ME2162 – Tutorial 2
1. The 104-mm-diameter of a cylindrical aluminium workpiece is to be reduced to 100 mm in a
turning operation, using a cutting speed of 5.0 m/s and feed of 0.40 mm/rev. The workpiece is
400 mm long. Determine the (a) time to complete the cut and (b) metal removal rate during the
cut.
2. An engine lathe is used to turn a cylindrical work part 144 mm in diameter by 350 mm long.
Cutting speed = 2.75 m/s, feed = 0.40 mm/rev, and depth of cut = 3.0 mm. Determine the (a)
cutting time and (b) metal removal rate.
3. The end of a large tubular work part is faced on a vertical boring mill. The outside diameter =
Can be considered turning operation
900 mm, inside diameter = 500 mm, and height = 450 mm. If the facing operation is performed
at a rotational speed = 40 rev/min, feed = 0.4 mm/rev, and depth of cut = 4.5 mm, determine
the (a) cutting time to complete the facing operation and (b) cutting speeds and metal removal
rates at the beginning and end of the cut.
4. A drilling operation is performed on a steel part using a 10-mm diameter twist drill with point
angle = 118°. The hole is a blind hole with a depth = 60 mm. Cutting speed = 20 m/min, and
feed = 0.20 mm/rev. Determine the (a) cutting time of the operation and (b) metal removal rate
after the drill bit reaches full diameter.
5. A gun-drilling operation is used to drill an 8.0-mm-diameter hole. It takes 3.5 min to perform
the operation using high-pressure fluid delivery of coolant to the drill point. The current spindle
speed = 3500 rev/min, and feed = 0.05 mm/rev. In order to improve surface finish in the hole,
it has been decided to increase the speed by 20% and decrease the feed by 25%. How long will
it take to perform the operation at the new cutting conditions?
6. Peripheral milling is performed on the top surface of a rectangular work part that is 425 mm
long by 55 mm wide. The milling cutter is 70 mm in diameter and has 5 teeth. It overhangs the
width of the part on both sides. Cutting speed = 75 m/min, chip load = 0.10 mm/tooth, and
depth of cut = 6.5 mm. Determine the (a) machining time of the operation and (b) maximum
material removal rate during the cut.
7. A face milling operation removes 6.0 mm from the top surface of a rectangular piece of
aluminium that is 250 mm long by 48 mm wide by 50 mm thick. Thickness after the cut = 44.0
mm. The cutter follows a path that is centered over the workpiece. It has 4 teeth and a 55-mm
diameter. Cutting speed = 4.0 m/s, and chip load = 0.12 mm/tooth. Determine the (a) machining
time and (b) maximum metal removal rate during cutting.
8. Slab milling is performed on the top surface of a rectangular workpiece that is 300 mm long by
62 mm wide by 100 mm thick. The helical milling cutter, which has a 75-mm diameter and 8
teeth, overhangs the width of the part on both sides. Cutting speed = 120 m/min, feed = 0.15
mm/tooth, and depth of cut = 8.0 mm. Determine the (a) machining time and (b) maximum
metal removal rate during the cut. (c) If an additional approach distance of 10 mm is provided
at the beginning of the pass (before cutting begins), and an overtravel distance is provided at
the end of the pass equal to the cutter radius plus 10 mm, what is the duration of the feed motion?
