m


 


m



Metal Forming: Basic principles of forging, drawing and extrusion; high energy rate forming; powder
metallurgy.
Metal Casing: Die casting, investment casting, shall moulding, Centrifugal Casting, Gating & Rising
design; Melting furnaces.
Fabrication Processes: Principles of Gas, Arc, Shielded are welding; Advanced Welding Processes,
Weldability Metallurgy of Welding.
Metal Cutting: Turning, Methods of Screw Production, Drilling, Boring, Milling, Gear Manufacturing,
Production offlat surfaces, Grinding & Finishing Processes, Computer controlled Measurement Systems ±
CNC, DNC, FMS, Automation and Robotics.
Cutting Tools Materials, Tool Geometry Mechanism of Tool Wear, Tool Life & Machinability;
Measurements of cutting forces. Economics of Machining. Uncoventional Machining Processes. Jigs and
Fixtures. Fits and tolerances, Measurement of surface texture, Comparators alignment tests and
reconditioning of Machine Tools.

    
 

m

 

Engineering Materials: Structure and mechanical properties of common engineering/metals, alloys,

plastics and ceramics, Heat treatment of steels.
Foundry: Patterns, Pattern allowances, moulding and more making, gating and Risering calculations.
Casting process; sand, die, Centrifugal, investment and shell mould casting. Defects in Casting.
Welding: Gas, arc and resistance welding. Tungsten inert gas(TIG), metal inert gas(MIG) and atomic
hydrogen welding; Power sources for welding, Brazing, Soldering and adhesive bouding.
Metal Working: Basic plasticity for metal forming. Hot and Cold working, Forming processes; blanking,
piercing and deep drawing. Technology of wire drawing, rolling and forging processes. Force and power
calculations. Elements of power metallurgy.
Machine Tools: Construction, operation, kinematics and applications. Automatic and semiautomatic
machine tools, indexing attachments, Jigs and fixtures. Elements of N/C machine Tools.
Metal Cutting: Tool materials, tool geometry and surface finish, Chip formation, mechanics of machining;
force, temperature, tool life, machinability and economics of maching.
Machining Processes: Turning, drilling, shaping, planning, boring, reaming, milling, grinding and
finishing processes. Production of screw threads. Gear manufacturing processes; hobbing and shaping,
Introduction to unconventional machining processes like EDM, ECM, USM, Laser machining etc.
Limits, Fits and Tolerances: Geometric tolerancing; straightness, flatness, roundness, parallelism,
cylindricity and location, Instruments and methods for linear and angular measurements. Limit gauging
and comparators. Surface finish.
Tool Engineering: Principles of work holding, design of jigs and fixtures.
Computer Integrated Manufacturing: Basic concepts of CAD, CAM, and their integration tools.
Manufacturing Analysis: Part-print analysis, tolerance analysis in manufacturing and assembly, time and
cost analysis.







 
 




m

m

Metal Casting: Casting processes; patterns-materials; allowances; moulds and cores-materials, making
and testing; melting and founding of cast iron, steels and nonferrous metals and alloys; solidification;
design of casting, getting and risering; Casting defects and inspection.
Metal Working: Stress-strain in elastic and plastic deformation; deformation mechanisms; hot and cold
working-forging, rolling, extrusion, wire and tube drawing; sheet metal working; analysis of rolling,
forging, extrusion and wire/rod drawing; metal working defects, high energy rate forming processes-
explosive, magnetic, electro and electro hydraulic.
Metal Joining Processes: Welding processes-gas shielded metal arc, TIG, MIG, submerged arc,
electroslag, thermit, resistance, prossure-soldering, brazing, braze welding; welding codes, welding
symbols, design of welded joings, defects and inspection; introduction to modern welding processes-
friction, ultrasonic, explosive, electron beam, laser and plasma.
Machining and Machine Tool Operations: Machining processes-turning, drilling, boring, milling, shaping,
planning, sawing, gear cutting, thread production, broaching, grinding, lapping, honing super finishing;
mechanics of cutting-Merchant¶s analysis, geometry of cutting tools, cutting forces, power requirements;
selection of process parameters; tool materials, tool wear and tool life, cutting fluids, machinability;
nontraditional machining processes, and hybrid processes-EDM, CHM, ECM, USM, LBM, EBM, AJM,
PAM, and WJM; economics of machining.
Metrology and Inspection: Limits and fits, linear and angular measurements by mechanical and optical
methods, comparators; design of limit gauges; interfermmetry; measurement of straightness, flatness,
roundness, squareness and symmetry; surface finish measurement; inspection of screw threads and gears;
alignment testing.
Powder Metallurgy and Processing of Plastics: Production of powders, compaction, sintering; polymers
and composites; injection, compression and blow molding, extrusion, calendaring and thermoforming;
molding of composites.
Tool Engineering: Work-holding-location and clamping; principles and methods; design of jogs and
fixtures; design of press working tools, forging dies.
Manufacturing Analysis: Sources of errors in manufacturing; process capability; part-print analysis;
tolerance analysis in manufacturing and assembly; process planning; parameter selection and comparison
of production alternatives; time and cost analysis; issues in choosing manufacturing technologies and
strategies.
Computer Integrated Manufacturing: Basic concepts of CAD, CAM, CAPP, group technology, NC, CNC,
DNC, FMS, Robotics and CIM.




 
 




 


m



 

Metal cutting or machining is the process of producing a work piece by removing unwanted material from
a block of metal, in the form of chips. The process of removing metal can be done by using two types of
cutting tools.
1.c Single point cutting tools
a)c Ground type
b)c Tipped type
2.c Multipoint cutting tools
a)c Drill bit
b)c Milling cutter
c)c Grinding wheel etc.
0c Single point cutting tools will have only one effective cutting edge to remove the excess material
effective cutting edge to remove excess material from work..
Ex:- Drilling, Milling, Broaching etc.
0c MRR obtained from Multipoint cutting tool is more than that from single point cutting tool.
0c The life of multipoint cutting tool is more than single point cutting tool.
0c Single point cutting tools are fed axially at a uniform feed per revolution. But multipoint cutting tools
are fed perpendicularly to the cutter axis of rotation.

 !"
1.c Properties of work material such as hardness, toughness, abrasion qualities, tendency to weld etc.
2.c The properties and geometry of the cutting tool - The tool material should be hard, strong, tough and
wear resistant.
3.c The interaction between the tool and the work during metal cutting.

! #!$"!
Cutting using single point cutting tool can be affected by six angles of tool and the nose radius of
tool. The arrangement of all these in a particular order is called single point cutting tool nomenclature or
designation. The two systems are widely used is this context.
a)c ASA system (American standards association system)
b)c Orthogonal Rake system (ORS).


 # % In this system the angles defined are measured with respect to three mutually
perpendicular planes. According to ASA system, the single point cutting tool can be designated as





 In this system angles defined are measured with respect to plane containing principal or side
cutting edge and the plane normal to it.
According to ORS the single point cutting tool can be designated as:




 
 




!!&$ "!
a)c 3' ' ! Its purpose is to guide the direction of the chip flow. The softer the material of
work piece, the greater should be the positive rake angle.
0c Excessive positive rake weakens the cutting edge and increases tool life slightly.
b)c
('!The amount that a chip is bent depends upon this angle. With increase in side rake
angle, the amount of chip has to bend decreases and hence the required to part and bend the chip
decreases.
0c Larger side rake angle produces smooth surface finish.
c)c ( ! ! This angle prevents the cutting tool from rubbing against the job. If this angle is
very large the cutting edge of the tool will be unsupported and will break off where as if this angle is
very small, the tool will rub the job and poor finish will be obtained on the job.
d)c 
( ! ! This angle permits the tool to be fed side ways into the job, so that it can cut
without rubbing. If this angle is very large the cutting edge of the tool will break because of
insufficient support, whereas if this is very small the tool cannot be fed into job, it will rub against the
job and will get overheated and became blunt and finish obtained is rough.
e)c ("(! It acts as a relief angle that it allows only small section of the end cutting
edge to contact the machined surface and prevents chatter and vibration.
f)c
("(!It avoids formation of built up edge, controls the direction of chip flow and
distributes the cutting force and heat produced over larger cutting edge.
g)c  (" Nose radius is favorable to long tool life and good surface finish. Too large a nose
radius will induce chatter. Nose radius also reduces high heat concentration at sharp point.

 ((!!
0c Back rake may be positive, zero or negative: Negative rake angles are used with carbide tipped tools
because they posses very high compressive strength and comparatively very low tensile and shear
strength. Negative rake angles are used with higher cutting speeds, with less tendency for a BUE, and
high heat distribution. Back rake for AI ± 30 to 35, steel ± 5 to 7, CI ± 3 to 5, Brass ± 0, etc with
H.S.S.
Back rake for steel ± 0 to ± 7, CI ± 0, AI ± 0 to 10, etc with carbide tools.
0c Side rake for AI ± 14 to 16, steel - 8 to 10, CI -10 to 12 etc with H.S.S and carbide tools.
0c End relief and side relief are 5 to 15 in general.
0c End cutting edge angle is 8 to 15 in general.
0c Side cutting edge angle is 0 to 90 in general.
0c Nose radius = 0.4mm for delicate components
= 0.4 to 1.2mm for carbide inserts
= 1.2 to 1.6mm for heavy duty inserts.

& &$ 

 In any machining operation, the material is removed from the work piece in the form of chips.
Chips are formed due to tearing and shearing.




 
 





In the process of chip formation by tear, the work piece material adjacent to tool face is
compressed and a crack runs ahead of cutting and towards the body of the work piece.
In the chip formation by shear, there is general movement of the chip over tool face. As the
cutting tool advances into the work piece, the metal ahead of the tool is severely stressed. The cutting tool
causes internal shearing action in the metal, such that metal below the cutting edge yields and flows
plastically in the form of chip.

3"!"$(3 
 When machining ductile materials, conditions of high local temperature and extreme pressure in
the cutting zone and also high friction in the tool chip interface many cause the work material to adhere or
weld to the cutting edge of the tool forming the BUE. Successive layers of work material are then added
to the BUE. When this edge becomes larger and unstable, it breaks up and part of it is carried away by
chip while the remaining is left over the surface being machined, which contributes to the roughness of
the surface. The BUE change its size during cutting operation. It first increases, then decreases, then again
increases etc. The only advantage with BUE is, it increases the tool life.

#$&$
The factors influencing the type of chip produced are
0c Properties of material to be cut such as ductility.
0c Cutting parameters such as depth of cut, feed rate, effective rake angle of the tool, cutting speed, type
of cutting fluid etc.
0c Factors such as surface finish of the tool face, coefficient of friction between the tool and chip, and
the temperature change in the region of cutting.
Commonly three types of chips are formed during metal cutting.
a)c "" &$   ( &$ ± materials such as gray CI lack ductility necessary for
appreciable plastic deformation. Hence the compressed material ahead of the tool fails in a brittle
facture along the shear zone producing small chips. These chips are called discontinuous chips. The
factors favorable for producing discontinuous chips are
0c Low cutting speed
0c Brittle work material
0c Small rake angle
0c Large uncut chip thickness
0c Cutting with the use of cutting fluid
£c "" &$ It can be obtained when cutting ductile materials such as low carbon steel,
Aluminum and copper. This chip is severely deformed either in the form of a long strip or curl into a
tied roll. This type of chip remains in contact with the tool face for a longer period, resulting in more
frictional heat. Also the chips may curl around work and the tool and may injure the operator when
breaks loose. These difficulties are avoided by attaching chip breaker.
The factors favourable for continuous chips are
0c Ductile work material
0c Small uncut chip thickness, fine feed
0c High cutting speed
0c Large rake angle
0c Suitable cutting fluid
0c Using sharp cutting edge




 
 




c ""&$)&3  The factors favorable are

0c Ductile work material
0c Low cutting speeds
0c Low rake angle and high feed
0c Heavy depth of cut
0c Absence of cutting fluid

&( & These are two methods
c Orthogonal cutting or two dimensional cutting
c Oblique cutting or three dimensional cutting
Orthogonal cutting Oblique cutting
1.c The cutting edge of the tool remains the 1.c The cutting edge of the tool is inclined normal
direction of tool feed. to at an acute angle to the direction of tool
2.c The direction of chip flow velocity is normal feed.
to the cutting edge of the tool 2.c The direction of chip flow velocity is at an
3.c The cutting edge clears the width of the work angle with the normal to the cutting edge of the
piece on either ends. tool.
4.c Only two components of cutting forces act on 3.c The cutting edge may or may not clear the
the tool. These two components are width of work.
perpendicular to each other. 4.c Three mutally perpendicular components of
5.c Examples are jack plane, broaching, sawing cutting forces act at the cutting edge of the tool.
etc. 5.c Examples are lathe turning, drilling, milling,
 shaping, planning etc.

&$&' It is an index of the amount of plastic deformation which the metal into chip has
undergone. So the chip thickness ratio is the ratio of the uncut chip thickness to the chip thickness.
Let t1 = uncut chip thickness
t2 = chip thickness
r = chip thickness ratio = t1/t2

&!* It is the angle made by shear plane with velocity of cutting. Use of proper cutting fluid
can increase shear angle. For a given depth of cut and shear strength of the work material, the reduction in
shear plane area reduces the forces required to produce sufficient shearing stress to cut the work.

Let t1 = uncut chip thickness

t2 = chip thickness
Ø = shear angle
Õ = rake angle (back)
r = chip thickness ratio = t1/t2 = cutting ratio
Vc = cutting velocity
Vf = chip flow velocity
Vs = shear velocity




 
 




As we know that volume of metal before is equal to after cutting

t1 L1 b = t2 L2 b
Where b = width of chip, which is constant that it is assumed that there is no side flow of metal
L1 = length of uncut chip/rev
L2 = length of chip/rev

t1/t2 = L2/L1 = r

Similarly
Vc b t1 = Vf b t2
t1/t2 = Vf/Vc = r

Note: chip reduction coefficient = 1/r=t2/t1=L1/L2 = Vc/Vf

Ú!#! In the cutting process there are three velocities are existed.
a)c Cutting velocity ± is the speed of tool relative to the work and directed parallel to the cutting force.
b)c Chip flow velocity ± represents the speed of the chip relative to the cutting tool and directed along the
tool face.
c)c Shear velocity ± is the speed of the chip relative to the work piece and directed along the shear plane.
According to sine rule :- Vf / Sin Ø = Vs / sin (90-Õ ) = Vc / sin (90-(Ø-Õ ) )

& Shear strain in cutting is the ration of the distance the material being cut travels along
Shear plane to the spacing of successive shear planes.
Shear strain = Ȗ = Tan (Ø-Õ ) + Cot Ø

  ! " The knowledge of forces acting on a tool is required for the estimation of the
power requirements and for designing the machine tool, which is adequately rigid and free from
vibrations. The cutting forces will vary with
0c The tool angles
0c The finish of the tool
0c The composition of the work and tool material
0c Cutting speed
0c Whether cutting fluid is used or not.

The forces acting on the chip in an orthogonal cutting are.

a)c Force ³Fs´ which is resistance to the shear of the metal in forming the chip. This force acts along the
shear plane.
b)c Force ³Fn´ which is normal to the shear plane and is called backing-up force provided by the work
piece on the chip.
c)c Force ³F´ is the force acting due to frictional resistance of the tool acting on the chip. This force acts
downwards against this as chip glides along the tool face.
d)c Force ³N´ which is actions on chip, which is normal to the frictional force.

The forces action on a chip can be represented on a free body diagram of the chip. The forces Fs and Fn
can be represented by the resultant ³R´ and the forces F and N can be represented by resultant ³R´. If the
chip were to be at equilibrium the forces R and R¶ should be equal in magnitude and opposite in direction
and collinear.
Fc and Ft can be measured by using two-component tool dynamometer, in which electrical strain gages
are used to measure the stain in the tool whenever the cutting force is supplied.




 
 
 



" $ (() &+!

1.c Shear surface is a plane extending upwards from the cutting edge.
2.c The tool is perfectly sharp and there is no contact along the clearance face.
3.c The cutting edge is a straight line extending perpendicular to the direction of motion and generates a
plane surface as the work moves past it.
4.c The chip does not flow to either side that is chip width is constant.
5.c The depth of cut remains constant.
6.c Width of the tool is greater than that of the work
7.c Work moves with uniform velocity relative tool tip.
8.c No BUE is formed

& ! It is used to analyze the forces acting in metal cutting. The analysis three forces
system, which balance each other for cutting to occur. Each system is a triangle of forces. The three
triangles are
a)c A triangle of forces fro the cutting forces
b)c A triangle of forces for the shear forces
c)c A triangle of forces for the frictional forces
Let F = frictional force
N = normal to frictional force
Fs = Shear force
Fn = normal to shear force
Fc = cutting force
Ft = thrust force or feed force
M = friction angle
= coefficient of friction = tan M

Fc and Ft are along and normal to the direction of velocity

Shear stress = Fs / As = Fs Sin
/ t1 x b
Normal stress = fn = Fn / As = Fn Sin
/ t1 x b
Let W = Work done = Fc x Vc
W1 = Work done is hearing = Fs Vs
W2 = Work done is friction = F Vf
W = W1 + W2
Fc Vc = Fs Vs + F Vf

For min work done

dW/d  = 0
W = Fc Vc
dW/d  = 0
2Ø + M ± Õ = Cos-1 0 = 90
Merchants Constant = 2Ø + M ± Õ = Cm = Machining Constant.
For min work or min power consumption in cutting Cm = 90
, According to lea and Shaffer
Ø + M± Õ = 45
- According to stabler
Ø + M ± Õ / 2 = 45
. Max shear angle for min work is 45 (if M = Õ = 0)
/ Cm can be increased with cold work






 
 
 



$#% It is the energy consumed per unit volume of metal removed.

Sp Energy = Fc Vc / Ao Vc = Fc / Ao = Sp cutting pressure
Sp energy can vary considerably for a given material and changes in Vc, feed, tool rate etc. for a given
tool rake at high cutting speed and large feeds the sp. Cutting energy tends to become constant.

&!(£!0""
In orthogonal cutting forces acting are cutting force which is acting in the direction of cutting
motion and the feed force, which is perpendicular to the cutting force. The resultant of these two forces is
given as

In case of oblique cutting, three forces are acting which are mutally at right angles. They are
cutting force in the direction of cutting motion, thrust force acting in the horizontal plane in the direction,
parallel to generated surface and a radial force acting on a horizontal plane in the direction perpendicular
to the generated surface. The relationship between these forces Fc, Ft and Fr depends upon the cutting
variables, geometry of tool point, the work material, and the tool wear. The resultant force is given as

, With the increase in the cutting speed, the ratio of Ft / Fc and Fr / Fc will be decreasing.
- The relative value of Ft and Fr increase with the ±ve rake angels and wear along the flank.
.The ratio Ft / Fc increases and Fr / Fc decreses with the increase in depth of cut and plance of
approach angle.

"$ 
1)c The tool forces does not change significantly by changing the cutting speed





2)c As chip size increase, the cutting force. Increase, Ft decreases if the nose radius is made large or if the
side cutting edge angle is increases.
3)c Fc reduced as back rack angle is increased, for the every degree of increase, the cutting force is
reduced by 10%
4)c Use of coolants reduce the forces required on the tool. Coolants also increase the tool life to a greater
extant.
5)c The distribution of the cutting forces on a single point cutting tool in
a)c Orthogonal cutting Fc ----- 67 %, Ft ----- 33 %
b)c Oblique cutting Fc ----- 67 %, Ft ---- 27 %, Ft ----- 6 %
6)c Motor power required for driving machine tool 
= (Fc Vc/ ), = motor efficiency; = efficiency of machining






 
 





m-   
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  32


The power or the total energy given by external source for cutting is spent in the form of shear energy,
frictional energy, and momentum energy. In practice the momentum energy per unit volume is negligible
compared other two energies. Hence for all practical purposes it can be assumed as the energy consumed
in plastic deformation on the shear plane and friction between the chip and the tool face.

Heat is generated at 3 zones during cutting

1)c Shear zone 2) Friction zone 3) Tool-Work interface

c
&3Max heat is generated in this zone due to the plastic deformation of the metal. The major
heat generated in this zone is carried away by the chip and remaining (less than 10%) is taken by
work piece. The total heat generated in the shear zone consists of heat of deformation and the heat of
distortion.
£c  3 &$ !  in this zone, as the chip moves upwards along the tool face, a
good amount of heat is generated due to friction at the chip tool interface, which further raises the
temp of chip. A part of the heat generated in this zone goes to the tool.
c Ñ' !  Due to friction between work and tool, the heat is generated. This heat is
carried away partly by the tool and partly by the work piece.
A ± Primary heat zone
B ± Secondary heat zone
C ± Tertiary heat zone

Heat distribution between chip, work and tool are 75%, 20% and 5% respectively.
In general tertiary heat zone is very less and so neglected.
Heat generated = heat carried by chip + heat carried by work

Heat carried by chip = m s ù t = V Cp
p = b t1 Vc Cp
p

V Cp
p = W ± a W;
p = W (1 ± a) / V C p
V = volume of metal = MRR = b t1 Vc
The temp of a chip tool interface can be measured by using following methods
1)c Tool work thermocouple 2) Calorimetric set up 3) Optical pyrometer
!"&
1)c Work material Hard ± more power required consequently more heat generated

Soft ± less
2)c Tool material --- cutting speed
3)c Cutting condition --- speed, feed, depth of cut.
4)c Use of cutting fluid
5)c Tools geometry more rake --- less heat

less rake --- more heat

! !" While cutting (or) machining the tool should perform satisfactory. Unsatisfactory
performance for the tool indicates the tool has failed. When the tool indicates the tool has failed. When
the tool failure occurs, the following can be observed.
-The tool ceases to produce work piece, according to required dimensions
-The tool gets over heated (due to rubbing)
-Poor surface finish
-Increased cutting forces and hence the power consumption.




