In an orthogonal machining operation, the cutting and thrust forces are equal in magnitude. The uncut chip thickness is 0.5 mm and the shear angle is 15°. The orthogonal rake angle of the tool is 0° and the width of cut is 2 mm. The workpiece material is perfectly plastic and its yield shear strength is 500 MPa. The cutting force is _______ N (round off to the nearest integer).

The best size wire is fitted in a groove of a metric screw such that the wire touches the flanks of the thread on the pitch line as shown in the figure. The pitch (p) and included angle of the thread are 4 mm and 60°, respectively. The diameter of the best size wire is _________ mm (round off to 2 decimal places).

In a direct current arc welding process, the power source has an open circuit voltage of 100 V and short circuit current of 1000 A. Assume a linear relationship between voltage and current. The arc voltage (V) varies with the arc length (l) as V = 10 + 5l where V is in volts and l is in mm. The maximum available arc power during the process is ______ kVA (in integer).

A cylindrical billet of 100 mm diameter and 100 mm length is extruded by a direct extrusion process to produce a bar of L-section. The cross sectional dimensions of this L-section bar are shown in the figure. The total extrusion pressure (p) in MPa for the above process is related to extrusion ratio (r) as

$\rm p=K_s σ_m\left[0.8+1.5\ ln(r)+\frac{2l}{d_0}\right] $

where σ_m, is the mean flow strength of the billet material in MPa, l is the portion of the billet length remaining to be extruded in mm, d₀ is the initial diameter of the billet in mm, and K_s is the die shape factor.

If the mean flow strength of the billet material is 50 MPa and the die shape factor is 1.05, then the maximum force required at the start of extrusion is _______ kN (round off to one decimal place).