Machining Science 2 Solution Copy 2

13.
25 page op khanna
Problem :
A square is to be broached into the hub of a carbon steel lever. If the length of
tooth system of the broach is 0.95 m calculate the machining time.
Solution :
Assuming value of v for carbon steel as 5 m/min
(Refer article 13.15)
L 0.95
T = = = 0.19 min (Ans.)
v 5
13.22 page op khanna

Problem :
The hole of an alloy steel part is to be broached to 35+0.01 mm diameter, the hole
prior to broaching being 34.50+0.05 mm diameter.
Calculate
(a) Pitch of teeth,
(b) Length of cutting portion,
(c) Force to pull broach through work of length of hole is 33 mm,
t = 0.025 mm, K = 4800 N and S = 5.
Solution :
(a) Pitch of teeth, P = 1.77 hole length hole length = 1.77 33 = 10.16
say10 mm.
33
= 3.3, this shows 3 teeth (N) cutting at a time, therefore 10 mm pitch is
10
satisfactory.
(b) Length of cutting portion,

T 
L = P + S 
t 
35 .01 − 34 .50
Where T = = 0.255 mm
2
 0.255 
∴ L =10  + 5
 0.025 
= 10 ( Say 10+5 )
= 10 × 15 = 150 mm.
T 0.255
= ≈10 . It means the number of finishing teeth will be 5.
t 0.025
The first roughing tooth will be 34.50 mm diameter. Each of the five
finishing teeth will have 35.01 mm diameter. There will be total 10 roughing
teeth with diameters rising in steps from the first tooth of 34.50 mm diameter to
35.01 mm diameter of the finishing teeth.
(c) Force to pull broach through work

FR = π d Ntk
= 3.14 × 35.01× 3 × 0.025 × 4800
= 39575.3 N
= 39.5753 kN ≈ 40 kN capacity machine will serve the purpose.
33.29 op khanna
EXAMPLE : To calculate the cutting length of a keyway broach for machining a
3 3 1
keyway in wide, in. deep in a boss 1 in. long.
8 16 2
SOLUTION : Taking the pitch of the teeth to be 0.35 L .
1 7
We have p = 0.35 1 =0.35 × 1.22 = 0.43 in., say in.
2 16
3
Depth of cut = in. = 0.187 in., and allowing 0.0035 in. per tooth.
16
0.187
No. of teeth = = 54 teeth.
0.0035
Adding six parallel teeth for finishing gives 60 teeth, so that total length of cutting
7 1
portion = 60 × = 26 in .
16 4
PAGE 735 R.K.Jain

Q.16.15. Determine the time required to mill a slot in a workpiece of 300 mm length with
a side milling cutter of 100 mm diameter, 25 mm wide and 18 teeth. The depth of cut is 5
mm and the feed per tooth is 0.1 mm, Cutting speed used is 30 m/min.
Cutter speed
Sol. RPM of cutter = , ( D = dia. of cutter = 100 mm = 0.1 m )
πD
30
= ≅100 rpm
π × 0.1
Feed per minute = Feed per tooth × No. or teeth on cutter × RPM
= 0.1 × 18 × 100 mm/min.
Approach distance distance travelled between first contact
= and cutting to full depth (Refer Fig. 16.80)
= Depth of cut ( Dia . of cutter − Depth of cut ) =
5(100 −5 = 5 ×95
= 21.79 mm
Length of cut
∴ Time for milling = Feed per miute
Length of cut = Length of workpiece + 2 × Approach distance + 2 × Clearance
It may be noted that approach distance has to be used twice as the same condition
( i.e. the distance cutter has to travel from first contact to full depth) exists both at start
and when cutter leaves the workpiece at the end of the cut.
Clearance is used to avoid collisions at rapid advance, which may be taken as about 2.5
mm.
∴ Length of cut = 300 + 2 × 21.79 + 2 × 2.5 ≅ 350 mm
350
∴ Time = ≅ 2 mi nutes .
180
736 R.K.Jain
Q.16.17. Determine the cutting time in cutting a 125 mm long keyway using HSS end mill
of 20 mm diameter, having four cutting teeth. The depth of keyway is to be 4.5 mm.
Feed per tooth is 0.1 mm and cutting speed is 90 m/min.
Cuttingspe ed 90 ×100
Sol. RPM of cutter = π × ( D / 1000 ) = π × 20 =1432
Feed per min = Feed per tooth × No. of teeth × rpm = 0.1 × 4 × 1432 = 572.8
mm/min.
Approach distance = Half the cutter diameter = 20/2 = 10 mm
in this case
∴ Length of cut = Length of keyway + Approach distance + Clearance
= 125 + 10 + 2.0 = 137 mm
137
∴ Cutting time = = 0.239 min . =14 .35 sec .
572 .8
736 R.K.Jain
Q.16.18. Determine the cutting time required in face milling a workpiece 400 mm long
and 250 mm wide with a face mill of 100 mm diameter having 8 teeth. Depth of cut is 3.0
mm. Cutting speed = 75 m/min and feed = 0.07 mm/tooth.
Cutting speed 75 750

