CH 20

Solutions for Fundamentals of Modern Manufacturing, 5/e (published by Wiley) MPGroover 2012
20 THEORY OF METAL MACHINING

Review Questions
20.1 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.
20.2 What distinguishes machining from other manufacturing processes?
Answer. In machining, material is removed from the work part so that the remaining material is the
desired part geometry.
20.3 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.
20.4 Name the three most common machining processes.
Answer. The three common machining processes are (1) turning, (2) drilling, and (3) milling.
20.5 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.
20.6 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.
20.7 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.
20.8 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.
20.9 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.
20.10 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.
20.11 Name and briefly describe the four types of chips that occur in metal cutting.
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes only to
students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work beyond that permitted
by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner is unlawful.
20-1
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.
20.12 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.
20.13 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.
20.14 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 ).
20.15 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.
20.16 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.
20.17 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.
20.18 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.
20.19 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.
Problems
Answers to problems labeled (A) are listed in an Appendix at the back of the book.
Chip Formation and Forces in Machining
20.1 (A) (SI units) The rake angle in an orthogonal cutting operation = 12. The chip thickness before
the cut = 0.30 mm, and the resulting chip thickness after the cut = 0.70 mm. Calculate (a) the shear
plane angle and (b) the shear strain for the operation.
Solution: (a) r = to/tc = 0.30/0.70 = 0.4286
20-1
= tan-1(0. 4286 cos 12/(1 - 0. 4286 sin 12)) = tan-1(0.4602) = 24.7

(b) Shear strain = cot 24.7 + tan (24.7 - 15) = 2.173 + 0.226 = 2.399
20.2 (SI units) In Problem 20.1, 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 20.1, = 12 and = 24.7. Using the Merchant Equation, Equation
(20.16):
= 45 + /2 - /2; rearranging, = 2(45) + - 2
= 2(45) + - 2() = 90 + 15 2(24.7) = 52.6
Now, with = 0 and remaining the same at 52.6, = 45 + 0/2 52.6/2 = 18.7
(b) Chip thickness at = 0: tc = to/tan = 0.30/tan 18.7 = 0.886 mm
(c) Shear strain = cot 18.7 + tan (18.7 - 0) = 2.954 + 0.338 = 3.292
20.3 (USCS units) The tool in an orthogonal cutting operation is 0.250 in wide and has a rake angle = 5.
The machine tool is set for a chip thickness before the cut of 0.012 in, and cutting speed = 100
ft/min. After the cut, the deformed chip thickness = 0.031 in. Calculate (a) the shear plane angle, (b)
the shear strain for the operation, and (c) material removal rate.
Solution: (a) r = to/tc = 0.012/0.031 = 0.3871
= tan-1(0. 3871 cos 5/(1 - 0. 3871 sin 5)) = tan-1(0.3980) = 21.7
(b) Shear strain = cot 21.7 + tan (21.7 5) = 2.512 + 0.300 = 2.812
(c) RMR = vtow = 100(12)(0012)(0.250) = 3.6 in3/min
20.4 (SI units) In a turning operation, cutting speed = 1.8 m/s. Feed = 0.30 mm/rev and depth of cut = 2.6
mm. Rake angle = 8. After the cut, the deformed chip thickness = 0.56 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 = 0.30/0.56 = 0.536
= tan-1(0. 536 cos 8/(1 0. 536 sin 8)) = tan-1(0.5736) = 29.8
(b) = cot 29.8 + tan (29.8 - 8) = 1.746 + 0.400 = 2.146
(c) RMR = (1.8 m/s x 103 mm/m)(0.3)(2.6) = 1404 mm3/s
20.5 (A) (SI units) The cutting force and thrust force in an orthogonal cutting operation are 1470 N and
1589 N, respectively. Rake angle = 5, width of the cut = 5.0 mm, chip thickness before the cut =
0.6, and 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
20.6 (USCS units) The cutting force and thrust force have been measured in an orthogonal cutting
operation to be 300 lb and 291 lb, respectively. Rake angle = 10 and width of cut = 0.200 in. Chip
20-1
thickness before the cut = 0.015 in, 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
20.7 (USCS units) 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
20.8 (A) (USCS units) The orthogonal cutting operation described in previous Problem 20.7 involves a
work material whose shear strength = 40,000 lb/in2. Based on your answers to the previous
problem, compute (a) 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
20.9 (SI units) 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
(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
20.10 (USCS units) The shear strength of a certain work material = 50,000 lb/in2. An orthogonal cutting
operation is performed using a tool with rake angle = 20 at a 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.
(b) As = (0.015)(0.15)/sin 29.5 = 0.00456 in2.
20-1
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
20.11 (USCS units) Solve previous Problem 20.10, 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
(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
20.12 (USCS units) Consider the data in Problem 20.10, 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 20.10 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.
20.13 (USCS units) A carbon steel bar with diameter = 7.64 in has a tensile strength of 65,000 lb/in2 and a
shear strength of 45,000 lb/in2. The diameter is reduced in a turning operation at a cutting speed of
350 ft/min. Feed = 0.011 in/rev and depth of cut = 0.120 in. The rake angle on the tool in the
direction of chip flow = 13. The cutting conditions result in a chip ratio of 0.52. Using the
orthogonal model as an approximation of turning, determine (a) shear plane angle, (b) shear force,
(c) cutting force and feed force, and (d) coefficient of friction between the tool and chip.
20-1
(b) As = tow/sin = (0.011)(0.12)/sin 29.8 = 0.00265 in2.

