ERRATA, August 3, 1999.
J. Tlusty, Manufacturing Processes and Equipment
The following corrections are to be entered in the Problem sections of several chapters.
The correct versions of the passages to be changed are put in brackets and underlined [ ].
P.6.3
.
Flow through round channel.
In a way analogous to Figs 6.11, 6.12, 6.13 write a Matlab computer program and
produce plots of velocity distribution and of strain rate distribution for a) Newtonian fluid with
viscosity 100 Pas at strain rate of 3,000/sec and b) NonNewtonian fluid with viscosity
characterized by parameters
K
=12,198 and
n
=0.4, see [ Eqs. (6.39), (6.40) and (6.47) ] for flow
in a round channel with
R
=2mm, length
L
=50mm and pressure drop
3
= 30 MPa.
Plot
u
and
gammadot
versus +
r.
P.7.4
A milling operation is being performed similar to the one shown in Fig. 7.30.
The
feed/tooth
c
= 0.2 mm, [
±
= 30
o
]
and the start and end angles are
s
φ
= 30
°
, and
e
φ
= 160
°
.
a)
Determine the [mean ] chip thickness [
h
m
]
.
b)
Indicate in a graph of
h
vs.
φ
, the variation of
h
on one tooth over two
revolutions of the cutter.
P.7.5
Graphically express the variation of torque in an end mill.
In a graph of torque vs. angle
φ
, plot the torque of three subsequent teeth and find the maximum total torque on the end
mill.
The cutter has 8 straight teeth and a diameter of 100 mm.
The workpiece engages
the cutter from
s
φ
= 45
°
to
e
φ
= 150
°
, and the axial depth of cut
a
a
= 20 mm.[ Chip load is
c
= 0.2 mm.] Assume a specific force of
K
s
= 2000 N/mm
2
.
P.7.6
A 4 fluted end mill of 40 mm diameter is performing an upmilling operation as shown in
Fig. 7.29a), into a workpiece of 1035 steel.
The axial depth of cut
a
a
= 20 mm and the
radial depth of cut
a
r
= 25 mm.
The cutting velocity
v
= 45 m/min, with a feed [per] tooth
of [
c
]
= 0.25 mm.
Determine:
a)
Spindle speed
n
(rev/min).
b)
Feed rate
f
(mm/min).
c)
Metal removal rate
Q
(cm
3
/min).
d)
[ Mean ] chip thickness [
h
m
] (mm).
e)
Specific power
K
s
[W/(cm
3
/ min)], from Table 7.1.
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 Spring '08
 Staff
 Shear Stress, Milling cutter, Cutting fluid, George Tlusty

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