2016

WORKBOOK
Detailed Explanations of
Try Yourself Questions

Mechanical Engineering
Production Engineering
 1 Mechanics of Basic
Machining Operation

T1 : Solution

(70 + 68 )
Length of uncut chip, l = = 216.66 mm
2
t L (Length of chip) 68.9
Cutting ratio = = c = = 0.318
tc L (Uncut length) 216.66
r cos ( ) 0.318 cos10
tan = = = 0.33147
1 r sin 1 0.318 sin10
= 18.34

T2 : Solution

t1 = 0.25, V = 60 m/min, = 0; V is cutting speed

t2 = 0.75, FC = 900 N, FT = 450 N; VC is chip velocity
t1 0.25 1
r = = =
t 2 0.75 3

r cos
= tan1 = 18.43
1 r sin
60
Power, P = FC V = 900 = 900 W
60
FT
tan( ) =
FC
Since = 0
F 450
= tan1 T = tan1 = 26.56
F
C 900
Coefficient of friction = = tan = 0.5

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 Workbook 3

F14C4244
V3 F{
SVS + F{
VC
Total power consumed in cutting
= Shearing power Frictional power

VC = 20 m/min.
Now friction force, F = FC sin + Ft cos
= 900 sin0 + 450 cos0 = 450 N

20
Now frictional power, P = F VC = 450 = 150N
80

Frioctional power 150

Percentage frictional power = 100 = 100 = 16.67%
Total Power 900

750
Percentage shearing power = 100 = 83.33%
900

T3 : Solution

Power FC V
PC = Specific cutting power = MRR = W t V
1

FC
PC =
w t1
t1
r =
t2
If sufficient data is not provided assume = 0
FS
= S
w t1
sin
s FS
= sin
PC FC

FS cos( + )
=
FC cos( )

As = 0
(cos cos sin sin )
sin = (cos sin tan)sin
cos
= cos sin sin2
cos
r = tan =
1
sin
r
sin
= r
cos
sin2 + cos2 = 1

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4 Mechanical Engineering Production Engineering

1
tan2 + 1 = = 1+ r 2
cos2
1
cos =
1+ r 2
r
sin =
1+ r 2

s 1 r r
=
PC 1+ r 2 1+ r 2 1+ r 2

r r2
=
1+ r 2 1+ r 2
s r (1 r )
=
PC 1+ r 2

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 23 Cutting Tool, Tool Life
and Cutting Fluid

T2 : Solution

Q T1 = 20 min at N1 = 200 rpm

T2 = 5 min at N2 = 400 rpm
But Taylors tool life equation for drill
N1 T 1 n = N 2 T 2n = constant ...(i)
200(20)n = 400(5) n
4n = 2
n = 0.5
Tool life at N3 = 300 rpm
N 1 T1 n = N3 T 3n
200(20)0.5 = 300 T30.5
2
200
T 3 = 20 = 8.89 min.
300

T2 : Solution

T 0 = Original tool life

V 0 = Original tool velocity
Given, V1 = 1.2 V0, T 1 = 0.5T0
V2 = 0.8 V0, T 2 = ?
V1T1n = V0T0n
n
T1 V0
T =
0 V1

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6 Mechanical Engineering Production Engineering

V0 1
ln ln
V1 1.2
n = = = 0.263
T l n0.5
ln 1
T0
V0T 0n = V2T 2n
1/ n 1/ 0.263
V V0
T 2 = T0 0 = T0
V 0.8V
2 0

3.8
1
= T0 = 2.33 T0
0.8
% change in tool life
T2 T0
= = 1.33 = 133%
T0

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 3 Economics of
Machining Operation

T1 : Solution

The constants in the tool life equation are 60 and 0.2

VT 0.2 = 60
Tool change time = 3 min
Tool regrind time = 3 min
Machine running cost = ` 0.5/min
Depreciation of tool regrind = ` 5.0
Direct running cost, K1 = Regrind time running cost/unit time
= 3 min 0.5/min = ` 1.5
Tool changing time, t = 3 min
Depreciation cost, K 2 = ` 5.0
Optimum speed, V for minimum cost,

C 60
= n
= 0.2
1 K2 1 5
1 t + 0.2 1 3 + 1.5
n K1

= 31.43 m/min.
Optimum cutting speed, V for maximum production

C 60
= n
= 0.2 = 36.5 m/min.
1 1
n 1 t 0.2 1 3

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8 Mechanical Engineering Production Engineering

