Josu Miguel Gavilanes Trivio

Homework Assignment 2
What are the three basic categories of material removal processes? The three basic categories of material removal processes are conventional machining, abrasive processes, and nontraditional processes. What distinguishes machining from other manufacturing processes? The machine operations remove material from the workpiece. What are the two basic categories of cutting tools in machining? Give two examples of machining operations that use each of the tooling types. Single-points tool, an example of the tooling types is the turning. Multiple-cutting-edge, for example milling, and drilling. Explain the difference between roughing and finishing operations in machining The difference is that the roughing operation is for remove a lot quantity of material of the initial works piece as fast as be possible, while the finishing operation is used to complement the works piece and reach de measure final. Why is the orthogonal cutting model useful in the analysis of metal machining? Because allow a simplified model of machining what discount a lot geometrical complexity and describe of the machining process with good precision. Name and briefly describe the four types of chips that occur in metal cutting Discontinuous chip. - When relatively brittle materials are machined at low cutting speeds, the chip often form into separate segments, the chips have an irregular texture to the machined surface. Continuous chip. - When work with ductile materials, and that materials are cut at high speeds and relatively small feeds and depths long continuous are formed. A good surface finish results when this chip type is formed. Continuous chip with Built-Up Edge. When work with ductile materials at low-to-medium cutting speeds, the friction between tool and chip tends to cause portions of the work material to adhere to the rake face of the tool near the cutting edge. This formation is calling BUE.

Serrated chip. This chip is semi continuous. This have a saw-tooth appearance, this is produced by a cyclical chip formation of alternating high shear strain followed by low shear strain.

Describe in words what the Merchant equation tells us The real value of the Merchant equation is that it defines the general relationship between rake angle, tool-chip friction, and shear plane angle. The shear plane angle can be increased by increasing the rake angle or decreasing the friction angle between the tool and the chip. Rake angle can be increased by proper tool design, and friction angle can be using a lubricant cutting fluid. What is a tool-chip thermocouple? The tool-chip thermocouple is the most frequently used measuring technique for measure the cutting temperature. This thermocouple consists of the tool and the chip as the two dissimilar metals forming the thermocouple board.

1. In an orthogonal cutting operation, the tool has a rake angle = 15. The chip thickness before the cut = 0.30 mm, and the cut yields a deformed chip thickness = 0.65 mm. Calculate (a) the shear plane angle, (b) the shear strain for the operation. Now, suppose the rake angle were changed = 0. Assuming that the friction angle remains the same, determine (c) the shear plane angle, (d) the chip thickness, and (e) the shear strain for the operation.

a) ( ( ) )

b)

( )

( With and c)

d) ( ) ( ) ( ) ( ) ( ) ( ) ( )

e)

( (

) )

( ) ( )

2. The shear strength of a certain work material = 50,000 lb/in2. An orthogonal cutting operation is performed using a tool with a rake angle = 20 at the following cutting conditions: cutting speed = 100 ft/min, chip thickness before the cut = 0.015 in, and width of cut = 0.150 in. The resulting chip thickness ratio = 0.50. Determine (a) the shear plane angle; (b) shear force, (c) cutting force and thrust force, (d) friction force, (e) Calculate again (a), (b), (c) and (d) but assume that rake angle changes to -5 and the resulting chip thickness ratio = 0.35. 20

a) ( )

b) ( )

( )

( c)

( ( ( ( ( ( ( d) ( ( ) )

) ) ) )

) ) )

e) If : -5

0.35

( ( ( ( ) ) )

( )

( )

( ( ( ( ( ( ( ( ( ( ( ( (

) ) ) )) )) ) )) )) )

3. Low carbon steel having a tensile strength of 300 MPa and a shear

strength of 220 MPa is cut in a turning operation with a cutting speed of 3.0 m/s. The feed is 0.20 mm/rev, and the depth of cut is 3.0 mm. The rake angle of the tool is 5 in the direction of chip flow. The resulting chip ratio will be determined using any of the data that you obtained in your Lab Session 2. Using the orthogonal model as an approximation of turning determine (a) the shear plane angle, (b) shear force, (c) cutting force and thrust force. For this exercise will use:

a) ( ( ) )

b)

( ) ( c) ) ( )

( ( ( ( ( ( ( ) ) ) ) ) )

4. Derive the equations proposed in class for F, N, Fs and Fn using the force diagram presented below.

( ( ( ( ( (

) ) ) ) ) )

[(

[(

i) )

ii) ( )

1. ( )

2.
1.=2.

( iii) Finally, from 1. Replace F from iii:

iv)

5. A turning operation is carried out on aluminum (100 BHN), and the cutting conditions are as follows: cutting speed = 5.6 m/s, feed = 0.25 mm/rev, and depth of cut = 2.0 mm. The lathe losses around 6% of their power due to the gear train of transmission, also around 12% because of the friction between its moving part. Based on the specific energy values in the table presented in class, determine (a) the cutting power and (b) gross power in the turning operation, in Watts. Solve again this problem with the following changes: cutting speed = 1.3 m/s, feed = 0.75 mm/rev, and depth = 4.0 mm. Note that although the power used in this operation is virtually the same as in the previous problem, the metal removal rate is 40% greater.

From the table the Unit specific for the aluminum is:

a)

b)

With the changes:

a)

This should be multiplied by the factor of correction: 0.8. This value is the correction for the change of to.

b)

6. A lathe performs a turning operation on a workpiece of 6.0 in diameter. The shear strength of the work is 40,000 lb/in 2 and the tensile strength is 60,000 lb/in2. The rake angle of the tool is 6. The machine is set so that cutting speed is 700 ft/min, feed = 0.015 in/rev, and depth = 0.090 in. The chip thickness after the cut is 0.025 in. Determine (a) the horse power required in the operation, (b) unit horsepower for this material under these conditions, and (c) unit horsepower as it would be listed in the table shown in class for a to of 0.010 in. Use the orthogonal cutting model as an approximation of the turning process.

( ) ( a) ( ) ) ( ( ) )

b)

c)

This should be multiplied by the factor of correction: 0.9 (from the table 21.14, page 498, chapter 21). This value is the correction for the change of to.

7. It is desired to estimate the cutting temperature for AISI 4340 steel. You should do some research about this steel to obtain the hardness (HBN), volumetric specific heat and thermal diffusivity. Compute the cutting temperature by means of the Cook equation for a turning operation in which the following conditions are used: cutting speed is 500 ft/min, feed is 0.005 in/rev, and depth of cut is 0.070 in. Assume that ambient temperature = 88F.
Brinell Hardness: 269

8. During a machining operation, a tool-chip thermocouple is used to measure cutting temperature. The following data was collected:

Cutting speed Temperature (C) (m/min) 160 504 190 595 210 660 Determine an equation for cutting temperature as a function of the cutting speed in the following form: ( ) ( ) ( ) Whit the minimum measure: ) ( ) ( ( ) ( ) ( ) ) ( ) ( ) ( )

Whit the maximum measure: 1)=2) And

) )

( (

) )

( ) ( (

( )

) ( ))

% programa graficador clc k=input('ingrese k: '); m=input('ingrese m: '); v=[0:15:500]; T=@(v) k.*(v.^m); plot(v, k.*(v.^m),'r'); title('T vs v ') xlabel('v(mm/s)') ylabel('T (C)')