 
 




Failure of cutting tool may be due to one or a combination of the following modes.
-Plastic deformation due to high temp and large stress
-mechanical breakage
-Failure through gradual wear

#$)
,c !' ) 4 the flank wear occurs on the flank below the cutting edge. This is due to abrasive
contact with machined surface.
Îc Brittle material tend to cause flank wear because the tool cutting edge tends to scrap over the
machined surface and due to the abrasive action of the fractured chips on the tool.
The following ways the flank wear takes place
Îc Abrasion by hard particles and inclusion in the work piece.
Îc Shearing of the micro weds between tool and work material
Îc Abrasion by fragments of BUE
Îc At high temp rapid wear takes place due to diffusion
Îc Study wear is caused by abrasion and rapid wear is caused by diffusion.
-c )4crater wear occurs on the face of the tool in the form of a pit, called crated. The carter
is formed at some distance from the cutting edge. The location of the max crater depth and the max
tool ± chip interface temperature coincides with each other. Hence, the catering is assumed as a
temperature dependent phenomena caused by diffusion and adhesion etc. The crater significantly
reduces the strength of the tool and may lead to the total failure.
The crater wear is mainly due to
Îc Sever abrasion between the chip and tool face
Îc High temperature in the tool chip interface
Îc Diffusion
!!4Tool life can be defined as the time elapsed between two successive grindings of the tool. The
tool life is one of the important economic considerations in metal cutting. The tool life can be expressed
in
I.c Minutes ± in general
II.c No on pieces produced ± in mass production
III.c Volume of metal removed ± in rough machining
The factors affecting tool life are
Îc cutting speed
Îc feed and depth of cut
Îc tool material
Îc work material
Îc tool geometry
Îc cutting fluids
Îc machine tool rigidity
Taylor¶s tool life equation is
VT = C Where V = cutting speed in m/s
T = tool life in min
C = constant
N = tool life exponent = 0.1 to 0.6

Generalized tool life equation is

VTn fp d q = C
Where f, d are feed and depth of cut in mm.
q < p indicates that tool life is more sensitive to the uncut chip thickness than to the width of cut
Effect of tool, life on cutting parameters is V > f > d.




 
 




&£!#Machinability can be evaluated using the following criteria

Îc Tool life ± more the tool life better the machinability
Îc Surface finish ± better the surface finish better the machinability
Îc Force and power consumption ± more the force poor the machinability
Îc Shear angle ± larger the shear angle better the machinability
Îc MRR ± higher the MRR better the machinability
Îc Sp energy
Îc Size of the chips
Îc Ease of chip disposal
Îc Temp of tool ± work interface
Machinability index = Vt / Vs
Where Vt = cutting speed o test piece for 60 min tool life
Vs = cutting speed on standard material (free cutting steel) for 60 min tool life.

   ""  & A high degree of homogeneity decreases the ease of
machinability giving rise to tearing, poor surface finish and formation of BUE. Hence it is difficult to
machine pure metals such as iron, copper and full solid solutions.
Îc Heterogeneous alloys whose components are segregated into bands or into excessively
large grains is also bad for machining.
Îc Alloys having hard and soft components uniformly dispersed (or) distributed tend to give
good properties.
Îc A uniform heterogeneous structure will give best machining.
Îc The machinability index may vary from metal to metal and also from process to process
like heave turning, light turning, forming or milling etc.
Îc The machinability index of free cutting steels is fixed at 100% and with this one the
machinability of other metals is calculated.




























 
 





m. 



 1
35 

 


Machining economic can be done based on the following criteria
a)c For minimum cost b) for max production rate c) for max profit

  "  Total cost of machining one component = machining cost + cost of setting up m/c +
cost loading and unloading of part + tooling cost.
Cp = Cm + Cs + C1 + Ct
Normally Cs and C1 are constant and does not have any effect due to change of cutting parameters.
Cm = Tm x L m
Tm = Machining time per piece = L / f N = l L D / 1000 f V
Lm = Labour + over head cost during machining per min
Z = No. of pieces produced per tool life
T = Tool life
The cutting velocity for min cost is






V=C

Lm = machining cost per min

Cg = Cost of regrinding of too (or) Cost of tip of tool if it is throw away type of tip.

 6 " $("Total processing time for a component = machining time + machine setting
time + leading and unloading of part +tool change time per piece.
T p = Tm + Ts + T1 + Tc/z
Ts and T1 are constant and does not vary with cutting parameters
Tp = Tm + Tc / z
d T p /dV = 0


V=Ci 

 


Where Tc = time needs to change the tool.
 67$ Profit = selling price ± production cost
Production cost = cost of raw material + cost of machining
So in this selling price and cost of raw material are constant and so the profit is mainly a
function of cost machining only. By minimizing the cost of machining we can maximize
the profit.

£!0""
c
&$($!%uncut chip thickness = t1 = f cos Ȝ
Width of cut = b = d / cos Ȝ
Where Ȝ = primary cutting edge angle f = feed d = depth of cut
Three components of cutting force
Îc cutting force = Fc
Îc feed component of force = Ff = Ft Cos Ȝ
Îc radial (or) normal component of force = Fr = Ft sin Ȝ
MRR = L x d x f x N
Where L= length of job N = No. of double strokes per unit time
Power = Fc x Vc. Where Vc = Avg. cutting speed
£c "(£%uncut chip thickness = t1 = f Cos Cs = f sin Ȝ
Width of cut = b = d / Cos Cs = d / Sin Ȝ
 Where Ȝ = Primary cutting edge angle
Cs = side cutting edge angle = 90 ± Ȝ




 
 




To fulfill the condition of orthogonal machining the condition to be satisfied is

Tan Õ b = Tan Õ s + Tan Cs
Three components forces are
Îc Cutting force = Fc
Îc Feed component = Ff = Ft Cos Cs
Îc Radial component = Fr = Ft Sin Cs
MRR = f x d x Vc
Vc = l DN
Power consumption = Fc x Vc
Normal rake angle = Õ =  "!
Where Õ = back rake angle Õ = side rake angle Cs = side cutting edge angle
Tan
 = Tan
 / cos i
c !!uncut chip thickness = (f/2) Sin B = t1; width of cut = b = D / 2 Sin B
Where f = feed rate D = Nominal dia of drill B = half of point angle
Total trust force = F = 5 Ft Sin B; total moment = torque = M = 0.6 Fc D
Normal rake angle = Õ = Tan-1 (1/2(Tan Õ / Sin B)
Note i) Greater the helix angles less torque is required in drilling
Note ii) Thrust and torque in drilling can be experimentally determined by strain gauge dynamometer. In
this dynamometer total ³8´ strain gauges are sued.
(c !!Max uncut chip thickness = t1max = 
f = table feed in mm/ min = fr x N = ft Z N
fr = feed per revolution
ft = feed per tooth
N = Rpm of the cutter; Z = No. of teeth on cutter; d = depth of cut
D = dia. of cutter, MRR = f b d
Avg. uncut chip thickness = (Max + Min / 2) = (Max + 0/2) = (Max chip/2)

" ! ! Cutting tool must be 35 to 50% harder then the work material. The important
qualities expected of a good cutting tool are
0c High hardness for easy penetration into the work.
0c High mechanical resistance to bending and to compression so that it can withstand cutting forces
0c Resistance to abrasion diffusion, and plastic deformation
0c Hot hardness
0c High toughness
0c Low frictional coefficient
0c Cost and easiness in fabrication
Different cutting tool materials used in practice are
a)c £
! &£
! composition C = 0.8 to 1.3% Si = 0.1 to 0.4%Mn = 0.1 to
0.4%
0c Used for machining soft metals like free cutting steels and brass and used as chisels etc.
0c These tools loose hardness above 250c.
0c Hardness of tool is about Rc = 65
0c Used at cutting speed of 5m/min
b)c &$(!General used HSS is 18 ± 4 ± 1
18 ± Tungsten ± used to increase hot harness and stability
4 ± Chromium ± used to increase strength
1 ± Vanadium ± used to maintain keenness of cutting edge in addition
2.5% to 10% - cobalt ± used to increase red hot hardness
0.8% - carbon




 
 





Rest ± iron.
0c H.S.S is used for drills, milling cutters, single point cutting tools, tops, dies, reamers etc.
0c It looses harness above 600c.
0c Some times tungsten is completely replaced by molybdenum, molybdenum based H.S.S
is cheaper than the tungsten based H.S.S and also slightly greater toughness. But less
wear resistance.
0c Used at cutting speeds 40 to 50 m/min.
c)c %"!!#!! It is an alloy of Cobalt ± 40 to 50%, Chromium ± 27 to
Tungsten - 14 ± 29%, Carbon - 2 to 4%
0c It can not heat treated and are used in the as cast form.
0c It looses its hardness about 800c.
0c It will give better tool life that H.S.S and can be sued at slightly higher cutting speeds.
0c They are weak in tension and like all cast materials tend to shatter when subjected to
shock load or when not properly supported.
d)c  (£( Produced by power metallurgy technique with sintering at 1500c 
0c Speed can be used 6 to 10 times that of H.S.S
0c Can withstand up to 1000c
0c High compressive strength
0c High wear resistance
0c High modulus of elasticity
0c Low coefficient of thermal expansion
0c High thermal conductivity
According to ISO the various grades of carbide tool materials grouped is
0c For cutting CI and non ferrous metals are designated as K01 to K40
0c For cutting steel are designated as p01 to p60
0c For general purpose application are designated as M10 to M30

Note: Harder and brittle materials have low in number; less hard and more tough have higher number

e)c   ( ( 6( It is basically AI203 containing additions like Mgo, Nio, Cr203,
Tiu, etc to improve grain structuring, cutting properties, and sintering. These are made by P.M
technique.
0c used for ever high speed (4 times carbides, 500m/min to times H.S.S)
0c used for continuous cutting only
0c can withstand upto 1200c
0c have very high abrasion resistance
0c used for machining CI and plastics.
0c Has less tendency to weld metals during machining
0c Generally used ceramic is sintered carbides
0c Another ceramic tool material is silicon nitride which is mainly used for CI
0c The tool life silicon nitride is effective over 1500 CI pieces, but for some work tungsten
carbide tool lasted only for 250 pieces.
f)c  Combination of ceramics and metals and produced by PM process. 
0c When they combine ceramics give high refractoriness and metals will give toughness and
thermal shock resistance.
0c For cutting tools usual combination as AI203 + W +M0 +Boron + Ti etc.
0c Usual combination 90% ceramic, 10% metals
0c Increase in % of metals reduces brittleness some extent and also reduces wear resistance.





 
 




g)c  ( It has

0c Extreme hardness
0c Low thermal expansion
0c High thermal conductivity
0c Very low coefficient of friction
0c Work materials are Cu, brass, Zn, AI, Mn alloys etc.
0c Cutting speeds are ranging from 200 to 500 m/min.
0c On ferrous metals diamonds are not suitable because of the diffusion of carbon atoms
from diamond to work.
0c Can withstand up to 2000c
0c A synthetic (man made) diamond with polycrystalline structure is recently introduced and
is called compacts and made by PM
0c Used as turning and boring tools, milling cutters, reamers, grinding wheels, honing tools,
grinding wheel dressing etc.
h)c "££(3
Îc The trade name is Borozone
Îc Consists of atoms of Nitrogen and Boron and produced by PM
Îc Used as a substitute for diamond during machining of steel
Îc Used as a grinding wheel on H.S.S tools, for machining high temp. allows like Tr,.
Nrimonic stainless steel, satellite and chilled CI
Îc Excellent surface finish is obtained.
i)c 
Developed by union carbide in USA. It consists of 
Columbium ± 50% Titanium ± 30% Tungsten ± 20%
This is refractory metal alloy which is cast, rolled into sheets and slit into blanks. Thought its hardness is
only 200 brindel, it is hardened by diffusing nitrogen into surface producing very hard surface with soft
core. It is not used because of its higher casts.
j)
! It is made by P.M with milled powders of N4 and AI2 O3 by sintering at 1800c. this is
tougher than ceramics and so it can be successfully used in interrupted cuts. Cutting speeds are 2 to 3
times ceramics. At present this is used for machining of aerospace alloys, Nickel based gas turbine blades
with a cutting speed of 3 to 5 m/sec.

8'(!!
During turning a cylindrical job the tool tip must coincide with centre line of job, if not the effects
are:
a)c If tool tip is above centre line, the toll will destroyed due to firiction
b)c If tool tip is below centre line, the tool tip will dull rapidly.
To reduce the above two effects the tool is filled at slightly inclined position, dut to this the back rake
and end relief angles will get changed. The effective rake and relief angles can be calculated as
follows:
Let Of = off set r = Radius of work Q = Angular change Sin
= Of/r
The consideration is
I.c Off set is taken as positive if the tip is above centre line and negative if the tip is below centre line
II.c Always subtract
from relief angle algebraically
III.c Always add
to back rake angle algebraically




 
 




 
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1.c A built up edge is formed while machining (2002)

a)c ductile material at high speed b) ductile materials at low speed
c)brittle material at high speed d) brittle materials at low speed

2.c During orthogonal cutting of MS with a 10deg rake angle tool, the chip thickness ration was
obtained as 0.4 the shear angle (in degrees) evaluated from this data is (2001)
a)c 6.53 b) 20.22 c) 22.94 d) 50.00

3.c What is the approximate % change in the life, t, of the tool with zero rake angle used in
orthogonal cutting when its clearance angle, Õ is changed from 10 to 7 deg? (1999)
(Hint: flank wear rate is proportional to cot Õ )
a)c 30% increase b) 30% decrease c) 70% increase d) 70% decrease

4.c In orthogonal machining operation, the chip thickness and the uncut chip thickness are equal to
0.45mm. if the tool rake angle is 0deg. The shear plane angle is (1998)
a)c 45 b) 30 c) 18 d) 60

5.c In a typical metal cutting operation, using a cutting tool of positive rake f = 10deg, it was
observed that the shear angel was 20deg. The friction angle is (1997)
a)c 45 b) 30 c) 60 d) 40

6.c The rake angle in a drill (1996)

a)c Increases from center to periphery b) decreases from center to periphery
c)Remains constant d) is irrelevant to the drilling operation

7.c Tool life of a 10 hors is obtained when cutting with a single point tool at 63m/min. if Taylor¶s
constant C = 257.35, tool life on doubling the velocity will be (1996)
a)c 5 hours b) 25.7 min c) 38.3 min d) unchanged

8.c Among the conventional machining processes, maximum specific energy is consumed in
a)c Turning b) drilling c) planning d) grinding

9.c Cutting power consumption can be significantly reduced by (1995)

a)c Increasing rake angle of the tool b) increasing cutting angle of the tool
c)Widening the nose radius of the tool d) increasing clearance angle of the tool

10.c The effect of rake angle on the mean friction angle in machining can be explained by
a)c Sliding model (coulomb) of friction b) striking friction
c)Striking and then sliding model of friction d) sliding and then sticking model of friction

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11.c Only negative rake angles are used with the following tool materials (1995)
a)c HSS b) carbon tool steels c) carbides d) diamonds

12.c In metal cutting BUE formation results in (1995)

a)c Improvement in surface finish b) reduction in cutting force
c)Deterioration of surface finish d) improvement in tool life




 
 
 



13.c The heat generated in metal cutting is dissipated in different proportions into environment, tool,
chip and work-piece. The correct order of this proportion in decreasing magnitude is
(no cutting fluid is used) (1994)
a)c Tool, work, chip, environment b) work, tool, chip, environment
c)Tool, chip, environment, work d) chip, tool, work, environment

14.c In metal cutting with a carbide tool, at the maximum recommended speed, the largest % of heat
generated goes to the (1992)
a)c Tool b) chip c) work d) tool post

15.c Increase in rake angle causes ««««. A «««««.. in chip thickness and «««««.. B
««««.. in shear angle (1991)
a)c Increasing / reducing b) increasing / reducing

16.c Thrust force in drilling can be reduced by «««««. A «««««« the point angle and by
«.. B ««. the helix angle of the drill (1991)
a)c Increasing / reducing b) increasing / reducing

17.c Amount of energy consumption for unit volume of metal removal is maximum in (1991)
a)c Turing b) milling c) reaming d) grinding

18.c BUE formation « A « the cutting force and «. B «. The surface finish (1990)
a)c Decreases / increases b) spoils / improves

19.c Assertion: a diamond tool is used for USM of glass work-piece (1990)
Reason: diamond is harder then glass

20.c Two different tools A and B having nose radius of 0.6mm and 0.33mm respectively are used to
machine C-45 steel employing feed rate of 0.2 mm/rev and 0.1 mm/rev respectively. The tool that
gives better finish and the value of ideal surface roughness are
a)c Tool A and 4.166 m respectively b) tool B and 3.78 m respectively
c)Tool A and 8.333 m respectively d) tool B and 8.333 m respectively



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21.c In the diagram shown:
a)c I is tool cost, II is machining cost, III is total cost
b)c I is total cost, II is tool cost, III is machining cost
c)c I is machining cost, II is tool cost, III is total cost
d)c None of the above.

22.c Which of the following has maximum influence on the life of a carbide tool?
a)c Feed b) depth of cut c) tool geometry d) cutting speed

23.c Addition of which of the following improves machining of copper?

a)c Sulphur b) Vanadium c) Tin d) Zinc

24.c The main alloying elements in high speed steel in order of increasing proportion are
a)c Vanadium, Chromium, Tungsten b) Tungsten, Titanium, Vanadium
c)Chromium, Titanium, Vanadium d) Tungsten, Chromium, Titanium




 
 
 



25.c Tool life is generally better when

a)c Grain size of the metal is large b) grain size of the metal is small
c)Hard constituents are present in the microstructure of the tool material
d)None of the above.

26.c Ease of machining is primarily judged by

a)c Life of cutting tool between sharpening b) rigidity of work-piece
c)Microstructure of tool material d) shape and dimensions of work

27.c Tool life is generally specified by

a)c Number of pieces machined b) volume of metal removed
c)Actual cutting time d) any of the above

28.c In metal cutting, use of low feeds and high cutting speeds is desired when the objective is
a)c High metal removal rate b) dry machining
c)Use of soft cutting tool d) surface finish

29.c A drill for drilling deep holes in aluminum should have

a)c High helix angle b) tubular shank c) small point angle d) no lip

30.c Which of the following has given the correct order of increasing hot hardness of cutting tool
materials?
a)c Diamond, Carbide, HSS b) Carbide, Diamond, HSS
c)HSS, Carbide, Diamond d) HSS, Diamond, Carbide

31.c If the chip-tool contact length is reduced slightly by grinding the tool face, then
a)c Both cutting force and interface temperature would decrease
b)c Both cutting force and interface temperature would increase
c)c The cutting force would decrease but the interface temperature would increase
d)c The cutting force would increase but the interface temperature would decrease

32.c Tool life in the case of a grinding wheel is the time

a)c Between two successive regrinds of the wheel
b)c Taken for the wheel to be balanced
c)c Taken between two successive wheel dressings
d)c Taken for a wear of 1 mm on its diameter

33.c For achieving a specific surface finish in single point turning the most important factor to be
controlled is
a)c Depth of cut b) cutting speed c) feed d) tool rake angle

34.c In ASA system, if the fool nomenclature in 8-6-5-5-10-15-2 mm, then the side rake angle will be
a)c 5 b) 6 c) 8 d) 10

35.c A µDynamometer¶ is a device used for the measurement of

a)c Chip thickness ratio b) forces during metal cutting
c)Wear of the cutting tool d) deflection of the cutting tool




 
 




36.c Which is the correct sequence of the following parameters in order of their maximum to
minimum influence on tool life?
1)c Feed rate 2) depth of cut 3) cutting speed
Select the correct answer using the codes given below:
a)c 1,2,3 b) 3,2,1 c) 2,3,1 d) 3,1,2

37.c Tool geometry of a single point cutting tool is specified by the following elements
1)c Back rake angle 2) side rake angle 3) end cutting edge angle
2)c Side cutting edge angle 5) side relief angle 6) end relief angle
3)c Nose radius
The correct sequence of these tool elements used for correctly specifying tool geometry is
a)c 1,2,3,6,4,7 b) 1,2,6,5,3,4,7 c) 1,2,5,6,3,4,7 d) 1,2,6,3,5,4,7

38.c Consider the following tool materials:

1.c Carbide 2. Cermets 3. Ceramic 4. Borazon
The correct sequence of these tool materials in increasing order of their ability to retain their hot
hardness is
a)c 1,2,3,4 b) 1,2,4,3 c) 2,1,3,4 d) 2,1,4,3

39.c Which of the following operation is carried out at the minimum cutting velocity if the machines
are equally rigid and the tool work materials are the same?
a)c Turning b) Grinding c) Boring d) Milling

40.c Cubic boron nitride is used

a)c As lining material in induction furnaces b) for making optical quality glass
c)For heat treatment d) as/for none of the above

41.c The angle between the face and the flank of ht single point cutting tool is known as
a)c Rake angle b) clearance angle c) lip angle d) point angle

42.c Single point thread cutting tool should ideally have

a)c Zero rake b) positive rake c) negative rake d) normal rake

43.c The straight grades of cemented carbide cutting tool materials contain
a)c Tungsten carbide only b) tungsten carbide and titanium carbide
c)Tungsten carbide and cobalt d) tungsten carbide and cobalt carbide

44.c Crater wear is predominant in

a)c Carbon steel tools b) tungsten carbide tools
c)High speed steel tools d) ceramic tools

45.c The primary tool force used in calculating the total power consumption in machining is the
a)c Radial force b) tangential force
c) axial force d) frictional force

46.c Chip equivalent is increased by

a)c An increase in side-cutting edge angle of tool
b)c An increase in nose radius and side cutting edge angle of tool
c)c Increasing the plan area of cut
d)c Increasing the depth of cut




 
 




47.c Cubic boron nitride

a)c Has a very high hardness which is comparable to that of diamond
b)c Has a hardness which is slightly more than that of HSS
c)c Is used for making cylinder blocks of aircraft engines
d)c Is used for making optical glasses

48.c A machinist desires to turn a round steel stock of outside diameter 100 mm at 1000 rpm. The
material has tensile strength of 75kg/mm. The depth of cut chosen is 3 mm at a feed rate of 0.3
mm/rev. Which of the following tool materials will be suitable for machining the component
under the specified cutting conditions?
a)c Sintered carbides b) Ceramic c) HSS d) Diamond

49.c Which of the following indicate better machinabilities?

