Tutorial sheet 2

1. During orthogonal cutting of a seamless tube rotating at 1000/π rpm and having 32 mm
outer diameter and 28 mm inner diameter using a cutting tool of rake angle 0°, principal
cutting edge angle 90°, moving at axial feed rate 0.5 mm/rev, if the length of continuous
chip from one revolution is 50 mm, calculate the Shear angle.

2. During turning of C-20 steel with a carbide cutting tool of 0-10-7-6-8-75°-1 mm ORS
configuration with a feed of 0.2 mm/revolution and depth of cut 2 mm at a cutting speed of
140 m/minute, a chip thickness of 0.36 mm has been obtained What are the amount of (i)
inclination angle (ii) orthogonal clearance angle (iii) shear angle and (iv) dynamic shear
strain?
3. A 100 mm diameter and 150 mm long shaft is turned by means of a tool having ORS
configuration 0-10-7-6-8-75°-1 m. The depth of cut is 5 mm while the feed rate is 0.25
mm/rev. If the mean length of a cut chip representing one rotation of the workpiece is 90.5
mm. find the shear plane angle. Also calculate the width of the chip.
4. Determine the three components of the machining force during orthogonal turning with
depth of cut = 2 mm, feed = 0.25 mm/revolution, orthogonal rake angle = 10°, principal
cutting edge angle = 60°, coefficient of friction between chip and tool = 0.6, ultimate shear
stress of workpiece material = 340 N/mm2, and shear angle = 24°.
5. During turning of AISI-304 with a carbide tool having a tool geometry 0-(-5)-6-6-8-75-1
mm ORS, following forces have been recorded by a two-dimensional dynamometer: Force
in ‘Z’ direction, PZ = 140 kgf and force in ‘X’ direction, Px = 85 kgf.
Calculate, the force in ‘Y’ direction (Fy) and kinetic coefficient of friction μ (using
Merchant’s force circle diagram).
During the machining of C-20 steel with a 0-10-6-6-8-90°-1 mm ORS-shaped triple carbide
cutting tool, the following observations have been made:
Depth of cut = 2 mm,
Feed = 0.2 mm/revolution
Cutting speed = 200 m/min
FC = 160 kgf and FT = 85 kgf
Average chip thickness = 0.39 mm
Calculate
i. The shear force and normal force at shear plane
ii. The kinematic coefficient of friction
iii. The specific energy of cutting
iv. The specific energy of friction