King Saud University College of Engineering Industrial

Engineering Dept.
IE-352
Section 1, CRN: 5022
Section 2, CRN: 32997
Second Semester 1432-33 H (Spring-2012) 4(4,1,1)
MANUFACTURING PROCESSES - 2
Sunday, Apr 29, 2012 (08/06/1433H)
Homework 3 Answers
Name:
Ahmed M. El-Sherbeeny, PhD

Student Number:
4

Section:
Su-8:00 / Su10:00

Answer ALL of the following questions [2 Points Each].

1. Let n=0.5 and C=90 in the Taylor equation for tool wear. What is
percent decrease in cutting speed is required to cause a (a) 2-fold
(i.e. 200%) and (b) 10-fold (i.e. 1000%) increase in tool life?
Solution:
Taylor Equation for tool life:
n

V T =C
n=0.5 ;

C=90

V T 0.5 =90 V 1 T 10.5=V 2 T 20.5

a)

T 2 =T 1 +200 T 1=3 T 1

V 1 T 10.5=V 2 (3 T 1)0.5
V 1= 3 V 2
V2

V = =0.577
3
1

V 1 V 2
V
=1 2 =10.577=0.423
V1
V1

decrease in cutting speed =

42.3
Note, less than half speed reduction is required for tool life to
triple

a)

T 3 =T 1 +1000 T 1=11 T 1

El-Sherbeeny, PhD

2012

Apr 29, 2012

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HW 3 Answers

IE 352 (01,02) - Spring

King Saud University College of Engineering Industrial

Engineering Dept.

V 1 T 10.5=V 3 (11 T 1)0.5

V 1= 11 V 3
V3

=0. 302
V =
11
1

V 1 V 3
V
=1 3 =10. 302=0.698
V1
V1

decrease in cutting speed =

69 . 8

2. In an orthogonal cutting operation, spindle speed is set to provide a

cutting speed of 1.8 m/s. The width and depth of cut are 2.6 mm and
0.30 mm, respectively. The tool rake angle is 8. After the cut, the
deformed chip thickness is measured to be 0.49 mm. Determine (a)
shear plane angle, (b) shear strain, and (c) material removal rate.
Given:
m
cutting speed: V =1.8 s

width: w=2.6 mm
thicknesses: t 0=0.30 mm , t c =0.49 mm
rake angle: 8
Required:
a)

b)

c)

R MR=?

Solution:
a) can be obtained from:
tan =

r cos
1r sin

t 0.30 mm
r= o =
=0. 612
t c 0. 49 mm

0.612 cos 8
1
1
tan 10.612 sin 8 =tan 0.663
El-Sherbeeny, PhD

2012

Apr 29, 2012

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HW 3 Answers

IE 352 (01,02) - Spring

King Saud University College of Engineering Industrial

Engineering Dept.

33.5
b)

can be obtained from:

cot+tan

cot 33.5 + tan ( 33.5 8 )

1.987
c)

R MR

(material removal rate) is the volume of material removed

(i.e. cut) every second which can be obtained from:

[(

R MR=w t o V =( 2.6 mm )( 0.30 mm ) 1.8

m
mm
(1000
)
s
m

]
mm3
R MR=1404
s

El-Sherbeeny, PhD

2012

Apr 29, 2012

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HW 3 Answers

IE 352 (01,02) - Spring

King Saud University College of Engineering Industrial

Engineering Dept.

3. Assume that, in orthogonal cutting, the rake angle is 25 and the

coefficient of friction is 0.2. Use the cutting ratio equation to determine
the percentage increase in chip thickness when the friction is
doubled.
Given:
rake angle: 25
coefficients of friction: 1=0.2 , 2=2 1=0.4
Required:
percentage increase in chip thickness
i.e.

t c t c
2

tc

tc

tc

1=?

Solution:
cutting ratio equation:

cos
t sin
r= o =
tc

Rearranging:
cos
t c =t o

Assuming rake angle (

constant

El-Sherbeeny, PhD

2012

) and depth of cut ( t o ) are kept

Apr 29, 2012

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HW 3 Answers

IE 352 (01,02) - Spring

King Saud University College of Engineering Industrial

Engineering Dept.
2

sin2

sin1

sin1

cos
t o
tc
=
tc
2

We lack the values for the shear angles( 1 and

use:

2 ), so we

45 +
2 2

Note how we use this equation since 1 and 2< 0.5

Also, note:
1=tan 1 1=tan 1 0.2=11.31
2=tan 1 2=tan 1 0.4=21.80

25 11.31
1 =45 + 1 =45 +

=51.85
2 2
2
2

25 21.80
2=45 + 2 =45 +

=46.60
2 2
2
2

Substituting in chip thickness formula we generated

tc

tc

cos ( 46.60 25 ) sin51.85

=1.13
cos ( 51.8525 ) sin 46.60

El-Sherbeeny, PhD

2012

Apr 29, 2012

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HW 3 Answers

IE 352 (01,02) - Spring

King Saud University College of Engineering Industrial

Engineering Dept.
t

c
increase in chip thickness t 1=1.131=13
c
2

El-Sherbeeny, PhD

2012

Apr 29, 2012

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HW 3 Answers

IE 352 (01,02) - Spring

King Saud University College of Engineering Industrial

Engineering Dept.

