THIAGARAJAR COLLEGE OF ENGINEERING, MADURAI-625 015

(An ISO 9001:2008 Certified Govt. Aided Autonomous Institution affiliated to Anna University)
DEPARTMENT OF MECHANICAL ENGINEERING
Course: 14ME430 – Machining Processes

FORMULA
Taylor’s Tool Life Equation V – Cutting Speed (m/min)
Do – Original diameter of the work (m)
𝑉 . 𝑇𝑛 = 𝐶
N – Spindle Speed (revolutions per min)
𝜋 𝐷𝑜 𝑁 T – Tool Life (min)
𝑉= n – Depends on tool material, cutting conditions (No unit)
60
C – Depends on work piece material (No unit)

PROBLEMS:
1. A tool cutting at 24 m/min gave a life of 1 hour between regrinds when operating on roughening cuts with mild steel.
What will be the probable life when engaged on light finishing cuts? Take n = 1/6 for roughening and n = 1/7.5 for
finishing cuts.
2. The relationship for HSS tools is V.T1/8 = C1 and for Tungsten carbide tool V.T1/5 = C2. Assuming that at a speed of 25
m/min the tool life was 180 min in each case, compare the cutting lives at 32 m/min.
3. A carbide tool with mild steel work piece was found to give a life of 2 hours while cutting at 50 m/min. If Taylor’s
exponent, n = 0.27, Determine (i) tool life of the same tool used at a speed of 25% higher than the previous one. (ii)
Cutting speed if the tool is required to have a tool life of 3 hours.
4. During straight turning of a 25 mm diameter bar at 300 rpm with a HSS tool, a tool life of 10 min was obtained. When
the same bar was turned at 250 rpm, the tool life increased to 52.5 min. What will be the tool life at a speed of 275
rpm? Ans: 22 min
5. A mild steel is being machined by two different tool A and B under identical machining conditions. The tool life
equation for cutting tool A is V.T0.31 = 34.3 and for cutting tool B is V.T0.43 = 89.5 where V and T are in m/s and s
respectively. Determine the cutting speed above which tool B will give a better tool life. Ans: 4.71 m/s
6. Let n = 0.4 and C = 400 in Taylor’s tool life equation. What is the percent increase in tool life if the cutting speed is
reduced by (a) 20% and (b) 40%?
7. The tool life of a HSS tool and carbide tool have the same tool life of 60 minutes when the cutting speed is 75 m/min.
The exponent of tool life in Taylor’s equation (n) is 0.15 for HSS and 0.2 for carbide tool, Compare the life two tools
when the cutting speed is 90m/min.
8. The following data relate to orthogonal cutting process: Obtained chip thickness = 0.85mm, breadth of cut = 2.5 mm,
depth of cut = 0.3mm, tool rake angle = 10o, tangential force = 2000 N, Feed force = 200 N. Determine (i) the
coefficient of friction between tool and chip, (ii) Shear stress of the material. Ans: µ = 0.74, τ = 318.24 N/mm2
9. A mild steel part is orthogonally cut at 200m/min with a cutting tool having 12 o rake angle. The width of the cut is 1.8
mm while the uncut chip thickness is 0.2 mm. The ultimate shear stress of the material is 390 N/mm2 and the
coefficient of friction between tool and chip is 0.55. Calculate (i) Shear angle and (ii) cutting and thrust components.
Ans: ϕ = 36.6o, Fc = 378.2 N, Ft = 114.2 N.
10. The orthogonal cutting of steel is done with 10o rake angle tool, depth of cut 2 mm, feed rate of 0.2 mm/rev at a
cutting speed of 200 m/min. The chip thickness ratio is 0.31. The vertical cutting force is 1200 N and the horizontal
cutting force is 650 N. Calculate the percentage of power dissipated for shear and friction.
Ans: PS = 49745.14 N m/min, PF = 80254.77 N m/min, Total Power = 130000 N m/min, % of power in shear – 38.27%,
% of power in friction – 61.73%

C Selva Kumar
APME, TCE