting conditions has the strongest effect on
cutting temperature?
(a) feed or (b) speed.
11) Back rake of a turning tool is measured on its
(a) machine longitudinal plane
(b) machine transverse plane
(c) orthogonal plane
(d) normal plane
12) 2. Normal rake and orthogonal rake of a turning tool will be same when its
(a) φ = 0
(b) φ = 0
1

(c) λ = 0
o
(d) φ = 90
1

13) Normal plane of a turning tool is always perpendicular to its

(a) π plane
X

4
 (b) π plane
Y

(c) π plane
C

(d) none of them

14) Principal cutting edge angle of any turning tool is measured on its
(a) π
R

(b) π
Y

(c) π
X

(d) π
o

15) A cutting tool can never have its

(a) rake angle – positive
(b) rake angle – negative
(c) clearance angle – positive
(d) clearance angle – negative
16) Orthogonal clearance and side clearance of a turning tool will be same if its
perpendicular cutting edge angle is
o
(a) φ = 30
o
(b) φ = 45
o
(c) φ = 60
o
(d) φ = 90
17) Inclination angle of a turning tool is measured on its
(a) reference plane
(b) cutting plane
(c) orthogonal plane
(d) normal plane
18) Normal rake and side rake of a turning tool will be same if its

5
 o o
(a) φ = 0 and λ = 0
o o
(b) φ = 90 and λ = 0
o o
(c) φ = 90 and λ = 90
o o
(d) φ = 0 and λ = 90

Problems
Chip Formation and Forces in Machining
1) In an orthogonal cutting operation, the tool has a rake angle = 15 o. The chip
thickness before the cut = 0.30 mm and the cut yields a deformed chip
thickness = 0.65 mm. Calculate (a) the shear plane angle and (b) the shear
strain for the operation.
2) In Problem 1, suppose the rake angle were changed to a = 0o. Assuming that
the friction angle remains the same, determine (a) the shear plane angle, (b)
the chip thickness, and (c) the shear strain for the operation.
3) In an orthogonal cutting operation, the tool has a rake angle = -5o. The chip
thickness before the cut = 0.012 in and the cut yields a deformed chip
thickness = 0.028 in. Calculate (a) the shear plane angle and (b) the shear
strain for the operation.
4) The cutting conditions in a turning operation are: v = 2 m/s, f = 0.25 mm,
and d = 3.0 mm. The tool rake angle = 10o which produces a deformed chip
thickness tc = 0.54 mm. Determine: (a) shear plane angle, (b) shear strain,
and (c) material removal rate. Use the orthogonal cutting model as an
approximation of the turning process.

6
5) The cutting force and thrust force in an orthogonal cutting operation are: Fc
= 1470 N and Ft = 1589 N. The rake angle = 5o, the width of the cut = 5.0
mm, the chip thickness before the cut = 0.6, and the chip thickness ratio =
0.38. Determine (a) the shear strength of the work material and (b) the
coefficient of friction in the operation.
6) The cutting force and thrust force have been measured in an orthogonal
cutting operation: Fc = 300 lb and Ft = 291 lb. The rake angle = 10o, the
width of the cut = 0.200 in, the chip thickness before the cut = 0.015in, and
the chip thickness ratio = 0.4. Determine (a) the shear strength of the work
material and (b) the coefficient of friction in the operation.
7) An orthogonal cutting operation is performed using a rake angle of 15 o, to =
0.012 in and w = 0.100 in. The chip thickness ratio is measured after the cut
to be 0.55. Determine: (a) the chip thickness after the cut, (b) the shear
angle, (c) the friction angle, (d) the coefficient of friction, and (e) the shear
strain.
8) The orthogonal cutting operation described in previous Problem 7 involves a
work material whose shear strength is 40,000 lb/in2. Based on your answers
to the previous problem, compute: (a) the shear force, (b) the cutting force,
(c) the thrust force, and (d) the friction force.
9) In an orthogonal cutting operation, the rake angle = -5o, to = 0.2 mm and w =
4.0 mm. The chip ratio r = 0.4. Determine: (a) the chip thickness after the
cut, (b) the shear angle, (c) the friction angle, (d) the coefficient of friction,
and (e) the shear strain.
10) The shear strength of a certain work material = 50,000 lb/in2. An
orthogonal cutting operation is performed using a tool with a rake angle =
20o at the following cutting conditions: Speed = 100 ft/min, chip thickness
before the cut = 0.015 in, and width of cut = 0.150 in. The resulting chip

