Production Question and Answer All 2012

7/12/2011
1
TheoryofMetalCutting
BySKMondal
Compiled By:SK Mondal Made Easy
Q. Why even a battery operated
pencil sharpener cannot be
accepted as a machine tool?
A I i f h i ll h j f f Ans. In spite of having all other major features of
machine tools, the sharpener is of lowvalue.
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)
IES1995
Singlepointthreadcuttingtoolshouldideally
have:
a) Zerorake )
b) Positiverake
c) Negativerake
d) Normalrake
Ans.(a)
GATE1995;2008
Cuttingpowerconsumptioninturningcanbe
significantlyreducedby
(a)Increasingrakeangleofthetool
(b)Increasingthecuttinganglesofthetool
(c)Wideningthenoseradiusofthetool
(d)Increasingtheclearanceangle
Ans.(a)
IES1993
Assertion (A): For a negative rake tool, the specific
cutting pressure is smaller than for a positive rake
tool under otherwise identical conditions.
Reason (R): The shear strain undergone by the chip
in the case of negative rake tool is larger 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
(c) A is true but R is false
(d) A is false but R is true Ans. (d)
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IES 2005
Assertion (A): Carbide tips are generally given
negative rake angle.
Reason (R): Carbide tips are made from very hard
materials.
( ) B th A d R i di id ll t d R i th (a) Both A and R are individually true and R is the
(d) A is false but R is true
Ans. (b)
IES 2002
Assertion (A): Negative rake is usually provided on
carbide tipped tools.
Reason (R): Carbide tools are weaker in
compression.
Ans. (c)
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 flowdirection
(b) To reduce the friction between the tool flanks and
the machined surface
(c) To add keenness or sharpness to the cutting edges.
(d) To provide better thermal efficiency.
Ans. (b)
IAS 1994
Considerthefollowingcharacteristics
1. Thecuttingedgeisnormaltothecuttingvelocity.
2. Thecuttingforcesoccurintwodirectionsonly.
3. Thecuttingedgeiswiderthanthedepthofcut.
Thecharacteristicsapplicabletoorthogonalcutting
wouldinclude
(a) 1and2 (b) 1and3
(c) 2and3 (d) 1,2and3
Ans.(d)
IES2006
Whichofthefollowingisasinglepointcutting
tool?
(a) Hacksawblade
(b) Millingcutter (b) Millingcutter
(c) Grindingwheel
(d) Partingtool
Ans.(d)
IES1995
The angle between the face and the flank of the
single point cutting tool is known as
a) Rake angle
b) Clearance angle g
c) Lip angle
d) Point angle
Ans. (c)
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IES2006
Assertion (A): For drilling cast iron, the tool is
provided with a point angle smaller than that
required for a ductile material.
Reason (R): Smaller point angle results in lower
k l rake angle.
(d) A is false but R is true Ans. (c)
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)
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?
(a) 2 only (b) 3 only
(c) 2 and 3 only (d) 1, 2 and 3
Ans. (c)
IES1995
Consider the following statements about nose
radius
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
6. End relief angle
7. Nose radius
The correct sequence of these tool elements used for
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) Compiled By:SK Mondal Made Easy
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
(c) Back rake angle
(d) Side clearance angle
Ans. (b)
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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)
GATE1995
Plainmillingofmildsteelplateproduces
(a)Irregularshapeddiscontinuouschips
(b)Regularshapeddiscontinuouschip
( )C ti hi ith tb ilt d (c)Continuouschipswithoutbuiltupedge
(d)Joinedchips
Ans.(b)
IES2007
Duringmachining,excessmetalisremovedintheform
ofchipasinthecaseofturningonalathe.Whichofthe
followingarecorrect?
Continuousribbonlikechipisformedwhenturning
1. Atahighercuttingspeed g g p
2. Atalowercuttingspeed
3. Abrittlematerial
4. Aductilematerial
Selectthecorrectanswerusingthecodegivenbelow:
(a) 1and3 (b) 1and4
(c) 2and3 (d) 2and4
Ans.(b)
GATE2002
Abuiltupedgeisformedwhilemachining
(a)Ductilematerialsathighspeed
(b)Ductilematerialsatlowspeed p
(c)Brittlematerialsathighspeed
(d)Brittlematerialsatlowspeed
Ans.(b)
IES1997
Assertion (A): For high speed turning of cast iron pistons,
carbide tool bits are provided with chip breakers.
Reason (R): High speed turning may produce long, ribbon
type continuous chips which must be broken into small
lengths which otherwise would be difficult to handle and
may prove hazardous.
( ) B h A d R i di id ll d R i h (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
Ans. (d)
GATE2001
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
degrees) evaluated fromthis data is g )
(a)6.53 (b)20.22
(c)22.94 (d)50.00
Ans.(c)
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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 is
1 8 mm The shear angle is approximately 1.8 mm. The shear angle is approximately
(a) 22
(b) 26
(c) 56
(d) 76
Ans. (b)
IES1994
The following parameters determine the
model of continuous chip formation:
1. True feed
2. Cutting velocity g y
3. Chip thickness
4. Rake angle of the cutting tool.
The parameters which govern the value of shear
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)
Co mpiled By:SK Mondal Made Easy
Minimum shear strain in orthogonal turning
witha cutting tool of zero rake angle is
(a) 0.0
(b) 0.5
GATE2009
(b) 0.5
(c) 1.0
(d) 2.0
Ans. (d)
In a machining operation chip thickness ratio
is 0.3 and the back rake angle of the tool is 10.
