IES Officer (Railway); GATE Percentile 99.

96 Teaching Experience (6 Years); NTPC Ltd (5 Years) Years)

E-mail: swapan_mondal_01@yahoo.co.in

TheoryofMetalCutting

BySKMondal

IAS 2009 main IAS2009main

Name four independent variables and three dependent variables in metal cutting. cutting [5marks] IndependentVariables d d bl Startingmaterials g (tool/work) Toolgeometry l CuttingVelocity Lubrication DependentVariables d bl Forceorpowerrequirements p q Maximumtemperaturein cutting Surfacefinish

IES 2001 IES2001

For cutting of brass with singlepoint cutting tool on a lathe, tool should have (a) Negativerakeangle (b) Positiverakeangle (c) Zerorakeangle (d) Zerosidereliefangle Ans.(c)

IES 1995 IES1995

Singlepointthreadcuttingtoolshouldideally have: a) Zerorake b) Positiverake ) c) Negativerake d) Normalrake Ans.(a)

GATE 1995 2008 GATE1995;2008

gp p g Cuttingpowerconsumptioninturningcanbe significantlyreducedby (a)Increasingrakeangleofthetool ( )I i k l f h l ( ) (b)Increasingthecuttinganglesofthetool g g g (c)Wideningthenoseradiusofthetool (d)Increasingtheclearanceangle Ans.(a) A ( )

IES 1993 IES1993

Assertion (A): For a negative rake tool, the specific cutting pressure is smaller than for a positive rake i i ll h f ii k tool under otherwise identical conditions. Reason (R) Th shear strain undergone b th chip R (R): The h t i d by the hi in the case of negative rake tool is larger. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (d)

IES 2005 IES

Assertion (A): Carbide tips are generally given negative rake angle. i k l Reason (R): Carbide tips are made from very hard materials. t i l (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. Ans (b)

IES 2002 IES

Assertion (A): Negative rake is usually provided on carbide tipped tools. bid i d l Reason (R): Carbide tools are weaker in compression. i (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. Ans (c)

IES 2011 IES2011

Which one of the following statement is NOT correct with reference to the purposes and effects of rake angle of a cutting tool? (a) ( ) To guide the chip fl d d h h flow direction (b) To reduce the friction between the tool flanks and the machined surface h hi d f (c) To add keenness or sharpness to the cutting edges. (d) To provide b d better thermal efficiency. h l ff Ans. (b)

Statement(I):Negativerakeanglesarepreferredonrigid setupsforinterruptedcuttinganddifficulttomachine materials. materials Statement(II):Negativerakeangledirectsthechipsonto themachinedsurface (a) Both Statement (I) and Statement (II) are individually true and Statement (II) is the correct explanation of Statement ( ) (I) (b) Both Statement (I) and Statement (II) are individually true but Statement (II) is not the correct explanation of Statement (I) Ans. (b) (c) Statement (I) is true but Statement (II) is false (d) Statement (I) is false but Statement (II) is true

IES 2012 S 0

GATE 2008 (PI) GATE 2008(PI)

Brittle materials are machined with tools having zero or negative rake angle because it (a) results in lower cutting force (b) improves surface finish (c) provides adequate strength to cutting tool (d) results in more accurate dimensions Ans. Ans (c)

IAS 1994 IAS

Considerthefollowingcharacteristics 1. Thecuttingedgeisnormaltothecuttingvelocity. 2. Thecuttingforcesoccurintwodirectionsonly. 3. Thecuttingedgeiswiderthanthedepthofcut. Thecharacteristicsapplicabletoorthogonalcutting wouldinclude (a) 1and2 (b) 1and3 (c) 2and3 (d) 1,2and3 Ans.(d)

IES 2006 IES2006

Whichofthefollowingisasinglepointcutting tool? ( ) (a) Hacksawblade (b) Millingcutter (c) Grindingwheel (d) Partingtool Ans.(d) Ans (d)

IES 1995 IES1995

g The angle between the face and the flank of the single point cutting tool is known as a) Rake angle b) Clearance angle c) Lip angle ) p g d) Point angle. ( ) Ans. (c)

Assertion (A): For drilling cast iron, the tool is provided with a point angle smaller than that required for a ductile material. Reason ( ) Smaller point angle results in l (R): ll l l lower rake angle. (a) Both ( ) B h A and R are i di id ll true and R i the d individually d is h correct explanation of A (b) B th A and R are i di id ll t Both d individually true b t R i not th but is t the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (c)

S 2006 IES2006

IES 2002 IES2002

Consider the following statements: The strength of a single point cutting tool depends upon 1. Rake angle 2. Clearance angle 3. Lip angle Which of these statements are correct? (a) 1 and 3 (b) 2 and 3 ( ) (c) 1 and 2 ( ) (d) 1, 2 and 3 , Ans. (d)

IES 2012 IES

Toollifeincreasewithincreasein (a)Cuttingspeed (b)Noseradius (c)Feed (d)Depthofcut Ans.(b)

IES 2009 IES2009

Consider the following statements with respect to the effects of a large nose radius on the tool: 1. It deteriorates surface finish. 2. It increases the possibility of chatter. 3. It improves tool life. Which of the above statements is/are correct? y (b) 3 only y (a) 2 only (c) 2 and 3 only (d) 1, 2 and 3 ( ) Ans. (c)

IES 1995 IES1995

Consider the following statements about nose radius di 1. It improves tool life 2. It reduces the cutting force 3. It improves the surface finish. Select the correct answer using the codes given below: (a) 1 and 2 (b) 2 and 3 (c) 1 and 3 (d) 1, 2 and 3 Ans. (c)

IES1994
Tool geometry of a single point cutting tool is specified by the following elements: 1. Back rake angle 2. Side rake angle 3. End cutting edge angle 4. Side cutting edge angle 5. Side relief angle d l f l 6. End relief angle 7. 7 Nose radius The correct sequence of these tool elements used for y p y g g y correctly specifying the tool geometry is (a) 1,2,3,6,5,4,7 (b) 1,2,6,5,3,4,7 (c) 1,2,5,6,3,4,7 (d) 1, 2, 6, 3, 5, 4,7 Ans. (b)

IES 2009 IES2009

The following tool signature is specified for a single point cutting tool in American system: 10, 12, 8, 6, 15, 20, 3 What does the angle 12 represent? (a) Side cuttingedge angle (b) Side rake angle g (c) Back rake angle (d) Side clearance angle ( ) Ans. (b)

IES 1993 IES1993

In ASA System, if the tool nomenclature is 8655 10152mm, then the side rake angle will be (a) 5 (b) 6 (c) 8 (d) 10

Ans.(b)

ISRO2011
A cutting tool having tool signature as 10, 9, 6, 6, 8, 8, 8 8 2 will have side rake angle (a) 10o Ans. (b) (b) 9o (c) 8o (d) 2o

GATE 2008 GATE2008

In a single point turning tool, the side rake angle and orthogonal rake angle are equal. is the d h l k l l i h principal cutting edge angle and its range is The hi flows i th orthogonal plane. in the th l l 0o 90o . Th chip fl The value of is closest to (a) 00 (b) 450 (c) 600 (d) 900 Ans. (d) principal cutting edge angle i = 90 cs A i i l tti d l is

IAS 2009Main

GATE 2001 GATE2001

g g g During orthogonal cutting of mild steel with a 10 rake angle tool, the chip thickness ratio was obtained as 0.4. The shear angle (in 4 g ( degrees) evaluated from this data is (a)6.53 (a)6 53 (b)20.22 (b)20 22 (c)22.94 (d)50.00 Ans.(c) A ( )

GATE 2011 GATE2011

A single point cutting tool with 12 rake angle is used to machine a steel work piece. The depth of cut, i.e. uncut thickness is 0.81 mm. The chip thickness under orthogonal machining condition i thi k d th l hi i diti is 1.8 mm. The shear angle is approximately (a) 22 22 (b) 26 (c) 6 ( ) 56 (d) 76 Ans. (b) A

The following parameters determine the model of continuous chip formation: d l f i hi f i 1. True feed 2. Cutting velocity 3. 3 Chip thickness 4. Rake angle of the cutting tool. The Th parameters which govern the value of shear hi h h l f h angle would include (a) 1,2 and 3 (b) 1,3 and 4 (c) 1,2 and 4 (d) 2,3 and 4 Ans. (b)

IES 1994 IES1994

IES 2009 IES

g Minimum shear strain in orthogonal turning with a cutting tool of zero rake angle is (a) ( ) 0.0 (b) 0.5 (c) 1.0 (d) 2.0 Ans. (d)

IES 2004
In a machining operation chip I hi i i hi thickness ratio is 0.3 and the rake angle of the tool is 10. What is the value of the shear strain? (a) 0.31 (b) 0.13 (c) ( ) 3.00 (d) 3.34 ( ) Ans. (d)

GATE 2012 GATE2012

Details pertaining to an orthogonal metal cutting process are given below. below Chip thickness ratio 0.4 Undeformed thi k U d f d thickness 0.6 mm 6 Rake angle +10 Cutting C i speed d 2.5 m/s / Mean thickness of primary shear zone 25 microns The shear strain rate in s1 during the process is (b) 0.7754105 (a) 0.1781105 (c) 1.0104105 (d) 4.397105 Ans. (c)

GATE 2007 GATE2007

In orthogonal turning of a low carbon steel bar of diameter 150 mm with uncoated carbide tool, the cutting velocity is 90 m/min. The feed is i 0.24 mm/rev and th d th of cut i 2 mm. / d the depth f t is The chip thickness obtained is 0.48 mm. If the orthogonal rake angle is zero and the principal cutting edge angle is 90, the shear angle is degree is g (a) 20.56 (b) 26.56 ( )3 5 (c) 30.56 ( )3 5 (d) 36.56 Ans. (b) ( )

IES 2004 IES2004

Considerthefollowingstatementswithrespectto thereliefangleofcuttingtool: h li f l f i l 1.Thisaffectsthedirectionofchipflow 2.Thisreducesexcessivefrictionbetweenthetool andworkpiece 3.Thisaffectstoollife Thi ff llif 4.Thisallowsbetteraccessofcoolanttothetool workpieceinterface k i i t f Whichofthestatementsgivenabovearecorrect? (a) d ( ) 1and2 (b) 2and3 d (c) 2and4 (d) 3and4 Ans.(b)

IES 2006 IES2006

Considerthefollowingstatements: 1. Alargerakeanglemeanslowerstrengthofthe cuttingedge. 2. Cuttingtorquedecreaseswithrakeangle. Whichofthestatementsgivenaboveis/arecorrect? (a) Only1 (b) Only2 (c) Both1and2 (d) Neither1nor2 Ans.(c)

IES 2004 IES2004

Match.ListIwithListIIandselectthecorrectanswer usingthecodesgivenbelowtheLists: i th d i b l th Li t ListI ListII A. A Planapproachangle 1. 1 Toolface B. Rakeangle 2. Toolflank C. C Clearanceangle 3. 3 Toolfaceandflank D. Wedgeangle 4. Cuttingedge 5. 5 (a) (c) A 1 4 B 4 1 C 2 2 D 5 3 (b) (d) Toolnose[Ans (c)] Ans.(c)] A B C D 4 1 3 2 1 4 3 5

IES 2003 IES2003

The angle of inclination of the rake face with respect to the tool base measured in a plane h l b d i l perpendicular to the base and parallel to the width of the tool is called (a) Back rake angle (b) Side rake angle (c) Side cutting edge angle (d) E d cutting edge angle End tti d l Ans. (b)

IES 2004 ISRO 2009 IES2004,ISRO2009

The rake angle of a cutting tool is 15, shear angle 45 and cutting velocity 35 m/min. What is the velocity of chip along the tool face? ( ) (a) 28.5 m/min 5 ( ) 73 (b) 27.3 m/min (c) 25.3 m/min (d) 23.5 m/min Ans. Ans (a)

IES 2008 IES2008

Considerthefollowingstatements: Inanorthogonalcuttingthecuttingratioisfoundtobe 075.Thecuttingspeedis60m/minanddepthofcut24 mm.Whichofthefollowingarecorrect? mm Whichofthefollowingarecorrect? 1. Chipvelocitywillbe45m/min. 2. Chipvelocitywillbe80m/min. 3. Chipthicknesswillbe18mm. 4. Chipthicknesswillbe32mm. Chipthicknesswillbe3 2mm. Selectthecorrectanswerusingthecodegivenbelow: ( ) (a) 1and3 3 ( ) (b) 1and4 4 (c) 2and3 (d) 2and4 Ans.(b)

If is the rake angle of the cutting tool, 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)
V cos cos( )
V cos sin( )

IES 2001 IES2001

(b) (d)

V sin cos ( )

V sin sin( )

Ans. (a)

IES 2003 IES2003

An orthogonal cutting operation is being carried out under the following conditions: cutting speed = 2 m/s, depth of cut = 0.5 mm, chip thickness = 0.6 mm. Then the chip velocity is (a) 2.0 m/s (b) 2.4 m/s (c) 1.0 m/s (d) 1.66 m/s Ans. (d)

IAS 2003 IAS2003

Inorthogonalcutting,shearangleistheanglebetween (a) Shearplaneandthecuttingvelocity ( ) (b) Shearplaneandtherakeplane (c) Shearplaneandtheverticaldirection ( ) Sh l d h i ldi i (d) Shearplaneandthedirectionofelongationofcrystalsin thechip Ans.(a) Ans (a)

IAS 2002 IAS2002

Ans.(a) A ( )

IAS 2000 IAS2000

Ans.(d) Ans (d)

IAS 1998 IAS1998

The cutting velocity in m/sec, for turning a work piece of diameter 100 mm at the spindle speed of 480 RPM is f di t t th i dl d f 8 i (a) 1.26 (b) 2.51 (c) 48 (d) 151 Ans. Ans (b)

IAS 1995 IAS1995

In an orthogonal cutting, the depth of cut is halved and the feed rate is double. If the chip thickness ratio is th f d t i d bl th hi thi k ti i unaffected with the changed cutting conditions, the p actual chip thickness will be (a) Doubled (b) halved ( ) Q (c) Quadrupled p ( ) (d) Unchanged. g Ans. (b)

GATE 2009 (PI) Common Data S 1 GATE 2009(PI)CommonDataS1

An orthogonal turning operation is carried out at 20 m/min cutting speed, using a cutting tool of rake angle 15o. The chip thickness is 0 4 mm and the uncut chip 0.4 thickness is 0.2 mm. The shear plane angle (in degrees) is (a) 6 8 ( ) 26.8 Ans. ( ) (c) (b) 27.8 8 (c) 8 8 ( ) 28.8 (d) 29.8 8

GATE 2009 (PI) Common Data S 2 GATE 2009(PI)CommonDataS2

An orthogonal turning operation is carried out at 20 m/min cutting speed, using a cutting tool of rake angle 15o. The chip thickness is 0 4 mm and the uncut chip 0.4 thickness is 0.2 mm. The chip velocity (in m/min) is (a) ( )8 ( ) Ans. (b) (b) 10 (c) ( ) 12 (d) 14

GATE 1995 GATE1995

Plainmillingofmildsteelplateproduces (a)Irregularshapeddiscontinuouschips (b)Regularshapeddiscontinuouschip (c)Continuouschipswithoutbuiltupedge (d)Joinedchips (d)J i d hi Ans.(b) A (b)

IES 2007 IES2007

Duringmachining,excessmetalisremovedintheform ofchipasinthecaseofturningonalathe.Whichofthe ofchipasinthecaseofturningonalathe Whichofthe followingarecorrect? Continuousribbonlikechipisformedwhenturning p g 1. Atahighercuttingspeed 2. Atalowercuttingspeed g p 3. Abrittlematerial 4. Aductilematerial Selectthecorrectanswerusingthecodegivenbelow: (a) 1and3 (b) 1and4 (c) 2and3 (d) 2and4 Ans.(b)

IAS 1997 IAS1997

Considerthefollowingmachiningconditions:BUEwill formin f i (a) Ductilematerial. (b) Highcuttingspeed. (c) Smallrakeangle (d) Smalluncutchipthickness Smallrakeangle. Smalluncutchipthickness. Ans.(a) Ans (a)

GATE 2002 GATE2002

Abuiltupedgeisformedwhilemachining (a)Ductilematerialsathighspeed (b)Ductilematerialsatlowspeed (c) (c)Brittlematerialsathighspeed tt e ate a s at g speed (d)Brittlematerialsatlowspeed

Ans.(b) Ans (b)

IES 1997 IES1997

Assertion (A): For high speed turning of cast iron pistons, carbide tool bits are provided with chip i t bid t l bit id d ith hi breakers. Reason (R): High speed turning may produce long, ribbon type continuous chips which must b b k ibb i hi hi h be broken into small lengths which otherwise would be difficult to handle and may prove hazardous. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. Ans (d)

Ch 1 M h i f B i M hi i O ti Ch1:MechanicsofBasicMachiningOperation
Q. No 1 2 3 4 5 6 7 8 9 10 Option C B D C B D B A B B Q. No 11 12 13 14 15 16 17 18 19 20 Option D D B C D B B D D B

Force & Power in Metal Cutting g

BySKMondal

ESE 2000 (C ti l) ESE2000(Conventional)

g g g The following data from the orthogonal cutting test is available. Rake angle = 100, chip thickness ratio = 0.35, uncut chip thickness = 0.51 mm, width of cut = 3 mm, yield shear stress of work material = 285 i ld h f k i l N/mm2, mean friction coefficient on tool force = 0.65, 0 65 Determine (i) Cutting force (Fc) (ii) Radial force (iii) Normal force (N) on tool and (iv) Shear f (i ) Sh force on the tool (Fs ) h l Ans. 1597 N, 0 N, 1453.8 N, 1265 N

ESE 2005 C ti l ESE2005Conventional

g g Mild steel is being machined at a cutting speed of 200 m/min with a tool rake angle of 10. The width of cut and uncut thickness are 2 mm and 0.2 mm respectively. If the average value of coefficient of friction between the tool and the chip is 0.5 and the shear stress of 4 / the work material is 400 N/mm2, Determine (i) shear angle and (ii) Cutting and thrust component of the force. [Ans. 429 N , 127 N]

GATE 2008 (PI) Linked S1 GATE 2008(PI)LinkedS 1

In an orthogonal cutting experiment, an HSS tool having the following tool signature in the orthogonal reference system (ORS) has been used: 0107710751. Given width of cut = 3.6 mm; shear strength of workpiece material = 460 N/mm2; depth of cut = 0 25 mm; 0.25 coefficient of friction at toolchip interface = 0.7. Shear plane angle (in degree) for minimum cutting force is (a) 20.5 (b) 24.5 (c) 28.5 (d) 32.5 [Ans. (d)]

GATE 2008 (PI) Linked S2 GATE 2008(PI)LinkedS 2

In an orthogonal cutting experiment, an HSS tool having the following tool signature in the orthogonal reference system (ORS) has been used: 0107710751. Given width of cut = 3.6 mm; shear strength of workpiece material = 460 N/mm2; depth of cut = 0 25 mm; 0.25 coefficient of friction at toolchip interface = 0.7. Minimum power requirement (in kW) at a cutting speed of 150 m/min is (a) 3.15 (b) 3.25 (c) 3.35 (d) 3.45 [Ans. (b)]

GATE 2007 (PI) Common Data1 GATE 2007(PI)CommonData1

In an orthogonal machining test, the following observations were made Cutting force 1200 N Thrust force Th t f 500 N Tool rake angle zero Cutting C i speed d 1 m/s / Depth of cut 0.8 mm Chip thickness 1.5 mm Friction angle during machining will be (a) 22.6o (b) 32.8o (c) 57.1o (d) 67.4o [Ans. (a)]

GATE 2007 (PI) Common Data2 GATE 2007(PI)CommonData2

In an orthogonal machining test, the following observations were made Cutting force 1200 N Thrust force Th t f 500 N Tool rake angle zero Cutting C i speed d 1 m/s / Depth of cut 0.8 mm Chip thickness 1.5 mm Chip speed along the tool rake face will be (a) 0.83 m/s (b) 0.53 m/s (c) 1.2 m/s (d) 1.88 m/s [Ans. (b)]

ESE2003 Conventional S 003 o e t o a

During turning a carbon steel rod of 160 mm diameter by a carbide tool of geometry; 0, 0, 10, 8, 15, 75, 0 (mm) at speed of 400 rpm, feed of 0.32 mm/rev and 4.0 mm depth of cut, the f d f / d d th f t th following observation were made. Tangential component of the cutting force, Pz = 1200 N a ge t a co po e t o t e cutt g o ce, 00 Axial component of the cutting force, Px = 800 N Chip thickness (after cut), 2 = 0.8 mm. For the above machining condition determine the values of (i) Friction force, F and normal force, N acting at the chip tool interface. i t f (ii) Yield shears strength of the work material under this g machining condition. (iii) Cutting power consumption in kW. Ans. 828 N, 1200 N, 231.15 Mpa, 4.021 kW

GATE 1995 C ti l GATE 1995Conventional

g 5 While turning a C15 steel rod of 160 mm diameter at 315 rpm, 2.5 mm depth of cut and feed of 0.16 mm/rev by a tool of geometry 00, 100, 80, 90,150, 750, 0(mm), the f ll i observations were made. ( ) h following b i d Tangential component of the cutting force = 500 N Axial component of the cutting force = 200 N Chip thickness = 0.48 mm Draw schematically the Merchants circle diagram for the cutting force in the present case. Ans. F = 291 N, N = 457.67 N, Fn = 355.78 N, Fs = 408.31 N, Friction angle = 32.49o

IAS2003 Main Examination IAS 2003MainExamination

During turning process with 7 ? 6 6 8 30 1 (mm) ASA tool the undeformed chip thickness of 2.0 mm and width of cut of 2.5 mm were used. The side rake angle of the tool was a chosen that the g machining operation could be approximated to be orthogonal cutting. The tangential cutting force and thrust f h force were 1177 N and 560 N respectively. d 6 i l Calculate: [30 marks] (i) Th side rake angle The id k l (ii) Coefficient of friction at the rake face (iii) h dynamic shear strength of the work material ( ) The d h h f h k l Ans. 12o, 0.82, 74.43 MPa