7
 thickness ratio = 0.50. Determine: (a) the shear plane angle; (b) the shear
force; (c) cutting force and thrust force, and (d) friction force.
11) Solve the previous problem except that the rake angle has been changed to
-5o and the resulting chip thickness ratio = 0.35.
12) A turning operation is performed using the following cutting conditions: v
= 300 ft/min, f = 0.010 in/rev, and d = 0.100 in. The rake angle on the tool
in the direction of chip flow = 10o, resulting in a chip ratio = 0.42. The
shear strength of the work material = 40,000 lb/in2. Using the orthogonal
model as an approximation of turning, determine: (a) the shear plane angle;
(b) the shear force; (c) cutting force and feed force.
13) Turning is performed on a work material with shear strength of 250 MPa.
The following conditions are used: v = 3.0 m/s, f = 0.20 mm/rev, d = 3.0
mm, and rake angle = 7o in the direction of chip flow. The resulting chip
ratio = 0.5. Using the orthogonal model as an approximation of turning,
determine: (a) the shear plane angle; (b) the shear force; (c) cutting force
and feed force.
14) A turning operation is made with a rake angle of 10 o, a feed of 0.010 in/rev
and a depth of cut = 0.100 in. The shear strength of the work material is
known to be 50,000 lb/in2, and the chip thickness ratio is measured after the
cut to be 0.40. Determine the cutting force and the feed force. Use the
orthogonal cutting model as an approximation of the turning process.

8
15) Show how tan φ = r cos α / (1 - r sin α) is derived from the definition
of chip ratio, r = to / tc and the next Figure.

Q.E.D.
16) Show how γ = tan (φ - α) + cot φ is derived from the next Figure.

Q.E.D.

9
 17) Derive the force equations for F, N, Fs, and Fn
 F = Fc sin α + Ft cos α
 N = Fc cos α – Ft sin α
 Fs = Fc cos φ – Ft sin φ
 Fn = Fc sin φ + Ft cos φ
Using the force diagram shown in Figure.

Power and Energy in Machining

18) In a turning operation on stainless steel with hardness = 200 HB, the
cutting speed = 200 m/min, feed = 0.25 mm/rev, and depth of cut = 7.5
mm. How much power will the lathe draw in performing this operation if
its mechanical efficiency = 90%. Use specific energy value U = 2.8 N-
m/mm3 = 2.8 J/mm3.
19) A turning operation is to be performed on a 20 hp lathe with efficiency =
90%. The work material is an alloy steel whose hardness is in the range 360
to 380 HB. Cutting conditions are: v = 400 ft/min., feed = 0.010 in/rev, and
depth of cut = 0.150 in. Based on these values, can the job be performed on
the 20 hp lathe? Use Table 1.1 to obtain the appropriate unit horsepower
value.
20) Suppose the cutting speed in Problems 7 and 8 is v = 200 ft/min. From your
answers to those problems, find: (a) the horsepower consumed in the
operation, (b) the metal removal rate in in.3/min, (c) the unit horsepower
(hp-min/(in3), and (d) the specific energy (in-lb/in3).
21) For Problem 12, the lathe has a mechanical efficiency = 0.80. Determine:
(a) the horsepower consumed by the turning operation; (b) the horsepower

10
 that must be generated by the lathe; (c) the unit horsepower and specific
energy for the work material in this operation.
22) In a turning operation on low carbon steel (175 BHN), the cutting
conditions are: v = 400 ft/min, f = 0.010 in/rev, and d = 0.075 in. The lathe
has a mechanical efficiency = 0.85. Based on the unit horsepower values in
Table 1.1, determine: (a) the horsepower consumed by the turning
operation; (b) the horsepower that must be generated by the lathe.
23) A turning operation is carried out on aluminum (100 BHN), the cutting
conditions are: v = 5.6 m/s, f = 0.25 mm/rev, and d = 2.0 mm. The lathe has
a mechanical efficiency = 0.85. Based on the specific energy values in
Table 1.1, determine: (a) the cutting power and (b) the gross power in the
turning operation, in Watts.
24) A lathe performs a turning operation on a workpiece of 6.0 in diameter.
The shear strength of the work = 40000 lb/in2. The rake angle of the tool =
10o. The machine settings are: rotational speed = 500 rev/min, feed =
0.0075 in/rev, and depth = 0.0075 in. The chip thickness after the cut is
0.015 in. Determine: (a) the horsepower required in the operation, (b) the
unit horsepower for this material under these conditions, and (c) the unit
horsepower as it would be listed in Table 1.1 for a to of 0.010 in. Use the
orthogonal cutting model as an approximation of the turning process. Use
Correction factor = 1.15
(c) Correction factor = 1.15 from to account for the fact that f = 0.0075 in/rev
instead of 0.010 in/rev. Taking this correction factor into account, HPu =
0.375/1.15 = 0.326 hp/(in3/min) as it would appear in Table 1.1 for a feed f = 0.010
in/rev.

11