Slip Test

Slip Test I (Jan 2014) ME 2252 MANUFACTURING TECHNOLOGY II Part A 1. 2. 3. 4. List the various metal removal processes?
ses? How chip formation occurs in metal cutting? What is electrochemical wear in tools? What arte the four important characteristics of materials used for cutting tools? Part B 5. a. (i) From the machining performance viewpoint which type of chip is preferred? Explain your answer with suitable justifications? Also show the conditions which favour such a chip formation. (2+2+2 = 6) a. (ii) During a metal cutting test under orthogonal conditions in a lathe with a tool of rake angle 20, with a depth of cut of 3 mm and feed rate of 0.38 mm/rev. the following data was recorded. Average chip thickness = 0.89 mm Horizontal component of the cutting force = 1000 N Vertical component of the cutting force = 2340 N Calculate the following: (a) Chip Thickness Ratio (2) (b) Coefficient of friction at the chip tool interface (3) (c) Shear plane angle, and (3) (d) Shear stress at the shear plane. (2) Slip Test I (Jan 2014) ME 2252 MANUFACTURING TECHNOLOGY II Part A 1. 2. 3. 4. Give four examples for both orthogonal cutting & Oblique Cutting Briefly explain the effect of rake angle during metal cutting? What are the factors responsible for built-up edge in cutting tools? Name the factors that contribute to poor surface finish in metal cutting. Part B 5. a. (i) Show schematically Merchant's force circle in orthogonal cutting. Derive the equations for shear and friction forces in terms of the material properties and cutting process parameters. Give in detail the assumptions made while arriving at the final equations. (4+4+4=12) a. (ii) How do you define tool life? Explain the parameters that control the tool life of a single point cutting tool. (2+4 = 6) Slip Test I (Jan 2014) ME 2252 MANUFACTURING TECHNOLOGY II Part A 1. 2. 3. 4. List out the difference between orthogonal cutting and oblique cutting. What is meant by tool signature? What are the objectives and functions of cutting fluids? What are the functions of chip breakers? Part B 5. a. (i) How is metal removed in metal cutting? Explain the process by giving any simple model to explain the metal removal process. (4 + 4 = 8) a. (ii) The following equation for tool life is given for a turning operation: T0.13 f0.77 d0.37 = C, a 60 minute tool life was obtained while cutting at V=30 m/min, f=0.3 mm/rev and d=2.5mm. Determine the change in tool life if the cutting speed, feed and depth of cut are increased by 20% individually and also taken together. (8) Or 4X2=8 4X2=8 4X2=8
Or b. (i)In an orthogonal cutting test the following values were known or obtained from experimentation. Rake angle = 20 Thrust force = 500 N, Uncut chip thickness = 0.14 mm Width of cut = 5 mm Cutting speed = 2 m/s Chip thickness = 0. 70 mm, If the force in the culling speed direction is two times that of the thrust force, calculate the average yield shear stress of the work material. (8) b. (ii) Explain with a neat sketch what you understand by the word Orthogonal Cutting and its relevance in metal cutting study. How can orthogonal cutting be realised in practice? (4+2+2 = 8) 6. a. (i) What is the measure of metal removing process machinability? What are the factors that affect it? (6) (ii) Explain the basic actions of cutting fluids (6) (iii) How do you expect the coatings on carbides to improve the machining performance? (4) Or b. (i) The tool life of a high speed steel (HSS) tool and carbide tool have the same tool life of 60 minutes at a cutting speed of 75 m/min. The exponent of tool life in Taylor's equation (n) is 0.15 for HSS while it is 0.2 for carbide. Compare the life of the two tools at a speed of 90 m/min. (8) b. (ii) What are the factors that control surface finish in turning? How do you select the cutting-process parameters for finish turning? (4+4 = 8) Or b. (i)The following data were obtained from an orthogonal cutting test. Rake angle = 20,Depth of cut = 6 mm,Feed rate = 0.25 mm/rev,Cutting speed = 0.6 m/s,Chip length before cutting = 29.4mm Vertical cutting force = 1050 N, Horizontal cutting force = 430 N, Chip length after cutting = 12.9 mm Using Merchant's analysis, calculate: (a) direction and magnitude of resultant force. (4) (b) shear plane angle. (4) (c) friction force and friction angle. And (4) (d) various energies consumed. (4) 6. a. (i) List the various tool materials used in industry. State the optimum temperature of each of the tool materials. ( 4 + 4 = 8) (ii) Explain the basis for the selection of a specific cutting fluid for a given application. Take the example of turning, milling and grinding and suggest the type of cutting fluid is used. (8) Or b. (i) In a metal cutting experimentation the tool life was found to vary with the cutting speed in the following manner. Cutting speed V, m/min Tool Life, T/min 100 120 130 50 Derive Taylor's tool life equation for this operation and estimate the tool life at a speed of 2.5 m/s. Also estimate the cutting speed for a tool life of 80 minutes. (4+2+2 = 8) b. (ii) What are the various forms of wear found in cutting tools? Show with a near sketch. (8)
b. (i) A mild steel tube is cut with a carbide tool having a rake angle 5 orthogonally at a culling speed of 250 m/min. The feed used is 0.21 mm/rev while the depth of cut is 2 mm. The cutting ratio is 0.31. The vertical cutting force is 1030 N and the horizontal cutting force is 550N. Calculate from Merchant's theory, the various work done in metal cutting and shear stress(10) b. (i) What are the standard angles of cutting tool? Illustrate with an example. (3+3 = 6) Or 6. a. (i) In an orthogonal cutting operation on a workpiece of width 2.5mm, the uncut chip thickness was 0.25mm and the tool rake angle was zero degree. It was observed that the chip thickness was 1.25mm.The cutting force was measured to be 900N and the thrust force was found to be 810 N. (a) Find the shear angle. (b) If the coefficient of friction between the chip and the tool, was 0.5, what is the machining constant CM (4+4 = 8) a. (ii) Explain the geometry of a single point cutting tool with suitable sketches? (8) Or b. (i) State the parameters that influence the life of tool and discuss. (8)
b. (i) What is a chip? Describe the different types of chips produced during metal machining with neat sketches.
(8)

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Slip Test I (Jan 2014) ME 2252 MANUFACTURING TECHNOLOGY II Part A 1. 2. 3. 4. List the various metal removal processes?

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