IES 2004 IES

A medium carbon steel workpiece is turned on a lathe at 50 m/min. cutting speed 0.8 mm/rev feed l h / i i d 8 / f d and 1.5 mm depth of cut. What is the rate of metal removal? (a) 1000 mm3/min (b) 60 000 mm3/min 60,000 (c) 20,000 mm3/min (d) C not b calculated with th given d t Can t be l l t d ith the i data Ans. (b)

GATE 2007 GATE2007

g g Inorthogonalturningofmediumcarbonsteel.The specificmachiningenergyis2.0J/mm3.Thecutting velocity,feedanddepthofcutare120m/min,0.2 mm/revand2mmrespectively.Themaincutting / d i l h i i forceinNis (a)40 ( ) (b)80 (b)8 (c)400 (d)800 Ans.(d) (d)

ForPSU&IES
In strain gauge dynamometers the use of how many active gauge makes the dynamometers more effective (a) Four (b) Three (c) Two (d) One Ans. (a) ( )

i ( ) GATE2006CommonDataQuestions(1)
g g p Inanorthogonalmachiningoperation: Uncutthickness=0.5mm g p / g 5 Cuttingspeed=20m/min Rakeangle=15 Widthofcut=5mm Chipthickness=0.7mm Thrustforce 200N Thrustforce=200N Cuttingforce 1200N Cuttingforce=1200N AssumeMerchant'stheory. Thecoefficientoffrictionatthetoolchipinterfaceis (a)0.23 (b)0.46 (c)0.85 (c)0 85 (d)0.95 (d)0 95 Ans.(b)

i ( ) GATE2006CommonDataQuestions(2)
g g p Inanorthogonalmachiningoperation: Uncutthickness=0.5mm g p / g 5 Cuttingspeed=20m/min Rakeangle=15 Widthofcut=5mm Chipthickness=0.7mm Thrustforce 200N Thrustforce=200N Cuttingforce 1200N Cuttingforce=1200N AssumeMerchant'stheory. Thepercentageoftotalenergydissipateddueto frictionatthetoolchipinterfaceis (a)30% (b)42% (c)58% (d)70% Ans.(a)

i ( ) GATE2006CommonDataQuestions(3)
g g p Inanorthogonalmachiningoperation: Uncutthickness=0.5mm g p / g 5 Cuttingspeed=20m/min Rakeangle=15 Widthofcut=5mm Chipthickness=0.7mm Thrustforce 200N Thrustforce=200N Cuttingforce 1200N Cuttingforce=1200N AssumeMerchant'stheory. Thevaluesofshearangleandshearstrain, Thevaluesofshearangleandshearstrain respectively,are (a)30.3 and1.98 (a)30 3 and1 98 (b)30.3 and4.23 (b)30 3 and4 23 (c)40.2 and2.97 (d)40.2 and1.65Ans.(d)

i ( ) GATE2003CommonDataQuestions(1)
y g A cylinder is turned on a lathe with orthogonal machining principle. Spindle rotates at 200 rpm. The axial feed rate is 0.25 mm per revolution. Depth of cut is 0.4 mm. The rake angle i 10. In the analysis i i f h k l is h l i it is found d that the shear angle is 27.75 Thethicknessoftheproducedchipis Th thi k fth d d hi i (a)0.511mm (b)0.528mm (c)0.818mm ( ) (d)0.846mm (d) Ans.(a)

i ( ) GATE2003CommonDataQuestions(2)
y g A cylinder is turned on a lathe with orthogonal machining principle. Spindle rotates at 200 rpm. The axial feed rate is 0.25 mm per revolution. Depth of cut is 0.4 mm. The rake angle i 10. In the analysis i i f h k l is h l i it is found d that the shear angle is 27.75 Intheaboveproblem,thecoefficientoffrictionat I th b bl th ffi i t ff i ti t thechiptoolinterfaceobtainedusingEarnestand Merchanttheoryis (a)0.18 (b)0.36 (c)0.71 (c)0 71 (d)0.98 (d)0 98 Ans.(d) Ans (d)

i ( ) GATE2008CommonDataQuestion(1)
g g performed on a cylindrical work y Orthogonal turning is p piece with shear strength of 250 MPa. The following conditions are used: cutting velocity is 180 m/min. feed is i 0.20 mm/rev. d h of cut i 3 mm. chip thickness / depth f is hi hi k ratio = 0.5. The orthogonal rake angle is 7o. Apply Merchant s Merchant's theory for analysis analysis. Theshearplaneangle(indegree)andtheshear forcerespectivelyare (a)52:320N (b)52:400N (c)28:400N (d)28:320N Ans.(d) Ans (d)

i ( ) GATE2008CommonDataQuestion(2)
g g performed on a cylindrical work y Orthogonal turning is p piece with shear strength of 250 MPa. The following conditions are used: cutting velocity is 180 m/min. feed is i 0.20 mm/rev. d h of cut i 3 mm. chip thickness / depth f is hi hi k ratio = 0.5. The orthogonal rake angle is 7o. Apply Merchant s Merchant's theory for analysis analysis. Thecuttingandthrustforces,respectively,are (a)568N;387N (b)565N;381N (a) 68N 38 N (b) 6 N 38 N (c)440N;342N (d)480N;356N [Ans.(b)]

GATE 2010 (PI) Li k d S 1 GATE2010(PI)LinkedS1

In orthogonal turning of an engineering alloy, it has been observed that the friction force acting at the chip b b d h h fi i f i h hi tool interface is 402.5 N and the friction force is also perpendicular to the cutting velocity vector The feed vector. velocity is negligibly small with respect to the cutting velocity. The ratio of friction force to normal force y associated with the chiptool interface is 1. The uncut chip thickness is 0.2 mm and the chip thickness is 0.4 mm. The cutting velocity is 2 m/s. The shear force (in N) acting along the primary shear plane i l is (a) 180.0 (b) 240.0 (c) 360.5 (d) 402.5 Ans. (a)

GATE 2010 (PI) Li k d S 2 GATE2010(PI)LinkedS2

In orthogonal turning of an engineering alloy, it has been observed that the friction force acting at the chip chip tool interface is 402.5 N and the friction force is also p p perpendicular to the cutting velocity vector. The feed g y velocity is negligibly small with respect to the cutting velocity. The ratio of friction force to normal force associated with the chiptool interface is 1 The uncut 1. chip thickness is 0.2 mm and the chip thickness is 0.4 mm. The cutting velocity is 2 m/s. Assume that the energy expended during machining is completely converted to heat. The rate of heat generation (in W) at the primary shear plane is (a) 180.5 (b) 200.5 (c) 302.5 (d) 402.5 Ans. (d)

GATE 2011 (PI) Linked S1 GATE 2011(PI)LinkedS1

During orthogonal machining of a mild steel specimen with a cutting tool of zero rake angle, the following data angle is obtained: Uncut chip thickness = 0.25 mm Chip thickness = 0.75 mm Width of cut = 2 5 mm 2.5 Normal force = 950 N Thrust force = 475 N [Ans. [Ans (b)] The shear angle and shear force, respectively, are (a) 71 565o, 150 21 N 71.565 150.21 (b) 18 435o , 751 04 N 18.435 751.04 (c) 9.218o, 861.64 N (d) 23.157o , 686.66 N

GATE 2011 (PI) Linked S2 GATE 2011(PI)LinkedS2

During orthogonal machining of a mild steel specimen with a cutting tool of zero rake angle, the following data angle is obtained: Uncut chip thickness = 0.25 mm Chip thickness = 0.75 mm Width of cut = 2 5 mm 2.5 Normal force = 950 N Thrust force = 475 N Theultimateshearstress(inN/mm2)ofthework materialis [Ans.(d)] [Ans (d)] (a)235 (b)139 (c)564 (d)380

IES 2012 IES

Duringorthogonalcutting,anincreaseincuttingspeed causes (a)Anincreaseinlongitudinalcuttingforce (b)Anincreaseinradialcuttingforce ( ) (c)Anincreaseintangentialcuttingforce (d)Cuttingforcestoremainunaffected Ans.(d)

IES 2010 IES2010

The relationship between the shear angle , the friction angle and cutting rake angle h f i i l d i k l is given as

Ans.(b)

IES 2005 IES2005

g Which one of the following is the correct expression for the Merchant's machinability constant? (a) 2 + (b) 2 + (c) 2 (d) + ( (Where = shear angle, = friction angle g , g and = rake angle) Ans. (a)

GATE 1997 GATE1997

yp g p , g Inatypicalmetalcuttingoperation,usinga cuttingtoolofpositiverakeangle=10,it wasobservedthattheshearanglewas20. g Thefrictionangleis (a)45 (a)45 (b)30 (b)30 (c)60 (d)40 Ans.(c)

IAS 1999 IAS

In an orthogonal cutting process, rake angle of the tool is 20 and friction angle is 25.5. Using l i d f i i l i U i Merchant's shear angle relationship, the value of shear angle will be (a) 39.5 (b) 42.25 (c) 47 75 47.75 (d) 50 5 50.5 Ans. (b) A

IES 2003 IES2003

g g , g In orthogonal cutting test, the cutting force = 900 N, the thrust force = 600 N and chip g 3 p shear angle is 30o. Then the chip shear force is (a) 1079.4 N (b) 969.6 N (c) 479 4 N 479.4 (d) 69 6 N 69.6 Ans. (c)

IES 2000 IES2000

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

( b)2

( c)

( d) 2 2

Ans.(a)

IES 1996 IES1996

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

GATE 2007 GATE2007

g g In orthogonal turning of low carbon steel p p with pipe principal cutting edge angle of 90, the main cutting force is 1000 N and the feed force is 800 N. The shear angle i 25 and orthogonal rake angle i zero. l is d h l k l is Employing Merchants theory, the ratio of friction force to normal force acting on the cutting tool is (a) 1.56 (b) 1.25 (c) 0 80 0.80 (d) 0 64 0.64 Ans. ( ) A (c)

IES 1997 IES1997

g g Consider the following forces acting on a finish turning tool: 1. 1 Feed force 2. Thrust force 3. C i f Cutting force. The correct sequence of the decreasing order of the magnitudes of these forces is ( ) , , (a) 1, 2, 3 ( ) , (b) 2, 3, 1 (c) 3, 1, 2 (d) 3, 2, 1 [Ans. (c)]

IES 1999 IES1999

g p g The radial force in singlepoint tool during turning operation varies between (a) 0 2 to 0 4 times the main cutting force 0.2 0.4 (b) 0.4 to 0.6 times the main cutting force (c) ( ) 0.6 to 0.8 times the main cutting f i h i i force (d) 0.5 to 0.6 times the main cutting force Ans. Ans (a)

IES 1995 IES1995

y g The p primary tool force used in calculating the total power consumption in machining is the (a) Radial force (b) Tangential force (c) Axial force (d) Frictional force force. Ans. (b)

IES 2002 IES2002

g process, the p , g In a machining p percentage of heat carried away by the chips is typically (a) 5% (b) 25% (c) 50% (d) 75% Ans. (d)

IES 1998 IES1998

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

IAS 2003 IAS

Asthecuttingspeedincreases (a) Moreheatistransmittedtotheworkpieceandless heatistransmittedtothetool (b) ( ) Moreheatiscarriedawaybythechipandlessheatis transmittedtothetool (c) Moreheatistransmittedtoboththechipandthe ( ) M h i i d b h h hi d h tool (d) M h ti t Moreheatistransmittedtoboththeworkpieceand itt dt b thth k i d thetool Ans.(b)

IES 2001 IES2001

p g Power consumption in metal cutting is mainly due to (a) Tangential component of the force (b) Longitudinal component of the force (c) Normal component of the f ( )N l f h force (d) Friction at the metaltool interface Ans. Ans (a)

IAS 1995 IAS

Thrustforcewillincreasewiththeincreasein (a) Sidecuttingedgeangle (b)Toolnoseradius (c) Rakeangle (d)Endcuttingedgeangle. Ans.(a)

IES 2010 IES2010

Consider the following statements: In an orthogonal, singlepoint metal cutting, as the sidecutting edge angle is increased, 1. The tangential force increases. 2. 2 The longitudinal force drops drops. 3. The radial force increases. Which f h Whi h of these statements are correct? ? (a) 1 and 3 only (b) 1 and 2 only (c) 2 and 3 only (d) 1, 2 and 3 Ans. (c)

IES 1993 IES1993

y A 'Dynamometer' is a device used for the measurement of (a) Chip thickness ratio (b) Forces during metal cutting (c) Wear f h ( ) W of the cutting tool i l (d) Deflection of the cutting tool Ans. Ans (b)

IES 2011 IES2011

Theinstrumentordeviceusedtomeasurethe cuttingforcesinmachiningis: (a)Tachometer (b)Comparator (c)Dynamometer (d)Lactometer Ans.(c)

IAS 2001 IAS2001

Assertion (A): Piezoelectric transducers and preferred over strain gauge transducers in the dynamometers for measurement of threedimensional cutting forces. Reason (R): In electric transducers there is a significant leakage of signal from one axis to the other, such cross error is negligible in the case of piezoelectric transducers. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true b R is not the h d d d ll but h correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (c)

IAS 2003 IAS

The heat generated in metal conveniently be determined by i l b d i db (a) Installing thermocouple on the job (b) ( ) Installing thermocouple on the tool (c) Calorimetric setup (d) Using radiation pyrometer cutting can

Ans. (c)

IES 1998 IES1998

p The g g factor of a resistive p gauge pickup of cutting force dynamometer is defined as the ratio of (a) Applied strain to the resistance of the wire (b) The proportional change in resistance to the applied strain (c) The i ( ) Th resistance to the applied strain h li d i (d) Change in resistance to the applied strain Ans. (b)

IES 2000 IES2000

g, Assertion ( ) In metal cutting, the normal (A): laws of sliding friction are not applicable. Reason (R): Very high temperature is produced at the toolchip interface. (a) Both A and R are individually true and R is the correct explanation of A (b) B h A and R are i di id ll true b R i Both d individually but is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (a)

GATE 1992 GATE1992

The effect of rake angle on the mean friction angle in machining can be explained by ( ) (A) sliding (Coulomb) model of friction g( ) (B) sticking and then sliding model of friction (C) sticking friction (D) Sliding and then sticking model of friction Ans. (b)

IES 2004 IES2004

Assertion (A): The ratio of uncut chip thickness to actual chip thickness is always less than one and is t l hi thi k i l l th d i termed as cutting ratio in orthogonal cutting Reason (R): The frictional force is very high due to the occurrence of sticking friction rather than sliding friction (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true b R is not the h d d d ll but h correct explanation of A (c) A is true but R is false (d) A is false but R is true

Ans. (b)

GATE 1993 GATE1993

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

Ans. (b)

ToolWear,ToolLife&Machinability ToolWear,ToolLife& Tool Wear, Tool Life & Machinability

BySKMondal

IAS 2009Main
Explainsuddendeathmechanismoftoolfailure. [4 marks]

IES 2009 C ti l IES2009Conventional

g p Showcraterwearandflankwearonasinglepoint cuttingtool.Statethefactorsresponsibleforwear onaturningtool. [2marks]

IES 2010 IES2010

Flank wear occurs on the (a) Relief face of the tool ( ) (b) Rake face (c) Nose of the tool (d) Cutting edge Ans. (a)

IES 2007 IES

Flankwearoccursmainlyonwhichofthe following? f ll i ? (a) Nosepartandtopface (b) ( ) Cuttingedgeonly (c) Nosepart,frontreliefface,andsiderelieffaceofthe cuttingtool i l (d) Faceofthecuttingtoolatashort distancefrom thecuttingedge th tti d Ans.(c)

IES 2004 IES

Consider the following statements: During the third stage of toolwear, rapid deterioration of tool edge takes place because 1. Flank wear is only marginal 2. Flank wear is large 3. Temperature of the tool increases gradually 4. Temperature of the tool increases drastically Which of the statements given above are correct? (a) 1 and 3 (b) 2 and 4 (c) 1 and 4 (d) 2 and 3 Ans. (b)

IES 2002 IES

Craterwearontoolsalwaysstartsatsomedistance fromthetooltipbecauseatthatpoint f h l i b h i (a) Cuttingfluiddoesnotpenetrate (b) ( ) Normalstressonrakefaceismaximum (c) Temperatureismaximum (d) Toolstrengthisminimum Ans.(c)

IAS 2007 IAS

Whydoescraterwearstartatsomedistancefrom thetooltip? h l i ? (a) Toolstrengthisminimumatthatregion (b) ( ) Cuttingfluidcannotpenetratethatregion (c) Tooltemperatureismaximuminthatregion (d) Stressonrakefaceismaximumatthatregion

Ans.(c)

IES 2000 IES

Craterwearstartsatsomedistancefromthetooltip because (a) Cuttingfluidcannotpenetratethatregion (b) ( ) Stressonrakefaceismaximumatthatregion (c) Toolstrengthisminimumatthatregion (d) Tooltemperatureismaximumatthatregion Ans.(d)

IES 1996 IES

Notchwearattheoutsideedgeofthedepthofcutis dueto d (a) Abrasiveactionoftheworkhardenedchipmaterial (b) ( ) Oxidation (c) Slipstickactionofthechip (d) Chipping. Ans.(b)

IES 1995 IES

MatchListIwithListIIandselectthecorrect answerusingthecodesgivenbelowthelists: i h d i b l h li ListI(Weartype) ListII(Associatedmechanism) A. Abrasivewears 1. Galvanicaction B. Adhesivewears 2. Ploughing action C. Electrolyticwear 3. Moleculartransfer D. Diffusionwears 4. Plasticdeformation 5. Metallicbond [Ans.(a)] Code:A B C D A B C D (a) 2 5 1 3 (b) 5 2 1 3 3 4 (d) 5 2 3 4 (c) 2 1

IES 1995 IES

Craterwearispredominantin (a) Carbonsteeltools (b) Tungstencarbidetools (c) Highspeedsteeltools (d) Ceramictools Ans.(a)

IES 1994 IES

Assertion(A):Toolwearisexpressedintermsof flankwearratherthancraterwear. fl k h h Reason(R):Measurementofflankwearissimple andmoreaccurate. d t (a) BothAandRareindividuallytrueandRisthe correctexplanationofA (b) BothAandRareindividuallytruebutRisnot the correctexplanationofA (c) AistruebutRisfalse (d) AisfalsebutRistrue [Ans.(c)] [Ans (c)]

IES 2008 IES

Whatarethereasonsforreductionoftoollifeina machiningoperation? hi i i ? 1. Temperatureriseofcuttingedge 2. Chippingoftooledgeduetomechanicalimpact 3. Gradualwearsattoolpoint 4. Increaseinfeedofcutatconstantcuttingforce Selectthecorrectanswerusingthecodegiven below: (a) 1,2and3 (b) 2,3and4 (c) 1,3and4 (d) 1,2and4 [Ans.(a)]

IAS 2002 IAS

Consider the following actions: 1. Mechanical abrasion 2. Diffusion 3. Plastic deformation 4. Oxidation Which of the above are the causes of tool wear? (a) 2 and 3 (b) 1 and 2 (c) 1, 2 and 4 (d) 1 and 3 Ans. (c)

IAS 1999 IAS

The type of wear that occurs due to the cutting action of the particles in the cutting fluid is i f h i l i h i fl id i referred to as (a) Attritions wear ( ) Att iti (b) Diffusion wear (c) Erosive ( ) E i wear (d) Corrosive wear Ans. (c)

IAS 2003 IAS

Consider the following statements: Chipping of a cutting tool is due to 1. Tool material being too brittle 2. Hot hardness of the tool material. 3. High positive rake angle of the tool. Which of these statements are correct? (a) 1, 2 and 3 (b) 1 and 3 (c) 2 and 3 (d) 1 and 2 ( ) Ans. (b)

IES 2012 IES

InTaylorstoollifeequationVTn =C,theconstantsn andCdependupon dCd d 1.Workpiecematerial 2.Toolmaterial 3.Coolant (a)1,2,and3 (b)1and2only (c)2and3only (d)1and3only Ans.(a)

IFS2009
With the help of Taylors tool life equation, determine the shape of the cur e bet een velocity curve between elocit of cutting and life of the tool. Assume an HSS tool and steel as work material. [10Marks] [ M k ]

IES 1996 IES1996

Chip equivalent is increased by (a) An increases in sidecutting edge angle of tool (b) An increase in nose radius and side cutting edge angle of tool (c) Increasing the plant area of cut (d) Increasing the depth of cut. Ans. (b)

IES 1992 IES

Toollifeisgenerallyspecifiedby (a) Numberofpiecesmachined (b) Volumeofmetalremoved (c) Actualcuttingtime (d) Anyoftheabove Ans.(d)

GATE 2004 GATE2004

In a machining operation, doubling the 1 cutting speed reduces the tool life to 8 th of the original value. The exponent n in Taylor's tool life equation VTn = C, is
(a) 1 8 (b) 1 4 (c ) 1 3 (d ) 1 2

Ans.(c) A ( )

IES 2000 IES

In a tool life test, doubling the cutting speed reduces the tool life to 1/8th of the original. The d h l lif /8 h f h i i l Th Taylor's tool life index is
1 a ) ( 2 1 b ) ( 3 1 c ) ( 4 1 d ) ( 8

Ans.(b)

IES 1999 IES

Inasinglepointturningoperationofsteelwitha cementedcarbidetool,Taylor'stoollifeexponentis d bid l T l ' llif i 0.25.Ifthecuttingspeedishalved,thetoollifewill increaseby (a) Twotimes (b) Fourtimes (c) Eighttimes (d) Sixteentimes Ans.(d) A (d)

IES 2008 IES

InTaylor'stoollifeequationisVTn =constant. Whatisthevalueofnforceramictools? (a) 0.15to0.25 (b) 0.4to0.55 (c) 0.6to0.75 (d) 0.8to0.9 Ans.(c)

IES 2006 IES

Which of the following values of index n is associated with carbide tools when Taylor's tool life i d ih bid l h T l ' l lif equation, V.Tn = constant is applied? (a) ( ) 01 t 015 to (b) 02 t 04 to (c) 0.45 to 06 (d) 065 to 09 Ans. (b)

IES 1999 IES

The approximately variation of the tool life exponent 'n' of cemented carbide tools is ' ' f d bid l i (a) 0.03 to 0.08 (b) 0.08 to 0.20 (c) ( ) 0.20 to 0.48 (d) ( ) 0.48 to 0.70 Ans. (c)

IAS 1998 IAS

MatchList I(Cuttingtoolmaterial)withList II (Typicalvalueoftoollifeexponent n intheTaylor s (Typicalvalueoftoollifeexponent'n'intheTaylor's equationV.Tn =C)andselectthecorrectanswerusing thecodesgivenbelowthelists: List I List II A. HSS 1. 0.18 B. B Castalloy 2. 2 0.12 0 12 C. Ceramic 3. 0.25 Ans.(d) D. D Sinteredcarbide 4 4. 0.5 05 Codes:A B C D A B C D (a) 1 2 3 4 (b) 2 1 3 4 (c) 2 1 4 3 (d) 1 2 4 3

GATE2009(PI)
In an orthogonal machining operation, the tool life obtained is 10 min at a cutting speed of 100 m/min 0 00 m/min, while at 75 m/min cutting speed, the tool life is 30 min. The value of index (n) in the Taylors tool life equation (a) 0.262 Ans. (a) (b) 0.323 (c) 0.423 (d) 0.521

ISRO 2011 ISRO2011

A 50 mm diameter steel rod was turned at 284 rpm and tool failure occurred in 10 minutes. The speed was changed to 232 rpm and the tool failed in 60 minutes. g g p g Assuming straight line relationship between cutting speed and tool life, the value of Taylorian Exponent is (a) 0.21 Ans. Ans (c) (b) 0.13 (c) 0.11 (d) 0.23

IES 2010 IES2010

The above figure shows a typical relationship between tool life and l i hi b l lif d cutting speed for different materials. Match the graphs for g p HSS, Carbide and Ceramic tool materials and select the correct answer using the code given below the lists: Code: HSS Carbide Ceramic (a) 1 2 3 (b) 3 2 1 (c) ( ) 1 3 2 (d) 3 1 2

Ans.(a)

During machining, the wear land (h) has been plotted against machining time (T) as given in the following figure.

