TECHNICAL UNIVERSITY OF KENYA (TUK)

UNIVERSITY EXAMINATIONS JULY 2016

FIRST YEAR SECOND SEMESTER EXAMINATION FOR

MASTER OF TECHNOLOGY (MTech) IN MECHANICAL ENGINEERING TECHNOLOGY

EMMU 7244 MACHINE TOOL VIBRATIONS AND CUTTING DYNAMICS

DATE: TIME: 3 HOURS

INSTRUCTIONS TO CANDIDATES
You should have the following for this examination.
Answer book-let.
Mathematical tables/calculator.

This paper contains SEVEN questions.

Answer any FIVE Questions
All Questions have equal marks
Maximum marks for each part of a question are as indicated.
Q1 (a) (i) Briefly explain three types of machine tool vibrations and their causes. How can vibration be
controlled in a machine tool?
(ii) Describe the adverse effects of vibrations and chatter in machining.

(b) Consider the translational vibrations of a small rigid lathe along the cutting direction. A model of
this system has a stiffness element k= 20 x 106 N/m, an inertia element m =22.5 kg, and a damping
coefficient c = 21205N.s/m. Determine the free response of this system for a 5 mm initial displacement
and zero initial velocity. Plot the response and discuss it. How does the nature of the response of the
system change when the damping coefficient is increased to 43,000N.s/m?

Q2 (a) Suppose a turning operation is to be performed with HSS tooling on mild steel, with Taylor tool
life parameters n = 0.125, C =70 m/min. If the work piece length =500mm, diameter = 100 mm, feed =
0.25 mm/rev, handling time per piece = 5.0 min, tool change time = 2.0 min, cost of machine and
operator = KES 3000/hr and tooling cost = KES 300 per cutting edge, determine:
i) cutting speed for maximum production rate,
ii) cutting speed for minimum cost, and
iii) the hourly production rate and cost per piece for the two cutting speeds computed in (i) and (ii)
above.
(b) xxxxxx

Q3 (a) (i) Explain why the cutting force, F c, increases with increasing depth of cut and decreasing rake
angle.
(ii) What are the effects of performing a cutting operation with a dull tool tip or a very sharp tip?
(b) The table below gives data obtained from experiments carried out on orthogonal cutting. In both
cases, depth of cut (feed) to = 0.13 mm, width of cut w = 2.5 mm, rake angle = 50, and cutting speed
V = 2 m/s.
Work piece material
Aluminum Steel
Chip thickness, tc, mm 0.23 0.58
Cutting force, Fc, N 430 890
Thrust force, Ft, N 280 800
Work piece properties are:
Flow strength Yf , MPa 120 325
Thermal diffusivity, K, mm2/s 97 14
20
Volumetric specific heat, c, N/mm C 2.6 3.3
Determine the:
i) shear angle ,
ii) friction coefficient ,
iii) shear stress , and shear strain on the shear plane,
iv) chip velocity Vc,
v) shear velocity Vs, and
vi) Energies uf , us and ut
vii) Estimate the temperatures for the given work piece properties.

Q4 (a) What do you understand by transmissibility in relation to vibrations?

(b) Establish an expression for the amplitude of forced damped vibrations, and use the expression to
derive an equation for the transmissibility ratio (TR).
(c) A machine tool of mass 75 Kg is mounted on springs of stiffness 1200KN/m and a damping factor
of 0.2. A piston within the machine of mass 2 Kg has a reciprocating motion with a stroke of 80mm
and a speed of 3000rev/min., assuming the motion to be SHM, determine:
 i) The amplitude of the motion of the machine, and its phase angle with respect to the exciting
force.
ii) The force transmitted to the foundation, and its phase angle with respect to the exciting
force.

Q5 (a). What are the causes and effects of vibrations?

(b) Use a graph to discuss the difficult encountered when using dampers to isolate vibrations.
(c) What do you understand by vibration isolation? Explain how it is accomplished.
(d) xxxxxx

Q6. (a) (i) What is the effect of cutting speed, feed and depth of cut on tool life?
(ii) Explain desirable properties of cutting tool materials?
(iii) What is machinability of metal? What factors affect the machinability?
(iv) What are the types of chips formed during machining various materials on the lathe?

(b) A lathe toolbit with a rake angle of 20 is cutting a section of an aluminum pipe with an inner
diameter of 150mm and an outer diameter of 156mm. The cut has a depth of 0.25mm and the chip has
a thickness of 0.50mm. If the lathe is turning at 200 rpm, and the measured cutting forces are F c =
1360N, and Ft = 568N, state the assumptions made and then determine:
i) the following values: Fs, Fn, F, N, , , , Vc, Vf, Vs; and
ii) the minimum power required for the machine

(c) During an orthogonal machine cutting on a lathe, the feed rate is 0.1mm, the chip thickness after
the cut is 0.2mm, the depth of the chip being cut is 5mm and the surface cutting speed of the tool is
2m/s. The tangential force is measured as 200N, and the cutting force is 500N. If cutting tool has a
rake angle of 100, calculate:
i) the shear force and velocity.
ii) the total energy produced in the cut,
iii) the energy used to shear,

Q7 (a) A series of tool life tests are conducted on two work materials under identical cutting
conditions, varying only speed in the test procedure. The first material, defined as the base material,
yields a Taylor tool life equation vT0.28 = 350, and the other material (test material) yields a Taylor
equation vT0.27 = 440, where speed is in m/min and tool life is in minutes. Determine the machinability
rating of the test material using the cutting speed that provides a 60-min tool life as the basis of
comparison.

(b) A carbide-cutting tool when machined with mild steel work piece material at a cutting speed of 50
m/min lasted for 100 minutes. Determine the life of the tool when the cutting speed is increased by
25%. At what speed the tool is to be used to get a tool life of 180 minute. Assume n = 0.26 in the
Taylors expression.

Q8. (a) (i) Describe the effects of cutting fluids on chip formation. Explain why and how they
influence the cutting operation. Explain under what conditions you would discourage the use of cutting
fluids.
(ii) In a dry cutting operation using a 5 0 rake angle, the measured forces were Fc = 1330 N and Ft =
740 N. When a cutting fluid was used, these forces were Fc = 1200 N and Ft = 710 N. What is the
change in the friction angle resulting from the use of a cutting fluid?

(b) A 200 mm-diameter stainless-steel bar is being turned on a lathe at 600 rpm and at a depth of cut, d
= 2.54 mm. If the power of the motor is 3.75 KW and has a mechanical efficiency of 80%, what is the
maximum feed that you can have at a spindle speed of 500 rpm before the motor stalls?