IE 3304

EXAM II SAMPLE QUESTIONS

Dr. S. Raman
NAME:________________
Student ID #:____________

____
_______

IE 3304
EXAM II
(Closed Book, Closed Notes)
Note:
2

1. Show all steps while solving numerical examples.

2. State all assumptions explicitly.

Question 1. (30 points)

Observe the specification of the part shown below. Do not scale drawing. All dimensions are in
inches.

A. The raw material is AISI 1213 steel bar (diameter of 3.38 inches and length of 6.38 inches) of
hardness 150 BHN
B. The inventory of cutting tools available to the company are indexable carbide (uncoated)
single point tool inserts, 120 degree lip standard HSS drills, coated carbide counterboring and
countersinking tools and0 carbide, indexable end-milling tool inserts.

a.

Compare the features on your specified part with the feature tables
provided. Identify features on your part. List all your features in the table shown below.
(HINT: you might be required to flip the part over at some point. Check raw material
specifications to determine the number of passes).
Feature
F1

Feature Classification
Externa, rotational

Feature Name and Type

End facing, left

Ex,rotational

Threads, right

F2
F3

External

Shoulder, right

F4

External

End facing, right

F5

External

Cylinder

F6

Internal,rotational

Flat shoulter,right

F7

Internal

Flat face hole, right

b. Decompose every feature into one or more operations. Make entries into the table as shown
below.
Feature
F1
F2
F5

Feature Name and Type

End facing, left
Threads , right

Operation
O1

Operation Name
Face turning

O2

threading

cylinder

O3
O4

Rough straight turning

Finish straight turning

shoulder, right

O5

Rough shoulder turning

finish shoulder turning
Face turning

F3
F4

End face, right

O6
O7

F6

Blind hole, right

O8

drilling

Flat shoulder

O9

counterboring

F7

c. Prepare a precedence table as shown below. Make sure you write the rule for each
precedence.

Operation
O1

Preceding operations and reason for precedence

---

O2
O3

O2 (location)

O4

O3 (intermediate surface )

O5

O2 (dimension) (location)

O6

O5 (intermediate surface )

O7

O6 (location)

O8

O6 (location)

O9

O8,O6 ( location)

(30 Points)
2 For the data specified in Problem II, and the additional data below, perform a machining time
analysis as specified below in sub-questions 1-6.
C. The machine tool to be used is an ACME (10HP) Lathe. Work holder is a standard three-jaw
chuck.
D. The maximum allowable depth of cut in turning and facing, on the ACME lathe used, is 0.15
inch while the minimum depth of cut is 0.04. (Hint: depth of cut is a radial distance)
E. All critical tolerances for part (size and geometry) are achievable without use of grinding,
honing, lapping, polishing or ultraprecision operations.
F. Standard shank width of single-point tools is 0.6 inch with tool tip at the center of the shank
width. Included angle at the tip of the single-point tool is 90
G. All overtravel allowances can be approximated as 0.1 inch.

1. Determine the approach in straight turning of the bar stock for the first and last passes.
2. Determine the feed rate and cutting speed for each of the first and last passes, for straight
turning, from the accompanying table (machining data handbook).
3. Calculate the linear speed and machining time in straight turning for the first and last
passes.

4. Determine the feedrate and cutting speed for drilling the central hole in the part, from the
accompanying table.
5. Calculate the approach allowance for drilling the central hole.
6. Calculate the linear speed and machining time in drilling the central hole.
Question 3 (40 points)
Answer the following in 2-3 sentences each.
a. What is process planning?
Process planning is the coordinated selection and sequencing of machining operations to convert a raw
material to a finished product. It contained an orderly listed process details.

b. Explain (with suitable examples) any three type of precedence employed while preparing
operation sequences.
i. Intermediate feature: example, rough turning has to be done prior to finishing. Similarly,
drilling is done before boring, reaming, counterboring, or countersinking. In other words,
the hole has to be drilled before modifications.
ii. Dimensioning: for example, facing perpendicular to the cylinder. Then datum feature a,
has to be established first, or facing has to be done prior to turning.
iii. Work piece locations: some machinists do an end facing and partial cylindrical turning of
one end of work material prior to other machining operations. Therefore, the partially turned
cylinder becomes the locating surface for subsequent machining operations.
c. What are the four components of time in the calculation of production time? Explain each in
a sentence or two.
Machining Time: Total time when feed is engaged
Non-machining Time: All extra/repetitive activities during machining of a part.
Down Time: Time spent fixing breakdowns and bottlenecks.
Setup Time: Time to gather tools and get machine ready.
d. What is the difference between drilling, reaming and boring operations?
Drilling: It is a multipoint hole-making operation done with a standard size.
Boring: Expansion of an existing hole, created after drilling. Single point, non-standard hole
making operation.
Reaming: Multipoint, precise, more accurate hole making operation, carried out after drilling.
e. What is a tapping operation? What is counter-boring?
Counter-boring:

Creates seat or depression for bolt heads.

