Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010

21 THEORY OF METAL MACHINING

Review Questions
21.1 What are the three basic categories of material removal processes?
Answer. As organized in this text, the three basic categories of material removal processes are (1)
conventional machining, (2) abrasive processes, and (3) nontraditional processes.
21.2 What distinguishes machining from other manufacturing processes?
Answer. In machining, material is removed from the workpart so that the remaining material is the
desired part geometry.
21.3 Identify some of the reasons why machining is commercially and technologically important.
Answer. The reasons include the following: (1) it is applicable to most materials; (2) it can produce
a variety of geometries to a part; (3) it can achieve closer tolerances than most other processes; and
(4) it can create good surface finishes.
21.4 Name the three most common machining processes.
Answer. The three common machining processes are (1) turning, (2) drilling, and (3) milling.
21.5 What are the two basic categories of cutting tools in machining? Give two examples of machining
operations that use each of the tooling types.
Answer. The two categories are (1) single-point tools, used in operations such as turning and
boring; and (2) multiple-edge cutting tools, used in operations such as milling and drilling.
21.6 What are the parameters of a machining operation that are included within the scope of cutting
conditions?
Answer. Cutting conditions include speed, feed, depth of cut, and whether or not a cutting fluid is
used.
21.7 Explain the difference between roughing and finishing operations in machining.
Answer. A roughing operation is used to remove large amounts of material rapidly and to produce a
part geometry close to the desired shape. A finishing operation follows roughing and is used to
achieve the final geometry and surface finish.
21.8 What is a machine tool?
Answer. A machine tool can be defined as a power-driven machine that positions and moves a tool
relative to the work to accomplish machining or other metal shaping process.
21.9 What is an orthogonal cutting operation?
Answer. Orthogonal cutting involves the use of a wedge- shaped tool in which the cutting edge is
perpendicular to the direction of speed motion into the work material.
21.10 Why is the orthogonal cutting model useful in the analysis of metal machining?
Answer. Orthogonal cutting is useful in the analysis of metal machining because it simplifies the
rather complex three-dimensional machining situation to two dimensions. In addition, the tooling in
the orthogonal model has only two parameters (rake angle and relief angle), which is a simpler
geometry than a single-point tool.
21.11 Name and briefly describe the four types of chips that occur in metal cutting.

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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010

Answer. The four types are (1) discontinuous, in which the chip is formed into separated segments;
(2) continuous, in which the chip does not segment and is formed from a ductile metal; (3)
continuous with built-up edge, which is the same as (2) except that friction at the tool-chip interface
causes adhesion of a small portion of work material to the tool rake face, and (4) serrated, which are
semi-continuous in the sense that they possess a saw-tooth appearance that is produced by a cyclical
chip formation of alternating high shear strain followed by low shear strain.
21.12 Identify the four forces that act upon the chip in the orthogonal metal cutting model but cannot be
measured directly in an operation.
Answer. The four forces that act upon the chip are (1) friction force, (2) normal force to friction, (3)
shear force, and (4) normal force to friction.
21.13 Identify the two forces that can be measured in the orthogonal metal cutting model.
Answer. The two forces that can be measured in the orthogonal metal cutting model are (1) cutting
force and (2) thrust force.
21.14 What is the relationship between the coefficient of friction and the friction angle in the orthogonal
cutting model?
Answer. The relationship is that the coefficient of friction is the tangent of the friction angle ( =
tan ).
21.15 Describe in words what the Merchant equation tells us.
Answer. The Merchant equation states that the shear plane angle increases when rake angle is
increased and friction angle is decreased.
21.16 How is the power required in a cutting operation related to the cutting force?
Answer. The power required in a cutting operation is equal to the cutting force multiplied by the
cutting speed.
21.17 What is the specific energy in metal machining?
Answer. Specific energy is the amount of energy required to remove a unit volume of the work
material.
21.18 What does the term size effect mean in metal cutting?
Answer. The size effect refers to the fact that the specific energy increases as the cross-sectional
area of the chip (to x w in orthogonal cutting or f x d in turning) decreases.
21.19 What is a tool-chip thermocouple?
Answer. A tool-chip thermocouple is comprised of the tool and chip as the two dissimilar metals
forming the thermocouple junction; as the tool-chip interface heats up during cutting, a small
voltage is emitted from the junction that can be measured to indicate cutting temperature.
Multiple Choice Quiz
There are 17 correct answers in the following multiple choice questions (some questions have multiple
answers that are correct). To attain a perfect score on the quiz, all correct answers must be given. Each
correct answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point, and
each additional answer beyond the correct number of answers reduces the score by 1 point. Percentage score
on the quiz is based on the total number of correct answers.
21.1 Which of the following manufacturing processes are classified as material removal processes (two
correct answers): (a) casting, (b) drawing, (c) extrusion, (d) forging, (e) grinding, (f) machining, (g)
molding, (h) pressworking, and (i) spinning?
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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010

Answer. (e) and (f).