1.c Smaller shear angle 2. Higher cutting forces
2.c Longer tool life 4. Better surface finish
a)c 1 and 3 b) 2 and 4 c) 1 and 2 d) 3 and 4

50.c Small amounts of which one of the following elements / pairs of elements is added to steel to
increase its machinability?
a)c Nickel b) sulphur and phosphorus c) silicon d) manganese and copper

51.c Specific energy requirements in a grinding process are more than those in turning for the same
metal removal rate because of the
a)c Specific pressures between wheel and work being high
b)c Size effort of the larger contact areas between wheel and work
c)c High cutting velocities
d)c high heat produced during grinding

52.c In orthogonal cutting, the depth of cut is 0.5 mm at a cutting speed of 2 m/s. If the chip thickness
is 0.75 mm, the chip velocity is
a)c 1.33 m/s b) 2 m/s c) 2.5 m/s d) 3 m/s

53.c Consider the following elements:

1.c Nose radius 2. Cutting speed3. Depth of cut 4. Feed
The correct sequence of these operations in machining a product is
a)c 2,4,3,1 b) 4,2,3,1 c) 2,4,1,3 d) 4,2,1,3

54.c Which of the following processes does not cause tool wear?
a)c Ultrasonic machining b) electrochemical machining
c)Electric discharge machining d) anode mechanical machining

55.c Consider the following operations:

1.c Under cutting 2. Plain turning 3. Taper turning 4. Thread cutting
The correct sequence of these operations in machining a product is
a)c 2,3,4,1 b) 3,2,4,1 c) 2,3,1,4 d) 3,2,1,4

56.c In metal cutting operation, the approximate ratio of heat distributed among chip, tool and work, in
that order is
a)c 80:10:10 b) 33:33:33 c) 20:60:10 d) 10:10:80




 
 




57.c Poor machinability of centrifugally cast iron pipe is due to

a)c Chilling b) segregation
c) dense structure d) high mould rotation speed

58.c Which of the following sets of forces are encountered by a lathe parting tool while groove
cutting?
a)c Tangential, radial and axial b) Tangential and radial
c)Tangential and axial d) Radial and axial

59.c In s single ± point turning operation of steel with a cemented carbide tool, Taylor¶s tool life
exponent is 0.25. If the cutting speed is halved, the tool life will increase by
a)c Two times b) four times c) eight times d) sixteen times

60.c Consider the following approaches normally applied of the economic analysis of machining:
1.c Maximum production rate 2. Maximum profit criterion
2.c Minimum cost criterion
The correct sequence in ascending order of optimum cutting speed obtained by these approaches
is
a)c 1, 2, 3 b) 1, 3, 2 c) 3, 2, 1 d) 3, 1, 2

61.c Consider the following statements: For precision machining of non ± ferrous alloys, diamond is
preferred because it has
1.c Low coefficient of thermal expansion 2. High wear resistance
2.c High compression strength 4. Low fracture toughness
Which of these statements are correct?
a)c 1 and 2 b) 1 and 4 c) 2 and 3 d) 3 and 4

62.c In turning operation, the feed could be doubled to increase the metal removal rate. To keep the
same level of surface finish, the nose radius of the fool should be
a)c Halved b) kept unchanged c) doubled d) made four times

63.c The radial force in single ± point tool during turning operation varies between
a)c 0.2 to 0.4 times the main cutting force
b)c 0.4 to 0.6 times the main cutting force
c)c 0.6 to 0.8 times the main cutting force
d)c 0.5 to 0.6 times the main cutting force

64.c Cermets are

a)c Metals for high temperature use with ceramic like properties
b)c Ceramics with metallic strength and luster
c)c Coated tool materials
d)c Metal ± ceramic composites

65.c In an orthogonal cutting test, the cutting force and thrust force were observed to be 1000 N and
500 N respectively. If the rake angle of tool is zero, the coefficient of friction in chip ± tool
interface will be
a)c 1 / 2 b) 2 c) 1 / « d) «




 
 




66.c The magnitude of the cutting speed for maximum profit rate must be
a)c In between the speeds for minimum cost and maximum production rate
b)c Higher than the speed for maximum production rate
c)c Below the speed for minimum cost
d)c Equal to the speed for minimum cost

67.c In a tool life test, doubling the cutting speed reduces the tool life to 1/8th of the original. The
Taylor¶s tool life index is
a)c ½ b) 1/3 c) ¼ d) 1/8

68.c Crater wear starts at some distance form the tool tip because
a)c Cutting fluid cannot penetrate that region
b)c Stress on rake face is maximum at the region
c)c Tool strength is minimum at that region
d)c Tool temperature is maximum at that region

69.c Consider the following tool materials:

a)c HSS b) Cemented carbide c) Ceramics d) Diamond
The correct sequence of these materials in decreasing order of their cutting speed is
a)c 4, 3, 1, 2 b) 4, 3, 2, 1 c) 3, 4, 2, 1 d) 3, 4, 1, 2

70.c If Õ is the rake angle of the cutting tool. Ø is the shear angle and V is the cutting velocity, then
the velocity of chip sliding along the shear plane is given by
a)c b) c) d)

71.c For cutting of brass with single ± point cutting tool on a lathe, tool should have
a)c Negative rake angle. b) positive rake angle
c)Zero rake angle d) zero side relief angle

72.c Power consumption in metal cutting is mainly due to

a)c Tangential component of the force b) longitudinal component of the force
c)Normal component of the force d) friction at the metal ± tool interface

73.c In a shaper machine, the mechanism for tool feed is

a)c Geneva mechanism b) whitworth mechanism
c)Ratchet and pawl mechanism d) ward ± leonard system

74.c Specific cutting energy is more in grinding process compared to turning because
a)c Grinding (cutting) speed is higher
b)c The wheel has multiple cutting edges (grains)
c)c Ploughing force is significant due to small chip size
d)c Grinding wheel undergoes continuous wear

75.c The ratio of thrust force to cutting force is nearly 2.5 in

a)c Turning b) broaching c) grinding d) plain milling

76.c The following parameters determine the model of continuous chip formation:
1.c True feed 2. Cutting velocity 3. Chip thickness 4. Rake angle of the
cutting tool
The parameters which govern the value of shear angel would include
a)c 1, 2 and 3 b) 1, 3 and 4 c) 1, 2 and 4 d) 2, 3 and 4




 
 




77.c Consider the following statements about nose radius

1.c It improves tool life 2. It reduces the cutting force 3. It improves the surface finish
of these statements:
a)c 1 and 2 are correct b) 2 and 3 are correct
c)1 and 3 are correct d) 1, 2 and 3 are correct

78.c The compositions of some of the alloy steels are as under:

1.c 18 W 4 Cr 1 V 2. 12 Mo 1 W 4 Cr 1 V
2.c 6 Mo 6 W Cr 1 V 4. 18 M 8 Cr 1 V
The compositions of commonly used high speed steels would include
a)c 1 and 2 b) 2 and 3 c) 1 and 4 d) 1 and 3

79.c Match list ± I with list ± II and select the correct answer using the codes given below the list:
List ± I (Wear type) List ± II (Associated mechanism)
A.c Abrasive wear 1. Galvanic action
B.c Adhesive wear 2. Ploughing action
C.c Electrolytic wear 3. Molecular transfer
D.c Diffusion wear 4. Plastic deformation
Metallic bond
A B C D A B C D
a) 2 5 1 3 b) 5 2 1 3
 c) 2 1 3 4 d) 5 2 3 4

80. Consider the following work materials

1. Titanium 2. Mild steel 3. Stainless steel 4. Grey cast iron
The correct sequence of these materials in terms of increasing order of difficulty in machining is
a)c 4, 2, 3, 1 b) 4, 2, 1, 3 c) 2, 4, 3, 1 d) 2, 4, 1, 3

81.c The limit to the maximum hardness of work material which can be machined with HSS tools even
at low speeds is set be which one of the following tool failure mechanisms?
a)c Attrition b) Abrasion
c)Diffusion d) Plastic deformation under compression

82.c Notch wear at the outside edge of the depth of cut is due to
a)c Abrasive action of the work hardened chip material
b)c Oxidation c) Slip ± stick action of the chip d) chipping

83.c In turning of slender rods, it is necessary to keep the transverse force minimum mainly to
a)c Improve the surface finish b) increase productively
c)Improve cutting efficiency d) reduce vibrations and chatter

84.c Which of the following forces are measured directly by strain gauges or force dynamometers
during metal cutting?
1.c Force exerted by the tool on the chip acting normally to the tool face
2.c Horizontal cutting force exerted by the tool on the work piece
3.c Frictional resistance of the fool against the chip flow acting along the tool face
4.c Vertical force which helps in holding the tool in position
a)c 1 and 3 b) 2 and 4 c) 1 and 4 d) 2 and 3




 
 





85.c Consider the following forces acting on a finish turning tool

1.c Feed force 2. Thrust force 3. Cutting force
The correct sequence of the decreasing order of the magnitudes of these forces is
a)c 1, 2, 3 b) 2, 3, 1 c) 3, 1, 2 d) 3, 2, 1

86.c Which of the following are the advantages of a hydraulic shaper over a mechanically driven
shaper?
1.c More strokes per minute can be obtained at a given cutting speed
2.c The cutting stroke has a definite stopping point
3.c It is simple in construction
4.c Cutting speed is constant throughout most of the cutting stroke
Select the correct answer using the codes given below:
a)c 1 and 2 b) 1 and 4 c) 2 and 4 d) 1,3 and 4

87.c Consider the following criteria is evaluating machinability:

1.c Surface finish 2. Type of chips 3. Tool life 4. Power consumption
In modern high speed CNC machining with coated carbide tools, the correct sequence of these
criteria in DECREASING order of their importance is
a)c 1,2,4,3 b) 2,1,4,3 c) 1,2,3,4 d) 2,1,3,4

88.c The guage factor of resistive pick-up cutting dynamometer is defined as the ratio of
a)c Applied strain to the resistance of the wire
b)c The proportional change in resistance to the applied strain
c)c The resistance to the applied strain
d)c Change in resistance to the applied strain

89.c The magnitude of the cutting speed for maximum profit rate must be
a)c In between the speeds for minimum cost and maximum production rate
b)c Higher than the speed for maximum production rate
c)c Below the speed for minimum cost
d)c Equal to the speed for minimum cost

90.c Power consumption in metal cutting is mainly due to

a)c Tangential component of the force b) longitudinal component of the force
c)Normal component of the force d) friction at the metal ± tool interface

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91.c The tool for spinning copper is usually made for
a)c Brass b) copper c) tool steel d) aluminum

92.c The cutting force and thrust force in an orthogonal cutting operation are found to be 76 kg and 50
kg respectively. The width of cut is 3 mm, depth of cut is 0.5 mm and chip thickness is 1.2 mm.
Assuming rake angle to be 0, the specific cutting energy would be
a)c 21.1 kg/mm b) 33.3 kg/mm c) 50.7 kg/mm d) 83.3 kg/mm

93.c During an orthogonal machining operation if the cutting speed is increased, the power
consumption
a)c Reduces because the cutting force drops with an increase in the cutting speed
b)c Increases though the cutting force drops with an increase in the cutting speed
c)c Remains unchanged as it depends on the depth of cut and the feed only
d)c May decrease or increase depending on other conditions




 
 




94.c In machining cast iron using a high ± speed steel tool, a 10% change in cutting speed will result in
a change in tool life approximately equal to
a)c 10% b) 20% c) 40% d) 80%

95.c Consider the following pairs:

1.c Rough machining of cast iron
2.c Finish machining of steel
3.c Finish machining of aluminum
4.c Rough machining of steel
Of these pairs
a)c 2, 3 and 4 are correctly matched
c)1, 2 and 4 are correctly matched
- sintered carbide of grade K 30
- sintered carbide of grade P 10
- sintered carbide of grade K 10
- sintered carbide of grade K 30
b) 1, 3 and 4 are correctly matched
d) 1, 2 and 3 are correctly matched

96.c Helix angle of a twist drill has direct effect on the

a)c Clearance angle b) rake angel c) inclination angle d) point angle

97.c Consider the following cutting tool materials used for metal ± cutting operation at high speed:
1.c Tungsten carbide 2. Cemented titanium carbide
2.c High ± speed steel 4. Ceramet
The correct sequence in increasing order of the range of cutting speeds for optimum use of these
materials is
a)c 3,1,4,2 b) 1,3,2,4 c) 3,1,2,4 d) 1,3,4,2

98.c Match list ± I (cutting tool materials) with List ± II (fabrication processes) and select the correct
answer using the codes given below lists:
List ± I List ± II
A.c HSS 1. Casting
B.c Satellite 2. Powder metallurgy
C.c Carbide 3. Forging
D.c UCON 4. Extrusion
1.c Rolling
(
a)c A B C D (3 1 2 4) b) A B C D (1 5 3 4) c) A B C D (2 4 3 5) d) A B C D (3 1 2 5)

99.c Throwaway tungsten carbide tip tools are manufactured by
a)c Forging b) brazing c) powder metallurgy d) extrusion

100.cIn an orthogonal cutting process, rake angle of the tool is 20 and friction angle is 25.5. using
merchant shear angel relationship, the value of shear angle will be
a)c 39.5 b) 42.25 c) 47.75 d) 50.5

101.c The approximate variation of the tool life exponent µn¶ of cemented carbide tools is 
a)c 0.03 to 0.08 b) 0.08 to 0.20 c) 0.20 to 0.48 d) 0.48 to 0.70

102.cThe type of wear that occurs due to the cutting action of the particles in the cutting fluid is
referred to as
a)c Abrasion wear b) diffusion wear c) erosive wear d) corrosive wear

103.cThe cutting velocity in m/sec, for turning a work piece of diameter 100mm at the spindle speed
of 480 RPM is
a)c 1.26 b) 2.51 c) 48 d) 151




 
 




104.cIn the Taylor¶s tool life equation, V T = C, the value f N = 0.5. The tool has a life of 180 minutes at
a cutting speed of 18 m/min. if the tool life is reduced to 45minute, then the cutting speed will be
a)c 9m/min b) 18m/min c) 36m/min d) 72m/min

105.cIn turning, the ratio of the optimum cutting speed of minimum cost and optimum cutting speed for
maximum rate of production is always
a)c Equal to 1 b) in the range of 0.6 to 1
b)c In the range of 0.1 to 0.6 d) greater than 1

106.cThe tool life increases with the

a)c Increase in side cutting edge angle 
b)c Decrease in side rake angle
c)c Decrease in nose radius
d)c Decrease in back rake angle

107.cGiven that, S = feed in mm/rev and; R = nose radius in mm, the maximum height of surface
roughness Hmax produced by a single - point turning tool is given by
a)c S2/ 2R b) S2 / 4R c) S2 / 6R d) S2 / 8R

108.c Consider the following characteristics 
1.c The cutting edge is normal to the cutting velocity
2.c The cutting forces occur in two directions only
3.c The cutting edge is wider than the depth of cut
The characteristics applicable to orthogonal cutting would include
a)c 1 and 2 b) 1 and 3 c) 2 and 3 d) 1, 2 and 3

109.cIn an orthogonal cutting, the depth of cut is halved and the feed rate is doubled. It the chip thickness
ratio is unaffected with the changed cutting condition, the actual chip thickness will be
a)c Doubled b) halved c) quadrupled d) unchanged

110.cIn a single point turning operation with a cemented carbide and steel combination having a Taylor
exponent of 0.25, if the cutting speed is halved, then the tool life will become
a)c Half b) two times c)eight times d) sixteen times

111.c The chip thickness ratio r is given by

112.c Consider the following statements: the tool life is increased by

1.c Built ± up edge formation 2. Increasing cutting velocity
2.c Increasing back rake angle up to certain value
Which of these statements are correct?
a)c 1 and 3 b) 1 and 2 c) 2 and 3 d) 1, 2 and 3

113.c Assertion (A): During cutting, the diamond tool is keep flooded with coolant.
Reason (R): The oxidation of diamond starts at about 450c.




 
 
 



114.c Match list ± I (Cutting tool material) with list ± II (typical value of tool life exponent µn¶ in the
Taylor¶s equation V. T = C) and select the correct answer using the codes given below the lists:
List - I List ± II
A.c HSS 1. 0.18
B.c Cast alloy 2. 0.12
C.c Ceramic 3. 0.25
D.c Sintered carbide 4. 0.50
(
a)c A B C D (1 2 3 4) b) A B C D (2 1 3 4) c) A B C D (2 1 4 3) d) A B C D (1 2 4 3)

115.c Which of the following tool materials have cobalt as a constituent element?
1.c Tungsten carbide 2. CBN 3. Stellite 4. UCON
Select the correct answer using the codes the codes given below:
a)c 1 and 2 b) 1 and 3 c) 1 and 4 d) 2 and 3

116.c Assertion (A): Cutting tools made of high carbon steel have shorter tool life.
Reason (R): During machining, the tip of the cutting tool is heated to 600/700c which causes the
tool tip to lose its harness.

117.c Consider the following machining conditions:

1.c Ductile material 2. High cutting speed
2.c Small rake angle 4. Small uncut chip thickness
Continuous chips without built ± up edge would be formed under the machining conditions listed at
a)c 1, 2 and 4 b) 1, 2 and 3 c) 2, 3 and 4 d) 1, 3 and 4

118.c In turning, the ratio of the optimum cutting speed of minimum cost and optimum cutting speed
for maximum rate of production is always
a)c Equal to 1 b) in the range of 0.6 to 1
c) in the range of 0.1 to 0.6 d)Greater than 1

119.c Which of the following processes can be used for producing thin, hard, wear resistant coatings
such at Tin, on HSS?
1.c Physical vapour deposition 2. Sintering under reducing atmosphere
2.c Chemical vapour deposition with post treatment 4. Plasma spraying
Select the correct answer using the codes given below:
(
a)c 1 and 3 b) 2 and 3 c) 2 and 4 d) 1 and 4

120.c Match list ± I with list ± II and select the correct answer using the codes given below the lists:
List ± I List ± II
A.c Stellite 1. Tungsten
B.c H.S.S 2. Cobalt
C.c Ceramic 3. Alumina
D.c UCON 4. Columbium
i.c Titanium
(
a)c A B C D (5 1 3 4) b) A B C D (2 1 4 3) c) A B C D (2 1 3 4) d) A B C D (2 5 3 4)

121.c Assertion (A): An increase in depth of cut shortens the tool life.
Reason (R): Increase in depth of cut gives rise to relatively small increase in tool temperature.




 
 
 



122.c Assertion (A): The characteristic feature of high speed steel is its red hardness
Reason (R): Chromium and cobalt in high speed steel promote marten site formation when the tool is
cold worked
(
a)c Both A and R are true and R is the correct explanation of A
b)c Both A and R are true but R is not a correct explanation of A
c)c A is true but R is false
d)c A is false but R is true

123.c Assertion (A): Cemented carbide tool tips are produced by powder metallurgy
Reason (R): Carbides cannot be melted and cast

124.c Thrust force will increase with the increase in

a)c Side cutting edge angle b) tool nose radius
c)Rake angle d) end cutting edge angle

m  
3 Ú

125.c During turning a steel rod at feed 0.25 mm per revolution and depth of cut 4.00 mm by a tool of
geometry (mm); the following observation were made Tangential force
= 1,600 N, Axial force in feed direction = 800 N, chip thickness = 0.60mm. the coefficient of friction
between chip tool interface is
a)c 0.2 b) 0.5 c) 0.8 d) 1.0

126.c In orthogonal cutting of a steel tube of wall thickness 4mm on a center lathe at a cutting
Speed of 40m/min, feel of 0.1 mm/rev, tool normal rake of 10, the chip thick of 0.3mm and cutting
force components measured using a 2 component dynamometer mounted on the tool post were as
follows, horizontal component is 1000N, vertical component is 2000N.
I.c mean shear strength of the work material in the primary shear zone is «««««««..
II.c specific cutting energy in MN/sq.m
a)c 2000 b) 3000 c) 4000 d) 5000

127.c In an orthogonal cutting operation the cutting force and the thrust force were respectively 900 and
600N. The rake angel was 0. Depth of cut 0.5mm, width of cut is 2.5mm and chip thickness 1mm.
Using merchant¶s model
I.c The specific cutting energy is «««««««««..
II.c The shear strength of the work material ««««««««

128.c In a turning trail using orthogonal tool geometry a chip length of 84mm was obtained for an uncut
chip length of 200mm. The cutting conditions were V = 30m/min, t1 = 0.5mm, rake angle = 20,
cutting tool HSS.
I.c The shear plane angle is
a)c 15 b) 20 c) 25 d) 30
II.c The chip thickness and shear plane angle for minimum chip strain.
a)c 0.8 and 60 b) 1.2 and 60 c) 0.8 and 35 d) 1.2 and 35

129.cA throw away carbide insert was used to machine a steel work piece with a cutting speed of
60m/min and tool life 40min. When the speed was increased to 100m/min the tool life was reduced to
10min.
i.c The cutting speed for maximum productivity, if the tool change time is 2min.
a)c 148m/min b) 45m/min c) 85m/min d) 233m/min
ii.c The cutting speed for maximum productivity, if the tool change time is 2min.




