UTA002 Manufacturing Processes

Assignment
Due date : 15th May 2020

1. The 60 mm diameter steel bar is to be turned down to 56 mm diameter on a standard lathe. The
length of the bar to be turned is 250 mm and the tool has a pre-travel of 5 mm. If the machine
produces 40 parts per hour find the cutting speed in m/min assuming the feed = 0.2 mm/rev.
The depth of cut using an HSS tool cannot exceed 1 mm. Also calculate the Material Removal
Rate.
2. The outside diameter of a cylinder made of titanium alloy is to be turned. The starting diameter
= 500 mm and the length = 1000 mm. Cutting conditions are: feed, f = 0.4 mm/rev, and depth of
cut, d = 3.0 mm. The cut will be made with a cemented carbide cutting tool whose Taylor tool
life parameters are: n = 0.23 and C = 400. Units for the Taylor equation are minutes for tool life
and m/min for cutting speed. Compute the cutting speed that will allow the tool life to be just
equal to the cutting time for this part.
3. The 45 mm diameter steel bar is to be turned down to 28mm diameter on a standard lathe. The
overall length of the bar is 475mm and the region to be turned is 420mm. Since you want to
reduce the bar from 45 to 28mm, you have a total depth of cut, d of 8.5mm. You decide you want
to make two cuts, a roughing pass and a finishing pass. Rough at d = 7.5mm using HSS tool at
speed 30m/min and feed = 0.5mm/rev. For finish cut (d = 1mm), a coated carbide tool is used
with speed = 280 m/min and feed = 0.18mm/rev. The bar is held in a chuck with a feed through
the hole in the spindle and is supported on the right end with a live centre. The ends of the bar
have been centre drilled. Allowance should be 12mm for approach (pre-travel). Allow 2.0 min
to reset the tool after the first cut. Determine the inputs to the lathe and the total time required
for machining the component.
4. Tool life of 75 min was obtained at a cutting speed of 25m/min and that of 10 min when cutting
at 60 m/min. Establish the tool life equation and calculate the cutting speed for 5 minutes tool
life.
5. A 0.50 m long annealed copper-alloy round bar is required to be rough turned on a lathe from a
60 mm diameter to a 55 mm diameter, using a HSS tool. While holding the bar on the lathe, 10%
of its total length is used for gripping in the chuck and another 12.5 mm is left un-machined at
the chuck side. An approach distance (tool pre-travel) of 7.5 mm is used during each pass for
turning. The maximum cutting speed employed is 50 m/min, feed 0.4 mm/rev and maximum
depth of cut per pass allowed is 1.0 mm. Estimate the total time required to complete the job
assuming a set up change time of 2 mins after each pass.
6. The component of aluminium shown below is to be manufacture. A 50 mm diameter blank, 120
mm long, is to be used. Write a CNC part program for its manufacturing in CNC machine. Mark
the work reference point in the picture and list down all the assumptions that have been taken
during machining operation (such as depth of cut in turning, drilling etc.). Consider following
parameters during machining:
i. Tool pre-travel allowance is 2 mm.
ii. Spindle speed during turning, drilling and threading operation are 2000, 1000 and 500 rpm,
respectively.
iii. Feed rate during roughing and finish operations in turning are 100 and 60 mm/min,
respectively.
iv. Feed rate in drilling is 60 mm/min.
iii. The workpiece has to face of 2 mm before other operation.
iv. The depth of cut during roughing and finishing operations are 0.5 and 0.1 mm, respectively.
v. The DOC and tool retract distance in drilling are 0.5 and 1 mm, respectively.
vi. The included angle of thread is 60°. No. of finishing passes are 4. Finishing allowance is
0.01mm. Minimum DOC for threading is 0.04 mm and depth of cut for first pass is 0.1 mm,
respectively.

7. For a particular type of cutting tool used during rough machining of steel jobs the following are
noted:
 Cutting speed 160 m/min gives tool life of 5.75 min and cutting speed 100 m/min gives tool life
of 25 min. Establish the Taylor tool life equation. If the Taylor tool life index for finish
machining reduces to 0.8 times the index calculated for rough machining, predict the tool life
during the rough and finish cutting at a cutting speed of 60 m/min.
8. A steel plate is rolled to reduce its thickness from 25 mm to 18 mm using a 2-Hi mill roll with a
roll diameter of 500 mm. Assuming the friction coefficient at roll-plate interface as 0.15, check
whether it is possible to roll this plate in one pass. If it is not possible to roll in one pass using
this mill, you have an option to change the roll size. Calculate what should be the size of the roll
if this plate has to be rolled in one pass assuming the coefficient of friction remains same as
above. If the rolls rotate at 100 rpm, calculate the roll force and power required in this
operation. Assume the width the plate is 150 mm and the average flow stress of the material as
180 MPa.
9. The overall size of the aluminium plate, 12 mm thick, is 100 × 100 mm. Write a manual part
program for making slots of depth 2 mm and width 10 mm as shown below figure. Mark the
work reference point in the picture and list down all the assumptions that have been taken
during machining operation. Consider tool rotational speed and feed rate are 2500 rpm and 100
mm/min, respectively.

10. A blanking die is to be designed to blank the part outline shown in Figure. The material is 4-mm
thick stainless steel. Determine the dimensions of the blanking punch and the die opening.
 Determine the blanking force required if the shear strength of the steel is 321 MPa. All
dimensions are in mm.

11. A compound die will be used to blank and punch a washer out of 6061 aluminum alloy sheet
stock 3.50 mm thick. Dimensions (in mm) of the washer are shown in figure below. Determine
(i) the punch and die sizes for the blanking operation and (ii) the punch and die sizes for the
punching operation.

20

50

12. A round billet made of 70-30 brass is extruded at a temperature of 675°C. The billet diameter is
125mm and the diameter of the extrusion is 50mm. Calculate the extrusion force required.
Assume the extrusion constant to be 250 MPa.
13. Take two solid, cylindrical specimens of equal diameter (= 75 mm), but different heights (100
mm and 150 mm), and compress them (frictionless) to the same 10% percentage reduction in
height. Calculate the final diameters for both the components.
14. During spot welding of MS sheets 6mm thick, 2000A current is passed for 0.5µs. Sheet interface
resistance is 130Ώ and 40% of the heat generated is lost due to radiation and other losses. If
10,000J is the heat required to melt one gram of material melting, determine the size of the
nugget formed? Assume the nugget is spherical and density of steel is 7.8 g/cm 3.
15. During submerged arc welding with constant voltage characteristics curve being used for the
welding operation. If arc length changes from 3mm to 4mm, current drops by 200A. Open
circuit voltage is 80V. Find short circuit current. Also find welding voltage and current for 3.5
mm arc length. Arc voltage characteristic curve is v = 20+4l.