What is the value of the shear strain?
(a) 0.31 (b) 0.13
IES2004
( ) 3 ( ) 3
(c) 3.00 (d) 3.34
Ans. (d)
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 0.24 mm/rev and the depth of cut is 2 mm.
The chip thickness obtained is 0 48 mm If the 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
(a) 20.56 (b) 26.56
(c) 30.56 (d) 36.56
Ans. (b)
GATE2008
Inasinglepointturningtool,thesiderakeangle
andorthogonalrakeangleareequal.isthe
principalcuttingedgeangleanditsrangeis
.Thechipflowsintheorthogonalplane.
Thevalueofisclosestto
0 90
o o

Thevalueofisclosestto
(a) 0
0
(b) 45
0
(c) 60
0
(d) 90
0
Ans.(d)

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IES2004
Considerthefollowingstatementswithrespectto
thereliefangleofcuttingtool:
1.Thisaffectsthedirectionofchipflow
2.Thisreducesexcessivefrictionbetweenthetool
d k i andworkpiece
3.Thisaffectstoollife
4.Thisallowsbetteraccessofcoolanttothetool
workpieceinterface
Whichofthestatementsgivenabovearecorrect?
(a) 1and2 (b) 2and3
(c) 2and4 (d) 3and4Ans.(b)
IES2006
Considerthefollowingstatements:
1. Alargerakeanglemeanslowerstrengthofthe
cuttingedge.
2. Cuttingtorquedecreaseswithrakeangle.
Whichofthestatementsgivenaboveis/arecorrect?
(a) Only1 (b) Only2
(c) Both1and2 (d) Neither1nor2
Ans.(c)
IES2004
Match.ListIwithListIIandselectthecorrectanswer
usingthecodesgivenbelowtheLists:
ListI ListII
A. Planapproachangle 1. Toolface
B. Rakeangle 2. Toolflank g
C. Clearanceangle 3. Toolfaceandflank
D. Wedgeangle 4. Cuttingedge
5. Toolnose
A B C D A B C D
(a) 1 4 2 5 (b) 4 1 3 2
(c) 4 1 2 3 (d) 1 4 3 5
Ans.(c)
IES2003
The angle of inclination of the rake face with
respect to the tool base measured in a plane
perpendicular to the base and parallel to the width
of the tool is called
(a) Back rake angle (a) Back rake angle
(b) Side rake angle
(c) Side cutting edge angle
(d) End cutting edge angle
Ans. (b)
IES2004
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 (b) 27.3 m/min
(c) 25.3 m/min (d) 23.5 m/min
Ans. (a)
[IES2008]
Inanorthogonalcuttingthecuttingratioisfoundtobe
075.Thecuttingspeedis60m/minanddepthofcut24
mm.Whichofthefollowingarecorrect?
1. Chipvelocitywillbe45m/min.
2. Chipvelocitywillbe80m/min.
3. Chipthicknesswillbe18mm.
4. Chipthicknesswillbe32mm.
(a) 1and3 (b) 1and4
(c) 2and3 (d) 2and4
Ans.(b)
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IES2001
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) (b)
(c) (d)
Ans. (a)
cos
cos( )
V

( )
sin
cos
V

cos
sin( )
V

sin
sin( )
V

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)
IAS1997
Considerthefollowingmachiningconditions:BUEwill
formin
(a) Ductilematerial. (b) Highcuttingspeed.
(c) Smallrakeangle. (d) Smalluncutchipthickness.
Ans.(a)
IAS2003
Inorthogonalcutting,shearangleistheanglebetween
(a) Shearplaneandthecuttingvelocity
(b) Shearplaneandtherakeplane
(c) Shearplaneandtheverticaldirection
(d) Sh l d h di i f l i f l i (d) Shearplaneandthedirectionofelongationofcrystalsin
thechip
Ans.(a)
IAS2002
Ans.(a)
IAS2000
Ans.(d)
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IAS1998
The cutting velocity in m/sec, for turning a work piece
of diameter 100 mmat the spindle speed of 480 RPM is
(a) 1.26 (b) 2.51
(c) 48 (d) 151
Ans. (b)
IAS1995
In an orthogonal cutting, the depth of cut is halved and
the feed rate is double. If the chip thickness ratio is
unaffected with the changed cutting conditions, the
actual chip thickness will be
(a) Doubled (b) halved ( ) ( )
(c) Quadrupled (d) Unchanged.
Ans. (b)
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For c e & Power i n Met al Cut t i ng
BySKMondal
Compiled by:SK Mondal Made Easy
ESE2003 Conventional
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
following observation were made.
Tangential component of the cutting force, P
z
= 1200 N
Axial component of the cutting force P = 800 N Axial component of the cutting force, P
x
= 800 N
Chip thickness (after cut),
For the above machining condition determine the values of
(i) Friction force, F and normal force, N acting at the chip tool
interface.
(ii) Yield shears strength of the work material under this
machining condition.
(iii) Cutting power consumption in kW.
Ans F = 827 N N = 1200 N 256 7 Mpa 4 021 KW
=
2
0.8mm.
GATE 1995Conventional
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 0
0
, 10
0
, 8
0
, 9
0
,15
0
, 75
0
,
0(mm), the following observations were made.
