TURNING AND RELATED OPERATIONS

22.1 A cylindrical workpiece with a diameter of 200 mm and a length of 700 mm is going to be turned on
a mechanical lathe. The cutting conditions are as follows: cutting speed of 2.30 m/s, the
feed rate of 0.32 mm/rev and the cutting depth of 1.80 mm. Determine: a) the cutting time, and
b) the metal removal rate

22.2 In a turning operation, the operator has determined that only one must be completed.
step in the cylindrical workpiece of 5.0 min. The piece is 400 mm long and 150 mm
diameter. Using a feed of 0.30 mm/rev and a depth of cut of 4.0 mm, what
What cutting speed should be used to meet this machining time?

22.3 A facing operation is carried out on a mechanical lathe. The diameter of the workpiece
The cylindrical part is 6 inches in diameter and the length is 15 inches. The small component is set to rotate at a cutting speed.
at 180 rev/min. The depth of cut is 0.110 in and the feed is 0.008 in/rev. Assume that
the cutting tool moves from the outer diameter of the workpiece to
exactly the center at a constant speed. Determine: a) the speed of the tool at
measurement that moves from the outer diameter towards the center, and b) the cutting time.

22.4 A threaded surface is going to be turned on an automatic lathe. The workpiece has 750
mm long with minimum and maximum diameters of 100 mm and 200 mm at the opposite ends.
The automatic controls in the surroundings allow the speed on the surface to be maintained at
a constant value of 200 m/min, adjusting the rotational speed according to the diameter of the
workpiece. The feed rate is 0.25 mm/rev and the depth of cut is 3.0 mm. The shape
The rigid piece has already been formed and this operation will be the final cut. Determine: a)
time required to turn the thread, and b) the rotation speeds at the beginning and at the end
of the cut.
22.5 In the turning work of the thread of the previous problem, suppose that the automatic lathe
with surface speed control not available and that a lathe should be used
conventional. Determine the rotational speed that will be required to perform the work in
exactly the same time that was specified in the answer to item a) of that problem.

22.6 A work bar with a diameter of 4.5 in and a length of 52 in is threaded in a lathe.
mechanical and supported at the opposite end using a live center. A piece of 46.0 in of the
Total length will be converted to a diameter of 4.25 in in a pass at a speed of 450 ft/min.
the material removal speed must be 6.75 in3Determine: a) the depth of
required cut, b) the required advance, and c) the cutting time

22.7 A work bar with a diameter of 4.00 in and a length of 25 in will be turned to
a diameter of 3.50 in using two passes on a mechanical lathe using the conditions of
cutting conditions: cutting speed of 300 ft/min, feed rate of 0.015 in/rev, and depth of cut
from 0.125 in. The bar will be held in a chuck and will be supported at the opposite end in a
living center. With this working clamping configuration, one end must be turned to diameter;
Then the bar must be inverted to turn the other end. Using a crane that is
find available on the lathe, the time required to load and unload the bar is
5.0 min and the time to invert the bar is 3.0 min. For each cut on the lathe, it must be added
a clearance to the length of the cut for approach and overflight. The total clearance (approach
more about travel) is 0.50 in. Determine the total cycle time to complete this operation of
tornadoed.
22.8 The end of a large tubular piece is faced on a vertical drill. The piece has a
external diameter of 38.0 in and an internal diameter of 24 in. If the facing operation is carried out at
a rotation speed of 40.0 rev/min, the feed is 0.015 in/rev and the depth of cut
It is 0.180 in, determine a) cutting time to complete the facing operation and the
cutting and metal removal speeds at the beginning and end of cutting.

22.9 Repeat problem 22.8, except that the controls of the machine tool operate at
a constant cutting speed, continuously adjusting the rotation speed to
position the tool with respect to the axis of rotation. The rotational speed at the beginning of cutting
it is 40 rpm, and from this point it continuously increases to maintain a
constant cutting speed.
DRILL

On October 22, a drilling operation is carried out with a 12.7 mm diameter spiral drill.
a piece of steel work. The hole is a blind hole that has a depth of 60 mm
and the tip angle is 118°. The cutting speed is 25 m/min and the feed is 0.30
mm/rev. Determine: a) the cutting time to complete the drilling operation, and b) the
removal speed of metal during operation after the drill bit has
reached the corresponding diameter.

