VIT

UNIVERSITY
(Estd. u/s 3 of UGC Act 1956)

Vellore - 632 014, Tamil Nadu, India

School of Mechanical Engineering
M. Tech CAD/CAM
Course: MEE551 Advanced Manufacturing Technology
UNIT-I
Descriptive Questions
1. Explain with a neat sketch what you understand by the word Orthogonal Cutting and
its relevance in metal cutting study. How can orthogonal cutting be realised in
practice?
2. What are the conditions that would allow a continuous chip to be formed in metal
cutting?
3. From the machining performance viewpoint which type of chip is preferred? Explain
your answer with suitable justifications? Also show the conditions which favour such a
chip formation.
4. In an orthogonal cutting tool what are the important angles that are to be maintained?
For each of the angle explain its influence on the machining performance.
5. How is metal removed in metal cutting? Explain the process by giving any simple model
to explain the metal removal process.
6. What is meant by built-up-edge (BUE)? With a neat sketch explain the formation of a
BUE. Explain the conditions which promote the growth of BUE along with its
consequences.
7. Derive the expression-for shear angle in orthogonal cutting in terms of rake angle and
chip thickness ratio.
8. Show schematically Merchant's force circle in orthogonal cutting. Derive the equations
for shear and friction forces in terms of the material properties and cutting process
parameters. Give in detail the assumptions made while arriving at the final equations.
9. Derive the expression for the main cutting force in orthogonal cutting in terms of work
material properties and cutting process parameters.
10. Derive the shear angle relationship based on Merchant's minimum energy principle.

Discuss its validity from the experimental observations.

11. Discuss the importance of shear angle from the standpoint of metal cutting performance.
What factors influence its value?
12. What are the various forms of wear found in cutting tools? Show with a neat sketch.
13. How do the cutting process parameters affect the cutting tool wear in single point tools?
14. Show diagrammatically the variation of flank wear of cutting tool with time and explain
its importance from the tool life point of view.
15. What are the types of cutting tool wear patterns observed in single point tools? How do
they affect the metal cutting performance?
16. What are the desirable characteristics of a cutting tool material? Explain how these are
satisfied in the case of high speed steel tools.
17. How are the cemented carbides classified by ISO? Explain the general applications of
each category.
18. How do you expect the coatings on carbides to improve the machining performance?
19. Explain the advantages of coated carbides over uncoated carbides. Name any three
materials used for coatings.

20. How do you compare cutting tools made of CBN to that made by cemented carbides?
Your answer should be based on tool material composition, structure and cutting
performance.
21. Why are synthetic diamonds preferred to natural diamonds as cutting tools?
22. What are the advantages and disadvantages of ceramics as cutting tool materials?
23. What are the main applications of cutting fluids?
24. What are the mechanisms that are generally responsible for the effectiveness of cutting
fluid in improving machining performance?
25. What is meant by machinability? Explain the method of representing the machinability.
26. What are the factors that control surface finish in turning? How do you select the cutting
process parameters for finish turning?

Numerical Exercises
1. A 100 mm bar is turned by means of a tool with a rake angle of 15 orthogonally. 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.
2. During a metal cutting test under orthogonal conditions in a lathe with a tool of rake angle 20,
with a depth of cut of 3 mm and feed rate of 0.38 mm/rev, the following data was recorded.
Average chip thickness = 0.89 mm
Horizontal component of the cutting force = 1000 N
Vertical component of the cutting force = 2340 N
Calculate the following:
(a) Coefficient of friction at the chip tool interface
(b) Shear plane angle, and
(c) Shear stress at the shear plane.
3. The following data was obtained from an orthogonal cutting test.
Rake angle = 20 Depth of cut = 6 mm
Feed rate = 0.25 mm/rev
Chip length before cutting = 29.4 mm
Chip length after cutting = 12.9 mm
Vertical cutting force = 1050 N
Horizontal cutting force = 430 N
Using Merchant's analysis, calculate:
(a) direction and magnitude of the resultant force,
(b) shear plane angle,
(c) friction force and friction angle, and
(d) various energies consumed.

4. In an orthogonal cutting of a steel component with a carbide tool, the following data was
obtained. Tool rake angle = 10 Chip width = 6 mm
Uncut chip thickness = 0.10 mm
Chip thickness ratio = 0.33
Horizontal cutting force = 1290 N
Vertical cutting force = 1650 N
Sketch the force diagram and calculate the mean shear stress on the shear plane.
5. In an orthogonal cutting test with a tool of rake angle 10, the following observations were
made. Chip thickness ratio = 0.37
Horizontal component of the cutting force = 1000 N
Vertical component of the cutting force = 1500 N
From Merchant's theory, calculate the various components of the cutting forces and the
coefficient of friction at the chip tool interface.
6. SAE 113 cold rolled steel is orthogonally cut on a lathe with a HSS tool having a rake angle of
20. The following data are obtained during the test.
Width of cut

= 5 mm

Uncut chip thickness = 0.25 mm

Vertical cutting force = 1030 N

Cutting speed = 8.5 m/min

Cutting ratio = 0.351
Horizontal cutting force = 550 N

Calculate the friction, shear and total energies consumed during the metal cutting process.
7. A mild steel tube is cut with a carbide tool having a rake angle 5 orthogonally at a cutting
speed of 250 m/min. The feed used is 0.21 mm/rev while the depth of cut is 2 mm. The
cutting ratio is 0.31. The vertical cutting force is 1030 N and the horizontal cutting force is
550 N. Calculate from Merchant's theory, the various work done in metal cutting and shear
stress.
8. In an orthogonal cutting of C35 steel with HSS tool, the following conditions were noted.
Width of cut = 1.2 mm

Rake angle = 15

Cutting force = 800 N

Thrust force = 800 N

Calculate the shear angle and other force components.

9. In an orthogonal cutting test on an alloy of aluminium, the following values were known or
obtained from experimental data.
Rake angle

= 20

Thrust force = 340 N

Uncut chip thickness = 0.125 mm

Width of cut = 3.75 mm

Cutting speed

Chip thickness = 0.51 mm

= 0.5 m/s

If the force in the cutting speed direction is 3.1 times that of the thrust force, calculate the
average yield shear stress of the work material. State the assumptions made and derive any
expression required for the calculations from the first principles.
10. For a production turning operation, past records have shown that the tool life varies with the
cutting speed as follows:
Cutting speed, V, mls

tool Life, T, min

2.08

110

2.54

37

Estimate the tool life for this operation at a speed of 2.3 mls. Outline all the assumptions used
to obtain this estimate.
11. A carbide cutting tool has tool life exponent n = 0.27. It gives a tool life of 60 minutes while
machining a mild steel workpiece at a cutting speed of 120 m/min. Compute the tool life if it
is to be cut at a 20% higher cutting speed. Also what is the cutting speed if the tool life is to
be doubled?