GATE2008(PI) G 008 ( )

For a critical wear land of 1.8 mm, the cutting tool life (in minute) is ) Ans.(b) Ans (b) (a) 52.00 (b) 51.67 (c) 51.50 (d) 50.00

GATE 2010 GATE2010

For tool A, Taylors tool life exponent (n) is 0.45 and constant (K) is 90. Similarly for tool B, n = 0.3 and K = 60. The cutting speed (in m/min) above which tool A will have a higher tool life than tool B is (a) 26.7 (b) 42.5 (c) 80.7 (d) 142.9 Ans. (a)

GATE 2003 GATE2003

A batch of 10 cutting tools could produce 500 components while working at 50 rpm with a t hil ki t ith tool feed of 0.25 mm/rev and depth of cut of 1 mm. mm A similar batch of 10 tools of the same specification could produce 122 components while working at 80 rpm with a feed of 0.25 mm/rev and 1 mm depth of cut. How many p p components can be produced with one cutting tool at 60 rpm? 9 (b) 31 3 (a) 29 (c) 37 (d) 42 Ans. (a)

IES 1994 2007 IES 1994,2007

Forincreasingthematerialremovalrateinturning, withoutanyconstraints,whatistherightsequence ih i h i h i h toadjustthecuttingparameters? 1. S Speed d 2. Feed F d 3. Depthofcut D th f t Selectthecorrectanswerusingthecodegivenbelow: S l h i h d i b l (a) 1 2 3 (b) 2 3 1 (c) ( ) 3 2 1 (d) ( ) 1 3 2 Ans.(c)[readquestionagain,commonerror(a)]

IES 2010 IES2010

Tool life is affected mainly with (a) Feed ( ) p (b) Depth of cut (c) Coolant (d) Cutting speed Ans. (d)

IES 1997 IES

Considerthefollowingelements: 1. Noseradius 2. Cuttingspeed 3. Depthofcut 4. Feed ThecorrectsequenceoftheseelementsinDECREASING orderoftheirinfluenceontoollifeis (a) 2,4,3,1 (b) 4,2,3,1 (c) 2,4,1,3 (d) 4,2,1,3 Ans.(a)

ISRO2012
What is the correct sequence of the following parameters in order of their maximum to minimum influence on tool lif ? i fl l life? 1. Feed rate 2. Depth of cut 3. Cutting speed Select the correct answer using the codes given below (a) 1, 2, 3 (b) 3, 2, 1 (c) 2, 3, 1 (d) 3, 1, 2 Ans. (d)

IES 1992 IES

Toollifeisgenerallybetterwhen (a) Grainsizeofthemetalislarge (b) Grainsizeofthemetalissmall (c) Hardconstituentsarepresentinthemicrostructure ofthetoolmaterial (d) Noneoftheabove Ans.(a)

IAS 2003 IAS

ThetoollifecurvesfortwotoolsAandBareshownin thefigureandtheyfollowthetoollifeequationVTn =C. th fi dth f ll th t llif ti VT C Considerthefollowingstatements:
1. 2. 3. 4. Valueofnforboththetoolsissame. ValueofCforboththetoolsissame. ValueofCfortoolAwillbegreaterthanthatforthetoolB. ValueofCfortoolBwillbegreaterthanthatforthetoolA.

Whichofthesestatementsis/arecorrect? (a) 1and3 (b) 1and4 (c) 2only (d) 4only

Ans.(a)

IAS 2002 IAS

UsingtheTaylorequationVTn =c,calculatethe percentageincreaseintoollifewhenthecutting i i llif h h i speedisreducedby50%(n=05andc=400) (a) ( ) 300% % (b) 400% % (c) 100% (d) 50%

Ans.(a) ( )

IAS 2002 IAS

Optimum cutting speed for minimum cost (Vc min ) and optimum cutting speed for maximum d i i d f i production rate (Vr max ) have which one of the following relationships? (a) Vc min = Vr max (b) Vc min > Vr max (c) Vc min < Vr max (d) V2c min = Vr max

Ans. (c)

IES 2010 IES2010

With increasing cutting velocity, the total time for machining a component i f hi i (a) Decreases (b) Increases (c) Remains unaffected (d) First decreases and then increases Ans. (d)

IAS 2000 IAS

Considerthefollowingstatements: Thetoollifeisincreasedby 1. Builtupedgeformation 2. Increasingcuttingvelocity 3. Increasingbackrakeangleuptocertainvalue Whichofthesestatementsarecorrect? 3 (b) 1and2 (a) 1and3 (c) 2and3 (d) 1,2and3 Ans.(a)

IAS 1997 IAS

In the Taylor's tool life equation, VTn = C, the value of n = 0.5. The tool has a life of 180 minutes at a f Th l h lif f 8 i cutting speed of 18 m/min. If the tool life is reduced to 45 minutes then the cutting speed will be minutes, (a) 9 m/min (b) 18 m/min (c) 36 m/min (d) 72 m/min Ans. ( ) A (c)

IAS 1996 IAS

Thetoollifeincreaseswiththe (a) Increaseinsidecuttingedgeangle (b) Decreaseinsiderakeangle (c) Decreaseinnoseradius (d) Decreaseinbackrakeangle Ans.(a)

IAS 1995 IAS

Inasinglepointturningoperationwithacemented carbideandsteelcombinationhavingaTaylor bid d l bi i h i T l exponentof0.25,ifthecuttingspeedishalved,then thetoollifewillbecome (a) Half (b) Twotimes (c) Eighttimes (d) Si t Sixteentimes. ti Ans.(d) A (d)

IAS 1995 IAS

Assertion (A): An increase in depth of cut shortens the tool life. h l lif Reason(R): Increases in depth of cut gives rise to relatively small i l ti l ll increase i t l t in tool temperature. t (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true [Ans. [Ans (a)]

IES 2006 conventional IES 2006conventional

An HSS tool is used for turning operation. The tool life is 1 hr. when turning is carried at 30 m/min. The tool life will be reduced to 2.0 min if the cutting speed is doubled. Find the suitable speed in RPM for turning 300 mm diameter so that tool life is 30 min.

Ans. (36.66 Ans (36 66 rpm)

ESE 1999; IAS 2010 Conventional ESE1999;IAS2010Conventional

The following equation for tool life was obtained for HSS tool. A 60 min tool life was obtained using the following l 6 i l lif b i d i h f ll i cutting condition VT0.13f0.6d0.3= C. v = 40 m/min, f = 0.25 mm, mm d = 2 0 mm Calculate the effect on tool life if 2.0 mm. speed, feed and depth of cut are together increased by 25% and also if they are increased individually by 25%; 5 y y y 5 ; where f = feed, d = depth of cut, v = speed. Ans. 2.3 min, 10.78 min, 21.42 min, 35.85 min

IES 2009 Conventional IES2009Conventional

Determine the optimum cutting speed for an operation on a Lathe machine using the following i L h hi i h f ll i information: Tool h T l change ti time: 3 min i Tool regrinds time: 3 min Machine M hi running cost R i Re.0.50 per min i Depreciation of tool regrinds Rs. 5.0 The constants in the tool life equation are 60 and 0.2 Ans. 26 m/min A 6 / i

ESE 2001 Conventional ESE2001Conventional

In a certain machining operation with a cutting speed of 50 m/min, tool life of 45 minutes was observed. When the cutting speed was increased to 100 m/min, the tool life decreased to 10 min. Estimate the cutting speed for maximum productivity if tool change time is 2 minutes. Ans. 195 m/min

GATE 2009 Li k d A Q i (1) GATE2009LinkedAnswerQuestions(1)

Inamachiningexperiment,toollifewasfoundtovary withthecuttingspeedinthefollowingmanner: i h h i di h f ll i Cuttingspeed(m/min) Toollife(minutes) 60 81 90 36 Theexponent(n)andconstant(k)oftheTaylor's toollifeequationare (a)n=0.5andk=540 ( ) (b)n=1andk=4860 ( ) (c)n=1andk=0.74 (d)n0.5andk=1.15 Ans.(a)

GATE 2009 Li k d A Q i (2) GATE2009LinkedAnswerQuestions(2)

Inamachiningexperiment,toollifewasfoundtovary withthecuttingspeedinthefollowingmanner: i h h i di h f ll i Cuttingspeed(m/min) Toollife(minutes) 60 81 90 36 Whatisthepercentageincreaseintoollifewhen thecuttingspeedishalved? (a)50% ( ) (b)200% ( ) (c)300% (d)400% Ans.(c)

GATE 1999 GATE1999

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

GATE 2005 GATE2005

Ans.(a)

IAS 2007 Contd IAS 2007Contd

A diagram related to machining economics with various cost components is given above. Match List I above (Cost Element) with List II (Appropriate Curve) and select the correct answer using the code given below g g the Lists: ListI ListII (CostElement) ( ) (AppropriateCurve) ( ) A. Machiningcost 1. Curvel B. Toolcost B T l 2. Curve2 C C. Toolgrindingcost 3. Curve3 D. Nonproductivecost 4. D N d ti t Curve4 C 5. Curve5

Contd. From previous slide

Ans.(b) A (b)

Code:A C d A (a) 3 (c) ( ) 3

B 2 1

C 4 4

D 5 2

(b) (d)

A 4 4

B 1 2

C 3 3

D 2 5

IES 1998 IES

The variable cost and production rate of a machining process against cutting speed are shown hi i i i d h in the given figure. For efficient machining, the range of best cutting speed would be between (a) 1 and 3 (b) 1 and 5 (c) 2 and 4 (d) 3 and 5 d

Ans.(c)

IES 1999 IES

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

IES 2011 IES2011

The optimum cutting speed is one which should have: 1. High metal removal rate 2. High cutting tool life 3. Balance the metal removal rate and cutting tool life (a) 1, 2 and 3 (b) 1 and 2 only (c) 2 and 3 only (d) 3 only Ans. (d)

IES 2000 IES

The magnitude of the cutting speed for maximum profit rate must be fi b (a) In between the speeds for minimum cost and maximum production rate i d ti t (b) Higher than the speed for maximum production rate (c) Below h ( ) B l the speed f minimum cost d for i i (d) Equal to the speed for minimum cost Ans. (a)

IES 2004 IES

Consider the following statements: 1. As the cutting speed increases, the cost of production A th tti d i th t f d ti initially reduces, then after an optimum cutting speed it increases 2. As the cutting speed increases the cost of production also increases and after a critical value it reduces 3. 3 Higher feed rate for the same cutting speed reduces cost of production 4 4. Higher feed rate for the same cutting speed increases the g g p cost of production Which of the statements given above is/are correct? (a) ( ) 1 and 3 d (b) 2 and 3 d (c) 1 and 4 (d) 3 only [Ans. (a)]

IES 2002 IES

Ineconomicsofmachining,whichoneofthe followingcostsremainsconstant? f ll i i ? (a) Machiningcostperpiece (b) ( ) Toolchangingcostperpiece (c) Toolhandlingcostperpiece (d) Toolcostperpiece

Ans.(c)

IAS 2007 IAS

Assertion (A): The optimum cutting speed for the minimum cost of machining may not maximize the i i f hi i i i h profit. Reason (R) Th profit also d R (R): The fit l depends on rate of d t f production. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true [Ans. (a) ]

IAS 1997 IAS

Inturning,theratiooftheoptimumcuttingspeed forminimumcostandoptimumcuttingspeedfor f i i d i i df maximumrateofproductionisalways (a) Equalto1 ( ) E lt (b) Intherangeof0.6to1 (c) Intherangeof0.1to0.6 ( ) I h f 6 (d) Greaterthan1 Ans.(b)

IES 2012 IES

The usual method of defining machinability of a material is by an index based on i li b i d b d (a) Hardness of work material (b) ( ) Production rate of machined parts (c) Surface finish of machined surfaces (d) Tool life Ans. (d)

IES 2011 Conventional IES2011Conventional

Discuss the effects of the following elements on the machinability of steels: (i) Aluminium and silicon (ii) S l h and S l i Sulphur d Selenium (iii) Lead and Tin (iv) Carbon d Manganese (i ) C b and M (v) Molybdenum and Vanadium [5 Marks]

IES 1992 IES

Easeofmachiningisprimarilyjudgedby (a) Lifeofcuttingtoolbetweensharpening (b) Rigidityofworkpiece (c) Microstructureoftoolmaterial (d) Shapeanddimensionsofwork Ans.(a)

IES 2007 2009 IES 2007,2009

Considerthefollowing: 1. Toollife 2. Cuttingforces 3. Surfacefinish Whichoftheaboveis/arethemachinability criterion/criteria? (a) 1,2and3 (b) 1and3only (c) 2and3only (d) 2only Ans.(a)

ISRO2007
Machinablity depends on (a) Microstructure, physical and mechanical properties and composition of workpiece material. (b) Cutting forces (c) Type of chip (d) Tool life Ans. (a) ( )

IES 2003 IES

Assertion (A): The machinability of steels improves by adding sulphur to obtain so called 'Free Free Machining Steels. Reason (R): Sulphur in steel forms manganese sulphide inclusion which helps to produce thin ribbon like continuous chip. (a) ( ) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (c)

IES 2009 IES

The elements which, added to steel, help in chip formation during machining are f i d i hi i (a) Sulphur, lead and phosphorous (b) ( ) Sulphur, lead and cobalt (c) Aluminium, lead and copper (d) Aluminium, titanium and copper Ans. (a)

IES 1998 IES

Considerthefollowingcriteriainevaluating machinability: hi bili 1. Surfacefinish 2. Typeofchips 3. Toollife 4. Powerconsumption InmodernhighspeedCNCmachiningwithcoated carbidetools,thecorrectsequenceofthesecriteria bid l h f h i i inDECREASINGorderoftheirimportanceis (a) ( ) 1,2,4,3 (b) 2,1,4,3 (c) 1,2,3,4 (d) 2,1,3,4 Ans.(c) A ( )

IES 1996 IES

Which of the following machinability? hi bili ? 1. Smaller shear angle 2. Higher cutting forces 3. Longer tool life 4. Better surface finish. (a) 1 and 3 (b) 2 and 4 (c) 1 and 2 (d) 3 and 4 Ans. (d) indicate better

IES 1996 IES

Small amounts of which one of the following elements/pairs of elements is added to steel to l / i f l i dd d l increase its machinability? (a) Nickel ( ) Ni k l (b) S l h and phosphorus Sulphur d h h (c) Silicon (d) Manganese and copper

Ans. (b)

IES 1995 IES

Inlowcarbonsteels,presenceofsmallquantities sulphur improves l h i (a) Weldability (b) Formability (c) ( ) Machinability (d) ( ) Hardenability

Ans.(c)

IES 1992 IES

Machiningoftitaniumisdifficultdueto (a) Highthermalconductivityoftitanium (b) Chemicalreactionbetweentoolandwork (c) Lowtoolchipcontactarea (d) Noneoftheabove

Ans.(b)

IAS 1996 IAS

Assertion(A):Themachinabilityofamaterialcan bemeasuredasanabsolutequantity. b d b l i Reason(R):Machinabilityindexindicatesthecase withwhichamaterialcanbemachined ith hi h t i l b hi d (a) BothAandRareindividuallytrueandRisthe correctexplanationofA (b) BothAandRareindividuallytruebutRisnot the correctexplanationofA (c) AistruebutRisfalse (d) AisfalsebutRistrue Ans.(d)

GATE 2009 GATE2009

Frictionatthetoolchipinterfacecanbe reducedby (a)decreasingtherakeangle ( ) g g (b)increasingthedepthofcut (c)Decreasingthecuttingspeed (d)increasingthecuttingspeed Ans.(d)

IES 2002 IES

The value of surface roughness 'h' obtained during the turning operating at a feed 'f' with a round nose h i i f d ih d tool having radius 'r' is given as

Ans.(b)

IAS 1996 IAS

Given that S = feed in mm/rev. and R = nose radius in mm, the maximum height of surface roughness Hmax produced by a singlepoint turning tool is given by (a) S2/2R (b) S2/4R (c) S2/4R (d) S2/8R Ans. (d)

IES 1999 IES

In turning operation, the feed could be doubled to increase the metal removal rate. To keep the same i h l l T k h level of surface finish, the nose radius of the tool should be (a) Halved (b) Kept unchanged (c) doubled (d) Made four times Ans. (d)

GATE 1997 GATE

Acuttingtoolhasaradiusof1.8mm.Thefeedrate foratheoreticalsurfaceroughnessofRa =5mis f h i l f h fR i (a) 0.36mm/rev (b) ( ) 0.187mm/rev (c) 0.036mm/rev (d) 0.0187mm/rev Ans.(none)

GATE 2007 (PI) GATE 2007(PI)

A tool with Side Cutting Edge angle of 30o and End Cutting Edge angle of 10o is used for fine E d C i Ed l f i d f fi turning with a feed of 1 mm/rev. Neglecting nose radius of the tool, the maximum ( di f h l h i (peak to valley) k ll ) height of surface roughness produced will be (a) 0.16 mm (b) 0.26 mm ( ) 3 (c) 0.32 mm ( ) 4 (d) 0.48 mm Ans. (a)

Two tools P and Q have signatures 5566830 5 ) p y 0 and 5 5 7 7 55778150 ( (both ASA) respectively. They are used to turn components under the same machining conditions. If hp and hQ denote the peak tovalley heights of surfaces produced by the tools P and Q, the ratio hp/hQ will be

GATE 2005 GATE

tan 8 + cot15 (a) o o tan 8 + cot 30 tan15o + cot7o (c ) o o tan 30 + cot7

tan15 + cot 8 (b) o o tan 30 + cot 8 tan7o + cot15o (d ) o o tan7 + cot 30

Ans.(b)

IES 1993 ISRO2008 IES 1993,ISRO2008

For achieving a specific surface finish in single point turning the most important factor to be controlled i h i f b ll d is (a) Depth f t ( ) D th of cut (b) C tti speed Cutting d (c) Feed (d) Tool rake angle Ans. (c)

IES 2006 IES

In the selection of optimal cutting conditions, the requirement of surface finish would put a limit on i f f fi i h ld li i which of the following? (a) The ( ) Th maximum f d i feed (b) The maximum depth of cut (c) The ( ) Th maximum speed i d (d) The maximum number of passes Ans. (a)

GATE 2010 (PI) GATE2010(PI)

During turning of a low carbon steel bar with TiN coated carbide insert, one need to improve surface finish without sacrificing material removal rate. To achieve improved surface finish, one should (a) decrease nose radius of the cutting tool and increase depth of cut (b) Increase nose radius of the cutting tool (c) Increase feed and decrease nose radius of the cutting tool (d) Increase depth of cut and increase feed [Ans.(b)]

IAS 2009 Main IAS 2009Main

Whatareextremepressurelubricants? [3 marks] [3 Where high pressures and rubbing action are encountered, hydrodynamic lubrication cannot be y y maintained; so Extreme Pressure (EP) additives must be added to the lubricant. EP lubrication is provided by a number of chemical components such as boron boron, phosphorus, sulfur, chlorine, or combination of these. The compounds are activated by the higher temperature resulting from extreme pressure. As the temperature rises, EP molecules become reactive and release derivatives such as iron chloride or iron sulfide and forms a solid protective coating.

