Scribd
Upload
220 views

Sample Solution On The Exercises (Lecture 3)

The document discusses four tutorial problems related to machining processes involving turning steel rods with ceramic or carbide tools. The first problem asks the reader to calculate the power consumed during a turning operation given various machining parameters. The second problem involves using Merchant's circle diagram and velocity diagrams to calculate forces, energy requirements, and power given cutting forces and chip thickness from a turning operation. The third problem is similar to the first, asking the reader to calculate power consumed during another turning operation. The fourth problem mirrors the second, requiring the use of Merchant's circle diagram and velocity diagrams to determine values and perform calculations for given cutting and axial forces and chip thickness.

Uploaded by

murwanashyaka augustin
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
220 views

Sample Solution On The Exercises (Lecture 3)

The document discusses four tutorial problems related to machining processes involving turning steel rods with ceramic or carbide tools. The first problem asks the reader to calculate the power consumed during a turning operation given various machining parameters. The second problem involves using Merchant's circle diagram and velocity diagrams to calculate forces, energy requirements, and power given cutting forces and chip thickness from a turning operation. The third problem is similar to the first, asking the reader to calculate power consumed during another turning operation. The fourth problem mirrors the second, requiring the use of Merchant's circle diagram and velocity diagrams to determine values and perform calculations for given cutting and axial forces and chip thickness.

Uploaded by

murwanashyaka augustin
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
You are on page 1/ 3

Academic year 2018/2019

Tutorials – Production Technology II – MEE2266


1. During turning a steel rod of diameter 100 mm by a ceramic tool of geometry:
0o, —10o, 8o, 7o, 15o, 60o, 0.5 (mm) at speed 625 rpm, feed 0.36 mm/rev. and depth of cut
4.0 mm the average chip thickness was found to be 1.0 mm. Roughly how much power
will be consumed in the above mentioned machining process if the work material is semi-
ductile and the Brinnel hardness number of the work material is 240 (kg/mm2).

2. During turning a steel rod of diameter 150 mm by a carbide tool of geometry:


0o, —15o, 8o, 6o, 15o, 60o, 0 (mm) at speed 560 rpm, feed 0.32 mm/rev. and depth of cut
4.0 mm the followings were observed : cutting force 1000 N, radial force 200 N, chip
thickness 0.8 mm.
a) Using Merchant’s Circle Diagram (scale of 1cm = 200 N), determine the values of
other possible forces developed during the machining process.
b) Draw the velocity diagram and Calculate: the specific energy requirement for the
above mentioned machining operation, shearing power and friction power.

3. During turning a steel rod of diameter 100 mm by a ceramic tool of geometry:


0o, —10o, 8o, 7o, 15o, 75o, 0.5 (mm) at speed 625 rpm, feed 0.36 mm/rev. and depth of cut
5.0 mm the average chip thickness was found to be 1.0 mm. Roughly how much power
will be consumed in the above mentioned machining work if the work material is semi -
ductile and the Brinnel hardness number of the work material is 340 (kg/mm2)

4. During turning a steel rod of diameter 150 mm by a carbide tool of geometry:


0o, 15o, 8o, 6o, 15o, 60o, 0 (mm) at speed 625 rpm, feed 0.23 mm/rev. and depth of cut 5.0
mm the followings were observed : cutting force 1200 N, axial force 400 N, chip
thickness 1 mm.
a) Using Merchant’s Circle Diagram (scale of 1cm = 200 N), determine the values of
all possible forces developed during the machining process.
b) Draw the velocity diagram and Calculate: the specific energy requirement for the
above mentioned machining operation, shearing power and friction power.

2) Solution :
2. During turning a steel rod of diameter 150 mm by a carbide tool of geometry;
0o, —12o, 8o, 6o, 15o, 60o, 0 (mm) at speed 560 rpm, feed to = 0.32 mm/rev. and depth
of cut w = 4.0 mm the followings were observed : cutting force FZ = 1000 N, Radial
force FX = 200 N, thickness of removed chip tc =0.8 mm
Determine, without using MCD, the expected values of Friction force, Normal friction
force, coefficient of friction μ, shear force Fs, normal friction force Fn, Shear stress

Production Technology II – MEE2266 UR -CST


Academic year 2018/2019

τs, cutting power and specific energy requirement for the above mentioned machining
operation.

/10

• FXY = FX/ sinφ = 200/cos60o = 400 N


• F = FZ sinα + FXYcosα ;
Here α = - 12o , sinα = - 0.208 and cosα = 0.978
F = 1000(-0.208) + 400(0.978) = 600 N answer /2marks
and N = FZ cosα - FXY sinα
= 1000(0.978) - 400(-0.208) = 1060 N answer /1mark
So, μa = F/N = 600/1060 = 0.566 answer /1mark
• FS = FZcosφ - FXY cosφ
where φ= tan-1(cosα / (ζ-sinα))
Here, ζ = tc/(to sinφ) = 0.8/(0.32 x sin60o) = 2.88
φ= tan-1{(0.978/(2.88+0.208)} = 17.6o answer /2marks

So, FS= 1000xcos (17.6o) – 400xsin (17.6o) = 832 N answer /1mark


and FN= 1000sin(17.6o) + 400cos(17.6o) = 683 N answer /1 mark
• FS = (w to τs)/sinα
∴τs = FS sinα /( w to) = 832sin(17.6o)/(4x0.32) = 200 N/mm2 answer /1mark
• Cutting power, PC = FZ.VC
Where VC = πDN/1000 = πx150x560/1000 = 263 m/min
∴PC = 1000x263 N-m/min = 4.33 KW answer /2marks
• Specific energy consumption, EC
EC= power/MRR = (FZ.VC)/(VC.w.to) N-m/m-mm2
= 1000x263 (Joules/min) / {263x0.32x4x1000(mm3/min)}
= 0.78 Joules/mm3

Production Technology II – MEE2266 UR -CST


Academic year 2018/2019

Production Technology II – MEE2266 UR -CST

You might also like