Problems

21.1 In an orthogonal cutting operation, the tool has a rake angle = 15°. The chip thickness before
the cut = 0.30 mm and the cut yields a deformed chip thickness = 0.65 mm. Calculate (a)
the shear plane angle and (b) the shear strain for the operation.
Solution: (a) r = to/tc = 0.30/0.65 = 0.4615
φ = tan-1(0.4615 cos 15/(1 - 0.4615 sin 15)) = tan-1(0.5062) = 26.85°
(b) Shear strain γ = cot 26.85 + tan (26.85 - 15) = 1.975 + 0.210 = 2.185
21.2 In Problem 21.1, suppose the rake angle were changed to α = 0°. Assuming that the friction
angle remains the same, determine (a) the shear plane angle, (b) the chip thickness, and
(c) the shear strain for the operation.
Solution: From Problem 21.1, α = 15° and φ = 26.85°. Using the Merchant Equation, Eq.
(21.16):
φ = 45 + α/2 - β/2; rearranging, β = 2(45) + α - 2φ
β = 2(45) + α - 2(φ) = 90 + 15 – 2(26.85) = 51.3°
Now, with α = 0 and β remaining the same at 51.3°, φ = 45 + 0/2 – 51.3/2 = 19.35°
(b) Chip thickness at α = 0: tc = to/tan φ = 0.30/tan 19.35 = 0.854 mm
(c) Shear strain γ = cot 19.35 + tan (19.35 - 0) = 2.848 + 0.351 = 3.199
21.5 The cutting force and thrust force in an orthogonal cutting operation are 1470 N and 1589 N,
respectively. The rake angle = 5°, the width of the cut = 5.0 mm, the chip thickness
before the cut = 0.6, and the chip thickness ratio = 0.38. Determine (a) the shear strength
of the work material and (b) the coefficient of friction in the operation.
Solution: (a) φ = tan-1(0.38 cos 5/(1 - 0.38 sin 5)) = tan-1(0.3916) = 21.38°
Fs = 1470 cos 21.38 – 1589 sin 21.38 = 789.3 N
As = (0.6)(5.0)/sin 21.38 = 3.0/.3646 = 8.23 mm2
S = 789.3/8.23 = 95.9 N/mm2 = 95.9 MPa
(b) φ = 45 + α/2 - β/2; rearranging, β = 2(45) + α - 2φ
β = 2(45) + α - 2(φ) = 90 + 5 – 2(21.38) = 52.24°
μ = tan 52.24 = 1.291
21.9 In an orthogonal cutting operation, the rake angle = -5°, chip thickness before the cut = 0.2
mm and width of cut = 4.0 mm. The chip ratio = 0.4. Determine (a) the chip thickness
after the cut, (b) shear angle, (c) friction angle, (d) coefficient of friction, and (e) shear
strain.
Solution: (a) r = to/tc, tc = to/r = 0.2/.4 = 0.5 mm
(b) φ = tan-1(0.4 cos(–5)/(1 - 0.4 sin(–5))) = tan-1(0.3851) = 21.1°
(c) β = 2(45) + α - 2(φ) = 90 + (-5) - 2(21.8) = 42.9°
(d) μ = tan 42.9 = 0.93
(e) γ = cot 31.8 + tan(31.8 - 15) = 2.597 + 0.489 = 3.09
21.12 A carbon steel bar 7.64 inch in diameter has a tensile strength of 65,000 lb/in2 and a shear
strength of 45,000 lb/in2. The diameter is reduced using a turning operation at a cutting
speed of 400 ft/min. The feed is 0.011 in/rev and the depth of cut is 0.120 in. The rake
angle on the tool in the direction of chip flow is 13°. The cutting conditions result in a
chip ratio of 0.52. Using the orthogonal model as an approximation of turning, determine

This study source was downloaded by 100000813136873 from CourseHero.com on 06-12-2022 20:38:51 GMT -05:00

https://www.coursehero.com/file/5677024/hmwk-3-Problem-solutions/
 (a) the shear plane angle, (b) shear force, (c) cutting force and feed force, and (d)
coefficient of friction between the tool and chip.
Solution: (a) φ = tan-1(0.52 cos 13/(1 - 0.52 sin 13)) = tan-1(0.5738) = 29.8°
(b) As = tow/sin φ = (0.011)(0.12)/sin 29.8 = 0.00265 in2.
Fs = AsS = 0.00587(40,000) = 119.4 lb
(c) β = 2(45) + α - 2(φ) = 90 + 10 - 2(29.8) = 43.3°
Fc = Fscos (β – α)/cos (φ + β – α)
Fc = 264.1 cos (43.3 - 13)/cos (29.8 + 43.3 - 13) = 207 lb
Ft = Fssin (β – α)/cos (φ + β – α)
Ft = 264.1 sin (43.3 - 13)/cos (29.8 + 43.3 - 13) = 121 lb
(d) μ = tan β = tan 43.3 = 0.942

