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Chapter:

6. The ratio of cutting force to cross-sectional area being cut is called:

specific cutting force thrust force frictional force none of the mentioned

specific cutting force

The ratio of cutting force to cross-sectional area being cut (i.e., product of width of cut and depth of cut) is referred to as specific cutting force. The thrust force, Ft, acts in a direction normal to cutting force.

Hint Answer

7. Continuous chips with built up edge are formed during machining of

brittle metals ductile metals hard metals soft metals

ductile metals

Discontinuous chips are formed during machining of brittle metals while continuous chips with built up edge are formed during machining of ductile materials at low cutting speed.

Hint Answer

8. In an orthogonal machining operation :
Uncut thickness = 0.5 mm
Cutting speed = 20 m/min
Rake angel = 15⁰
Width of cut = 5 mm Chip thickness = 0.7 mm
Thrust force = 200 N Cutting force = 1200 N
The values of shear angle and shear strain, respectively, are

30.3⁰ and 1.98 30.3⁰ and 4.23 40.2⁰ and 2.97 40.2⁰ and 1.65

40.2⁰ and 1.65

Given : t= 0.5mm, V = 20 m/min, ?= 15⁰, w= 5mm, t_c = 0.7 mm,
F_t = 200 N, F_c = 1200 N
We know, from merchant?s ory
Chip thickness ratio, r = t/t_c = 0.5/0.7 = 0.714

For shear angle, tan? = [rcos?/1 – rsin?]

Substitute values, we get
tan? = [0.714cos15⁰/1 – 0.714sin15⁰] = 0.689/0.815 = 0.845

? = tan^-1(0.845) = 40.2⁰
Shear strain, s = cot? + tan(? ? ?)
s = cot(40.2⁰) + tan(40.2⁰ ? 15⁰)
= cot 40.2⁰ + tan 25.2 = 1.183 + 0.470 = 1.65.

Hint Answer

9. The continuous chips are in form of long coils having same thickness throughout.

True False

True

None

Hint Answer

10. Crater wear is predominant in

carbon steels tungsten carbide tools high speed steel tools ceramic tools

tungsten carbide tools

Crater wear is usually found while machining brittle materials and tungsten carbide tools favour this phenomenon.

Hint Answer

11. In determining various forces on chip, Merchant assumed that

cutting edge of the tool is sharp and it does not make any flank contact with the workpiece only continuous chip without built up edge is produced cutting velocity remains constant all of the mentioned

all of the mentioned

None

Hint Answer

12. Flank wear occurs mainly on

nose part, front relief face and side relief face of the cutting tool face of the cutting tool at a short distance from the cutting edge only cutting edge only front face only

nose part, front relief face and side relief face of the cutting tool

Crater wear occurs on rake face of tool, while flank wear occurs on relief (flank) face of tool.

Hint Answer

13. Using Taylor Equation for tool life and letting n = 0.5 and C = 120, calculate percentage increase in tool life when cutting speed is reduced by 50%.

100% 200% 300% 400%

300%

Since n = 0.5, Taylor equation can be rewritten as VT^0.5 = 120.

Let’s denote V₁ as initial speed and V₂ reduced speed; thus, V₂ = 0.5 V₁. Because C is constant 120, we have relationship
0.5V₁ sqrt T₂ = V₁sqrt T₁

Simplifying this equation, T₂/T₁ = 1/0.25 = 4. This
indicates that change in tool life is
(T₂ – T₁/ T₁) = (T₂/T₁) – 1 = 4 – 1 = 3,

or that tool life is increased by 300%. Thus, a reduction in cutting speed has resulted in a major increase in tool life. Note also that, for this problem, magnitude of C is not relevant.

Hint Answer

14. Discontinuous chips are formed during machining of

brittle metals ductile metals hard metals soft metals

brittle metals

Discontinuous chips are formed during machining of brittle metals while continuous chips are formed during machining of ductile materials.

Hint Answer

15. In metal machining, zone where maximum heat is generated due to plastic deformation of metal is called:

friction zone work tool contact zone shear zone none of the mentioned

shear zone

In metal machining, zone where maximum heat is generated due to plastic deformation of metal, is called shear zone while zone where heat is generated due to friction between moving chip and tool face, is called friction zone.

Hint Answer

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Topics

This Chapter consists of the following topics

Cutting-Tool Materials and Cutting Fluids

The ratio of cutting force to cross-sectional area being cut is called:

Continuous chips with built up edge are formed during machining of

In an orthogonal machining operation :
Uncut thickness = 0.5 mm
Cutting speed = 20 m/min
Rake angel = 15⁰
Width of cut = 5 mm Chip thickness = 0.7 mm
Thrust force = 200 N Cutting force = 1200 N
The values of shear angle and shear strain, respectively, are

The continuous chips are in form of long coils having same thickness throughout.

Crater wear is predominant in

In determining various forces on chip, Merchant assumed that

Flank wear occurs mainly on

Using Taylor Equation for tool life and letting n = 0.5 and C = 120, calculate percentage increase in tool life when cutting speed is reduced by 50%.

Discontinuous chips are formed during machining of

In metal machining, zone where maximum heat is generated due to plastic deformation of metal is called:

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