2.2 Force, Power in Metal Cutting Q&A For Student DD PDF

7/13/2011
ESE2003 Conventional
Force & Power in Metal Cutting
BySKMondal
Compiledby:SKMondalMadeEasy
GATE 1995Conventional
While turning a C15 steel rod of 160 mm diameter at
315 rpm, 2.5 mm depth of cut and feed of 0.16
mm/rev by a tool of geometry 00, 100, 80, 90,150, 750,
0(mm), the following observations were made.
Tangential component of the cutting force = 500 N
Axial component of the cutting force = 200 N
Chip thickness = 0.48 mm
Draw schematically the Merchants circle diagram
for the cutting force in the present case.
Ans. F = 2 9 1 , N = 457.67 N, Fn = 3 5 5.78 N, Fs = 40 8.31 N
.49o
Friction angle = 32Compiledby:SKMondalMadeEasy
During turning a carbon steel rod of 160 mm diameter by a

carbide tool of geometry; 0, 0, 10, 8, 15, 75, 0 (mm) at speed of
400 rpm, feed of 0.32 mm/rev and 4.0 mm depth of cut, the
following observation were made.
Tangential component of the cutting force, Pz = 1200 N
Axial component of the cutting force,
force Px = 800 N
Chip thickness (after cut), 2 = 0.8 mm.
For the above machining condition determine the values of
(i) Friction force, F and normal force, N acting at the chip tool
interface.
(ii) Yield shears strength of the work material under this
machining condition.
(iii) Cutting power consumption in kW.
Ans F = 800 N N = 1200 N 256 7 Mpa 4 021 KW
ESE2000(Conventional)
The following data from the orthogonal cutting test
is available. Rake angle = 100, chip thickness ratio =
0.35, uncut chip thickness = 0.51, width of cut = 3
mm, yield stress of work material = 285 N/mm2,
mean friction coefficient on tool force = 0.65,
5,
Determine
(i)
Cutting force (Fc)
(ii) Radial force (Ft)
(iii) Normal force (N) on tool and
(iv) Shear force on the tool (Fs ).
Ans. Fc = 1597 N; Ft = 678 N; Fs = 1265 N; F = 944.95 N, N =
1453.8 N
ESE2005Conventional
IAS2003MainExamination
Mild steel is being machined at a cutting

speed of 200 m/min with a tool rake angle of
10. The width of cut and uncut thickness are 2
mm and 0.2 mm respectively.
p
y If the average
g
value of coefficient of friction between the
tool and the chip is 0.5 and the shear stress of
the work material is 400 N/mm2,
Determine (i) shear angle and [Ans. 36.7o
(ii) Cutting and thrust component of the
machine on force. [Ans. Fc = 420 N, Ft = 125 N ]
During turning process with 7 6 6 8 30 1 (mm)

