Alexandria University Second Year Production

Faculty of Engineering 1st Semester (2017/2018)

Production Engineering Department Theory of Metal Cutting – PE 232

1. General concepts and Mechanics of Metal Cutting

1. State the major differences between machining and forming
processes.

2. What are conditions that make machining processes obligatory

solutions compared to other manufacturing processes?

3. Show the general classification of the machining processes.

4. State the main limitations of traditional machining methods.

5. What are the advantages offered by nontraditional machining

processes?

6. Give examples for abrasion machining using loose and bonded

abrasives.

7. Explain the following terms and give example for both: erosion
machining, abrasion machining.

8. What are the main variables of a machining process?

9. What are the main factors that affect the selection of a machining
process?

10. For the following machining operations specify which operations are
performed using single point cutting tools and which are performed
using multipoint cutting tools.
• Drilling • Reaming
• Boring • Turning
• Shaping • Sawing
• Planning • Milling

11. Show using neat sketches five different machining operations that can
be performed on a center lathe.

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12. Sketch five different milling operations and explain the application of
each of them.

Mechanics of Metal Cutting

13. In an orthogonal cutting operation, the following data have been
observed:
Shear velocity = 35 m/min Cutting Force = 2000 N.
Cutting velocity = 30 m/min. Shear Force = 1500 N.
Mechanical Efficiency = 0.90. Rake angle = - 10 degrees.
• Find graphically and analytically the following using Merchant
theory:
[Thrust force, Normal force on shear plane, Friction force, Normal
to friction force, shear angle (Graphically only), Friction angle,
shear velocity and chip velocity]
• Then find analytically the following:
[Cutting power, Shear power, Friction power and motor power].
Normal and Shear stresses if the shear plane area = (30 mm2).
• Also find specific cutting energy, specific shear energy, specific
friction energy, where the undeformed chip cross-sectional area
= (5 mm2).

• Calculate the shear angle using (Ernst & Merchant) theory and (Lee
& Shaffer) theory.

14. For orthogonal cutting process:

Shear angle = 35 degrees.
Rake angle = 10 degrees.
Cutting Force = 600 N.
Thrust force = 250 N.
• Calculate the percentage of total energy that goes into overcoming
friction at the tool chip interface.
• Calculate the shear angle using (Ernst & Merchant) theory and (Lee
& Shaffer) theory.

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