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 = 2 9 1 , N= 457.67 N, F
n
= 3 5 5.78 N, F
s
= 40 8.31 N
Frictionangle = 32
.49o
ESE2000(Conventional)
The following data from the orthogonal cutting test
is available. Rake angle = 10
0
, chip thickness ratio =
0.35, uncut chip thickness = 0.51, width of cut = 3
mm, yield stress of work material = 285 N/mm
2
,
mean friction coefficient on tool force = 0.65, 5,
Determine
(i) Cutting force (F
c
)
(ii) Radial force (F
t
)
(iii) Normal force (N) on tool and
(iv) Shear force on the tool (F
s
).
Ans. F
c
= 1597 N; F
t
= 678 N; F
s
= 1265 N; F = 944.95 N, N =
1453.8 N
ESE2005Conventional
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 p y g
value of coefficient of friction between the
tool and the chip is 0.5 and the shear stress of
the work material is 400 N/mm
2
,
Determine (i) shear angle and [Ans. 36.7
o
(ii) Cutting and thrust component of the
machine on force. [Ans. F
c
= 420 N, F
t
= 125 N ]
IAS2003MainExamination
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 machining operation
could be approximated to be orthogonal cutting The could be approximated to be orthogonal cutting. The
tangential cutting force and thrust force were 1177 N and
560 N respectively. Calculate:
[30 marks]
(i) The side rake angle [Ans. 12
o
]
(ii) Coefficient of friction at the rake face [Ans. 0.82]
(iii) The dynamic shear strength of the work material
[Ans. 74.43 Mpa]
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GATE2006CommonDataQuestions(1)
Inanorthogonalmachiningoperation:
Uncutthickness=0.5mm
Cuttingspeed=20m/min Rakeangle=15
Widthofcut=5mm Chipthickness=0.7mm Widthofcut 5mm Chipthickness 0.7mm
Thrustforce=200N Cuttingforce=1200N
AssumeMerchant'stheory.
Thecoefficientoffrictionatthetoolchipinterfaceis
(a)0.23 (b)0.46
(c)0.85 (d)0.95
Ans.(b)
Thepercentageoftotalenergydissipateddueto
frictionatthetoolchipinterfaceis
(a)30% (b)42%
(c)58% (d)70% Ans.(a)
Thevaluesofshearangleandshearstrain,
respectively,are
(a)30.3 and1.98 (b)30.3 and4.23
(c)40.2 and2.97 (d)40.2 and1.65Ans.(d)
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 is 10. In the analysis it is found
th t th h l i that the shear angle is 27.75
Thethicknessoftheproducedchipis
(a)0.511mm (b)0.528mm
(c)0.818mm (d)0.846mm
Ans.(a)
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 is 10. In the analysis it is found
th t th h l i that the shear angle is 27.75
Intheaboveproblem,thecoefficientoffrictionat
thechiptoolinterfaceobtainedusingEarnestand
Merchanttheoryis
(a)0.18 (b)0.36
(c)0.71 (d)0.908
Ans.(d)
GATE2008CommonDataQuestion(1)
Orthogonal turning is performed on a cylindrical work
piece with shear strength of 250 MPa. The following
conditions are used: cutting velocity is 180 m/min. feed
is 0.20 mm/rev. depth of cut is 3 mm. chip thickness
ti Th th l k l i
o
A l ratio = 0.5. The orthogonal rake angle is 7
o
. Apply
Merchant's theory for analysis.
Theshearplaneangle(indegree)andtheshear
forcerespectivelyare
(a)52:320N (b)52:400N
(c)28:400N (d)28:320N
Ans.(d)
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GATE2008CommonDataQuestion(2)
Orthogonal turning is performed on a cylindrical work
piece with shear strength of 250 MPa. The following
conditions are used: cutting velocity is 180 m/min. feed
is 0.20 mm/rev. depth of cut is 3 mm. chip thickness
ti Th th l k l i
o
A l ratio = 0.5. The orthogonal rake angle is 7
o
. Apply
Merchant's theory for analysis.
Thecuttingandfrictionalforces,respectively,are
(a)568N;387N (b)565N;381N
(c)440N;342N (d)480N;356N
Ans.(b)
IES2010
The relationship between the shear angle ,
the friction angle and cutting rake angle
is given as
Ans.(b)
IES2005
Which one of the following is the correct
expression for the Merchant's machinability
constant?
(a) 2 + (a)
(b)
(c)
(d)
(Where = shear angle, = friction angle
and = rake angle) Ans. (a)
2 +
2 +
2
+


GATE1997
Inatypicalmetalcuttingoperation,usinga
cuttingtoolofpositiverakeangle=10,it
wasobservedthattheshearanglewas20.
Thefrictionangleis g
(a)45 (b)30
(c)60 (d)40
Ans.(c)
IAS 1999
In an orthogonal cutting process, rake angle of the
tool is 20 and friction angle is 25.5. Using
Merchant's shear angle relationship, the value of
shear angle will be
(a) 39 5 (b) 42 25 (a) 39.5 (b) 42.25
(c) 47.75 (d) 50.5
Ans. (b)
IES2003
In orthogonal cutting test, the cutting force =
900 N, the thrust force = 600 N and chip
shear angle is 30
o
. Then the chip shear force is
(a) 1079 4 N (b) 969 6 N (a) 1079.4 N (b) 969.6 N
(c) 479.4 N (d) 69.6 N
Ans. (c)
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IES2000
In an orthogonal cutting test, the cutting force and
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
( ) ( ) ( ) ( )
1 1
a b2 c d 2
2
2
Ans.(a)
IES1996
Which of the following forces are measured directly by
strain gauges or force dynamometers during metal
cutting ?
1. Force exerted by the tool on the chip acting normally to
the tool face.
2. Horizontal cutting force exerted by the tool on the work
piece.
3. Frictional resistance of the tool against the chip flow
acting along the tool face.
4. Vertical force which helps in holding the tool in
position.
(a) 1 and 3 (b) 2 and 4
(c) 1 and 4 (d) 2 and 3 Ans. (b)
GATE2007
Inorthogonalturningofmediumcarbonsteel.The
specificmachiningenergyis2.0J/mm
3
.Thecutting
velocity,feedanddepthofcutare120m/min,0.2
mm/revand2mmrespectively.Themaincutting
f i Ni forceinNis
(a)40 (b)80
(c)400 (d)800
Ans.(d)
GATE2007
In orthogonal turning of low carbon steel pipe with
principal cutting edge angle of 90, the main cutting
force is 1000 N and the feed force is 800 N. The shear
angle is 25 and orthogonal rake angle is zero.
E l i M h t th th ti f f i ti 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 (d) 0.64
Ans. (c)
IES1997
Consider the following forces acting on a
finish turning tool:
1. Feed force
2 Thrust force 2. Thrust force
3. 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)
IES1999
The radial force in singlepoint tool during
turning operation varies between
(a) 0.2 to 0.4 times the main cutting force
(b) 0 4 to 0 6 times the main cutting force (b) 0.4 to 0.6 times the main cutting force
(c) 0.6 to 0.8 times the main cutting force
(d) 0.5 to 0.6 times the main cutting force
Ans. (a)
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IES1995
The primary tool force used in calculating
the total power consumption in machining is
the
(a) Radial force (b) Tangential force (a) Radial force (b) Tangential force
(c) Axial force (d) Frictional force
Ans. (b)
IES2002
In a machining process, the percentage of
heat carried away by the chips is typically
(a) 5% (b) 25%
(c) 0% (d) % (c) 50% (d) 75%
Ans. (d)
IES1998
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 (a) 80: 10: 10 (b) 33: 33: 33
(c) 20: 60: 10 (d) 10: 10: 80
Ans. (a)
IAS 2003
Asthecuttingspeedincreases
(a) Moreheatistransmittedtotheworkpieceandless
heatistransmittedtothetool
(b) Moreheatiscarriedawaybythechipandlessheatis
t itt dt th t l transmittedtothetool
(c) Moreheatistransmittedtoboththechipandthe
tool
(d) Moreheatistransmittedtoboththeworkpieceand
thetool
Ans.(b)
IES2001
Power consumption in metal cutting is
mainly due to
(a) Tangential component of the force
(b) Longitudinal component of the force (b) Longitudinal component of the force
(c) Normal component of the force
(d) Friction at the metaltool interface
Ans. (a)
IAS 1995
Thrustforcewillincreasewiththeincreasein
(a) Sidecuttingedgeangle
(b)Toolnoseradius
(c) Rakeangle
(d)Endcuttingedgeangle
Ans.(a)
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IES2010
In an orthogonal, singlepoint metal cutting,
as the sidecutting edge angle is increased,
1. The tangential force increases. g
2. The longitudinal force drops.
3. The radial force increases.
(a) 1 and 3 only (b) 1 and 2 only
(c) 2 and 3 only (d) 1, 2 and 3 Ans. (c)
IES1993
A 'Dynamometer' is a device used for the
measurement of
(a) Chip thickness ratio
(b) Forces during metal cutting (b) Forces during metal cutting
(c) Wear of the cutting tool
(d) Deflection of the cutting tool
Ans. (b)
IES2011
Theinstrumentordeviceusedtomeasurethecutting
forcesinmachiningis:
(a)Tachometer
(b)Comparator
(c)Dynamometer
(d)Lactometer
Ans.(c)
IAS 2003
The heat generated in metal cutting can
conveniently be determined by
(a) Installing thermocouple on the job
(b) Installing thermocouple on the tool
(c) Calorimetric setup
(d) Using radiation pyrometer
Ans. (c)
IES1998
The gauge factor of a resistive pickup of
cutting force dynamometer is defined as the
ratio of
(a) Applied strain to the resistance of the wire (a) Applied strain to the resistance of the wire
(b) The proportional change in resistance to the
applied strain
(c) The resistance to the applied strain
(d) Change in resistance to the applied strain
Ans. (b)
IES2000
Assertion (A): In metal cutting, the normal
laws of sliding friction are not applicable.
Reason (R): Very high temperature is
produced at the toolchip interface produced at the toolchip interface.
(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
(d) A is false but R is true Ans. (a)
Co mpiled by:SK Mondal Made Easy
Page 14 of 79
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GATE1992
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 sliding model of friction
(C) sticking friction
(D) Sliding and then sticking model of friction
Ans. (b)
IES2004
Assertion (A): The ratio of uncut chip thickness to
actual chip thickness is always less than one and is
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 g g
friction
(a) Both A and R are individually true and R is the correct
explanation of A
(d) A is false but R is true Ans. (b)
GATE1993
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 g g
(c) Sticking friction
(d) sliding and then sticking model of friction
Ans. (b)
Compiled by:SK Mondal Made Easy Compiled by:SK Mondal Made Easy
Page 15 of 79
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1
ToolWear,ToolLife& ToolWear,ToolLife&Machinability Machinability
BySKMondal
IES2010
Flank wear occurs on the
(a) Relief face of the tool
(b) Rake face
(c) Nose of the tool (c) Nose of the tool
(d) Cutting edge
Ans. (a)
IES 2007
Flankwearoccursmainlyonwhichofthe
following?
(a) Nosepartandtopface
(b) Cuttingedgeonly
(c) Nosepart,frontreliefface,andsiderelieffaceofthe
cuttingtool
(d) Faceofthecuttingtoolatashort distancefrom
thecuttingedge
Ans.(c)
IES 2004
During the third stage of toolwear, rapid
deteriorationof tool edge takes place because
1. Flank wear is only marginal
2 Flank wear is large 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
Craterwearontoolsalwaysstartsatsomedistance
fromthetooltipbecauseatthatpoint
(a) Cuttingfluiddoesnotpenetrate
(b) Normalstressonrakefaceismaximum
(c) Temperatureismaximum
(d) Toolstrengthisminimum
Ans.(c)
IAS 2007
Whydoescraterwearstartatsomedistancefrom
thetooltip?
(a) Toolstrengthisminimumatthatregion
(b) Cuttingfluidcannotpenetratethatregion
(c) Tooltemperatureismaximuminthatregion
(d) Stressonrakefaceismaximumatthatregion
Ans.(c)
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2
IES 2000
Craterwearstartsatsomedistancefromthetooltip
because
(a) Cuttingfluidcannotpenetratethatregion
(b) Stressonrakefaceismaximumatthatregion
(c) Toolstrengthisminimumatthatregion
(d) Tooltemperatureismaximumatthatregion
Ans.(d)
IES 1996
Notchwearattheoutsideedgeofthedepthofcutis
dueto
(a) Abrasiveactionoftheworkhardenedchipmaterial
(b) Oxidation
(c) Slipstickactionofthechip
(d) Chipping.
Ans.(b)
IES 1995
MatchListIwithListIIandselectthecorrect
answerusingthecodesgivenbelowthelists:
ListI(Weartype) ListII(Associatedmechanism)
A. Abrasivewears 1. Galvanicaction
B. Adhesivewears 2. Ploughing action
C. Electrolyticwear 3. Moleculartransfer
D. Diffusionwears 4. Plasticdeformation
[Ans.(a)] 5. Metallicbond
Code:A B C D A B C D
(a) 2 5 1 3 (b) 5 2 1 3
(c) 2 1 3 4 (d) 5 2 3 4
IES 1995
Craterwearispredominantin
(a) Carbonsteeltools
(b) Tungstencarbidetools
(c) Highspeedsteeltools
(d) Ceramictools
Ans.(a)
IES 1994
Assertion(A):Toolwearisexpressedintermsof
flankwearratherthancraterwear.
Reason(R):Measurementofflankwearissimple
andmoreaccurate.
( ) B thA dR i di id ll t dRi th (a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
Ans.(c)
IES 2008
Whatarethereasonsforreductionoftoollifeina
machiningoperation?
1. Temperatureriseofcuttingedge
2. Chippingoftooledgeduetomechanicalimpact
3. Gradualwearsattoolpoint
4. Increaseinfeedofcutatconstantcuttingforce
Selectthecorrectanswerusingthecodegiven
below:
(a) 1,2and3 (b) 2,3and4
(c) 1,3and4 (d) 1,2and4
Ans.(a) Compiled by:SK Mondal Made Easy
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3
IAS 2002
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
The type of wear that occurs due to the cutting
action of the particles in the cutting fluid is
referred to as
(a) Attritions wear
(b) Diff i (b) Diffusion wear
(c) Erosive wear
(d) Corrosive wear
Ans. (a)
IAS 2003
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.
(a) 1, 2 and 3 (b) 1 and 3
(c) 2 and 3 (d) 1 and 2
Ans. (b)
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 edge angle of tool
(c) Increasing the plant area of cut
(d) Increasing the depth of cut.
Ans. (b)
IES 1992
Toollifeisgenerallyspecifiedby
(a) Numberofpiecesmachined
(b) Volumeofmetalremoved
(c) Actualcuttingtime
(d) Anyoftheabove
Ans.(d)
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4
GATE2004
In a machining operation, doubling the
cutting speed reduces the tool life to th of
the original value. The exponent n in Taylor's
tool life equation VT
n
= C, is
1
8
Ans. (c)
1 1 1 1
( ) ( ) ( ) ( )
8 4 3 2
a b c d
IES 2000
In a tool life test, doubling the cutting speed
reduces the tool life to 1/8th of the original. The
Taylor's tool life index is
( ) ( ) ( ) ( )
1 1 1 1
a b c d
2 3 4 8
Ans. (b)
( ) ( ) ( ) ( )
2 3 4 8
IES 1999
Inasinglepointturningoperationofsteelwitha
cementedcarbidetool,Taylor'stoollifeexponentis
0.25.Ifthecuttingspeedishalved,thetoollifewill
increaseby
(a) Twotimes (b) Fourtimes (a) Twotimes (b) Fourtimes
(c) Eighttimes (d) Sixteentimes
Ans.(d)
IES 2008
InTaylor'stoollifeequationisVT
n
=constant.
Whatisthevalueofnforceramictools?
(a) 0.15to0.25 (b) 0.4to0.55
(c) 0.6to0.75 (d) 0.8to0.9
Ans.(c)
IES 2006
Which of the following values of index n is
associated with carbide tools when Taylor's tool life
equation, V.T
n
= constant is applied?
(a) 01 to 015 (b) 02 to 04
( ) t 6 (d) 6 t (c) 0045 to 06 (d) 065 to 09
Ans. (b)
IES 1999
The approximately variation of the tool life
exponent 'n' of cemented carbide tools is
(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)
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5
IAS 1998
MatchList I(Cuttingtoolmaterial)withList II
(Typicalvalueoftoollifeexponent'n'intheTaylor's
equationV.T
n
=C)andselectthecorrectanswerusing
thecodesgivenbelowthelists:
List I List II
A HSS 8 A. HSS 1. 0.18
B. Castalloy 2. 0.12
C. Ceramic 3. 0.25
D. Sinteredcarbide 4. 0.5 [Ans.(d)]
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
IES2010
The above figure shows a typical
relationship between tool life and
cutting speed for different
materials. Match the graphs for
HSS, Carbide and Ceramic tool
i l d l h materials and select the correct
answer using the code given
belowthe lists:
Code: HSS Carbide Ceramic
(a) 1 2 3
(b) 3 2 1
(c) 1 3 2
(d) 3 1 2
Ans.(a)
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)
GATE2003
A batch of 10 cutting tools could produce 500
components while working at 50 rpm with a
tool feed of 0.25 mm/rev and depth of cut of 1
mm. A similar batch of 10 tools of the same
specification could produce 122 components 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
components can be produced with one
cutting tool at 60 rpm?
(a) 29 (b) 31
(c) 37 (d) 42 [Ans. (a)]
IES 1994,2007
Forincreasingthematerialremovalrateinturning,
withoutanyconstraints,whatistherightsequence
toadjustthecuttingparameters?
1. Speed 2. Feed 3. Depthofcut
(a) 1 2 3 (b) 2 3 1
(c) 3 2 1 (d) 1 3 2
Ans.(c)
IES2010
Tool life is affected mainly with
(a) Feed
(b) Depth of cut
(c) Coolant (c) Coolant
(d) Cutting speed
Ans. (d)
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IES 1997
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,I,3
Ans.(a)
IES 1992
Toollifeisgenerallybetterwhen
(a) Grainsizeofthemetalislarge
(b) Grainsizeofthemetalissmall
(c) Hardconstituentsarepresentinthemicrostructure
ofthetoolmaterial
(d) Noneoftheabove
Ans.(a)
IAS 2003
ThetoollifecurvesfortwotoolsAandBareshownin
thefigureandtheyfollowthetoollifeequationVT
n
=C.
1. Valueofnforboththetoolsissame.
2. ValueofCforboththetoolsissame.
3. ValueofCfortoolAwillbegreaterthanthatforthetoolB.
4. ValueofCfortoolBwillbegreaterthanthatforthetoolA.
Whichofthesestatementsis/arecorrect?
(a) 1and3 (b) 1and4
(c) 2only (d) 4only
Ans.(a)
IAS 2002
UsingtheTaylorequationVT
n
=c,calculatethe
percentageincreaseintoollifewhenthecutting
speedisreducedby50%(n=05andc=400)
(a) 300% (b) 400%
( ) % (d) % (c) 100% (d) 50%
Ans.(a)
IAS 2002
Optimum cutting speed for minimum cost (V
c min
)
and optimum cutting speed for maximum
production rate (V
r max
) have which one of the
following relationships?
(a) V = V (b) V > V (a) V
c min
= V
r max
(b) V
c min
> V
r max
(c) V
c min
< V
r max
(d) V
2
c min
= V
r max
Ans. (c)
IES2010
With increasing cutting velocity, the total
time for machining a component
(a) Decreases
(b) Increases ( )
(c) Remains unaffected
(d) First decreases and then increases
Ans. (d)
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IAS 2000
Thetoollifeisincreasedby
1. Builtupedgeformation
2. Increasingcuttingvelocity
3. Increasingbackrakeangleuptocertainvalue
Whichofthesestatementsarecorrect?
(a) 1and3 (b) 1and2
(c) 2and3 (d) 1,2and3
Ans.(a)
IAS 1997
In the Taylor's tool life equation, VT
n
= C, the value
of n = 0.5. The tool has a life of 180 minutes at a
cutting speed of 18 m/min. If the tool life is reduced
to 45 minutes, then the cutting speed will be
(a) 9 m/min (b) 18 m/min (a) 9 m/min (b) 18 m/min
(c) 36 m/min (d) 72 m/min
Ans. (c)
IAS 1996
Thetoollifeincreaseswiththe
(a) Increaseinsidecuttingedgeangle
(b) Decreaseinsiderakeangle
(c) Decreaseinnoseradius
(d) Decreaseinbackrakeangle
Ans.(a)
IAS 1995
Inasinglepointturningoperationwithacemented
carbideandsteelcombinationhavingaTaylor
exponentof0.25,ifthecuttingspeedishalved,then
thetoollifewillbecome
(a) Half
(b) Twotimes
(c) Eighttimes
(d) Sixteentimes.
Ans.(d)
IAS 1995
Assertion (A): An increase in depth of cut shortens
the tool life.
Reason(R): Increases in depth of cut gives rise to
relatively small increase in tool temperature.
Ans. (a)
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. N = 36.66 rpm]
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8
ESE1999Conventional
The following equation for tool life was obtained for HSS
tool. A 60 min tool life was obtained using the following
cutting condition VT
0.13
f
0.6
d
0.3
= C. v = 40 m/min, f = 0.25
mm, d = 2.0 mm. Calculate the effect on tool life if
speed, feed and depth of cut are together increased by speed, feed and depth of cut are together increased by
25% and also if they are increased individually by 25%;
where f = feed, d = depth of cut, v = speed.
