Question

1. A certain work material has shear strength of = 50,000 lb/in. An orthogonal cutting operation is performed using a tool with a rake angle = 20° at the following cutting conditions: cutting speed - 100 ft/min, chip thickness before the cut = 0.015 in, and width of cut = 0.150 in. The resulting chip thickness ratio = 0.50. Determine (a) The shear plane angle; (b) Shear force; (c) Cutting force and thrust force, and (d) Friction force. 2.1 The Circle the correct answer The material removal processes are a family of shaping operations in which excess material is removed from a starting work part so that what remains is the desired final geometry: (a) true or (b) false? 2.2 Which of the following manufacturing processes are classified as material removal processes: (a) casting, (b) drawing, (c) extrusion, (d) forging, (e) grinding, (f) machining, (g) molding, (h) pressworking, and (i) spinning? 2.3 Which of the following are the three most common machining operations: (a) broaching, (b) drilling, (c) lapping, (d) milling, (e) planing, (f) shaping, or (g) turning? 2.4 What are the following Acronyms mean: FMEA, DSA, TQM, TPM, DFSS, SPC

Answer 1

Given Is-Su Xlo?eblin? 20' V = 100ft/min: 12ou in /min t,=0.olsin b=o.isoin r = t-/- 0.5 (a ) Shear plane angle (o): d = tant/ ro.scos (20) rrcosa Tetunt - L larsind I Llossin(20) PANS [9= 29.54" Go and (b) shear force (Fs) Es = TSX As As = shear area. As = tib Fs=2 sx sind tib sing i Forso x103 x 0.01s xoris Sin (29,54) Fs=228-18eb

(c) cutting force (F.) & Thrust force (F): from Merchant's circiei Fsn . Es Is Re Fc Cos (ß-d) Fr - search FC dà . projecte Sin (ß-d ß2t - R9o.pl Cos(90-8) (merchant's circle) Now; From merchan't relation! 28+8-0=go ß= friction angle. ., 2 x 29,54+ ß -20= go' :-(R = 50.gzal Fc 2 28.18 . cos(29.54+ 50.92 -20) I cos (50.92-20) - [Fc z 3.97401 — Cool sin (50,92-23) cos (29.54 +50.92-20) :| Fr= 237.8116 Fr=237.81 lb And )

wl friction force (FE): Fs cos (908) cos (atp-a) 228.18 Cos (90-50.92) Cos (29.54750-92-20) :-(F= 359,26201 — CROS)