IES 2001 IES

Dry and compressed air is used as cutting fluid for machining hi i (a) Steel (b) Aluminium (c) ( ) Cast iron ( ) Brass (d) Ans. (c)

IES 2012 IES

Themostimportantfunctionofthecuttingfluidis to (a)Providelubrication (b)Coolthetoolandworkpiece ( ) (c)Washawaythechips (d)Improvesurfacefinish Ans.(b)

Ch 3 C tti T l T l Lif d C tti Fl id Ch3:CuttingTools,ToolLifeandCuttingFluid

Q. No 1 2 3 4 5 6 7 8 9 10 11 Option B A A D D D B A D D A Q. No 12 13 14 15 16 17 18 19 20 21 22 Option C A A B B B A B A B B Q. No 23 24 25 26 27 28 29 30 31 32 33 Option A C C B B A B A C B C

Ch 4: Economics of Machining Operation Ch4:EconomicsofMachiningOperation

Q. No 1 2 3 4 5 Option C B A C A Q. No 6 7 8 9 Option B A C A

MetalForming M t lF i
BySKMondal d l

IES 2011 IES2011

Assertion (A): Lead, Zinc and Tin are always hot worked. Reason (R) : If they are worked in cold state they cannot retain their mechanical properties. h h h l (a) Both A and R are individually true and R is the correct explanation of A l i f (b) Both A and R are individually true but R is NOT the th correct explanation of A t l ti f (c) A is true but R is false (d) A i f l b R i true is false but is Ans. (b) A

GATE 2003 GATE2003

Cold working of steel is defined as working (a) At its recrystallisation temperature (b) Above its recrystallisation temperature (c) Below its recrystallisation temperature (d) At two thirds of the melting temperature of the metal Ans. (c)

GATE 2002 ISRO 2012 GATE2002,ISRO2012

Hot rolling of mild steel is carried out (a) At recrystallisation temperature (b) Between 100C to 150C (c) Below recrystallisation temperature (d) Above recrystallisation temperature Ans. (d)

ISRO2010
Materials after cold working are subjected to following process to relieve stresses (a) Hot working (b) T Tempering i (c) Normalizing (d) Annealing g Ans. (d)

IES 2006 IES

Which one of the following is the process to refine the grains of metal after it has been distorted by h i f l f i h b di d b hammering or cold working? (a) Annealing ( ) A li (b) S ft i Softening (c) Recrystallizing (d) Normalizing

Ans. ( ) (c)

IES 2004 IES

Consider the following statements: In comparison to hot working, in cold working, 1. Higher forces are required 2. No heating is required 3. Less ductility is required 4. Better surface finish is obtained Which of the statements given above are correct? g (a) 1, 2 and 3 (b) 1, 2 and 4 ( ) (c) 1 and 3 ( ) , (d) 2, 3 and 4 Ans. (b)

IES 2009 IES

Consider the following characteristics: 1. Porosity in the metal is largely eliminated. 2. Strength is decreased. 3. Close tolerances cannot be maintained. Which of the above characteristics of hot working is/are correct? (a) 1 only (b) 3 only (c) 2 and 3 (d) 1 and 3 Ans. (d)

IES 2008 IES

Consider the following statements: 1. Metal forming decreases harmful effects of impurities and improves mechanical strength. 2. Metal working process is a plastic deformation process. 3. V Very i i intricate shapes can b produced b f i h be d d by forging process as compared to casting process. Which f the t t Whi h of th statements given above are correct? t i b t? (a) 1, 2 and 3 (b) 1 and 2 only (c) ( ) 2 and 3 only d l (d) 1 and 3 only d l Ans. (b) A

IES 2008 IES

Cold forging results in improved quality due to which of the following? hi h f h f ll i ? 1. Better mechanical properties of the process. 2. Unbroken grain flow. 3. Smoother finishes. 4. High pressure. Select the correct answer using the code given below: (a) 1, 2 and 3 (b) 1, 2 and 4 (c) 2, 3 and 4 (d) 1, 3 and 4 Ans. (a)

IES 2004 IES

Assertion (A): Cold working of metals results in increase of strength and hardness i f h dh d Reason (R): Cold working reduces the total number of di l f dislocations per unit volume of th material ti it l f the t i l (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. Ans (c)

IES 2003 IES

Cold working produces the following effects: 1. Stresses are set up in the metal 2. Grain structure gets distorted 3. Strength and hardness of the metal are decreased 4. Surface finish is reduced Which of these statements are correct? (a) 1 and 2 (b) 1, 2 and 3 (c) 3 and 4 (d) 1 and 4 ( ) Ans. (a)

IES 2000 IES

Assertion (A): To obtain large deformations by cold working intermediate annealing is not required. ki i di li i i d Reason (R): Cold working is performed below the recrystallisation t t lli ti temperature of th work material. t f the k t i l (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. Ans (d)

ISRO2009
In the metal forming process, the stresses encountered are (a) Greater than yield strength but less than ultimate strength (b) Less than yield strength of the material (c) Greater than the ultimate strength of the material i l (d) Less than the elastic limit Ans. (a)

IES 1997 IES

In metals subjected to cold working, strain hardening effect is due to h d i ff i d (a) Slip mechanism (b) ( ) Twining mechanism (c) Dislocation mechanism (d) Fracture mechanism Ans. (c)

IES 1996 IES

Considerthefollowingstatements: Whenametaloralloyiscoldworked 1. Itisworkedbelowroomtemperature. 2. Itisworkedbelowrecrystallisation temperature. 3. Itshardnessandstrengthincrease. 4. Itshardnessincreasesbutstrengthdoesnot increase. Ofthesecorrectstatementsare (a) 1and4 (b) 1and3 (c) 2and3 (d) 2and4 Ans.(c)

IES 2006 IES

Assertion (A): In case of hot working of metals, the temperature at which the process is finally stopped t t t hi h th i fi ll t d should not be above the recrystallisation temperature. Reason (R): If the process is stopped above the recrystallisation temperature, grain growth will take place again and spoil the attained structure. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true b R is not the h d d d ll but h correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (d)

IES 1992 IES

Specify the sequence correctly (a) Grain growth, recrystallisation, stress relief (b) Stress relief, grain growth, recrystallisation (c) Stress relief, recrystallisation, grain growth (d) Grain growth, stress relief, recrystallisation Ans. (c)

IAS 1996 IAS

For mild steel, the hot forging temperature range is (a) 4000C to 6000C (b) 7000C to 9000C (c) 10000C to 12000C (d) 13000Cto 15000C Ans. (c)

IAS 2004 IAS

Assertion (A): Hot working does not produce strain hardening. h d i Reason (R): Hot working is done above the re crystallization t t lli ti temperature. t (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. Ans (a)

IAS 2002 IAS2002

Assertion (A): There is good grain refinement in hot working. ki Reason (R): In hot working physical properties are generally i ll improved. d (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (b) Ulta hai. Assertion reason me hona chaihe.

IES 2008 IES2008

Which one of the following is correct? Malleability is the property by which a metal or alloy can be plastically deformed by applying (a) ( ) Tensile stress (b) ( ) Bending stress (c) Shear stress (d) Compressive stress Ans. (d)

Rolling R lli
BySKMondal

ISRO2006
Which of the following processes would produce strongest components? (a) Hot rolling (b) Extrusion (c) Cold rolling (d) Forging Ans. Ans (c)

ISRO2009
Ring rolling is used (a) To decrease the thickness and increase diameter (b) To increase the thickness of a ring (c) For producing a seamless tube (d) For producing large cylinder Ans. (a) ( )

IES 2006 IES

Which one of the following is a continuous bending process in which opposing rolls are used to produce i hi h i ll d d long sections of formed shapes from coil or strip stock? (a) Stretch forming (b) Roll forming (c) Roll bending (d) Spinning Ans. ( ) A (c)

GATE 2009(PI)
Anisotropy in rolled components is caused by (a) h ( ) changes in d dimensions (b) scale formation sca e o a o (c) closure of defects (d) grain orientation Ans. (d) A

GATE 2008 GATE2008

In a single pass rolling operation, a 20 mm thick plate with plate width of 100 mm, is reduced to 18 l ih l id h f i d d 8 mm. The roller radius is 250 mm and rotational speed is 10 rpm The average flow stress for the plate rpm. material is 300 MPa. The power required for the rolling operation in kW is closest to g p (a) 15.2 (b) 18.2 (c) 30.4 (d) 45 6 45.6 Ans. Ans (a)

GATE 2007 GATE2007

The thickness of a metallic sheet is reduced from an initial value of 16 mm to a final value of 10 mm in i ii l l f 6 fi l l f i one single pass rolling with a pair of cylindrical rollers each of diameter of 400 mm The bite angle mm. in degree will be (a) 5 936 5.936 (b) 7.936 (c) 8 936 8.936 (d) 9.936 Ans. (d)

GATE 2004 GATE2004

In a rolling process, sheet of 25 mm thickness is rolled to 20 mm thickness. Roll is of diameter 600 ll d hi k R ll i f di 6 mm and it rotates at 100 rpm. The roll strip contact length will be (a) 5 mm (b) 39 mm (c) 78 mm (d) 120 mm Ans. (b) A

GATE 1998 GATE1998

A strip with a crosssection 150 mm x 4.5 mm is being rolled with 20% reduction of area using 450 b i ll d i h % d i f i mm diameter rolls. The angle subtended by the deformation zone at the roll centre is (in radian) (a) 0.01 (b) 0.02 (c) 0 03 (d) 0 06 0.03 0.06 Ans. (d) it i i radian. A is in di

GATE 2012 SameQinGATE 2012(PI) GATE 2012

In a single pass rolling process using 410 mm diameter steel rollers, a strip of width 140 mm and thickness 8 mm undergoes 10% reduction of thickness. The angle of bite in radians is g (a) 0.006 (c) 0.062 (b) 0.031 (d) 0.600

Ans. Ans (c)

GATE 2006 GATE2006

A 4 mm thick sheet is rolled with 300 mm diameter rolls to reduce thickness without any charge in its ll d hi k ih h i i width. The friction coefficient at the workroll interface is 0 1 The minimum possible thickness of 0.1. the sheet that can be produced in a single pass is (a) 1 0 mm 1.0 (b) 1 5 mm 1.5 (c) 2.5 mm (d) 3.7 mm Ans. (c) find hmin

GATE 2011 (PI) GATE 2011(PI)

The thickness of a plate is reduced from 30 mm to 10 mm by successive cold rolling passes using identical rolls of diameter 600 mm. Assume that there i no change i width. If th coefficient of th is h in idth the ffi i t f friction between the rolls and the work piece is 0.1, the minimum number of passes required is (a) 3 (b) 4 (c) 6 (d) 7 Ans. Ans (d)

IES 2003 IES

Assertion (A): While rolling metal sheet in rolling mill, the edges are sometimes not straight and flat mill but are wavy. Reason (R): Nonuniform mechanical properties of Non uniform the flat material rolled out result in waviness of the edges. (a) ( ) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (c)

IES 2002 IES

In rolling a strip between two the neutral point in the arc h l i i h depend on (a) Amount of reduction (b) ( ) A t f d ti (c) Coefficient of friction (d) Ans. (d) rolls, the position of of contact does not f d Diameter of th rolls Di t f the ll Material of the rolls

IES 2001 IES

Which of the following assumptions are correct for cold rolling? 1. The material is plastic. 2. 2 The arc of contact is circular with a radius greater than the radius of the roll. 3 3. Coefficient of friction is constant over the arc of contact and acts in one direction throughout the arc of contact. Select h S l the correct answer using the codes given b l i h d i below: Codes: (a) ( ) 1 and 2 d (b) 1 and 3 d (c) 2 and 3 (d) 1, 2 and 3 Ans. (a)

IES 2001 IES

A strip is to be rolled from a thickness of 30 mm to 15 mm using a twohigh mill having rolls of i hi h ill h i ll f diameter 300 mm. The coefficient of friction for unaided bite should nearly be (a) 0.35 (b) 0.5 (c) 0 25 0.25 (d) 0 07 0.07

GATE 2008(PI) GATE2008(PI)

g process, thickness of a strip is reduced from 4 p In a rolling p mm to 3 mm using 300 mm diameter rolls rotating at 100 rpm. Th velocity of the strip i ( / ) at the neutral The l i f h i in (m/s) h l point is (a) 1.57 (b) 3.14 (c) 47.10 (d) 94.20

Ans. Ans (a)

IES 2000 GATE 2010(PI) IES 2000,GATE2010(PI)

In the rolling process, roll separating force can be decreased by d db (a) Reducing the roll diameter (b) ( ) Increasing the roll diameter (c) Providing backup rolls (d) Increasing the friction between the rolls and the metal Ans. (a)

IES 1999 IES

Assertion (A): In a two high rolling mill there is a limit to the possible reduction in thickness in one li i h ibl d i i hi k i pass. Reason (R) Th reduction possible i th second R (R): The d ti ibl in the d pass is less than that in the first pass. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (b)

IES 1993 IES

In order to get uniform thickness of the plate by rolling process, one provides lli id (a) Camber on the rolls (b) ( ) Offset on the rolls (c) Hardening of the rolls (d) Antifriction bearings Ans. (a)

IES 1993 IES

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 larger than the pitch diameter of the thread Ans. (d)

IES 1992 IES

Threadrollingisrestrictedto (a) Ferrousmaterials (b) Ductilematerials (c) Hardmaterials (d) Noneoftheabove Ans.(b)

IAS 2004 IAS

Assertion (A): Rolling requires high friction which increases forces and power consumption. i f d i Reason (R): To prevent damage to the surface of the rolled products, l b i ll d d t lubricants should b used. t h ld be d (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. Ans (c)

IAS 2001 IAS

Consider the following characteristics of rolling process: 1. Shows work hardening effect 2. Surface finish is not good 3. Heavy reduction in areas can be obtained Which of these characteristics are associated with hot rolling? (a) ( ) 1 and 2 (b) ( ) 1 and 3 (c) 2 and 3 (d) 1, 2 and 3 Ans. (c)

IAS 2000 IAS

Rollingverythinstripsofmildsteelrequires (a) Largediameterrolls (b) Smalldiameterrolls (c) Highspeedrolling (d) Rollingwithoutalubricant Ans.(b)

IAS 1998 IAS

Match List I (products) with List II (processes) and select the correct answer using the codes given d l h i h d i below the lists: List Li t I List II Li t II A. M.S. angles and channels 1. Welding B. Carburetors B C b 2. Forging F i C. Roof trusses 3. Casting D. Gear wheels 4. Rolling [Ans.(d)] Codes:A B C D A B C D (a) 1 2 3 4 (b) 4 3 2 1 (c) 1 2 4 3 (d) 4 3 1 2

IAS 2007 IAS

Match List I with List II and select the correct answer using the code given below the Lists: List I List II (Type of Rolling Mill) (Characteristic) A. Two high nonreversing mills 1. Middle roll rotates by friction B. Three high mills 2. By small working roll, power for rolling is reduced C. Four high mills 3. Rolls of equal size are rotated only in one direction D. Cluster ill D Cl t mills 4. Di Diameter of working roll i t f ki ll is very small Ans.(d) B C D A B C D Code:A (a) 3 4 2 1 (b) 2 1 3 4 (c) 2 4 3 1 (d) 3 1 2 4

IAS 2003 IAS

In one setting of rolls in a 3high rolling mill, one gets (a) One reduction in thickness (b) ( ) Two reductions in thickness (c) Three reductions in thickness (d) Two or three reductions in thickness depending upon the setting Ans. (b)

IAS 2007 IAS

Consider the following statements: Roll forces in rolling can be reduced by 1. Reducing friction 2. Using large diameter rolls to increase the contact area. 3. Taking smaller reductions per pass to reduce the contact area. Which of the statements given above are correct? (a) 1 and 2 only (b) 2 and 3 only (c) 1 and 3 only (d) 1, 2 and 3 Ans. (c)

GATE 2011 GATE2011

The maximum possible draft in cold rolling of sheet increases with the (a) increase in coefficient of friction (b) decrease in coefficient of friction (c) decrease in roll radius (d) increase in roll velocity Ans. (a)

[ForIESConventionalOnly]

A ti i R lli AssumptionsinRolling
1. Rolls are straight, rigid cylinders. 2. Strip is wide compared with its thickness, so that no

widening of strip occurs (plane strain conditions). 3. The arc of contact is circular with a radius greater than the radius of the roll. 4. Th material i rigid perfectly plastic ( The i l is i id f l l i (constant yield i ld strength). 5. Th coefficient of f i ti The ffi i t f friction i constant over th t l is t t the tool work interface.

StressEquilibriumofanElementinRolling

Considering the thickness of the element perpendicular to the plane of paper to be unity, We get equilibrium equation in x direction as, - x h + ( x +d x ) (h + dh) - 2pR d sin
+ 2 x R d cos = 0

For sliding friction, x = p Simplifying and neglecting second order terms, sin and cos = 1, we get , , g d ( x h ) = 2 pR ( ) d 2 p x = 0 = 0' 3 d ' h ( p 0 ) = 2 pR ( ) d d ' p 0 h ' 1 = 2 pR ( ) d 0 d d p p ' 0 h + ' 1 0' h ) = 2 pR ( ) ( ' d 0 0 d

' Due to cold rolling, 0 increases as h decreases,

thus h nearly a constant and itsderivative zero zero.

' 0

d ' ( p / 0 ) 2R d = ( ) ' p /0 h h = h f + 2 R (1 cos ) h f + R 2 d ( p /

' 0

( p / )
' 0 ' 0

)=

2R ) d 2 ( h f + R 2R 2R h f + R 2 d = I II (say)

Integrating both side 2R 2R d ln ( p / ) = 2 h f + R

2Rd I= = 2 h f + R

2Rd h =

2d h h / R = ln R

hf Now h / R = + 2 R d h or R = 2 d 2R II = d 2 h f + R 2 = d 2 hf / R + = 2 R R 1 .tan . h hf f

ln p /
' 0

' 0

h = ln 2 R

R .tan 1 hf

R . + ln C h f

h H p = C e R R .tan 1 hf R . h f

where H = 2

Now at entry , = Hence H = H0 with replaced by in above equation H ith l db i b ti At exit = 0 Therefor p = '0

 h o Ho In the entry zone, p = C. e R R Ho and C = .e ho

' 0

h ( H0 H ) p= . e h0
' 0

In the exit zone h H p = .e hf At the neutral po int above equations

' 0

will give same results

hn hn ( H0 Hn ) Hn = . e . e h0 hf ho ( H0 2Hn ) =e or hf h0 1 1 or Hn = H0 ln 2 hf R R 1 From H = 2 .tan . h hf f h f Hn hf n = .tan . R 2 R and h n = h f + 2R (1 cos n )

If back tension b is there at Entry, h ( H0 H ) p = ( b ) . e o h0 If front tension f is there at Exit, h p = ( f ) . e H o hf

IFS 2010
Calculate the neutral plane to roll 250 mm wide annealed copper strip from 2.5 mm to 2.0 mm thickness with 350 mm diameter steel rolls Take = rolls. 0.05 and o =180 MPa. [10 marks] [10marks]

RollingCh14
Q.No 1 2 3 4 5 6 7 8 9 10 11 12 Option C B D D A A B D C C B C

Forging F gi g
BySKMondal

GATE 2010 (PI) GATE2010(PI)

g p g g Hot die steel, used for large solid dies in drop forging, should necessarily have (a) high strength and high copper content (b) high hardness and low hardenability (c) high toughness and low thermal conductivity (d) high hardness and high thermal conductivity Ans. (c)

IFS2011
What advantages does press forging have over drop forging ? Why are pure metals more easily cold worked than alloys ? [5marks]

IAS2011Main
Compare Smith forging, drop forging, press forging and upset forging Mention three points forging. for each. [10 Marks]

IES 2007
Sometimes the parting plane between two forging dies is not a hori ontal plane gi e the main reason horizontal plane, give for this design aspect, why is parting plane provided, in closed die forging? [2marks] [ k ]

GATE 2007 GATE2007

In opendie forging, a disc of diameter 200 mm and height 60 mm is compressed without any barreling h i h 6 i d ih b li effect. The final diameter of the disc is 400 mm. The true strain is (a) 1.986 (b) 1.686 (c) 1 386 1.386 (d) 0 602 0.602 Ans. ( ) A (c)

GATE 1992 ISRO 2012 GATE1992,ISRO2012

Thetruestrainforalowcarbonsteelbarwhichis doubledinlengthbyforgingis ( ) 3 7 (a) 0.307 (b) 0.5 (c) 0.693 (d) 1.0 Ans.(c)

GATE 2012 S Q GATE 2012 (PI) GATE2012SameQGATE2012(PI)

y g 50 A solid cylinder of diameter 100 mm and height 5 mm is forged between two frictionless flat dies to a height f h i h of 25 mm. Th percentage change i The h in diameter is (a)0 (b)2.07 (c)20.7 (d)41.4

Ans.(d) Ans (d)

IES 2006 IES

Assertion (A): Forging dies are provided with taper or draft angles on vertical surfaces. d f l i l f Reason (R): It facilitates complete filling of die cavity and f it d favourable grain fl bl i flow. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. Ans (c)

IES 2005 IES

Consider the following statements: 1. Forging reduces the grain size of the metal, which results in a decrease in strength and toughness. 2. Forged components can be provided with thin sections, without reducing the strength. Which f h Whi h of the statements given above i / i b is/are correct? ? (a) Only 1 (b) Only 2 (c) ( ) Both 1 and 2 (d) ( ) Neither 1 nor 2 Ans. (b)

IES 1996 IES

Which one of the following is an advantage of forging? f i ? (a) Good surface finish (b) ( ) Low tooling cost (c) Close tolerance (d) Improved physical property Ans. (d)

IES 2012 IES

Which of the following statements is correct for forging? (a) Forgeability is property of forging tool, by which forging can be done easily. (b) ( ) Forgeability decreases with temperature upto lower critical temperature. (c) Certain mechanical properties of the material are ( ) C i h i l i f h i l influenced by forging. (d) P Pure metals h t l have good malleability, th f d ll bilit therefore, poor forging properties. Ans. Ans (c)

St t t (I): is difficult to i t i l Statement (I) It i diffi lt t maintain close t l tolerance i in normal forging operation. Statement (II): Forging is workable for simple shapes and has limitation for parts having undercuts. ( ) (a) Both Statement (I) and Statement (II) are () ( ) individually true and Statement (II) is the correct explanation of Statement (I) (b) B th St t Both Statement (I) and St t t d Statement (II) are t individually true but Statement (II) is not the correct explanation of Statement (I) p () (c) Statement (I) is true but Statement (II) is false ( ) (d) Statement (I) is false but Statement (II) is true () ( ) Ans. (b)

IES 2012

IES 1993 IES

Which one of the following manufacturing processes requires the provision of gutters? i h i i f ? (a) Closed die forging (b) ( ) Centrifugal casting (c) Investment casting (d) Impact extrusion Ans. (a)

IES 1997 IES

Assertion (A): In drop forging besides the provision for flash, provision is also to be made in the forging flash die for additional space called gutter. Reason (R): The gutter helps to restrict the outward flow of metal thereby helping to fill thin ribs and bases in the upper die. (a) ( ) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (c)

IES 2003 IES

A forging method for reducing the diameter of a bar and in the process making it longer is termed as di h ki i l i d (a) Fullering (b) Punching (c) ( ) Upsetting ( ) Extruding (d) Ans. (a)

IES 2002 IES

Consider the following steps involved in hammer forging a connecting rod from bar stock: f i i df b k 1. Blocking 2. Trimming 3. Finishing 4. Fullering 5. Edging Which of the following is the correct sequence of operations? i ? (a) 1, 4, 3, 2 and 5 (b) ( ) 4, 5, 1, 3 and 2 (c) 5, 4, 3, 2 and 1 (d) 5, 1, 4, 2 and 3 Ans. (b)