Fs = AsS = 0.00265(45,000) = 119.3 lb
(c) = 2(45) + - 2() = 90 + 10 - 2(29.8) = 43.3
Fc = Fscos ( )/cos ( + )
Fc = 119.3 cos (43.3 - 13)/cos (29.8 + 43.3 - 13) = 207 lb
Ft = Fssin ( )/cos ( + )
Ft = 119.3 sin (43.3 - 13)/cos (29.8 + 43.3 - 13) = 121 lb
(d) = tan = tan 43.3 = 0.942
20.14 (A) (SI units) Low carbon steel having a tensile strength = 300 MPa and a shear strength = 220
MPa is turned at a cutting speed = 2.5 m/s. Feed = 0.20 mm/rev and depth of cut = 3.0 mm. The
rake angle = 5 in the direction of chip flow. The resulting chip ratio = 0.45. Using the orthogonal
model to approximate turning, determine the cutting force and feed force.
As = tow/sin = (0.2)(3.0)/sin 25.0 = 1.42 mm2.
Fs = AsS = 1.42(220) = 312 N
= 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
20.15 (USCS units) 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 after the cut = 0.40. Determine the cutting force and the feed force. Use the
orthogonal cutting model as an approximation of the turning process.
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
20.16 Show how Equation (20.3) is derived from the definition of chip ratio, Equation (20.2), and Figure
20.5(b).
Solution: Begin with the definition of the chip ratio, Equation (20.2): r = to/tc = sin /cos ( - )
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.
20.17 Show how Equation (20.4) is derived from Figure 20.6.
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.
20-1
20.18 Derive the force equations for F, N, Fs, and Fn (Eqs. (20.9) through (20.12) in the text) using the
force diagram of Figure 20.11.
Solution: Equation (20.9): 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.
Equation (20.10): 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.
Equation (20.11): 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.
Equation (20.12): 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
20.19 (A) (SI units) In a turning operation on stainless steel, cutting speed = 150 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 20.2 to obtain the appropriate specific
energy value.
Solution: From Table 20.2, U = 2.8 N-m/mm3 = 2.8 J/mm3
RMR = vfd = (150 m/min)(103 mm/m)(0.25 mm)(7.5 mm) = 281,250 mm3/min = 4688 mm3/s
Pc = (4688 mm3/s)(2.8 J/mm3) = 13,125 J/s = 13,125 W = 13.125 kW
Accounting for mechanical efficiency, Pg = 13.125/0.90 = 14.6 kW
20.20 (SI units) In Problem 20.19, compute the lathe power requirements if feed = 0.50 mm/rev.
Solution: This is the same basic problem as the previous, except that a correction must be made for
the size effect. Using Figure 20.14, for f = 0.50 mm, correction factor = 0.87.
From Table 20.2, U = 2.8 J/mm3. With the correction factor, U = 2.8(0.87) = 2.44 J/mm3.
RMR = vfd = (150 m/min)(103 mm/m)(0.50 mm)(7.5 mm) = 562,500 mm3/min = 9,375 mm3/s
Pc = (9,375 mm3/s)(2.44 J/mm3) = 22,838 J/s = 22,838 W = 22.84 kW
Accounting for mechanical efficiency, Pg = 22.84/0.90 = 25.4 kW
20.21 (USCS units) 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 20.2 to obtain the appropriate unit horsepower value.
20-1
Solution: From Table 20.2, 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 20.14. 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
20.22 (SI units) Plain carbon steel with Brinell hardness of 275 HB is turned at a cutting speed = 200
m/min. Depth of cut = 6.0 mm. The lathe motor is rated at 25 kW (gross), and its mechanical
efficiency = 90%. Using the appropriate specific energy value from Table 20.2, determine the
maximum feed that can be used in this operation. Use of a spreadsheet calculator is recommended
for the iterative calculations required in this problem.
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 20.14 = 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 20.14.
20.23 (USCS units) A rough turning operation is performed on a 20 hp lathe that has a 92% efficiency.
The cut is made on alloy steel whose hardness is 325 HB. Cutting speed = 375 ft/min, feed = 0.030
in/rev, and depth of cut = 0.150 in. Based on these values, can the job be performed on the 20 hp
lathe? Use Table 20.2 to obtain the appropriate unit horsepower value.
Solution: From Table 20.2, 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 20.14, 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.
At efficiency E = 87%, available horsepower = 0.92(20) = 18.4 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.
20.24 (USCS units) Suppose the cutting speed in Problems 20.7 and 20.8 = 300 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 20.8, Fc = 155 lb. HPc = 155(300)/33,000 = 1.41 hp
(b) RMR = vfd = (300 x 12)(0.012)(0.100) = 4.32 in3/min
20-1
(c) HPu = 1.41/4.32 = 0.326 hp/(in3/min)

