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4 March, 18:48

In a turning operation, spindle speed is set to provide a cutting speed of 1.8 m/s. The feed and depth 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.

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  1. 4 March, 18:53
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    (a) shear plane angle (∅) = 33.53°

    (b) shear strain (y) = 1.989

    (c) material removal rate (MRR) = 1404mm³/s

    Explanation:

    Cutting speed = 1.8m/s

    Feed = 0.3mm

    Depth = 2.6mm

    Angle = 8°

    Thickness = 0.49

    (a) calculating the chip thickness ratio using the formula;

    r = t₀/tc

    = 0.3/0.49

    = 0.6122

    Calculating the shear angle using the formula;

    ∅ = tan⁻¹[rcosα/1-rsinα]

    = tan⁻¹[ (0.6122*cos8) / (1-0.6122sin8) ]

    = 33.53°

    (b) Calculating the shear strain using the formula;

    y = cot∅ + tan (∅-α)

    = cot 33.53 + tan (33.53-8)

    = 1.509 + 0.477

    = 1.989

    (c) Calculating the material removal rate using the formula;

    MRR = f*d*V

    = 0.3 * 2.6 * 1.8 * 1000mm

    = 1404mm³/s
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