 
 




a)c 1min b) 1.7min c) 2.8min d) 3.4min

130.c50 flat pieces 1mm thick and initial dimensions of 205 X 30 are to be milled in a single cut to final
dimension of 205 X 25 using end milling. If the cutter of diameter 25mm has 10 teeth and rotates at
100rpm. The maximum uncut chip thickness if the horizontal feed of the table is 10mm/min, and
assuming single tooth in contact,
a)c 2 m b) 3.5 m c) 4.5 m d) 5.5 m

131.c A drilling machine is to be designed to have 6 spindle speeds ranging from about 110rpm to
about 650rpm. Assuming proper series for the lay out of the speeds the third speed will be«..
a)c 155 b) 225 c) 315 d) 440

132.c While turning a C15 steel rod of 160mm diameter at 315rpm. 2.5mm depth of cut and feed of
0.16mm per rev, by a tool of geometry . The following observations were made.
Tangential component of cutting force is 500N, axial component of cutting force 200N, chip thick
0.48mm, the dynamic yield strength of the work material is
a)c 214Mpa b) 316Mpa c) 187Mpa d) 416Mpa

133.c The Taylor¶s equation for tool life. Is defined as VT = C, the units of V and T are
a)c m/sec & min b) m/sec and sec c) m/min & sec d) m/min & min

134.c A single point cutting tool made of HSS has the values of constant C = 80 and n = 0.2 in the basic
tool life equation. If the tool cost per regrind is Rs.2 and the machine hour rate is Rs.30
i.c The most economical cutting speed is
a)c 16min b) 45.95 min c) 35.6m/min d) 45.95m/min
ii.c The most economical tool life is
a) 16min b) 45.95 min c) 35.6m/min d) 45.95m/min

135.c In an orthogonal cutting operation on a work piece of width 2.5mm, the uncut chip thickness was
0.25mm and the rake angle was 0. It was observed that the chip thickness was 1.25mm. The cutting
force was measured to be 900N and thrust force to be 810N.
i.c The shear strength of the work material is ««««««««««.
a)c 178 b) 227 c) 272 d) None
ii.c If the coefficient of friction between the chip and the tool was 0.5, what is the machining
constant is
a)c 90deg b) 95deg c) 85deg d) 49.2deg

136.c In an orthogonal cutting process the following observation were made depth of cut is 0.25mm,
chip thickness ratio is 0.45, width of cut is 4mm, cutting velocity 40m/min, cutting force component
parallel to cutting velocity vector 1150N, cutting force component normal to cutting velocity vector
140N, rake angle of the tool is 18.
i.c The diameter of the merchants circle if 1 N = 2mm
a)c 579.25mm b) 1158.5mm c) 2318mm d) None
ii.c The power of cutting is «««««««««««
iii.c The force component parallel to shear plane is «««««««««««..
a)c 423N b) 769N c) 968N d) 1051N

137.c A mild steel block of width 40mm is being milled using a straight stab cutter 70mm diameter
with 30 teeth. If the cutter rotates at 40rpm and the depth of cut is 2mm. the value of maximum uncut
chip thickness when the table feed is 30mm/min
a)c 8.45mm b) 8.45cm c) 8.45 microns d) None




 
 




138.c The merchant¶s constant for aluminum for the following orthogonal machining data. Rake angle
of tool is 35, cutting force 200N, thrust force 90N, uncut chip thickness is 0.15mm, chip thickness
0.3mm with of cut 2.5mm, cutting speed 30m/min is
a)c 59.22 b) 89.08 c) 64.36 d) 83.95

139.c For certain metal cutting process work material is steel, UTS = 980MN/sq.m, tool materials HSS,
depth of cut 1.6mm, feed 0.8mm/rev, cutting speed 5.5m/min, power consumed = 0.67KW. The MRR
and the specific cutting pressure for the above cutting conditions are.
a)c 7.04mm/min b) 7040mm/min c) 7040cc/min d) 7.04cc/min

140.c A MS block is being drilled with a drill of 10mm dia. given, helix angle = 30, point angle = 118,
feed = 0.2mm/rev, shear stress =450N/sq.mm. the drilling torque and thrust using min work criteria
shear angle relation. Assume = 0.75 of the tool life exponent is n = 0.125«««.

142.c During the conventional turning of a MS bar of 75mm dia, the observations made are turning tool
is mm, depth of cut = 2mm, feed = 0.15mm/rev, speed = 300rpm,
shear stress = 450N/sq.mm, = 0.8. The three components of turning force following lee and Shaffer
shear angle relation is ««««««««««««.

143.c A tube is orthogonally machined in a lathe to reduce its length under the following conditions.
Outside diameter of the tube 100mm, inside diameter of the cube 96mm, RPM of the work piece 120,
longitudinal feed 0.5mm/rev, cutting ratio 0.3, tangential force 800N, axial force 600N. the total
power consumption is KW is
a)c 502 b) 256 c) 1.04 d) 0.5

144.c In an orthogonal cutting the following observations were made. Uncut chip thickness 0.25mm, t2
= 0.75mm. Fc = 900N, Ft = 450 N, V = 1m/sec, rake angle 0.
I.c The shear angle is ««««««.
a)c 13.2 b) 16.4 c) 18.4 d) 22.2
II.c The total power in making the cut in KW is «««««««««..
a)c 0.45 b) 0.9 c) 1.35 d) None
III.c The coefficient of friction between the chip and tool is «««««««««.
a)c 26.56 b) 18.42 c) 42.5 d) None

145.c Two cutting tools are being tried for an operation, tailor¶s tool life equations for them are as
follows: HSS tool, VT0.1= 200, carbide tool VT0.35 = 500. At a cutting speed of 50m/min which tool
is Economical
a)c HSS b) carbide c) both d) none

146.c The heat generated in metal cutting is dissipated to different proportions into the environment
tool, chip, and work piece. The correct order of proportion in decreasing magnitude is (no cutting
fluid is used) ««««««««««««.
147.c Side cutting edge angle (according to American system) of a single point tool is 30 and this
cutting edge lies in a plane parallel to the base of the tool. The effective rake angle measured in a
plane perpendicular to both the base and the cutting edge is 20. The back rake and side rake angles
are««««««««««««.
a)c 10.3 & 17.5 b) 17.5 & 10.3 c) 12.9 & 16.2 d) 16.2 & 12.9

148.c A conventional lathe and a CNC lathe are under consideration for machining a given part. The
relevant date are shown below:
Preparation Cost Production time Machine and



 
 




(Rs) per part (min) operator cost (Rs)

 Conventional Lathe 30 30 75
 CNC Lathe 150 15 120
The machine preferred for producing 100 pieces is
a)c Conventional lathe b) CNC lathe c) Any of the above d) None

149.c In orthogonal machining of MS with cutting tool having a rake angle of 10deg, the chip thickness is
measured to be 0.4mm. The uncut chip thickness is 0.2mm and the width of cut is 2mm. for a cutting
speed of 200mm/min and a shear stress of 400N/mm for the material, use merchants relation: 2  + 
± Õ = 90deg where 2 is shear angle, Ȝ is friction angle and Õ is the back rake angle. The specific
energy (in J/mm) is cutting is««««««««««.
a)c 1483 b) 148.3 c) 14.83 d) 1.483




 
 




  


"m!"
Let f = Feed in mm/rev d = depth of cut
N = speed of job in RPM = 1000 V/ lD D = outer diameter of job in mm
L = Length of tool travel = length of job + approach + over run

Time per cut = T = min

Total Time = Time per cut X no.of cuts = Txn


n = number of cuts =

where Dr = required final diameter in mm
Note : Planning is used to reduce diameter of a job.

"
Ö
Time per cut = T = 
min
Here L = D/2 for slid jobs = (    /2 for hallow jobs
 , Di = outer and inner diameter respective
Note: Facing is used to reduce length of job
Total Time = T x n
N = number of cuts = Li ± Lf / d
Where Li , Lf=initial and final length of job d =depth of cut
Note : In face turning trust force is greater than cutting force (FT > Fe)
Thread cutting :
Ö
T =  = Time / cut
Here f= pitch of threads L = length of tool travel
Total time = T x n
n = number of cuts = 25 / TPC for external threads
= 30 / TCP for internal threads
Where TPC = Threads per cm

$"

Tan
 Ö
" £"9,4-:-((9($&"
Ö
Average time per cut = = Ta


La = Avg. length of tool travel = L1 + Ln/2

L1 = length of tool travel in first cut = d / Sin

Ln = length of tool travel in last cut = nd / Sin

N= number of cuts d = depth of cut
Total time for turning = n x Ta




 
 




&!"!!&("&("
During cutting of threads on lathe we have to control the movement of tool with respect to work.
Here the work is always rotating but this rotation is transferred to lead screen through gear box, the tool
will move as the lead screw moves. If the rotation of work and lead screw are equal then the number of
threads produced per unit length is equal to the number per threads per unit length on lead screw.
¥Train value = Gear Ratio = speed of follower / Speed of driver
=no. of teeth on driver gear / no. of teeth on driver gear
=pitch to be cut on job (mm) / pitch on lead screw(mm)
=Lead of job threads (mm) / lad of lead screw threads (mm)
Lead = number of starts x pitch
In general on lathe change gears are available in the range of 20 to 120 with 5 teeth step that is
20, 25, 30, 335, «««..120 and one 127 teeth gear is available for cutting British threads. Also for each
teeth one gear is available
Note: Threads per unit length on lead screw is called lathe constant.
Ex: Calculate suitable gear trains for cutting 10 mm pitch 3 starts on a lathe with a lead screw having 6.25
mm pitch. How can you change the hand of thread and how can you cut second and third start threads.
Note: For cutting left hand threads the spindle and lead screw must rotate in the same direction that is
carriage should move from left to right (hand stock to tail stock). So during design of change gears:
i)c If we get compound gear train, the rotation is in same direction, so we have to use 0 (or)
4««««.. even number of idlers
ii)c If we get simple gear train, the rotation is opposite we have to use 1, (or) 3, (or) ««« odd
number of idlers.
Similarly for R.H.threads the whole story is just reversed.
Note: For getting different start the carriage has to be engaged at certain specified positions of half-nut
mechanism.
Ex2:Find the change wheels for cutting 1.75 mm pitch threads on a Lathe of 6 TPI lead screw.
Ex3:calculate the gears necessary to cut 16TPI. The lathe constant is 10, the gear progression is $ and the
gears available are 24, 28, 32, ««..100.
Ex4:Calculat gears train needed to cut a 2 mm thread on an English Lathe. The lathe constant is 8, the
gear progression is and the gears available are 24, 28, 32««.100 and 127.
Range of speeds: in general , lathe or drilling or milling machine will have two or more speeds which are
in the geometric progression.
Let S = first speed
N = n th speed
R = common ratio between any consecutive speeds
1st speed = S
2nd speed = r.S
3rd speed = Ó  .S
nth speed = N = Ó  .S
   
¥ = x  ««««.X
 
 

$"!&
Common methods of taper turning are
1.Compound rest method 2.Tail stock set-over method 3.taper attachment method
4.Forming tool method
,7 $"( &(
The base can be swiveled for any angle on a graduate circular base. The swiveling angle can be
calculated as

Tan
= Ö




 
 





Where D = larger diameter d = smaller diameter

L = length of taper on job 
= swiveling angel
This method can be used to feed the tool at the required angle manually

!'8 &( used for small tapers on long jobs for external tapers only. It requires that
the centre line of the work piece be offset from the centre line of the machine. The tool traces a path
parallel to the centre line of the machine.
Normally offset of the tail stock may be toward the rear of the machine, in which case big end of taper
will be at the tail stock end of the work.
¢Ö

Offset= Ö
where Lw = total length of work
Lt = taper length

Let Tt = taper per cm = Ö

Imaginary larger diameter = Di = [Tt(LT +length of large dia side)] + smaller dia(d)
Imaginary smaller dia = di =D-Tt9lt + Smaller dia side length)
Ex: D = 3 ; d = 2 and with the above fig dimension

¢   !"

Tt = Ö
= 
=  !"

¢Ö
¢
 #
Offset = Ö
= = cm
 $

Imaginary larger dia = Di=(1/20)(20+15) + 2 =3.75

Imaginary smaller dia = di =3- (1/20)(20+10) = 1.5

 

Off set = 
= 
= 1.125

$"&  &( First cross slide is disconnected from the saddle so that it is free to
move along its ways. Now the taper turning attachment guide plate is swilled to get the required angle.

¥M= xC
Ö
M = the required no. of mm division through which the guide plate is to be swiveled.
D = large dia in mm d = smaller dia in mm L = length of taper in mm
C = half of the total length of guide plate in mm.
In general max included angle is 16 degrees and max. length of taper of that can be turned in one
setting is 235 mm.

 ! &(This tool is such that it can have half the taper angle. Used only for short tapers
say up to max of 20mm length.


&$(m!
Let M = the ratio of return stroke time to cutting stroke time (or) ratio of velocity of cutting stroke
to the return stroke.
M < 1 (always) V = Velocity of ram during cutting stroke (or) cutting speed in m / min
-Time for cutting stroke = L / V
L = length of tool travel = length of stroke = length of job + approach + over run
Time fro Return stroke = time for cutting stroke x M = L/V(M)
-Total time for double stroke = Time for cutting stroke + Return stroke
=(L / V) + (LM / V) =(L / V) (I + M)
Note: Double stroke is nothing but one cutting stroke plus one return stroke.



 
 




Let B = width of job f = feed / stroke (double)

-No . of double strokes per cut = (B/ f)
Let N = no. of double strokes per min = 9V / [L (1 + M)]
%%& %'()*+,%-**,'+
Total time per cut = 
= B / fN

!!
Machine tie = L/fN where L =length of tool travel = depth of hole + 0.3 D for blind hole = depth
of hole + 0.5 D²for through hole, D = dia of the drill bit

0.3 D and 0.5D are the approach and over run in drilling. These are compulsory whether he asked to
consider or not, Some times he will give approach and over run in the problems , in such cases , the given
given amount is added to the above values.

!!
Let Z = no. of teeth on the periphery of the cutter
Ft = feed fpr tooth fr = feed per revolution = ft x Z
Fm = feed per min = L / frN = L / ftZN
L = length of tool travel to complete cut = length of job + approach + over run.
Milling is done in two ways
a)Slab milling b)Face (End) milling

!£ !!It is done with a cutter having teeth on its periphery. This is used for cutting key ways and
slots.
Let D = dia of cutter d = depth of cut
Approach = «
(D ± d)

  !!

Approach = ½ [D - «  - .  ]
Where w = width of job

3&In this chapter our aim is to determine the effective length of broach and machining time for
broaching
Let Ei = Effective length of broach d = depth of cut thickness of metal to be removed
P = pitch of broach teeth h = rise per tooth
El = no. of teeth x pitch of teeth = [d / h]p
In general a broach will have three types of teeth which are
a)roughing teeth b)semi-finishing teeth c)finishing teeth.

Rise per tooth in roughing teeth is greater than semi finishing and which is greater semi- finishing teeth
-Effective length of broach = effective length of rough teeth + effective length of semi finishing
teeth + Effective length of finishing teeth

Machining time = Effective length of broach / cutting speed = El / V


(Grinding is a machining operation where in each abrasive will act as a cutting tool. Because of
small size abrasive, the MRR will be reduces. The mechanism of grinding will be as follows:
0c The grains on the surface of a grinding wheel will take part in cutting and so called active abrasive
grains.
0c The sharp edges of active grains, wear out and become blunt gradually.
0c Resulting in larger forces on the active grains during machining.




 
 




0c When the cutting edge is too blunt and the force is sufficiently high, the grain may either get
fractured or break away from the wheel.
0c When a fracture takes place, new sharp cutting edges are generated and when the whole grain is
removed, new grains becomes exposed and active. This gives the Gw self sharpening characteristics.
0c The specific cutting energy of grinding is more because of
a)c Due to the nature of the process, very hot and small chips ae produced which may readily get
welded to either the abrasive grit or back on to the work piece.
b)c Due to random abrasive grit orientation, a no. of grits may have very large ±ve rake angle and
may rub rather than
c)c Since the material is removed in the form of exceedingly small chips, the size effect is very
prominent.

&(These are two types a)Plunge grinding b)Surface grinding
Let us consider plunge grinding
t1 = uncut chip thickness per grit in mm f = feed off the job in mm / mim
Z = no. of active grains per revolution in one line N = RPM of the wheel
-t1 = f / Z N mm
³Z´ also can be found out as
Z = l D C b D = dia of the wheel in mm C = Surface density of active grains /  
B = avg. grain width of cut in mm
Let rg = ratio of width to uncut chip thickness = b / t1 = the value varies between 10 and 20
By substituting the above
t1 = /0 / l D C N rg
Note: Uncut section have approximately triangular cross section.
Let Uc = specific energy
The power required = W =(MRR . Uc / 60) = (A f Uc / 0)
Where A = cross sectional area of job ( )
The force per single grit works out to be Fc = (60W / Z N)««««KN
=(f Uc) / (l 1  

Note: A wheel appears to be softer if D, C or N decrease or f increase and vice cersa.

Surface Grinding: Here also uncut cross section is triangular but thickness and width are not constant, that
is it has max values of t1max, bmax and min values as zero like in milling
-Avg. length of chip = l= /¢
 where D = dia. Of grinding wheel,
D = depth of cut

timax =234 5 Ó («
/ D)]
mRR = fdB, where B = width of cut in mm
-Power require =W=(MRRUc / 60)W = Bd f Uc / 60

7Ñ7
$ For easy selevction an identifying a grinding wheel, it can be designated with
a)Five factors indicating abrasive type, grit sie, grade, structure and bond
b)A prefix number which is optional indicating manufactures code number to indicate exact type of
abrasive
c)A suffix number which is also optional indicating manufactures code number








 
 
 



 &8
4 indicates the type of abrasive
A ± A  6 (Aluminium oxide)
C ± Sic (Silicon carbide)
D ± Diamond
All the above are synthetic abrasives, but natural abrasives are emery, quartz, sand stone garnet
etc. the natural abrasives are not widely used for precision grinding because of the impurities in their
structures.

Îc SiC is harder than A  6 and dulls rapidly

Îc SiC is more brittle and so less tougher than A  6
Îc A  6 is will withstand greater stresses than SiC
Îc A  6 
Ó


Ó


Ó such as steel, bronze,
wrought iron etc.
Îc SiC is used to grind low tensile strength material and non metallic material such as gray iron,
stainless steel, marble stone, rubber etc.

( ± indicates grain size or grit size

It it indicated by number
10 ± 24 -----coarse
30 ± 60------medium
70 ± 180-----fine
220 ± 600 ----very fine
Grit size indicates the actual size of abrasive grit. Normally the shape of abrasive is assumed as square
Îc Larger the size of grains, more MRR but quality of surface finish is less
Îc -So grain size is selected based on surface finish required

&(%%%%indicates grade
It refers to the strength of the bond. The hardness of a wheel refers tto the strength of the bond,
but not the hardness of the grit. Hard wheels means strong bonding and the abrasives can with stand for
higher cutting forces. Even though the abrasive is diamond , if the bonding is soft then it breaks easily.
A to H ----- soft
J to P --------medium
Q to Z --------- hard

Îc Soft wheels for hard work and hard wheels for soft work
Îc When the work material is share, the grains wear out easily and the sharpness of the cutting edges
is quickly lost. It is called glazing of the wheel
Îc Glazed wheel cuts less and rubs more
Îc Too hard a wheel caused glazing and too soft a wheel wears out very fast
Îc Grade of G.W can be selected base on
Îc A)Rough grinding jobs require harder grades and precision grinding require softer grades
Îc B)Harder the work, softer the wheel and vice versa
Îc C)Area of contact is less, harder grades is required
Îc D)As the ratio of speed of work to speed of wheel increases, harder wheel is required because the
grinding action is softer
Îc E)Harder grades are used if coolants are used
Îc F)Harder grades should also be used on old machines where vibrations is likely to be present.




