Course Code and Title: 140ME0303 – Manufacturing Process-2

Question Bank

Unit 1: Theory of Metal Cutting

1 Give the difference between orthogonal cutting and oblique cutting with neat sketches.
2 With neat sketches, give nomenclature of single point cutting tool.
3 Briefly describe the factors affecting tool life.
4 Why the tool fails during cutting? Explain, giving reason, tool wear.
5 Explain the following with a neat sketch.
a) Back rake angle c) End clearance angle.
b) Side cutting edge angle e) Rake angle
c) Nose radius. f) Clearance angle
d) Side relief angle. g) End cutting edge angle.
6 With a neat sketch, explain the various parameters which make up the tool signature of a single point
cutting tool.
7 Derive an expression for a shear angle in orthogonal cutting, in terms of rake angle and chip thickness ratio.
8 Derive an expression for a shear angle in orthogonal cutting, in terms of rake angle and chip thickness co-
efficient.
9 With neat sketches, explain flank and crater wear.
10 Derive the conditions 2ϕ+β-γ= . Explain its significance with usual notation.
11 What are the different modes of tool failure? Explain.
12 Define tool life? Give the relation between tool life and cutting speed.
13 Explain the relationship between cutting velocity and chip flow velocity and chip flow velocity and cutting
velocity and shear velocity and prove the same.
14 Derive an expression for shear plane angle, with respect to orthogonal cutting.
15 Explain the functions of cutting fluids.
16 Define tool life. List out the factors that affect tool life.
17 During orthogonal turning operation, the following data was obtained.
Cutting force FH = 1200N
Feed force FV = 300N
Rake angle = 100
Feed = 0.2 mm/revolution
Width of cut = 2.3 mm
Chip thickness = 0.4 mm
Cutting speed = 120 m/min
Determine: (i) Chip thickness ratio (ii) Shear angle (iii) Shear stress
18 During the orthogonal turning operation following observations were made, cutting force =1000N, thrust
force= 375 N, rake angle=100 Feed mm/revolution=.25, width of cut=2.0 mm, chip thickness=0.6 mm.
determine the following (i) shear plane angle (ii) shear stress on work material.
Following data refer to the orthogonal cutting process. Chip thickness 0.62 mm, feed 0.2mm, rake angle
19 150. Calculate chip reduction co-efficient and shear angle.
20 A tool life of 80 min is obtained at a speed of 30 rpm and 8 min at 60 rpm. Determine the following: (i) tool
life (ii) cutting speed for 4 min tool life.
21 In an orthogonal cutting process, the following data were observed.
T=depth of cut=0.25 mm; Fh= Horizontal force=1135 N; Fv= force component normal to Fh=110 N; chip
thickness ratio=r€=0.47; α=Rake angle=200 ; b= width of cut= 4mm; V= cutting velocity= 30 m/min;
determine the friction angle, shear plane angle, resultant cutting force and power.
22 In an experiment on orthogonal cutting chip length of 95 mm was obtained from an uncut chip length of
225 mm while cutting with a tool of 200 rake angle using a depth of cut of 0.5mm. Determine the shear
plane angle, friction angle and chip thickness, if the horizontal and vertical components of cutting force are
1200 N and 360 N respectively.
23 A tool of 80 minutes is obtained at a speed of 30 rpm and 8 minutes at 60rpm.
Determine the following (i) tool life (ii) Cutting speed for 4 min tool life.
24 Sketch a three principle views of a 25mm square tool bit having tool signature of 15, 15, 10,10,15,10
(3mm). Show the various angles on it.