21.2 A lathe is used to perform which one of the following manufacturing operations: (a) broaching, (b)
drilling, (c) lapping, (d) milling, or (e) turning?
Answer. (e).
21.3 With which one of the following geometric forms is the drilling operation most closely associated:
(a) external cylinder, (b) flat plane, (c) round hole, (d) screw threads, or (e) sphere?
Answer. (c).
21.4 If the cutting conditions in a turning operation are cutting speed = 300 ft/min, feed = 0.010 in/rev,
and depth of cut = 0.100 inch, which one of the following is the material removal rate: (a) 0.025
in3/min, (b) 0.3 in3/min, (c) 3.0 in3/min, or (d) 3.6 in3/min?
Answer. (d).
21.5 A roughing operation generally involves which one of the following combinations of cutting
conditions: (a) high v, f, and d; (b) high v, low f and d; (c) low v, high f and d; or (d) low v, f, and d,
where v = cutting speed, f = feed, and d = depth?
Answer. (c).

21.6 Which of the following are characteristics of the orthogonal cutting model (three best answers): (a)
a circular cutting edge is used, (b) a multiple-cutting-edge tool is used, (c) a single-point tool is
used, (d) only two dimensions play an active role in the analysis, (e) the cutting edge is parallel to
the direction of cutting speed, (f) the cutting edge is perpendicular to the direction of cutting speed,
and (g) the two elements of tool geometry are rake and relief angle?
Answer. (d), (f), and (g).

21.7 The chip thickness ratio is which one of the following: (a) tc/to, (b) to/tc, (c) f/d, or (d) to/w, where tc =
chip thickness after the cut, to = chip thickness before the cut, f = feed, d = depth, and w = width of
cut?
Answer. (b).
21.8 Which one of the four types of chip would be expected in a turning operation conducted at low
cutting speed on a brittle work material: (a) continuous, (b) continuous with built-up edge, (c)
discontinuous, or (d) serrated?
Answer. (c).
21.9 According to the Merchant equation, an increase in rake angle would have which of the following
results, all other factors remaining the same (two best answers): (a) decrease in friction angle, (b)
decrease in power requirements, (c) decrease in shear plane angle, (d) increase in cutting
temperature, and (e) increase in shear plane angle?
Answer. (b) and (e).
21.10 In using the orthogonal cutting model to approximate a turning operation, the chip thickness before
the cut to corresponds to which one of the following cutting conditions in turning: (a) depth of cut d,
(b) feed f, or (c) speed v?
Answer. (b).
21.11 Which one of the following metals would usually have the lowest unit horsepower in a machining
operation: (a) aluminum, (b) brass, (c) cast iron, or (d) steel?
Answer. (a).
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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010

21.12 For which one of the following values of chip thickness before the cut to would you expect the
specific energy in machining to be the greatest: (a) 0.010 inch, (b) 0.025 inch, (c) 0.12 mm, or (d)
0.50 mm?
Answer. (c).
21.13 Which of the following cutting conditions has the strongest effect on cutting temperature: (a) feed
or (b) speed?
Answer. (b).
Problems
Chip Formation and Forces in Machining
21.1 In an orthogonal cutting operation, the tool has a rake angle = 15 . The chip thickness before the cut
= 0.30 mm and the cut yields a deformed chip thickness = 0.65 mm. Calculate (a) the shear plane
angle and (b) the shear strain for the operation.
Solution: (a) r = to/tc = 0.30/0.65 = 0.4615
= tan-1(0.4615 cos 15/(1 - 0.4615 sin 15)) = tan-1(0.5062) = 26.85
(b) Shear strain = cot 26.85 + tan (26.85 - 15) = 1.975 + 0.210 = 2.185
21.2 In Problem 21.1, suppose the rake angle were changed to 0 . Assuming that the friction angle
remains the same, determine (a) the shear plane angle, (b) the chip thickness, and (c) the shear strain
for the operation.
Solution: From Problem 21.1, = 15 and = 26.85 . Using the Merchant Equation, Eq. (21.16):
= 45 + /2 - /2; rearranging, = 2(45) + - 2
= 2(45) + - 2( ) = 90 + 15 2(26.85) = 51.3
Now, with = 0 and remaining the same at 51.3 , = 45 + 0/2 51.3/2 = 19.35
(b) Chip thickness at = 0: tc = to/tan = 0.30/tan 19.35 = 0.854 mm
(c) Shear strain = cot 19.35 + tan (19.35 - 0) = 2.848 + 0.351 = 3.199
21.3 In an orthogonal cutting operation, the 0.250 in wide tool has a rake angle of 5 . The lathe is set so
the chip thickness before the cut is 0.010 in. After the cut, the deformed chip thickness is measured
to be 0.027 in. Calculate (a) the shear plane angle and (b) the shear strain for the operation.
Solution: (a) r = to/tc = 0.010/0.027 = 0.3701
= tan-1(0.3701 cos 5/(1 - 0.3701 sin 5)) = tan-1(0.3813) = 20.9
(b) Shear strain = cot 20.9 + tan (20.9 5) = 2.623 + 0.284 = 2.907
21.4 In a turning operation, spindle speed is set to provide a cutting speed of 1.8 m/s. The feed and depth
of cut of cut are 0.30 mm and 2.6 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. Use the orthogonal cutting model as an approximation of the
turning process.
Solution: (a) r = to/tc = 0.30/0.49 = 0.612
= tan-1(0.612 cos 8/(1 0.612 sin 8)) = tan-1(0.6628) = 33.6
(b) = cot 33.6 + tan (33.6 - 8) = 1.509 + 0.478 = 1.987
(c) RMR = (1.8 m/s x 103 mm/m)(0.3)(2.6) = 1404 mm3/s

