Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 23, Problem 3RQ
What is the thrust force in turning? What is the cutting force? Which is used to calculate the power required?
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Discuss the effects of cutting speed, feed rate, and depth of cut on the tool wear rate during a turning operation.
How does each parameter influence the surface finish of the workpiece?
Provide a detailed explanation based on the principles of metal cutting mechanics.
A flat milling operation will be carried out with a horizontal milling machine, in a piece of 250 mm in length and 50 mm in width, using a felicoidal bur with a diameter of 75 mm, with 10 teeth. If the feed per tooth is 0.2mm, and the cutting speed is 0.75 m / s, how would you determine the speed of metal removal to remove 6 mm from the surface of this piece?
A 78 mm thick plate is to be milled down to a thickness of 60 mm using an 80 mm face milling cutter. Calculate the processing time if the cutting depth is 6 mm, the feed/rev is 1.1 mm and the cutting speed is 15 m/min, and if the over run for a 620 mm long plate is 10 mm.
Chapter 23 Solutions
Manufacturing Engineering & Technology
Ch. 23 - Describe the types of machining operations that...Ch. 23 - What is turning? What kind of chips are produced...Ch. 23 - What is the thrust force in turning? What is the...Ch. 23 - What are the components of a lathe?Ch. 23 - (a) What is a tracer lathe? (b) What is an...Ch. 23 - Describe the operations that can be performed on a...Ch. 23 - Why were power chucks developed?Ch. 23 - Explain why operations such as boring on a lathe...Ch. 23 - Why are turret lathes typically equipped with more...Ch. 23 - Describe the differences between boring a...
Ch. 23 - How is drill life determined?Ch. 23 - What is the difference between a conventional...Ch. 23 - Why are reaming operations performed?Ch. 23 - Explain the functions of the saddle on a lathe.Ch. 23 - Describe the relative advantages of (a)...Ch. 23 - Explain how external threads are cut on a lathe.Ch. 23 - Prob. 17RQCh. 23 - Explain the reasoning behind the various design...Ch. 23 - Note that both the terms tool strength and...Ch. 23 - (a) List and explain the factors that contribute...Ch. 23 - Explain why the sequence of drilling, boring, and...Ch. 23 - Why would machining operations be necessary even...Ch. 23 - A highly oxidized and uneven round bar is being...Ch. 23 - Describe the difficulties that may be encountered...Ch. 23 - (a) Does the force or torque in drilling change as...Ch. 23 - Explain the similarities and differences in the...Ch. 23 - Describe the advantages and applications of having...Ch. 23 - Assume that you are asked to perform a boring...Ch. 23 - Explain the reasons for the major trend that has...Ch. 23 - Describe your observations concerning the contents...Ch. 23 - The footnote to Table 23.12 states that as the...Ch. 23 - In modern manufacturing, which types of metal...Ch. 23 - Sketch the tooling marks you would expect if a...Ch. 23 - What concerns would you have in turning a powder...Ch. 23 - The operational severity for reaming is much lower...Ch. 23 - Review Fig. 23.6, and comment on the factors...Ch. 23 - Explain how gun drills remain centered during...Ch. 23 - Comment on the magnitude of the wedge angle on the...Ch. 23 - If inserts are used in a drill bit (see Fig....Ch. 23 - Refer to Fig. 23.11b, and in addition to the tools...Ch. 23 - Calculate the same quantities as in Example 23.1...Ch. 23 - Estimate the machining time required to rough turn...Ch. 23 - A high-strength cast-iron bar 8 in. in diameter is...Ch. 23 - A 0.30-in.-diameter drill is used on a drill press...Ch. 23 - In Example 23.4, assume that the workpiece...Ch. 23 - For the data in Problem 23.45, calculate the power...Ch. 23 - A 6-in.-diameter aluminum cylinder 10 in. in...Ch. 23 - A lathe is set up to machine a taper on a bar...Ch. 23 - Assuming that the coefficient of friction is 0.25,...Ch. 23 - A 3-in.-diameter, gray cast iron cylindrical part...Ch. 23 - Would you consider the machining processes...Ch. 23 - Would it be difficult to use the machining...Ch. 23 - If a bolt breaks in a hole, it typically is...Ch. 23 - An important trend in machining operations is the...Ch. 23 - Review Fig. 23.8d, and explain if it would be...Ch. 23 - Boring bars can be designed with internal damping...Ch. 23 - A large bolt is to be produced from extruded...Ch. 23 - Make a comprehensive table of the process...
