Mechanical Engineering Department
MACHINE TOOL TECHNOLOGY - ASSIGNMENT 1
Date of Submission: 15th Feb 2016.
<Problems on Merchant’s Theory>
1. The following data was obtained from an orthogonal cutting test.
Rake Angle = 200, Feed Rate = 0.25mm/rev, Depth of cut = 6mm, cutting speed = 0.6m/s,
chip length before cutting = 29.4mm, chip length after cutting = 12.9mm, FV = 1050N, FH =
630N. Using Merchant’s analysis, calculate;
(a) Magnitude of resultant force (R)
(b) Shear Plane Angle
(c) Friction force and Fiction Angle.
(d) Various Energies consumed. & also draw a neat sketch of Merchants’ Circle.
(e) Calculate the percentage of the total energy that goes into overcoming the friction at
the tool-chip interface.
2. In an orthogonal cutting of a steel component with carbide tool, the following data was
obtained,
Tool Rake Angle = 130, Chip Width = 6mm, t = 0.10mm, r = 0.33, FH = 1290N, FV = 1650N.
Calculate the various components of cutting forces involved also sketch the force diagram
and calculate the shear stress on shear plane.
3. In an Orthogonal cutting test, the following data was found,
Chip thickness ratio = 0.5, chip width = 2.0mm, Cutting force = 900N, Thrust force = 600N,
Rake angle= 100, Cutting speed = 0.6m/s.
Calculate the friction angle at the chip tool interface, shear stress, and energies consumed
in friction and shear.
4. In an Orthogonal cutting test, the following valves were known or obtained from experiment.
Rake angle = 200, Thrust force = 500N, t = 0.14mm, Width of cut = 5mm, Cutting speed =
2m/s, tC = 0.70mm.
If the force in the cutting speed direction is 2 times that of the thrust force, calculate the
shear stress and calculate the various components of cutting forces involved using
Merchant’s Theory.
5. The data in the following table are obtained in orthogonal cutting in AISI 4130 steel using a
HSS Tool and at a cutting speed V = 27.44m/min, depth of cut = 0.8mm, width of cut =
12.065mm. Calculate the various components of cutting forces involved, and describe your
observations in graph concerning variation of forces and energies with increasing rake angle.
Coeff of Cutting Force
Rake Angle Shear Angle Thrust Force (N)
Friction(µ) (N)
25 20.9 1.46 1690N 1000N
35 31.6 1.53 1130N 454N
40 35.7 1.54 1032N 316N
45 41.9 1.83 1032N 303N
6. An orthogonal cutting operation is being carried out under the following conditions.
Chip compression ratio = 3.3, Width of cut = 5mm, V = 2m/s, Rake angle = 100 , FC = 500N, FT
= 200N.
Calculate the percentage of the total energy that is dispatched in the shear plane.
7. For a production turning operation, past records have shown that the tool life varies with
cutting speed as shown.
Cutting Speed (V) m/s Tool Life (T) min
2.08 110
2.54 37
Estimate the tool life for this operation at a speed of 100m/min.
8. The tool life of a HSS tool and carbide tool have same tool life of 60 min at a cutting speed of
75m/min. the exponent of the tool life in Taylor equation (n) is 0.15 for HSS while it is 0.2 for
carbide. Compare the life of the two tools at a speed of 90m/min and 140m/min.
9. In the dry Machining of Al with a 100 rake angle tool, it is found that the shear angle is 25 0.
Determine the new shear angle if the cutting fluid is applied which decreases the friction
coefficient by 15%.
10. List and explain the factors that contribute to poor surface finfish in machining operations.
11. A carbide cutting tool has tool life exponent n = 0.27. It gives a tool life of 60 minutes while
machining a mild steel work piece at a cutting speed of 120 m/min. compute the tool life if it
is to be cut at a 20% higher cutting speed. Also, what is cutting speed if the tool life is to be
doubled?
****************************
