UNIVERSITY OF AGRICULTURE, MAKURDI

COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
FIRST SEMESTER 2013/2014 EXAMINATION
COURSE CODE : EME 615/715
COURSE TITLE : Advanced Machine Tools
TIME ALLOWED : 3 Hours
INSTRUCTIONS : Answer Question one And Any Other Three Questions

1. (a) Using Merchant analysis of forces for orthogonal machining of metals and stating
necessary assumptions made, derive expressions for:
(i) All the forces acting on the tool-chip interface
(ii) The velocity relationships
(iii) The coefficient of friction
(b) In an orthogonal cutting test on an alloy of aluminium, the following data were
obtained from experimental data:
𝛼 = 200 , 𝑡 = 0.13𝑚𝑚, 𝑏 = 4𝑚𝑚, 𝜏 = 2.4 × 108 𝑁𝑚−2 , 𝜇 = 0.77, 𝑣 = 0.5𝑚𝑠 −1 ,
𝐿𝑐 + 𝐿 = 153.5𝑚𝑚. If all the symbols have their usual meanings and the ratio of
𝐿𝑐 𝑡𝑜 𝐿 is 1:43 determine:
i) The cutting forces and power consumption required in this cut,
ii) The force and power required to shear the material
iii) The chip and shear velocity.
(c) If the relationship between 𝜙, 𝛽 𝑎𝑛𝑑 𝛼 is given by 𝜙 = 𝐾1 + 𝐾2 (𝛼 − 𝛽) , determine
the forces and power required to take the cut stated above when 𝛼 is changed to 100 ,
𝜇 = 0.7 and 𝐾1 = 500 .

2. A gearbox is required to provide nine speeds based upon the geometric ratio,
r=1.26, maximum speed of 2800rpm at input shaft. There are three shafts and three
changes required between input and intermediate shafts and three changes between
intermediate shafts. Calculate:
i) The gear ratios between the shafts using a speed diagram.
ii) The number of teeth in each gear
iii) The actual revolutions per minute of the nine output speeds.

3. (a) Name and discuss the different sources of heat generation in metal cutting.
(b) Discuss the tool wear mechanism
(c) Show that for orthogonal machining with zero degree rake angle tool, the rate of heat
generation in the shear plane can be expressed as:

𝐹𝑃 𝑉(1 − 𝜇𝑟𝑐 )
𝑄𝑠 =
𝐽
Where: 𝐹𝑃 = 𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒
𝑉 = 𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑
𝜇 = 𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛
𝑟𝑐 = 𝐶ℎ𝑖𝑝 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑎𝑡𝑖𝑜
𝐽 = 𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑜𝑓 ℎ𝑒𝑎𝑡
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4. (a) Explain the term, equivalent cutting speed with reference to tool life testing.
(b) Discuss in details, ultrasonic and electrochemical machining processes.
(c) State and explain five (5) abrasive processes in common use.
(d) Use sketches to explain the mechanism of chip formation process in metal cutting.

5. (a) Differentiate between flank wear and crater wear.

(b) With the aid of sketches, differentiate between single and multiple point cutting tools.
(c) What are the effects of cutting fluid in metal cutting?
(d) What do you understand by the term tool life? Explain the factors affecting tool life