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    EMG 2523 MECHANICS OF METAL CUTTING PP1 (1)

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    EMG 2523 MECHANICS OF METAL CUTTING PP1 (1)

    Uploaded by

    Felix Saguu
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    1 views3 pages

    EMG 2523 MECHANICS OF METAL CUTTING PP1 (1)

    Uploaded by

    Felix Saguu

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    TECHNICAL UNIVERSITY OF MOMBASA

    Faculty of Engineering and Technology

    DEPARTMENT OF MECHANICAL AND AUTOMOTIVE ENGINEERING

    UNIVERSITY EXAMINATIONS FOR DEGREE IN BACHELOR OF SCIENCE IN


    MECHANICAL ENGINEERING

    (BSME) Y5-S2

    EMG 2523: MECHANICS OF METAL CUTTING

    END OF SEMESTER EXAMINATIONS

    SERIES: MAY 2016

    TIME: 2 HOURS

    INSTRUCTIONS:

     You should have; Answer booklet,; Drawing instruments and Scientific calculator
     This paper consists of FIVE questions
     Attempt any THREE questions.

    This paper consists of THREE printed pages

    QUESTION 1

    a) (i) State THREE indicators of tool failure (1.5 marks)


    (ii) State FOUR characteristics of orthogonal as opposed to oblique cutting (2 marks)
    (iii) Working from first principles, establish Merchant’s shear angle expression (3 marks)
    b) In an orthogonal cutting experiment:
    Chip thickness after cutting…………………………………………..= 2.0mm
    Coefficient of friction………………………………………………..=0.9
    Width of cut…………………………………………………………= 10mm
    Feed…………………………………………………………………. = 1.25mm/rev
    Rake angle……………………………………………………………= 10o
    Shear strength……………………………………………………. …= 6000kg/cm2
    Cutting speed…………………………………………………………= 30m/min
    Determine, by way of Merchant’s theory:
    i) The shear plane angle Ø
    ii) The friction angle
    iii) The cutting force
    iv) H.P of motor of mechanical ɳ = 0.95 (13.5 marks)
    QUESTION 2

    a) Working from first principles, establish the optimum cutting speed VT where the total cost of
    machining a batch is a minimum. (12 marks)
    b) (i) In a certain machining operation on a component, n = 0.25, C = 150, tool change time = 8
    minutes, tool regrind time = 5 minutes, machine running cost =£2.00 per hour, depreciation of
    tool per regrind = £0.125. Calculate the optimum cutting speed. (3 marks)
    (ii) If 1000 components are required with a machine length of 100mm at 65mm diameter
    using a feed of 0.2mm/rev, calculate the time required to machine the batch of 1000, and
    the total cost YT (5 marks)

    QUESTION3

    a) With the aid of sketches, describe the circumstances that favour the formation of the following
    types of chips:
    (i) Discontinuos chip
    (ii) Continuous chip
    (iii) Continuous chip with chip welding (6 marks)
    (b) Discuss briefly the following cutting fluids:
    (i) Solid lubricants
    (ii) Emulsions
    (iii) Chemical solutions
    (iv) Straight fatty oils
    (v) Aqueous solutions (10 marks)
    (c) The power to cut a material under certain conditions is 2.6 W/mm3/s. A cut 5.2 mm
    deep x 0.22mm/rev feed is taken at a cutting speed of 18 m.p.m and the work cooled
    by a flow of 3.5 litres of coolant per minute, specific heat capacity 3.6 kJ/kg oC,
    which conducts away 82% of the heat. The specific gravity of the coolant is 0.92.
    Determine the rise in temperature of the coolant due to this cut. (4 marks).

    QUESTION4

    a) Discuss vibration and chatter on machine tools (3 marks)


    b) In a machining operation the cutting force FC is related to the depth of cut (d) and feed (f) by the
    expression:
    FC = 1958 d0.88f0.65
    A lathe,under such conditions, consumes 5.5kW on a workpiece of diameter 125mm, depth of
    cut 4.5mm and feed 0.2mm/rev. Determine the maximum spindle speed (R.P.M)(6 marks).
    c) In an orthogonal cutting process, the cutting velocity was 13m/minute and the forces normal to
    the shear plane (FNS) are 1400N. If the rake angle was 10o, chip thickness ratio 0.35 and the
    coefficient of friction was 1.2, determine the motor horsepower if the efficiency is 0.9 (6 marks)
    d) An end mill cutter of diameter 120mm is to face mill a workpiece 100mm wide. The optimum
    power available is 4 kW, depth of cut is 3mm, cutting speed is 22m/minute and the cutter has
    16teeth. If the material removal rate (K) is 25,000mm3/(min.kW), determine the feed rate per
    tooth. (5 marks)

    QUESTION5
    a) With the aid of a sketch, describe the principle of the cutting tool dynamometer (7 marks)
    b) In an orthogonal cutting experiment the cutting force was 201N, feed force 120N, rake
    angle 28o and chip thickness ratio 25 . If the cutting speed was 25 m.p.m, determine the
    friction work at the tool rake face. (6 marks)
    c) Define the following terms:
    i) waviness
    ii) roughness
    iii) Errors of form (3 marks)
    d) Fig 1 shows the area trace in a roughness test with the attendant magnification.
    Calculate Ra value for the surface in micrometers. (4 marks)

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