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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010

21.5 The cutting force and thrust force in an orthogonal cutting operation are 1470 N and 1589 N,
respectively. The rake angle = 5 , the width of the cut = 5.0 mm, the chip thickness before the cut =
0.6, and the chip thickness ratio = 0.38. Determine (a) the shear strength of the work material and
(b) the coefficient of friction in the operation.
Solution: (a) = tan-1(0.38 cos 5/(1 - 0.38 sin 5)) = tan-1(0.3916) = 21.38
Fs = 1470 cos 21.38 1589 sin 21.38 = 789.3 N
As = (0.6)(5.0)/sin 21.38 = 3.0/.3646 = 8.23 mm2
S = 789.3/8.23 = 95.9 N/mm2 = 95.9 MPa
(b) = 45 + /2 - /2; rearranging, = 2(45) + - 2
= 2(45) + - 2( ) = 90 + 5 2(21.38) = 52.24
= tan 52.24 = 1.291
21.6 The cutting force and thrust force have been measured in an orthogonal cutting operation to be 300
lb and 291 lb, respectively. The rake angle = 10 , width of cut = 0.200 in, chip thickness before the
cut = 0.015, and chip thickness ratio = 0.4. Determine (a) the shear strength of the work material
and (b) the coefficient of friction in the operation.
Solution: = tan-1(0.4 cos 10/(1 - 0.4 sin 10)) = tan-1(0.4233) = 22.94
Fs = 300 cos 22.94 - 291sin 22.94 = 162.9 lb.
As = (0.015)(0.2)/sin 22.94 = 0.0077 in2
S = 162.9/0.0077 = 21,167 lb/in2
= 2(45) + - 2( ) = 90 + 10 - 2(22.94) = 54.1
= tan 54.1 = 1.38
21.7 An orthogonal cutting operation is performed using a rake angle of 15 , chip thickness before the
cut = 0.012 in and width of cut = 0.100 in. The chip thickness ratio is measured after the cut to be
0.55. Determine (a) the chip thickness after the cut, (b) shear angle, (c) friction angle, (d) coefficient
of friction, and (e) shear strain.
Solution: (a) r = to/tc, tc = to/r = 0.012/0.55 = 0.022 in
(b) = tan-1(0.55 cos 15/(1 - 0.55 sin 15)) = tan-1(0.6194) = 31.8
(c) = 2(45) + - 2( ) = 90 + 15 - 2(31.8) = 41.5
(d) = tan 41.5 = 0.88
(e) = cot 31.8 + tan(31.8 - 15) = 1.615 + 0.301 = 1.92
21.8 The orthogonal cutting operation described in previous Problem 21.7 involves a work material
whose shear strength is 40,000 lb/in2. Based on your answers to the previous problem, compute (a)
the shear force, (b) cutting force, (c) thrust force, and (d) friction force.
Solution: (a) As = (0.012)(0.10)/sin 31.8 = 0.00228 in2.
Fs = AsS = 0.00228(40,000) = 91.2 lb
(b) Fc = 91.2 cos (41.5 - 15)/cos (31.8 + 41.5 -15) = 155 lb
(c) Ft = 91.2 sin (41.5 - 15)/cos (31.8 + 41.5 -15) = 77.2 lb
(d) F = 155 sin 15 - 77.2 cos 15 = 115 lb
21.9 In an orthogonal cutting operation, the rake angle = -5 , chip thickness before the cut = 0.2 mm and
width of cut = 4.0 mm. The chip ratio = 0.4. Determine (a) the chip thickness after the cut, (b) shear
angle, (c) friction angle, (d) coefficient of friction, and (e) shear strain.
Solution: (a) r = to/tc, tc = to/r = 0.2/.4 = 0.5 mm

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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010