21.18 In a turning operation on stainless steel with hardness = 200 HB, the cutting speed = 200
m/min, feed = 0.25 mm/rev, and depth of cut = 7.5 mm. How much power will the lathe
draw in performing this operation if its mechanical efficiency = 90%. Use Table 21.3 to
obtain the appropriate specific energy value.
Solution: From Table 21.3, U = 2.8 N-m/mm3 = 2.8 J/mm3
RMR = vfd = (200 m/min)(103 mm/m)(0.25 mm)(7.5 mm) = 375,000 mm3/min = 6250
mm3/s
Pc = (6250 mm3/s)(2.8 J/mm3) = 17,500 J/s = 17,500 W = 17.5 kW
Accounting for mechanical efficiency, Pg = 17.5/0.90 = 19.44 kW
21.19 In previous Problem 21.18, compute the lathe power requirements if feed = 0.50 mm/rev.
Solution: This is the same basic problem as the previous, except that a correction must be
made for the “size effect.” Using Figure 21.14, for f = 0.50 mm, correction factor = 0.85.
From Table 21.3, U = 2.8 J/mm3. With the correction factor, U = 2.8(0.85) = 2.38 J/mm3.
RMR = vfd = (200 m/min)(103 mm/m)(0.50 mm)(7.5 mm) = 750,000 mm3/min = 12,500
mm3/s
Pc = (12,500 mm3/s)(2.38 J/mm3) = 29,750 J/s = 29,750 W = 29.75 kW
Accounting for mechanical efficiency, Pg = 29.75/0.90 = 33.06 kW

21.22 A turning operation is to be performed on a 20 hp lathe that has an 87% efficiency rating.
The roughing cut is made on alloy steel whose hardness is in the range 325 to 335 HB.
The cutting speed is 375 ft/min. The feed is 0.030 in/rev, and the depth of cut is 0.150 in.
Based on these values, can the job be performed on the 20 hp lathe? Use Table 21.3 to
obtain the appropriate unit horsepower value.
Solution: From Table 21.3, HPu = 1.3 hp/(in3/min)
Since the uncut chip thickness (0.030 in) is different from the tabular value of 0.010, a
correction factor must be applied. From Figure 21.14, the correction factor is 0.7.
Therefore, the corrected HPu = 0.7*1.3 = 0.91 hp/(in3/min)
RMR = vfd = 375 ft/min(12 in/ft)(0.03 in)(0.150 in) = 20.25 in3/min
HPc = (20.25 in3/min)(0.91 hp/(in3/min)) = 18.43 hp required.
At efficiency E = 87%, available horsepower = 0.87(20) = 17.4 hp
Since required horsepower exceeds available horsepower, the job cannot be
accomplished on the 20 hp lathe, at least not at the specified cutting speed of 375 ft/min.
21.27 In a turning operation is carried out on aluminum (100 BHN), the cutting conditions are as
follows: cutting speed = 5.6 m/s, feed = 0.25 mm/rev, and depth of cut = 2.0 mm. The

This study source was downloaded by 100000813136873 from CourseHero.com on 06-12-2022 20:38:51 GMT -05:00

