This question paper contains 02 pages

NATIONAL INSTITUTE OF TECHNOLOGY, ROURKELA-8

MID SEMESTER EXAMINATION, 2018
Session: 2018-19 Semester: Autumn
M. Tech.: First Semester, Production Engg.
Subject: Metal Cutting & Tool Design Deptt. Code: ME6205Full marks: 80
Duration of examination: 2 hrs

Answer ANY FOUR questions.

Figures at the right are marks. All parts of a question should be answered at one place.
Q No. Marks
1. (a) Describe slipline field model based on Lee and Shaffer theory for orthogonal cutting. 14
Derive shear angle relationship due to Lee and Shaffer. Write down the assumptions made in
the derivation.
(b) Define True or Effective rake angle. State how it is different from setting angle. 02

(c) State the difference between positive and negative insert. Sketch square inserts( both 04
positive and negative) and indicate their parameters.
2. (a) Determine tangential cutting force, feed force and radial force in turning operation. 16
The signature of the cutting tool is (-100)-150-80-70-90-300-1.5mm(MRS). Dynamic
shear strength of work material is 400N/mm2. Feed, depth of cut and cutting velocity
are 0.4mm/revolution, 4mm and 250m/minute.Average co-efficient of friction at the
chip/tool interface is 0.8. Calculate specific power due to cutting and chip-velocity.
Use Lee and Shaffer theory.
(b) Determine the average co-efficient of friction at which initiation of built-up edge takes 04
place as per Lee and Shaffer theory. All other data remain same as Q2(a).

3 (a) Sketch a cutting tool geometry for turning operation in MRS and ORS system of 05
nomenclature and write down the tool signature in each case.

(b) Derive necessary expressions to express orthogonal rake angle and inclination angle 10
in terms of back rake angle, side rake angle and principal cutting edge angle for a turning tool.
(c) State different types of chip-breakers commonly used in machining operation. What 05
do you mean by under-breaking and over-breaking limit? State the cutting variable which
directly controls the chip-breaking operation and influences the chip-breaker design.
4 (a) During machining of AISI-304 with a carbide cutting tool having a tool geometry 15
given by 50-(-50)-60-60-80-750-1mm ORS, the following forces have been recorded by
a dynamometer: tangential cutting force Fc=1400N and feed force Fx=850N.
Calculate: i) the radial component of force Fy
ii) the friction force, F and the normal force N at the chip/tool interface

(b) State the conditions favourable for the formation of continuous chip without built-up 5
edge formations. What are the important conclusions about the machining operation

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 can be made by studying the shape, size and colour of chips.
5 (a)Derive necessary expressions to determine average co-efficient of friction in 08
oblique cutting operation using Zorev’s analysis for turning operation. Draw the free
hand sketch of work-piece and cutting tool for oblique turning operation showing the
forces required for the Zorev’sanalysis.
(b)Determine average co-efficient of friction using Zorev’s analysis for turning operation. The 12
tool signature of the cutting tool is 60-150-80-80-100-750-1mm(ORS). The tangential cutting
force, feed force and radial force are 850N, 250N and 120N respectively. Calculate the angles
between i) principal cutting edge and feed force and ii) the principal cutting edge and radial
force.

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