King Fahd University of Petroleum & Minerals

Mechanical Engineering Department

ME 572: Analysis of Manufacturing Processes

Semester (232)

Homework # 1

Assigned date: Monday, January 22, 2024

Due date: Tuesday, January 30, 2024

Ahmed Jawad Alhayki ID#: 202321158

Name: ________________________ _____________________

Problems Marks Grades

Obtained

1 20

2 20

3 20

4 20

5 20

Total 100
1) Two thousand bars 80 mm in diameter and 300 mm long must be turned down to 65 mm in
diameter for 150 mm of their length. The surface-finish and accuracy requirements are such
that a heavy roughing cut (removing most of the material) followed by a light-finishing cut
is needed. The roughing cut is to be taken at maximum power. The light-finishing cut is to
be taken at a feed of 0.13 mm/rev, a cutting speed of 1.5 m/s, and at maximum power.
If the lathe has a 2-kW motor and an efficiency of 50%, calculate the total production
time in kiloseconds (ks) for the batch of work. Assume that the specific cutting energy for
the work material is 2.73 GJ/m3, the time taken to return the tool to the beginning of the cut
is 15 s, and the time taken to load and unload a workpiece is 120 s.

2) In a pipe flange facing operation carried out on a lathe, the depth of cut is 12 mm, and the
inside and outside diameters of the flange are 250 mm and 500 mm, respectively. The
specific cutting energy of the work material is 2.6 GJ/m3, the maximum rotational frequency
of the lathe spindle is 6 s–1, and the maximum feed that can be applied is 0.25 mm. The
major cutting-edge angle of the tool is 60 degrees. Find:
a. The maximum power required for machining when the machine is operating at
maximum capacity
b. The cutting force
c. The machining time

3) In a drilling operation using a twist drill, the rotational frequency of a drill is 5 s–1, the feed
0.25 mm, the major cutting-edge angle 60 degrees, and the drill diameter 12 mm. Assuming
that the specific cutting energy for the work material is 2 GJ/m3, calculate:
a. The maximum metal removal rate
b. The undeformed chip thickness
c. The drill torque, in Newton-meters (N-m)

4) In a slab-milling operation, the cutter has 20 teeth and is 100 mm in diameter. The rotational
frequency of the cutter is 5 s–1, the workpiece feed speed is 1.3 mm/s, the working
engagement (depth of cut) is 6 mm, and the back engagement (width of the workpiece) is 50
 mm. The relationship between the maximum undeformed chip thickness acmax and the
specific cutting energy ps in gigajoules per cubic meter (GJ/m3), for the work material is:

a. The maximum metal removal rate

b. The maximum power, in kilowatts (kW), required at the cutter

5) In a finish-surface-grinding operation on a horizontal-spindle surface grinder, the length of

the workpiece is 100 mm and its width 50 mm. The cross-feed is applied every stroke of the
worktable and is set at 0.25 mm, the back engagement (depth of cut) is 0.1 mm, and the
maximum traverse speed is 250 mm/s. The frequency of worktable reciprocation is 1s–1.
Calculate:
a) The machining time
b) The maximum metal removal rate
c) The maximum power consumption in watts (W) if the specific cutting energy for the
conditions employed is 25 GJ/m3
d) The maximum tangential force on the grinding wheel if its diameter is 150 mm and has a
rotational frequency of 60 s–1
 N = 2000

da = 20mm

65 mm
* dm
before
=

300 mm
1n =

j
D=
20 mm 150 mm
Im
=

Dismn e↓
[

Light finishing
Dissi.a
:
150
mm
- = 0 . 13
MM/veu/U = 1 .
5 M/sec

Roughing cut :

15 mm

PeM
ap-
m

Pe = -
Pm = = 2000X0 . 5

M
Pm 1000 =
Walt .

Pm PsZw =

7
M/Sec Xic mm
-

1000
/
3 66 X1 366

=
=
ec

zw
->
1m3
.

F
73
-
9
2 X10 /JIm

at the
Note I considered of
Finishing : :
end of the process since

Zu FapV
=
"sec
tm- 28 mm jamm the d in the finishing will

Zw = = 1 .

be 65mm ,
so 69 mm will
X153X
,
1 /M
/
= 13 /
and
=

after roughing cut ,

.

ap be
0
$
.

150 X65 157 08 Sec

finishing cul
π
Im - - X -
T
.

65mr after
tm
=
1 5X183
Frm 0 13 .
.

V =
πdm"w

Roughing :

* (882 69 (x150
Volume-dilm
-

=
= 527 e
tm-
Zur 366

Total Production Time

t tload unlad)
(finishing troughing
+ +
+ =
2000 return

- [2000 (157 . 88 + 527 6 + .

15x2 + 120))x(
- 1669KS