Assignment 1
1. What are the main features of orthogonal cutting? Give practical examples.
2. For a better machining performance, which type of chip is preferred?
3. Also what are the conditions that favor the formation of such a chip?
4. For an orthogonal cutting tool, what are the important angles to be maintained? Explain
their effect on the machining performance.
5. What is meant by BUE? Explain how they are formed. What conditions promote their
formation?
6. Derive an expression describing the shear angle in orthogonal cutting in terms of the rake
angle and chip thickness ratio.
7. Schematically show the Merchant force circle in orthogonal cutting. Derive the equations
for shear and friction forces in terms of material properties and cutting parameters.
8. Derive an expression for the main cutting force in orthogonal cutting in terms of the
workpiece material properties and cutting conditions.
9. Explain the formation of chip. Discuss the types of chips with neat sketches.
10. How can you classify cutting tools? Define the single point cutting tool elements.
11. What are the various types of tool failure? Explain them with neat sketches.
12. What is Taylor’s modified tool life? Explain how the cutting parameters affects the tool
life.
13. Explain how ɣ and Φ influence tool life.
14. Explain why studying the types of chips produced is important in understanding cutting
operations.
15. Explain the consequences of allowing temperatures to rise to high levels in cutting.
16. The cutting force increases with the depth of cut and decreasing rake angle. Explain why.
17. What are the effects of performing a cutting operation with a dull tool? A very sharp tool?
18. Why does the temperature in cutting depend on the cutting speed, feed, and depth of cut?
Explain in terms of the relevant process variables.
19. Describe the effects that a dull tool can have on cutting operations.
20. Explain whether it is desirable to have a high or low (a) n value and (b) C value in the
Taylor tool-life equation.
21. Why are tool temperatures low at low cutting speeds and high at high cutting speeds?
22. Can high-speed machining be performed without the use of a cutting fluid?
23. Given your understanding of the basic metal-cutting process, what are the important
physical and chemical properties of a cutting tool?
24. Explain why so many different types of cutting-tool materials have been developed over
the years. Why are they still being developed further?
25. Why does temperature have such an important effect on tool life?
26. Can cutting fluids have any adverse effects in machining? If so, what are they?
27. Why are chemical stability and inertness important in cutting tools?
28. Negative rake angles generally are preferred for ceramic, diamond, and cubic-boron-nitride
tools. Why?
29. Ceramic and cermet cutting tools have certain advantages over carbide tools. Why, then,
are they not completely replacing carbide tools?
30. Describe in detail your thoughts regarding the technical and economic factors involved in
tool-material selection.
31. Identify the four forces that act upon the chip in the orthogonal metal cutting model but
cannot be measured directly in an operation.
32. Identify the two forces that can be measured in the orthogonal metal cutting model.
33. What is the specific energy in metal machining?
Assignment 2
1. In an orthogonal cutting operation, Fc = 1000 N, Ft = 0, Rake angle 45° and Shear angle
45°, Determine (a) the coefficient of friction, (b) the shear power if Vs = 20 m/min, and (c)
the cutting power.
2. In a orthogonal cutting operation, t0 = 0.13 mm, V = 120 m/min, α = 10° and the width of
cut = 6 mm. It is observed that tc = 0.23 mm, Fc = 500 N, and Ft = 200 N. Calculate the
percentage of the total energy that goes into overcoming friction at the tool-chip interface.
3. The cutting force and thrust force have been measured in an orthogonal cutting operation
to be 300 lb and 291 lb, respectively. The rake angle = 10º, width of cut = 0.200 in, chip
thickness before the cut = 0.015, and chip thickness ratio = 0.4. Determine (a) the shear
strength of the work material and (b) the coefficient of friction in the operation.
4. An orthogonal cutting operation is performed using a rake angle of 15º, chip thickness
before the cut = 0.012 in and width of cut = 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) shear angle, (c)
friction angle, (d) coefficient of friction, and (e) shear strain.
5. In an orthogonal cutting operation, to = 0.13 mm, V = 120 m/min, α = 10° and the width of
cut = 6 mm. It is observed that tc = 0.23 mm, Fc = 500 N, and Ft = 200 N. Calculate the
percentage of the total energy that goes into overcoming friction at the tool-chip interface.
[r = 0.565, β = 32o, F = 286N, 32%]
6. Using the Taylor Equation for tool life and letting n = 0.5 and C = 120, calculate the
percentage increase in tool life when the cutting speed is reduced by 50%. [300%]
7. Let n = 0.5 and C = 90 in the Taylor equation for tool wear. What is the percent increase
in tool life if the cutting speed is reduced by (a) 50% and (b) 75%?
8. A lathe tool bit with a rake angle of 20° is cutting a section of pipe with an inner diameter of 6”
and an outer diameter of 6.25”. The cut has a depth of 0.010” and the chip has a thickness of
0.020”. If the lathe is turning at 200 rpm, and the measured cutting forces are Fc = 300 lb, and Ft
= 125lb,
a) What assumption must you make.
b) Find the following values using a graphical or numerical solution: Fs, FN, F, N, τ, φ, μ, Vc, Vf,
Vs.
c) What is the minimum horsepower required for the machine?
9. Calculate the average tool–chip interface temperature for an orthogonal cutting of steel using
cemented carbide tool under the following conditions:
1. Tool rake angle 10°
2. Shear stress of the work material 200 N/mm2
3. Uncut chip thickness 0.1 mm
4. Width of cut 2 mm
5. Chip thickness ratio 0.25 mm
6. Cutting speed 1 m/s
7. Coefficient of friction 0.0674
8. Density of workpiece 6000 kg/m3
9. Specific heat of the work material 500 J/kg K
10. Thermal conductivity of the work material 50 W/m K
11. Tool–chip contact length 0.25 mm [354DegC]
10. The durability of a cutting tool is 40 min at a cutting speed of 140 m/min and100 min at a
cutting speed of 60 m/min. Calculate
1. Taylor constants
2. The tool life for V = 1 m/min
3. The cutting speed for a tool life T = 1 min
4. The tool life for V = 70 m/min
5. The cutting speed for durability of 120 min