Unit 2: Cutting tool materials

1 Briefly explain the desirable properties and purpose of cutting fluids.
2 What are the desirable properties or characteristics of an ideal cutting tool material? Briefly explain the
cemented carbide tool material.
3 List the various methods of measuring chip-tool interface temperature. Explain briefly tool work
thermocouple method of measuring it.
4 Explain the factors which affect the machinability of a material.
5 A cast iron bar stock was turned at 50 m/min, for each, the tool life was 3hors. For the same material, at 40
m/min, the tool life was 5 hours. Find the value of constant c and n in the Taylor’s tool life equation. Also
state the type of tool material based on the value of n.
6 Explain the affect of alloying elements on HSS tool.
7 Mention least four factors which improve cutting efficiency.
8 Mention the affect of adding following alloying elements in tool materials
(i) Carbon (ii) Chromium (iii) Tungsten
9 Clearly explain the different factors that are to be considered during the selection of cutting tool materials.
10 With a neat sketch explain different heat affected zones during orthogonal cutting.
11 Discuss the salient features of the following cutting tool materials:
a) CBN b) Ceramics c) Cemented carbides.
12 Explain the three zones of heat generation in metal cutting.
13 Explain with help of neat sketches, heat distribution at tool and workpiece.
14 List various cutting tool materials in the increasing order of their hardness.
15 What are the methods of measurement of temperature of cutting tool tip? Explain any one of them.
16 Discuss the effect of cutting speed on temperature in metal cutting
17 Derive an expression for the temperature rise in the primary zone.

Unit 3: Turning (Lathe), Shaping and planing machines

1 Differentiate between a capstan and a turret lathe.
2 How do you classify lathes? Explain in brief.
3 Give the brief specification of lathe
4 Describe the working of feed mechanism in a lathe.
5 With simple sketch explain the function of tumbler gear mechanism.
6 What are the different methods of turning a taper on lathe? Explain the methods and state the formula.
7 Explain the thread cutting mechanism used in a lathe.
8 What is function of “half nut” in a lathe?
9 Draw the tool layout for producing a hexagonal headed bolt on a capstan lathe from a hexagonal bar
stock.
10 With a help of a neat sketch, explain whitworth quick return mechanism of a shaper.
 11 With a help of neat sketch, explain the turret indexing mechanism.
12 Explain the working of Hydraulic shaper mechanism, with a neat sketch.
13 Compare shaper and planer in terms of their operation, type of workpiece and their applications.
14 Explain with sketch keyway cutting on a shaping machine.
15 Distinguish between saddle type turret lathe and Ram type turret lathe.
16 Explain the difference between side hung type cross slide and reach over type of cross slide.
17 With a neat sketch, explain any one of the driving mechanism used in a shaping mechanism.
18 Sketch a planning machine indicating major parts. Name any one of the mechanism for quick return
movement in a planer.
19 Briefly explain the different operations can be done on shaper.
20 Explain the crank and slotted link mechanism to obtain such quick return motion.
21 A mild steel plate 500mmX 750mmX25mm it to be shaped along the wider face by taking only one cut.
The ratio of return time to cutting time is 2:3 and the feed per cycle is 3mm. Tool approach and the over
travel are 40 mm each. The cutting speed is 24 m/min. The side clearance is 5 mm on each side. Calculate
the time required for machining the given plate on the shaper.
22 Draw a neat sketch of a double housing planning machine. Show all the parts and explain the principle of
operation.

Unit 4: Drilling machines

1 Explain universal radial arm drilling machine, with a neat sketch.
2 Give the detailed classification of drilling machine.
3 Explain the constructional features of an upright drilling machine with a sketch.
4 What is purpose of socket and sleeve in drilling operation explain with figure.
5 What are the different work holding devices used in drilling operation? Explain any two with simple
sketch.
6 A hole of40 mm diameter and 50 mm depth is to be drilled in a mild steel component, the cutting speed
can be taken as 65m/min and feed of 0.25 mm/rev. Calculate the machining time and the material
removal rate take as 590.
7 Calculate the time required to drill 5 holes of 10 mm dia on 100 pcd of a CI flange of 12 mm thick. Take
cutting speed of 20 m/min and feed rate of 0.25 mm/rev. Neglect headlining and setting time.
8 Find the time of drilling 0.18mm hole in a work piece having thickness of 50 mm. Assume cutting speed
as 12m/min and feed as 0.2 m/rev. Neglect the length of approach.
9 With a simple sketch, explain the following drilling machine operations.
a) Tapping b) Trepanning.
10 Explain the following twist drill nomenclature: Flutes, Flank, Face, land, lips, and body clearance, with a
neat sketch.
11 Draw a neat diagram of radial drilling machine. Name all the parts and explain the principle of operation.
12 Explain the following operations, with simple sketches:
a) Reaming b) Boring c) Counter boring d) Trepanning
13 Sketch and explain the nomenclature of a twist drill.
14 Sketch a radial drilling machine and lable all parts.
15 List out drill bit materials.
16 Explain the following operations: a) Boring b) Countersinking
17 Find the time required for drilling a 18mm hole in a workpiece having thickness of 50 mm. Assume
cutting speed of 12m/min and feed 0.2 mm/revolution. Neglect the length of approach.
18 List various drilling machines.