 
 
 



"&Indicates structure and indicated by a number

0 to 7 ± dense
8 to 16 ± open
G.W is similar to milling cutter with large number of teeth at randomly oriented, it must have
voids to allow space for the chips.
- If the voids are too small for the chips, the chips stay in the wheel, blocking the voids called loading
- If the voids are too large, very few cutting edges will be available
- In open structure grain are not too densely packed
- In closed structure grains are tightly packed
- For grinding soft work, chips are large and to reduce loading open structure is preferred.
- Rough cut require open structure

& Indicates bond and indicates by a letter as

V = vitrified
B = resinoid
S = Silicate
R = Rubber
E = Shellac
-most common is vitrified because it is strong and rigid
- Rubber bond is used for making flexible wheels
-V and S are organic bond and B, R and E are celluloid and oxidizing materials.
-Vitrified bonds are used for fast cutting and general industrial finishing
-Silicate bonds are restricted to grinding fine edges on cutting tools and broad contact surface grinding
operation. Also very large wheels should be silicate bonded
-Rubber and shellac bonds are used for making buffering wheels
Ex: The sides of a HSS cutting tool bar have to be finish ground bon a surface grinder. The machine
restricts the dia of wheel to 150 mm and no coolant is used find out the type of wheel require for the
operation.

m8"4&!£
8

1.c A lead screw with half nuts in a lathe, free to rotate in both directions has (2002)
a)V-Threads b)With-worth threads c)Buttress threads d)Acme threads

2.c The hardness of a grinding wheel is determined by the (2002)

a)hardness of abrasive grains b)ability of the bond to retain abrasives
c)hardness of the bond d)ability of the grinding wheel to penetrate the work piece

3.c Allowance in limits and fits refers to (01)

a)maximum clearance between shaft and hole
b)minimum clearance between shaft and hole
c)difference between maximum and minimum sie of hole
d)difference between maximum and minimum size of shaft

4.c Abrasive material used in grinding wheel selected for grinding ferrous alloy is (2000)
a)SiC b)diamond c)Al203 d)boron carbide

5.c Deep hole drilling of small dia, say 0.2mm is done with EDM by selecting the tool material as (2000)
a)copper wire b)tungsten wire c)brass wire d)tungsten carbide




 
 




6. Ideal surface roughness ,as measured by the maximum height of unevenness, is best achieved when the
material is removed by
a)an end mill b) a grinding wheel c) a ball mill d) a tool with zero nose
radius

7. Helix angle of fast drill is normally

a)35 b)60 c) 90 d)5

8. Slip gages are calibrated by outside micrometers

9. Checking the dia of hole using GO,NO-GO geges is an example of inspection by-------
(variable/attributes)

10. A. talysurf 1.T-slots

B. Telescopic gage 2.flatness
C. auto callimeter 3.internal diameter
D. auto callimeter 4.rouhness

11. both the live center and dead center of center lathe are hardened and lubricated for reducing
friction and wear (T/F)

12. To have good surface finish on a turned job,one should use a tool with a------------feed and -----------
speed of rotation of the job.

13. A milling cutter having 10 teeth is rotating, at 100 rpm. The table feed is set at 50mm/min. feed per
tooth in millimeters is
a)0.5 b)0.2 c)0.05

m Ú

 4m


3 Ú


14. In with worth quick return mechanism (used in shapers) the velocity of the ram is maximum at(01)
a)middle of the forward stroke b) beginning of return stroke
c) end of return stroke d) none of the above

15. A grinding wheel is said to be glazed if

a) grains have become blunt, but do not fall out
b) gap between the grains is filled by swarf
c)it becomes black due to burning
d)part of the wheel is chipped off

16. Reamers have usually even number of teeth so that the cutting forces on teeth are properly
balanced( T/F)

17. Assertion: Grinding needs higher specific cutting energy than milling
Reasoning: Milling cutter material is harder than abrasive grains

18. In a grinding wheel marked with AA-48-L-7-V-25,L refers to

a)abrasive type b) wheel structure
c)wheel hardness d)manufacturers code




 
 





19. If the index crank of a dividing head is turned through one complete revolution and 10 holes in a 30
hole circlet plate ,the work piece turns through in ( degrees)
a) 6 b)12 c)240 d)480

20. A blind hole is better tapped with a tap having

a)right hand flutes b) left hand flutes c)straight flutes d)no flutes

21. The teeth of both external and internal spur gears can be cut on
a)milling machine b) gear shaping machine
c)gear hobbing machine d) gear shaving machine

22. Reamers have even number of flutes mainly to

a) have accurate measurement of its diameter b) align the reamer axis
c)balance the cutting force d)standardize by convention

23. A milling cutter having 8 cutting edges is rotating at 100 rpm. T he work piece is set at 40mm.min
the feed per tooth is
a)0.05 b)o.4 c)o.2 d)5

24. Assertion : single start threads are used for fastening purposes
Reason : single start threads are easier to produce in a lathe

26. Spline holes are machined by

a)milling b)boring c)drilling d)broaching



3 Ú

27. A boring machine is primarily used to
a)finish the hole b)drill the hole c)enlarge the hole
d)overcome the difficulty of costs and sizes of drills

28. Machine tool frame should have

a)high rigidity to weight ratio b) graphite in the form of nodules
c)low hardness d)high work hardness

29. Low helix angle drills are preferred for drilling holes in
a)plastics b)copper c)cast steel d)carbon steel

30. Which of the machine tools can be used for boring

1.Lathe 2.Drilling machine 3.Vertical milling machine
4.Horizontal milling machine
a)1,2,3 b)1,3,4 c)2 and 4 d)1,2,3,4

31. Tail stock set over method of taper turning in preferred for
a)internal tapers b)small tapers c)long slender tapers d)steep tapers

32. Which of the following statement incorrect with reference of lathe cutting tools?
a) The flank of the tool is the surface or surfaces below and adjacent to the cutting edges
b) The nose is the corner, arc, or chamfer joining the side cutting and the end cutting edges
c) The heel is the part of the tool which is shaped to produce the cutting edges and face
d) The base is that surface of the shank which bears against the support and takes tangent pressure
of the cut




 
 





33. Buffing wheels are made of

a)softer material b) cotton fabric c) carbon d)graphite

34. Consider the following parameters :

1.Grinding wheel diameter.
2.regulating wheel diameter
3.speed of the grinding wheel.
4.speed of the regulating wheel.
5.Angle between the axes of grinding and regulating wheels.
Among these parameters those which influence the axial the feed rate in centreless
Grinding would include
a)2,4 and 5 b)1,2 and 3 c)1,4and 5 d)3,4and 5

35.The main purpose of boring operation as, compared to drilling is to

a)drill a hole b)finish the drilled hole
c)correct the hole d)enlarge the existing hole

36.Climbing milling is chosen while machining because

a)the chip thickness increases gradually
b)it enables the cutter to dig in and start the cut
c)the specific power consumption is reduced
d)better surface finish can be obtained

37.Internal gears can be made by

a)hobbing b)shaping with pinion cutter
c)shaping with rack cutter d)milling

38. In centre less grinding ,the work piece centre will be

a)above the line joining the two wheels centers
b)below the line joining the two wheel centers
c)on the line joining the two wheel centers
d)at the intersection of the line joining the wheel centers with the work plate plane

39.A µ block¶ of information in NC machine program means

a)one row on tape b)a work comprising several rows on tape
c)one complete instruction d)one complete)e program for a job

40.Enlarging an existing circular hole with a rotating single point tool is called
a)boring b) drilling c) reaming d)internal turning

41.Consider the following operations :

1.cutting key way on shafts 2.cutting external screw threads
3.cutting teeth of spur gear 4.cutting external splines
Those which can be performed with milling cutters would include
a)1 and 2 b)2,3 and 4 c)1 and 3 d)1,2,3 and 4

42.In reaming process

a) metal removal rate is high b)high surface finish is obtained
c)high form accuracy is obtained d)high dimensional accuracy




 
 





43.The ratio between two consecutive spindle speeds diameter for a six ±speed drilling machine using
drills of diameter 6.25 to 25mm and at a cutting velocity of 18m/min is
a)1.02 b)1.32 c)1.06 d)1.82

44.In a transfer line

a)all the machine tools must be automatic
b)all the work stations form a closed loop
c)the cycle time if total time taken by all machining operations
d)all the machine tools must be of conventional and general purpose type

45.In the grinding wheels of A 60 G7 B23, B stands for

a)resinoid bond b)rubber bond c)shellac bond d)silicate bond

46.Soft materials cannot be economically ground due to

a)the high temperatures involved b)frequent wheel clogging
c)rapid wheel wear d)low work piece stiffness

47. In a milling operation two side milling cut mounted with a desired distance between them so that
both sides of a work piece can be milled simultaneously.
a)gang milling b)straddle milling c)string milling d)side milling

48. While cutting helical gears on a non-differential gear hobber, the feed change gear ratio is
a)independent of index change gear ratio b)dependent on speed change gear ratio
c)interrelated to index change gear ratio d)independent of speed and index change GR

49. A grinding wheel of 150mm diameter is rotating at 3000rpm. The grinding speed is
a)7.5 l m/s b)15 lm/s c)45 l m/s d)450 l m/s

50. Grinding wheel is said to be loaded when the

a)metal particles get embedded in the wheel surface blocking the inter-spaces between cutting
grains
b)bonding material comes on the surface and the wheel becomes blunt
c)work piece being ground comes to a stop in cylindrical grinding
d)grinding wheel stops because of very large depth of cut

51. Which of the following statements are correct ?

1.A boring machine is suitable for a job shop
2.A jig boring machine is designed specially for doing more accurate work when compared to a
Vertical milling machine
3.A vertical precision boring machine is suitable for boring holes in cylinder blocks and liners.
a)1, 2 and 3 b)1 and 2 c)2 and 3 d)1 and 3

52. Consider the following processes of gear manufacture:

1.Milling with form cutter 2.Rack type shaper(gear planner)
3.Rotary gear shaper (gear shaper) 4.Gear hobbing
The correct sequence of these processes in increasing order of accuracy of convolute profile of the
Gear is
a)3,2,4,1 b)2,3,4,1 c)3,2,1,4 d)2,3,1,4




 
 





54. Gear cutting on a milling machine using an involute profile cutter is a

a)gear forming process b)gear generating process
c)gear shaping process d)highly accurate gear producing process

55. Which of the following materials is used as the bonding material for grinding wheels?
a)silicon carbide b)sodium silicate c)Boron carbide d)Aluminum oxide

56. Consider the following statements: In up milling process,

1.The cutter starts the cut from the machined surface and proceeds upwards
2. The cutter starts the cut from the top surface and proceeds downwards
3.The job is fed in a direction opposite to that of cutter rotation
4.Rhe lob is fed in the same direction as that of cutter rotation
Of these statements
a)1 and 3 correct b)1 and 4 c)2 and 3 d)2 and 4

57.Match list-I (Gear component) with List-II (preferred method of manufacturing) and select the correct
answer using the codes given below the lists:

%     
%
ºc Gear for clocks 1. Hobbing
3c Bakelite gears 2. Stamping
¬c Aluminum compacting 3. Power compacting
~c Automobile transmission gears 4. Sand casting
5. Extrusion



A B C D A B C D
a)2 3 5 1 b) 5 3 4 2
c)5 1 2 3 d) 2 4 5 3

58. The type of quick return mechanism employed mostly in shaping machines is:
a)Dc reversible motor b)Fast and loose pulleys
c)Whit worth motion d)Slotted link mechanism

59. A single start thread of pitch 2mm is to be produced on a lathe having a lead screw with a double
Start thread of pitch 4mm. The ratio of speeds between the spindle and lead screw for this operation
Is
a)1 : 2 b)2 :1 c)1 : 4 d)4 : 1

60. Which one of the following pairs of parameters and effects is not correctly matched?
a)Large wheel diameter ± Reduced wheel wear
b)Large depth of cut ± Increased wheel wear
c)Large work diameter ±b Increased wheel wear
d)Large wheel speed ± Reduced wheel wear

61. A component requires a hole which must be within the two limits of 25.03 and 25.04 mm
Diameter. Which off the following statements about the reamer size are correct?
Vc Reamer size cannot be below 25.03mm
|c Reamer size cannot be above 25.04mm
c Reamer size can be 25.04mm
c Reamer size can be 25.03mm
Select the correct answers using codes given below
a)1 and 3 b)1 and 2 c)3 and 4 d)2 and 4



 
 






62. In tape preparation for an NC machine tool the code S 624 would represent spindle speeds of
a)624 rpm, 240 rpm and 246 rpm b)624 rpm and 240 rpm
c)624 rpm and 246 rpm d)240 rpm and 246 rpm

63. Match the List-I (Matching process) with List-II(associated medium) and select the correct
Answer using the codes given below the lists:

%   
%
ºc Ultrasonic machining 1. Kerosene
3c EDM 2. Abrasive slurry
¬c ECM 3. Vacuum
~c EBM 4. Salt solution



a) 2 3 4 1 b) 2 1 4 3 c) 4 1 2 3 d) 4 3 2 1

64. Match list-I (Drill bits) with List-II (Applications) and select the correct answer using the codes given
below the lists:

%     
%
A.c Core drill 1. To enlarge a hole to a certain depth so as to accommodate
The bolt head of a screw
B.c Reamer 2. To drill and enlarge an already existing hole in a casting
C.c Counter bore drill 3. To drill a hole before making internal thread
D.c Tap drill 4. To improve the surface finish and dimensional accuracy of the
Already drilled hole
CODES:
3   3
a) 1 3 2 4 b) 2 3 1 4
c) - 4 1 3 d) 3 2 4 1

65. Consider the following reasons:
1. Grinding wheel is soft 2. RPM of grinding wheel is too low
2. Cut is very fine 3. An improper cutting fluid is used
A grinding wheel may become loaded due to reasons started at
1)1 and 4 b)1 and 3 c)2 and 4 d)2 and 3

66. Which one of the following processes results in the best accuracy of the hole made?
a)Drilling b)Reaming c)Broaching d)Boring

67. Consider the following processes for the manufacture of gears:

1. Casting 2. Powder metallurgy
3. Machining from bar stock 3. Closed die forging
The correct sequence in increasing order of bending strength of gear teeth is
a)1,2,3,4 b)1,2,4,3 c)2,1,4,3 d)2,1,3,4

68. Match list-I with List-II and select the correct answer using the codes given below the lists:

%     
%
ºc Die sinking 1. Abrasive jet machining
3c Deburring 2. Laser beam machining
¬c Fine hole drilling(thin materials) 3. EDM
~c Cutting/ sharpening hard materials 4. Ultrasonic machining
5. Electrochemical grinding



 
 





CODES:
3   3
a) 3 5 4 1 b) 2 4 1 3
c). 1 2 5 d) 4 5 1 3

69. Consider the following statements regarding remaining process:

1. Remaining generally produces a hole larger than its own diameter
2. Generally rake angles are not provided on reamers
3. Even numbers of teeth are preferred in reamer design
Which of these statements are correct ?
a)c1 and 3 b)2 and 3 c)1 and 3 d)1,2 and 3

70. A 60 ± teeth gear when hobbed on a differential hobber with a two ± start hob, the index change
Gear ratio is governed by which one of the following kinematic balance equations?
a)1 revolution of gear blank = 1/60 of hob revolutions.
b)1 revolution of gear blank = 2/60 of hob revolutions
c)1 revolution of hob = 2/60 of blank revolutions
d)1 revolution of hob = 1/60 of blank revolutions

71. Transfer machines can be defined as

a)material processing machines b)material handling machines
c)material processing and material handling machines
d)component feeders for automatic assembly

72. Consider the following advantages:

1. Rapid process 2.Work with keyways can be ground
3. No work holding device is required
Which of these are the advantages of centre less grinding?
a)1, 2 and 3 b)1 and 2 c)2 and 3 d)1 and 3

73. Which one of the following sets of tools or tools and processes are normally employed for making
Large diameter holes?
a)Boring tool b)BTA tool (Boring and trepanning association) and gun drill
c)Gun drill and boring tool d)Boring tool and trepanning

74. Which of the following processes of gear manufacture results in best accuracy of the involute
Gear tooth profile?
a)Milling b)Hobbing c)Rotary gear shaper

75. Match list-I with List-II and select the correct answer using the codes given below the lists:

%     
%
ºc Quick Return mechanism 1.Lathe
3c Apron mechanism 2. Milling machine
¬c Indexing Mechanism 3. Shaper
~c Regulating wheel 4. Centre less grinding
CODES:
3   3
3 2 1 1 b) 2 3 4 1
/ 2 3 1 d) 3 1 2 4





 
 





76. The marking on a grinding wheel is 51 A 36 L 5 V 93. The code 36 represents the
a)structure b)grade c)grain size d)manufacturer¶s number

77. The spindle sped range in a general ± purpose lathe is divided into steps which approximately follow
a)arithmetic progression b)geometric progression
c)harmonic progression d)logarithmic progression

78. The indexing of the in a single ± spindle automatic lathe is done using
a)Geneva mechanism b)Ratchet and Pawl mechanism
c)Rack and pinion mechanism d)Whit ± worth mechanism

79. Which one of the following grinding wheels (with grade, grit and Bond) is suitable for cutter grinding
a)K 60 vitrified b)K 320 vitrified c)T 60 resinoid d)T 320
resinoid

80.Which of the following statements are correct in respect of up-milling and down-milling ?
1. In up-milling the cutter rotates in a direction opposite to that of work piece travel whereas in
Down-milling the cutter rotates in a direction similar to that of work piece travel.
2. In down-milling chip will be thin at the beginning and increase to a maximum at the end of
The cut and reverse will be the case for a chip formed by up-milling
3. Down-milling is desirable with milling cutters having a high radial rake angle when compared to
Up-milling
4.Down-milling forces the work piece against the milling table to exert more pressure while
Up-milling tends to lift the work piece from the table.
Select the corrct answer using the codes given below:



a)1,2 and 3 b)1 ,2 and 4 c)3 and 4 d)1, 3 and 4

81. Consider the following motions and setting in a hobbing machine:

1. Hob rotation 2.Job rotation
3. Axial reciprocating hob rotation 4.Tilting of hob to its helix angle
Which of these motions and setting in a hobbing machine are required to machine a squr gear?
a)1,2 and 3 b)2,3 and 4 c)1,2 and 4 d)1, 3 and 4

82. Consider the following machining disadvantages:

1.Low
metal removal rate 2.Poor surface finish 3.High tooling cost
Which of these disadvantages are associated with ultrasonic machine (USM)?
a)c1 and 3 b)1 and 2 c)2 and 3 d)1,2 and 3

83. In a shaping operation, the average cutting speed is (Stroke length S, Number of strokes per minute
N, Quick return ratio R)
a)NSR b)NSR/2 c)NS (1 + R) d)NS(1 +R)/2
84. Match list I with list II and select the correct answer using the codes given below the lists:

List ± I List ± II
(Grinding Wheel Characteristics) (Product Characteristics)
A.c Mesh number 1. Grinding temperature
B.c Abrasive material 2. Work material
C.c Wheel dressing 3. Accuracy
D.c Wheel loading 4. Surface finish




 
 





(
a)c A B C D (1 2 3 4) b) A B C D (4 2 3 1) c) A B C D (1 3 2 4) d) A B C D (2 4 1 3)

85. Consider the following statements in respect of a grinding wheel of specification, 51 ± A ± 36 ± L ± 7

± R ± 23, using the standard alphanumeric codification:
1.c Abrasive used in the wheel is aluminum oxide
2.c The grain size of abrasive is medium
3.c The wheel grade is medium hard
4.c It has an open structure
5.c It has resinoid as bounding agent
Which of these statements are correct?
a)c 1, 2 and 3 b) 1, 3 and 4 c) 2,3 and 5 d) 1,4 and 5

86. Machining center is

a) an automatic tool changing unit b) a group of automatic machine tools
c) a next logical step beyond NC machine d) an NC machine tool

87. Consider the following operations and time required on a multispindle automatic machine to produce
a particular job.
1. Tuning « 1.2 minutes
2. Drilling « 1.6 minutes
3. Forming « 0.2 minutes
4. Parting « 0.6 minutes
The time required to make one piece (cycle time) will be
a)c 0.6 minutes b) 1.6 minutes c) 3.6 minutes d) 0.9 minutes

88. Consider the following mechanisms:

1. Geneva gearing 2. Rack and pinion 3. Ratchet and pawl
Which of these mechanisms are used to index the work table on a transfer machine?
a)c 1 and2 b) 2 and 3 c) 1 and 3 d) 1, 2 and 3

89. Which of the following mechanisms are suitable for indexing the table of rotary transfer line?
1. Rack and pinion 2. Ratchet and pawl 3. Lead screw 4. Geneva mechanism
Select the correct answer by using the codes given below:
(
a)c 1, 2 and 3 b) 2, 3 and 4 c) 1, 3 and 4 d) 1, 2 and 4

90. Assertion (A): The grade of a grinding wheel is a measure of hardness of the abrasive used for the
wheel.
Reason (R): Grading is necessary for making right selection of the wheel for a particular work.