(b) = tan-1(0.4 cos(5)/(1 - 0.4 sin(5))) = tan-1(0.3851) = 21.1

(c) = 2(45) + - 2( ) = 90 + (-5) - 2(21.8) = 42.9
(d) = tan 42.9 = 0.93
(e) = cot 31.8 + tan(31.8 - 15) = 2.597 + 0.489 = 3.09
21.10 The shear strength of a certain work material = 50,000 lb/in2. An orthogonal cutting operation is
performed using a tool with a rake angle = 20 at the following cutting conditions: cutting speed =
100 ft/min, chip thickness before the cut = 0.015 in, and width of cut = 0.150 in. The resulting chip
thickness ratio = 0.50. Determine (a) the shear plane angle, (b) shear force, (c) cutting force and
thrust force, and (d) friction force.
Solution: (a) = tan-1(0.5 cos 20/(1 - 0.5 sin 20)) = tan-1(0.5668) = 29.5
(b) As = (0.015)(0.15)/sin 29.5 = 0.00456 in2.
Fs = AsS = 0.00456(50,000) = 228 lb
(c) = 2(45) + - 2( ) = 90 + 20 - 2(29.5) = 50.9
Fc = 228 cos (50.9 - 20)/cos (29.5 + 50.9 -20) = 397 lb
Ft = 228 sin (50.9 - 20)/cos (29.5 + 50.9 -20) = 238 lb
(d) F = 397 sin 20 + 238 cos 20 = 359 lb
21.11 Consider the data in Problem 21.10 except that rake angle is a variable, and its effect on the forces
in parts (b), (c), and (d) is to be evaluated. (a) Using a spreadsheet calculator, compute the values of
shear force, cutting force, thrust force, and friction force as a function of rake angle over a range of
rake angles between the high value of 20 in Problem 21.10 and a low value of -10 . Use intervals
of 5 between these limits. The chip thickness ratio decreases as rake angle is reduced and can be
approximated by the following relationship: r = 0.38 + 0.006 , where r = chip thickness and =
rake angle. (b) What observations can be made from the computed results?
Solution: (a) The authors spreadsheet calculations (using Excel) returned the following results:
r Fs (lb) Fc (lb) Ft (lb) F (lb)
20 0.5 228 397 238 359
15 0.47 245 435 309 411
10 0.44 265 480 399 476
5 0.41 288 531 515 559
0 0.38 317 592 667 667
-5 0.35 351 665 870 809
-10 0.32 393 754 1150 1001
(b) Observations: (1) All forces increase as rake angle decreases. (2) The change in forces with rake
angle increases at an accelerating rate as rake angle is reduced. (3) Thrust force is less than cutting
force at high rake angles (e.g., 20 ) but increases at a faster rate than cutting force so that its value is
greater at low and negative rake angles. (4) Chip thickness ratio decreases with decreasing rake
angle, as indicated by the given relationship r = 0.38 + 0.006 .
21.12 Solve previous Problem 21.10 except that the rake angle has been changed to -5 and the resulting
chip thickness ratio = 0.35.
Solution: (a) = tan-1(0.35 cos(5)/(1 - 0.35 sin(-5))) = tan-1(0.3384) = 18.7
(b) As = (0.015)(0.15)/sin 18.7 = 0.00702 in2.
Fs = AsS = 0.00702(50,000) = 351 lb
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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010

(c) = 2(45) + - 2( ) = 90 + (-5) - 2(18.7) = 47.6

Fc = 351 cos(47.6 - (-5))/cos(18.7 + 47.6 - (-5)) = 665 lb
Ft = 351 sin(47.6 - (-5))/cos(18.7 + 47.6 - (-5)) = 870 lb
(d) F = 665 sin (-5) + 870 cos (-5) = 809 lb
21.13 A carbon steel bar with 7.64 in diameter has a tensile strength of 65,000 lb/in2 and a shear strength
of 45,000 lb/in2. The diameter is reduced using a turning operation at a cutting speed of 400 ft/min.
The feed is 0.011 in/rev and the depth of cut is 0.120 in. The rake angle on the tool in the direction
of chip flow is 13 . The cutting conditions result in a chip ratio of 0.52. Using the orthogonal model
as an approximation of turning, determine (a) the shear plane angle, (b) shear force, (c) cutting force
and feed force, and (d) coefficient of friction between the tool and chip.
Solution: (a) = tan-1(0.52 cos 13/(1 - 0.52 sin 13)) = tan-1(0.5738) = 29.8
(b) As = tow/sin = (0.011)(0.12)/sin 29.8 = 0.00265 in2.
Fs = AsS = 0.00587(40,000) = 119.4 lb
(c) = 2(45) + - 2( ) = 90 + 10 - 2(29.8) = 43.3
Fc = Fs
Fc = 264.1 cos (43.3 - 13)/cos (29.8 + 43.3 - 13) = 207 lb
Ft = Fs
Ft = 264.1 sin (43.3 - 13)/cos (29.8 + 43.3 - 13) = 121 lb
(d) = tan = tan 43.3 = 0.942
21.14 Low carbon steel having a tensile strength of 300 MPa and a shear strength of 220 MPa is cut in a
turning operation with a cutting speed of 3.0 m/s. The feed is 0.20 mm/rev and the depth of cut is
3.0 mm. The rake angle of the tool is 5 in the direction of chip flow. The resulting chip ratio is
0.45. Using the orthogonal model as an approximation of turning, determine (a) the shear plane
angle, (b) shear force, (c) cutting force and feed force.
Solution: (a) = tan-1(0.45 cos 5/(1 - 0.45 sin 5)) = tan-1(0.4666) = 25.0
(b) As = tow/sin = (0.2)(3.0)/sin 25.0 = 1.42 mm2.
Fs = AsS = 1.42(220) = 312 N
(c) = 2(45) + - 2( ) = 90 + 5 - 2(25.0) = 45.0
Fc = Fscos ( )/cos ( + )
Fc = 312 cos(45 - 5)/cos(25.0 + 45.0 - 5) = 566 N
Ft = Fssin( )/cos( + )
Ft = 312 sin(45 - 5)/cos(25.0 + 45.0 - 5) = 474 N
21.15 A turning operation is made with a rake angle of 10 , a feed of 0.010 in/rev and a depth of cut =
0.100 in. The shear strength of the work material is known to be 50,000 lb/in2, and the chip
thickness ratio is measured after the cut to be 0.40. Determine the cutting force and the feed force.
Use the orthogonal cutting model as an approximation of the turning process.
Solution: = tan-1(0.4 cos 10/(1 - 0.4 sin 10)) = tan-1(0.4233) = 22.9
As = (0.010)(0.10)/sin 22.9 = 0.00257 in2
Fs = AsS = 0.00256(50,000) = 128 lb
= 2(45) + - 2( ) = 90 + 10 - 2(22.9) = 54.1
Fc = 128 cos (54.1 - 10)/cos (22.9 + 54.1 - 10) = 236 lb
Ft = 128 sin (54.1 - 10)/cos (22.9 + 54.1 - 10) = 229 lb
21.16 Show how Eq. (21.3) is derived from the definition of chip ratio, Eq. (21.2), and Figure 21.5(b).
Solution: Begin with the definition of the chip ratio, Eq. (21.2): r = to/tc = sin /cos ( - )
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Rearranging, r cos ( - ) = sin

