Manufacturing Processes II · Machining · 2 marks · Numerical answer
Two tools turn at feed 0.2 mm/rev. Tool 1 has zero nose radius, side cutting-edge angle 20° and end cutting-edge angle 10°. Tool 2 has nose radius 0.5 mm. Find the ratio of ideal maximum unevenness height, Tool 1/Tool 2, to one decimal.
For the sharp tool, $h_1=f/(\cot10^\circ+\tan20^\circ)=0.03314$ mm. For the rounded nose, $h_2\approx f^2/(8r)=0.2^2/(8\times0.5)=0.010$ mm. Ratio is about **3.3**. The exact circular-sagitta formula for h₂ gives nearly the same rounded ratio.
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