91. For remaining operation of a blind hole, the type of reamer required is
a) straight flute reamer b) right hand spiral fluted reamer
c) left hand spiral fluted reamer d) none of the above

92. Consider the following statements associated with the lathe accessories:
1. steady rest is used for supporting a long job in between head stock and tail stock
2. mandrel is used for supporting a long job in between head stock and tail stock
3. collects are used for turning disc ± shaped job
Of these statements
a)c 1 and 2 are correct b) 2 and 3 are correct c) 3 alone is correct d) 1 alone is correct




 
 





93. Which of the following statements are true of face milling?

1. face milling cutter is held on an arbor
2. it has two rake angles ± axial rake and radial rake
3. the maximum chip thickness equals the feed per tooth
4. the chip thickness varies from a minimum at the start of cut to a maximum at the end of cut.
Select the correct answer using the codes given below:
(
a)c 1 and 2 b) 2 and 3 c) 2 and 4 d) 3 and 4

94. To drill a 10mm diameter hole through a 20mm thick MS plate with a drill bit running at 300rpm and
a feed of 0.25mm per revolution, time taken will be
a) 8s b) 16s c) 24s d) 32s

95. Which one of the following processing sequences will give the best accuracy as well as surface finish?
a) Drilling, reaming and grinding b) Drilling, boring and grinding
c) Drilling, reaming and lapping d) Drilling, reaming and electroplating

96. Which of the following pairs are correctly matched?

1. Drill press : Trepanning
2. Centreless grinding : Through feeding
3. Capstan lathe : Ram type turret
Select the correct answer using the codes given below:
(
a)c 1 and 2 b) 1, 2 and 3 c) 1 and 3 d) 2 and 3

97. Match list I (Mechanism) with list II (Associated function) and select the correct answer using the
codes given below the lists:
List I List II
A.c Geneva gearing 1. Feed motion in shaper
B.c Rachet and Pawl 2. Feed motion in drilling machine
C.c Whit-worth 3. Indexing of turret
D.c Rack and pinion 4. Quick return motion in shaper
(
a)c A B C D (3 1 2 4) b) A B C D (1 3 2 4) c) A B C D (1 3 4 2) d) A B C D (3 1 4 2)

98. A standard gear has an outside diameter of 96mm and module 3mm. The number of teeth on the gear
is
a) 32 b) 30 c) 16 d) 15

99. A part from hexagonal turret, the element(s) in a turret lathe includes(s)
a) cross ± slide tool post b) cross ± slide tool post and rear tool post
c) cross ± slide tool post and tail stock d) rear tool post tail stock

100. Geneva mechanism is used to transfer components from one station to the other in
a) an inline transfer machine b) a rotary transfer machine
c) a linked line d) an unlinked flow line

101. Internal gears can be made by

a) hobbing b) gear shaping with rack cutter
c) gear shaping with pinion cutter d) gang milling




 
 





102. During ultrasonic machining, the metal removal is affected by the

a) hammering action of abrasive particles b) rubbing action between tool and work piece
c) high frequency sound waves d) high frequency eddy currents

103. In designing the flutes of multiple ± edged tools such as broaches and milling cutters, which of the
following factors are taken into consideration?
1. The work material 2. The size of the tool
3. the degree to which the chip curls 4. The rake angle of the tool
Select the correct answer using the codes given below:
(
a)c 1, 2 and 3 b) 1, 2 and 4 c) 1, 3 and 4 d) 2, 3 and 4

104. Assertion (A): Gang process chart is an aid in studying the activities of a group of people working
together
Reason (R): Gang process chart analyses the cycle or routine followed by each member of the gang

105. The time (in minutes) for drilling a hole is given by t = Depth of the hole + h
__________________
Feed x RPM
Where µh¶ is the
a)c Length of the drill b) drill diameter
c)Flute length of the drill d) cone height of the drill

106. A standard dividing head is equipped with the following index plates
1. Plate with 15, 16, 17, 18, 19, 20 holes circles
2. Plate with 21, 23, 27, 29, 31, 33 holes circles
3. Plate with 37, 39, 41, 43, 47, 49 holes circles
For obtaining 24 divisions on a work piece by simple indexing
a)c Hole plate 2 alone can be used b) hole plates 1 and 2 can be used
c)Hole plate 1 and 3 can be used d) any of the three hole plates can be used.

107. Stroke of a shaping machine is 250mm. it makes 30 double strokes per minute. Overall average
speed of operation is
a) 3.75m/min b) 5.0m/min c) 7.5m/min d) 15.0m/min

108. A multispindle automat performs four operations with times 50, 60, 65 and 75 seconds at each of its
work centres. The cycle time (time required to manufacture one work piece) in seconds will be
a) 50 + 60 + 65 + 75 b) (50 + 60 + 65 + 75)/4 c) 75/4 d) 75

109. Size of a shaper is given by

a) stroke length b) motor power c) weight of the machine d) table size

m  
3 Ú


110. A soft steel shaft of 8cm dia and 30cm long is to be reduced in diameter to 6.5cm over a length of
20cm and total length of component is to be reduced form 30 to 28cm. Take depth of cut 2.5mm
maximum and feed as 0.12mm/rev. The time to machine with high speed tool bit of 150mm/min is «..
111. A 16mm hole is to be drilled into a CI block with a feed of 0.15mm/rev. The thickness of block is
6cm and drill is made by HSS having max cutting speed of 50m/min. The rpm of tool and time taken to
machine is ««««««««««««««.
a) 1 & 27 sec b) 995 & 27 min c) 995 & 27 sec d) 60 & 27 sec




 
 




112. A 15cm dia carbide inserted milling cutter is to be used to cut a key way on medium hardness steel,
with a feed of 0.08mm/rev. if the depth of the cut is to be 0.5mm and the length of work is 20cm. If
cutting speed used is 120m/min, the time taken for key dept upto 2mm is «««««««««..
a) 10.2 min b) 41 min c) 11 min d) 44 min

113. A medium carbon steel block is to machined with a HSS tool bit on a crank shaper at a feed of
0.1mm/stroke. The width of the block is 10cm and length of stroke is 14cm and 5mm approach and ver
travel on width wise is to be considered. If the m/c is running at 10 double strokes per min, the time to
machine the work piece and assume speed ratio of cutting stoke to return stroke as 0.67«««««..
a) 110 min b) 1100 min c) 100 min d) none

114. A MS plate 800 x 400 x 300mm is to be machined to 800 x 400 x 27mm the ratio of return time to
cutting time is 2 : 3 and the feed per cycle and depth of cut are 0.5mm and 2mm respectively. Tool
approach and over travel respectively are 50mm each on length wise and 5mm each on width wise. The
machining time with HSS tool to 60m/min speed«««««««..
a) 20.5 min b) 31 min c) 41 min d) 62 min

115. While machining a work piece on a shaper a quick return ratio of 3/2 is obtained. If the work piece is
20mm long and is machined at a cutting speed of 18m/min, the RPM of crank is «««««««..
a) 45 b) 54 c) 82 d) 98

116. The circumference of a regulating wheel on a centreless grinder is 300mm and its RPM is 400. The
angle of regulating wheel to achieve a through feed of 830cm per min using the relation f = S. N. Sin Õ
where S ± circumference of R. W is «««««««««
a) 0.4 b) 0.8 c) 1.98 d) 3.96

117. A 63.5mm dia plain milling cutter having 6 teeth is used to face mill a block of A1 18cm long and
3cm wide. The spindle speed is 1500rpm and feed is 0.125mm per teeth per rev. The cutting time is
a) 0.16 min b) 1.6 min c) 16 min d) none

118. The time required for completing a 2mm deep finishing cut on a 150mm wide, 400mm long face of a
100mm thick steel block using a face milling cutter of 250mm diameter with 8 teeth: The cutting speed
1.2m/sec and feet per tooth is 0.1mm is««««««««««««
a) 46.3 min b) 46.3 sec c) 227.7 min d) None

119. A 20mm dia drill with pong angle 120 degrees is used to drill a through hole in a plate 30mm thick,
assume the length of approach and over travel as 2mm and 3mm respectively. The time required for
drilling if the feed is 0.1mm/rev and the material is cut with a velocity of 20m/min««««««.
a) 0.14 min b) 1.4 min c) 14 min d) None

120. Double start right hand metric threads with 0.5mm pitch are machined in a general purpose lathe
having a lead screw of 6mm lead. Gears, one number each of 20 teeth in steps of 5 teeth are available. A
compound gear train for transmitting the required motion from the spindle to lead screw is ««««««
a) 20/120 b) (20 x 20) / (40 x 60) c) (20 x 25) / (60 x 100) d) (20 x 25) / (40 x 75)

121. The mechanism used for cutting the second start thread is
a) gear box b) feed mechanisms c) back gear mechanisms d) half nut




 
 




122. Diameter of a MS bar has to be reduced from 80mm to 60mm over a length of 116mm at a feed rate
of 0.2mm/rev, depth of cut 2.5mm and average cutting velocity of 132 m/min. Assume approach and over
travel distances as 2.5mm and 1.5mm respectively, times for return and for resetting of tool in between
the passes as 10sec and 30sec respectively. Spindle speed and total machining time is«««.
a) 5.1 min b) 6.2 min c) 4.2 min d) None

123. A drilling machine has to be designed with 8 spindle speeds ranging approximately between 120 to
1200 rpm. The 5th spindle speed is «««««««««..
a) 445 b) 480 c) 620 d) 865

124. A surface 80 x 160 mm is rough ± machined using 150 mm diameter face milling cutter having 10
teeth. The cutter center is offset by 15 mm and a cutting speed of 20m/min are employed, the time to
rouge machine the surface is
a) 17.5 sec b) 17.45 sec c) 35 sec d) 35 min

125. The time taken for a single pass of a boring operation given the following data. Bore diameter
200mm, length of cut including approaching 100mm, cutting speed 30m/min feed mm/rev««««««.
a) 31.4 min b) 31.4 sec c) 31.4 hrs d) None

126. The transformation ration of the gear train connecting the spindle and the lead screw of 4 TPI
required to cut 1 mm pitch screw threads in a centre lathe«««««««««««««..

127. When milling a slot 20mm wide and 10 cm long in a rectangular plate 10 X 20 cm the cutting
conditions used were, cutting speed = 60m/min, diameter of end mill = 20mm no. of flute = 8, feed = 0.01
mm/flute, depth of cut = 3 mm. The cutting time for these operation is ««««««««.
a) 84 sec b) 86.5 sec c) 78.5 sec d) None

128. If a plate 100mm wide has to be machined in 10 min with a feed of 0.001mm. The cutting speed in
m/sec. The ratio of return to cutting speeds is 2 : 1 and the length of the stroke is 150mm is ««««
a) 2250 b) 225 c) 37.5 d) 3.75

129. In a slab milling operation the following data was observed, dia of cutter is 90mm, no.of teeth on
cutter 10, cutting speed 30 m/min, table feed 180 mm/min, depth of cut 3 mm. The maximum and average
chip thickness in milling are respectively««««.
a) 0.031 & 0.062 b) 0.31 & 0.62 c) 0.62 & 0.31 d) 0.062 & 0.031

130. The shortest machining time required in shaper to machine a plate of 200 X 90 mm under the
following condition. Cutting speed 13.5 m/min, feed 0.57 mm/double stroke, no. of passes 1, approach
and over run longitudinal 20 mm, lateral 4 mm and ratio of cutting speed to rapid speed 0.83
««««««.
a) 4.92 min b) 5.34 min c) 5.12 min d) None

131. The surface of a metal slab of 278 mm length and 80 mm width is machined by a face milling cutter
of 120 mm diameter, having 10 teeth, rotating at 50 rpm. The milling feed is 0.1 mm/tooth of the cutter.
The combined time for job loading and unloading is 2 min. The approach and over travel of the tool are 1
mm each. The production rate per hour is «««««««««««««.
a) 5.2 b) 7.6 c) 10.1 d) None




 
 




 
 
m 


The following are the operation involved during sheet metal working.

1.c Punching or piercing

2.c Blanking
3.c Deep drawing
4.c Bending
The first two involved shearing action and the last two involved plastic deformation
The process of shear starts with the punch sinking into the metal and stressing the metal to its
elastic limit. As the punch penetrates further into the metal, the elastic limit of the material is
exceeded and a rupture appears at the cutting edge of the punch. There is rupture at the cutting
edge of the die also. As the punch penetration continues, the fractures meet and a clean break
results

Clearance is the space between the pouch and die. For a round punch and die opening it is the
difference of the two radii. If the clearance is correct, based on the type and thickness of material, the
two fractures will met as stated above and a blank having good clean edges will result. The edge of the
blank will appear burnished for about one third of its edge length. This is the depth to which the punch
penetrated before complete fracture took place.

m"&$Here the hole produced on the sheet is useful one. In this punch is made to the
correct size and clearance is provided on die.
 ¥Size of punch = size of hole to be produced
Size of die = size of punch + 2C
Where C = Clearance on radius
*Shear is provided on punch

3!' Here blank coming out during punching is useful one. In this die is made to correct size and
clearance is provided on punch.
¥ Size of die = size of blank
Size of punch = size of die - 2C
Where C = Clearance on radius
*Shear is provided on die
*Clearance = C = 0.0032 .t. « .mm
Where  is N/ , µt¶ is in mm (or) 5 to 10% 0f µt¶.

"!( (
Force required for blanking or punching = As x  " 
Where As = Sheared area = perimeter x thickness = l D t . . . . . . . . . . . . for circular blanks
= 4 .a .t . . . . . . . for square = 2 (a+b) t . . . . . . . . for rectangle
Energy required for punching or blanking = E = Force x punch travel = "  .K.t.
Where K = % penetration required for rupture; t = thickness of sheets
Note: Some times a factor µx¶ is considered to account extra energy required due to friction etc.
The value of x = 1.16 in general.
¥ 9e
 ;776




 
 




Methods of reducing cutting force:

In the above case, of calculating force we assumed that the bottom of punch and top of die are
flat and parallel. But due to this as very high punch forces are required in short time. To avoid this and
making smooth punching operation two methods were adopted.
1.c By providing shear 2. By staggering of punches.

&  The working faces of punch or die are ground off so that these do not remain parallel to the
horizontal plane but are inclined to it. This angle of inclination is called shear . This has the effect of
reducing the sheared area at any one time and the max force is much less. This may be reduced by as
much as 50%.
The amount of shear to be applied is a matter of compromise. If the shear is quite big, say 2t or
3t , then the cutting edges of tool will become too acute and liable to break away easily. However, the
shear must be at least equal to the percentages penetration
Let I = shear provided on punch or die
F = actual force with shear on punch (or) die
"  = max. force to be applied without shear on punch or die = As 
Energy required for completing punching or blanking operation = "  K.t = E
Punch travel required for completing punching with shear is = K.t + I
¥Energy required if shear is provided = F (k.t + I), always F<" 
Theoretically, the energy required for punching or blanking to particular size is same with and without
providing shear.
¥ "  K.t =F (K.t + I)
F = [("  K.t) / ( K.t + I)] (or)
I = [( "  - F) K.t] / F
If we go for more and more amount of shear, no doubt operation is smooth but the dimensions
of the cut tend to increase in proportional to the angle of shear
Note: Shear angle chosen should provided a change in punch length of about 0.5 to 2 t
Note: In piercing the direction of shear angles must be such that the cut proceeds form outer extremities
of the contour towards the center. This avoids stretching the material when it is cut free.
£
$"&An effect similar to shear can be obtained by staggering two or more punches
that all operate in one strike of press. For staggering the punches are arranged so that one dose not enter
the material until the one before it has penetrated through. In this manner, the cutting load may be
reduced to 50% if two punches are taking party in one stroke.

 " 3$"&
Let fc = Crushing stress of punch  = shear stress of sheet
By assuming hole produced is in circular shape
Force required for punching = l .d. t. 
Force that can be withstand by punch = ( l/4)
 .fc
For min size of hole.
Force on punch = force required for punching
(l/4)
 .fc = l .d. t. , let fc =  the equation becomes d = 4t
If fc = 4  , d = t

$$!#"











 
 





a = edge of blank to side of the strip

= back or front scrap = t + 0.015 h
b = scrap bridge
= 0.8 mm ; when t < 0.8 mm;
=t ; 0.8 < t < 3.2 mm;
= 3.2 mm ; t > 3.2 mm
Feed or advance = S = w + b
No. of blanks = N = ( L ± b0/S
Scrape remaining = L ± (NS + b)
% Utilization = Area of material used/ Total area of sheet
Á Á
= ¢Á   = ¢Á  ¢ 
)
Drawing is the process of forming a flat piece of material (blank) into a hallow shape by means
of punch which causes the blank to flow into the die cavity.
The depth of draw may be shallow, moderate or deep.
If depth / diameter ï 0.5 --------called shallow drawing
If depth / diameter > 1 ------- called deep drawing
 The blank between die wall and punch surface is subjected to pure tension and tends to stretch and
become thinner. This is called ³necking´
 Due to blank holding force the outer portion of blank become thicker during drawing. If the
clearance not enough to accommodate this increased thickness, then the µironing´ will takes place. This is
useful if uniform thickness of part is required.

)It is the ratio of max blank diameter to the diameter of the cup drawn from the blank, that is
D/d. For a given material there is a limiting draw ratio (LDR) after which the punch will pierce a hole in
the blank instead of drawing the blank.
This ratio depends upon many factors such as type of material, amount of friction present etc.
the usual range is 1.6 to 2.3
Venting (i. e. a hole is provided in punch ) in punch serves as
a)Eliminates suction, which would hold the cup on punch during return stroke
b)Providing passage for lubricants

7()it can be done in two ways
a)draw reduction ratio b)limiting draw ratio
In draw reduction ratio method
Ist draw reduction = 45 to 50% = ( D -
 )/D

 = dia. of Ist draw punch
IInd draw reduction = 30% = (
 -
 ) /

IIIrd draw reduction = 25% = (
 -
 ) /

IVth and above draws = 16%
Whenever dia. of punch is less than or equal to the required dia of component, the
corresponding draw number is the no. of draws.
3!' 3  () The basic assumption in calculating blank size in drawing is the area of the
developed blank before drawing should be the same as the surface area of the shell after drawing,
providing the thickness of the material remains unchanged.
Blank dia = D = «
 + 4dh ---------------------for d/r > 20
d= dia of part h = height of part r= carner radius

D = «
+ 4dh ----0.5 r . . . . . . . . . if 15 < d/r < 20
D = «
 + 4dh ----- r . . . . . . . . . if 10 < d/r < 15
D = «
 + 4dh ( t/T) , . . . . .t = wall thickness T= bottam thickness



 
 




Drawing force = p = l .d. t.fy [ (D/d) ± c] . . . . . Newton

Where t = thickness blank ;
D = dia of punch ; fy = yield strength N /  
C = constant to cover friction and bend = 0.6 or 0.7
Blank holding force = 1 / 3 drawing force
 Corner radius of punch and die is more for first draw and become equal to the corner radius of
required part at the last draw . Generally for 1st draw corner radius is 10 t

3(
 Bend allowance = ( / 180)
(r + K)
Where
= bend angle in degrees
= part which makes angle with horizontal plane
R = inside radius of bend
K = distance of neutral axis from inside surface of the bend.
If r < 2t k = 1/3 t = 0.33 t
r  2t k = ½ t = 0.5 t
Bending pressure = F == C. l. fy .   / W Newton¶s
l = length of part fy = yield strength W = width of die opening
t = blank thickness
C = die opening factor = 1.2 for die opening of 16 f
= 1.33 for die opening of 8 t.
Note: For ³U´ or channel bending , the pressure will be twice as for ³V´ bending and for edge bending it
will be about one- half of that for V ±bending
#$(Accounting to the method of operation the dies are classified as
a)Single operation (or) simple dies
b)Compound dies c)Combination dies d)Progressive dies

 $!(These will perform single operation for each stroke of the press slide. The operation may be
a cutting operation like blanking, punching etc (or) forming operation like bending, drawing etc.

 $"((In these dies two or more operations will perform at one station and at one stroke. Also
these are considered only as cutting dies. The example is washer is provided by blanking and piercing
operations simultaneously. These are accurate and economical in mass production.

 £( In this die also two more operations will perform at one station and one stroke. But
the operation are not only cutting, here the cutting operation is combined with forming operation for
example blanking is combined with bending or drawing operations.

m8( It is also called follow on die. It is like a compound die, but the difference is here all the
operations will be completed in one stroke but not at one stage. Between the strokes the strip is
transferred or moved to the next stages, but finally one component or product will comes out per stroke.
But the advantage here is we can stagger the punches to reduce the max force capacity of a punch press.

 ( unless the progressive dies where the stroke is fed progressively from one station to
another, in transfer dies the already cut blanks are fed mechanically from station to station.

"!$!( multiple or gang dies produce two or more work pieces at each stroke of the press.