T2 : Solution

C = 80, n = 0.2
30
Cg = ` 2, Lm = = 0.5
60
n 0.2
n Lm 0.2 0.5
Vopt = C = 80
1 n Cg 0.8 2
= 45.95 m/min

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 4 Lathe

T1 : Solution

Taking the speed to be in geometric progression common ratio

1
N Dmax Dmin 200 120 6 1
r = n 1 max = n 1
V V = 100 40 = 1.43
Nmin min max
1000 40
N1 = = 200
200
N2 = rN 1 = 286 285
N3 = r 2N 1 410
N4 = r 3, V1 585
N5 = r 4N1 835
1000 120
N6 = = 1200
100
T2 : Solution
l 576
Time/cut = = = 20 min
fN 0.2 144
DN 100 144
V = = = 45.2 m/min
1000 1000
VT 0.75 = 75
1/ 0.75
75
T = = 1.96 min
V
20
Number of tool regrinds = = 10.2 10
1.96
The time required to produce one piece = 20 + 10 3 = 50 min

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 5 Shapping and
Planning

T1 : Solution

1
Time taken in one stroke = min
60
Width
Total number of stroke =
Lateral feed
Width 1
Total time/cut =
Feed 60
36 1
= = 1min.
0.6 60

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 6 Drilling Boring
and Reaming

T1 : Solution

1000V 1000 20
Speed (N ) = =
D 20
= 318.5 rpm
d/2
20
x = = 5.7735 mm
2 tan60
120 x
Length to be machined,
L = l + approach + overrun + x
= 30 + 2 + 3 = 35 + 5.7735 mm

40.7735
Time taken = = 1.28 min
0.1 318.5

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 7 Milling

T1 : Solution

Width of slot = 20 mm = b
length of slot = 100 mm = l
1000 V 1000 60
N = = = 955 rpm
D 20
Cutting length = length of slot + approach
D 20
= 100 + = 100 + = 110 mm
2 2
L 110
Time/cut = = = 1.44 min
f1zN 0.01 8 955

T2 : Solution
Given D = 150 mm Width b = 80 mm
Offset Of = 0.15 m Number of teeth z = 10
l = 160 mm Feed f = 0.25 mm
Vc = 20 m/min
1000 V 1000 20
N = = = 42.5 rpm
D 150
Length of approach l0 = x = 75 752 552 = 24.0098 ; 24 mm

Length of machining
L = l + l0 = 160 + 24 = 184 mm
L 184
Time = = = 1.73 min/cut
fzN 0.25 10 42.5

10 Non-conventional
Machining Operation

T1 : Solution

1 % volume
=
e atomic weight
0.18 2 0.62 2 0.2 6
+ +
58.93 58.71 51.99

1
= 0.050311
e
MRR = SI

eI 19.876 500
=
F 96500 8.28
MRR = 0.0124 cm3/sec

T2 : Solution

Charging resistance R = 40
Charging capacitance C = 20 F
Supply voltage Vs = 220 V
Charging voltage Vc = 110 V

Vs
Cycle time = R C ln V V sec
s c

6 220
= 40 20 10 ln = 0.55 ms
110

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14 Mechanical Engineering Production Engineering

Total energy consumed per cycle (or)

spark energy = 0.5 CVc2 = 0.5 20 106 (110)2 = 0.121 J/Cycle

Total energy consumed per cycle

Average power input =
cycle time

0.121
= = 0.22 kW
0.55 103

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11 NC, CNC, Robotics

T1 : Solution
P4 110 D P5
PAR
ARTT DESCRIPTION
DESCRIPTION:: C1
L2
SET PT = POINT / 0, 0, 0 B R30
P1 = POINT / 160, 20, 0 P3
L3 110
P2 = POINT / 20, 20, 0
P3 = POINT / 20, 140, 0 L1
120
P4 = POINT / 50, 170, 0 C2 P6
20
P5 = POINT / 160, 170, 0 L4
P1
P6 = POINT / 160, 60, 0 P2 100
L1 = LINE / P 2, P 3 20 40

L2 = LINE / P 4, P 5
L3 = LINE / P 5, P 6
L4 = LINE / P1, P2, PARLEL, (LINE/ X -AXIS)
C1 = CIRCLE / 50, 140, 30
C2 = CIRCLE / CENTRE, P1, RADIUS, 40
MACHINING INSTRUCTIONS
INSTRUCTIONS::
PART NO / GNEN FIGURE
CUTTER / 20
TOLER / 0.01
SPINDLON
COOLNT ON
GO TO / L1, TAN TO C1
GOFWD / C 1, TANTO L 2
GO RGT / L 2, PAST L 3
GO FWD / L 3, PAST INT OF C 2, P 6
GO LFT / C 2, PAST L 4