IES 2003 IES

Consider the following steps in forging a connecting rod from the bar stock: df h b k 1. Blocking 2. Trimming 3. Finishing 4. Edging Select the correct sequence of these operations using the codes given b l d i below: Codes: (a) ( ) 1234 (b) ( ) 2341 (c) 3412 (d) 4132 Ans. (d)

IES 2005 IES

The process of removing the burrs or flash from a forged component in drop forging is called: f d i d f i i ll d (a) Swaging (b) Perforating (c) ( ) Trimming ( ) Fettling (d) Ans. (c)

IES 2011 IES2011

Which of the following processes belong to forging operation ? 1. Fullering 2. Swaging 3. Welding (a) 1 and 2 only y (b) 2 and 3 only (c) 1 and 3 only ( ) , (b) 1, 2 and 3 only y Ans. (a) ( )

IES 2008 IES

The balls of the ball bearings are manufactured from steel rods. The operations involved are: f l d Th i i l d 1. Ground 2. Hot forged on hammers 3. Heat treated 4. Polished What is the correct sequence of the above operations from start? (a) 3241 (b) 3214 (c) 2314 (d) 2341 Ans. (None) Correct sequence is 2 1 3 4

IES 2001 IES

Intheforgingoperation,fullering isdoneto (a) Drawoutthematerial (b) Bendthematerial (c) Upsetthematerial (d) Extrudingthematerial Ans.(a)

IES 2011 IES2011

Consider the following statements : 1. Any metal will require some time to undergo complete plastic deformation particularly if deforming metal has to f ll cavities and corners of small radii. fill d f ll d 2. For larger work piece of metals that can retain toughness at f i temperature i i preferable to use h forging it is f bl forge press rather than forge hammer. (a) ( ) 1 and 2 are correct and 2 i th reason f 1 d t d is the for (b) 1 and 2 are correct and 1 is the reason for 2 (c) ( ) 1 and 2 are correct b unrelated d but l d (d) 1 only correct Ans. (b)

IES 2005 IES

Match List I (Type of Forging) with List II (Operation) and select the correct answer using the code given below the Lists: List I List II A. Drop Forging 1. Metal is gripped in the dies and pressure is applied on the heated end B. B Press Forging 2 2. Squeezing action C. Upset Forging 3. Metal is placed between rollers and p pushed D. Roll Forging 4. Repeated hammer blows Ans.(c) A B C D A B C D (a) 4 1 2 3 (b) 3 2 1 4 (c) 4 2 1 3 (d) 3 1 2 4

IES 2008
Match ListI with ListII and select the correct answer using g the code given below the lists: ListI(Forging ListII(Process) Technique) A.SmithForging B.DropForging C.PressForging D.Machine Forging Code: A (a) 2 (c) 2 B 3 1 1. Materialisonlyupsettogetthedesiredshape 2. Carriedoutmanuallyopendies 3. Done in closed impression dies by hammers in blows 4. Done in closed impression dies by continuous squeezing force C 4 4 D 1 3 A 4 4 B 3 1 C 2 2 D 1 3
Ans.(a)

(b) (d)

IES 1998 IES

Which one of the following processes is most commonly used for the forging of bolt heads of l d f h f i f b l h d f hexagonal shape? (a) Closed die drop f i ( ) Cl d di d forging (b) Open die upset forging (c) Close di press f i ( ) Cl die forging (d) Open die progressive forging Ans. ( ) (c)

IES 1994 ISRO 2010 IES 1994,ISRO2010

In drop forging, forging is done by dropping (a) The work piece at high velocity (b) The hammer at high velocity. (c) The die with hammer at high velocity (d) a weight on hammer to produce the requisite impact. Ans. (c)

IAS 2003 IAS

Match List I (Forging Operation) with List II (View of the Forging Operation) and select the correct answer using the codes given below the lists: ListI ListII (Forging Operation) (View of the Forging Operation) (A) Edging 1. 2. 2 (B) Fullering (C) Drawing 3. 4. 4 (D) S Swaging i Codes:A B C D A B C D (a) 4 3 2 1 (b) 2 1 4 3 (c) 4 1 2 3 (d) 2 3 4 1
Ans.(a)

IAS 2001 IAS

Match List I (Forging operations) with List II (Descriptions) g and select the correct answer using the codes g given below the Lists: List I List II A. Flattening 1. Thickness is reduced continuously at different sections along length B. Drawing 2. Metal is displaced away from centre, g reducing thickness in middle and increasing length C. Fullering 3. Rod is pulled through a die D. D Wire drawing 4 4. Pressure a workpiece between two flat dies Codes:A B C D A B C D (a) 3 2 1 4 (b) 4 1 2 3 (c) 3 1 2 4 (d) 4 2 1 3
Ans.(b)

IAS 2000 IAS

Drop forging is used to produce (a) Small components (b) Large components (c) Identical Components in large numbers (d) Mediumsize components

Ans. (a)

IAS 1998 IAS

The forging defect due to hindrance to smooth flow of metal in the component called 'Lap' occurs f l i h ll d 'L ' because (a) The ( ) Th corner radius provided i t l di id d is too large (b) The corner radius provided is too small (c) Draft is ( ) D f i not provided id d (d) The shrinkage allowance is inadequate

Ans. (b)

IAS 2002 IAS

Considerthefollowingstatementsrelatedto forging: f i 1. Flashisexcessmaterialaddedtostockwhichflows aroundpartingline. d ti li 2. Flashhelpsinfillingofthinribsandbossesinupper die. die 3. Amountofflashdependsuponforgingforce. Whichoftheabovestatementsarecorrect? Whi h fth b t t t t? (a) 1,2and3 (b) 1and2 (c) d ( ) 1and3 (d) 2and3 d Ans.(b)

IES 2011 IES2011

Assertion (A) : Hot tears occur during forging because of inclusions in the blank material b fi l i i h bl k i l Reason (R) : Bonding between the inclusions and the parent material is through physical and chemical bonding. ( ) (a) Both A and R are individually true and R is the y correct explanation of A (b) Both A and R are individually true but R is NOT the correct explanation of A h l i f (c) A is true but R is false (d) A i f l b t R i t is false but is true Ans. ( ) A (c)

Matchthefollowing Group1 P. Wrinkling i kli Q.Centreburst R.Barrelling S.Coldshut

GATE2008(PI)
Group2 1.Upsetting i 2.Deepdrawing 3.Extrusion 4.Closeddieforging (b)P 3,Q 4,R 1,S2 (d)P 2,Q 4,R 3,S1 Ans.(c)

(a)P 2,Q 3,R 4,S1 (c)P 2,Q 3,R 1,S4

IES 2005 Conventional IES 2005Conventional

p 4 4 A strip of lead with initial dimensions 24 mm x 24 mm x 150 mm is forged between two flat dies to a final i fi l size of 6 mm x 96 mm x 150 mm. If the f 6 h coefficient of friction is 0.25, determine the maximum forging force. The average yield stress of lead in tension is N/mm2 l d i t i i 7 N/ [10] Will be discussed in class

IES 2007 Conventional IES 2007Conventional

A cylinder of height 60 mm and diameter 100 mm is forged at room temperature between two flat dies. Find f d b fl di Fi d the die load at the end of compression to a height 30 mm, mm using slab method of analysis The yield strength of analysis. the work material is given as 120 N/mm2 and the coefficient of friction is 0.05. Assume that volume is 5 constant after deformation. There is no sticking. Also [20Marks] find mean die pressure. Will be discussed in class

IES 2006 Conventional IES 2006

A certain disc of lead of radius 150 mm and thickness 50 mm is reduced to a thickness of 25 mm by open die i d d hi k f b di forging. If the coefficient of friction between the job and die is 0 25 determine the maximum forging force The 0.25, force. average shear yield stress of lead can be taken as 4 N/mm2. / [ [10 Marks] ] Will be discussed in class

Practice Problem 1 PracticeProblem1

A strip of metal with initial dimensions 24 mm x 24 mm x 150 mm is forged between two flat dies to a final size of 6 mm x 96 mm x 150 mm If the coefficient of friction is 0 mm. 0.05, determine the maximum forging force. Take the average yield strength in tension is 7 N/mm2

[ [Ans. 178.24 kN] 7 4 ]

Practice Problem 2 PracticeProblem2

A circular disc of 200 mm in diameter and 100 mm in height is compressed between two flat dies to a height of 50 mm Coefficient of friction is 0 and a erage yield 0 mm. 0.1 average ield strength in compression is 230 MPa. Determine the maximum die pressure.

[ [Ans. 405 MPa] 4 5 ]

Practice Problem 3 PracticeProblem3

A cylindrical specimen 150 mm in diameter and 100 mm in height is upsetted by open die forging to a height of 50 mm. mm Coefficient of friction is 0 2 and flow curve 0.2 equation is
f = 1030 0.17

MPa . Calculate the maximum

forging force. [ [Ans. 46.26 MN] 4 ] [Hint. First calculate true strain and put the value in the equation
f = 1030 0.17 = y

Practice Problem 4 PracticeProblem4

A circular disc of 200 mm in diameter and 70 mm in height is forged to 40 mm in height. Coefficient of friction is 0 05 The flow curve equation of the material 0.05. is given by
f = 200(0.01 + ) 0.41 MPa

. Determine maximum

forging load, mean die pressure and maximum pressure. [ Ans. 9.771 MN, 178 MPa, 221 MPa] 9 77 , 7 , ] [Hint. First calculate true strain and put the value in the equation
f = 200(0.01 + ) 0.41 = y

PracticeProblem5{GATE2010(PI)} { ( )}
During open die forging process using two flat and parallel dies, a solid circular steel disc of initial radius (R IN ) 200 mm and initial N height (H IN ) 50 mm attains a height (H FN ) of 30 mm and radius of R FN . Along the die-disc interfaces.
R IN i. the coefficient of friction ( ) is: = 0.35 1 + e RFN ii. in the region R ss r RFN ,sliding friction prevails, and

p = 3Ke

2 ( RFN r ) H FN

and = p,

where p and are the normal and shear stresses, respectively; K is the shear yield strength of steel and r is the radial distance of any point (contd ........)

Contd.

PracticeProblem5{GATE2010(PI)}
iii.In the region 0 r R SS ,sticking condition prevails The value of R SS (in mm), where sticking condition changes to sliding friction, is (a) 241.76 (b) 254.55 (c) 265.45 (d) 278.20

Ans.(b) ( )

Ch 15: Forging Ch15:Forging

Q. No 1 2 3 4 5 Option A A A A B Q. No 6 7 8 9 Option B C C C

Extrusion&Drawing g

BySKMondal d l

IAS 2010 Main IAS2010Main

How are metal toothpaste tubes made commercially ? Draw the tools configuration with the help of a neat sketch. [30Marks] [30 Marks]

IES 2009 C ti l IES2009Conventional

IES 2011 C ti l IES 2011Conventional

A 12.5 mm diameter rod is to be reduced to 10 mm diameter by drawing in a single pass at a speed of 100 di b d i i i l d f m/min. Assuming a semi die angle of 5o and coefficient o of friction between the die and steel rod as 0.15, ct o betwee t e d e a d stee od 0. 5, calculate: (i) The power required in drawing (ii) Maximum possible reduction in diameter of the rod (iii) If the rod is subjected to a back pressure of 50 N/mm2 , what would b the d N/ h ld be h draw stress and maximum d i possible reduction ? Take stress of the work material as 400 N/mm2 . Willbediscussedintheclass[15Marks]

GATE 2011 (PI) Common DataS1 GATE 2011(PI)CommonDataS1

In a multipass drawing operation, a round bar of 10 mm diameter and 100 mm length is reduced in cross section crosssection by drawing it successively through a series of seven dies of decreasing exit diameter. During each of these g g drawing operations, the reduction in crosssectional area is 35%. The yield strength of the material is 200 MPa. Ignore strain h d i I i hardening. The total true strain applied and the final length (in mm), respectively, are ) ti l (a) 2.45 and 8 17 (b) 2.45 and 345 (c) ( ) 3.02 and 2043 d (d) 3.02 and 3330 d Ans. (c)

GATE 2011 (PI) Common DataS2 GATE 2011(PI)CommonDataS2

In a multipass drawing operation, a round bar of 10 mm diameter and 100 mm length is reduced in cross section crosssection by drawing it successively through a series of seven dies of decreasing exit diameter. During each of these g g drawing operations, the reduction in crosssectional area is 35%. The yield strength of the material is 200 MPa. Ignore strain h d i I i hardening. Neglectingfrictionandredundantwork,theforce(in kN)requiredfordrawingthebarthroughthefirstdie,is kN) i df d i th b th hth fi tdi i (a)15.71 (b)10.21 (c)6.77 ( ) (d)4.39 (d) Ans.(d)

JWM 2010 JWM2010

Assertion (A) : Extrusion speed depends on work material. material Reason (R) : High extrusion speed causes cracks in the material material. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (a)

GATE 2006 GATE2006

In a wire drawing operation, diameter of a steel wire is reduced from 10 mm to 8 mm. The mean flow i d d f Th fl stress of the material is 400 MPa. The ideal force required for drawing (ignoring friction and redundant work) is (a) 4 48 kN 4.48 (b) 8 97 kN 8.97 (c) 20.11 kN (d) 31.41 kN Ans. Ans (b)

GATE 2001 GATE 2007 (PI) GATE2001,GATE2007(PI)

For rigid perfectlyplastic work material, negligible interface friction and no redundant work, the i f f i i d d d k h theoretically maximum possible reduction in the wire drawing operation is (a) 0.36 (b) 0.63 (c) 1 00 1.00 (d) 2 72 2.72 Ans. (b)

GATE2008(PI)LinkedS1 G 008 ( ) ed S
A 10 mm diameter annealed steel wire is drawn through a die at a speed of 0.5 m/s to reduce the diameter by 20%. The yield stress of the material is 800 MPa. y Neglecting friction and strain hardening, the stress required for drawing (in MPa) is (a) 178 5 (b) 357 0 178.5 357.0 Ans. (b) (c) 1287 5 1287.5 (d) 2575 0 2575.0

GATE2008(PI)LinkedS2 G 008 ( ) ed S
A 10 mm diameter annealed steel wire is drawn through a die at a speed of 0.5 m/s to reduce the diameter by 20%. The yield stress of the material is 800 MPa. y The power required for the drawing process (in kW) is (a) 8.97 Ans.(a) Ans (a) (b) 14.0 (c) 17.95 (d) 28.0

GATE 2003 GATE2003

A brass billet is to be extruded from its initial diameter of 100 mm to a final diameter of 50 mm. di f fi l di f The working temperature of 700C and the extrusion constant is 250 MPa The force required MPa. for extrusion is (a) 5 44 MN (b) 2 72 MN 5.44 2.72 (c) 1.36 MN (d) 0.36 MN

Ans. (b)

GATE 2009 (PI) GATE 2009(PI)

Using direct extrusion process, a round billet of 100 mm length and 50 mm diameter is extruded. Considering an ideal deformation process (no friction and no redundant work), extrusion ratio 4, and average flow stress of material 300 MPa, the p pressure (in MPa) on the ram will be ( ) (a) 416 Ans. (a) (b) 624 (c) 700 (d) 832

GATE 1996 GATE1996

A wire of 0.1 mm diameter is drawn from a rod of 15 mm diameter. Dies giving reductions of 20%, 40% di Di i i d i f % % and 80% are available. For minimum error in the final size the number of stages and reduction at size, each stage respectively would be (a) 3 stages and 80% reduction for all three stages (b) 4 stages and 80% reduction for first three stages followed by a finishing stage of 20% reduction (c) 5 stages and reduction of 80%, 80%.40%, 40%, 20% in a sequence q (d) none of the above Ans. (b)

GATE 1994 GATE1994

The process of hot extrusion is used to produce (a) Curtain rods made of aluminium (b) Steel pipes/or domestic water supply (c) Stainless steel tubes used in furniture (d) Large she pipes used in city water mains Ans. (a)

IES 2007 IES

Which one of the following is the correct statement? (a) Extrusion is used for the manufacture of seamless tubes. (b) Extrusion is used for reducing the diameter of round bars and tubes by rotating dies which open and close rapidly on the work? (c) Extrusion is used to improve fatigue resistance of the metal by setting up compressive stresses on its surface (d) Extrusion comprises pressing the metal inside a chamber to force it out by high pressure through an orifice which is shaped to provide the desired from of the finished part. Ans. (d)

IES 2007 IES

Assertion (A): Greater force on the plunger is required in case of direct extrusion than indirect one. i f di t t i th i di t Reason (R): In case of direct extrusion, the direction of the force applied on the plunger and the direction of the movement of the extruded metal are the same. ( ) (a) Both A and R are individually true and R is the correct y explanation of A (b) Both A and R are individually true but R is not the correct explanation of A l f (c) A is true but R is false (d) A i f l b R i true is false but is Ans. (b) A

IES 2012 IES

Which of the following are correct for an indirect hot extrusion process? i ? 1. Billet remains stationary 2. There is no friction force between billet and container walls. 3. Th f The force required on the punch i more i i d h h is in comparison to direct extrusion. 4. E t i parts h Extrusion t have t b provided a support. to be id d t (a) 1, 2, 3 and 4 (b) 1, 2 and 3 only (c) ( ) 1, 2 and 4 only d l (d) 2, 3 and 4 only d l Ans. (c)

IES 1993 IES

Assertion (A): Direct extrusion requires larger force than indirect extrusion. h i di i Reason (R): In indirect extrusion of cold steel, zinc phosphate coating i used. h h t ti is d (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans.(b) Ans (b)

IES 1994 IES

Metal extrusion process is generally used for producing d i (a) Uniform solid sections (b) ( ) Uniform hollow sections (c) Uniform solid and hollow sections (d) Varying solid and hollow sections. Ans. (c)

IES 2009 IES

Which one of the following statements is correct? (a) In extrusion process, thicker walls can be obtained by increasing the forming pressure (b) ( ) Extrusion is an ideal process for obtaining rods from metal having poor density (c) As ( ) A compared to roll f d ll forming, extruding speed i hi h i di d is high (d) Impact extrusion is quite similar to Hooker's process including the flow f i l di th fl of metal b i i th same di ti t l being in the direction Ans. (c)

IES 1999 IES

Which one of the following is the correct temperature range for hot extrusion of aluminium? f h i f l i i ? (a) 300340C (b) 350400C (c) ( ) 430480C ( ) 550650C (d) Ans. (c)

IES 2000 IES

Consider the following statements: In forward extrusion process I f d t i 1. The ram and the extruded product travel in the same direction. 2. The ram and the extruded product travel in the opposite direction. 3. The speed of travel of the extruded product i same as that h d f l f h d d d is h of the ram. 4. 4 The speed of travel of the extruded product is greater than that of the ram. Which of these Statements are correct? (a) 1 and 3 (b) 2 and 3 (c) 1 and 4 (d) 2 and 4 Ans. (c)

IES 2009 IES

What is the major problem in hot extrusion? (a) Design of punch (b) Design of die (c) Wear and tear of die (d) Wear of punch

Ans. (b)

IES 2012 IES

Extrusion process can effectively reduce the cost of product through d h h (a) Material saving (b) ( ) process time saving (c) Saving in tooling cost (d) saving in administrative cost Ans. (c)

IES 2008 IES

Which one of the following methods is used for the manufacture of collapsible toothpaste tubes? f f ll ibl h b ? (a) Impact extrusion (b) Direct extrusion (c) ( ) Deep drawing (d) ( ) Piercing Ans. (a)

IES 2003 IES

The extrusion process (s) used for the production of toothpaste tube is/are h b i / 1. Tube extrusion 2. Forward extrusion 3. Impact extrusion Select the correct answer using the codes given below: Codes: (a) 1 only (b) 1 and 2 (c) 2 and 3 (d) 3 only Ans. (d)

IES 2001 IES

Which of the following statements are the salient features of hydrostatic extrusion? 1. It is suitable for soft and ductile material. 2. It is suitable for highstrength superalloys. g g p y 3.The billet is inserted into the extrusion chamber and pressure is applied by a ram to extrude the billet through the die. 4. The bill i i h billet is inserted i d into the extrusion chamber where i i h i h b h it is surrounded by a suitable liquid. The billet is extruded g y pp y g p q through the die by applying pressure to the liquid. Select the correct answer using the codes given below: Codes: (a) 1 and 3 (b) 1 and 4 (c) 2 and 3 (d) 2 and 4 Ans. (d)

IES 2006 IES

What does hydrostatic pressure in extrusion process improve? i ? (a) Ductility (b) Compressive strength (c) ( ) Brittleness (d) ( ) Tensile strength

Ans. (a)

IES 2010 IES2010

Assertion (A): Pickling and washing of rolled rods is carried out before wire drawing. drawing Reason (R): They lubricate the surface to reduce friction while drawing wires wires. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is NOT the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. Ans (c)

IES 2009 IES

Which one of the following stress is involved in the wire drawing process? i d i ? (a) Compressive (b) Tensile (c) ( ) Shear (d) ( ) Hydrostatic stress Ans. (b)

IES 1993 IES

Tandem drawing of wires and tubes is necessary because (a) It is not possible to reduce at one stage (b) ( ) Annealing is needed between stages (c) Accuracy in dimensions is not possible otherwise (d) Surface finish improves after every drawing stage Ans. (a)

IES 2000 IES

Match List I (Components of a table fan) with List II (Manufacturing processes) 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 Ans.(d) 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

IES 1999 IES

Match ListI with ListII and select the correct answer using the codes given below the Lists: ListI ListII A. A Drawing 1. 1 Soap solution B. Rolling 2. Camber C. C Wire drawing 3. 3 Pilots D. Sheet metal operations using 4. Crater progressive dies 5. Ironing Code:A B C D A B C D ( ) (a) 2 5 1 4 ( ) (b) 4 1 5 3 (c) 5 2 3 4 (d) 5 2 1 3
Ans.(d)

IES 1996 IES

Match List I with List II and select the correct answer List I (Metal/forming process) List II (Associated force)

A. Wire drawing B. Extrusion C. Blanking D. Bending Codes:A B C (a) 4 2 1 (c) 2 3 1

1. 2. 3. 4. D 3 4 (b) (d)

