diff options
Diffstat (limited to '3250/CH4')
52 files changed, 614 insertions, 0 deletions
diff --git a/3250/CH4/EX4.1/Ex4_1.sce b/3250/CH4/EX4.1/Ex4_1.sce new file mode 100755 index 000000000..0b768c5e9 --- /dev/null +++ b/3250/CH4/EX4.1/Ex4_1.sce @@ -0,0 +1,11 @@ +clc +// Given that +alpha = 10 // Rake angle in Degree +t = 0.4 // Chip thickness in mm +T = 0.15 // Uncut chip thickness in mm +// Sample Problem 1 on page no. 187 +printf("\n # PROBLEM 4.1 # \n") +r = T/t +phi = atand((r*cosd(alpha))/(1-r*sind(alpha))) +gama = cotd(phi) + tand(phi-alpha) +printf("\n Shear plane angle = %f°, \n Magnitude of the shear strain = %f",phi,gama) diff --git a/3250/CH4/EX4.1/Ex4_1.txt b/3250/CH4/EX4.1/Ex4_1.txt new file mode 100755 index 000000000..cb6cb9d65 --- /dev/null +++ b/3250/CH4/EX4.1/Ex4_1.txt @@ -0,0 +1,4 @@ +# PROBLEM 4.1 #
+
+ Shear plane angle = 21.555321°,
+ Magnitude of the shear strain = 2.735935
\ No newline at end of file diff --git a/3250/CH4/EX4.10/Ex4_10.sce b/3250/CH4/EX4.10/Ex4_10.sce new file mode 100755 index 000000000..2dbf8da2f --- /dev/null +++ b/3250/CH4/EX4.10/Ex4_10.sce @@ -0,0 +1,25 @@ +clc +// Given that +d= 4 // Depth of cut in mm +f = 0.25 // Feed in mm/stroke +alpha = 10 // Rake angle in degree +shi = 30 // Principal cutting edge angle in Degree +mu =0.6 // Cofficient of friction between chip and tool +T_s = 340 // Ultimate shear stress of cast iron in N/mm^2 +N = 60 // Cutting stroke/min +L = 200 // Length of the job in mm +H = 180 // Hardness of the workpiece in BHN +// Sample Problem 10 on page no. 221 +printf("\n # PROBLEM 4.10 # \n") +lambda = atand(mu) +phi = 45 +alpha-lambda +Fc = f*d*T_s*(cosd(lambda-alpha))/((sind(phi))*(cosd(phi+lambda-alpha))) +Fc_ = Fc*(L/1000) +Wav =Fc_*N/60 +t1 = f*cosd(shi) +U_0 = 0.81 // By using table 4.4 given in the book, In J/mm^3 +Uc = U_0*((t1)^(-.4)) +Q = f*d*L*N/60 +Wav_ = Uc*Q +printf(" \n Avg power consumption = %d W,\n Specific power consumption when hardness of the workpiece is 180 BHN = %d W.",Wav,Wav_) +// Answer in the book for Specific power consumption is given as 294 W diff --git a/3250/CH4/EX4.10/Ex4_10.txt b/3250/CH4/EX4.10/Ex4_10.txt new file mode 100755 index 000000000..b4203e8cb --- /dev/null +++ b/3250/CH4/EX4.10/Ex4_10.txt @@ -0,0 +1,4 @@ + # PROBLEM 4.10 #
+
+ Avg power consumption = 220 W,
+ Specific power consumption when hardness of the workpiece is 180 BHN = 298 W.
\ No newline at end of file diff --git a/3250/CH4/EX4.11/Ex4_11.sce b/3250/CH4/EX4.11/Ex4_11.sce new file mode 100755 index 000000000..23b32d151 --- /dev/null +++ b/3250/CH4/EX4.11/Ex4_11.sce @@ -0,0 +1,15 @@ +clc +// Given that +alpha_b = 6 // Back rake angle in Degree +alpha_s = 10 // Side rake angle in Degree +gama = 7 // Front clearance angle in Degree +gama_ = 7 // Side clearance angle in Degree +Shi = 10 // End cutting edge angle in Degree +shi = 30 // Side cutting edge angle in Degree +r= 0.5 // Nose radius in mm +// Sample Problem 11 on page no. 224 +printf("\n # PROBLEM 4.11 # \n") +k = tand(alpha_b) * cosd(shi) - tand(alpha_s) * sind(shi) +printf("\n The value of k=%f,which is near to 0. Hence the case is close to orthogonal one.\n",k) +alpha= atand(((tand(alpha_b) * sind(shi) ) + (tand(alpha_s) * (cosd(shi))))/ (sqrt(1+((tand(alpha_b)*cosd(shi)) - (tand(alpha_s)*sind(shi)))^(2)))) +printf(" \n Normal rake angle = %f°.",alpha) diff --git a/3250/CH4/EX4.11/Ex4_11.txt b/3250/CH4/EX4.11/Ex4_11.txt new file mode 100755 index 000000000..34d742ba0 --- /dev/null +++ b/3250/CH4/EX4.11/Ex4_11.txt @@ -0,0 +1,5 @@ + # PROBLEM 4.11 #
+
+ The value of k=0.002859,which is near to 0. Hence the case is close to orthogonal one.
+
+ Normal rake angle = 11.599142°.