(d) U = 155(300)/4.32 = 10,764 ft-lb/in3 = 129,167 in-lb/in3
20.25 (SI units) A turning operation is carried out on aluminum. Based on the specific energy values in
Table 20.2, determine material removal rate and cutting power in the operation under the following
sets of cutting conditions: (a) Cutting speed = 5.6 m/s, feed = 0.25 mm/rev, and depth of cut = 2.0
mm; and (b) cutting speed = 1.3 m/s, feed = 0.75 mm/rev, and depth = 4.0 mm.
Solution: (a) From Table 20.2, U = 0.7 N-m/mm3 for aluminum.
RMR = vfd = 5.6(103)(.25)(2.0) = 2.8(103) mm3/s.
Pc = U RMR = 0.7(2.8)(103) = 1.96(103) N-m/s = 1960 W
(b) Because feed is greater than 0.25 mm/rev in the table, a correction factor must be applied from
Figure 20.14. 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
Note that although the power in (b) is only about 10% greater than in (a), the metal removal rate is
almost 40% greater.
20.26 (USCS units) 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 20.2, determine (a) the horsepower consumed by the turning
operation and (b) the horsepower that must be generated by the lathe.
Solution: (a) From Table 20.2, 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
20.27 (A) (USCS units) A cast iron workpiece is turned on a lathe whose mechanical efficiency = 0.87.
Cutting speed = 400 ft/min, feed = 0.011 in/rev, and depth of cut = 0.120 in. Cutting force = 250 lb.
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) Given Fc = 250 lb, HPc = Fcv/33,000 = 250(400)/33,000 = 3.03 hp
(b) HPg = HPc/E = 3.03/0.87 = 3.48 hp
(c) RMR = 12 vfd = (400 x 12)(0.011)(0.120) = 6.336 in3/min
HPu = HPc/RMR = 3.03/6.336 = 0.478 hp/(in3/min)
U = Fcv/RMR = 250(400 x 12)/6.336 = 189,394 in-lb/in3
20.28 (USCS units) 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. Feed =
0.015 in/rev, depth of cut = 0.125 in, and cutting speed = 300 ft/min. After the cut, the chip
thickness ratio = 0.45. (a) Using the appropriate value of specific energy from Table 20.2, compute
the horsepower at the drive motor, if the lathe 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 20.2, U = Pu = 520,000 in-lb/in3 for this 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 20.14. For f = 0.015 in/rev = to, correction factor = 0.95. Thus,
20-1
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 20.2 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.
20.29 (USCS units) A lathe performs a turning operation on a workpiece with diameter = 6.0 in. Shear
strength of the work = 40,000 lb/in2 and tensile strength = 60,000 lb/in2. Rake angle of the tool = 6.
Cutting speed = 700 ft/min, feed = 0.015 in/rev, and depth = 0.090 in. The chip thickness after the
cut = 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 20.2 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(45) + - 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 ( + )
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 = 0.92 from Fig. 20.14 to account for the fact that f = 0.015 in/rev instead of
0.010 in/rev. Taking this correction factor into account, HPu = 0.319/0.92 = 0.347 hp/(in3/min) as it
would appear in Table 20.2 for a feed (to) = 0.010 in/rev.
