Speed of Cutting wheel (N)

Jain (2008) stated that cutter wheel of up to 0.1 mm thickness can be operated at
speeds ranging from 300 to 5000 m/min. Expressed in revolutions per minute, using,

N  60U
D

Where, U = linear velocity at the

Circumference of the wheel, and
D = diameter of the abrasive cutter i.e. 100 to 300 mm

The range of speed is thus 1591 to 2652 rpm. A speed of 2500 rpm is selected which
corresponds to 39.3 m/s.

Feed Speed (fV)

Nagpal (2005) and Jain (2008) noted that a typical value of feed ranges between
0.2 to 0.6 m/s. A feed speed of 0.6 m/s, which corresponds to 100 mm/min, is chosen.

Feed Rate (f)

This is the feed of the cutter in one revolution and is obtained using
𝑓𝑣
f 𝑁
But fV = 100 mm/min; and N = 2500 rpm. Therefore,
100
f   0.04mm / rev The feed rate is 0.04 mm/rev.Type equation here.
2500

Depth of Cut (t)

This is the thickness of the layer removed in one pass in a direction Perpendicular to
the direction of feed motion (Nagpal, 2005). The feed is across the cross section of the
work piece. Hence, the depth of cut equals the thickness of the abrasive cutter.

t = 4 mm

2.2.7 Width of Cut (W)

This is taken as the greatest width of the work piece to be cut. A maximum width
of 100 mm is selected for the design.

2.2.8 Volume of Material removed per Unit Time (V)

According to Singh, 2008 and Jain, 2008 this can be derived using

V  fvtW
 mm
 100 min  4mm 100mm

mm3
 40,000 min

2.2.9 Power Required (P)

This is calculated, Nagpal, 2005; Jain, 2008 using

𝑉𝑒
P Watts
60

Where, e = specific energy of the material =5.5 J/mm3 for steel with BHN 400 (Singh,

2008)
Therefore,

P  40,000  5.5W
60

P  3666.7W

The power required for cutting is 0.367 kW.

2.2.10 Total Tangential Cutting Force

2.2.10 Total Tangential Cutting Force

This is evaluated by using (Jain, 2008; Singh, 2008)
F  60,000  P
T
DN
F  60,000  3666.67
T
  300  2500
FT  93.4N

2.2.11 Radial Force (FR)

This is the force perpendicular to the total tangential force (Jain, 2008) and is
taken as the required feed force. It is evaluated, Singh, 2008, using

FR  2FT

FR  2 93.4 N

FR  186.8 N