https://www.coursehero.com/file/5677024/hmwk-3-Problem-solutions/
 lathe has a mechanical efficiency = 0.85. Based on the specific energy values in Table
21.3, determine (a) the cutting power and (b) gross power in the turning operation, in
Watts.
Solution: (a) From Table 21.3, U = 0.7 N-m/mm3 for aluminum.
RMR = vfd = 5.6(103)(.25)(2.0) = 2.8(103) mm3/s.
Pc = U RMR = 0.7(2.8)(103) = 1.96(103) n-m/s = 1960 W
(b) Gross power Pg = 1960/0.85 = 2306 W
21.30 A lathe performs a turning operation on a workpiece of 6.0 in diameter. The shear strength
of the work is 40,000 lb/in2 and the tensile strength is 60,000 lb/in2. The rake angle of the
tool is 6°. The machine is set so that cutting speed is 700 ft/min, feed = 0.015 in/rev, and
depth = 0.090 in. The chip thickness after the cut is 0.025 in. Determine (a) the
horsepower required in the operation, (b) unit horsepower for this material under these
conditions, and (c) unit horsepower as it would be listed in Table 21.3 for a to of 0.010 in.
Use the orthogonal cutting model as an approximation of the turning process.
Solution: (a) Must find Fc and v to determine HP.
r = 0.015/0.025 = 0.6
φ = tan-1(0.6 cos 6/(1 - 0.6 sin 6)) = tan-1 (0.6366) = 32.5°
β = 2(45) + α - 2(φ) = 90 + 6 -2(32.5) = 31.0°
As = tow/sin φ = (0.015)(0.09)/sin 32.5 = 0.00251 in2
Fs = SAs = 40,000(0.00251) = 101 lb.
Fc = Fs cos (β – α)/cos (φ + β – α)
Fc = 101 cos(31 - 6)/cos(32.5 + 31.0 – 6) = 170 lb.
HPc = Fcv/33,000 = 170(700)/33,000 = 3.61 hp.
(b) RMR = 700 x 12(0.0075)(0.075) = 11.3 in3/min
HPu = HPc /RMR = 3.61/11.3 = 0.319 hp/(in3/min)
(c) Correction factor = 0.85 from Fig. 21.14 to account for the fact that f = 0.015 in/rev
instead of 0.010 in/rev. Taking this correction factor into account, HPu = 0.375/0.85 =
0.441 hp/(in3/min) as it would appear in Table 21.3 for a feed (to) = 0.010 in/rev.

21.31 Orthogonal cutting is performed on a metal whose mass specific heat = 1.0 J/g-C, density =
2.9 g/cm3, and thermal diffusivity = 0.8 cm2/s. The following cutting conditions are used:
cutting speed is 4.5 m/s, uncut chip thickness is 0.25 mm, and width of cut is 2.2 mm.
The cutting force is measured at 1170 N. Using Cook's equation, determine the cutting
temperature if the ambient temperature = 22°C.
Solution: ρC = (2.9 g/cm3)(1.0 J/g-°C) = 2.90 J/cm3-°C = (2.90x10-3) J/mm3-°C
K = 0.8 cm2/s = 80 mm2/s
U = Fcv/RMR = 1175 N x 4.5 m/s/(4500 mm/s x 0.25 mm x 2.2 mm) = 2.135 N-m/mm3
T = 0.4U/(ρC) x (vto/K)0.333
T = 22 + (0.4 x 2.135 N-m/mm3/(2.90x10-3) J/mm3-C) [4500 mm/s x 0.25 mm/80
mm2/s]0.333
T = 22 + (0.2945 x 103 C)(14.06).333 = 22 + 294.5(2.41) = 22° + 710° = 732°C
21.34 It is desired to estimate the cutting temperature for a certain alloy steel whose hardness =
240 Brinell. Use the appropriate value of specific energy from Table 21.3 and compute
the cutting temperature by means of the Cook equation for a turning operation in which
the following cutting conditions are used: cutting speed is 500 ft/min, feed is 0.005
in/rev, and depth of cut is 0.070 in. The work material has a volumetric specific heat of

This study source was downloaded by 100000813136873 from CourseHero.com on 06-12-2022 20:38:51 GMT -05:00

https://www.coursehero.com/file/5677024/hmwk-3-Problem-solutions/
 210 in lb/in3-F and a thermal diffusivity of 0.16 in2/sec. Assume ambient temperature =
88°F.
Solution: From Table 21.3, U for alloy steel (310 BHN) = 320,000 in-lb/in3.
Since f = 0.005 in/rev, correction factor = 1.25.
Therefore U = 320,000(1.25) = 400,000 in-lb/in3.
v = 500 ft/min x 12 in/ft/60 sec/min = 100 in/sec.
T = Ta + (0.4U/ρC)(vto/K)0.333 = 88 + (0.4 x 400,000/210)(100 x 0.005/0.16)0.333
= 88 + (762)(3.125)0.333 = 88 + 1113 = 1201°F
21.36 A turning operation uses a cutting speed = 200 m/min, feed = 0.25 mm/rev, and depth of
cut = 4.00 mm. The thermal diffusivity of the work material = 20 mm2/s and the
volumetric specific heat = 3.5 (10-3) J/mm3-C. If the temperature increase above ambient
temperature (20°F) is measured by a tool-chip thermocouple to be 700°C, determine the
specific energy for the work material in this operation.
Solution: Rearranging the Cook equation, U = T(ρC/0.4)(K/vto)0.333
U = (700 – 20)(3.5 x 10-3/0.4)(20/{(200/60)(103)(0.25)})0.333
U = 680(8.75 x 10-3)(0.024)0.333 = 5.95(0.2888) = 1.72 N-m/mm3