Sol. RPM = 2 π × ( D / 1000 ) = 2 π × (100 / 1000 ) = 2 π =113 .8 =120 RPM .
Feed/min = Feed/tooth × No. of teeth × RPM = 0.07 × 8 × 120 = 67.2
mm/min.
Next step is to find the number of passes of cutter required across the work to
finish complete width. It may be noted that it is essential to provide some overhang
(Refer Fig. 16.82) to ensure a full cut. Its value may be taken as about 5 mm.
∴ Width of workpiece to be covered = 250 + 2 × 5 = 260 mm.
It is usual to move the cutter by about 80-90% of cutter diameter across the width
of the workpiece for next cut. Taking it 0.8 D.
260
∴ No. of passes (N) of cutter = ≅4
0.8 ×100
Length which cutter has to travel
= N ( L + D + 2 clearance ) + ( N – 1 ) × 0.8 D
= 4 ( 400 + 100 + 2 × 2.5 ) + ( 4 – 1 ) × 0.8 × 100 = 4 × 505 + 3 × 80 = 2020 +
240 = 2260 mm.
737 R.K.Jain
Q.16.21. A certain component can be milled with either a slab mill of 90 mm diameter, or
a 150 mm diameter face mill. Each cutter has 16 teeth and the cutting speed is 20 m/min.
If the feed for the slab mill is 0.15 mm per tooth and for the face mill 0.25 mm per tooth,
what is the rate of feed for each cutter?
Ans. Rate of feed/min = Feed per tooth × No. of teeth × Speed
(rev/min)
Cutting speed ( m / min) ×10 3
Speed (rev/min) =
π × Dia of cutter ( mm )
20 ×10 3
∴ RPM of slab mill = = 70 .7
90 π
20 ×10 3
and RPM of face mill = = 42 .4
150 π
∴ Total feed/min in case of slab mill = 0.15 × 16 × 70.7 = 169.7 mm/min
and table feed/min in case of face mill = 0.25 × 16 × 42.4 = 169.6 mm/min.
787 R.K.Jain
Q.18.1. Fig.18.31. shows various elements of a twist drill. Match parts I and II in regard
to terminology.
Part I Part II
1. A (a) web thickness
2. B (b) margin
3. C (c) diameter
4. D (d) lip length
5. E (e) face
6. F (f) chisel edge angle
7. G (g) point angle
8. H (h) point
9. I (i) body clearance depth
10. J (j) chisel edge
11. K (k) flank
Ans. 1.(c), 2.(g), 3.(e), 4.(i), 5.(a) 6.(d), 7.(b), 8.(f), 9.(h), 10.(k), 11.(j)
Q.18.2. Match Parts A and B in relation to drilling tool.

A B
1. the sharp edge at the extreme tip end of the drill, formed by (a) lip clearance
the intersection of the cone-shaped surfaces of the point in
the centre of the axis of the drill.
2. the entire cone-shaped surface at the cutting end of the drill. (b) web
3. that part of the point of a drill that actually cuts away the (c) margin
material when drilling a hole.
4. surface of the point that is ground away or relieved just back (d) dead centre
of the cutting edge of the drill.
5. the end of drill shank designed to fit into a slot in the socket (e) rake angle
or spindle of drilling machine.
6. end of drill which enables it to be quickly and accurately (f) cutting angle
inserted into the spindle of a machine without the use of
screws or clamps.
7. a narrow strip on the drill which is of full diameter of the (g) point
drill and extends the entire length of the flute.
8. the portion of drill from margin to reamaining portion of (h) tang
body upto flute made smaller in diameter than diameter at
margin to reduce friction between the drill and the walls of
hole being drilled.
9. a drill that penetrates the work slowly, becomes very hot, (i) cutting edge
and produces squealing noise and produces rough hole.
10.the angle subtended by two cutting edges of a drill. (j) dull drill
11.the angle of a flute in relation to the work. (k) body clearance
12.the metal column which separates the flutes and runs the (l) tapered shank.
entire length of the drill between the flutes.
Ans. 1- d, 2-g, 3-i, 4-a, 5-h, 6-l,

7-c, 8-k, 9-j, 10-f, 11-e, 12-b,

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13.

13.22 page op khanna

(b) Length of cutting portion,

(c) Force to pull broach through work

PAGE 735 R.K.Jain

Cutting speed 75 750

Q.18.2. Match Parts A and B in relation to drilling tool.

Ans. 1- d, 2-g, 3-i, 4-a, 5-h, 6-l,

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