Assignment 1

Roll number 1-10 : problem No. 1-3 Roll number 11-20 : problem No. 4-6 Roll number 21-30 : problem No. 7-9 Roll number 31-40 : problem No. 10-12 1. Draw and explain the TTT curve at Eutectoid composition. 2. A component as shown in figure is to be machined from a stock of steel, 40 mm in diameter and 72 mm long. Calculate the machining time if the Cutting speed, feed rate and depth of cut are 30 m/min, 0.30 mm/rev and 2mm respectively. The available spindle speeds are 70, 110, 176,280,440,700 and 1100 RPM.

3. Derive an expression of the cutting force Fc in terms of tool angles assuming constant shear strength at the work material. 4. Draw and label the Iron-Iron carbide phase diagram. Describe any two reactions responsible for generation of different phases. 5. Two thousand bars 80 mm in diameter and 300 m long are to be turned down to 65 mm diameter for 150mm of their length. The surface finish and accuracy requirements are such that a heavy roughing cut followed by a light finishing cut are needed. The roughing cut is to be taken at maximum power. The light-finishing cut is to be taken at a feed of 0.13mm, a cutting speed of 1.5m/s. If the lathe has 2 kW motor and an efficiency of 50%, calculate the total production time in kilo seconds for the batch of the work. Assume that the specific cutting energy for the work material is 2.73 GJ/m3, the time take to return the tool to the beginning of the cut is 15s, and the time taken to load the work piece is 120s. 6. During Orthogonal machining rake angle is 5, the un-deformed chip thickness is 1 mm and chip thickness is found to be 3 mm. what will be the chip thickness if the rake angle is increased to 15.Explain hypo-eutectoid and hyper-eutectoid transformations and associated microstructures. 7. For the orthogonal cutting of a particular material it is found that the length of chip tool contact is always equal to the chip thickness and that the mean shear stress at the chip-tool interface is equal to the mean shear stress on the shear plane. Show that, under these conditions, the mean coefficient of friction must be equal to or less than 4/3. 8. During turning a steel rod of diameter 150 mm by a carbide tool of geometry 0,12,8,6,15,60,0 mm at speed 560 rpm, feed 0.32 mm/rev, depth of cut =4 mm, cutting force =1000 N and thrust force =400N, chip thickness =0.8 mm. Determine chip tool friction coefficient and specific energy.

9. Draw CCT diagram and explain its significance in estimating the properties of materials. 10. A particular material follows s= s0+ where and are shear strength and tensile strength of material. Derive a relation between shear angle, friction angle and rake angle in case of orthogonal metal cutting. 11. The component shown in the figure is to be manufactured on a lathe machine using a steel bar of diameter 100 mm. The taper turning is carried out with compound slide method. If the allowable depth of cut and feed rate are 5 mm and 0.3 mm/ revolution respectively and the spindle rpm is 300, calculate the machining time for one component, ignoring the idle time. All dimensions in mm.

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