Using the trigonometric identity cos( - ) = cos cos + sin sin
r (cos cos + sin sin ) = sin
Dividing both sides by sin , we obtain r cos /tan + r sin = 1
r cos /tan = 1 - r sin
Rearranging, tan = r cos /(1 - r sin ) Q.E.D.
21.17 Show how Eq. (21.4) is derived from Figure 21.6.
Solution: In the figure, = AC/BD = (AD + DC)/BD = AD/BD + DC/BD
AD/BD = cot and DC/BD = tan ( - )
Thus, = cot + tan ( - ) Q.E.D.
21.18 Derive the force equations for F, N, Fs, and Fn (Eqs. (21.9) through (21.12) in the text) using the
force diagram of Figure 21.11.
Solution: Eq. (21.9): In Figure 23.11, construct a line starting at the intersection of Ft and Fc that is
perpendicular to the friction force F. The constructed line is at an angle with Fc. The vector F is
divided into two line segments, one of which = Fc sin and the other = Ft cos .
Thus, F = Fc sin + Ft cos . Q.E.D.
Eq. (21.10): In Figure 23.11, translate vector N vertically upward until it coincides with the
previously constructed line, whose length = Fc cos . Next, translate vector Ft to the right and
downward at an angle until its base is at the arrowhead of F. Ft now makes an angle with F.
The arrowhead of Ft will now be at the base of the translated base of N. The distance along the
previously constructed line between the Ft arrowhead (base of translated N vector) and F is Ft sin .
Hence, N = Fc cos - Ft sin Q.E.D.
Eq. (21.11): In Figure 23.11, extend vector Fs in the opposite direction of its arrowhead, and from
the intersection of Ft and Fc construct a line that is perpendicular to vector Fs. A right triangle now
exists in which Fc is the hypotenuse and the two sides are (1) the extended Fs vector and (2) the
constructed line that runs between Fs and the intersection of Fc and Ft. The extended Fs vector is
related to Fc as Fc cos . The length difference between the extended Fs vector and the original Fs
vector is Ft sin .
Thus Fs (original) = Fc cos - Ft sin Q.E.D.
Eq. (21.12): In Figure 23.11, construct a line from the intersection of Ft and Fc that is perpendicular
to and intersects with vector Fn. Vector Fn is now divided into two line segments, one of which = Ft
cos and the other = Fc sin .
Hence, Fn = Fc sin + Ft cos Q.E.D.
Power and Energy in Machining
21.18 In a turning operation on stainless steel with hardness = 200 HB, the 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 = 90%. Use Table 21.2 to obtain the
appropriate specific energy value.
Solution: From Table 21.2, U = 2.8 N-m/mm3 = 2.8 J/mm3
RMR = vfd = (200 m/min)(103 mm/m)(0.25 mm)(7.5 mm) = 375,000 mm3/min = 6250 mm3/s
Pc = (6250 mm3/s)(2.8 J/mm3) = 17,500 J/s = 17,500 W = 17.5 kW
Accounting for mechanical efficiency, Pg = 17.5/0.90 = 19.44 kW
21.19 In Problem 21.18, compute the lathe power requirements if feed = 0.50 mm/rev.