 
 




 5 <m


 
m 



1.c A washer has a 12.7mm hole and an outside diameter of 25.4mm it is 1.25mm thick and made by
SAE 1020 steel having shear strength of 800Mpa. If the radial clearance is taken as 0.04mm, The
piercing punch size and the piercing die opening size are
a)12.7 & 25.4 b)12.7 & 12.78 c)12.78 & 12.7 d)12.78 & 25.48

2.c A washer has a 12.7mm hole and an outside diameter of 25.4mm it is 1.25mm thick and made by
SAE 1020 steel having shear strength of 800Mpa. If the radial clearance is taken as 0.04mm. The
blanking die opening size and blanking die punch size is
a)25.4 & 25.32 b)25.32 & 25.4 c)25.48 & 25.32 d)25.4 & 25.4

3.c A washer has a 12.7mm hole and an outside diameter of 25.4mm it is 1.25mm thick and made by
SAE 1020 steel having shear strength of 800Mpa. The force required if compound die is used.
Take clearance as 0.04mm
a)40KN b)120KN c)80KN d)200KN

4.c A washer has a 12.7mm hole and an outside diameter of 25.4mm it is 1.25mm thick and made by
SAE 1020 steel having shear strength of 800Mpa. If the progressive die system is used with
staggering of punches, the max force required is
a)40KN b)120KN c)80KN d)200KN

5.c A washer has a 12.7mm hole and an outside diameter of 25.4mm it is 1.25mm thick and made by
SAE 1020 steel having shear strength of 800Mpa. Assume 60% penetration for steel and shear for
both provided as 1mm,the force needed if both punches act together in progressive die working is
a)40KN b)51.5KN c)63.25KN d)None

6.c Given that an equilateral triangle of 50mm on each side is required to be produced from sheet.
Take the value of front scrap, back scrap and scrap bridge as 2mm

i)The percentage utilization of the strip is

a)44% b)60% c)77.3% d)91.1%
ii)The no. of pieces produced if the strip length is 220mm is
a)3 b)4 c)5 d)none

7.c The max punch force necessary to blank a steel washer 44.5mm outside dia 22.25mm inside dia
and 1.6mm thick. If  =400Mpa with compound die system is
a)4409 kN b)8905 kN c)134 kN d)None




 
 
 



8.c During blanking a steel washer 44.5 mm outside dia 22.25mm inside dia and 1.6mm thick. If
 =400Mpa with compound die system. The work done if % penetration is 25%.
a)135Kn b)100KN c)50KN d)None

9.c The amount of shear which must be ground upon the tool, if the max punch force is to be reduced
to 60Kn in producing a blank of steel washer 44.5mm outside dia 22.25mm inside dia and 1.6mm
thick. If  =400Mpa with compound die system with % penetration is 25%
a)0.25mm b)0.5mm c)1mm d)1.2mm

10.c A blank has a perimeter of 31.75cm the metal is 1mm thick cold worked 0.15% carbon steel with
a shear strength of 420Mpa and percent penetration of 25%. Two holes 1.25cm dia each are to be
pierced during the same stroke when the piece is blanked. The forces required for blanking and
for punching are
a)133.3kN & 33kN b)33 kN & 133.3kN c)166.3kN & 133.3kN d)None

11.c A blank has a perimeter of 31.75cm. The metal is 1 mm thick cold worked 0.15% carbon steel
with a shear strength of 420Mpa and percent penetration of 25%. Two holes of 1.25cm dia each
are to be pierced during the same stroke when the piece is blanked. The max force the press must
exert at any one time without shear is
a)c 133.3 kN b) 33 kN c) 166.3 kN d) 100 kN

12.c A blank has a perimeter of 31.75cm. The metal is 1 mm thick cold worked 0.15% carbon steel
with a shear strength of 420Mpa and percent penetration of 25%. Two holes of 1.25cm dia each
are to be pierced during the same stroke when the piece is blanked. The energy required per stoke
is««««««««.
a)c 41.5 kJ b) 41.5 kJ c) 33.3 kJ d) 33.3 J

13.c The utilization of the sheet for producing a part with the lay out shown
below is «««.. (Take scarp bridge, front scarp and back scrap as
2mm)

a)c 95.8% b) 67.8%

c) 96.7% d) None.

14.c For the above shown lay out with scrap bridge, back scrap and front scrap as 2mm, the length of
strip required to produce 100 such pieces will be ««««««««««««
a)c 1520 cm b) 2020 cm c) 2500 cm d) None.

15.c The developed length of the part show below

is««««««««««««««««
a)c 190.75 mm b) 183.84 mm
b)c c) 193.89 mm d) 180.75 mm




 
 
 



16.c The developed length of the part shown below is

a)c 260 mm b) 270 mm c) 285 mm d) 295 mm

17.c The developed length of the part shown below is «««««««««««««..

18.c The developed length of the part show below is «««««««««««««««..

19.c The blank diameter for the component shown below is «««««««««««««««..

20.c Fig. below shows a shell to be drawn form a circular blank. The diameter of the blank needed to
draw the shell is ««««««««««««««««««««.
21.c The blank diameter of the parts shown below and neglect the thickness of sheet.

22.c A symmetrical cup work- piece shown in fig is to be drawn form cold rolled steel 0.8mm thick. If
fy = 427 Mpa, the blank holding force is««««««««««..

23.c A cup 5cm in dia and 7.5cm in deep is to be drawn from 1.5mm thick drawing steel with a stesile
yield strength of 315 Mpa. The corner radius is negligible.




 
 




i)c The blank diameter is ««««««««««««

a)c 10cm b) 12.5cm c) 13.2cm d) 14.8cm
ii)c The least on. Of drawing operation with draw ratio of 1.8 is ««««««««««
a)c 1 b) 2 c) 3 d) 4
iii)c The force and energy for the first draw with draw ratio of 1.8 and neglect friction, bend and
black holding force is «««
a)c 197 KN & 8 KJ b) 8 KN & 197 KJ c) 197 KJ & 8 KN d) None
24.c A symmetrical cup work-piece shown in fig is to be drawn form cold rolled steel 0.8mm thick.
Calculate
i)c Blank diameter
a)c 111.8 mm b) 118 mm c) 181 mm d) none
ii)c Least no. of draws with Dr = 1.8
a)c 1 b) 2 c) 3 d) 4
iii)c Drawing pressure if fy = 427 Mpa
a)c 119.98 kN b) 40 kN c) 65 kN d) 79.98 kN
iv)c Blank holding force
a)c 26.66 kN b) 13.33 kN c) 22 kN d) 40 kN
25.c The part shown in fig is to be blanked form a steel strip of 2 mm thickness. Assuming the
penetration to be 40% & the ultimate shear strength of the material to 145 Mpa.
i)c The force required for blanking operation would be ««««««««««««««
ii)c Work done in blanking operation would be «««««««««««««
iii)c The shear to be provided to carried out this operation on a 24 KN press is««««..

26.c A cylindrical cup of diameter 12mm & height 16 mm has a corner radius of 0.5 mm, it is made
out of sheet of 2 mm thick & the material has a constant flow of 35Mpa. Neglecting the corner
radius.
i)c The diameter of the blank would be«««««««««««««
a)c 20mm b) 30.2mm c) 36.1mm d) 41.6mm
ii)c The drawing stress based on idle deformation (neglecting friction, blank holding force & effect
of punch corner radil) is«««««««««««««««««««
a)c 52Mpa b) 68 Mpa c) 98Mpa d) 106Mpa
iii)c The no. of draws required is to draw the part if the draw reduction ratio for first and subsequent
draws is 40% and 25% is««««««««««««
a)c 2 b) 3 c) 4 d) 5
27.c The end view of a drawing board clip is shown in fig. below. The width of the clip is 20 mm.
the length of flat starting strip is ««««««««««««««««««

28.c The minimum no. of hot rolling process necessary to reduce an ingot of 200mm thick to 100mm
thick in 2 high reversible rolling mill with roll diameter of 500mm. the coefficient of friction
between the rolls & the hot material is 0.2
a)c6 b) 8 c) 10 d) 12
29.c A blank of 200 mm diameter is mass produced from a sheet of 4 mm thick with ultimate shear
strength of 30 Mpa, shear provided on one of the tools is 1 mm.




 
 




i)c The punch force required assuming punch penetration as 35% is «««.
a)c 34 KN b) 44 KN c) 54 KN d) 64 KN
ii)c The shear is provided on
a)c Punch b) die c) both d) any
30.c A cup of 50mm diameter & 75 mm deep is to be drawn form 1.5 mm thick steel sheet of deep
drawing quality of tensile strength 300 N/sq mm. Neglecting the corner radius,
i)c The diameter of the blank required is «««««.
ii)c Force and energy must be applied for first draw with 40% reduction is ««««««««
31.c A strip of steel 100mm thick is to be cold rolled in a single pass rolling mill of 600mm diameter
rolls. The coefficient of friction between a strip & a roll is 0.1
i)c The maximum possible reduction in thickness per pass is «««««««««««..
ii)c The roll separation distance in this case is «««««««««««««
32.c The smallest punch diameter that can be designed for piercing sheet metal strip with the
following data. Crushing strength of the punch material is 1500 Mpa. Thickness of the sheet in
2mm, factor of safety is 3, shear strength of the sheet material 500 Mpa is««««««««
a)c2mm b) 6mm c) 8mm d) 24mm
33.c A contour having a perimeter of 200 mm is pierced out form a 3 mm sheet having ultimate shear
strength of 250N/sq mm. the amount of shear to be provided to reduce the punch force to 60%
(Assume the penetration to be 30%) is««««««««..
a)c0.6mm b) 1.35mm c) 0.75mm d) None
34.c A cylindrical shell 30mm diameter & 150mm deep is to be drawn from aluminum sheet 1mm
thick the limits on draw ratio (diameter of drawn part/diameter before drawing) are 0.6 & 0.8 for
the first & each of the subsequent draws respectively, neglecting corner radius & trimming
allowance
i)c The no. of draws needed is ««««««««««
a)c2 b) 4 c) 6 d) 8
ii)c The diameter of third draw is «««««««««««««
a)c 66mm b) 52.8mm c) 42.34mm d) 33.4mm
35.c Figure shows a part, which is to be blanked. The table shows the dimensions of the product in
mm. The sheet thickness is 1mm & the clearance per side required 5% of thickness. The table &
fill up the dimensions for the punch & die of the blanking tool
A B C D
PRODUCT 30 25 10 15
PUNCH - - - -
DIE - - - -

36.c A circular up of 100mm out side diameter & 25mm height is to be drawn from an aluminum sheet
of 1 mm thickness. The corner radius of cup is 6 mm. Assuming a trimming allowance of 3 mm,
the diameter of the blank require is««««««««««««««..
a)c138.42mm b) 141.42mm c) 144.42mm d) 147.42mm
37.c 5 holes of diameter 10 mm each are to be punched in a sheet 3 mm thick at a pitch of 25 mm. The
minimum capacity of the press (in tones) if yield point of material is 50 Mpa if five holes are
punched in a single stroke««««««««««..
a)c4.7 kN b) 23.56 kN c) 117 kN d) None
38.c A steel cup of height 30mm & internal diameter 40mm with a flange width of 10mm is to be
deep drawn from a sheet 1mm thick. The no. of draws required a draw the cup with limiting
draw ratio of 1.9 is ««««««««««
a)c1 b) 2 c) 3 d) 4




 
 




39.c A strip of thickness T mm is rolled in a 2 high single pass rolling mill having roll diameters
down, to a final thickness of T-2ùT mm. if friction coefficient between the rolls & strip is . The
maximum reduction 2 ù T possible in this operation using this relation for D = 300mm, T =
30mm & = 0.3 is ««««««««««««««««.
a)c27mm b) 19mm c) 13.5mm d) 6.75mm
40.c Circular blanks 50mm is diameter are to be produced form 3mm thick electrolyte copper sheet for
which the resistance to shear is 350N/sq.mm. The force required for blanking assuming no shear
on the punch««««««««««««««..
a)c164 kN b) 82 kN c) 41 kN d) 20.5 kN
41.c The blanking force change hexagonal balks of 25mm side are produced by a punch having shear
of 2mm & 50% penetration on sheet of thickness 3 mm and resistance to shear is 350Mpa is «..
a)c67.5 kN b) 157.5 kN c) 90 kN d) None
42.c Equal no. of circular blanks of 60 & 10mm diameter is required for a product line.
i)c For the lay of shown below the % utilization (with margin and bridge taken as 2mm) is
ii)c For the lay of shown below the % utilization (with margin and bridge taken as 2mm) is
iii)c
43.c A cup shown if fig is to be drawn from low carbon steel thickness 0.8mm. The edge trimming
allowance to be provided 4mm on radius. Neglecting corner radius, thinning & spring back. The
diameter of the blank required is ««««««««««««««««««««.
a)c91.65mm b) 95.65mm c) 99.65mm d) None
44.c The pressure required to cut a circular blank 30cm in diameter form steel 3mm thick, if it has a
shear strength of 376N/mm.
a)c106.3 kN b) 1063.1 kN c) 531.5 kN d) None.
45.c A piece of stock 2.35mm thick bent to an angle of 120 with an inside radius of 6.25mm. the
original length of stock that goes into the bend is ««««««««««««««..
a)c9.1mm b) 14.5mm c) 15.5mm d) None
46.c The maximum punch force necessary to blank a steel washer 44.5mm outside diameter 22.25mm
inside diameter and 1.60mm thick, if l2 = 400 N/mm is ««««««««««««.
a)c134.2 kN b) 89.5 kN c) 44.7 kN d) 40.8 Kn

m Ú

 %  
3 Ú


1.c In blanking operation, clearance is provided on

a)the die b)both die and punch equally c)the punch d)neither the punch nor the die

2.c The cutting force in punching and blanking operations mainly depends on
a)the modulus of elasticity of metal b)the shear strength of metal
c)the bulk modulus of the metal d)the yield strength of the metal

3.c Identify the stress strain in the FLANGE portion of a PARTICULAR DRAWN CYLINDRICAL
CUP when deep drawing without a blank holder
a)tensile in all three directions
b)no stress in the flange at all, because there is no blank holder
c)tensile stress in one direction and compressive stress in other direction
d)compressive in two directions and tensile in third direction




 
 




4.c A 50mm dia hole is to be punched out from a carbon steel sheet 1.0mm thick. The dia of the
punch should be
a)49.925mm b)50.00mm c)50.075 d)none

5.c In deep drawing of sheets the value of limiting draw ratio depends on
a)percentage elongation of the sheet metal b)yield strength of the sheet metal
c)type of press used d)thickness of sheet

m Ú

 4m


3 Ú

6.c Minimum required bend radius on the inner side of a bent steel sheet in press bending operation is
a)half of sheet thickness b)equal to sheet thickness
c)1.5 times sheet thickness d)twice the sheet thickness

7.c In a bending operation, if the modulus of elasticity E is increased keeping all other parameters
unchanged, the spring back will
a)increase b)decrease c)remains unchanged d)be independent of E

8.c In blanking operations, the best way to improve the smoothness and squarness of the edges is to
a)have reduce gap between punch and die b)increase the ductility of the sheet
c)decrease the speed of blanking d)provide shear on the punch

9.c The function of draw bead in the deep drawing operation is to

a)produce a balance between the amount of stretching and drawing
b)produce a circular groove on the flange
c)reduce the drawing hold d)reduce the friction on the flange

10.c In metal forming operations, the true strain in the X-direction is 0.3 and in the y-direction is 0.1
the true strain in the Z-direction is
a)0 b)-0.2 c)0.2 d)-0.03

11.c In producing a punched hole of 20mm dia, the dimention of the punch is ««««given the
radial die clearance of 0.1mm

12.c Wall thickness of drawn cup is controlled by

a)deep drawing b)reverse drawing c)redrawing d)ironing

13.c A hemispherical cup of radius µR¶ is formed in a press working operation. The radius of blank
would be
a)« R b)« R c)« /3 R d)«/2 R

14.c In progressive die ( for sheet metal), a spring loaded stripper is used to clamp the stock until
a)the punch penetrates the stock depth b)it flatten out wrinkles
c)the automatic feed unit release it d)the punch is withdrawn from the stock

15.c In «««««.A«««««««« operation the diameter of the desired hole will be smaller
than the diameter of the ««««««««..B««««««««««.
A.blanking/piercing B.punch/die




 
 




     
%
3 Ú

16.c The order of radial clearance between the punch and die for shearing a steel plate of thickness µt¶
(t ” 2mm) is
a)0.05 t b)0.15 t c) 0.20 t d)0.25 t

17.c The force required for piercing a round hole when die and punch are not provided with any shear
is given by
a)L S T b)l D S c)D L S T d)l D S T
Where L= length of die land, D = diameter of hole, T = thickness, S = shear strength

18.c In sheet metal work, the cutting force on the tool can be reduced by
a)grinding the cutting edges sharp b)increasing the hardness of tool
c)providing shear angle on tool d)increasing the hardness of die

19.c The blank diameter used in thread rolling will be

a)equal to minor diameter of the thread
b) equal to pitch diameter of the thread
c)a little large than the minor diameter of the thread
d) a little large than the pitch diameter of the thread

20.c Match List-I with List-II and select the correct answer using the codes given below the lists:
List-I (Metal forming process) List-II (A similar process)
A.Blanking 1.Wire drawing
B.Coining 2.Piercing
C.Extrution 3.Embossing
D.Cup drawing 4.Rolling
5.Bending
CODES:
A B C D A B C D
a) 2 3 4 1 b) 3 2 1 5
c) 2 3 1 4 d) 2 3 1 5

21.c In sheet metal blanking is provided on punches and dies so that.

a)press load is produced b)good cut edge is obtained
c)warping of sheet is minimized d)cut blanks are straight

22.c For obtained a cup of diameter 25 mm and height 15 mm by drawing the size of the round blank
should be approximately
a)42 mm b)44 mm c)46 mm d)48 mm

23.c For 50% penetration of work material, a punch with single shear equal to thickness will
a)reduce the punch load to half the value b)increase the punch load by half the value
c)maintain the same punch load d)reduce the punch load to quarter load

24.c A cup of 10 cm height and 5 cm diameter is to be made from a sheet metal of 2 mm thickness.
The number of deductions necessary will be
a)one b)two c)three d)four




 
 





25.c The bending force required for V ± bending, U ± bending and Edge ± bending will be in the ratio
of
a)1 : 2 : 0.5 b)2 : 1 : 0.5 c)1 : 2 : 1 d)1 : 1 : 1

26.c Consider the following statements:

Earing in a drawn cup can be due to non ± uniform
1.speed of press 2.clearance between tools
3.material properties 4.blank holding
Which of these statements are correct?
a)1 , 2 and 3 b)2 , 3 and 4 c)1 , 3 and 4 d)1 , 2 and 4

27.c Best position of crank for blanking operation in a mechanical press is

a)top dead center b)20 degrees below top dead center
c)20 degrees before bottom center d)bottom dead center

28.c Match List ± I (Components of a table fan) with List ± II (Manufacturing process) and select the
correct answer using the codes given below the lists:
List ± I List ± II
A.Base with stand 1.Stamping and pressing
B.Blade 2.Wire drawing
C.Armature coil wire 3.Turning
D.Armature shaft 4.Casting
CODES:
A B C D A B C D
a) 4 3 2 1 b) 2 1 4 3
c) 2 3 4 1 d) 4 1 2 3

29.c Match List ± I (Components ) with List ± II (Manufacturing process) and select the correct
answer using the codes given below the lists:
List ± I List ± II
A.Car body (metal) 1.Machining
B.Clutch lining 2.Casting
C.Gears 3.Sheet metal pressing
D.Engine block 4.Power metallurgy
CODES:
A B C D A B C D
a) 3 4 2 1 b) 4 3 1 2
c) 4 3 2 1 d) 3 4 1 2

30.c A blank of 30 mm diameter is to be produced out of 10 mm thick sheet on a simple die. If 6%

clearance is recommended, then the nominal diameters of die and punch are espectively
a)30.6mm & 29.4mm b)30.6 mm & 30 mm c)30 mm & 29.4 mm d)30 mm & 28.8 mm

31.c Match List ± I (Operations ) with List ± II (stresses induced) and select the correct answer using
the codes given below the lists:
List ± I List ± II
A.Blanking 1.Tension
B.Stretch forming 2.Compression
C.Coining 3.Shearing
D.Deep drawing 4.Tension and compression




 
 




CODES:
A B C D A B C D
a) 2 1 3 4 b) 2 4 3 1
c) 3 4 2 1 d) 3 1 2 4

32.c In the banking operations for a circular disc, the size of the punch equals the size of
a)die b)blank plus two times the clearance
c)blank minus two times the clearance d)blank

33.c Match List ± I (Metal forming process ) with List ± II (Associated feature) and select the correct
answer using the codes given below the lists
List ± I List ± II
A.Blanking 1.Shear angle
B.Flow forming 2.Coiled stock
C.Roll forming 3.Mandrel
D.Embossing 4.Closed matching dies
CODES:
A B C D A B C D
a) 1 3 4 2 b) 3 1 4 2
c) 1 3 2 4 d) 3 1 2 4

34.c Which one of the following factors promotes the tendency for wrinkling in the process of drawing
?
a)Increase in the ratio of thickness to blank diameter of the work material
b)Decrease in the ratio of thickness to blank diameter of the work material
c)Decrease in the holding force on the blank
d)Use of solid lubricants

35.c Compound die performs

a)two or more operations at one station in one stroke
b) two or more operations at different stations in one stroke
c)only one operation and that too at one work station
d)two operations at two different work stations in the same work

36.c Assertion (A) : A flywheel is attached to a punching press so as to reduce its speed fluctuations.
Reason (R) : The flywheel stores energy when its speed increases.

37.c In a blanking operations to produce steel washer, the maximum punch load used is 2 x 7 N. the
plate thickness is 4 mm and percentage is 25. The work done during this shearing operations is
a)200 j b)400 j c)600 j d)800 j

38.c Consider the following the factors

1.Clearance between the punch and the die is too small 2.The
finish at the corners of the punch is poor 3.The finish at
the corners of the die is poor 4.The punch
and die alignment is not proper The factors
responsible for the vertical lines parallel to the axis noticed on the outside of a drawn cylindrical
cup would include a)2, 3 and 4 b)1 and 2 c)2 and 4 d)1, 3
and 4




 
 




39.c In blanking operations the clearance provided is

a)50% on punch and 50% on die b)on die
c)on punch d)on die or punch depending upon designer¶s choice
40.c Consider the following states of stress:
1.Compressive stress in flange
2.Tensile stress in the wall
3.Tensile stress in the bottom part
During drawing operations, the states of stress in cup would include
a)1 and 2 b)1 and 3 c)2 and 3 d)1, 2 and 3

 
m




  Metal forming is a process in which the desired size and shape are obtained through the
plastic deformation of a material. The stresses included during the process are greater than yield
and less than fracture. The type of loading may be tensile, compressive, bending, shearing or
combination
Îc This process is very economical because of no loss of material
Îc Some time strength also can be improved through strain hardening

The forming process can be divided into

i)cold forming ii)hot forming

- If the working temperature is above recrystallisation temperature, it is termed as hot working

and those below are termed as cold forming or cold working

- Under the action of heat and force, when the atoms reach a certain higher energy level, the new
crystals start forming which is termed as recrystallisation.

