Code No: 53112/MT

NR
M.Tech. – I Semester Supplementary Examinations,
September, 2008

THEORY OF METAL CUTTING & TOOL DESIGN

(Advanced Manufacturing Systems )

Time: 3hours Max. Marks:60

Answer any FIVE questions

All questions carry equal marks
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1.a) Explain various types of chip formations.

b) During orthogonal machining with a cutting tool having a zero rake
angle, the un cut chip thickness and cut chip thickness found to
be equal. Determine the shear angle, Shear strain and friction
angle.

2.a) When the rake angle is zero during orthogonal cutting. Show that
τ s (1 − µ rc )
= .rc
Uc 1 + rc 2
Where τ s =shear stress of material
Vc= specific cutting energy
µ = co-efficient of friction between tool-chip interface
rc= chip thickness ratio.
b) Explain effect of cutting parameters on cutting force

3.a) Sketch and explain single point tool geometry in ASA system.
b) Calculate
i) orthogonal rake ii) Inclination angle
iii) normal rake angle of a cutting for having side rake of (-10o)
back rake of (-5o) and side cutting edge angle of 30o

4.a) Sketch the geometry of milling cutter.

b) Derive an expression for average chip thickness in milling
operation.

Contd…2
Code No: 53112/MT ::2::

5.a) Describe ‘The Indian Standards’ method of specifying a grinding

wheel by taking a granite example
b) Estimate the power requirement during plunge grinding for MS bar
(20mmx15mm) using a grinding wheel with 3 grits/mm2. The
diameter of the wheel is 250 mm and the wheel rotates at 2000
rpm. The plunge feed rate is 5mm/min.

6.a) Explain, how tool life is evaluated? Describe various tool wear
mechanisms.
b) A SPCT having a 10o rake angle of a 6o clearance angle. Assuming
the volume rate of wear from the flank face of the tool to be
constant. What will be the percentage increase in the tool life if the
clearance angle is increased to 10o.
c) Explain effect of tool angles on tool wear.

7.a) Derive an expression for optimum cutting velocity for minimum

cast criteria.
b) Explain tool work thermocouple method for determination of
temperature in metal cutting.

8. Write short notes on:

a) Chip brakers
b) Theories of formation of BUE
c) Throwaway inserts
d) Machinability index.

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