\ No newline at end of file diff --git a/3250/CH4/EX4.12/Ex4_12.sce b/3250/CH4/EX4.12/Ex4_12.sce new file mode 100755 index 000000000..531b6bb73 --- /dev/null +++ b/3250/CH4/EX4.12/Ex4_12.sce @@ -0,0 +1,26 @@ +clc +// Given that +alpha_b = 6 // Back rake angle in Degree +alpha_s = 10 // Side rake angle in Degree +gama = 5 // Front clearance angle in Degree +gama_ = 7 // Side clearance angle in Degree +Shi = 10 // End cutting edge angle in Degree +shi = 30 // Side cutting edge angle in Degree +r= 0.55 // Nose radius in mm +d = 2.5 // Depth of cut in mm +f = 0.125 // Feed in mm/revolution +N = 300 // Rpm of the job +T_S = 400 // Ultimate shear stress of the workpiece in N/mm^2 +mu = .6 // Cofficient of the friction between the tool and the chip +// Sample Problem 12 on page no. 225 +printf("\n # PROBLEM 4.12 # \n") +lambda = atand(mu) +alpha= atand(((tand(alpha_b) * sind(shi) ) + (tand(alpha_s) * (cosd(shi))))/ (sqrt(1+((tand(alpha_b)*cosd(shi)) - (tand(alpha_s)*sind(shi)))^(2)))) +phi = 45 + alpha - lambda +t1 = f*cosd(phi) +w = d/cosd(phi) +Fc = w*t1*T_S*(cosd(lambda-alpha))/((sind(phi))*(cosd(phi+lambda-alpha))) +Ft = Fc*tand(lambda-alpha) +Ff = Ft*cosd(shi) +Fr = Ft*sind(shi) +printf(" \n Component of the machining force are as follows -\n Feed force component = % d N, \n Normal thrust force component = % d N.",ceil(Ff),ceil(Fr)) diff --git a/3250/CH4/EX4.12/Ex4_12.txt b/3250/CH4/EX4.12/Ex4_12.txt new file mode 100755 index 000000000..4fe61e0ce --- /dev/null +++ b/3250/CH4/EX4.12/Ex4_12.txt @@ -0,0 +1,6 @@ +
+ # PROBLEM 4.12 #
+
+ Component of the machining force are as follows -
+ Feed force component = 118 N,
+ Normal thrust force component = 68 N.
\ No newline at end of file diff --git a/3250/CH4/EX4.14/Ex4_14.sce b/3250/CH4/EX4.14/Ex4_14.sce new file mode 100755 index 000000000..c1aa294c8 --- /dev/null +++ b/3250/CH4/EX4.14/Ex4_14.sce @@ -0,0 +1,23 @@ +clc +// Given that +D = 20 // Nominal diameter of the drill in mm +T_S = 400 // Shear yield stress of work material in N/mm^2 +N = 240 // Rpm +f = 0.25 // Feed in mm/revolution +mu = 0.6 // Cofficient of friction +// Sample Problem 14 on page no. 230 +printf("\n # PROBLEM 4.14 # \n") +Beta = 118/2 // From the table 4.12 given in the book +shi = 30 // From the table 4.12 given in the book +alpha = atand(((2*(D/4)/(D))*tand(shi))/sind(Beta)) +t1 = (f/2)*sind(Beta) +w = (D/2)/sind(Beta) +lambda = atand(mu) +phi = 45+alpha-lambda +t1 = f/2 +Fc = w*t1*T_S*(cosd(lambda-alpha))/((sind(phi))*(cosd(phi+lambda-alpha))) +Ft = w*t1*T_S*(sind(lambda-alpha))/((sind(phi))*(cosd(phi+lambda-alpha))) +M = .6*Fc*D/1000 +F = 5*Ft*sind(Beta) +printf(" \n The drilling torque = %f N-m, \n Thrust force = %d N.",M,F) +// Answer in the book for drilling torque is given as 18.2 N-m, and for thrust force is given as 1500 N diff --git a/3250/CH4/EX4.14/Ex4_14.txt b/3250/CH4/EX4.14/Ex4_14.txt new file mode 100755 index 000000000..87b1810dd --- /dev/null +++ b/3250/CH4/EX4.14/Ex4_14.txt @@ -0,0 +1,4 @@ + # PROBLEM 4.14 #
+
+ The drilling torque = 17.924639 N-m,
+ Thrust force = 1401 N.
\ No newline at end of file diff --git a/3250/CH4/EX4.15/Ex4_15.sce b/3250/CH4/EX4.15/Ex4_15.sce new file mode 100755 index 000000000..44957246f --- /dev/null +++ b/3250/CH4/EX4.15/Ex4_15.sce @@ -0,0 +1,28 @@ +clc +// Given that +w = 20 // Width of the mild steel block in mm +Z = 20 // No of teeth in milling cutter +D = 50 // Diameter of the milling cutter in mm +alpha = 10 // Radial rake angle in Degree +f = 15 // Feed velocity of the table in mm/min +N =60 // Rpm of the cutter +t = 1 // Depth of cut in mm +mu = 0.5 // Cofficient of friction +T_s = 400 // Shear yield stress in N/mm^2 +t_a = 0.0018 // Avg uncut thickness in mm +// Sample Problem 15 on page no. 235 +printf("\n # PROBLEM 4.15 # \n") +Beta = asind(2*(t/D)) +theta = 2*%pi/Z +t1_max = (2*f/(N*Z))*sqrt(t/D) +lambda = atand(mu) +phi = 45+alpha -lambda +Fc_max = ((w*t1_max*T_s*cosd(lambda-alpha)))/((sind(phi))*(cosd(45))) +T_max = Fc_max*D/(2*1000) +M_av = (1/2)*(Beta*T_max)/theta +omega = 2*%pi*N/60 +U_0 = 1.4 // From the table 4.4 given in the book +Uc_ms = U_0*((t_a)^(-0.4)) +R = f*t*w/60 +U = Uc_ms * R +printf(" \n Power consumption = %f W.",U) diff --git a/3250/CH4/EX4.15/Ex4_15.txt b/3250/CH4/EX4.15/Ex4_15.txt new file mode 100755 index 000000000..2e3d32928 --- /dev/null +++ b/3250/CH4/EX4.15/Ex4_15.txt @@ -0,0 +1,4 @@ +
+ # PROBLEM 4.15 #
+
+ Power consumption = 87.697869 W.