- Recrystallisation temperature is the approximate minimum temperature at which complete

recrystallisation of a cold worked metal occur with in a specified time.

- R. C. T will be generally 1/3 to ½ of M.P of most metals.

- R. C. T also depends on the amount of cold work a metal has already. Higher the cold work,
lower will be RCT.

- For some of the metals like leas and Tim RCT is below room temperature, Cadmium and Zinc
RCT is room temperature.

- In hot working, the temperature at which the working is completed is important since any extra
heat left after working will aid in grain growth thus giving poor mechanical properties.

(8&)'

1.cAny amount of work can be imparted because no strain hardening

2.cNo limit on working because at high temperature material is more ductile and also brittle
materials also can be hot worked.
3.cDue to reduction is shear stress at higher temperature, hot working requires much less force
of achieving necessary deformation.
4.cVery favorable grain size can be achieved
5.cCoefficient of friction for cold working is 0.1, but for hot working it is 0.6
(8




 
 
 



1.cSome metals can not be hot worked due to their brittleness at high temperature.
2.cSurface finish is poor due to formation of scales
3.cNo dimensional stability
4.cHandling and maintaining of hot metal is difficult
&#$! $
i)cRolling ii) Forging iii) Drawing iv) deep drawing
ii)c Bending vi) Extrusion vii) Punching and blanking ± actually it
is not
Forming process but due to similarity it also comes under this.
!!It is a process where the metal is compressed between two rotating rolls for reduction its
CS area. It is most widely used due to higher productivity and low cost. General application are I,
T, C and channel section etc.
Îc Rolling is a hot working process unless specifically mentioned as cold rolling.
Îc In rolling metal is taken into rolls by friction
Îc Rougher rollers will achieve greater reduction than smoother rolls, but rolled metal also be
rough.
Îc The reduction that would be achieved with a given set of rolls is designated as the angle of
bite.

Îc Volume flow of metal remains scene before and after rolling and so velocity of billet after
rolling is higher than before rolling.
Îc When the metal enters the rolls the surface speed of rolls is higher than incoming metal, but
metal velocity at exist is higher than that of surface speed of rolls
Îc Between the entrance and exit the velocity of metal is continuously changing, but roll velocity
remains constant. Some where in the contact length the velocities of metal and rolls are same
which is called neutral plane.
Îc Typical value of angle of bite are
Cod rolling with lubrication 3 and 4
  Hot rolling of tubes 12 to 14
Hot rolling of sheets 15 to 22
Hot rolling with rough rolls 27 to 34
Îc Pressure on rolls increases from inlet to neutral point, maximum at neutral point and then
decreases till it reaches exit
Îc Roll separating force = average roll pressure x total contact area
Îc Average roll pressure is a function of contact length, so roll separating force can be reduced by
reducing contact length.
Îc Contact length can be reduced by reduced by reducing roll diameter, because smaller rollers
will have less contact length than larger rolls for large reductions and cold rolling.
Îc So smaller rollers are used for large reductions and cold rolling.
Îc The smaller rollers are less rigid to withstand for roll separating force, so back up rolls are
attached to provide necessary rigidity.
!!( 




 
 
 



Îc Most commonly used (2-high non-reversible)

Îc 2 high reversible ± more expensive for reversing direction
Îc 3 high used for two continuous process
Îc 4 high similar to 2 high, but alter two rollers acts as back up rollers
Îc Cluster ± similar to 4 high, but better back up is achieved
Îc Planetary rolling mill ± used for achieving large reduction

2



m










a)c!£%The metal contacts each of the rolls along the are AE which is known as the are
of contact.
The angle ³ b ³between the entrance plane and the centre line of rolls is called angle of
bite or angle of contact. The max. permissible angle of bite depends upon the
Îc Materials of rolls, and the bar being rolled.
Îc Roughness of their surfaces
Îc Rolling temperature and speed
Îc b = 24 to 30 in rolling heavy billets
Îc b = 15 to 20 hot rolling sheets and strip stock
Îc b = 2 to 10 in cold rolling oiled sheet and strip.

From the figure

CD = Neutral plane ACDB = Lagging zone ( y8 > y9:: )
CDFE = Leading zone ( y8 < y9:: )
ù H = Draft = H0 ± H1= 2. FL
= D (1 ± Cos b)
Where R = Roll radius
¥ Cos b = 1 ± (ù H / 2 R) = 1 ± ¢ù
b)c Length of deformation zone
From the OAE,
l = R Sin Õ = length of deformation Zone
= R ¢     b
= R 3    ¢ù ;
____________
= « ù H - ¢ù 

but ù < < < < Rù H, and so neglected

¥ l = « R ù
Also Tan Õ = l / R - (ù/2) = « ù / R ± (ù/2)

Since R > > > > ù/2

Tan Õ = «ù/R = « ù/« = « ù/R




 
 




c)cÚ!          

Let y = Entrance speed of strip;
y = Speed at which strip is delivered
y = Surface speed of rolls.
y < y < y
Forward slip = (y - y )/ y

Forward slip can be increased with

-Increase in radius of roll
-decrease in thickness of bar
-increases of coefficient of friction

Backward slip = (y - y )/ y

The point on the path of metal deformation where velocity of strip is equal to velocity of
Roll, the corresponding point is called no slip point (or) neutral plane

d)c (" !!

Two forces will act at the entry of the metal as

N = normal (or) radial forces T = Tangential force
ȕ = Angle of friction
T= .N
+ Coefficient of friction
Rx = T Cos Õ - N Sin Į • 0

For the biting (strip is pushed into roll opening) to take place when Rx • 0
¥ Rx = T Cos Į ± N Sin Į • 0
Tan ȕ • Tan Į, i.e, ȕ • Į
Therefore rolls bite a strip only when the angle of friction is greater than the angle of biting.
When
ȕ = Į, it gives the maximum possible angle of bite , i.e Į is maximum
ù H =  R = max. possible reduction
Note: Max. draft condition is called coulomb friction condition.

e)c"!$!
Let n = constant = 2 ȝ l/ù H
Pressure on the surface of lagging zone is
Px = (
 / n)[ ( n ± 1)¢  + 1] - ¢  .

Pressure on the surface of leading zone
Px = (
 / n)[ ( n + 1)¢  - 1] -
 ¢ 
Where
 = black tension

 = front tension
Hx = thickness at neutral section.
Backward slip = [(y - y )/y ] = 1 ±( y -y ) = 1 ± ( )
Forward slip = [(y -y )/y] = (y -y ) - 1 = ( ) ± 1
Max. pressure = (Px)max = (
 / n) [ (n ± 1) ¢  + 1]
Roll separating force = P = (2 / «)
 . w . 1 [1+ ( 1/4 H) ]
Where




 
 
 



 = yield stress (or) flow stress of work

W = width of the strip being rolled
L = length of deformation zone = « ù H = R Õ
H = average thickness of sheet = ( +  ) / 2
Specific roll pressure P = (P / Contact area) = (P / W .1)
Roll separating force can be reduced by
Îc Using small roll diameter
Îc Lower friction
Îc Higher work piece temperature
Îc Small bites
Îc By applying front tension and back tension

Angle of nip = 2 x max, angle of bite

Rolling torque on each roll = T = P. a
Where P = Roll separating force
a = moment arm =1
Ȝ = arm factor = 0.3 to 0.4
1 = length of deformation zone = «ù H
Power required to drive a roll = (T / 1000) ««.. KW
Total power required = 2 x (T /1000) «««KW
Power loss in bearing = Ö =  P
 . 
Where  = Coefficient friction in bearing

 = diameter of bearing
 = angular speed roller
P = roll separating force.

) Ñ ( "£ In this process rod or tube is pulled through a dia. resulting in reduction on
cross sectional area. Drawing is usually in the cold state and is applied to
i)c Non ferrous metals and alloys ii) steels and alloys steels
In drawing process the dia. of hole is divided into four zones as
a)c Deforming zone (I)
b)c Lubricating zone (II)
c)c Sizing zone (III)
d)c Out let zone (IV)
The sizing zone is usually of a cylindrical form and other zones are conical. The taper angle ³Õ ³of the
deforming zone varies between 7 to  depending on type of work, and metal being drawn
The commonly used lubricants in drawing are
Îc Mineral and vegetable oils and their emulsions
Îc Graphite
Îc Soap solution.
Let  = Initial diameter of rod = 2   = final diameter of rod = 2 
= = (l / 4) ( )2 = cross section of rod before drawing
= = (l / 4) ( )2 = cross section of rod after drawing
K = coefficient of elongation = (= / = ) = 1.25 to 1.3
J = % reduction in area = (= - = ) / = = 30 to 35%
Õ half diameter angle = 6 to   M half the angle of entry = 36 to 7




 
 
 



The variable which will affect drawing process are:

Îc Work material propertied
Îc Die angle
Îc Drawing speed
Îc Lubrication
Îc Die material
Îc Final size of rod

* Die materials can be alloy steels, carbides and diamonds

*Drawing speed ranges:
- 9 mpm for largest diameter rod
- 90 mpm for small rods and coils
- 1500 mpm for very fine wires

Drawing stress =
 =
 (1 + B) / B [1 ± (  ) ] + (  )


Where B = Cot ;

 = back tension
For the case of strip drawing, the expression is

 =
 (1+B) / B [ 1 ± ¢   > ; + ¢   >

 = initial depth of strip ;  = initial depth of strip
Total drawing stress =
 (
 -
 
Where = coefficient of friction L = length of die land
Total drawing load +
 . l R
Die pressure =  +
 -


 =
 (1+B) / B [ 1- ¢ !  > ; + ¢ !  >

67 ( It is limited by the strength of the deformed product. The exit end of the drawn rod will
fracture at the die exit when
 /
 = 1 (if there is not strain hardening)
With zero back stress

 =
 (1+B) / B [ 1- ¢ !  > ; + 0

 /
 = 1 = (1+B) / B [ 1- ¢ !  > ;
1 = 1 + B / B [1 ± ¢  "> ; and B = cot Õ
From the above equation the value of ³J´ can be calculated which gives max. reduction for example
= 0.1, and Õ = 4
B = 0.1 Cot 4 = 0.9515
On substitution, J = 0.505. i.e with = 0.1, Õ = 4 the max possible reduction is 50.5%

Note: harder the metal to be drawn, smaller the die angle, for ex:
Õ =  for Al
Õ =   for Cu
Õ = 4 for steel

"£() In tube drawing in general the reduction in internal diameter is less but only thickness of
pipe is reduced
Let  = initial thickness  = final thickness




 
 
 



And also there is no hoop strain and the analysis is based on plane strain condition

Drawing stress =
 =
 (1+B) / B [ 1- ¢   > ;

Where B =  +  / (tan Õ - tan M )
For cylindrical plug M = 0
B = (  +  ) Cot Õ
 coefficient of friction between die and pipe
 = coefficient of friction between pipe and plug

In plug drawing, the friction drag acts in the backward direction (i.e towards the die
entrance) both at die tube interface and tube plug interface. But in tube drawing with moving mandrel
interface get reversed because with while the tube is getting elongated, the mandrel remains un-deformed.
In tube drawing with moving mandrel
B = (  +  ) / (tan Õ - tan M )
If the mandrel is cylindrical, M = 0
B = (  +  ) / tan Õ
If (  +  ) then B = 0, by taking equilibrium condition is basic equation
Drawing stress =
 = ?@A 7 [1 / [¢    - 1]

For max. draft, similar to wire drawing
 /
 = 1 (non work hardening)
Îc (1+B) / B [1 ± ¢   > ;= 1
Let  =  = 0.05, Õ = B , M 7
B =  +  / tan Õ = 0.1 / 0.268 = 0.373
On substitution
= 0.4275 = 42.75%

6"It is the process of forcing metal enclosed in a container through the opening of a die. In its
CS the extruded metal acquires the contour and dimensions of the die opening. Extrusion is more widely
used in fabricating non-ferrous metals and their alloys. However steel and other ferrous alloys can also be
successfully processed.

The main advantage of extrusion is that high compressive stresses are set up in the billet
due to its reaction with the container and the die. These stresses are effective in reducing the cracking of
materials during primary breakdown from the billet. Due to this large reductions are possible and also the
difficult metals like, SS, Nickel based alloys, high temperature materials can be extruded.

Extrusion is generally considered as a closed die forging, the difference is that the main
body of the metal is the product and flash is cut away and almost no slug remaining but in extrusion the
flash itself is the product and there is a slug remaining in the die.

There are two types of extrusion process:

1.c Direct extrusion
2.c Indirect extrusion
In the direct extrusion, the heated metal billet comes out from the die opening as the
ram moves. In this billet has to move w.r.t container, and so lot of frictional forces will comes into
picture, which are to be over come by the ram force. But in the indirect extrusion there is no frictional
force between container and billet because extruded metal is not moving in the die, but it is going back in
the hallow ram. Also in the indirect extrusion the force is independent of length of billet.

0c Force in indirect extraction is 5 to 30% less than direct extraction.




 
 
 



0c A long hallow ram is required in indirect extrusion, which limit the loads can applied.
0c To reduce frictional forces, a hydraulic press is used, so that it can also act as lubricant.
0c The pressures used in hydrostatic extrusion are 1100 to3250 Mpa.
0c The commonly used fluids in hydrostatic extrusion are Glycerine, Ethyleglycol, SAE 30, castor
oil etc.
0c Applications are - making wires of less ductile materials, and extrusion of nuclear reactor fuel
rods.
0c The cold impact extraction is used to produce short length of hallow shapes such as collapsible
tooth paste tubes, however it is limited to soft and ductile materials like Al, tin, lead etc.
0c Hallow work pieces can be produced by attaching a mandrel to the end of the ram in forward
extrusion and also known as Hooker extrusion .
0c Extrusion ratio is the ratio of billet area to product area which is 40 in case of steel and in case of
Al.

Let =! = crosses sectional area of container, A = cross sectional area of die opening coefficient of
elongation or Extrusion ratio =K = = /= = 8 to 50 (in general)
Reduction of metal =  = (=   = )/=
The process is similar to wire drawing without any back tension.
C¢ >
¥Extrusion Pressure =
 =
>
[1 ± ¢  > ]
C¢ >
= >
[1 ± ¢= = > ]
C¢ >
= > [1 - > ]
For a flat strip K =   / 
Where  = initial thickness of strip
 = final thickness of strip
To account for the container friction.

Let D = ream pressure required by container friction.

 = uniform interface shear stress between billet and container wall
¥ D l/4   = l D  L, D = 4   L / D
Where L = length of billet in container, D = internal diuameter of container
¥Total extrusion pressure = D =
 + D
Extrusion load = D x l

Forging: Forging is the process of shaping heated metal by the application of sudden blows or steady
pressure and by making use of characteristic of plasticity of the material.
Forging process can be classified as
1.c Smith forging
a)c Hand of forging
b)c Power forging
i)c Power hammers
ii)c Press forging
2.c Impression die or closed die forging
a)c Drop forging
b)c Machine forging
c)c Press forging




 
 





Bar forging: This process is used to reduce an ingot heated at round 77 c into a bar. Two flat dies
placed opposite to each other squeeze the metal to reduce its thickness. In this  /  should be less than
1.3.
Forging force = 2 b w  [1 + (b + 4  )]
Where b = width of die;
W = width of work
 = shear flow stress
 = final thickness
 = initial thickness

2  [1 + (b + 4  )] = average pressure under the dies

0c In order to avoid distortion w /  ï 1.5
0c In order that the billet is properly squeezed  / b ï 3

m8" %&!
£
8


1.c Hot rolling of mild steel is carried out (02)
a)At recrystallisation temp c) Below recrystallisation temp
b)between 100C to 150C d) above recrystallisation temp

2.c The true strain a low carbon steel bar which is doubled in length by forging is (92)
a)0.307 b)0.5 c)0.693 d)1.0

3.c A strip with CS 150 x 4.5 mm is being rolled with 29% reduction of area using 450mm dia rolls. The
angle subtended by the deformation zone at the roll centre is (in radians)
a)0.01 b)0.02 c)0.03 d)0.06

4.c The process of hot extrusion is used to produce

a)certain rod made of aluminum b)steel pipes for domestic water supply
c)stainless steel tubes used in furniture d)large size pipes used in city water mains

m8" 4m("£
8
5.c The sequence of operations performed during a closed die forging of a connecting rod is : (2001)
a)edgering ± fullering-blocking-finishing
b)fullering-edgering-blocking-finishing
c)edgering-blocking ± fullering ±finishing
d)fullering- blocking ± edgering ± finishing

6.c In order to reduce roll pressure in strip rolling, back tension must be applied to strip.

7.c A thin tube in pure tension is an example of

a)plain stress and plain strain b)plain strain only
c)plain stress only d)Biaxial stretching




 
 
 



40. Match list I (process) with list II (Production of parts) and select the correct answer using the codes
given below lists:

List I List II
A.c Rolling 1. Discrete parts
B.c Forging 2. Rod and wire
C.c Extrusion 3. Wide variety of shapes with thin walls
D.c Drawing 4. Solid and hollow parts
(
a)c A B C D (2 5 3 4) b) A B C D (1 2 5 4) c) A B C D (4 1 3 2) d) A B C D (4 1
5 2)
41. Match list I (Forging operations) with list II (Descriptions) and select the correct answer using the
codes given below lists:
List I List II
A.c Fattening 1. Thickness is reduced continuously at different
Sections along length
B.c Drawing 2. Metal is displaced away from center reducing
Thickness in middle and increasing length
C.c Fullering 3. Rod is pulled through a dies
D.c Wire drawing 4. Pressing a work piece between two flat dies
(
a)c A B C D (3 2 1 4) b) A B C D (4 1 2 3) c) A B C D (3 1 2 4) d) A B C D (4 2
1 3)
42. Assertion (A): Brittle materials such as grey cast iron cannot be extruded by hydrostatic extrusion
Reason (R): In hydrostatic extrusion, billet is uniformly compressed from all sides by the liquid.
43. Consider the following characteristics of rolling process:
1. Shows work hardening effect
2. Surface finish is not good
3. Heavy reduction in areas be obtained
Which of these characteristics are associated with hot rolling?
a)c 1 and 2 b) 1 and 3 c) 2 and 3 d) 1, 2 and 3
44. Rolling very think strip of mild steel requires
a) large diameter rolls b) small diameter rolls
c) high speed rolling d) rolling without a lubricant
45. Drop forging is used to produce
a) small components b) large components
c) identical components in large numbers d) medium ± size components
46. In cold rolling of sheet metal, the rolls are cambered so that
a) rolled sheets is uniformly thick b) rolled sheet gets better surface finish
c) wear on rolls is reduced d) it is easier to lubricate
47. In hot forging of a certain mild steel (0.3% carbon) component, the forging temperature is maintained
at 777 C till the finishing stage. This results in
a) fine grain size b) the formation of coarse grain size
c) the depletion of carbon in the core d) the formation of hot tears
48. The most suitable lubricant for hot extrusion of steel is




 
 
 



a) graphite b) sulphur c) glass d) none of the above

49. In rolling process 25mm thick plate is rolled to 20mm in four high mill. Roll diameter is 500mm
I) the backward and forward slips are if the neutral point is 21mm,
y = 40 Mpa
a) 5 & 16% b) 16 & 5% c) 10 & 15% d) 15 & 10%
50. The minimum no. of hot rolling passes necessary to reduce an ingot of 200mm thickness to 100mm
thickness in a two high reversible mill with roller diameter of 500mm. The coefficient of friction between
the roll and the hot material are 0.2 is«««««««««..
a) 10 b) 12 c) 14 d) 20
51. A cylindrical block of diameter ³do´ and height ³ho´ is forged to a disc of diameter ³df´ and height
³hf´ in an open die forging operation. The final disc diameter is ««««««««.
a)
 

52. The bite angle when rolling plates of 15mm thick using rollers 400mm diameter and reducing the
thickness by 3mm is ««««««««««..
a) 0.9 b) 3 c) 7 d) None
53. A number of cold rolling passes are required in a two high rolling mill to reduce thickness of a plate
form 50mm to 25mm. The roll diameter is 700mm and the coefficient of friction at the roll work interface
is 0.1 it is required that the draft in each pass must be the same.
Assuming no front and back tensions.
i)The min. number of passes required is ««««««««««
a)c 7 b) 8 c) 10 d) 12
ii) The draft in each pass for equal passes is «««««««««.
a)c 1.5 b) 2.5 c) 3.5 d) None

54. The maximum reduction per pass in a wire drawing using the following data, ȝ = 0.12,die angle = 18

a)32% b)52% c)62% d)72%

55. In wire drawing operation initial wire dia is 5mm, die angle is 4 and die land is 3mm and coefficient
of friction is 0.1. The drawing load when take
 25Mpa is.

a)50KN b)100KN c)150KN d)200KN

56. An annealed copper wire of 25 mm dia is drawn into a wire of 5 mm dia. The average yield stress in
this operation if the flow curve of the material is given as
= 315 
Mpa«

a)592Mpa b)458Mpa c)342Mpa d)none

57. A strip of steel 100mm thick is to be cold rolled mill of 600mm dia rolls. The coefficient of friction
between the strip and roll is 0.1
i)The max possible reduction in thickness««..
a)1mm b)2mm c)3mm d)none
ii)The roll separation distance in this case is«««
a)100mm b)94mm c)97mm d)none

58. The capacity of the press required to extrude Al channels having across sectional area of 3
  from
billet of 100mm dia. The yield stress for Al is 10kg/  and the process efficiency for the case of
extrusion is 0.4 is ««««

a)100tons b)150tons c)200tons d)none