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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010

Solution: This is the same basic problem as the previous, except that a correction must be made for
the size effect. Using Figure 21.14, for f = 0.50 mm, correction factor = 0.85.
From Table 21.2, U = 2.8 J/mm3. With the correction factor, U = 2.8(0.85) = 2.38 J/mm3.
RMR = vfd = (200 m/min)(103 mm/m)(0.50 mm)(7.5 mm) = 750,000 mm3/min = 12,500 mm3/s
Pc = (12,500 mm3/s)(2.38 J/mm3) = 29,750 J/s = 29,750 W = 29.75 kW
Accounting for mechanical efficiency, Pg = 29.75/0.90 = 33.06 kW
21.20 In a turning operation on aluminum, cutting speed = 900 ft/min, feed = 0.020 in/rev, and depth of
cut = 0.250 in. What horsepower is required of the drive motor, if the lathe has a mechanical
efficiency = 87%? Use Table 21.2 to obtain the appropriate unit horsepower value.
Solution: From Table 21.2, HPu = 0.25 hp/(in3/min) for aluminum. Since feed is greater than 0.010
in/rev in the table, a correction factor must be applied from Figure 21.14. For f = 0.020 in/rev = to,
correction factor = 0.9.
HPc = HPu x RMR, HPg = HPc/E
RMR = vfd = 900 x 12(.020)(0.250) = 54 in3/min
HPc = 0.9(0.25)(54) = 12.2 hp
HPg = 12.2/0.87 = 14.0 hp
21.21 In a turning operation on plain carbon steel whose Brinell hardness = 275 HB, the cutting speed is
set at 200 m/min and depth of cut = 6.0 mm. The lathe motor is rated at 25 kW, and its mechanical
efficiency = 90%. Using the appropriate specific energy value from Table 21.2, determine the
maximum feed that can be set for this operation. Use of a spreadsheet calculator is recommended
for the iterative calculations required in this problem.
Solution: From Table 21.2, U = 2.8 N-m/mm3 = 2.8 J/mm3
RMR = vfd = (200 m/min)(103 mm/m)(6 mm)f = 1200(103)f mm3/min = 20(103)f mm3/s
Available power Pc = Pg E = 25(103)(0.90) = 22.5 (103) = 22,500W = 22,500 N-m/s
Required power Pc = (2.8 N-m/mm3)( 20 x 103) f = 56,000 f (units are N-m/s)
Setting available power = required power, 22,500 = 56,000 f
f = 22,500/56,000 = 0.402 mm (this should be interpreted as mm/rev for a turning operation)
However, for this feed, correction factor in Figure 21.14 = 0.9. Thus U = 2.8(0.90) = 2.52 N-m/mm3
and an iterative calculation procedure is required to match the unit power value with the feed, taking
the correction factor into account.
Required Pc = (2.52)(20 x 103) f = 50,400 f
Again setting available power = required power, 22,500 = 50,400 f
f = 22,500/50,400 = 0.446 mm/rev
One more iteration using the correction factor yields a value around f = 0.45 mm/rev.
The authors spreadsheet calculations (using Excel) returned a value closer to f = 0.46 mm/rev.
However, whether a spreadsheet is used or not, the difficulty that remains is reading the values of
the feed and the correction factor in Figure 21.14.
21.22 A turning operation is to be performed on a 20 hp lathe that has an 87% efficiency rating. The
roughing cut is made on alloy steel whose hardness is in the range 325 to 335 HB. The cutting
speed is 375 ft/min, feed is 0.030 in/rev, and depth of cut is 0.150 in. Based on these values, can the
job be performed on the 20 hp lathe? Use Table 21.2 to obtain the appropriate unit horsepower
value.
Solution: From Table 21.2, HPu = 1.3 hp/(in3/min)
Since the uncut chip thickness (0.030 in) is different from the tabular value of 0.010, a correction
factor must be applied. From Figure 21.14, the correction factor is 0.8. Therefore, the corrected HPu
= 0.8*1.3 = 1.04 hp/(in3/min)
RMR = vfd = 375 ft/min(12 in/ft)(0.03 in)(0.150 in) = 20.25 in3/min
HPc = (20.25 in3/min)(1.04 hp/(in3/min)) = 21.06 hp required.
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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010

