Kathmandu
University
Mechanical
Engineering Department
Manufacturing
Process III (MP III)
Tutorial
Assignment :
(Module Five)
1.What are the elements of tool signature? What does following tool signature signify?
12-14-6-6-8-15-4
2.What are the advantages of tools with negative rake angle?
3. Draw neat diagrams to show different tool angles.
4. Differentiate between orthogonal cutting and oblique cutting. Which method of cutting is followed mostly?
5. Discuss various types of chips that are produced during metal cutting.
6.Define
following terms:
a) shear plane b) shear angle c) shear zone d) chip reduction coefficient
7. Derive the expression for chip reduction coefficient:
rt = Cos (b-g)
Sin b
8. A tool has orthogonal rake angle of 12° during a machining operation. The thickness of chip is 1.5 times the uncut thickness. Find the shear angle and shear strain.
9.Shear angle during a metal cutting operation is 42° and the orthogonal rake angle is 11°. Velocity of chip flow is found to be 20mm/s . find the cutting velocity.
10. Find orthogonal rake angle for a tool having following tool signature in ASA system.
10-12-11-13-6-8-4.
11. Draw the free body diagram of
a chip in orthogonal machining. Show all the forces acting on it.
12. Draw Merchant's circle diagram to show the relationship between various forces acting on the chip.
13. During an orthogonal metal cutting process the resistance to shear force is found to be 50N and the normal force exerted upon the shear plane by the work piece is found to be 150N. The thickness of chip is found to be 0.6 mm, the uncut thickness being 0.35 mm . Calculate the coefficient of friction between the chip and tool face. Rake angle of the too is 13°.
14. Explain the mechanism of formation of BUE.
15. Derive the expression for shear strain in orthogonal chip formation.