Fall 2025 EML6324 Fundamentals of Production Engineering HW-6 (Due November 21, 2026)
Q1. Answer Yes or No to the following questions about a cutting operation performed on a steel rod.
(a) If the depth of cut is increased, does the cutting force increase?
(b) If the rake angle is decreased, does the shear cutting force decrease?
Q2. Describe three major roles of cutting fluids in cutting operation.
Q3. In the orthogonal cutting operation shown in Figure 8.8 in the textbook, let the tool rake angle α be 0°, the chip width b be 5 mm, the shear-plane angle φ be 28°, and the cutting speed v be 3 m/s. The chip thickness before the cut is 0.25 mm, the force F is 2200 N, and the angle β is 20°. Calculate (a) the chip thickness h2 [mm] after the cut, (b) the shearing velocity vs [m/s], (c) the chip velocity vc [m/s], (d) the shearing force Fs [N], (e) the shearing power Ps [W], (f) the friction force Ff [N], and (g) the friction power Pf [W].
Q4. Explain why the maximum temperature in cutting is located approximately at the middle of the tool- chip interface? (Hint: Note that there are two principal sources of heat: the shear plane and the tool-chip interface.)
Q5. Describe three basic requirements of cutting tool materials.
Q6. Explain the purposes ofchamfers on cutting tools.
Q7. Why does temperature have such an important effect on cutting-tool performance? Give at least two reasons.
Q8. Is diamond or cubic boron nitride more suitable for machining steels? Explain why.
Q9. Why should complex grades be used instead of straight grades of cutting tools to cut steels?
Q10. What are the consequences of a cutting tool coating that has a different coefficient of thermal expansion than the substrate? Explain.
Q11. Which of the following processes are used to provide the thin coatings on the surface of coated carbide inserts (two best answers): (a) chemical vapor deposition, (b) electroplating, (c) physical vapor deposition, (d) pressing and sintering, and (e) spray painting?
Q12. Which one of the following materials has the highest hardness: (a) aluminum oxide, (b) cubic boron nitride, (c) high speed steel, (d) titanium carbide, or (e) tungsten carbide?
Q13. Why are ceramic cutting tools generally designed with negative rake angles?
Q14. Ceramic cutting tools have certain advantages over carbide tools. Why, then, are carbide tools not replaced to a greater extent?