Neel Nadpara

HW# 1
Due: Wed, Sept 16th
Qualitative Problems:

1) Identify some of the reasons why machining is commercially and technologically important.
(10 points)

Parts that are manufactured from other processes such as sand casting are often crude and need to

be further processed in order to generate parts that have a nice surface finish, great deal of demanding

geometric/dimensional accuracy, or special features such as threads. These types of parts are typically

generated by machining as machining can be used for a wide variety of materials, it can product many

different types of geometries, it is able to achieve closer tolerances than most other processes, and it is

able to produce nice surface finishes. Being one of the only processes that is able to achieve all of these

goals makes machining very important. Also, for small scale and custom manufacturing machining is

often one of the best means of quickly generating parts as the setup is often less difficult and much

more cost effective as there is no need for expensive precision molds or other custom made tooling.

Another key advantage is the fact that machining, when done properly, does not significantly alter

mechanical properties of materials as some other processes such as forging and forming do. Overall,

machining is a very important both technologically and commercially.

2) Explain the main features of an orthogonal cutting operation. (10 points)

In an orthogonal cutting operation, metal cutting is simplified from a complex three dimensional

machining situation into two dimensions. In orthogonal cutting there is a wedge shaped tool with a

cutting edge that moves with a certain feed rate perpendicular to the workpiece. Also, the tooling is

simplified in the model as well since it only has a rake angle and a relief angle.

3) What are the differences between orthogonal and oblique cutting? (10 points)

In orthogonal cutting the model is two dimensional and the cutting edge of the tool is moving with a

velocity perpendicular to the workpiece. This can cause chips to break off square to the cut and
interferes with the surface finish and accuracy of the part produced. However, in oblique cutting the

model is three dimensional as the cutting edge is inclined at an angle relative the axial surface of the

workpiece. This allows chips to fly off of at an angle relative to the work surface preventing them from

entering the cutting area and interfering with cutting operations.

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4) Describe in words what the Merchant equation (𝝓 = 𝟒𝟓° + 𝟐 − 𝟐 ) tells us. (10 points)

The Merchant equation states that the shear angle is equal to 45°plus the rake angle divided by two

minus the friction angle divided by two. Thus, the shear angle increases when rake angle is increased

and friction angle is decreased.

5) Explain the difference between positive and negative rake angles. What is the importance of
the rake angle? (10 points)

Positive rake angles means that the cutting edge of the rake face is the first point of contact with the

workpiece that is being machined. Thus, the cutting edge leads the tool making the tool sharper thereby

reducing cutting forces and power requirements while preventing built up edges. A negative rake angle

on the other hand, means that the rake face drags along the workpiece with the actual cutting edge

being the last part to touch the workpiece. This makes the tool more blunt which increases the strength

of the tool thereby making the cutting tool more economical and these tools also provide better surface

finishes. However, the tool requires an increase in cutting forces, and addition friction generates more

heat for the tool.

Quantitative Problems: