SHORT TYPE QESTIONS Module 1 1.

What class of materials on machining give discontinuous chips and what class give continuous chips? [2009] 2. If shear plane angle is 200, orthogonal rake angle is 100 and cutting velocity is 30m/min, what is the magnitude of chip velocity and velocity of shear? [2009] 3. If cutting force is 100N, Thrust force is 60N and force on the shear plane is 30N, what according to Merchants analysis is the magnitude of the force normal to the shear plane? [2009] 4. What the advantages and disadvantages are of built up edge? [2009] 5. Why are mechanical spring not normally used as transducer in tool force dynamometers? [2009] 6. What are the various types of chips? Under what conditions is each formed? [2008][2006] 7. Explain the back rake and side rake angle. [2008] 8. What angle does the direction of chip flow make with the cutting edge in orthogonal cutting? [2007] 9. Name two parameters which should be increased to improve surface finish. [2007] 10.How is roughness of a surface expressed? [2007] 11.Define cross-sensitivity with reference to tool dynamometers. [2007] 12.Name two disadvantages of mechanical storing for use as sensing elements to record cutting forces. [2007] 13.Define orthogonal cutting. [2006] 14.Write down the relation between the shear angle and the cutting ratio. [2006] 15.State the limitations of single shear plane theory. [2006] 16.Show graphically how surface roughness varies with speed and feed. [2006] 17.Name any two elements for sensing cutting forces. [2006] Module 2 1. How are milling machines specified? [2009][2006]

2. Name the different methods of production of gears by machining. [2009] 3. Name two machine tools where quick return mechanism is used. [2009] 4. By what parameters are grinding wheels specified? [2009] 5. What type of surfaces can be produced by a milling cutter? [2008] 6. What is copying lathe? [2008] 7. What is meant by grade and Structure of a grinding wheel? [2008] 8. Name and describe two devices or method for holding work to be drilled. [2008] 9. Quick return mechanism used in which machine tool and why? [2008] 10.Differentiate between plain milling machine and universal milling machine. [2007] 11.Name two gear generating processes. [2007] 12.Define generatrix and directrix. [2007] 13.In which cutting operation is the speed reversal mechanism used? [2007] 14. Name the different types of single spindle automatic lathes. [2006] 15.Name the different indexing methods used in milling machines. [2006] Module 3 1. Name the non-traditional machining methods which are used to (i) make holes in glass plates and (ii) produce dies and punches for stamping. [2009] 2. Name the common dielectric fluids used in EDM. [2008] 3. What are the main advantages of Ultra sonic Machining? [2008] 4. Name the abrasives used in Abrasive Jet machining. [2008] 5. Name two process variables in Abrasive Jet machining. [2007] 6. Name the unconventional machining processes used for making holes in a glass plate. [2006] 7. Name an application of wire EDM. [2006]

Medium/ Long type questions Module 1

1. Using any shear angle relation explain how the chip thickness ratio and cutting forces are influenced by tool rake angle. [2009] 2. Explain the limitations of Merchants analysis. [2009] 3. State the sign conventions for rake and clearance angles. [2009][2007] 4. With reference to a tool force dynamometer, explain the terms: frequency response and cross sensitivity. [2009] 5. Explain with a neat sketch the working of a drill dynamometer showing clearly the position of the strain gauges and their connection in the strain bridge. [2009] 6. Explain how the chips are classified on the basis of chip shape. [2007] 7. State the requirements for a good dynamometer. [2007] 8. Write down the tool signature according to ASA system and sketch the geometry of a cutting tool according to this system. [2006] 9. Sketch and describe a strain gauge type 3-D turning dynamometer indicating clearly how the strain gauges are connected in the wheat-stone bridge to record the cutting forces. [2006]

Module 2 1. Name the different taper turning methods. [2009] [2007] 2. Differentiate between automatics and semiautomatics. [2009] 3. Provide a neat sketch of dividing head. [2009] 4. Differentiate between profile sharpened and form relieved milling cutters. [2009] 5. With a suitable sketch show the position of the change gears and cutting tool with reference to lead screw and the spindle. [2009] 6. Write short note on: [2009] a. b. Job holding devices in machine tools, [2008] multi spindle automatics,

c. Centre-less grinding. [2009][2007] 7. Explain the processes of dressing and truing of grinding wheel. [2008]

8. Differentiate between forming and generating. [2007] 9. Distinguish between turret and capstan lathe. [2007] 10.Explain how grinding machines are classified. [2007] 11.Name different tool holding devices for machine tools. [2006]

Module 3 1. Explain with a neat sketch the principle of ultrasonic machining. [2009] 2. Write short notes on: a. Laser machining [2008][2009] b. Electro discharge machining [2009] c. Abrasive Jet Machining d. Wire EDM e. Plasma Arc Machining f. Electro chemical machining [2006] [2007] [2007] [2006][2007] [2006]

3. Explain in detail with neat diagram the principle, working and functions of different components of electro chemical machining. [2008] 4. What are the advantages and disadvantages of EDM? [2008] 5. Discuss the process parameters that affect metal removal rate in ultrasonic machining. [2006] 6. In an electro chemical machining process with a pure iron work piece a metal removal rate of 5 cm 3/ min is desired. The gram atomic weight of iron is 56 g, valence is 2 and density is 7.8 g/cm 3. Determine the current required. [2006] 7. Discuss the principle of metal removal in Electro Chemical Machining. [2007] 8. Identify the process variables in electro discharge machining and indicate how they influence the metal removal rate. [2007]

Problems/ Long type Questions Module 1

1. The tool nomenclature of a single point cutting tool is specified as 5-10-3-8-10-75-3 mm ORS Determine the tool angles for the cutting tool in ASA and sketch its geometry. [2009] 2. In an orthogonal cutting test with a cutting tool geometry 0-5-10-10-1565-3 mm ORS the following observations were made: Cutting force Fc = 800 N Feed force Fx =600 N Depth of cut = 2mm Feed = 0.2 mm Chip thickness = 0.5 mm Calculate the radial force, the coefficient of friction, forces on the shear plane and specific cutting energy. [2009] 3. Sketch a single point cutting tool under ASA system. Define various tool angles and discuss their importance. [2008] 4. The cutting and thrust components of the machining force during orthogonal machining of aluminium with a rake angle of 10 0 are found to be 312 N and 185 N respectively. i. ii. Estimate the coefficient of friction between the tool and the chip. If the rake angle is reduced to 0 0, keeping all the others parameters the same, and if the coefficient of friction also remains unchanged, estimate the new values of cutting and thrust components of the machining force using merchants first solution. [2008]

5. In an orthogonal cutting test the following observations were made: Orthogonal rake angle = 100 Chip thickness ratio = 2.2 Cutting velocity = 30 m/min

Calculate chip velocity and velocity of shear. 6. For cutting toolBack rake angle = 100 Side rake angle = 100 Side relief angle = 50 Side cutting edge angle = 150

[2007]

Calculate orthogonal rake angle, orthogonal relief angle and inclination angle for the tool. [2007] 7. In a cutting operation the cutting data were as follows: Nature of cutting = Orthogonal Orthogonal rake angle = 50 Uncut chip thickness= 0.2 mm Width of cut = 2 mm Cutting force = 1000 N Feed force = 600 N Principal cutting edge angle = 750 Cutting velocity = 30 m /min If merchants shear angle is assumed for the operation, calculatei. ii. iii. iv. Shear plane angle Forces on the shear plane Dynamic shear stress Specific cutting energy [2007]

8. Draw Merchants circle and express the normal and shear forces on the tool and the shear plane in terms of cutting force F c and thrust force Ft. Using the velocity relationships show that: F c Vc = FsVs+ FVchip Where, Vc, Vs and Vchip are the cutting, shear and chip velocities respectively and Fs and F are the forces along the shear plane and the friction force respectively. [2006]