Shear force Tensile force Compressive force Spring back force A B C D 2 1 3 4 4 3 2 1 Ans.(c)

IES 1996 IES

In wire drawing process, the bright shining surface on the wire is obtained if one h i i b i d (a) does not use a lubricant (b) ( ) uses solid powdery lubricant. (c) uses thick paste lubricant (d) uses thin film lubricant Ans. (d)

IES 1994 IES

MatchListIwithListIIandselectthecorrectanswer usingthecodesgivenbelowtheLists: i h d i b l h Li
ListI(Metalfarmingprocess)ListII(Asimilarprocess)

A. A B. C. C D.

Blanking Bl ki Coining Extrusion E i Cupdrawing B 3 2 C 4 1 D 1 5

1. 2. 3. 4. 5. (b) (d)

Codes:A (a) 2 (c) 3

Wiredrawing Wi d i Piercing Embossing E b i Rolling Ans.(d) Bending A B C D 2 3 1 4 2 3 1 5

IES 1993 ISRO 2010 IES 1993,ISRO2010

Match List I with List II and select the correct answer using the codes given below the lists: List I (Mechanical property) List II (Related to) A. A Malleability 1. 1 Wire drawing B. Hardness 2. Impact loads C. C Resilience 3. 3 Cold rolling D. Isotropy 4. Indentation 5. Direction Ans.(b) Ans (b) Codes:A B C D A B C D ( ) (a) 4 2 1 3 ( ) (b) 3 4 2 5 (c) 5 4 2 3 (d) 3 2 1 5

IES 2007 IES

Which metal forming process manufacture of long steel wire? f fl l i ? (a) Deep drawing (b) Forging (c) ( ) Drawing (d) ( ) Extrusion is used for

Ans. (c) Wire Drawing

IES 2005 IES

Which of the following types of stresses is/are involved in the wiredrawing operation? i l di h i d i i ? (a) Tensile only (b) ( ) Compressive only (c) A combination of tensile and compressive stresses (d) A combination of tensile, compressive and shear stresses Ans. (a)

IES 2000 IES

Which one of the following lubricants is most suitable for drawing mild steel wires? i bl f d i ild l i ? (a) Sodium stearate (b) Water (c) ( ) Limewater (d) ( ) Kerosene Ans. (c)

IES 1993 IES

A moving mandrel is used in (a) Wire drawing (b) Tube drawing (c) Metal cutting (d) Forging Ans. (b)

IES 2002 IES

Match List I with List II and select the correct answer:
List I (Parts) List II (Manufacturing processes)

A. Seamless t b A S l tubes 1. B. Accurate and smooth tubes 2. C. Surfaces h i hi h C S f having higher 3. hardness and fatigue strength4. Codes: A B C A (a) 1 4 2 (b) 2 (c) 1 3 2 (d) 2

Roll forming R ll f i Shot peening Forging F i Cold forming B C 3 1 4 1 Ans.(a)

IAS 2004 IAS

Assertion (A): Indirect extrusion operation can be performed either by moving ram or by moving the f d ih b i b i h container. Reason (R) Ad R (R): Advantage i i di t extrusion i l t in indirect t i is less quantity of scrap compared to direct extrusion. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (d)

IAS 1995 IAS

The following operations are performed while preparing the billets for extrusion process: i h bill f i 1. Alkaline cleaning 2. Phosphate coating 3. Pickling 4. Lubricating with reactive soap. The correct sequence of these operations is (a) 3, 1, 4, 2 (b) 1, 3, 2, 4 (c) 1, 3. 4, 2 (d) 3, 1, 2, 4 Ans. (d)

IAS 2001 IAS

Match List I (Products) with List II (Suitable processes) and select the correct answer using the ) d l h i h codes given below the Lists: List Li t I List Li t II A. Connecting rods 1. Welding B. Pressure vessels B P l 2. Extrusion E i C. Machine tool beds 3. Forging D. Collapsible tubes 4. Casting Ans. ( ) (a) Codes:A B C D A B C D (a) 3 1 4 2 (b) 4 1 3 2 (c) 3 2 4 1 (d) 4 2 3 1

IAS 1997 IAS

Extrusion force DOES NOT depend upon the (a) Extrusion ratio (b) Type of extrusion process (c) Material of the die (d) Working temperature

Ans. (c)

IAS 2000 IAS

Assertion (A): Brittle materials such as grey cast iron cannot be extruded by hydrostatic extrusion. i b d db h d i i Reason(R): In hydrostatic extrusion, billet is uniformly compressed f if l d from all sides b th li id ll id by the liquid. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. Ans (d)

IAS 2002 IAS

Assertion (A): In wiredrawing process, the rod crosssection is reduced gradually by drawing it cross section several times in successively reduced diameter dies. Reason (R): Since each drawing reduces ductility of the wire, so after final drawing the wire is normalized. (a) ( ) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (b)

IES 2011 IES2011

MatchListIwithListIIandselectthecorrectanswerusing thecodegivenbelowthelists:

ListI A.Connectingrods A Connectingrods B.Pressurevessels C.Machinetoolbeds D.Collapsibletubes D Collapsibletubes

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

ListII 1.Welding 1 Welding 2.Extrusion 3.Forming 4.CastingAns.(b) 4 CastingAns (b)

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

IAS 1994 IAS1994

Which of the following methods can be used for manufacturing 2 metre long seamless metallic tubes? 1. 1 Drawing 2. 2 Extrusion 3. Rolling 4. Spinning Select the correct answer using the codes given below Codes: (a) ( ) 1 and 3 d (b) 2 and 3 d (c) 1, 3 and 4 (d) 2, 3 and 4 Ans. (b) A

WireDrawingAnalysis(HomeWork) g y ( )

The equilibrium equation in x-direction will be

( x + d x ) ( r + dr )

dx x r + x cos 2 r cos dx + Px sin 2 r =0 cos

2

or x 2rdr + d x r + 2r x dx + Px 2rdx tan = 0

2

Dividing by r dr and taking dx/dr = cot we get d x 2 2 x + ( x + Px ) + cot = 0 dr r r Vertical component of Px Px due to small half die
2

angles and that of x can be neglected. neglected Thefore, two principal stresses are x and Px Both Tresca's and Von-Mises criteria will give x + Px = o

and x = Px = ( o x )

d x 2 o 2 ( o x ) + + cot = 0 dr r r Let cot = B d x 2 = B x (1 + B ) o dr d r d x 2 or = dr B x (1 + B ) o r Integrating both side 1 ln B x (1 + B ) o = 2 ln ( rC ) B {Cis integration cont.}

or B x (1 + B ) o = ( rC ) B.C s at r = ro , x = b B b (1 + B ) o C = ro
1 2B

2B

r 2 B r 2 B o (1 + B ) 1 + . b or x = B ro ro Drawing stress ( d ) =

o (1 + B )
B

rf rf 1 + . b ro ro
2B 2B

ExtrusionAnalysis(HomeWork) y ( )
For a round bar both wire drawing and extrusion will give same equation except B.Cs BC B x (1 + B ) o = ( rC ) B.C s at r = rf , x = 0 (1 + B ) o C = rf
1 2B 2B

(at exit stress is zero)

o (1 + B ) r 1 or x = B rf

2B

at r = ro

xo

o (1 + B ) ro 1 = B rf

2B

Ao ro Extrusion ratio R = ratio, = for round bar A f rf ho = h f 1 R 2 B for flat stock

xo =

o (1 + B )
B

If effect of container friction is considered p f = ram pressure required by container friction

i = uniform interface shear stress between

billet and container wall 2 i L p f . r0 = 2 r0 i L or p f = ro
2

Total Extrusion Pressure(Pt ) = xo + p f and E t i Load = pt . r0 2 d Extrusion L d

Ch 17: Extrusion Ch17:Extrusion

Q. No 1 2 3 4 5 6 7 Option D C D D B C B Q. No 8 9 10 11 12 13 Option B B A B B A

Ch 16: Drawing Ch16:Drawing

Q. No 1 2 3 4 5 6 Option A C C B C D

SheetMetalOperation

BySKMondal

Example
Determine the die and punch sizes for blanking a circular disc of 20mm diameter from a sheet whose thickness is 1.5 di f di t f h t h thi k i mm. Shear strength of sheet material = 294 MPa Also determine the die and punch sizes for punching a circular hole of 20mm diameter from a sheet whose thickness is 1.5 mm.

Example
g 5 Estimate the blanking force to cut a blank 25 mm wide and 30 mm long from a 1.5 mm thick metal strip, if the ultimate shear strength of the material i 450 N/ li h h f h i l is N/mm2. Also determine the work done if the percentage penetration is 25 percent of material thickness.

Ans. 74.25 kN, 27.84 Nm

IAS2011Main
For punching a 10 mm circular hole, and cutting a rectangular blank of 50 x 200 mm from a sheet of 1 mm thickness ( ild steel, shear stress = 240 hi k (mild l h N/mm2), Calculate, in each case : (i) Si of punch Size f h (ii) Size of die (iii) F Force required. i d [10Marks] [ M k ]

IES 1999 IES

A hole is to be punched in a 15 mm thick plate having ultimate shear strength of 3Nmm2. If the h i li h h f N h allowable crushing stress in the punch is 6 Nmm2, the diameter of the smallest hole which can be punched is equal to (a) 15 mm (b) 30 mm (c) 60 mm (d) 120 mm Ans. (b)

ISRO 2008 2011 ISRO2008,2011

With a punch for which the maximum crushing stress is 4 times the maximum shearing stress of the plate, the biggest hole that can be punched in the plate would be of diameter equal to
1 (a) Thickness of plate 4 1 (b) Thickness of plate 2 (c) Pl t thi k ( ) Plate thickness (d) 2 Plate thickness

Ans.(c)

E l Example
A hole, 100 mm diameter, is to be punched in steel plate hole diameter 5.6 mm thick. The ultimate shear stress is 550 N/mm2 . With normal clearance on the tools, cutting is complete 4 p p p at 40 per cent penetration of the punch. Give suitable shear angle for the punch to bring the work within the capacity of a 30T press. it f T

Ans. 4.2o

Example
A washer with a 12.7 mm internal hole and an outside diameter of 25.4 mm is to be made from 1.5 mm thick 25 4 15 strip. The ultimate shearing strength of the material of the washer is 280 N/mm2. (a) Find the total cutting force if both punches act at the same time and no shear is applied to either punch or the die. (b) What will be the cutting force if the punches are staggered, so that only one punch acts at a time. (c) ( ) Taking 60% penetration and shear on punch of 1 k % d h h f mm, what will be the cutting force if both punches act g together. Ans. 50.25 kN, 33.51 kN, F = 45.24 kN

GATE 2010 Statement Linked 1 GATE2010StatementLinked1

Statement for Linked Answer Questions: In a shear cutting operation, a sheet of 5 mm thickness is cut along a length of 200 mm. The cutting blade is 400 mm long and zeroshear (S = 0) is provided on the edge zero shear edge. The ultimate shear strength of the sheet is 100 MPa and penetration to thickness ratio is 0.2. Neglect friction.
400

Assuming force vs displacement curve to be rectangular, the work d h k done (i J) i (in is (a) 100 (b) 200 (c) 250 (d) 300 [Ans. (a)]

GATE 2010 Statement Linked 2 GATE2010StatementLinked2

Statement for Linked Answer Questions: In a shear cutting operation, a sheet of 5mm thickness operation is cut along a length of 200 mm. The cutting blade is 400 mm long and zeroshear (S = 0) is provided on the edge. The ultimate shear strength of the sheet is 100 MPa and penetration to thickness ratio is 0.2. Neglect friction.
400

A shear of 20 mm (S = 20 mm) is now provided on the blade. blade Assuming force vs displacement curve to be trapezoidal, the maximum force (in kN) exerted is (a) 5 (b) 10 (c) 20 (d) 40 [Ans. (b)]

GATE 2011 GATE2011

The shear strength of a sheet metal is 300 MPa. The blanking force required to produce a blank of 100 mm diameter from a 1.5 mm thick sheet is close to (a) kN ( ) 45 k (b) 70 kN (c) 141 kN (d) 3500 kN

Ans. (c)

GATE 2009 (PI) GATE 2009(PI)

A disk of 200 mm diameter is blanked from a strip of an aluminum alloy of thickness 3.2 mm. The material shear strength to fracture is 150 MPa. The blanking force (in ) kN) is (a) 291 (b) 301 (c) 311 (d) 321

Ans. (b) A

ISRO 2009 ISRO2009

The force required to punch a 25 mm hole in a mild steel plate 10 mm thick, when ultimate shear stress of the plate is 500 N/mm2 will be nearly (a) 78 kN (b) 393 kN (c) 98 kN (d) 158 kN

Ans. Ans (b)

GATE 2007 GATE2007

The force requirement in a blanking operation of low carbon steel sheet is 5.0 kN. The thickness of l b l h i kN Th hi k f the sheet is t and diameter of the blanked part is d For the same work material if the diameter of d. material, the blanked part is increased to 1.5 d and thickness is reduced to 0.4 t, the new blanking force in kN is 4 , g (a) 3.0 (b) 4.5 (c) 5.0 (d) 8.0 Ans. (a)

GATE 2004 GATE2004

10 mm diameter holes are to be punched in a steel sheet of 3 mm thickness. Shear strength of the h f hi k Sh h f h material is 400 N / mm2 and penetration is 40%. Shear provided on the punch is 2 mm The blanking mm. force during the operation will be (a) 22 6 kN 22.6 (b) 37 7 kN 37.7 (c) 61.6 kN (d) 94.3 kN Ans. (a)

GATE 2003 GATE2003

A metal disc of 20 mm diameter is to be punched from a sheet of 2 mm thickness. The punch and the f h f hi k Th h d h die clearance is 3%. The required punch diameter is (a) ( ) 19.88 mm (b) 19.94 mm 88 (c) 20.06 mm (d) 20.12 mm Ans. (a)

GATE 2012
Calculate the punch size in mm, for a circular blanking operation for which details are given below. Size of the blank 25 mm Thickness of the sheet 2 mm Radial clearance between punch and die 0.06 mm Die allowance 0.05 mm (a) 24.83 (b) 24.89 ( ) 5 (c) 25.01 ( ) 5 7 (d) 25.17 Ans. (a)

GATE2008(PI)
A blank of 50 mm diameter is to be sheared from a sheet of 2.5 mm thickness. The required radial clearance between the die and the punch is 6% of sheet thickness The punch and die diameters (in mm) thickness. for this blanking operation, respectively, are (a) 50.00 and 50.30 (c) 49.70 and 50.00 Ans. (c) (b) 50.00 and 50.15 (d) 49.85 and 50.00

GATE 2002 GATE2002

In a blanking operation, the clearance is provided on (a) The die (b) ( ) Both the die and the punch equally (c) The punch (d) Brittle the punch nor the die Ans. (c)

GATE 2001 GATE2001

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

GATE 1996 GATE1996

A 50 mm diameter disc is to be punched out from a carbon steel sheet 1.0 mm thick. The diameter of b l h hi k Th di f the punch should be (a) ( ) 49.925 mm (b) 50.00 mm (c) 50.075 mm (d) none of the above Ans. (d)

IES 1994 IES

In sheet metal blanking, shear is provided on punches and dies so that h d di h (a) Press load is reduced (b) ( ) Good cut edge is obtained. (c) Warping of sheet is minimized (d) Cut blanks are straight Ans. (a)

IES 2002 IES

Consider the following statements related to piercing and blanking: i i d bl ki 1. Shear on the punch reduces the maximum cutting force 2. Shear increases the capacity of the press needed 3. Sh Shear i increases the lif of the punch h life f h h 4. The total energy needed to make the cut remains unaltered d t provision of shear lt d due to i i f h Which of these statements are correct? (a) ( ) 1 and 2 d (b) 1 and 4 d (c) 2 and 3 (d) 3 and 4 Ans. (b)

IAS 1995 IAS

In blanking operation 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 designers choice Ans. (c)

IES 2006 IES

In which one of the following is a flywheel generally employed? l d? (a) Lathe (b) Electric motor (c) ( ) Punching machine (d) ( ) Gearbox Ans. (c)

IES 2004 IES

Which one of the following statements is correct? If the size of a flywheel in a punching machine is increased (a) ( ) Then the fluctuation of speed and fluctuation of energy will both decrease (b) Th the fl Then h fluctuation of speed will d i f d ill decrease and the d h fluctuation of energy will increase (c) Then the fluctuation f ( ) Th th fl t ti of speed will i d ill increase and th d the fluctuation of energy will decrease (d) Then the fluctuation of speed and fluctuation of energy both will increase Ans. (a)

IES 1997 IES

For 50% penetration of work material, a punch with single shear equal to thickness will i l h l hi k ill (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 Ans. (a)

IAS 2000 IAS

A blank of 30 mm diameter is to be produced out of 10 mm thick sheet on a simple die. If 6% clearance is hi k h i l di l i recommended, then the nominal diameters of die and punch are respectively (a) 30.6 mm and 29.4 mm (b) 30 6 mm and 30 mm 30.6 (c) 30 mm and 29.4 mm (d) 30 mm and 28.8 mm d 88 Ans. (d) A

GATE 2007 (PI) GATE 2007(PI)

Circular blanks of 35 mm diameter are punched from a steel sheet of 2 mm thickness. If the f l h f hi k h clearance per side between the punch and die is to b k be kept as 40 microns, the sizes of punch and i h i f h d die should respectively be

(a) 35+0.00 and 35+0.040 (b) 350.040 and 350.080 4 (c) 350.080 and 35+0.00 (d) 35+0.040 and 350.080 Ans.(c)

IAS 1994 IAS

In a blanking operation to produce steel washer, the maximum punch load used in 2 x 105 N. The plate i hl d di N Th l thickness is 4 mm and percentage penetration is 25. The work done during this shearing operation is (a) 200J (b) 400J (c) 600 J (d) 800 J

Ans. (a) A ( )

IAS 2002 IAS

In deciding the clearance between punch and die in press work in shearing, the following rule is helpful: ki h i h f ll i l i h l f l (a) Punch size controls hole size die size controls blank size i (b) Punch size controls both hole size and blank size (c) Die i ( ) Di size controls b h h l size and bl k size l both hole i d blank i (d) Die size controls hole size, punch size controls blank size i Ans. ( ) A (a)

IAS 2007 IAS

For punching operation the clearance is provided on which one of the following? hi h f h f ll i ? (a) The punch (b) ( ) The die (c) 50% on the punch and 50% on the die (d) 1/3rd on the punch and 2/3rd on the die Ans. (b)

IAS 1995 IAS

Assertion (A): A flywheel is attached to a punching press so as to reduce its speed fluctuations. d i d fl i Reason(R): The flywheel stores energy when its speed increase increase. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (a)

IES 2002 IES

Which one is not a method of reducing cutting forces to prevent the overloading of press? f h l di f ? (a) Providing shear on die (b) ( ) Providing shear on punch (c) Increasing die clearance (d) Stepping punches Ans. (c)

IAS 2003 IAS

Match List I (Presspart) with List II (Function) and select the correct answer using the codes given below the lists: ListI ListII (Presspart) (Function) ( ) (A) Punch plate p 1. Assisting withdrawal of the punch g p (B) Stripper 2. Advancing the workpiece through correct distance ( ) (C) Stopper pp 3 3. Ejection of the workpiece from die cavity j p y (D) Knockout 4. Holding the small punch in the proper position Codes: A B C D A B C D (a) 4 3 2 1 (b) 2 1 4 3 (c) 4 1 2 3 (d) 2 3 4 1
Ans. (c)

IES 1999 IES

Assertion (A): In sheet metal blanking operation, clearance must be given to the die. l b i h di Reason (R): The blank should be of required dimensions. di i (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. Ans (d)

IAS 2003 IAS

The 'spring back' effect in press working is (a) Elastic recovery of the sheet metal after removal of the load (b) ( ) Regaining the original shape of the sheet metal (c) Release of stored energy in the sheet metal (d) Partial recovery of the sheet metal Ans. (a)

IES 1997 IES

A cup of 10 cm height and 5 cm diameter is to be made from a sheet metal of 2 mm thickness. The d f h l f hi k Th number of deductions necessary will be (a) One ( ) O (b) Two (c) Three ( ) Th (d) Four Ans. (c)

IFS 2009
What is deep drawing process for sheet metal forming? E plain the function of a blank holder Explain holder. What is drawing ratio and how is the drawing ratio increased ? [10 [ marks] k ]

GATE 2008 GATE2008

In the deep drawing of cups, blanks show a tendency to wrinkle up around the periphery (flange). i kl d th i h (fl ) The most likely cause and remedy of the phenomenon are, respectively, respectively (A) Buckling due to circumferential compression; Increase blank holder pressure p (B) High blank holder pressure and high friction; Reduce blank holder pressure and apply lubricant (C) High temperature causing increase in circumferential length: Apply coolant to blank (D) B kli Buckling d to circumferential compression; d due i f i l i decrease blank holder pressure [Ans. (a)]

GATE 1999 GATE1999

Identify the stress state in the FLANCE portion of a PARTIALLYDRAWN CYLINDRICAL CUP when deep h d drawing without a blank holder (a) Tensile in ll three di ti ( ) T il i all th directions (b) No stress in the flange at all, because there is no blankholder blank holder (c) Tensile stress in one direction and compressive in the one other direction (d) Compressive in two directions and tensile in the third direction Ans. (b)

GATE 2003 GATE2003

A shell of 100 mm diameter and 100 mm height with the corner radius of 0.4 mm is to be produced by h di f i b d d b cup drawing. The required blank diameter is (a) 8 ( ) 118 mm (b) 161 mm 6 (c) 224 mm (d) 312 mm Ans. (c)

ISRO2011
The initial blank diameter required to form y p a cylindrical cup of outside diameter 'd and total height 'h' having a corner radius 'r' is g obtained using the formula

(a ) Do = d 2 + 4dh 0.5r (b) Do = d + 2h + 2r (c) Do = d + 2h + 2r

2 2

(d ) Do = d + 4dh 0.5r
2

Ans.(d)