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- Calculate the spindle speed for a Lathe Machine, if the cutting speed for a mild steel material workpiece is 34 m/min and the diameter of the cylindrical workpiece is 46 mm.arrow_forwardPlease give the correct solution A cylinder of 25 mm diameter and 100 mm length is turned with a tool, for which the relation VT0.25 = 55 is applicable. The cutting velocity is 22 m/min. For a tool feed of 0.046 mm/rev, the number of tool regrinds required to produce 425 cylinders is?arrow_forwarda rod is to be manufactured using turning operations and is made of Nickel alloy. The rod is 80 mm in length and 15 mm in diameter. The final required diameter is 10 mm and the spindle rotates at N = 500 rpm while the tool axial speed is 100 mm/ min. Calculate material removal rate, cutting speed, cutting time, the power dissipated, and cutting force.arrow_forward
- Assuming that the coefficient of friction is 0.25, calculate the maximum depth of cut forturning a hard aluminium alloy on a 15-kW lathe (with a mechanical efficieny of 80%) at awidth of cut of 6 mm, rake angle of 0˚, and a cutting speed of 90 m/min, shear strength of 150 MPa.arrow_forwardIn orthogonal turning of a bar 100 mm diameter with a feed of 0.25 mm/rev., depth of cut = 4 mm, cutting velocity = 90 m/min. it is observed that the main cutting force is perpendicular to friction force acting at the chip tool interface and cutting force is 1500 N. find (i) rake angle (ii) normal force.arrow_forwardNote: Read the question carefully and give me right solutions according to the question. In orthogonal cutting of steel tube of 150 mm diameter and 2 mm thick, the cutting force was 130 kg and feed force was 35 kg for chip thickness of 0.3mm. The orthogonal cut was taken at 60 meter per minute with a feed of 0.14 mm/rev. If the back rack angle of the cutting tool was - 8 o (minus 8 degree), then calculate the shear strain and strain energy per unit volume.arrow_forward
- A 200 mm long magnesium alloy bar, 63 mm in diameter is turned on a lathe using a high speed steel cutter travelling at 180 mm/min. The spindle rotates at 450 rpm and lathe is equipped with a 10 kW motor, operating at a mechanical efficiency of 92%. The final diameter of the magnesium alloy bar is 59,5 mm. Indicate with a sketch the recommend size and location of the following tool angles: back rake, side rake, end relief, side relief and side and end cutting edge. Calculate the cutting time for the machining process.Calculate the required cutting force.arrow_forwardA motorised metal guillotine machine is required to cut 45 mm diameter hole in a plate of 20 mm thickness at rate of 35 holes per minute. It requires a torque of 7 Nm for an area of hole in mm2. If the cutting takes 1/10 of a second and the speed of its flywheel varies from 165 rpm to 145 rpm, calculate:arrow_forwardDraw the forces and angles involved in the cutting process and calculate shear angle (0), friction coefficient and tangential force if ,cutting force = 80 kN, resultant of forces =100kN, friction force=75kN, rake angle =20° undeformed chip thickness = 0.65mm and deformed chip thickness = 0.72mmarrow_forward
- Assume that in orthogonal cutting the rake angle is 15o and the coefficient of friction is 0.15. Using Eq. 8.20, determine the percentage increase in chip thickness when the coefficient of friction is doubled.arrow_forwardA student is using a lathe with 80-hp and 80% efficiency to fabricate a copper alloy with Sy = 1200ksi If the width of cut is 0.30 inand the student set a rake angle of 0and a cutting speed of 200fl / min while she assumed a coefficient of friction to be 0.5. What is the maximum depth of cut the student can achieve?arrow_forwardIn face milling, assume that the Diameter of the cutter is 200 mm, the width of the block is 60 mm, and the length of the block is 344 mm, if the depth of cut is 3 mm, = 0.6 mm/min, and N = 100 rpm. The cutter has 12 inserts, and the workpiece material is bronze. Calculate the estimated power required, the cutting force, and the torque.arrow_forward
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