\ No newline at end of file diff --git a/3250/CH4/EX4.16/Ex4_16.sce b/3250/CH4/EX4.16/Ex4_16.sce new file mode 100755 index 000000000..6353972bb --- /dev/null +++ b/3250/CH4/EX4.16/Ex4_16.sce @@ -0,0 +1,29 @@ +clc +// Given that +w = 20 // Width of the mild steel block in mm +Z = 10 // No of teeth in milling cutter +D = 75 // Diameter of the milling cutter in mm +alpha = 10 // Radial rake angle in Degree +f = 100 // Feed velocity of the table in mm/min +N =60 // Rpm of the cutter +t = 5 // Depth of cut in mm +mu = 0.5 // Cofficient of friction +T_s = 400 // Shear yield stress in N/mm^2 +t_a = 0.043 // Avg uncut thickness in mm +// Sample Problem 16 on page no. 238 +printf("\n # PROBLEM 4.16 # \n") +Beta = asind(2*(t/D)) +theta = 2*%pi/Z +t1_max = (2*f/(N*Z))*sqrt(t/D) +lambda = atand(mu) +phi = 45+alpha -lambda +Fc_max = ((w*t1_max*T_s*cosd(lambda-alpha)))/((sind(phi))*(cosd(45))) +T_max = Fc_max*D/(2*1000) +M_av = (1/2)*(Beta*T_max)/theta +omega = 2*%pi*N/60 +U_0 = 1.4 // From the table 4.4 given in the book +Uc_ms = U_0*((t_a)^(-0.4)) +R = f*t*w/60 +U = Uc_ms * R +printf(" \n Power required = %d W.",U) +// Answer in the book for Power required is given as 817 W diff --git a/3250/CH4/EX4.16/Ex4_16.txt b/3250/CH4/EX4.16/Ex4_16.txt new file mode 100755 index 000000000..9c58b5dce --- /dev/null +++ b/3250/CH4/EX4.16/Ex4_16.txt @@ -0,0 +1,3 @@ + # PROBLEM 4.16 #
+
+ Power required = 821 W.
\ No newline at end of file diff --git a/3250/CH4/EX4.17/Ex4_17.sce b/3250/CH4/EX4.17/Ex4_17.sce new file mode 100755 index 000000000..dd1e0a4df --- /dev/null +++ b/3250/CH4/EX4.17/Ex4_17.sce @@ -0,0 +1,20 @@ +clc +// Given that +B = 20 // Width of the cut in mm +Z = 10 // No of teeth in milling cutter +D = 75 // Diameter of the milling cutter in mm +alpha = 10 // Radial rake angle in Degree +f = 25 // Feed velocity of the table in mm/min +N =60 // Rpm of the cutter +t = 5 // Depth of cut in mm +mu = 0.5 // Cofficient of friction +T_s = 400 // Shear yield stress in N/mm^2 +t_a = 0.043 // Avg uncut thickness in mm +// Sample Problem 17 on page no. 240 +printf("\n # PROBLEM 4.17 # \n") +t1_max = 0.01 +lambda = 0.28 // From the table 4.13 Given in the book +nu = 1400 // From the table 4.13 Given in the book +t1_av = t1_max/2 +P = nu*B*t*f*(10^-4)/(6*((t1_av)^(lambda))) +printf(" \n Power required = %f W.",P) diff --git a/3250/CH4/EX4.17/Ex4_17.txt b/3250/CH4/EX4.17/Ex4_17.txt new file mode 100755 index 000000000..655b02783 --- /dev/null +++ b/3250/CH4/EX4.17/Ex4_17.txt @@ -0,0 +1,3 @@ + # PROBLEM 4.17 #
+
+ Power required = 257.161051 W.
\ No newline at end of file diff --git a/3250/CH4/EX4.18/Ex4_18.sce b/3250/CH4/EX4.18/Ex4_18.sce new file mode 100755 index 000000000..b60b4ec4d --- /dev/null +++ b/3250/CH4/EX4.18/Ex4_18.sce @@ -0,0 +1,18 @@ +clc +// Given that +w = 20 // Width of the mild steel block in mm +Z = 10 // No of teeth in milling cutter +D = 75 // Diameter of the milling cutter in mm +alpha = 10 // Radial rake angle in Degree +f = 25 // Feed velocity of the table in mm/min +N =60 // Rpm of the cutter +t = 5 // Depth of cut in mm +mu = 0.5 // Cofficient of friction +T_s = 400 // Shear yield stress in N/mm^2 +t_a = 0.043 // Avg uncut thickness in mm +// Sample Problem 18 on page no. 240 +printf("\n # PROBLEM 4.18 # \n") +R = f*t*w/60 +Uc = 3.3 // Specific energy in J/mm^3 from the table 4.14 Given in the book +U = Uc * R +printf(" \n Power required = %d W.",ceil(U)) diff --git a/3250/CH4/EX4.18/Ex4_18.txt b/3250/CH4/EX4.18/Ex4_18.txt new file mode 100755 index 000000000..c316ee89d --- /dev/null +++ b/3250/CH4/EX4.18/Ex4_18.txt @@ -0,0 +1,4 @@ +
+ # PROBLEM 4.18 #
+
+ Power required = 138 W.
\ No newline at end of file diff --git a/3250/CH4/EX4.19/Ex4_19.sce b/3250/CH4/EX4.19/Ex4_19.sce new file mode 100755 index 000000000..fad6a2c33 --- /dev/null +++ b/3250/CH4/EX4.19/Ex4_19.sce @@ -0,0 +1,18 @@ +clc +// Given that +d = 25 // Diameter of circular hole in mm +t = 20 // Thickness of the steel plate in mm +D = 27 // Enlarged diameter of hole in mm +c= 0.08 // Cut per tooth in mm +alpha = 10 // Radial rake angle in Degree +mu = 0.5 // Cofficient of friction +T_s = 400 // Shear yield stress in N/mm^2 +// Sample Problem 19 on page no. 241 +printf("\n # PROBLEM 4.19 # \n") +lambda=atand(mu) +phi = 45-lambda+alpha +w = %pi*(d+D)/2 +Fc = w*c*T_s*(cosd(lambda-alpha))/((sind(phi))*(cosd(45))) +s = 1.75*sqrt(t) +F = 3*Fc +printf(" \n Peak broaching load = %d N.",ceil(F)) diff --git a/3250/CH4/EX4.19/Ex4_19.txt b/3250/CH4/EX4.19/Ex4_19.txt new file mode 100755 index 000000000..6748f118c --- /dev/null +++ b/3250/CH4/EX4.19/Ex4_19.txt @@ -0,0 +1,3 @@ + # PROBLEM 4.19 #
+
+ Peak broaching load = 22323 N.