Tapping:

It is used for making smaller (depth) internal threads.

f. What is face milling? How is it different than peripheral milling? What is end milling?
Face: Uses a tool that is Perp to the work part. Face of tool is doing machining.
Peripheral: The axis of the tool is parallel to the direction of cut. Edge of cylindrical side is doing
machining.
End Milling: Is a type of peripheral milling, face and the peripheral are used for slotting, milling etc

g. What are the advantages to using CNC Machines, in terms of time and cost?

Higher production rate

Shorter lead times
Multiple milling, turning, and drilling operations
High precision
Reduced waste

h. What are three basic types of automation in manufacturing?

Fixed automation - the processing or assembly steps and their sequence are fixed by the
equipment configuration ( automobile assembly line )
Programmable automation - equipment is designed with the capability to change the program
of instructions to allow production of different parts or products ( CNC machine )
Flexible automation - an extension of programmable automation in which there is virtually no
lost production time for setup changes or reprogramming

i. What are open loop control systems? What are closed loop systems?

j. Explain the working of a CNC Machining system.

The CNC machine comprises of the computer in which the program is fed for cutting of the
metal of the job as per the requirements. All the cutting processes that are to be carried out
and all the final dimensions are fed into the computer via the program. The computer thus
knows what exactly is to be done and carries out all the cutting processes. CNC machine
works like the Robot, which has to be fed with the program and it follows all your
instructions.
Some of the common machine tools that can run on the CNC are: Lathe, Milling machines,
Drilling Machine etc. The main purpose of these machines is to remove some of the metal so
as to give it proper shape such as round, rectangular, etc. In the traditional methods these
machines are operated by the operators who are experts in the operation of these machines.
Most of the jobs need to be machined accurately, and the operator should be expert enough to
make the precision jobs. In the CNC machines the role of the operators is minimized. The
operator has to merely feed the program of instructions in the computer, load the required
tools in the machine, and rest of the work is done by the computer automatically. The
computer directs the machine tool to perform various machining operations as per the
program of instructions fed by the operator.
You dont have to worry about the accuracy of the job; all the CNC machines are designed to
meet very close accuracies. In fact, these days for most of the precision jobs CNC machine is
compulsory. When your job is finished, you dont even have to remove it, the machine does
that for you and it picks up the next job on its own. This way your machine can keep on
doing the fabrication works all the 24 hours of the day without the need of much monitoring,
of course you will have to feed it with the program initially and supply the required raw
material.
Most of the manufacturing companies are now equipped with the CNC machines as the markets
have got very competitive; however, getting the expert labors for operating these machines is
becoming quite difficult. Even the machine operators of these days prefer to operate the
machine by programming instead of operating it manually. In most of the machine tools
training institutes the new operators are taught manual machining as well as CNC machining
and programming.

Extra:
What are operation precedencies? And why are they needed ?
Operation precedence is the table to indicate how an operation must be done prior to
other operations. They are needed to determine feasible operation sequence.
What is the difference between internal threading and tapping of holes
on a lathe? When is each employed?
Tapping with a tap is a multipoint operation whereas threading is performed using a
single point tool. Internal threading is used when deeper threads are required and
tapping is employed when small threads are needed.
What are 4 main factors used to assess machinability? Explain in some
detail.
Tool life: The life of the tool usually determines number of tool changes. More tool
changes means less productivity and low quality
Surface Roughness: The finish of the part is governed by the material combination and
cutting parameter selection
Forces and power: Cutting forces are measured to calculate power
Type of chip: Continuous chips are common. Long chips must be broken and short
chips fly out a lot. Built up edge is undesirable
Give two examples of single-point operations and two examples of multipoint (fixed geometry) operations
Single point operations: Turning, Boring
Multi-point (fixed geometry): Milling and Drilling
What is spot facing? How is it different than Counter-Boring? What is Counter
Sinking?
Spot facing is performed to flatten/smooth the surrounding surface around a hole to provide,
for example, a good seating for nuts, bolts, and washers.
Counterboring on the other hand, produces a depression on the surface to accommodate the
heads of screws and bolts below the workpiece surface.
Countersinking produces a conical cavity to allow a screw head to sit flat on the workpiece
surface.

What instrument is used to measure cutting forces during machining?