ASA tool the undeformed chip thickness of 2.0 mm and
width of cut of 2.5 mm were used. The side rake angle of
the tool was a chosen that the machining operation
could be approximated to be orthogonal cutting.
cutting The
tangential cutting force and thrust force were 1177 N and
560 N respectively. Calculate:
[30 marks]
(i) The side rake angle [Ans. 12o ]
(ii) Coefficient of friction at the rake face [Ans. 0.82]
(iii) The dynamic shear strength of the work material
[Ans. 74.43 Mpa] Compiledby:SKMondalMadeEasy
7/13/2011
GATE2006CommonDataQuestions(1)
Inanorthogonalmachiningoperation:
Uncutthickness=0.5mm
Cuttingspeed=20m/min Rakeangle=15
Widthofcut
5mm
Chipthickness
0.7mm
Widthofcut=5mm
Chipthickness=0.7mm
Thrustforce=200N
Cuttingforce=1200N
AssumeMerchant'stheory.
Thecoefficientoffrictionatthetoolchipinterfaceis
(a)0.23
(b)0.46
(c)0.85
(d)0.95
Ans.(b)
Widthofcut
Widthofcut=5mm
5mm
Chipthickness
Chipthickness=0.7mm
0.7mm
Thrustforce=200N
Cuttingforce=1200N
Thevaluesofshearangleandshearstrain,
respectively,are
(a)30.3 and1.98
(b)30.3 and4.23
(c)40.2 and2.97
(d)40.2 and1.65Ans.(d)
A cylinder is turned on a lathe with orthogonal
machining principle. Spindle rotates at 200 rpm. The
axial feed rate is 0.25 mm per revolution. Depth of cut is
0.4 mm. The rake angle is 10. In the analysis it is found
that
th t the
th shear
h
angle
l is
i 27.75
Intheaboveproblem,thecoefficientoffrictionat
thechiptoolinterfaceobtainedusingEarnestand
Merchanttheoryis
(a)0.18
(b)0.36
(c)0.71
(d)0.908
Ans.(d)
Widthofcut
5mm
Chipthickness
0.7mm
Widthofcut=5mm
Chipthickness=0.7mm
Thrustforce=200N
Cuttingforce=1200N
Thepercentageoftotalenergydissipateddueto
frictionatthetoolchipinterfaceis
(a)30%
(b)42%
(c)58%
(d)70%
Ans.(a)
A cylinder is turned on a lathe with orthogonal
machining principle. Spindle rotates at 200 rpm. The
axial feed rate is 0.25 mm per revolution. Depth of cut is
0.4 mm. The rake angle is 10. In the analysis it is found
th t the
that
th shear
h
angle
l is
i 27.75
Thethicknessoftheproducedchipis
(a)0.511mm
(b)0.528mm
(c)0.818mm
(d)0.846mm
Ans.(a)
GATE2008CommonDataQuestion(1)
Orthogonal turning is performed on a cylindrical work
piece with shear strength of 250 MPa. The following
conditions are used: cutting velocity is 180 m/min. feed
is 0.20 mm/rev. depth of cut is 3 mm. chip thickness
ratio
ti = 0.5. The
Th orthogonal
th
l rake
k angle
l is
i 7o. Apply
A l
Merchant's theory for analysis.
Theshearplaneangle(indegree)andtheshear
forcerespectivelyare
(a)52:320N
(b)52:400N
(c)28:400N
(d)28:320N
Ans.(d)
7/13/2011
GATE2008CommonDataQuestion(2)
Orthogonal turning is performed on a cylindrical work
piece with shear strength of 250 MPa. The following
conditions are used: cutting velocity is 180 m/min. feed
is 0.20 mm/rev. depth of cut is 3 mm. chip thickness
ratio
ti = 0.5. The
Th orthogonal
th
l rake
k angle
l is
i 7o. Apply
A l
Merchant's theory for analysis.
Thecuttingandfrictionalforces,respectively,are
(a)568N;387N (b)565N;381N
(c)440N;342N
(d)480N;356N
Ans.(b)
IES2010
The relationship between the shear angle ,
the friction angle and cutting rake angle
is given as
Ans.(b)
IES2005
Which one of the following is the correct
expression for the Merchant's machinability
constant?
(a) 2 +
(b) 2 +
(c) 2
(d) +
(Where = shear angle, = friction angle
and = rake angle)
Ans. (a)
GATE1997
Inatypicalmetalcuttingoperation,usinga
cuttingtoolofpositiverakeangle=10,it
wasobservedthattheshearanglewas20.
Thefrictionangleis
g
(a)45
(b)30
(c)60
(d)40
Ans.(c)
IAS 1999
In an orthogonal cutting process, rake angle of the
tool is 20 and friction angle is 25.5. Using
Merchant's shear angle relationship, the value of
shear angle will be
(a) 39.5
39 5
(b) 42.25
42 25
(c) 47.75
(d) 50.5
IES2003
In orthogonal cutting test, the cutting force =
900 N, the thrust force = 600 N and chip
shear angle is 30o. Then the chip shear force is
(a) 1079.4
1079 4 N
(b) 969.6
969 6 N
(c) 479.4 N
(d) 69.6 N
Ans. (c)
Ans. (b)
7/13/2011
IES2000
IES1996
In an orthogonal cutting test, the cutting force and

thrust force were observed to be 1000N and 500 N
respectively. If the rake angle of tool is zero, the
coefficient of friction in chiptool interface will be
1
(a)2
( b)2
( c)
( d) 2
2
Ans.(a)
Which of the following forces are measured directly by