A double spindle drill simultaneously drills a ½ inch hole and another ¾ inch hole.
through a workpiece 1.0 in wide. Both holes are made with the spiral drill with
angles at the tip of 118°. The cutting speed for the material is 230 ft/min. The speed
The rotation of each spindle can be configured individually. The feed rate of
Both holes must be set to the same value, as the two spindles lower at the same time.
speed. The feed speed is configured in such a way that the total removal speed of
metal does not exceed 1.50 in3/min. Determine a) the maximum feed rate (in/rev) that can
to be used, b) the individual advances (in/rev) that result in each hole, and c) the required time
to drill the holes.
22.12 A CNC drilling press executes a series of complete holes in a thick plate.
1.75 in aluminum, which is a component of a heat exchanger. Each hole is ¾ of
in diameter. There are 100 holes in total arranged in a 10 x 10 matrix, and the
the distance between the centers of adjacent holes (along the frame) is 1.5 in.
The cutting speed is 300 ft/min, the penetration feed (z direction) is 0.015 in/rev and the
the feed rate between holes (x-y plane) is 15.0 ft/min Assume that the x-y movements
they are made at a distance of 0.05 in above the work surface and this distance must be included
in the penetration advance speed for each hole. Likewise, the speed at which the
The drill retracts from each hole at twice the feed rate of penetration. The drill bit
an angle of 100°. Determine the time required from the beginning of the first hole
until the completion of the last; assume that the most efficient drilling sequence will be used to
complete the work.

A drilling operation is used to make a hole 9/64 in diameter at a certain

depth. The execution of the operation takes 4.5 minutes of drilling, using a fluid of
high-pressure refrigerant at the tip of the drill. The cutting conditions include a speed
from a spindle speed of 4000 rev/min at a feed rate of 0.0017 in/rev. To improve the surface finish
In the hole, it has been decided to increase the speed by 20% and decrease the advance by 25%.
How long will it take to carry out the operation under the new cutting conditions?

PROBLEMS
25.1 In a certain surface grinding operation, the diameter of the wheel = 150 mm and the
0.07 mm
m/s and the transverse advance = 5 mm. The number of active grains per area of the surface of the
wheel = 0.75 grains/mm2the average length per chip
removal of metal and c) the number of chips formed per unit of time for the portion of the
operation when the wheel is working.

25.2 The following conditions and configurations are used in a certain grinding operation.
surface; wheel diameter = 6.0 in, wheel speed = 4750 ft/min, work speed
= 50 ft/min and the cross feed = 0.20 in. The number of active grains per square inch of
la superficie de la rueda = 500. Determine a) longitud promedio por viruta, b) la velocidad de
removal of metal, and c) the number of chips formed per unit of time for the portion of the
operation when the wheel is working.

25.3 Cylindrical grinding operation is used to finish the interior of a hole from a
initial diameter of 250.00 mm to a final diameter of 252.5 mm. The orifice has a length
of 125 mm. A grinding wheel with an initial diameter of 150.00 mm and a width is used.
of 20.0 mm. After the operation, the diameter of the grinding wheel has been reduced to 149.75
mm. Determine the grinding ratio in this operation.

25.4 In a surface grinding operation carried out on a flat piece of steel at

hardened carbon, the grinding wheel has a diameter = 200 mm and a width of 25 mm.
wheel rotates at 2400 rpm, with a cutting depth (normal feed) = 0.05 mm/step and a
transversal advance = 3.50 mm. The oscillating speed of the work is 6 m/min and the operation is
ejecuta en seco. Determine a) la longitud de contacto entre la rueda y el trabajo y b) la velocidad
of the volume of metal removed, c) if there are 64 active grains/cm2on the surface of the wheel, I estimate
the number of chips formed per unit of time, d) What is the average volume per
shavings?, e) if the tangential shear force on the work = 30N, calculate the specific energy in
this operation.