GATE 2006 GATE2006

Match the items in columns I and II. Column I Column II P. Wrinkling 1. Yield point elongation Q. Orange peel Q O l 2. Anisotropy A i R. Stretcher strains 3. Large grain size S. Earing S E i 4. Insufficient bl k h ldi I ffi i t blank holding force 5. 5 Fine grain size 6. Excessive blank holding force (a) P 6 Q 3 R 1 S 2 (b) P 4 Q 5 R 6 S 1 6, 3, 1, 4, 5, 6, (c) P 2, Q 5, R 3, S 4 (d) P 4, Q 3, R 1, S 2
Ans. (d)

IES 2008 IES

A cylindrical vessel with flat bottom can be deep drawn by d b (a) Shallow drawing (b) ( ) Single action deep drawing (c) Double action deep drawing (d) Triple action deep drawing Ans. (c)

IES 1999 IES

Consider the following statements: Earring in a drawn cup can be due to nonuniform d b d if 1. Speed of the 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 Ans. (b)

IES 1994 IES

For obtaining a cup of diameter 25 mm and height 15 mm by drawing, the size of the round blank should b d i h i f h d bl k h ld be approximately (a) ( ) 42 mm (b) 44 mm (c) 46 mm (d) 48 mm Ans. (c)

IAS 2007 IAS

In drawing operation, proper lubrication essential for which of the following reasons? i lf hi h f h f ll i ? 1. To improve die life 2. To reduce drawing forces 3. To reduce temperature 4. To improve surface finish Select the correct answer using the code given below: (a) 1 and 2 only (b) 1, 3 and 4 only (c) 3 and 4 only (d) 1, 2, 3 and 4 Ans. (d) is

IAS 1997 IAS

Which one of the following factor promotes the tendency for wrinking in the process of drawing? d f i ki i h fd i ? (a) Increase in the ratio of thickness to blank diameter of work material f k t i l (b) Decrease in the ratio thickness to blank diameter of work material (c) Decrease in the holding force on the blank (d) U of solid l b i Use f lid lubricants t Ans. ( ) A (c)

IAS 1994 IAS

Consider the following 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 d d (c) 2 and 4 (d) 1, 3 and 4 Ans. (d)

IES 1998 IES

Assertion (A): The first draw in deep drawing operation can have up to 60% reduction, the second draw up to h t 6 % d ti th d d t 40% reduction and, the third draw of about 30% only. Reason (R): Due to strain hardening the subsequent hardening, draws in a deep drawing operation have reduced percentages. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true b R is not the h d d d ll but h correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (a)

GATE 1992 GATE1992

Thethicknessoftheblankneededtoproduce,by powerspinningamissileconeofthickness1.5mm i i i il f hi k andhalfconeangle30,is (a) ( ) 3.0mm (b) 2.5mm (c) 2.0mm (d) 1.5mm Ans.(a)

IES 1994 IES

The mode of deformation of the metal during spinning is i i i (a) Bending (b) ( ) Stretching (c) Rolling and stretching (d) Bending and stretching. Ans. (d)

IFS2011
Comparemetalspinningwithpresswork. [2marks]

IES 2011 IES2011

High energy rate forming process used for forming components from thin metal sheets or deform thin tubes is: (a) ( ) Petroforming f (b) Magnetic pulse forming (c) Explosive forming (d) electrohydraulic forming Ans. (b)

JWM 2010 JWM2010

Assertion (A) : In magnetic pulseforming method, magnetic field produced by eddy currents is used to create force between coil and workpiece. Reason (R) : It is necessary for the workpiece material to have magnetic properties. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is NOT the correct explanation of A ( ) (c) A is true but R is false (d) A is false but R is true Ans. (a)

IES 2010 IES2010

Assertion (A) : In the high energy rate forming method, the explosive forming has proved to be an method excellent method of utilizing energy at high rate and utilizes both the high explosives and low explosives. g p p Reason (R): The gas pressure and rate of detonation can be controlled for both types of explosives. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is NOT the correct explanation of A (c) is ( ) A i true b R i f l but is false (d) A is false but R is true Ans. (c)

IES 2007 IES

Which one of the following metal forming processes is not a high energy rate forming process? i hi h f i ? (a) Electromechanical forming (b) ( ) Rollforming (c) Explosive forming (d) Electrohydraulic forming Ans. (b)

IES 2009 IES

Which one of the following is a high energy rate forming process? f i ? (a) Roll forming (b) ( ) Electrohydraulic forming (c) Rotary forging (d) Forward extrusion Ans. (b)

IES 2005 IES

Magnetic forming is an example of: (a) Cold forming (b) Hot forming (c) High energy rate forming (d) Roll forming Ans. (c)

IFS2011
Writefouradvantagesofhighvelocityformingprocess. [2marks]

GATE 2000 GATE2000

A 1.5 mm thick sheet is subject to unequal biaxial stretching and the true strains in the directions of hi d h i i h di i f stretching are 0.05 and 0.09. The final thickness of the sheet in mm is (a) 1.414 (b) 1.304 (c) 1 362 1.362 (d) 289 Ans. A (b)

IES1998 IES 1998

The bending force required for Vbending, 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 Ans. ( ) A (a)

GATE 2005 GATE2005

A 2 mm thick metal sheet is to be bent at an angle of one radian with a bend radius of 100 mm. If the di i h b d di f h stretch factor is 0.5, the bend allowance is (a) ( ) 99 mm (b) 100 mm (c) 101 mm (d) 102 mm
2mm

1 radian

Ans. (c)

GATE 2007 GATE2007

Match the correct combination for following metal working processes. processes Processes Associated state of stress P. P Blanking 1. 1 Tension Q. Stretch Forming 2. Compression R. R Coining 3. 3 Shear S. Deep Drawing 4. Tension and Compression 5. Tension and Shear Codes:P Q R S P Q R S ( ) (a) 2 1 3 4 ( ) (b) 3 4 1 5 (c) 5 4 3 1 (d) 3 1 2 4
Ans.(d)

GATE2012SameQinGATE2012(PI)
Match the following metal forming processes with their associated stresses in the workpiece. Metalformingprocess 1.Coining 2.WireDrawing g 3.Blanking 4.DeepDrawing ( ) , (a) 1S, 2P, 3Q, 4R , 3 Q, 4 (c) 1P, 2Q, 3S, 4R Typeofstress P.Tensile Q Q.Shear R.Tensileand compressive S.Compressive ( ) , (b) 1S, 2P, 3R, 4Q ,3 ,4 Q (d) 1P, 2R, 3Q, 4S
Ans.(a)

GATE 2004 GATE2004

Match the following Product Process P. Moulded luggage 1. Injection moulding Q. Packaging containers for liquid 2. Hot rolling R. Long structural shapes 3. Impact extrusion S. Collapsible tubes 4. Transfer moulding 5 5. Blow moulding g 6. Coining ( ) (a) P1 Q4 R6 S3 Q4 3 ( ) (b) P4 Q5 R2 S3 4Q 5 3 (c) P1 Q5 R3 S2 (d) P5 Q1 R2 S2
Ans. (b)

IAS 1999 IAS

Match List I (Process) with List II (Production of parts) and select the correct answer using the codes given below the lists: ListI ListII A. Rolling 1. Discrete parts B. Forging 2. Rod and Wire C. C Extrusion 3. i Wide variety of shapes with thin id i f h i h hi walls D. D Drawing 4. 4 Flat plates and sheets 5. Solid and hollow parts [Ans. (d)] Codes:A B C D A B C D (a) 2 5 3 4 (b) 1 2 5 4 (c) 4 1 3 2 (d) 4 1 5 2

IAS 1997 IAS

Match ListI (metal forming process) with ListII (Associated feature) and select the correct answer (A i d f ) d l h using the codes given below the Lists: Listl Li t l List Li t II A. Blanking 1. Shear angle B. Flow forming B Fl f i 2. Coiled C il d stock k C. Roll forming 3. Mandrel [Ans. (c)] 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

IES 2010 IES2010

Consider the following statements: The material properties which principally determine how well a metal may be drawn are 1. Ratio of yield stress to ultimate stress. 2.Rate of increase of yield stress relative to progressive amounts of cold work. 3. Rate of work hardening. g Which of the above statements is/are correct? (a) 1 and 2 only (b) 2 and 3 only (c) 1 only (d) 1, 2 and 3

Ans. (d)

Ch 18: Sheet Metal Forming Ch18:SheetMetalForming

Q. No 1 2 3 4 5 6 7 8 9 Option C B A A D A A A A Q. No 10 11 12 13 14 15 16 17 Option C C C C D A B D

PowderMetallurgy

BySKMondal

GATE2011(PI)
Which of the following powder production methods produces spongy and porous particles? i l ? (a) Atomization (b) Reduction of metal oxides (c) Electrolytic deposition (d) Pulverization Ans. (b)

IES 2012 IES

In electrolysis (a) For making copper powder, copper plate is made cathode in electrolyte tank (b) ( ) For making aluminum powder, aluminum plate is made anode (c) High ( ) Hi h amperage produces powdery d d d deposit of cathode i f h d metal on anode (d) At i ti process i more suitable f l Atomization is it bl for low melting lti point metals Ans. Ans (b)

IES 2007Conventional
Metal powders are compacted by many methods, but sintering is required to achieve which property? What is hot isostatic pressing?
[2Marks]

GATE2010(PI)
In powder metallurgy, sintering of a component (a) ( ) Improves strength and reduces h d h d d hardness (b) Reduces brittleness and improves strength educes b e ess a d p o es s e g (c) Improves hardness and reduces toughness (d) Reduces porosity and increases brittleness Ans. (b) A

IES 2011Conventional
Whatisisostatic pressingofmetalpowders? Whatareitsadvantage? [2Marks]

GATE 2009(PI)
Which of the following process is used to manufacture products with controlled porosit ? ith porosity? (a) Casting (b) welding (c) formation (d) Powder metallurgy Ans. Ans (d)

GATE 2011(PI)
The binding material used in cemented carbide cutting tools is (a) graphite (b) tungsten (c) nickel (d) cobalt Ans. (d) ( )

IES 2010 IES2010

Consider the following parts: 1. Grinding wheel g 2. Brake lining 3. Selflubricating bearings Which of these parts are made by powder metallurgy technique? (a) ( ) 1, 2 and 3 d (b) 2 only l (c) 2 and 3 only (d) 1 and 2 only Ans. (c)

IES 2010 IES2010

Metallic powders can be produced by (a) Atomization ( ) (b) Pulverization (c) Electrodeposition process (d) All of the above Ans. (d)

IES 2002 IES

The rate of production of a powder metallurgy part depends on d d (a) Flow rate of powder (b) ( ) Green strength of compact (c) Apparent density of compact (d) Compressibility of powder

Ans. (c)

IES 2001 IES

Match ListI (Components) with ListII (Manufacturing Processes) and select the correct (M f i P ) d l h answer using the codes given below the lists: List Li t I List Li t II A. Car body (metal) 1. Machining B. Clutch lining B Cl h li i 2. Casting C i C. Gears 3. Sheet metal pressing D. Engine block 4. Powder metallurgy Ans.(d) 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

GATE 2011 GATE2011

The operation in which oil is permeated into the pores of a powder metallurgy product is known as (a) mixing (b) sintering (c) impregnation (d) Infiltration

Ans. (c) ( )

IES 1998 IES

In powder metallurgy, the operation carried out to improve the bearing property of a bush is called i h b i f b hi ll d (a) infiltration (b) impregnation (c) ( ) plating (d) ( ) heat treatment

Ans. (b)

IES 1997 IES

Which of the following components can be manufactured by powder metallurgy methods? f db d ll h d ? 1. Carbide tool tips 2. Bearings 3. Filters 4. Brake linings Select the correct answer using the codes given below: (a) 1, 3 and 4 (b) 2 and 3 (c) 1, 2 and 4 (d) 1, 2, 3 and 4

Ans. (d)

IES 1999 IES

The correct sequence of the given processes in manufacturing by powder metallurgy is f i b d ll i (a) Blending, compacting, sintering and sizing (b) ( ) Blending, compacting, sizing and sintering (c) Compacting, sizing, blending and sintering (d) Compacting, blending, sizing and sintering

Ans. (a)

IES 2001 IES

Carbidetipped cutting tools are manufactured by powder metal technology process and have a d l h l d h composition of (a) ZirconiumTungsten ( % 65%) ( ) Zi i T t (35% 6 %) (b) Tungsten carbideCobalt (90% 10%) (c) Aluminium oxide Sili ( % 30%) ( ) Al i i id Silica (70% %) (d) NickelChromium Tungsten (30% 15% 55%)

Ans. (b)

IES 1999 IES

Assertion (A): In atomization process of manufacture of metal powder, the molten metal is forced through a t l d th lt t l i f d th h small orifice and broken up by a stream of compressed air. Reason (R): The metallic powder obtained by atomization process is quite resistant to oxidation. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true b R is not the h d d d ll but h correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (c)

IES 2007 IES

What are the advantages of powder metallurgy? 1. Extreme purity product 2. Low labour cost 3. Low equipment cost. Select the correct answer using the code given below (a) 1, 2 and 3 (b) 1 and 2 only y (d) 1 and 3 only y (c) 2 and 3 only

Ans. (b)

IES 2006 IES

Which of the following are the limitations of powder metallurgy? 1. High tooling and equipment costs. 2. 2 Wastage of material material. 3. It cannot be automated. 4. 4 Expensive metallic powders powders. Select the correct answer using the codes given below: (a) Only 1 and 2 (b) Only 3 and 4 (c) Only 1 and 4 (d) Only 1, 2 and 4 Ans. (c)

IES 2004 IES

Consider the following factors: 1. Size and shape that can be produced economically 2. Porosity of the parts produced 3. Available press capacity 4. High density Which of the above are limitations of powder metallurgy? (a) 1, 3 and 4 (b) 2 and 3 (c) 1, 2 and 3 (d) 1 and 2 Ans. (a)

St t t (I): Parts d by d t ll Statement (I) P t made b powder metallurgy d do not have as good physical properties as parts casted. Statement (II): Particle shape in powder metallurgy influences the flow characteristic of the powder. ( ) (a) Both Statement (I) and Statement (II) are () ( ) individually true and Statement (II) is the correct explanation of Statement (I) (b) B th St t Both Statement (I) and St t t d Statement (II) are t individually true but Statement (II) is not the correct explanation of Statement (I) p () (c) Statement (I) is true but Statement (II) is false ( ) (d) Statement (I) is false but Statement (II) is true () ( ) Ans. (b)

IES 2012

IES 2009 IES

Which of the following cutting tool bits are made by powder metallurgy process? d ll ? (a) Carbon steel tool bits (b) Stellite tool bits (c) ( ) Ceramic tool bits (d) ( ) HSS tool bits

Ans. (c)

IAS 2003 IAS

Which of the following are produced by powder metallurgy process? ll ? 1. Cemented carbide dies 2. Porous bearings 3. Small magnets 4. Parts with intricate shapes Select the correct answer using the codes given below: Codes: (a) 1, 2 and 3 (b) 1, 2 and 4 (c) 2, 3 and 4 (d) 1, 3 and 4 Ans. (a)

IAS 2003 IAS

In parts produced by powder metallurgy process, presintering is done to i i i d (a) Increase the toughness of the component (b) ( ) Increase the density of the component (c) Facilitate bonding of nonmetallic particles (d) Facilitate machining of the part

Ans. (d)

IAS 2000 IAS

Consider the following processes: 1. Mechanical pulverization M h i l l i i 2. Atomization 3. Ch i l reduction Chemical d ti 4. Sintering Which of these processes are used for powder preparation in powder metallurgy? (a) 2, 3 and 4 (b) 1, 2 and 3 (c) 1, 3 and 4 (d) 1, 2 and 4 Ans. (b)

IAS 1997 IAS

Assertion (A): Close dimensional tolerances are NOT possible with isostatic pressing of metal powder in powder metallurgy technique. Reason (R): In the process of isostatic pressing, the pressure is equal in all directions which permits uniform density of the metal powder. (a) ( ) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (d)

IAS 1998 IAS

Throwaway tungsten manufactured by f db (a) Forging (c) ( ) Powder metallurgy Ans. (c) carbide (b) (d) ( ) tip tools are Brazing Extrusion

IAS 1996 IAS

Which one of the following processes is performed in powder metallurgy to promote selflubricating i d ll lf l b i i properties in sintered parts? (a) Infiltration ( ) I filt ti (b) I Impregnation ti (c) Plating (d) Graphitization Ans. (b)

GATE 2008 (PI) GATE 2008(PI)

Matchthefollowing Group 1 G P.Mulling Q.Impregnation Q I i R.Flashtrimming S.Curing Group2 G 1.Powdermetallurgy 2.Injection moulding I j i ldi 3.ProcessingofFRPcomposites 4.Sandcasting (b)P Q (b)P 2,Q 4,R 3,S 1 R S (d)P 4,Q 1,R 2,S 3

(a)P Q R S ( )P 4,Q 3,R 2,S 1 (c)P 2,Q 1,R 4,S 3 Ans.(d)

IAS 2007 IAS

Assertion (A): Mechanical disintegration of a molten metal stream into fine particles by means of a jet of compressed air is known as atomization. Reason (R): In atomization process inertgas or inert gas water cannot be used as a substitute for compressed air. (a) ( ) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (c)

IAS 2004 IAS

The following are the constituent steps in the process of powder metallurgy: f d ll 1. Powder conditioning 2. Sintering 3. Production of metallic powder 4. Pressing or compacting into the desired shape Indentify the correct order in which they have to be performed and select the correct answer using the codes given below: (a) ( ) 1234 (b) 3142 (c) 2413 (d) 4321 Ans. (b)

IAS 2003 IAS

Assertion (A): Atomization method for production of metal powders consists of mechanical disintegration of t l d i t f h i l di i t ti f molten stream into fine particles. Reason (R): Atomization method is an excellent means of making powders from high temperature metals. ( ) (a) Both A and R are individually true and R is the correct y explanation of A (b) Both A and R are individually true but R is not the correct explanation of A l f (c) A is true but R is false (d) A i f l b R i true is false but is Ans. ( ) A (c)

IAS 2007 IAS

Consider the following basic steps involved in the production of porous bearings: d i f b i 1. Sintering 2. Mixing 3. Repressing 4. Impregnation 5. Colddiecompaction Which one of the following is the correct sequence of the above steps? Ans. (b)

C ti l Q ti ConventionalQuestions
1. Explain why metal powders are blended. Describe what

happens during sintering. h d i i i

[IES2010, 2 Marks] [IES M k ]

C ti l Q ti ConventionalQuestions
1. Discuss the terms fineness and particle size

distribution in powder metallurgy. [IES2010, 2 metallurgy [IES 2010 Marks] Ans. Fineness: Is the diameter of spherical shaped particle and mean diameter of nonspherical shaped particle. Particle size distribution: Geometric standard deviation (a measure for the bredth or width of a ( distribution), is the ratio of particle size diameters taken at 84.1 and 50% of the cumulative undersized weight plot respectively and mean mass diameter plot, define the particle size distribution.

C ti l Q ti ConventionalQuestions
Enumerate the steps involved in powder metallurgy process. Discuss these steps. Name the materials used Di h N h i l d in powder metallurgy. What are the limitations of powder metallurgy? [IES2005, [IES2005 10 Marks]

Ch12:PowderMetallurgy
Q. No 1 2 3 4 Option D B C A Q. No 5 6 7 8 Option C B D C

Limit,Tolerance&Fits ,

BySKMondal

ForPSU
Tolerancesarespecified (a) Toobtaindesiredfits (b) becauseitisnotpossibletomanufactureasize exactly (c) toobtainhigheraccuracy (d) tohaveproperallowances Ans.(b) ( )

ISRO2010
Expressing a dimension as 25.30.05 mm is the case of (a) ( ) Unilateral tolerance l l l (b) Bilateral tolerance a e a o e a ce (c) Limiting dimensions (d) All of the above Ans. A (b)

GATE 2010 ISRO2012 GATE 2010,ISRO2012

A shaft has a dimension,35 The respective values of fundamental deviation and tolerance are
0 009 0.009 0.025

(a) 0.025, 0.008 (c) 0.009, 0.008

Ans.(d)

(b) 0.025,0.016 (d) 0.009,0.016

GATE 1992 GATE

TwoshaftsAandBhavetheirdiametersspecifiedas 100 0.1mmand0.1 0.0001mmrespectively. d i l Whichofthefollowingstatementsis/aretrue? (a) ( ) ToleranceinthedimensionisgreaterinshaftA (b) Therelativeerrorinthedimensionisgreaterinshaft A (c) ToleranceinthedimensionisgreaterinshaftB (d) ( ) Therelativeerrorinthedimensionissameforshaft AandshaftB Ans.(a)

GATE 2004 GATE 2004

In an interchangeable assembly, shafts of size +0.020 25.000 mm mate with holes of size 25.0000.000 mm. The maximum possible clearance in the assembly will b ill be (a) 10 microns (b) 20 microns i (c) 30 microns (d) ( ) 60 microns
+0.040 0.0100

Ans. (c)

ISRO 2010 ISRO2010

Dimension of the hole is 50+0.02 mm and shaft is 50+0.02 mm. 0.00 +0.00 The minimum clearance is (a) 0.02 mm 0 02 (b) 0.00 mm 0 00 (c) -0.02 mm (d) 0.01 mm

Ans.(c)

GATE 2007 GATE

A hole is specified as 4 0 mm. The mating shaft has a clearance fit with minimum clearance of h f h l fi i h i i l f 0.01 mm. The tolerance on the shaft is 0.04 mm. The maximum clearance in mm between the hole and the shaft is (a) 0 04 0.04 (b) 0.05 (c) 0 10 0.10 (d) 0.11 Ans. (c)
0 .0 5 0 0 .0 0 0

IES 2005 IES

The tolerance specified by the designer for the diameter of a shaft is 20.00 0.025 mm. The shafts 20 00 0 025 mm produced by three different machines A, B and C have mean diameters of 1999 mm, 2000 mm and 9 99 20.01 mm respectively, with same standard deviation. What will be the percentage rejection for the shafts produced by machines A B and C? A, (a) Same for the machines A, Band C since the standard deviation is same for the three machines (b) Least for machine A (c) Least for machine B (d) Least for machine C Ans. (c)

GATE 2000 GATE

A slot is to be milled centrally on a block with a dimension of 40 0.05 mm. A milling cutter of 20 di i f illi f mm width is located with reference to the side of the block within 0 02 mm The maximum offset in 0.02 mm. mm between the centre lines of the slot and the block is (a) 0.070 (b) 0.070 (c) 0.020 (d) 0.045 Ans. Ans (c)

GATE 2007 (PI) GATE 2007(PI)

Diameter of a hole after plating needs to be controlled between 30
+0.050 +0.010

mm. If the plating thickness varies

between 10 - 15 microns, diameter of the hole before plating should be (a) 30+0.070 mm +0.030 (c) 30
+0.080 +0.030 0.065 (b) 30+0.020 mm +

mm

(d) 30

+0.070 +0.040

mm

Ans.(d)

IES 2011 IES2011

Interference fit joints are provided for: (a) Assembling bush bearing in housing (b) Mounting heavy duty gears on shafts (c) Mounting pulley on shafts (d) A Assembly of fl h l on shafts bl f flywheels h ft Ans. ( ) A (a)

GATE 2005 GATE

In order to have interference fit, it is essential that the lower limit of the shaft should be (a) Greater than the upper limit of the hole (b) Lesser than the upper limit of the hole (c) Greater than the lower limit of the hole (d) Lesser than the lower limit of the hole Ans. (a)

GATE 2011 GATE2011

A hole is of dimension 9
+0.015 +0

mm. The

corresponding shaft is of dimension The resulting assembly has (a) loose running fit g (b) close running fit (c) transition fit ( ) (d) interference fit Ans. (c)

+0.010 +0.001

mm.