4. A turning operation is performed on stainless steel with hardness 200

HB (with specific energy of 2.8 J/mm 3), cutting speed = 200 m/min,
feed = 0.25 mm/rev, and depth of cut = 7.5 mm. How much power will
the lathe draw in performing this operation if its mechanical efficiency
is 90%?
Given:
J
total specific energy: ut =2.8
m
cutting speed: V =200 min

mm

mm
feed: f =0.25 rev

depth of cut: t 0=7.5 mm

mechanical efficiency: mech =90
Required:
Total power drawn from source: Power source=?
Solution:
cutting power is related to power from source through:
Powerc =Power sourcemech

or
Power source=

Powerc
mech

also, total specific energy:

ut =

Power c
total cutting power
=
material removal rate
R MR

o Since turning operation is involved

[(

)]

m
m m min
m m3
R MR=f t 0 V =( 0.25 m m) ( 7.5 mm ) 200
1000
=6250
min
m 60 sec
s

)(

)(

o Thus,

Power c =u tR MR = 2.8

J
m m3
J
6250
=17500 =17.5 kW
3
s
s
mm

)(

Substituting into the source power equation:

Power source=

El-Sherbeeny, PhD

2012

Powerc 17.5 kW
=
=19.44 k W
mech
0.9

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HW 3 Answers

IE 352 (01,02) - Spring

King Saud University College of Engineering Industrial

Engineering Dept.

5. With a carbide tool, the temperature in a cutting operation is

measured as 650C when the speed is 90 m/min and the feed is 0.05
mm/rev. What is the approximate temperature if the speed is
doubled? What speed is required to lower the maximum cutting
temperature to 480C?
Given:
first operation:
o cutting temperature: T 1 =650 C
m
o cutting speed: V 1=90 min
mm
o feed: f =0.05 rev

Required:
a) second operation:
o V 2=2 V 1
o T 2 =?
b) third operation:
o T 3 =480 C
o V 3=?
Solution:
equation for mean temperature in orthogonal cutting (note, it is
mentioned if it is turning on a lathe or not):
T=

0.000665Y f 3 V t 0
c
K

since, Y f , c , K are material dependent, and assuming constant

depth of cut ( t 0 ) and rearranging equation above:
0.000665 Y f
T
=
c
V
3

t0
=C
K

Thus,
T1

T2
=
3 V 1 3 V 2
El-Sherbeeny, PhD

2012

Apr 29, 2012

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HW 3 Answers

IE 352 (01,02) - Spring

King Saud University College of Engineering Industrial

Engineering Dept.

El-Sherbeeny, PhD

2012

Apr 29, 2012

Page - 9

HW 3 Answers

IE 352 (01,02) - Spring

King Saud University College of Engineering Industrial

Engineering Dept.

a) second operation:

3 V 2 T = 3 2 V 1 T =3 2T =( 1. 26 ) (650 C )
1
1
V1 1
V 1

T2= 3

T 2 =819 C
b) third operation:
T

480 C

3 V 3= T 3 3 V 1= 650 C 90=3.309
1

V 3=3.3093
m
V 3=36.2 min

Alternative Solution:
assuming this was a turning operation, and using equation for
mean temperature in turning on a lathe
T mean V a f b

or: T mean=C V a f b
assuming constant feed ( f ), and using a=0.2 , b=0.125 (since
given that this is carbide tool)
T mean=C V a f b
T mean1
V

0.2
1

T mean2
V 0.2
2

a) second operation:
0.2

V
2V 1
T mean2 = 20.2 T mean1=
V1
V1

0.2

( )

T mean1= ( 20.2 ) ( T mean1 ) =( 1.1 5 ) ( 650 C )

T 2 =74 7 C
b) third operation:
V 0.2
3 =

T 3 0.2 480 C 0.2

V =
90 =1.816
T 1 1 650 C

El-Sherbeeny, PhD

2012

Apr 29, 2012

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HW 3 Answers

IE 352 (01,02) - Spring

King Saud University College of Engineering Industrial

Engineering Dept.
1

V 3=1.816 0.2 =1.8165

m
V 3=19.8 min

Note that the second solution did not produce a significantly large
difference in final temperature, and yet a large difference in cutting
speeds.

El-Sherbeeny, PhD

2012

Apr 29, 2012

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HW 3 Answers

IE 352 (01,02) - Spring