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16 Mechanical Engineering Production Engineering

GO LFT / L4, PAST L 1

GO TO / SETPT
FINI

T2 : Solution

The four types of statements in a complete APT part program are:

(i) Geometry
(ii) Motion
(iii) Post processor
(iv) Compilation control
Part description:
Y
Set PT = POINT / 0,0,0 30 40

P 1 = POINT / 90, 20, 0 20 P4 P5

C1
P 2 = POINT / 20, 20, 0 L2 L3

20
R
P 3 = POINT / 20, 100, 0 P3 135
P 4 = POINT / 50, 130, 0 L4
P 5 = POINT / 90, 130, 0 L1
80
P 6 = POINT / 110, 40 C2 P6
L 1 = LINE / P2, P3 L5
P2 20 R20 P1
L 2 = LINE / P3, P4, ATANGL, 45 X
L 3 = LINE / P4, P5, PARLEL, (LINE / XAXIS)
L 4 = LINE / P1, PERPTO, (LINE / XAXIS)
L 5 = LINE / P1, P2, PARLEL (LINE / XAXIS)
C 1 = CIRCLE / 90, 110, 20
C2 = CIRCLE / CENTER, P1, RADIUS, 20
Machining Instructions:
PART NO / GIVEN FIGURE
CUTTER / 20
TOLER / 0.01
SPINDL / ON
COOLNT / ON
GO TO / L 1, PAST L 2
GO RGT / L 2, AT ANGL 45, PAST L 3
GO RGT / L 3, TANTO C 1
GO FWD / C1, TANTO L 4
GO FWD / L 4, PAST, INTOF C2, P6
GO RGT / C2, PAST, L 5
GO LFT / L 5, PAST, L 1
SPINOL / OFF
COOLNT / OFF
GO TO / SET PT
FINI

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13 Metrology

T1 : Solution

Shaft size = 350.6

0.025

Minimum shaft size = 34.4 mm

= NO GO ring gauge size
Maximum shaft size = 34.975 mm
= GO ring gauge size
Hole size = 350.4
+0.00

Minimum hole size = 35.0 mm

= GO plug gauge size
Maximum hole size = 35.4 mm
NO GO plug gauge size
It will be a clearance fit as maximum shaft is lower then minimum hole diameter.
Minimum clearance
= 350 34.975 = 0.025 mm
Maximum clearance = 35.4 84.4 = 1 mm

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14 Rolling

T1 : Solution

O
R t1 t2
A B 2
C

(i) Highest possible reduction

H = 2R = (0.3)2 200 = 18 mm
or

(t1 t 2 )
=
R
( 60 t 2 )
0.3 =
200
60 t2 = 0.09 200 = 18
t2 = 60 18 = 42 mm, i.e. thickness after rolling
Highest possible reduction = t1 t2 = 60 42 = 18 mm
(ii) Length of contact on rolls = AC
(t1 t 2 )
Q BC = = 9 mm
2
OB = 200 9 = 191 mm

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 Workbook 19

191
= cos1 = 17.254 = 0.301 radian
200
AC = R
= 200 0.301 = 60.227 mm = 60.23 mm
(iii) Rolling load

= P (R w ) (R. = AC, w = width)

= 500 200 0.301 100
= 3011.365 kN

T2 : Solution

ti = 200 mm
D = 500 mm
tf = 100 mm
R = 250 mm
Maximum reduction per pass
t = 2R = 10 mm
Total reduction
Number of passes =
Reduction per pass
100
= = 10 passes
10

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15 Forging

T1 : Solution

Given,
Initial height of cylinder (hi ) = 60 mm
Initial diameter of cylinder (Di ) = 100 mm
Final height of cylinder after forging (h f ) = 30 mm
Final diameter of cylinder after forging (D f ) = Df mm
Coefficient of friction () = 0.05
Yield strength = 120 N/mm2
Sticking is not present (given)

Step I : Calculation of final diameter of cylinder after forging

as (volume of cylinder before forging) = (volume of cylinder after forging)

2
Di hi = Df2 hf
4 4

hi 60
Df2 = Di2 = 1002
hf 30

Df = 141.42 mm
Radius (R f ) = 70.71 mm
As we know all the forging calculations are done on the final dimensions of the billet.