GATE2012SameQinGATE2012(PI)
In an interchangeable assembly, shafts of size mm mate with holes of size

25

+0 04 0.04 0.01

25

+0.03 +0.02

mm.

The maximum interference (in microns) in the assembly is (a) 40 (b) 30 (c) 20 (d) 10 Ans. (c)

IAS2011Main
An interference assembly, of nominal diameter 20 mm, mm is of a unilateral holes and a shafts The shafts. manufacturing tolerances for the holes are twice that for the shaft. Permitted interference values are 3 9 0.03 to 0.09 mm. Determine the sizes, with limits, for the two mating parts. [10Marks] [ M k ]

IES 2007 IES

Ans.(a)

ISRO2011
Ashaftandholepairisdesignatedas50H7d8.This assemblyconstitutes (a)Interferencefit (b)Transitionfit ( ) (c)Clearancefit (d)Noneoftheabove Ans.(c) ( )

IES 2006 IES

Which of the following is an interference fit? (a) Push fit (b) Running fit (c) Sliding fit (d) Shrink fit

Ans. (d)

IES 2009 IES

Consider the following joints: 1. Railway carriage wheel and axle R il i h l d l 2. IC engine cylinder and liner Which f the b Whi h of th above j i t i / joints is/are th result(s) of the lt( ) f interference fit? (a) 1 only (b) 2 only (c) Neither 1 nor 2 (d) Both 1 and 2 Ans. (d)

IES 2008 IES

Consider the following statements: 1. The amount of interference needed to create a tight joint varies with diameter of the shaft. 2. An interference fit creates no stress state in the shaft. 3. Th stress state i the h b i similar to a thick The in h hub is i il hi k walled cylinder with internal pressure. Which f the t t Whi h of th statements given above are correct? t i b t? (a) 1, 2 and 3 (b) 1 and 2 only (c) ( ) 2 and 3 only d l (d) 1 and 3 only d l Ans. (d)

IES 2004 IES

Consider the following fits: 1. I.C. engine cylinder and piston 2. Ball bearing outer race and housing 3. Ball bearing inner race and shaft Which of the above fits are based on the interference system? (a) 1 and 2 (b) 2 and 3 (c) 1 and 3 (d) 1, 2 and 3 Ans. (b)

IES 2003 IES

Match ListI (Phenomenon) with ListII (Significant Parameters/Phenomenon) and select the correct answer using the codes given below the Lists: ListI ListII (Phenomenon) (Significant Parameters/Phenomenon) A. Interference fit 1. Viscosity index B. Cyclic loading 2. Interference C. Gear meshing 3. Notch sensitivity D. D Lubricating of bearings 4 4. Induced compressive stress [Ans. (b)] Codes:A B C D A B C D (a) ( ) 3 4 1 2 (b) 4 3 2 1 (c) 3 4 2 1 (d) 4 3 1 2

GATE 2001 GATE 2001

Allowance in limits and fits refers to (a) Maximum clearance between shaft and hole (b) Minimum clearance between shaft and hole (c) Difference between maximum and minimum size of hole (d) Difference between maximum and minimum size of shaft

Ans. (b)

GATE 1998 GATE

In the specification of dimensions and fits, (a) Allowance is equal to bilateral tolerance (b) Allowance is equal to unilateral tolerance (c) Allowance is independent of tolerance (d) Allowance is equal to the difference between maximum and minimum dimension specified by the tolerance. Ans. (c)

IES 2012 IES

Clearance in a fit is the difference between (a) Maximum hole size and minimum shaft size (b) Minimum hole size and maximum shaft size (c) Maximum hole size and maximum shaft size (d) Minimum hole size and minimum shaft size

Ans. (b)

ISRO2008
Basic shaft and basic hole are those whose upper deviations de iations and lo er de iations respecti el are lower deviations respectively (a) +ve, ve (c) Zero, Zero (b) ve, +ve (d) None of the above

Ans. Ans (c)

IES 2005 IES

Assertion (A): Hole basis system is generally preferred to shaft basis system in tolerance design f d h f b i i l d i for getting the required fits. Reason (R) H l h t b given a l R (R): Hole has to be i larger t l tolerance band than the mating shaft. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (c)

IES 2006 Conventional IES2006Conventional

Find the limit sizes, tolerances and allowances for a 100 mm diameter shaft and hole pair designated by di h f dh l i d i db F8h10. Also specify the type of fit that the above pair belongs to to. Given: 100 mm diameter lies in the diameter step range of 80120 mm The fundamental deviation for 80 120 mm. shaft designation f is 5.5 D0.41 The values of standard tolerances for grades of IT 8 and IT 10 are 25i and 64i respectively. , g Also, indicate the limits and tolerance on a diagram. Will be discussed in class [15Marks]

IES 2008 IES

Consider the following statements: A nomenclature 50 H8/p8 denotes that 1. Hole diameter is 50 mm. 2. It is a shaft base system. 3. 8 indicates fundamental deviation. Which of the statements given above is/are incorrect? (a) 1, 2 and 3 (b) 1 and 2 only ( ) (c) 1 and 3 only y (d) 3 only Ans. (a)

IES 2002 IES

In the tolerance specification 25 D 6, the letter D represents (a) Grade of tolerance (b) ( ) Upper deviation (c) Lower deviation (d) Type of fit

Ans. (c)

GATE 2009 GATE

What are the upper and lower limits of the shaft represented by 60 f8? Use the following data: Diameter 60 lies in the diameter step of 5080 mm. p 5 Fundamental tolerance unit, i, in m= 0.45 D1/3 + 0.001D, where D is the representative size in mm; Tolerance value for lT8 = 25i. Ans. (a) Fundamental deviation for 'f shaft = 5.5D0.41 f 5.5D (a) Lower limit = 59.924 mm, Upper Limit = 59.970 mm (b) Lower limit = 59.954 mm, Upper Limit = 60.000 mm 59 954 pp (c) Lower limit = 59.970 mm, Upper Limit = 60.016 mm (d) Lower limit = 60.000 mm, Upper Limit = 60.046 mm

GATE 2008 (PI) GATE 2008(PI)

Following data are given for calculating limits of dimensions and tolerances for a hole: Tolerance unit i (in m) = 0 4 D + 0 00 D The unit of D is mm Diameter 0.45 0.001D. mm. step is 1830 mm. If the fundamental deviation for H hole is zero and IT8 = 25 i, the maximum and minimum limits of dimension for a 25 mm H8 hole (in mm) are (a) 24.984, 24.967 (c) 25.033, 25.000 (b) 25.017, 24.984 (d) 25.000, 24.967 Ans. (c)

GATE 2000 GATE

A fit is specified as 25H8/e8. The tolerance value for a nominal diameter of 25 mm in IT8 is 33 microns i l di f i i i and fundamental deviation for the shaft is 40 microns. microns The maximum clearance of the fit in microns is (a) 7 7 (b) 7 (c) 73 (d) 106 Ans. (d)

GATE 1996 IES2012 GATE 1996,IES2012

The fit on a holeshaft system is specified as H7 s6.The type of fit is 6 Th f fi i (a) Clearance fit (b) ( ) Running fit ( (sliding fit) ) (c) Push fit (transition fit) (d) Force fit (interference fit) Ans. (d)

GATE 2003 GATE

The dimensional limits on a shaft of 25h7 are (a) 25.000, 25.021 mm (b) 25.000, 24.979 mm (c) 25.000, 25.007 mm (d) 25.000, 24.993 mm Ans. (b)

GATE 2010 (PI) GATE2010(PI)

A small bore is designated as 25H7. The lower 25H7 (minimum) and upper (maximum) limits of the bore are 25.000 mm and 25.021 mm, respectively. When the bore is designated as 25H8, then the upper (maximum) limit is 25.033 mm. When the bore is designated as 25H6, 25H6 then the upper (maximum) limit of the bore (in mm) is (a) 25.001 (b) 25.005 (c) 25.009 (d) 25.013

Ans.(d)

IAS2010main
What is the difference between hole basis system and shaft basis system ? Why is hole basis system the more extensive in use ? What are the differences between interchangeability and selective assembly ? y [12Marks]

GATE 2003 GATE 2003

[Ans.(b)]

GATE 1997 GATE

Three blocks B1 , B2 and B3 are to be inserted in a channel of width S maintaining a minimum gap of width T = 0.125 mm, as shown i Fi h in Figure. For P = 18. 75 0.08; Q = 25 00 0 12; 25.00 0.12; R = 28.125 0.1 and S = 72.35 + X, (where all 7 35 , ( dimensions are in mm), the tolerance X is
(a)+0.38 ( ) 8 (b) (b) 0.38 8 (c)+0.05 ( ) (d)0.05 (d) Ans.(d)

IES 2000 IES

Which one of the following tolerances set on inner diameter and outer diameter respectively of headed di d di i l fh d d jig bush for press fit is correct? (a) G7 ( ) G h6 (b) F n6 F7 6 (c) H 7h 6 (d) F7j6 Ans. (b)

ISRO2008
Plug gauges are used to (a) Measure the diameter of the workpieces (b) ( ) Measure the diameter of the holes in the workpieces (c) Check the diameter of the holes in the workpieces (d) Check the length of holes in the workpieces Ans. (c) ( )

GATE 2004 GATE

GO and NOGO plug gages are to be designed for a 0.05 0 05 hole 200.01 mm. Gage tolerances can be taken as 10% of the hole tolerance. Following ISO system of gage design, sizes of GO and NO GO gage will b d i i f d NOGO ill be respectively (a) 20 010 mm and 20 050 mm 20.010 20.050 (b) 20.014 mm and 20.046 mm (c) ( ) 20.006 mm and 20.054 mm 6 d (d) 20.014 mm and 20.054 mm Ans. (b) A

GATE 1995 GATE

Checking the diameter of a hole using GONOGO gauges is an, example of inspection by i l f i i b ..(variables/attributes) The b Th above statement i t t t is (a) Variables (b) A ib Attributes (c) Cant say (d) ( ) Insufficient data Ans. (b)

GATE 2006 VS2012 GATE 2006,VS2012

A ring gauge is used to measure (a) Outside diameter but not roundness (b) Roundness but not outside diameter (c) Both outside diameter and roundness (d) Only external threads Ans. (c)

MeasurementofLines&Surfaces

BySKMondal

ISRO2010
The vernier reading should not be taken at its face value before an actual check has been taken f k for (a) Zero error (b) Its calibration (c) Flatness of measuring jaws (d) Temperature equalization Ans. (a)

ISRO2008
The least count of a metric vernier caliper having 25 divisions ha ing 2 di isions on vernier scale matching ernier scale, with 24 divisions of main scale (1 main scale divisions = 0.5 mm) is (a) ( ) 0.005 mm ( ) (c) 0.02 mm Ans. (c) (b) 0.01 mm ( ) (d) 0.005 mm 5

ISRO2009,2011
In a simple micrometer with screw pitch 0.5 mm and di isions on thimble 50, the reading divisions 0 corresponding to 5 divisions on barrel and 12 divisions on thimble is (a) 6 ( ) 2.620 mm ( ) (c) 2.120 mm Ans. (a) (b) 2.512 mm ( )5 (d) 5.012 mm

GATE 2008 GATE 2008

S1 S1

A displacement sensor (a dial indicator) measures the lateral displacement of a mandrel mounted on the taper hole inside a drill spindle. The mandrel axis is an extension of the drill spindle taper hole axis and the p protruding portion of the mandrel surface is perfectly g p p y cylindrical. Measurements are taken with the sensor p placed at two positions P and Q as shown in the figure. p g The readings are recorded as Rx = maximum deflection minus minimum deflection, corresponding to sensor position at X, over one rotation.

GATE 2008 contd from S1 GATE 2008contdfromS1

If Rp= RQ>0, which one of the following would be consistent with the observation? (A) The drill spindle rotational axis is coincident with the drill spindle taper hole axis (B) The drill spindle rotational axis intersects the drill spindle taper hole axis at point P (C) The drill spindle rotational axis is parallel t th d ill spindle t ll l to the drill i dl taper h l hole axis (D) The drill spindle rotational axis intersects the d ill spindle taper h l i h drill i dl hole axis at point Q

Ans.(c)

ISRO 2010 ISRO2010

A master gauge is (a) A new gauge (b) An international reference standard (c) ( ) A standard gauge f checking accuracy of gauges used d d for h ki f d on shop floors (d) A gauge used by experienced technicians Ans. (c)

ISRO2008
Standards to be used for reference purposes in laboratories and workshops are termed as orkshops (a) Primary standards (b) Secondary standards (c) Tertiary standards (d) Working standards Ans. Ans (d)

PSU
Afeelergaugeisusedtocheckthe (a)Pitchofthescrew ( ) h f h (b) Su ace oug ess (b)Surfaceroughness (c)Thicknessofclearance (d)Flatnessofasurface Ans.(c) A ( )

ISRO2011
A sine bar is specified by (a) ( ) Its total l l length h (b) The size of the rollers es eo e o es (c) The centre distance between the two rollers (d) The distance between rollers and upper surface Ans. (c) A ( )

GATE2012(PI)
A sine bar has a length of 250 mm. Each roller mm has a diameter of 20 mm. During taper angle measurement of a component, the height p from the surface plate to the centre of a roller is 100 mm. The calculated taper angle ( degrees) is (in ) ( ) (a) 21.1 Ans. (a) ( ) (b) 22.8 ( ) 3 (c) 23.6 ( ) (d) 68.9 9

GATE 2011(PI)
The best wire size (in mm) for measuring effective diameter of a metric thread (included (i l d d angle i 6 o) of 20 mm di l is 60 f diameter and d 2.5 mm pitch using two wire method is (a) ( ) 1.443 (b) 0.723 (c) 2.886 (d) 2.086 Ans. (a)

IES 1992 IES

Which grade symbol represents surface rough of broaching? b hi ? (a) N12 (b) N8 (c) ( ) N4 ( ) N1 (d) Ans. (b)

IFS 2011 IFS2011

y g What is meant by interchangeable manufacture? Laser light has unique advantages for inspection. What are they ? Define the terms 'roughness height waviness width height', 'waviness width' and 'lay' in connection lay with surface irregularities. [10marks]

ISRO2011
CLAvalueandRMSvaluesareusedfor measurementof (a)Metalhardness (b)Sharpnessoftooledge (c)Surfacedimensions (d)Surfaceroughness Ans.(d)

IES 2006 IES

y gy The M and Esystem in metrology are related to measurement of: (a) Screw threads (c) Angularity (b) (d) Flatness Surface finish

Ans. (d)

IES 2007 IES

What is the dominant direction of the tool marks or scratches in a surface texture having a directional h i f h i di i l quality, called? (a) Primary t t ( ) Pi texture (b) S Secondary t t d texture (c) Lay (d) Flaw Ans. (c)

IES 2008 IES

g What term is used to designate the direction of the predominant surface pattern produced by

machining operation? hi i i ? ( ) (a) Roughness g (c) Waviness Ans. (b) ( ) (b) (d) Lay y Cut off

IES 2010 IES2010

Match List I with List II and select the correct answer using the code given below the lists: i th d i b l th li t List I List II (Symbols for direction of lay) ( y y) ( (Surface texture) )

[Ans.(b)] (a) (c) A 4 4 B 2 1 C 1 2 D 3 3 (b) (d) A 3 3 B 2 1 C 1 2 D 4 4

IES 2008 IES 2008

Ans.(c) ( )

ISRO2010
Surface roughness on a drawing is represented by (a) Triangles (b) Circles (c) Squares ( )S (d) Rectangles Ans. (a)

GATE 1997 GATE 1997

List I List II (A) Surface profilometer 1. Calibration S f fil C lib i (B) Light Section Microscope 2. Form tester (C) Mi k t Microkater 3. Film thickness Fil thi k measurement (D) Interferometer 4 4. Centre line average 5. Comparator 6. Surface lay measurement Codes:A B C D A B C D ( ) (a) 4 1 2 3 ( ) (b) 4 3 5 1 (c) 4 2 1 3 (d) 3 1 2 4
Ans.(b)

GATE 2003 GATE

Two slip gauges of 10 mm width measuring 1.000 mm and 1.002 mm are kept side by side in contact with each d k id b id i ih h other lengthwise. An optical flat is kept resting on the slip gauges as shown in the figure Monochromatic light figure. of wavelength 0.0058928 mm is used in the inspection. The total number of straight fringes that can be observed g g on both slip gauges is (a)2 (c)8 (b)6 (d)13

Ans.(a)

MiscellaneousofMetrology

BySKMondal

GATE 1998 GATE 1998

Auto collimator is used to check (a) Roughness (b) Flatness (c) Angle (d) Automobile balance. Ans. (c)

GATE 2009(PI)
An autocollimator is used to (a) ( ) measure small angular d l ll l displacements on fl surface flat f (b) compare known and unknown dimensions co pa e o a d u o d e so s (c) measure the flatness error (d) measure roundness error between centers Ans. (c) A ( )

ISRO 2010 ISRO2010

Optical square is (a) Engineer's square having stock and blade set at 90o (b) A constant deviation prism having the angle of deviation between the incident ray and reflected ray, equal to 90o (c) ( ) A constant d i i deviation prism h i i having the angle of h l f deviation between the incident ray and reflected ray, equal to 45o (d) Used to produce interference fringes Ans. (b)

IES 1998 IES

Match ListI with ListII and select the correct answer using the codes given below the lists: ListI ListII (Measuring Device) (Parameter Measured) A. Diffraction grating g g 1. Small angular deviations on long g g flat surfaces B. Optical flat 2. Online measurement of moving parts C. A C Auto collimators lli 3. Measurement of gear pitch M f i h D. Laser scan micrometer4. Surface texture using interferometer 5. Measurement of very small displacements di l t Code: A B C D A B C D (a) 5 4 2 1 (b) 3 5 1 2 (c) ( ) 3 5 4 1 (d) 5 4 1 2
Ans.(d)

GATE 1992 GATE

Match the instruments with the physical quantities they measure: Instrument Measurement ( ) (A) Pilottube () (1) R.P.M. of a shaft (B) McLeod Gauge (2) Displacement (C) Planimeter (3) Flow velocity (D) LVDT (4) Vacuum (5) Surface finish (6) A Area [Ans. (b)] [A Codes:A B C D A B C D (a) 4 1 2 3 (b) 3 4 6 2 (c) 4 2 1 3 (d) 3 1 2 4

GATE 2004 GATE

Match the following Feature to be inspected Instrument P Pitch and Angle errors of screw thread 1. Auto Collimator Q Fl Flatness error of a surface plate 2. O i l I f f l Optical Interferometer f R Alignment error of a machine slide way 3. Dividing Head and Dial Gauge S Profile of a cam 4. Spirit Level 5. 5 Sine bar 6. Tool maker's Microscope (a) P6 Q2 R4 S6 P 6Q 2R 4S 6 (b) P5 Q2 R1 S6 P 5Q 2R 1S 6 (c) P6 Q4 R1 S3 (d) P1 Q4 R4 S2
Ans.(b)

GATE 1995 GATE

List I (Measuring instruments) (A) Talysurf 1. (B) Telescopic gauge 2. (C) Transfer callipers 3. (D) Autocollimator 4. Codes:A B C D (a) 4 1 2 3 (b) ( ) (c) 4 2 1 3 ( ) (d) Ans. (b) List II (Application) Tslots Flatness Internal diameter Roughness A B C D 4 3 1 2 3 1 2 4

GATE 2010 GATE

A taper hole is inspected using a CMM, with a probe of 2 mm diameter. At a height, Z = 10 mm from the f di A h i h f h bottom, 5 points are touched and a diameter of circle (not compensated for probe size) is obtained as 20 mm. Similarly, a 40 mm diameter is obtained at a height Z = 40 mm. the smaller diameter (in mm) g 4 ( ) of hole at Z = 0 is 3 334 (a) 13.334 (b) 15.334 ( ) 5 44 (c) 15.442 (d) 15.542
Ans.(a)

GATE 2008 (PI) GATE2008(PI)

An experimental setup is planned to determine the taper of workpiece as shown in the figure. If the two precision rollers have radii 8 mm and 5 mm and the total thickness of slip gauges inserted between the rollers is 15.54 mm, the taper angle i l is (a) 6 degree (b) 10 d degree (c) 11 degree (d) 12 d degree

IES 2000 IES

AscrewthreadspecifiedbyM20x2.5CasperBIS threadsystemmeans h d (a) Metricthreadof20mmnominaldiameterand2.5 mmpitchhavingcoarsetolerance it hh i t l (b) Metricthreadof20mmrootdiameterand2.5mm pitchhavingcoarsetolerance (c) Metricthreadoffineclasshaving20mmroot diameterand2.5mmpitch diameterand2 5mmpitch (d) Metricthreadof20mmshankdiameterand2.5mm threaddepthwithcoarsetolerance Ans.(c)

Ch13:Metrology
Q.No 1 2 3 4 5 6 7 8 9 Option C C A C C B C B B Q.No 10 11 12 13 14 15 16 17 Option D A B B D B C B