An 8-inch diameter and 1.0-inch wide grinding wheel is used for grinding a certain
surface in a work on a flat piece of heat-treated 4340 steel. The wheel rotates
to achieve 5000 ft/min, with a cutting depth (normal feed) = 0.002 in per case and a
transversal advance = 0.15 in. The work oscillating speed is = 20 ft/min and the operation is
What is the contact length between the wheel and the work?
speed of the volume of material removed?, c) if there are 300 active grains/in2 on the surface of
the wheel, this is the number of chips produced per unit of time, d) What is the volume
average per chip?, e) If the tangential cutting force on the workpiece = 10 lbs, what is
the specific energy calculated for this work?

25.6 A grinding operation is performed on a workpiece made of steel.

6150 (with an approximate hardness of 200 BHN). The designation of the grinding wheel is C-24-D-5-V.
7 inches in diameter, 1.00 inches in width and operates at a rotational speed of 3000
rev/mi. The depth (normal advance) = 0.002 in per pass and the transverse advance = 0.5 in. The
workpiece speed = 20 ft/min. This operation has been a source of problems almost
from the beginning. The surface finish is not as good as the 16µ-in specified in the
label of the part and there are signs of metallurgical damage on the surface. In addition, the wheel seems to
saturate as soon as the operation starts. In summary, almost always things have turned out
bad from the beginning. a) Determine the metal removal speed when the wheel is
working, b) if the number of active grains per square inch = 200, determine the length
average of the chips and the number of them formed per unit of time, c) What changes
Would you recommend the grinding wheel to help solve the problems that have arisen?
found?. Explain the reasons for each recommendation.

(C)

Changes in the wheel to help resolve the mentioned issues: (1) use Al2O3 oxide
abrasive instead of silicon carbide; (2) use a grain size smaller than 24; (3)
use a shellac link instead of a vitrified link; and (4) use a structure
more open than number 5 to reduce the wheel blockage.

25.7 In a certain centerless grinding operation, the grinding wheel has a diameter of 200 mm.
and the regulating wheel has a diameter of 125 mm. The grinding wheel rotates at 3000 rpm and the
The regulating wheel does it at 200 rev/min. The angle of inclination of the regulating wheel = 2.5°
Determine the feed rate of the cylindrical workpieces that have a diameter of 25.0 mm.
diameter and 175 mm long.

25.8 A centerless grinding operation uses a regulating wheel with a diameter of 150 mm.
With a rotation speed of 500 rev/min, at what angle of inclination should the wheel be placed?
regulator if you want to feed a workpiece that is 3.5 m long and 18 mm in diameter to
through the operation in exactly 45 seconds?
25.9 In a certain centerless grinding operation, the grinding wheel is 8.5 inches in diameter and the
regulator wheel 5.0 in diameter. The grinding wheel rotates at 3500 rpm and the wheel
Regulating wheel rotates at 150 rev/min. The inclination angle of the regulating wheel = 3°. Determine the
advancing speed of cylindrical pieces that have a diameter of 1.25 in and a length of 8.0 in.

25.10 It is desired to compare the cycle times required for grinding a piece of
particular work using traditional surface grinding and high material removal grinding.
workpiece 300 mm long, 30 mm wide, and 75 mm thick. To make a
good comparison, the grinding wheel of both cases has a diameter of 250 mm, 35 mm of
width and rotates at 1500 rpm. It is desired to remove 25 mm of material from the surface. When using the
traditional grinding, the normal feed is executed at 0.025 mm and the wheel passes through twice
(back and forth) across the work surface at each step before readjusting the
normal advance. There is no lateral advance because the width of the wheel is greater than the width of the
work. Each step is taken at a work speed of 12 m/min, but the wheel exceeds the
piece on both sides. With acceleration and deceleration, the wheel works 50% of the time on each.
step. When high removal grinding is used, the depth increases by 1000 and the
advance forward decreases by 1000. How much time is required to complete the
grinding operation? A) With traditional grinding, and b) with high removal grinding.

Note: The crushing of the feed by dragging takes approximately 1/3 of the time.
of conventional superficial rectification for the situation defined here.