At efficiency E = 87%, available horsepower = 0.87(20) = 17.4 hp

Since required horsepower exceeds available horsepower, the job cannot be accomplished on the 20
hp lathe, at least not at the specified cutting speed of 375 ft/min.
21.23 Suppose the cutting speed in Problems 21.7 and 21.8 is 200 ft/min. From your answers to those
problems, find (a) the horsepower consumed in the operation, (b) metal removal rate in in3/min, (c)
unit horsepower (hp-min/in3), and (d) the specific energy (in-lb/in3).
Solution: (a) From Problem 21.8, Fc = 155 lb. HPc = 155(200)/33,000 = 0.94 hp
(b) RMR = vfd = (200 x 12)(0.012)(0.100) = 2.88 in3/min
(c) HPu = 0.94/2.88 = 0.326 hp/(in3/min)
(d) U = 155(200)/2.88 = 10,764 ft-lb/in3 = 129,167 in-lb/in3
21.24 For Problem 21.12, the lathe has a mechanical efficiency = 0.83. Determine (a) the horsepower
consumed by the turning operation; (b) horsepower that must be generated by the lathe; (c) unit
horsepower and specific energy for the work material in this operation.
Solution: (a) From Problem 21.12, Fc = 207 lb.
HPc = Fcv/33,000 = 207(400)/33,000 = 2.51 hp
(b) HPg = HPc/E = 2.51/0.83 = 3.02 hp
(c) RMR = 12 vfd = (400 x 12)(0.011)(0.120) = 6.336 in3/min
HPu = HPc/RMR = 2.51/6.336 = 0.396 hp/(in3/min)
U = Fcv/RMR = 207(400 x 12)/6.336 = 157,000 in-lb/in3
21.25 In a turning operation on low carbon steel (175 BHN), cutting speed = 400 ft/min, feed = 0.010
in/rev, and depth of cut = 0.075 in. The lathe has a mechanical efficiency = 0.85. Based on the unit
horsepower values in Table 21.2, determine (a) the horsepower consumed by the turning operation
and (b) the horsepower that must be generated by the lathe.
Solution: (a) From Table 21.2, HPu = 0.6 hp/(in3/min) for low carbon steel.
HPc = HPu x RMR
RMR = vfd = 400 x 12(.010)(0.075) = 3.6 in3/min
HPc = 0.6(3.6) = 2.16 hp
(b) HPg = 2.16/0.85 = 2.54 hp
21.26 Solve Problem 21.25 except that the feed = 0.0075 in/rev and the work material is stainless steel
(Brinell Hardness = 240 HB).
Solution: (a) From Table 21.2, HPu = 1.0 hp/(in3/min) for stainless steel. Since feed is lower than
0.010 in/rev in the table, a correction factor must be applied from Figure 21.14. For f = 0.0075
in/rev = to, correction factor = 1.1.
HPc = HPu x RMR
RMR = 400 x 12(0.0075)(0.12) = 4.32 in3/min
HPc = 1.1(1.0)(4.32) = 4.75 hp
(b) HPg = 5.01/0.83 = 5.73 hp
21.27 A turning operation is carried out on aluminum (100 BHN). Cutting speed = 5.6 m/s, feed = 0.25
mm/rev, and depth of cut = 2.0 mm. The lathe has a mechanical efficiency = 0.85. Based on the
specific energy values in Table 21.2, determine (a) the cutting power and (b) gross power in the
turning operation, in Watts.
Solution: (a) From Table 21.2, U = 0.7 N-m/mm3 for aluminum.
RMR = vfd = 5.6(103)(.25)(2.0) = 2.8(103) mm3/s.

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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010

Pc = U RMR = 0.7(2.8)(103) = 1.96(103) N-m/s = 1960 W

(b) Gross power Pg = 1960/0.85 = 2306 W
21.28 Solve Problem 21.27 but with the following changes: cutting speed = 1.3 m/s, feed = 0.75 mm/rev,
and depth = 4.0 mm. Note that although the power used in this operation is only about 10% greater
than in the previous problem, the metal removal rate is about 40% greater.
Solution: (a) From Table 21.2, U = 0.7 N-m/mm3 for aluminum. Since feed is greater than 0.25
mm/rev in the table, a correction factor must be applied from Figure 21.14. For f = 0.75 mm/rev =
to, correction factor = 0.80.
RMR = vfd = 1.3(103)(.75)(4.0) = 3.9(103) mm3/s.
Pc = U RMR = 0.8(0.7)(3.9)(103) = 2.184(103) N-m/s = 2184 W
(b) Gross power Pg = 2184/0.85 = 2569 W
21.29 A turning operation is performed on an engine lathe using a tool with zero rake angle in the
direction of chip flow. The work material is an alloy steel with hardness = 325 Brinell hardness.
The feed is 0.015 in/rev, depth of cut is 0.125 in and cutting speed is 300 ft/min. After the cut, the
chip thickness ratio is measured to be 0.45. (a) Using the appropriate value of specific energy from
Table 21.2, compute the horsepower at the drive motor, if the lathe has an efficiency = 85%. (b)
Based on horsepower, compute your best estimate of the cutting force for this turning operation.
Use the orthogonal cutting model as an approximation of the turning process.
Solution: (a) From Table 21.2, U = Pu = 520,000 in-lb/in3 for alloy steel of the specified hardness.
Since feed is greater than 0.010 in/rev in the table, a correction factor must be applied from Figure
21.14. For f = 0.015 in/rev = to, correction factor = 0.95. Thus,
U = 520,000(0.95) = 494,000 in-lb/in3 = 41,167 ft-lb/in3.
RMR = 300 x 12(.015)(0.125) = 6.75 in3/min
Pc = U RMR = 41,167(6.75) = 277,875 ft-lb/min
HPc = 277,875/33,000 = 8.42 hp
HPg = 8.42/0.85 = 9.9 hp
(b) HPc = vFc/33,000. Rearranging, Fc = 33,000 (HPc/v) = 33,000(8.42/300) = 926 lb.
Check: Use unit horsepower from Table 21.2 rather than specific energy. HPu = 1.3 hp/(in3/min).
Applying the correction factor correction factor = 0.95, HPu = 1.235 hp/(in3/min).
RMR = 300 x 12(.015)(0.125) = 6.75 in3/min, same as before
HPc = 1.235(6.75) = 8.34 hp
HPg = 8.34/0.85 = 9.8 hp
(b) Fc = 33,000 (8.3/300) = 913 lb.
21.30 A lathe performs a turning operation on a workpiece of 6.0 in diameter. The shear strength of the
work is 40,000 lb/in2 and the tensile strength is 60,000 lb/in2. The rake angle of the tool is 6 . The
cutting speed = 700 ft/min, feed = 0.015 in/rev, and depth = 0.090 in. The chip thickness after the
cut is 0.025 in. Determine (a) the horsepower required in the operation, (b) unit horsepower for this
material under these conditions, and (c) unit horsepower as it would be listed in Table 21.2 for a to
of 0.010 in. Use the orthogonal cutting model as an approximation of the turning process.
Solution: (a) Must find Fc and v to determine HP.
r = 0.015/0.025 = 0.6
= tan-1(0.6 cos 6/(1 - 0.6 sin 6)) = tan-1 (0.6366) = 32.5
- 2( ) = 90 + 6 -2(32.5) = 31.0
As = tow/sin = (0.015)(0.09)/sin 32.5 = 0.00251 in2
Fs = SAs = 40,000(0.00251) = 101 lb.
Fc = Fs cos ( )/cos ( + )
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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010