20.30 (USCS units) In a turning operation on an aluminum alloy workpiece, 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%. What is the maximum cutting speed that can be used on this job?
Solution: From Table 20.2, 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 20.14. For f = 0.020 in/rev = to,
correction factor = 0.87.
HPc = HPu x RMR, HPg = HPc/E
RMR = vfd = 12v(.020)(0.250) = 0.06 v in3/min
HPc = 0.87(0.25)(0.06 v) = 0.013 v hp
HPg = 0.013 v /0.92 = 0.01418 v = 20 hp
v = 20/0.01418 = 1410 ft/min
20.31 One of the foremen in the machine shop complains of a problem with an operation in the turning
section. It seems the lathe has a tendency to slow down or stall in the middle of the cutting
20-1
operation, indicating that the machine is underpowered for the work material and conditions of the
cut. Without knowing any more about the problem, what actions and changes can be made to
mitigate this power problem?
Solution: From Table 20.3, there are several changes that can be made to avoid this kind of power
problem: (1) reduce cutting speed, (2) reduce feed and/or depth of cut, (3) perform the operation on
a lathe with higher power capability, (4) use a cutting fluid, and (5) use a cutting tool that has a
larger rake angle.
Cutting Temperature
20.32 (A) (SI units) 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. Cutting speed = 3.5 m/s, uncut chip
thickness = 0.25 mm, and width of cut = 2.2 mm. Cutting force = 950 N. Determine the cutting
temperature if the ambient temperature = 22C.
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 = 950 N x 3.5 m/s/(3500 mm/s x 0.25 mm x 2.2 mm) = 1.727 N-m/mm3
T = 0.4U/(C) x (vto/K)0.333
T = 22 + (0.4 x 1.727 N-m/mm3/(2.90x10-3) J/mm3-C) [3500 mm/s x 0.25 mm/80 mm2/s]0.333
T = 22 + (0.2382 x 103 C)(10.94).333 = 22 + 238.3(2.22) = 22 + 528 = 550C
20.33 (SI units) Consider a turning operation performed on steel whose hardness = 225 HB at a cutting
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 20.2,
compute an estimate of cutting temperature. Assume ambient temperature = 20C.
From Table 4.1, = 7.87 g/cm3 = 7.87(10-3) g/mm3
From Table 4.2, 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 Equation (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 = 964C
20.34 (USCS units) An orthogonal cutting operation is performed on a certain metal whose volumetric
specific heat = 110 in-lb/in3-F and thermal diffusivity = 0.140 in2/sec. The cutting speed = 350
ft/min, chip thickness before the cut = 0.008 in, and width of cut = 0.100 in. Cutting force = 200 lb.
Determine the cutting temperature if the ambient temperature = 70F.
Solution: v = 350 ft/min x 12 in/ft/60 sec/min = 70 in/sec.
U = Fcv/vtow = 200(70)/(70 x 0.008 x 0.100) = 250,000 in-lb/in3.
T = 70 + (0.4U/C)(vto/K)0.333 =
T = 70 + (0.4 x 250,000/110)[70 x 0.008/0.14]0.333 = 70 + (909)(4)0.333 = 70 + 1436 = 1506 F
20.35 (USCS units) It is desired to estimate the cutting temperature for a certain alloy steel whose
hardness = 240 Brinell. Use the appropriate value of specific energy from Table 20.2 to compute the
cutting temperature for a turning operation in which the cutting speed is 500 ft/min, feed is 0.005
20-1
in/rev, and depth of cut is 0.070 in. The work material has a volumetric specific heat of 210 in
