1. Estimat
e the
cutting
forces
and
horsepo
wers
require
d for
each
cut
based
on the
data.
Note:
All
force,
veloci
ty,
horsep
ower,
and
angle
calcul
ations
were
based
on
equati
ons
from
the
notes.
Variab
le
Veloci
ty
Mean Rake Feed
Dia. Angle = (t1) =
= 5 deg. .0051
2.247 in/rev
in.
0.087266 (rad)
Shear
Angle
Chip Fc Ft (lb) F N Fs Fn t2 (rad)
# (lb) (in.)
1 101.61 149.49 157.78 88.19 35.58 177.22 0.0125 0.3988
2 116.90 164.44 174.00 102.12 57.39 193.42 0.0153 0.3295
3 143.65 178.72 190.56 127.52 81.06 214.48 0.0160 0.3157
4 167.03 182.61 196.47 150.48 104.95 224.12 0.0167 0.3029
Vc
Chip RPM (ft/min) Vs Vf HPc HPs HPf
# (HP)
1 90 52.94 55.41 21.60 0.1630 0.0597 0.1033
2 140 82.36 84.51 27.45 0.2917 0.1470 0.1448
3 215 126.48 129.36 40.31 0.5505 0.3178 0.2328
4 330 194.13 197.97 59.28 0.9826 0.6296 0.3530
Variab
le
Feed
Mean Rake RPM = 140
Dia. Angle =
= 5 deg.
2.247
in.
0.087266 (rad)
Feed Shear
Angle
Chip Fc Ft (lb) F N Fs Fn (in/rev) t2 (rad)
# (lb) (in.)
5 49.01 62.56 66.59 43.37 48.79 62.73 0.0012 0.0035 0.3385
6 78.01 93.29 99.74 69.58 77.37 93.82 0.0021 0.0068 0.3062
7 100.04 142.16 150.34 87.26 98.39 143.30 0.0045 0.0115 0.3836
8 173.10 227.63 241.85 152.60 167.98 231.44 0.0073 0.0223 0.3239
9 302.58 299.43 324.67 275.33 295.00 306.90 0.0102 0.0250 0.3988
Vc
Chip (ft/min) Vs Vf HPc HPs HPf
# (HP)
5 82.36 84.70 28.24 0.1223 0.1252 0.0570
6 82.36 84.05 25.43 0.1947 0.1971 0.0769
7 82.36 85.78 32.23 0.2497 0.2558 0.1468
8 82.36 84.39 26.96 0.4320 0.4296 0.1976
9 82.36 86.19 33.60 0.7551 0.7705 0.3306
2. Calcula
te HPu
and
correct
ion
factors
'c'
for
the
differe
nt
cutting
conditi
ons.
Compare
these
to
those
found
in the
notes.
Chip HPc Feed Depth Vc Q HPu * c c
#
(HP) (in/rev) (in) (ft/min) (in^3/mi (HP)
n)
1 0.1630 0.0051 0.491 52.94 1.5908 0.1025 1.0000
2 0.2917 0.0051 0.491 82.36 2.4749 0.1179 1.1503
3 0.5505 0.0051 0.491 126.48 3.8006 0.1448 1.4136
4 0.9826 0.0051 0.491 194.13 5.8335 0.1684 1.6439
5 0.1223 0.0012 0.491 82.36 0.5823 0.2100 2.0497
6 0.1947 0.0021 0.491 82.36 1.0191 0.1911 1.8646
7 0.2497 0.0045 0.491 82.36 2.1837 0.1143 1.1160
8 0.4620 0.0073 0.491 82.36 3.5424 0.1304 1.2728
9 0.7551 0.0102 0.491 82.36 4.9497 0.1526 1.4889
HPu = 0.1025
c HPu
Chip (table) % error (table) % error
#
1 1.2 16.67 0.3 65.83
2 1.2 4.14
3 1.2 17.80
4 1.2 36.99
5 1.5 36.65
6 1.4 33.19
7 1.2 7.00
8 1.05 21.22
9 1.02 45.97
3. For
variabl
e
feed,
plot
graphs
for Fc
and Ft
with
feed
on the
same
graph.
4. For
variabl
e
speed,
plot
graphs
for Fc
and Ft
with
velocit
y on
the
same
graph.