4th year mechanical engineering

Manufacturing engineering II assignment I 2016

1. Derive the following forces acting on single point tool cutting operation by using merchant’s circle
diagram and sin. and cos. law.
Fs =Fccosɸ -Ftsinɸ N= Fccosα -Ftsinα
Ns = Fcsinɸ +Ftcosɸ Ft+Fctanα
µ=Fc−Ft tanα
F= Fcsinα +Ftcosα
2. Using the Taylor equation VTn = C, calculate the percentage increase in tool life when the cutting
speed is reduced by 50% (n = 0∙5 and C = 400).
3. During plain turning a brass rod by a turning tool which principal cutting-edge angle is 90° and
auxiliary cutting-edge angle 20°, the maximum surface roughness has been found to be 0.20 mm.
At how much feed rate of the tool, the turning was carried out?
4. In a single point turning operation with cemented carbide tool and steel work piece, it is found
that the Taylor’s exponent is 0.25. If the cutting speed is reduced by 50% then what will be the
change in the tool life?
5. In a single-point turning operation of steel with a cemented carbide tool, Taylor’s tool life
exponent is 0.25. If the cutting speed is halved, how many times the tool life will increase?
6. In the Taylor’s tool life equation, VTn = C, the value of n = 0.5. The tool has a life of 180 minutes at
a cutting speed of 18 m/min. If the tool life is reduced to 45 minutes, then what will be the cutting
speed?
7. In a machining operation, doubling the cutting speed reduces the tool life to 1/8th of the original
value. What is the value of the exponent n in Taylor’s tool life equation?
8. A 50 mm diameter steel rod was turned at 284 rpm and tool failure occurred in 10 minutes. The
speed was changed to 232 rpm and the tool failed in 60 minutes. Assuming straight line
relationship between cutting speed and tool life, calculate the value of Taylorian Exponent (n).
9. In an orthogonal machining operation, the tool life obtained is 10 min at a cutting speed of 100
m/min, while at 75 m/min cutting speed, the tool life is 30 min. What is the value of index (n) in
the Taylor’s tool life equation?
10. In a machining test, a cutting speed of 100 m/min indicated the tool life as 16 min, and a cutting
speed of 200 m/min indicated the tool life as 4 min. What are the values of n and C?
11. A carbide tool while machining a mild steel workpiece was found to have a life of 1 hr and 40 min
when cutting at 50 m/min. Find the tool life if the tool is to operate at a speed 30% higher than
previous one. Also, calculate the cutting speed if the tool is required to have a life of 2 hr and 45
min. Assume n = 0.28.