Ans. (2.3 min; 10.78 min; 21.42 min; 35.85 min)
IES2009Conventional
Determine the optimum cutting speed for an
operation on a Lathe machine using the following
information:
Tool change time: 3 min
T l i d ti i Tool regrinds time: 3 min
Machine running cost Re.0.50 per min
Depreciationof tool regrinds Rs. 5.0
The constants in the tool life equation are 60 and
0.2
[Ans. 26 m/min]
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]
GATE2009LinkedAnswerQuestions(1)
Inamachiningexperiment,toollifewasfoundtovary
withthecuttingspeedinthefollowingmanner:
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)
GATE2009LinkedAnswerQuestions(2)
Inamachiningexperiment,toollifewasfoundtovary
withthecuttingspeedinthefollowingmanner:
Cuttingspeed(m/min) Toollife(minutes)
60 81
90 36
Whatisthepercentageincreaseintoollifewhen
thecuttingspeedishalved?
(a)50% (b)200%
(c)300% (d)400%
Ans.(c)
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 10
o
to 7
o
?
(Hint: Flank wear rate is proportional to cot
(a) 30 % increase (b) 30%, decrease
(c) 70% increase (d) 70% decrease
Ans. (b)
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GATE2005
Ans.(a)
IAS 2007Contd
A diagram related to machining economics with
various cost components is given above. Match List I
(Cost Element) with List II (Appropriate Curve) and
select the correct answer using the code given below
the Lists:
ListI ListII
(CostElement) (AppropriateCurve)
A. Machiningcost 1. Curvel
B. Toolcost 2. Curve2
C. Toolgrindingcost 3. Curve3
D. Nonproductivecost 4. Curve4
5. Curve5
Contd. From previous slide
Ans (b)
(a) 3 2 4 5 (b) 4 1 3 2
(c) 3 1 4 2 (d) 4 2 3 5
Ans.(b)
IES 1998
The variable cost and production rate of a
machining process against cutting speed are shown
in the given figure. For efficient machining, the
range of best cutting speed would be between
(a) 1 and 3 (a) 1 and 3
(b) 1 and 5
(c) 2 and 4
(d) 3 and 5
Ans.(c)
IES 1999
Consider the following approaches normally
applied for the economic analysis of machining:
1. Maximumproduction rate
2. Maximumprofit criterion
3. Minimumcost 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)
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)
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IES 2000
The magnitude of the cutting speed for maximum
profit rate must be
(a) In between the speeds for minimum cost and
maximumproduction rate
(b) Hi h th th d f i d ti t (b) Higher than the speed for maximum production rate
(c) Belowthe speed for minimumcost
(d) Equal to the speed for minimumcost
Ans. (a)
IES 2004
1. As the cutting speed increases, the cost of production
initially reduces, then after an optimum cutting speed it
increases
2. As the cutting speed increases the cost of production
l i d f i i l l i d also increases and after a critical value it reduces
3. Higher feed rate for the same cutting speed reduces cost
of production
4. Higher feed rate for the same cutting speed increases the
cost of production
Which of the statements given above is/are correct?
(a) 1 and 3 (b) 2 and 3
(c) 1 and 4 (d) 3 only Ans. (a)
IES 2002
Ineconomicsofmachining,whichoneofthe
followingcostsremainsconstant?
(a) Machiningcostperpiece
(b) Toolchangingcostperpiece
(c) Toolhandlingcostperpiece
(d) Toolcostperpiece
Ans.(c)
IAS 2007
Assertion (A): The optimum cutting speed for the
minimum cost of machining may not maximize the
profit.
Reason (R): The profit also depends on rate of
production production.
(d) A is false but R is true [Ans. (a) ]
IAS 1997
Inturning,theratiooftheoptimumcuttingspeed
forminimumcostandoptimumcuttingspeedfor
maximumrateofproductionisalways
(a) Equalto1
(b) I th f 6t (b) Intherangeof0.6to1
(c) Intherangeof0.1to0.6
(d) Greaterthan1
Ans.(b)
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11
IES 1992
Easeofmachiningisprimarilyjudgedby
(a) Lifeofcuttingtoolbetweensharpening
(b) Rigidityofworkpiece
(c) Microstructureoftoolmaterial
(d) Shapeanddimensionsofwork
Ans.(a)
IES 2009
Considerthefollowing:
1. Toollife
2. Cuttingforces
3. Surfacefinish
Whichoftheaboveis/arethemachinability
criterion/criteria?
(a) 1,2and3 (b) 1and3only
(c) 2and3only (d) 2only
Ans.(a)
IES 2007
Which of the following are the machinability
criteria?
1. Tool life
2. Cutting forces
3. Surface finish
Select the correct answer using the code given below:
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 1 and 3 only
(d) 2 and 3 only Ans. (a)
IES 2003
Assertion (A): The machinability of steels improves
by adding sulphur to obtain so called 'Free
Machining Steels.
Reason (R): Sulphur in steel forms manganese
sulphide inclusion which helps to produce thin
ribbon like continuous chip.