strain gauges or force dynamometers during metal
cutting ?
1. Force exerted by the tool on the chip acting normally to
the tool face.
2. Horizontal cutting force exerted by the tool on the work
piece.
3. Frictional resistance of the tool against the chip flow
acting along the tool face.
4. Vertical force which helps in holding the tool in
position.
(a) 1 and 3
(b) 2 and 4
Ans. (b)
(c) 1 and 4
(d) 2 and 3
GATE2007
Inorthogonalturningofmediumcarbonsteel.The
specificmachiningenergyis2.0J/mm3.Thecutting
velocity,feedanddepthofcutare120m/min,0.2
mm/revand2mmrespectively.Themaincutting
forceinNis
f
i Ni
(a)40
(b)80
(c)400
(d)800
GATE2007
In orthogonal turning of low carbon steel pipe with
principal cutting edge angle of 90, the main cutting
force is 1000 N and the feed force is 800 N. The shear
angle is 25 and orthogonal rake angle is zero.
E
Employing
l i
M h t theory,
Merchants
th
th ratio
the
ti off friction
f i ti
force to normal force acting on the cutting tool is
(a) 1.56
(b) 1.25
(c) 0.80
(d) 0.64
Ans.(d)
Ans. (c)
IES1997
Consider the following forces acting on a
finish turning tool:
1. Feed force
2.
2 Thrust force
3. Cutting force.
The correct sequence of the decreasing order of
the magnitudes of these forces is
(a) 1, 2, 3
(b) 2, 3, 1
(c) 3, 1, 2
(d) 3, 2, 1
Ans. (c)
IES1999
The radial force in singlepoint tool during
turning operation varies between
(a) 0.2 to 0.4 times the main cutting force
(b) 0.4
0 4 to 0.6
0 6 times the main cutting force
(c) 0.6 to 0.8 times the main cutting force
(d) 0.5 to 0.6 times the main cutting force
Ans. (a)
7/13/2011
IES1995
The primary tool force used in calculating
the total power consumption in machining is
the
(a) Radial force
(b) Tangential force
(c) Axial force
(d) Frictional force
IES2002
In a machining process, the percentage of
heat carried away by the chips is typically
(a) 5%
(b) 25%
(c) 50%
(d) 75%
0%
%
Ans. (d)
Ans. (b)
IAS 2003
IES1998
In metal cutting operation, the approximate
ratio of heat distributed among chip, tool
and work, in that order is
(a) 80: 10: 10 (b) 33: 33: 33
(c) 20: 60: 10 (d) 10: 10: 80
Ans. (a)
Asthecuttingspeedincreases
(a) Moreheatistransmittedtotheworkpieceandless
heatistransmittedtothetool
(b) Moreheatiscarriedawaybythechipandlessheatis
t
transmittedtothetool
itt dt th t l
(c) Moreheatistransmittedtoboththechipandthe
tool
(d) Moreheatistransmittedtoboththeworkpieceand
thetool
Ans.(b)
IAS 1995
IES2001
Power consumption in metal cutting is
mainly due to
(a) Tangential component of the force
(b) Longitudinal component of the force
(c) Normal component of the force
(d) Friction at the metaltool interface
Thrustforcewillincreasewiththeincreasein
(a) Sidecuttingedgeangle
(b)Toolnoseradius
(c) Rakeangle
(d)Endcuttingedgeangle
Ans.(a)
Ans. (a)
7/13/2011
IES2010
Consider the following statements:
In an orthogonal, singlepoint metal cutting,
as the sidecutting edge angle is increased,
g
1. The tangential
force increases.
2. The longitudinal force drops.
3. The radial force increases.
Which of these statements are correct?
(a) 1 and 3 only
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1, 2 and 3
Ans. (c)
IES1993
A 'Dynamometer' is a device used for the
measurement of
(a) Chip thickness ratio
(b) Forces during metal cutting
(c) Wear of the cutting tool
(d) Deflection of the cutting tool
Ans. (b)
IES2011
Theinstrumentordeviceusedtomeasurethecutting
forcesinmachiningis:
(a)Tachometer
(b)Comparator
(c)Dynamometer
(d)Lactometer
IAS 2003
The heat generated in metal
conveniently be determined by
(a) Installing thermocouple on the job
(b) Installing thermocouple on the tool
(c) Calorimetric setup
(d) Using radiation pyrometer
cutting
can
Ans. (c)
Ans.(c)
IES1998
The gauge factor of a resistive pickup of
cutting force dynamometer is defined as the
ratio of
(a) Applied strain to the resistance of the wire
(b) The proportional change in resistance to the
applied strain
(c) The resistance to the applied strain
(d) Change in resistance to the applied strain
Ans. (b)
IES2000
Assertion (A): In metal cutting, the normal
laws of sliding friction are not applicable.
Reason (R): Very high temperature is
produced at the toolchip interface.
interface
(a) Both A and R are individually true and R is
the correct explanation of A
(b) Both A and R are individually true but R is
not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
Ans. (a)
mpiledby:SKMondalMadeEasy
7/13/2011
GATE1992
The effect of rake angle on the mean friction angle in
machining can be explained by
(A) sliding (Coulomb) model of friction
(B) sticking and then sliding model of friction
(C) sticking friction
(D) Sliding and then sticking model of friction
Ans. (b)
IES2004
Assertion (A): The ratio of uncut chip thickness to
actual chip thickness is always less than one and is
termed as cutting ratio in orthogonal cutting
Reason (R): The frictional force is very high due to the
g friction rather than sliding
g
occurrence of sticking
friction
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
Ans. (b)
GATE1993
The effect of rake angle on the mean friction angle in
machining can be explained by
(a) Sliding (coulomb) model of friction
(b) sticking
g and then siding
g model of friction
(c) Sticking friction
(d) sliding and then sticking model of friction
Ans. (d)

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7/13/2011

Force & Power in Metal Cutting

During turning a carbon steel rod of 160 mm diameter by a

Mild steel is being machined at a cutting

During turning process with 7 6 6 8 30 1 (mm)

In an orthogonal cutting test, the cutting force and

Which of the following forces are measured directly by

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