\ No newline at end of file diff --git a/3250/CH4/EX4.2/Ex4_2.sce b/3250/CH4/EX4.2/Ex4_2.sce new file mode 100755 index 000000000..d7132e349 --- /dev/null +++ b/3250/CH4/EX4.2/Ex4_2.sce @@ -0,0 +1,17 @@ +clc +// Given that +t1 = 0.25 // Undercut thickness in mm +t2 = 0.75 // Chip thickness in mm +w = 2.5 // Width in mm +alpha = 0 // Rake angle in Degree +Fc = 950 // Cutting force in N +Ft = 475 // Thrust force in N +// Sample Problem 2 on page no. 192 +printf("\n # PROBLEM 4.2 # \n") +r = t1/t2 +mu = ((Fc*sind(alpha)) + (Ft*cosd(alpha)))/((Fc*cosd(alpha))-(Ft*sind(alpha))) +phi = atand((r*cosd(alpha))/(1-r*sind(alpha))) +As = t1*w/sind(phi) +Fs = Fc*cosd(phi) - Ft*sind(phi) +T_s = Fs/As +printf("\n Coefficient of the friction between tool and the chip = %f, \n The ultimate shear stress of the material = %f N/mm^2",mu,T_s) diff --git a/3250/CH4/EX4.2/Ex4_2.txt b/3250/CH4/EX4.2/Ex4_2.txt new file mode 100755 index 000000000..08c3a4e75 --- /dev/null +++ b/3250/CH4/EX4.2/Ex4_2.txt @@ -0,0 +1,4 @@ + # PROBLEM 4.2 #
+
+ Coefficient of the friction between tool and the chip = 0.500000,
+ The ultimate shear stress of the material = 380.000000 N/mm^2
\ No newline at end of file diff --git a/3250/CH4/EX4.20/Ex4_20.sce b/3250/CH4/EX4.20/Ex4_20.sce new file mode 100755 index 000000000..0f7abe200 --- /dev/null +++ b/3250/CH4/EX4.20/Ex4_20.sce @@ -0,0 +1,18 @@ +clc +// Given that +D = 250 // Diameter of the wheel in mm +N = 2000 // Rpm of the wheel +f =5 // Plung feed rate in mm/min +C = 3 // Surface density of active grain in mm^-2 +A = 20*15 // Area of mild steel prismatic bar in mm^2 +rg = 15 // In mm^-1 +// Sample Problem 20 on page no. 246 +printf("\n # PROBLEM 4.20 # \n") +t1 = sqrt(f/(%pi*D*N*C*rg)) +U_0 = 1.4 // From the table 4.4 given in the book +Uc= U_0*((t1)^(-.4)) +R = A*f/60 +P = Uc*R +Fc_ = 60000*(P)/(%pi*D*A*C*N) +printf(" \n Power requirement during plunge grinding of the mild steel primatic bar = %d W.",ceil(P)) +// Answer in the book is given as 94 W diff --git a/3250/CH4/EX4.20/Ex4_20.txt b/3250/CH4/EX4.20/Ex4_20.txt new file mode 100755 index 000000000..a8b766869 --- /dev/null +++ b/3250/CH4/EX4.20/Ex4_20.txt @@ -0,0 +1,3 @@ + # PROBLEM 4.20 #
+
+ Power requirement during plunge grinding of the mild steel primatic bar = 943 W.
\ No newline at end of file diff --git a/3250/CH4/EX4.21/Ex4_21.sce b/3250/CH4/EX4.21/Ex4_21.sce new file mode 100755 index 000000000..116ca2f96 --- /dev/null +++ b/3250/CH4/EX4.21/Ex4_21.sce @@ -0,0 +1,19 @@ +clc +// Given that +w = 25 // Width of mild steel block in mm +d= 0.05 // Depth of cut in mm +D = 200 // Diameter of the wheel in mm +N = 3000 // Rpm of the wheel +f =100 // Feed velocity of table in mm/min +C = 3 // No of grits in mm^-2 +rg = 15 // In mm^-1 +// Sample Problem 21 on page no. 248 +printf("\n # PROBLEM 4.21 # \n") +t1_max = sqrt(((6*f)/(%pi*D*N*C*rg))*sqrt(d/D)) +t1_a = t1_max/2 +U_0 = 1.4 // From the table 4.4 given in the book +Uc= U_0*((t1_a)^(-.4)) +R = w*d*f/60 +P = Uc*R +Fc = 60000*(P)/(%pi*D*N) +printf(" \n Grinding force = %d N",Fc) diff --git a/3250/CH4/EX4.21/Ex4_21.txt b/3250/CH4/EX4.21/Ex4_21.txt new file mode 100755 index 000000000..6a0d7bcbe --- /dev/null +++ b/3250/CH4/EX4.21/Ex4_21.txt @@ -0,0 +1,3 @@ + # PROBLEM 4.21 #
+
+ Grinding force = 3 N
\ No newline at end of file diff --git a/3250/CH4/EX4.22/Ex4_22.sce b/3250/CH4/EX4.22/Ex4_22.sce new file mode 100755 index 000000000..5de68f024 --- /dev/null +++ b/3250/CH4/EX4.22/Ex4_22.sce @@ -0,0 +1,14 @@ +clc +// Given that +d= 0.05 // Depth of cut in mm +f =200 // Feed rate in mm/min +theta = 850 // Surface temperature in °C +Theta = 700 // Maximum surface temperature of workpiece surface required to maintain in °C +// Sample Problem 22 on page no. 251 +printf("\n # PROBLEM 4.22 # \n") +K = theta * (f^0.2)/(d^0.9) +r = Theta/K +C = d*f +Dm = (r*C^0.2)^(1/1.1) +fm = C/Dm +printf(" \n Required depth of cut = %f mm,\n Required feed = %d mm/min",Dm,fm) diff --git a/3250/CH4/EX4.22/Ex4_22.txt b/3250/CH4/EX4.22/Ex4_22.txt new file mode 100755 index 000000000..c18cd0a74 --- /dev/null +++ b/3250/CH4/EX4.22/Ex4_22.txt @@ -0,0 +1,4 @@ + # PROBLEM 4.22 #
