ME EN 6010/5010

Spring 2024

HW 1

1. In an orthogonal machining operation, these conditions and/or measurements were

noted/performed: width of cut is 2.5 mm, the undeformed chip thickness is 0.25 mm, the
final chip thickness is 1 mm, the rake angle is -5 deg., the measured cutting force is 900
N, and the measured thrust force is also 900 N. Calculate i) the shear angle using a)
information given above, and b) using the Merchant equation and ii) the mean shear
stress (or shear strength) of this work material using a) the Merchant equation and b) the
information provided above. (20 points)

2. In an orthogonal machining operation, the tool has a rake angle of + 5 deg. And an
undeformed chip thickness of 1 mm. The final chip thickness is measured to be 3 mm.
What will the final chip thickness be if the rake angle is increased to + 15 deg.? Assume
that the Merchant theory is applicable, i.e. 2𝜙 + 𝛽 − 𝛼 = 𝜋/2.
Also assume that the friction coefficient is not influenced by any changes in the rake
angle. Also discuss if this assumption (of the rake angle not having any effect on friction)
is reasonable or incorrect. Explain your rationale behind your answer. (20 points)

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3. Show (or attempt to show) the derivation that leads from = 0 (𝑠𝑒𝑒 𝑙𝑒𝑐𝑡𝑢𝑟𝑒 𝑛𝑜𝑡𝑒𝑠)to
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the Merchant equation 2𝜙 + 𝛽 − 𝛼 = 𝜋/2 for predicting the shear angle. Consider the
shear stress to be invariable. The equation to be used for Fc is
& (" ) *+,(./0)
𝐹$% ,23 # *+,(#4./0)
(30 points)

4. The following data is available from orthogonal cutting experiments conducted on 4140
steel. The undeformed chip thickness = 0.13 mm, width of cut = 2.5 mm, rake angle = −5
degrees, and cutting speed (v) = 2 m/s. The main cutting force (Fc) was measured to be
890 N, the thrust force was 800 N, and the measured chip thickness was 0.58 mm.
Determine a) the shear angle (do not use Merchant equation), b) friction coefficient μ, c)
shear stress and d) shear strain on the shear plane. The shear strain (g) is found by using
this equation: 𝛾 = cot 𝜙 + tan(𝜙 − 𝛼).

Also1 attempt to calculate the chip velocity vc (velocity with which the chip is moving on
the tool rake face) and shear velocity vs (velocity at which the material in the shear plane
is moving along the shear plane). (30 points)

1We have not yet covered chip kinematics in class, but the basic schematic is provided here. If
possible, please try this question before next class and I will explain this further.