Manufacturing Processes Home Work #7 Solutions Yr 102

Review Questions
21.1 What are the two principal aspects of cutting-tool technology?
Answer. The two main aspects of cutting tool technology are (1) tool material and (2)
tool geometry.

21.2 Name the three modes of tool failure in machining.

Answer. The three tool failure modes are (1) fracture failure, (2) temperature failure, and
(3) gradual wear.

21.7 Identify three desirable properties of a cutting-tool material.

Answer. Three desirable properties are (1) toughness to resist fracture failure, (2) hot
hardness to resist temperature failure, and (3) wear resistance to prolong the life of the
tool during gradual wear.

Problems
21.8 (50%) Solution:
N1 = 120(100)/6.25 = 611 rev/min
fr = 611(0.025)(1) = 15.275 cm/min
A = D/2 = 6.25/2 = 3.125 cm
Tm = (37.5 + 3.125)/15.275 = 2.66 min
T1 = 3Tm = 3(2.66) = 7.98 min when v1 = 120 m/min
N2 = 60(100)/6.25 = 306 rev/min
fr = 306(0.025)(1) = 7.65 cm/min
Tm = (37.5 + 3.125)/7.65 = 5.31 min
T2 = 12Tm = 12(5.31) = 63.726 min when v2 = 60 m/min
n = ln (120/60)/ln (63.726/7.98) = 0.3336
n 0.3336
C = vT = 120(7.98 ) = 239.9
n 0.3336
Or C = vT = 60(63.726 ) = 239.9

21.17 Solution:
1/n
Tm = DL/fv and T = (C/v)
-6 -3 -1
Tm = (400)(1100)(10 )/0.35(10 )v = 3949/v = 3949 (v)
1/.24 4.1667 4.1667 -4.1667 8 -4.1667
T = (450/v) = (450/v) = 450 (v) = 1135(10 )(v)
-1 8 -4.1667
Setting Tm = T: 3949 v = 1135(10 )(v)
3.1667 8
v = 0.2874(10 )
8 1/3.1667 8 0.3158
v = {0.2874(10 )} = {0.2874(10 )} = 226.7 m/min
1
21.21 (50%) Solution:
-6 -3 -1
Tm = (300)(625)(10 )/0.35(10 )v = 1683/v = 1683 (v)
-1 -1
3Tm = 3(1683 (v) ) = 5049(v)
1/.24 4.1667 4.1667 -4.1667 8 -4.1667
T = (450/v) = (450/v) = 450 (v) = 1135(10 )(v)
-1 8 -4.1667
Setting 3Tm = T: 5049v = 1135(10 )(v)
3.1667 8
v = 0.2248(10 )
8 1/3.1667 8 0.3158
v = {0.2248(10 )} = {0.2248(10 )} = 209.747 m/min