+
+ Required depth of cut = 0.041910 mm,
+ Required feed = 238 mm/min
\ No newline at end of file diff --git a/3250/CH4/EX4.24/Ex4_24.sce b/3250/CH4/EX4.24/Ex4_24.sce new file mode 100755 index 000000000..ca2b6e9f4 --- /dev/null +++ b/3250/CH4/EX4.24/Ex4_24.sce @@ -0,0 +1,11 @@ +clc +// Given that +shi = 30 // Side cutting edge angle in Degree +lambda = 7 // End cutting edge angle in Degree +r = 0.7 // Nose radius in mm +f = 0.125 // Feed in mm +// Sample Problem 24 on page no. 260 +printf("\n # PROBLEM 4.24 # \n") +H_max = f/(tand(shi)+cotd(lambda)) +H_max_ = (f^2)/(8*r) +printf(" \n Maximum height of uneveness in first tool case = %f mm,\n In second tool case = %f mm",H_max,H_max_) diff --git a/3250/CH4/EX4.24/Ex4_24.txt b/3250/CH4/EX4.24/Ex4_24.txt new file mode 100755 index 000000000..a439e658e --- /dev/null +++ b/3250/CH4/EX4.24/Ex4_24.txt @@ -0,0 +1,5 @@ +
+ # PROBLEM 4.24 #
+
+ Maximum height of uneveness in first tool case = 0.014332 mm,
+ In second tool case = 0.002790 mm
\ No newline at end of file diff --git a/3250/CH4/EX4.25/Ex4_25.sce b/3250/CH4/EX4.25/Ex4_25.sce new file mode 100755 index 000000000..9cd7a56e9 --- /dev/null +++ b/3250/CH4/EX4.25/Ex4_25.sce @@ -0,0 +1,10 @@ +clc +// Given that +Z = 12 // No of teeth +d = 100 // Diameter of cutter in mm +N = 60 // Rpm of cutter +f = 25 // Table feed in mm/min +// Sample Problem 25 on page no. 262 +printf("\n # PROBLEM 4.25 # \n") +H_max = (f^2)/(4*d*(N^2)*(Z^2)) +printf(" \n Maximum height of uneveness = %f mm",H_max) diff --git a/3250/CH4/EX4.25/Ex4_25.txt b/3250/CH4/EX4.25/Ex4_25.txt new file mode 100755 index 000000000..5cb6d7583 --- /dev/null +++ b/3250/CH4/EX4.25/Ex4_25.txt @@ -0,0 +1,4 @@ +
+ # PROBLEM 4.25 #
+
+ Maximum height of uneveness = 0.000003 mm
\ No newline at end of file diff --git a/3250/CH4/EX4.26/Ex4_26.sce b/3250/CH4/EX4.26/Ex4_26.sce new file mode 100755 index 000000000..477c3f53c --- /dev/null +++ b/3250/CH4/EX4.26/Ex4_26.sce @@ -0,0 +1,12 @@ +clc +// Given that +n = 0.25 // Value of exponent of time in Taylor's tool life equation +C = 75 // Value of constant in Taylor's tool life equation +Lc = .15 // Labour cast in $/min +Tc = 2.50 // Total cast of tool in $ +t = 2 // Change time for tool in min +// Sample Problem 26 on page no. 268 +printf("\n # PROBLEM 4.26 # \n") +x = (C)^(1/n) // Where x = k/(f^(1/n)) +v_opt = ((n*x*Lc)/((1-n)*((Lc*t+Tc))))^(n) +printf(" \n Cutting speed that will be lead to minimum cast = %f m/min",v_opt) diff --git a/3250/CH4/EX4.26/Ex4_26.txt b/3250/CH4/EX4.26/Ex4_26.txt new file mode 100755 index 000000000..5411dad46 --- /dev/null +++ b/3250/CH4/EX4.26/Ex4_26.txt @@ -0,0 +1,3 @@ + # PROBLEM 4.26 #
+
+ Cutting speed that will be lead to minimum cast = 27.416642 m/min
\ No newline at end of file diff --git a/3250/CH4/EX4.27/Ex4_27.sce b/3250/CH4/EX4.27/Ex4_27.sce new file mode 100755 index 000000000..7516c28ca --- /dev/null +++ b/3250/CH4/EX4.27/Ex4_27.sce @@ -0,0 +1,24 @@ +clc +// Given that +L = 300 // Length of the bar in mm +d=30 // Diameter of the bar in mm +f_max = 0.25 // Maximum allowable feed in mm/revolution +Lc = .25 // Labour and overhead cast in $/min +Tc = 2 // Regrinding cast in $ +t = 1 // Change time for tool in min +C_X = 2.50 // Cast of tool of material X per piece in $ +C_Y = 3 // Cast of tool of material Y per piece in $ +n_x = 0.1 // Value of exponent of time in Taylor's tool life equation for material X +n_y = 0.16 // Value of exponent of time in Taylor's tool life equation for material Y +C_x = 30 // Value of constant in Taylor's tool life equation for material X +C_y = 76 // Value of constant in Taylor's tool life equation For material Y +// Sample Problem 27 on page no. 269 +printf("\n # PROBLEM 4.27 # \n") +x_x = (C_x)^(1/n_x) // Where x = k/(f^(1/n)) +v_opt_x = ((n_x*x_x*Lc)/((1-n_x)*((Lc*t+Tc))))^(n_x) +Rmin_x = C_X+Lc*t+(Lc*%pi*L*d/(1000*f_max*v_opt_x)) + (Lc*t*(%pi*L*d/(1000*x_x)))*(v_opt_x^(1/n_y))*(v_opt_x^-1)*(f_max^-1)+(Tc*((%pi*L*d/(1000*x_x)))*(v_opt_x^(1/n_x))*(v_opt_x^-1)*(f_max^-1)) +x_y = (C_y)^(1/n_y) // Where x = k/(f^(1/n)) +v_opt_y = ((n_y*x_y*Lc)/((1-n_y)*((Lc*t+Tc))))^(n_y) +Rmin_y = C_Y+Lc*t+(Lc*%pi*L*d/(1000*f_max*v_opt_y)) + (Lc*t*(%pi*L*d/(1000*x_y)))*(v_opt_y^(1/n_y))*(v_opt_y^-1)*(f_max^-1)+(Tc*((%pi*L*d/(1000*x_y)))*(v_opt_y^(1/n_y))*(v_opt_y^-1)*(f_max^-1)) +printf(" \n The minimum cast per piece\n When material X is used = %f $,\n When material Y is used = %f $",Rmin_x,Rmin_y) +printf("\n So material Y will be suitable for tool as it has low cast") diff --git a/3250/CH4/EX4.27/Ex4_27.txt b/3250/CH4/EX4.27/Ex4_27.txt new file mode 100755 index 000000000..38e0fc2ae --- /dev/null +++ b/3250/CH4/EX4.27/Ex4_27.txt @@ -0,0 +1,7 @@ +
+ # PROBLEM 4.27 #
+
+ The minimum cast per piece
+ When material X is used = 4.357033 $,
+ When material Y is used = 4.070737 $
+ So material Y will be suitable for tool as it has low cast
\ No newline at end of file diff --git a/3250/CH4/EX4.28/Ex4_28.sce b/3250/CH4/EX4.28/Ex4_28.sce new file mode 100755 index 000000000..f9f2f8e8a --- /dev/null +++ b/3250/CH4/EX4.28/Ex4_28.sce @@ -0,0 +1,12 @@ +clc +// Given that +n = 0.25 // Value of exponent of time in Taylor's tool life equation +C = 75 // Value of constant in Taylor's tool life equation +Lc = .15 // Labour cast in $/min +Tc = 2.50 // Total cast of tool in $ +t = 2 // Change time for tool in min +// Sample Problem 28 on page no. 271 +printf("\n # PROBLEM 4.28 # \n") +x = (C)^(1/n) // Where x = k/(f^(1/n)) +v_opt = ((n*x)/((1-n)*t))^(n) +printf(" \n Optimum cutting speed for maximum production rate for the job = %f m/min",v_opt) diff --git a/3250/CH4/EX4.28/Ex4_28.txt b/3250/CH4/EX4.28/Ex4_28.txt new file mode 100755 index 000000000..1b92aa9e6 --- /dev/null +++ b/3250/CH4/EX4.28/Ex4_28.txt @@ -0,0 +1,3 @@ + # PROBLEM 4.28 #
+
+ Optimum cutting speed for maximum production rate for the job = 47.920733 m/min
\ No newline at end of file diff --git a/3250/CH4/EX4.3/Ex4_3.sce b/3250/CH4/EX4.3/Ex4_3.sce new file mode 100755 index 000000000..3ac6506b9 --- /dev/null +++ b/3250/CH4/EX4.3/Ex4_3.sce @@ -0,0 +1,18 @@ +clc +// Given that +alpha = 10 // Rake angle of tool in Degree +v = 200 // Cutting speed in m/min +t1 = 0.2 // Uncut thickness in mm +w = 2 // Width of cut in mm +mu = 0.5 // Avg value of the cofficient of tbe friction +T_S = 400 // Shear stress of the work material in N/mm^2 +// Sample Problem 3 on page no. 193 +printf("\n # PROBLEM 4.3 # \n") +lambda = atand(mu) +phi = (90 + alpha - lambda)/2 +Fs = (w*t1*T_S)/(sind(phi)) +R = Fs/(cosd(phi+lambda-alpha)) +Fc = R*(cosd(lambda-alpha)) +Ft = R*(sind(lambda-alpha)) +printf("\n Shear angle = %f°, \n Cutting force = %d N, \n Thrust force = %d N,",phi,Fc,Ft) +// Answer in the book for cutting force is given as 420 N and for thrust force is given as 125 N diff --git a/3250/CH4/EX4.3/Ex4_3.txt b/3250/CH4/EX4.3/Ex4_3.txt new file mode 100755 index 000000000..7ab155fda --- /dev/null +++ b/3250/CH4/EX4.3/Ex4_3.txt @@ -0,0 +1,5 @@ + # PROBLEM 4.3 #
+
+ Shear angle = 36.717474°,
+ Cutting force = 429 N,
+ Thrust force = 127 N,
\ No newline at end of file diff --git a/3250/CH4/EX4.4/Ex4_4.sce b/3250/CH4/EX4.4/Ex4_4.sce new file mode 100755 index 000000000..319c7254a --- /dev/null +++ b/3250/CH4/EX4.4/Ex4_4.sce @@ -0,0 +1,25 @@ +clc +// Given that +alpha = 10 // Rake angle of tool in Degree +v = 200 // Cutting speed in m/min +t1 = 0.2 // Uncut thickness in mm +w = 2 // Width of cut in mm +mu = 0.5 // Avg value of the cofficient of tbe friction +T_S = 400 // Shear stress of the work material in N/mm^2 +Cm = 70 // Machining constant in Degree +// Sample Problem 4 on page no. 194 +printf("\n # PROBLEM 4.4 # \n") +lambda = atand(mu) +phi = (Cm + alpha - lambda)/2 +Fs = (w*t1*T_S)/(sind(phi)) +R = Fs/(cosd(phi+lambda-alpha)) +Fc = R*(cosd(lambda-alpha)) +Ft = R*(sind(lambda-alpha)) +// Using Lee and Shaffer relation +phi_ = 45-lambda+alpha +Fs_ = (w*t1*T_S)/(sind(phi_)) +R_ = Fs_/(cosd(phi_+lambda-alpha)) +Fc_ = R_*(cosd(lambda-alpha)) +Ft_ = R_*(sind(lambda-alpha)) +printf("\n Shear angle = %f°, \n Cutting force = %f N, \n Thrust force = %f N \n Using Lee and Shaffer relation- \n Shear angle = %f°, \n Cutting force = %f N, \n Thrust force = %f N,",phi,Fc,Ft,phi_,Fc_,Ft_) +// Answer in the book for cutting force is given as 486.9 N and for thrust force is given as 144.9 N , When using Lee and Shaffer relation answer in the book for cutting force is given as 481.9 N and for trust force is given as 160.6 N diff --git a/3250/CH4/EX4.4/Ex4_4.txt b/3250/CH4/EX4.4/Ex4_4.txt new file mode 100755 index 000000000..42f6574c5 --- /dev/null +++ b/3250/CH4/EX4.4/Ex4_4.txt @@ -0,0 +1,9 @@ + # PROBLEM 4.4 #
+
+ Shear angle = 26.717474°,
+ Cutting force = 468.567296 N,
+ Thrust force = 139.374821 N
+ Using Lee and Shaffer relation-
+ Shear angle = 28.434949°,
+ Cutting force = 455.482874 N,
+ Thrust force = 135.482874 N,
\ No newline at end of file diff --git a/3250/CH4/EX4.5/Ex4_5.sce b/3250/CH4/EX4.5/Ex4_5.sce new file mode 100755 index 000000000..497435ea5 --- /dev/null +++ b/3250/CH4/EX4.5/Ex4_5.sce @@ -0,0 +1,16 @@ +clc +// Given that +t1 = 0.25 // Uncut thickness in mm +w = 2.5 // Width of cut in mm +U_0 = 1.4 // In J/mm^3 +alpha = 0 // Rake angle in degree +mu = 0.5 // Cofficient of the friction +T_s = 400 // Shear stress in N/mm^2 +// Sample Problem 5 on page no. 196 +printf("\n # PROBLEM 4.5 # \n") +lambda = atand(mu) +Fc = 1000*(t1*w*U_0)*((t1)^(-.4)) +phi = 45 + alpha - atand(mu) +Fc_ = (w*t1*T_s*cosd(lambda-alpha))/((sind(phi)) *cosd(phi+lambda-alpha)) +printf(" \n The order of magnitude of cutting force = %d N,\n Using Lee and Shaffer relation- \n The order of magnitude of cutting force = %d N.",Fc,Fc_) +// Answer in the book for cutting force is given as 1517 N diff --git a/3250/CH4/EX4.5/Ex4_5.txt b/3250/CH4/EX4.5/Ex4_5.txt new file mode 100755 index 000000000..86c03f189 --- /dev/null +++ b/3250/CH4/EX4.5/Ex4_5.txt @@ -0,0 +1,5 @@ + # PROBLEM 4.5 #
+
+ The order of magnitude of cutting force = 1523 N,
+ Using Lee and Shaffer relation-
+ The order of magnitude of cutting force = 1000 N.
\ No newline at end of file diff --git a/3250/CH4/EX4.6/Ex4_6.sce b/3250/CH4/EX4.6/Ex4_6.sce new file mode 100755 index 000000000..5611c2b36 --- /dev/null +++ b/3250/CH4/EX4.6/Ex4_6.sce @@ -0,0 +1,32 @@ +clc +// Given that +v = 2 // Cutting speed in m/sec +D = 7200 // Density of mild steel in kg /m^3 +k = 43.6 // Thermal conductivity in W/m-°c +c = 502 // Specific heat of the material in J/kg-°c +t1 = 0.25 // Uncut thickness in mm +w =2 // Width of cut in mm +theta_0 = 40 // Initial temp of the workpiece in Degree +alpha = 0 // Rake angle in degree +mu = 0.5 // Cofficient of the friction +T_s = 400e6 // Shear stress in N/m^2 +// Sample Problem 6 on page no. 199 +printf("\n # PROBLEM 4.6 # \n") +lambda = atand(mu) +phi = 45 + alpha - lambda +Fs = (w*t1*T_s)*(10^-6)/(sind(phi)) +R = Fs / (cosd(phi+lambda-alpha)) +Fc = R *(cosd(lambda-alpha)) +r = sind(phi)/(cosd(phi-alpha)) +Ft= Fc *(tand(lambda - alpha)) +F = Fc *(sind(alpha))+Ft*(cosd(alpha)) +Ws = F*r*v +Wp = Fc*v-F*r*v +zeta = D*c*v*t1*(10^-3)/k +zeta_ = zeta*tand(phi) +nu = 0.15 *(log(27.5/(zeta_))) +theta_P = (1-nu)*Wp/(D*c*v*t1*w*(10^-6)) +theta_S = 1.13 *(sqrt(1/(D*c*v*t1*(10^-3)*k*(1+tand(phi-alpha)))))*(Ws/w)*(10^3) +theta = theta_0+theta_S+ theta_P +printf(" \n Maximum temperature along the rake face of the tool = %d°C.",theta) +// Answer in the book is given as 823°C diff --git a/3250/CH4/EX4.6/Ex4_6.txt b/3250/CH4/EX4.6/Ex4_6.txt new file mode 100755 index 000000000..f58c28a3e --- /dev/null +++ b/3250/CH4/EX4.6/Ex4_6.txt @@ -0,0 +1,3 @@ + # PROBLEM 4.6 #
+
+ Maximum temperature along the rake face of the tool = 835°C.
