# HW5 - depth of cut = 0.6mm and the chip thickness ratio =...

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Homework 5 (Due Wed. April 21) 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

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Unformatted text preview: depth of cut = 0.6mm, and the chip thickness ratio = 0.38. Determine (a) the shear strength of the work material and (b) the coefficient of friction in the operation. 6. An orthogonal cutting operation is performed using a rake angle of 15, t o = 0.012 in and w = 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) the shear angle, (c) the friction angle, (d) the coefficient of friction, and (e) the shear strain. 7. The orthogonal cutting operation described in previous Problem involves a work material whose shear strength is 40,000 lb/in2, cutting speed is 400ft/min, Based on your answers to the previous problem, compute: (a) the shear force, (b) the cutting force, (c) the thrust force, and (d) the friction force, (e) cutting power....
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