Unit 5: Milling machines

1 Differentiate between the following in a milling machine:
a) Up milling and Down milling b) Face milling and End milling.
2 Give brief classification of milling machines.
3 Explain the working of universal milling machine.
4 Give the brief classification of milling cutter
 5 A C50 steel flat surface of 100mmX250mm is to be produced on a horizontal axis milling machine. A
HSS slab mill of 100 mm dia and 150mm width is to be used for the purpose. The milling cutter has 8
teeth. Calculate the machining time assuming that the entire stock can be removed in one depth of 2mm.
Take cutting speed as 20m/min and feed 0.13mm/tooth.
6 What is indexing? Name different methods of indexing. Briefly explain compound indexing method.
7 Differentiate between:
a) Up milling and Down milling b) Simple indexing and Compound indexing.
8 69 teeth of a spur gear are to be cut around the periphery of a cylindrical blank. Recommend suitable
indexing method.
9 With a neat sketch, explain the working of a universal dividing head.
10 Clearly explain the up milling and down milling.
11 Show the calculations for a setting dividing head to mill 69 divisions on a spur wheel blank by compound
indexing.
12 Explain the various steps involved in differential indexing.
13 Show the calculation for indexing 87 divisions in a milling machine by compound indexing. The
following index plates are available.
Plate No 1 15 16 17 18 19 20
Plate No 2 21 23 27 29 31 33
Plate No 3 37 39 41 43 47 49
14 Draw a neat sketch to show the major parts of horizontal milling machine.
15 What is indexing? Explain compound indexing.

Unit 6: Grinding machines

1 Briefly explain external cylindrical centreless grinding with neat sketch. Mention the advantages of same
over centre type grinding.
2 Explain the following grinding wheel parameters:
a) Grit b) Grade c) Structure.
3 Explain the factors to be considered for selection of grinding wheels.
4 Write a note on: i) Dressing and turning of grinding wheels ii) wheel balancing.
5 With an example, explain the specification of a grinding wheel.
6 Explain the centreless grinding process with a neat sketch. Also discuss the advantages and limitations of
same.
7 Clearly explain the designation process of manufacture and properties of following grinding wheels with
i) Vitrified bond ii) Rubber bond.
8 With a neat sketch explain the principle of working of a centre type cylindrical grinding machine.
9 With respect to grinding process, differentiate between:
a) Glazing and loading.
b) Plunge cut and traverses grinding.
c) In feed and through feed.
d) Cylindrical grinding and centreless grinding.
e) Dressing and turning of grinding wheel.
10 List various grinding wheel abrasives and bonding process.
11 Sketch a centre type-cylindrical grinding machine indicating parts.
12 Differentiate between horizontal and vertical grinding machines.

Unit 7: Broaching process

1 Briefly explain the honing process with a neat sketch. State its advantages and disadvantages.
2 With a neat sketch, explain the lapping process. State its advantages and disadvantages.
3 Explain the following with neat sketches: i) Honing ; ii) Lapping.
4 List the factors that affect the lapping process. Discuss the influence of these parameters on lapping.
5 Sketch and explain the process of lapping on a lapping machine.
6 What is honing? Explain vertical honing process.
7 List out advantages and disadvantages of honing.
8 With a neat sketch explain the honing process.
9 With a neat sketch explain the lapping process.
10 Name the parts along with a neat sketch of a tool head for honing of holes.
11 List the uses of lapping process.

Signature of the Faculty HoD/Mech