Problems
22.1 A cylindrical workpart 200 mm in diameter and 700 mm long is to be turned in an engine
lathe. Cutting conditions are as follows: cutting speed is 2.30 m/s, feed is 0.32 mm/rev,
and depth of cut is 1.80 mm. Determine (a) cutting time, and (b) metal removal rate.
Solution: (a) N = v/(πD) = (2.30 m/s)/0.200π = 3.66 rev/s
fr = Nf = 6.366(.3) = 1.17 mm/s
Tm = L/fr = 700/1.17 = 598 s = 9.96 min
Alternative calculation using Eq. (22.5), Tm = 200(700)π/(2,300 x 0.32) = 597.6 sec =
9.96 min
(b) RMR = vfd = (2.30 m/s)(103)(0.32 mm)(1.80 mm) = 1320 mm3/s
22.3 A facing operation is performed on an engine lathe. The diameter of the cylindrical part is 6
in and the length is 15 in. The spindle is set to rotate at a cutting speed of 180 rev/min.
The depth of cut is 0.110 in and the feed is 0.008 in/rev. Assume the cutting tool moves
from the outer diameter of the workpiece to exactly the center at a constant velocity.
Determine (a) the velocity of the tool as it moves from the outer diameter towards the
center and (b) the cutting time.
Solution: (a) fr = fN = (0.008 in/rev)(180 rev/min) = 1.44 in/min
(b) L = distance from outside to center of part = D/2; Tm = L/fr = D/(2fr) = 6/(2 x 1.44) =
2.083 min
22.6 A workbar with 4.5 in diameter and 52 in length is chucked in an engine lathe and supported
at the opposite end using a live center. A 46.0 in portion of the length is to be turned to a
diameter of 4.25 in one pass at a speed of 450 ft/min. The metal removal rate should be
6.75 in3/min. Determine (a) the required depth of cut, (b) the required feed, and (c) the
cutting time.
Solution: (a) depth d = (4.50 - 4.25)/2 = 0.125 in
(b) RMR = vfd; f = RMR/(12vd) = 6.75/(12 x 450 x 0.125) = 0.010 in
f = 0.010 in/rev

This study source was downloaded by 100000813136873 from CourseHero.com on 06-12-2022 20:38:51 GMT -05:00