Step II : Calculation of forging stress

(No sticking) forging stress if sticking is not present is given by
2
(R r )
Pr1 = (2 K ) e h

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 Workbook 21

As we know forging of circular billet is a plane stress case

So, 2K = 0
where 0 = mean flow stress
0 = 120 N/mm2 (given)
70.71r
Pr1 = (120) e 300

R
So, forging load is given by = 0 Pr1 2r dr
70.71r
70.71 300
= (2) (120) r .e dr
0

(70.71r ) (70.71r )
= (240 ) ( 300) r e 300 ( 300)e 300 dr

(70.71r ) 70.71r 70.71

= (240 ) 300r e 300 (300)2 e 300

0

70.71
2 2
= (240) (300 70.71 300 ) 0 300 e 300



Forging load = 2.04 MN
Load
Mean die pressure =
Total area

2.04 106 2.04 106

= =
R 2 (70.71)2
Mean Die Pressure = 130 MPa

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16 Drawing

T1 : Solution

For maximum reduction in drawing process

d = y
B
1 + B Af
d = y 1
B Ai

B
1 + B Af
1 = 1
B Ai

B = cot = 0.2cot6 = 1.903
1.903
1 + 1.903 Af
1 = 1
1.903 Ai

df 2 Af
= = 0.571
di 2 Ai
df
= 0.756
di
d1 = 0.756 6 = 4.536
d2 = 0.756 4.536 = 3.429
d3 = 0.756 3.429 = 2.592
d4 = 0.756 2.592 = 1.96
d5 = 0.756 1.96 = 1.481
d6 = 0.756 1.481 = 1.12
< 1.34
Number of passes required = 6
Diameter after 2 passes = 3.429 mm

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18 Sheet Metal Forming

T1 : Solution

Diameter of a circular hole to be pierced = 20 mm = 0.02 m = d

(in a mild steel plate)
Thickness of the plate = 2 mm = 0.002 m = t
The shear strength of the work material = 350 MPa = = 350 106 N/m2 (mild steel)
Force required to pierce a circular hole,
F = ( d t )
= 0.02 0.002 350 106
= 0.04398 106 N
= 43.98 kN

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20 Welding

T1 : Solution

I = 5000 A, t = 0.15 sec, R = 75 106

Nugget dimensions, d = 5 mm, h = 2.5 mm
2
Volume of nugget, V = d h
4
hn
= (5)2 2.5 = 49.087 mm3
4
Energy required to melt nugget
= 49.087 2.9 J dn
= 142.353 J
Energy liberated from the heat source
= I 2R t
= (5000)2 75 106 0.15
= 281.25 J
Heat utilized in welding = 142.353 J

281.25 142.353
= = 49.386%
281.25
Rest 50.614% energy goes to parent metal by conduction.

T2 : Solution

Given,
thickness of each sheet (t) = 1 mm
current (I) = 30,000 A
time (t1) = 0.005 s

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 Workbook 25

Resistance (R) = 100 micro ohms dn

= 100 106
Welding is done by resistance projection welding process.
Nugget or spot generated is of cylindrical shape.
diameter of nugget (d n) = 5 mm hn
Height of nugget (hn) = 1.5 mm
density of steel () = 0.00786 gm/mm3
Heat needed for welding steel = 10 J/mm3
Total heat supplied for weld = I 2Rt1
Cylindrical Nugget
= (30,000)2 100 106 0.005
Total heat supplied for weld = 450 J (Projection welding)

Volume of cylindrical nugget = dn2 hn = 52 1.5 = 29.45 mm3
4 4
So, heat needed for welding steel = 10 volume
= 10 29.45 J
Heat needed = 294.5 J

Heat needed 294.5

So, efficiency of welding = 100 = 450 100
Heat supplied
Efficiency = 65.44%

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21 Conventional Casting
Process

T1 : Solution

For optimum cylindrical side riser, h = d

Volume of casting, Vc = 25 12.5 5
= 1562.5 cm3
Shrinkage of steel during solidification = 3%
Minimum volume of the riser necessary is,
Vr = 0.03 Vc 3
Vr = 46.875 cm3 3
= 140.625 cm3

2
Vr = d h = d3
4 4

1/ 3 1/ 3
4V 4 140.625
or d = r = = 5.627 cm
3.14
Dimension of optimum riser, h = d = 5.63 cm

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