9. During orthogonal machining of mild steel, the following observations were made: Tool rake angle = 50 Principal cutting edge angle = 750 Feed = 0.2 mm Depth of cut = 2mm Chip thickness =0.5 mm Cutting force = 1000 N Feed Force = 400 N Determine: i. ii. iii. iv. v. The coefficient of friction The yield stress in shear of work material Shear plane force normal to shear plane Normal force on tool face Specific cutting energy [2006]

Module 2
1. A nine speed all geared lathe head stock has to have the lowest spindle speed of 25 rpm. If the common ratio is 1.41, i. ii. Calculate the revolutions available at the spindle and the intermediate shaft. Show the position of the fixed and sliding gears with a suitable sketch and the corresponding ray diagram. [2009]

2. A universal dividing head is provided with change gears of 24,24,28,32,,40,44,48,64,72,86 and 100 teeth and 3 index plates with following hole circles Plate one: Plate two: 15,16,17,18,19,20 21,23,27,29,31,33

Plate three: 37,39,41,43,47,49 For the above dividing head, select the index plate and the change gears for indexing: i. ii. 3.2 degrees 83 divisions [2009]

3. A lathe is provided with a lead screw of 6mm pitch and a set of change gears with 20 to 120 teeth in steps of 10. Calculate the change gears for cutting a screw of 1.05 mm pitch on the above lathe. [2009] 4. Sketch the block diagram of a turret lathe. Name and explain the function of its major parts. [2008] 5. Calculate the machining time for the slab milling operation for the following data: Diameter of milling cutter= 100 mm, Cutter speed= 500 rpm, width of cutter= 100 mm, depth of cut 5 mm, table feed 100mm/min. length of work-piece 50 cm, width of work-piece= 80 mm, number of teeth in the cutter = 8 [2008] 6. Sketch the block diagram of a horizontal shaper. Name and explain the functions of its major parts. [2008] 7. A lathe is to be designed with an all general head stock. The number of rpms available with the machine is to be 6 with minimum rpm of 50. If standard common ratio is 1.26, calculate: i. ii. The rpm available on the lathe Provide a neat sketch of the gearing arrangement and the shafts. [2007]

8. A Brown and Sharpe universal dividing head has 3 index plates with following number of holes: Plate 1: Plate 2: Plate 3: 15, 16, 17, 18, 19, 20 21, 23, 27, 29, 31, 33 37, 39, 41, 43, 47, 49

The change gears provided with the dividing head has the following number of teeth: 24, 24, 28, 32, 40, 44, 48, 56, 64, 72, 86, 100

Select the change gears for indexing 71 divisions using the above device. Provide a neat sketch of the dividing head with change gears. [2007] 9. Pitch of 0.4 mm is to be cut on a job on a lathe having a 6 mm pitch lead screw. The lathe is provided with change gears with teeth between 20 and 120 in steps of 10. Select the change gears for the above operation and provide a neat sketch of the screw cutting arrangement. [2007] 10.A Brown and Sharpe universal dividing head has 3 index plates with following number of holes: Plate 1: Plate 2: Plate 3: 15, 16, 17, 18, 19, 20 21, 23, 27, 29, 31, 33 37, 39, 41, 43, 47, 49

The change gears provided with the dividing head has the following number of teeth: 24, 24, 28, 32, 40, 44, 48, 64, 72, 86, 100 Calculate the change gears for indexing 59 divisions using the above device. Provide a neat sketch of the dividing head with change gears. [2006] 11.Pitch of 1.2 mm is to be cut on a job on a lathe having a 6 mm pitch lead screw. The lathe is provided with change gears with teeth between 20 and 120 in steps of 10. Select the change gears for the above operation and provide a neat sketch of the screw cutting arrangement. [2006] 12.An 18 speed lathe gear box has to have a maximum speed of 3000 rpm. The lowest speed is to be around 20 rpm. The values of common ratios are 1.06, 1.12, 1.26 and 1.58. Determine the speeds for the gear box. Provide a neat sketch of the geared head stock.