lb/in3-F and a thermal diffusivity of 0.16 in2/sec. Assume ambient temperature = 88F.
Solution: From Table 20.2, U for alloy steel (310 BHN) = 320,000 in-lb/in3.
Since f = 0.005 in/rev, correction factor = 1.25.
Therefore U = 320,000(1.25) = 400,000 in-lb/in3.
v = 500 ft/min x 12 in/ft/60 sec/min = 100 in/sec.
T = Ta + (0.4U/C)(vto/K)0.333 = 88 + (0.4 x 400,000/210)(100 x 0.005/0.16)0.333
= 88 + (762)(3.125)0.333 = 88 + 1113 = 1201 F
20.36 (A) (USCS units) An orthogonal machining operation removes metal at 1.8 in3/min. Cutting force =
300 lb. The work material has a thermal diffusivity = 0.18 in2/sec and a volumetric specific heat =
124 in-lb/in3-F. If the feed = 0.010 in and width of cut = 0.100 in, compute the cutting temperature
in the operation given that ambient temperature = 70F.
Solution: RMR = vtow, v = RMR/tow = 1.8/(0.01 x 0.100) = 1800 in/min = 30 in/sec
U = Fcv/vtow = 300(30)/(30 x 0.010 x 0.100) = 300,000 in-lb/in3.
T = 70 + (0.4U/C)(vto/K)0.333 = 70 + (0.4 x 300,000/124)(30 x 0.010/0.18)0.333
= 70 + (968)(1.667)0.333 = 70 + 1147 = 1217 F
20.37 (SI units) In a turning operation, cutting speed = 200 m/min, feed = 0.25 mm/rev, and depth of cut =
4.00 mm. Thermal diffusivity of the work material = 20 mm2/s and volumetric specific heat = 3.5
(10-3) J/mm3-C. If the temperature increase above ambient temperature (20F) is measured by a
tool-chip thermocouple to be 700C, determine the specific energy for the work material in this
operation.
Solution: Rearranging the Cook equation, U = T(C/0.4)(K/vto)0.333
U = (700 20)(3.5 x 10-3/0.4)(20/{(200/60)(103)(0.25)})0.333
U = 680(8.75 x 10-3)(0.024)0.333 = 5.95(0.2888) = 1.72 N-m/mm3
20.38 (SI units) During a turning operation, a tool-chip thermocouple was used to measure cutting
temperature. The following temperature data were collected during the cuts at three different cutting
speeds (feed and depth were held constant): (1) v = 100 m/min, T = 505C, (2) v = 130 m/min, T =
552C, (3) v = 160 m/min, T = 592C. Determine an equation for temperature as a function of
cutting speed that is in the form of the Trigger equation, Equation (20.23).
Solution: Trigger equation T = Kvm
Choose points (1) and (3) and solve simultaneous equations using T = Kvm as the model.
(1) 505 = K(100)m and (3) 592 = K(160)m
(1) ln 505 = ln K + m ln 100 and (3) ln 592 = ln K + m ln 160
Combining (1) and (3): ln 505 - m ln 100 = ln 592 - m ln 160
6.2246 4.6052 m = 6.3835 5.0752 m
0.47 m = 0.1589 m = 0.338
(1) K = 505/1000.338 = 505/4.744 = 106.44
(2) K = 592/1600.338 = 592/5.561 = 106.45 Use K = 106.45
Check equation with data point (2): T = 106.45(130)0.338 = 551.87C (pretty close to the given value
of 552C).
20-1

CH 20

Uploaded by

Copyright:

Available Formats

CH 20

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CH 20

Uploaded by

Copyright:

Available Formats

Solutions for Fundamentals of Modern Manufacturing, 5/e (published by Wiley) MPGroover 2012

20 THEORY OF METAL MACHINING

= tan-1(0. 4286 cos 12/(1 - 0. 4286 sin 12)) = tan-1(0.4602) = 24.7

Fs = AsS = 0.00456(50,000) = 228 lb

(b) As = tow/sin = (0.011)(0.12)/sin 29.8 = 0.00265 in2.

(c) HPu = 1.41/4.32 = 0.326 hp/(in3/min)

U = 520,000(0.95) = 494,000 in-lb/in3 = 41,167 ft-lb/in3.

You might also like