Dynamometer, Strain-gauge

10 operations on a lathe Facing, Straight Turning, Taper turning, Cutting off,

Boring, Taper turning, Profiling with a form tool, Drilling, External Grooving, Internal
Grooving, Face Grooving, Threading, Knurling, Sanding, Reaming, Form Cutting
10 operations on a Mill: Slab milling, climb milling, slotting, side milling, straddle
milling, form milling, conventional face milling, partial face milling, face milling, end
milling, high speed end milling, form milling, Slitting, pocket milling, contour milling.
Drilling operations: Drilling, core drilling, step drilling, counter boring,
countersinking, reaming, center drilling, gun drilling, trepanning, tapping, orbital
drilling, vibration drilling, spot facing.

When is tapping employed as an alternate to internal threading?

One reason for using Tapping as alternative to internal threading is when the internal
diameter is too small to fit a tool.

Additionally, tapping presents the advantage of high speed production compared with
threading, nevertheless tapping doesnt allows for adjusting thread fit, means once the hole
is tapped, size and position of the thread is final.
Threading is used when higher pitch and depth of thread are desired.
List the basic types of tool materials employed in machining.

1. High Speed Steel (HSS):

Highly alloyed tool steel capable of maintaining hardness at elevated temperatures
better than high carbon and low alloy steels
Especially suited to applications involving complicated tool shapes: drills, taps,
milling cutters, and broaches
Two basic types of HSS (AISI)
1. Tungsten-type, designated T- grades
2. Molybdenum-type, designated M-grades
2.

Cemented Carbides
(WC) using powder metallurgy techniques with cobalt (Co) as the binder
Two basic types:
1. Non-steel cutting grades - only WC-Co
2. Steel cutting grades - TiC and TaC added to WC-Co

3.

Cermets:

Combinations of TiC, TiN, and titanium carbonitride (TiCN), with nickel and/or molybdenum
as binders.\

4.

Coated Carbides
Cemented carbide insert coated with one or more layers of TiC, TiN, and/or Al 2O3 or other
hard materials

5.

Ceramics
Primarily fine-grained Al2O3, pressed and sintered at high pressures and temperatures
into insert form with no binder

6.

Synthetic Diamonds
Sintered polycrystalline diamond (SPD) - fabricated by sintering very fine-grained
diamond crystals under high temperatures and pressures into desired shape with little or
no binder

7.

Cubic Boron Nitride

Next to diamond, cubic boron nitride (cBN) is hardest material known

E. What is the Taylors Tool Life Equation? If a speed of 400 fpm is employed in a
cutting process the tool life was 15 minutes. If the speed was increased to 600
fpm, the tool life was 6 minutes. At what speed can you achieve a tool life of 10
minutes?
Tool life equation:

vTn = C

where v = cutting speed; T = tool life; and n and C are parameters that depend on feed,
depth of cut, work material, tooling material, and the tool life criterion used
n is the slope of the plot
C is the intercept on the speed axis at one minute tool life

F. What are the main factors used to evaluate machinability?

1.

Machinability

o Relative ease with which a material (usually a metal) can be machined

using appropriate tooling and cutting conditions
o

Depends not only on work material

o Type of machining operation, tooling, and cutting conditions are also
important factors

o
o
o
o

Tool life longer tool life for the given work material means better machinability
Forces and power lower forces and power mean better machinability
Surface finish better finish means better machinability
Ease of chip disposal easier chip disposal means better machinability

In Addition the following should be noted.

o Hardness
o High hardness of work material means abrasive wear increases so tool life is
reduced
o Strength
o High strength of work material means higher cutting forces, specific energy,
and cutting temperature
o Ductility
o High ductility of work material means tearing of metal to form chip, causing
chip disposal problems and poor finish
More implicitly, other factors also come into play.
1. Tolerances and Surface Finish
o Tolerances
o Machining provides high accuracy relative to most other shape-making
processes
o Closer tolerances usually mean higher costs
o Surface roughness in machining is determined by:
o Geometric factors of the operation
o Work material factors
o Vibration and machine tool factors
2.

Selection of Cutting Conditions

o Cutting conditions: depth of cut, feed, speed, and cutting fluid

o These decisions must give due consideration to workpart
machinability, part geometry, surface finish, and so forth
3.
o

Product Design Considerations in Machining

Design parts that need no machining

If not possible, then minimize amount of machining required

o
o
o
o

Reasons why machining may be required:

Close tolerances
Good surface finish
Special geometric features:

o Use net shape processes such as precision casting, closed die

forging, or plastic molding
o Use near net shape processes such as impression die forging

o
o
o
o

Threads
Accurate holes
Accurate cylindrical sections
Flat and/or straight surfaces