\ No newline at end of file diff --git a/3250/CH4/EX4.7/Ex4_7.sce b/3250/CH4/EX4.7/Ex4_7.sce new file mode 100755 index 000000000..23d8e49ce --- /dev/null +++ b/3250/CH4/EX4.7/Ex4_7.sce @@ -0,0 +1,34 @@ +clc +// Given that +theta_ = 40 //Ambient temperature in°C +v = 2 // Cutting speed in m/sec +D = 7200 // Density of mild steel in kg /m^3 +k = 43.6 // Thermal conductivity in W/m-°c +c = 502 // Specific heat of the material in J/kg-°c +t1 = 0.25 // Uncut thickness in mm +w =2 // Width of cut in mm +alpha = 0 // Rake angle in degree +mu = 0.5 // Cofficient of the friction +T_s = 400e6 // Shear stress in N/m^2 +H = 350 // Hardness of SAE 1040 steel in HV(Vicker hardness) +// Sample Problem 7 on page no. 206 +printf("\n # PROBLEM 4.7 # \n") +lambda = atand(mu) +phi = 45 + alpha - lambda +Fs = (w*t1*T_s)*(10^-6)/(sind(phi)) +R = Fs / (cosd(phi+lambda-alpha)) +Fc = R *(cosd(lambda-alpha)) +r = sind(phi)/(cosd(phi-alpha)) +Ft= Fc *(tand(lambda - alpha)) +F = Fc *(sind(alpha))+Ft*(cosd(alpha)) +Ws = F*r*v +Wp = Fc*v-F*r*v +zeta = D*c*v*t1*(10^-3)/k +zeta_ = zeta*tand(phi) +nu = 0.15 *(log(27.5/(zeta_))) +Theta_0v = ((1-nu)*Wp + Ws)/ (D*c*v*t1*w*(10^-6)) +H_ = 1.5 *(H) +theta_lim = 700*((1-(H_/850))^(1/3.1)) +v_lim = (theta_lim/309)^(1/0.5) +printf(" \n Maximum speed at which cutting is passible = %f m/sec.",v_lim) + diff --git a/3250/CH4/EX4.7/Ex4_7.txt b/3250/CH4/EX4.7/Ex4_7.txt new file mode 100755 index 000000000..9e3d0dab5 --- /dev/null +++ b/3250/CH4/EX4.7/Ex4_7.txt @@ -0,0 +1,3 @@ + # PROBLEM 4.7 #
+
+ Maximum speed at which cutting is passible = 2.759951 m/sec.
\ No newline at end of file diff --git a/3250/CH4/EX4.8/Ex4_8.sce b/3250/CH4/EX4.8/Ex4_8.sce new file mode 100755 index 000000000..7b3793db1 --- /dev/null +++ b/3250/CH4/EX4.8/Ex4_8.sce @@ -0,0 +1,11 @@ +clc +// Given that +alpha = 0 // Rake angle in degree +gama = 3 // Clearance angle in Degree +w = 1 // Maximum length of flank wear allowed in mm +gama_ = 7 // Increased clearance angle in Degree +// Sample Problem 8 on page no. 212 +printf("\n # PROBLEM 4.8 # \n") +I_per = (((tand(gama_))-(tand(gama)))/tand(gama))*100 +printf(" \n Percentage increase in tool life = %d percent.",I_per) + diff --git a/3250/CH4/EX4.8/Ex4_8.txt b/3250/CH4/EX4.8/Ex4_8.txt new file mode 100755 index 000000000..15b9d8ba9 --- /dev/null +++ b/3250/CH4/EX4.8/Ex4_8.txt @@ -0,0 +1,3 @@ + # PROBLEM 4.8 #
+
+ Percentage increase in tool life = 134 percent.
\ No newline at end of file diff --git a/3250/CH4/EX4.9/Ex4_9.sce b/3250/CH4/EX4.9/Ex4_9.sce new file mode 100755 index 000000000..7b912e9d2 --- /dev/null +++ b/3250/CH4/EX4.9/Ex4_9.sce @@ -0,0 +1,18 @@ +clc +// Given that +d= 4 // Depth of cut in mm +f = 0.25 // Feed in mm/stroke +alpha = 10 // Rake angle in degree +shi = 30 // Principal cutting edge angle in Degree +mu =0.6 // Cofficient of friction between chip and tool +T_s = 340 // Ultimate shear stress of cast iron in N/mm^2 +// Sample Problem 9 on page no. 220 +printf("\n # PROBLEM 4.9 # \n") +lambda = atand(mu) +phi = 45 +alpha-lambda +Fc = f*d*T_s*(cosd(lambda-alpha))/((sind(phi))*(cosd(phi+lambda-alpha))) +Ft = Fc*(sind(lambda-alpha))/(cosd(lambda-alpha)) +Ff = Ft*(cosd(shi)) +Fn = Ft*(sind(shi)) +printf(" \n The three components of machinig force are as follows-\n Thrust force = %d N,\n Feed force component = %d N,\n Normal thrust force component = %d N.",Ft,Ff,Fn) + diff --git a/3250/CH4/EX4.9/Ex4_9.txt b/3250/CH4/EX4.9/Ex4_9.txt new file mode 100755 index 000000000..26760b0fb --- /dev/null +++ b/3250/CH4/EX4.9/Ex4_9.txt @@ -0,0 +1,6 @@ + # PROBLEM 4.9 #
+
+ The three components of machinig force are as follows-
+ Thrust force = 422 N,
+ Feed force component = 365 N,
+ Normal thrust force component = 211 N.
\ No newline at end of file |