Fc = 101 cos(31 - 6)/cos(32.5 + 31.0 6) = 170 lb.

HPc = Fcv/33,000 = 170(700)/33,000 = 3.61 hp.
(b) RMR = 700 x 12(0.0075)(0.075) = 11.3 in3/min
HPu = HPc /RMR = 3.61/11.3 = 0.319 hp/(in3/min)
(c) Correction factor = 0.85 from Fig. 21.14 to account for the fact that f = 0.015 in/rev instead of
0.010 in/rev. Taking this correction factor into account, HPu = 0.375/0.85 = 0.441 hp/(in3/min) as it
would appear in Table 21.2 for a feed (to) = 0.010 in/rev.
21.31 In a turning operation on an aluminum alloy workpiece, the feed = 0.020 in/rev, and depth of cut =
0.250 in. The motor horsepower of the lathe is 20 hp and it has a mechanical efficiency = 92%. The
unit horsepower value = 0.25 hp/(in3/min) for this aluminum grade. What is the maximum cutting
speed that can be used on this job?
Solution: From Table 21.3, HPu = 0.25 hp/(in3/min) for aluminum. Since feed is greater than 0.010
in/rev in the table, a correction factor must be applied from Figure 21.14. For f = 0.020 in/rev = to,
correction factor = 0.9.
HPc = HPu x RMR, HPg = HPc/E
RMR = vfd = 12v(.020)(0.250) = 0.06 v in3/min
HPc = 0.9(0.25)(0.06 v) = 0.0135 v hp
HPg = 0.0135 v /0.92 = 0.014674 v = 20 hp
v = 20/0.014674 = 1363 ft/min
Cutting Temperature
21.32 Orthogonal cutting is performed on a metal whose mass specific heat = 1.0 J/g-C, density = 2.9
g/cm3, and thermal diffusivity = 0.8 cm2/s. The cutting speed is 4.5 m/s, uncut chip thickness is 0.25
mm, and width of cut is 2.2 mm. The cutting force is measured at 1170 N. Using Cook's equation,
determine the cutting temperature if the ambient temperature = 22 C.
Solution: C = (2.9 g/cm3)(1.0 J/g- C) = 2.90 J/cm3- C = (2.90x10-3) J/mm3- C
K = 0.8 cm2/s = 80 mm2/s
U = Fcv/RMR = 1170 N x 4.5 m/s/(4500 mm/s x 0.25 mm x 2.2 mm) = 2.127 N-m/mm3
T = 0.4U/( ) x (vto/K)0.333
T = 22 + (0.4 x 2.127 N-m/mm3/(2.90x10-3) J/mm3-C) [4500 mm/s x 0.25 mm/80 mm2/s]0.333
T = 22 + (0.2934 x 103 C)(14.06).333 = 22 + 293.4(2.41) = 22 + 707 = 729 C
21.33 Consider a turning operation performed on steel whose hardness = 225 HB at a speed = 3.0 m/s,
feed = 0.25 mm, and depth = 4.0 mm. Using values of thermal properties found in the tables and
definitions of Section 4.1 and the appropriate specific energy value from Table 21.2, compute an
estimate of cutting temperature using the Cook equation. Assume ambient temperature = 20 C.
Solution: From Table 21.2, U = 2.2 N-m/mm3 = 2.2 J/mm3
From Table 4.1, = 7.87 g/cm3 = 7.87(10-3) g/mm3
From Table 4.1, C = 0.11 Cal/g- C. From note a at the bottom of the table, 1 cal = 4.186 J.
Thus, C = 0.11(4.186) = 0.460 J/ g- C
C = (7.87 g/cm3)(0.46 J/g- C) = 3.62(10-3) J/mm3- C
From Table 4.2, thermal conductivity k = 0.046 J/s-mm- C
From Eq. (4.3), thermal diffusivity K = k/ C
K = 0.046 J/s-mm- C /[(7.87 x 10-3 g/mm3)(0.46 J/g- C)] = 12.7 mm2/s
Using Cooks equation, to = f = 0.25 mm
T = (0.4(2.2)/3.62(10-3))[3(103)(0.25)/12.7]0.333 = 0.2428(103)(59.06)0.333
= 242.8(3.89) = 944.4 C
Final temperature, taking ambient temperature in account T = 20 + 944 = 964 C

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