https://www.coursehero.com/file/5677024/hmwk-3-Problem-solutions/
 (c) N = v/πD = 450 x 12/4.5π = 382 rev/min
fr = 382(0.010) = 3.82 in/min
Tm = 46/3.82 = 12.04 min
22.7 A 4.00 in diameter workbar that is 25 in long is to be turned down to a diameter of 3.50 in
using two passes on an engine lathe using the following cutting conditions: cutting speed
= 300 ft/min, feed = 0.015 in/rev, and depth of cut = 0.125 in. The bar will be held in a
chuck and supported on the opposite end in a live center. With this workholding setup,
one end must be turned to diameter; then the bar must be reversed to turn the other end.
Using an overhead crane available at the lathe, the time required to load and unload the
bar is 5.0 minutes, and the time to reverse the bar is 3.0 minutes. For each turning cut an
allowance must be added to the cut length for approach and overtravel. The total
allowance (approach plus overtravel) = 0.50 in. Determine the total cycle time to
complete this turning operation.
Solution: First end: cut 15 in of 25 in length.
N = 300 x 12/4π = 286.4 rev/min, fr = 286.4(0.015) = 4.297 in/min
Tm = (15 + 0.5)/4.297 = 3.61 min; this reduces diameter to 3.75 in
N = 300 x 12/3.75π = 305.5 rev/min, fr = 305.5(0.015) = 4.583 in/min
Tm = 15.5/4.583 = 3.38 min to reduce the diameter to 3.50 in
Reverse bar, which takes 3.0 min and cut remaining 10 in of 25 in length.
N = 300 x 12/4π = 286.4 rev/min, fr = 286.4(0.015) = 4.297 in/min
Tm = (10 + 0.5)/4.297 = 2.44 min; this reduces diameter to 3.75 in
N = 300 x 12/3.75π = 305.5 rev/min, fr = 305.5(0.015) = 4.583 in/min
Tm = 10.5/4.583 = 2.29 min to reduce the diameter to 3.50 in
Loading and unloading bar takes 5.0 min.
Total cycle time = 5.0 + 3.61 + 3.38 + 3.0 + 2.44 + 2.29 = 19.72 min
22.11 A two-spindle drill simultaneously drills a ½ in hole and a ¾ in hole through a workpiece
that is 1.0 inch thick. Both drills are twist drills with point angles of 118°. Cutting speed
for the material is 230 ft/min. The rotational speed of each spindle can be set,
individually. The feed rate for both holes must be set to the same value because the 2
spindles lower at the same rate. The feed rate is set so the total metal removal rate does
not exceed 1.50 in3/min. Determine (a) the maximum feed rate (in/min) that can be used,
(b) the individual feeds (in/rev) that result for each hole, and (c) the time required to drill
the holes.
Solution: (a) Total RMR = 1.50 = 0.25πD12fr + 0.25πD22fr = 0.25π( D12 + D22 )fr
1.50 = 0.25π( 0.52 + 0.752 )fr = 0.638fr
fr = 1.50/0.638 = 2.35 in/min
(b) For 1/2 in hole, N = v/πD = 230/(0.50π/12) = 1757
For 3/4 in hole, N = v/πD = 230/(0.75π/12) = 1171
f = fr/N. For 1/2 hole, f = 2.35/1757 = 0.0013 in/rev
For 3/4 hole, f = 2.35/1171 = 0.0020 in/rev
(c) Must use maximum Allowance for the 2 drills.
For 1/2 in hole, A = 0.5D tan (90 – θ/2) = 0.5(0.50) tan(90 – 118/2) = 0.150 in
For 3/4 in hole, A = 0.5D tan (90 – θ/2) = 0.5(0.75) tan (90 – 118/2) = 0.225 in
Tm= (t + A)/fr = (1.00 + 0.225)/2.35 = 0.522 min = 31.2 seconds
22.14 A peripheral milling operation is performed on the top surface of a rectangular workpart
which is 400 mm long by 60 mm wide. The milling cutter, which is 80 mm in diameter

This study source was downloaded by 100000813136873 from CourseHero.com on 06-12-2022 20:38:51 GMT -05:00

https://www.coursehero.com/file/5677024/hmwk-3-Problem-solutions/
 and has five teeth, overhangs the width of the part on both sides. The cutting speed is 70
m/min, the chip load is 0.25 mm/tooth, and the depth of cut is 5.0 mm. Determine (a) the
time to make one pass across the surface, and (b) the maximum material removal rate
during the cut.
Solution: (a) N = v/πD = 70,000 mm/80π = 279 rev/min
fr = Nntf = 279(5)(0.25) = 348 mm/min
A = (d(D-d))0.5 = (5(80-5))0.5 = 19.4 mm
Tm = (400 + 19.4)/348 = 1.20 min
(b) RMR = wdfr = 60(5)(348) = 104,400 mm3/min
22.17 A face milling operation is performed to finish the top surface of a steel rectangular
workpiece 12.0 in long by 2.0 in wide. The milling cutter has four teeth (cemented
carbide inserts) and a 3.0 in diameter. Cutting conditions are: cutting speed = 500 ft/min,
feed = 0.010 in/tooth, and depth of cut = 0.150 in. Determine (a) the time to make one
pass across the surface and (b) the maximum metal removal rate during the cut.
Solution: N = v/πD = 500(12)/3π = 636.5 rev/min
fr = 636.5(4)(0.010) = 25.46 in/min
A = O = 3/2 = 1.5 in
Tm = (12.0 + 2 x 1.5)/25.46 = 0.59 min
RMR = 2.0(.150)(25.46) = 7.64 in3/min

This study source was downloaded by 100000813136873 from CourseHero.com on 06-12-2022 20:38:51 GMT -05:00

https://www.coursehero.com/file/5677024/hmwk-3-Problem-solutions/
Powered by TCPDF (www.tcpdf.org)