Manufacturing Engineering, I (MENG 3181)

Assignment 1
For all group third year Mechanical Engineering students

1) In an orthogonal cutting operation, the cutting velocity is 30 m/min and the chip
velocity is 15 m/min. If the rake angle of the tool is 10 o, calculate the shear angle and
shear velocity.
2) The end of pipe was orthogonally cut with a tool of 20 o rake angle. The chip length
was measured as 85 mm whereas uncut chip length was 202 mm. determine shear
plane angle and chip thickness if the depth of cut was 0.5 mm
3) The following data related to an orthogonal cutting process: Chip length obtained =
96mm, Uncut chip length = 240mm,Rake angle used =200 and Depth of cut = 0.6mm
respectively with Horizontal and vertical components of cutting force =2400N and
240N respectively. Determine the following: - Shear plane angle, Chip thickness,
Friction angle and Resultant cutting force.
4) A turning operation has to be performed on an aluminum rod of diameter50 mm and
length 300mm. The Spindle speed of lathe is given to be 500 RPM. The feed and depth
of cut are 0.15mm/rev and 0.3 mm respectively from the below diagram. Find out the
cutting speed in mm/s and the volumetric material removal rate (MRR v).

5) During turning a metallic rod at a given condition, the tool life was found to
increase from 25 min to 50 min. when V C was reduced from 100 m/min to 80
m/min. How much will be the life of that tool if machined at 90 m/min?

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6) If 500 work piece of 120mm diameter and 200mm long is to be rough turned using a
feed of 0.2mm/rev .if the cost of a carbide insert is 160 birr , resting time of the cutting
edge is 1min, total machining rate (including operating cost) is 600birr/hr .If the
Taylor tool life equation is VT 0.25 =600, Determine:
a) Optimum cutting speed for minimum cost
b) The speed corresponding Tool life
c) Total production cost if the time taken to load and unload is 3min, and
tool setup time 3min
d) Total production time for the whole work piece
7) Drive the minimum energy on orthogonal cutting by Ernst-Merchant theory