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Shear Angle Calculation Based On Chip Thickness Ratio:: T R T T AB T AB T AB R T AB R R

This document provides formulas for calculating shear angle, cutting velocities, cutting forces, stresses, power requirements, and ideal drawing force for manufacturing processes. It also includes formulas for Bernoulli's theorem, Reynolds number, true stress, and average true stress which are applicable to fluid flow and metal forming.

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John TL
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127 views3 pages

Shear Angle Calculation Based On Chip Thickness Ratio:: T R T T AB T AB T AB R T AB R R

This document provides formulas for calculating shear angle, cutting velocities, cutting forces, stresses, power requirements, and ideal drawing force for manufacturing processes. It also includes formulas for Bernoulli's theorem, Reynolds number, true stress, and average true stress which are applicable to fluid flow and metal forming.

Uploaded by

John TL
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
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Formula Sheet for Manufacturing Processes ME Fundamental Exam 1

Shear angle calculation based on Chip Thickness Ratio:


t
r 0
tc
t0  AB sin 
tc  AB cos(   )
t0 AB sin  sin  sin 
r   
tc AB cos(   ) cos(   ) cos  cos   sin  sin 
r cos 
tan  
1  r sin 
Velocity Relationships:
Mass continuity
t0
Vt0  Vctc  Vc  Vr since r 
tc
Vc V Vs
 
sin  sin(90     ) sin(90   )
Vc V V
  s
sin  cos(   ) cos 
sin 
Vc  V
cos(   )

Cutting forces, stresses and power:


Formula Sheet for Manufacturing Processes ME Fundamental Exam 2
Fc =main cutting force  =friction angle
Ft =thrust force Fs =shear force on the shear plane
F =friction force on the rake face Fn =normal force on the shear plane
N =normal force on the rake face R =resultant force
 =shear angle

Merchant’s Force Diagram:


Fs  Fc cos   Ft sin   R cos(     )
Fn  Ft cos   Fc sin   Fs tan(     )
F  Fc sin   Ft cos   R sin 
N  Fc cos   Ft sin   R cos 
F Fc sin   Ft cos  Ft  Fc tan 
  
N Fc cos   Ft sin  Fc  Ft tan 
g = Gravitational constant

vD
2) Reynolds number: Re  
Where v = velocity of the liquid
D = Diameter of the channel
Cutting Energy and Forces:  = density of the fluid (assuming it is
Power=FcV incompressible)
Width of cut = w  = Viscosity of the liquid.
Material removed per unit time = wt0V
FcV F DRAWING FORMULAS
Specific power, Ut =  c
wt oV wt o
Ideal Drawing Force:
Power in the shear zone, Ps = FsVs
FsVs A 
F  Yavg A f ln  0 
Specific shear energy, Us =  Af 
wtoV  
Power for overcoming friction = FVc
FVc Drawing Force with friction and redundant force
Specific friction energy, Uf =     A  2 
wtoV
F  Yavg A f 1   ln  0    
    A f  3 
CASTING FORMULAS
p v2
1) Bernoulli’s Theorem: h    constant
g 2 g
for frictionless flow.

Where h = elevation above a certain reference plane


p = pressure at that elevation
v = velocity of the liquid at that elevation
 = density of the fluid (assuming it is
incompressible)
Formula Sheet for Manufacturing Processes ME Fundamental Exam 3

True Stress (Flow Stress)


  K n

Average True Stress


K n
Yavg 
1 n

where
K = strength coefficient
n = strain hardening exponent
 = true strain

(1 psi = 6.895*103 Pa)

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