Homework 5 ( Due Fri.
Nov 19th)
1. What are the advantage and the disadvantage of traditional metal machining process?
2. What are the fundamental mechanisms of four type of chip formation in metal
machining?
3. Based on the above Merchant’s circular force in the 2D cutting model,
1) Express the forces: Fs, Fn, Fc, Ft, F, N as functions of R and angles (
α
,
β
,
φ
).
2) Define the ratios of Fc/Fs, Ft/Fs, and F/Fs as functions of angles (
α
,
β
,
φ
).
4.
The cutting conditions in a turning operation are: v = 2 m/s, f = 3.0 mm, and d =
0.25mm. The tool rake angle = 10 which produces a deformed chip thickness t c
= 0.54 mm. Determine: (a) shear plane angle, (b) shear strain, and (c) material
removal rate. Use the orthogonal cutting model as an approximation of the turning
process.
5.
The cutting force and thrust force in an orthogonal cutting operation are: F
c
=
1470 N and F
t
= 1589 N. The rake angle = 5, the width of the cut = 5.0 mm, the
depth of cut = 0.6mm, and the chip thickness ratio = 0.38.
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 Spring '08
 Chunghorng,R
 Force, Friction, Shear Stress, Tensile strength, Shear strength, Tensile stress

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