(d) A is false but R is true [Ans. (c) ]
IES 2009
The elements which, added to steel, help in chip
formationduring machining are
(a) Sulphur, lead and phosphorous
(b) Sulphur, lead and cobalt
(c) Aluminium, lead and copper
(d) Aluminium, titaniumand copper
Ans. (a)
IES 1998
Considerthefollowingcriteriainevaluating
machinability:
1. Surfacefinish 2. Typeofchips
3. Toollife 4. Powerconsumption
InmodernhighspeedCNCmachiningwithcoated
carbidetools,thecorrectsequenceofthesecriteria
inDECREASINGorderoftheirimportanceis
(a) 1,2,4,3 (b) 2,1,4,3
(c) 1,2,3,4 (d) 2,1,3,4
Ans.(c)
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12
IES 1996
Which of the following indicate better
machinability?
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)
IES 1996
Small amounts of which one of the following
elements/pairs of elements is added to steel to
increase its machinability?
(a) Nickel (b) Sulphur and phosphorus
( ) Sili (d) M d (c) Silicon (d) Manganese and copper
Ans. (b)
IES 1995
Inlowcarbonsteels,presenceofsmallquantities
sulphur improves
(a) Weldability (b) Formability
(c) Machinability (d) Hardenability
Ans.(c)
IES 1992
Machiningoftitaniumisdifficultdueto
(a) Highthermalconductivityoftitanium
(b) Chemicalreactionbetweentoolandwork
(c) Lowtoolchipcontactarea
(d) Noneoftheabove
Ans.(b)
IAS 1996
Assertion(A):Themachinability ofamaterialcan
bemeasuredasanabsolutequantity.
Reason(R):Machinability indexindicatesthecase
withwhichamaterialcanbemachined
(d) AisfalsebutRistrue [Ans.(d) ]
GATE2009
Frictionatthetoolchipinterfacecanbe
reducedby
(a)decreasingtherakeangle
(b)increasingthedepthofcut (b)increasingthedepthofcut
(c)Decreasingthecuttingspeed
(d)increasingthecuttingspeed
Ans.(d)
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1
MetalForming MetalForming
BySKMondal
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.
(a) Both A and R are individually true and R is the (a) Both A and R are individually true and R is the
(b) Both A and R are individually true but R is NOT
the correct explanation of A
Ans. (b)
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)
GATE2002
Hot rolling of mild steel is carried out
(a) At recrystallisation temperature
(b) Between 100C to 150C
(c) Belowrecrystallisation temperature
(d) Above recrystallisation temperature
Ans. (d)
IES 2006
Which one of the following is the process to refine
the grains of metal after it has been distorted by
hammering or cold working?
(a) Annealing (b) Softening
( ) R t lli i (d) N li i (c) Recrystallizing (d) Normalizing
Ans. (c)
IES 2004
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
(a) 1, 2 and 3 (b) 1, 2 and 4
(c) 1 and 3 (d) 2, 3 and 4
Ans. (b)
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2
IES 2009
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
1. Metal forming decreases harmful effects of
impurities and improves mechanical strength.
2. Metal working process is a plastic deformation
process.
3. Very intricate shapes can be produced by forging
process as compared to casting process.
(a) 1, 2 and 3 (b) 1 and 2 only
(c) 2 and 3 only (d) 1 and 3 only
Ans. (b)
IES 2008
Cold forging results in improved quality due to
whichof the following?
1. Better mechanical properties of the process.
2. Unbroken grain flow.
3. Smoother finishes.
4. High pressure.
(a) 1, 2 and 3 (b) 1, 2 and 4
(c) 2, 3 and 4 (d) 1, 3 and 4
Ans. (a)
IES 2004
Assertion (A): Cold working of metals results in
increase of strengthand hardness
Reason (R): Cold working reduces the total number
of dislocations per unit volume of the material
Ans. (c)
IES 2003
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
(a) 1and 2 (b) 1, 2 and 3
(c) 3 and 4 (d) 1 and 4
Ans. (a)
IES 2000
Assertion (A): To obtain large deformations by cold
working intermediate annealing is not required.
Reason (R): Cold working is performed below the
recrystallisationtemperature of the work material.
Ans. (d)
Page 29 of 79
7/22/2011
3
IES 1997
Inmetalssubjectedtocoldworking,strain
hardeningeffectisdueto
(a) Slipmechanism
(b) Twiningmechanism
(c) Dislocationmechanism
(d) Fracturemechanism
Ans.(c)
IES 1996
Whenametaloralloyiscoldworked
1. Itisworkedbelowroomtemperature.
2. Itisworkedbelowrecrystallisation temperature.
3 Itshardnessandstrengthincrease 3. Itshardnessandstrengthincrease.
4. Itshardnessincreasesbutstrengthdoesnot
increase.
Ofthesecorrectstatementsare
(a) 1and4 (b) 1and3
(c) 2and3 (d) 2and4
Ans.(c)
IES 2006
Assertion (A): In case of hot working of metals, the
temperature at which the process is finally stopped
should not be above the recrystallisation temperature.
Reason (R): If the process is stopped above the
recrystallisation temperature, grain growth will take
place againand spoil the attained structure place againand spoil the attained structure.
explanation of A
Ans. (d)
IES 1992
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
For mild steel, the hot forging temperature range is
(a) 400
0
C to 600
0
C
(b) 700
0
C to 900
0
C
(c) 1000
0
C to 1200
0
C
(d) 1300
0
Cto 1500
0
C
Ans. (c)
IAS 2004
Assertion(A):Hotworkingdoesnotproducestrain
hardening.
Reason(R):Hotworkingisdoneabovethere
crystallizationtemperature.
(d) AisfalsebutRistrue
Ans.(a)
Page 30 of 79
7/22/2011
4
IAS2002
Assertion (A): There is good grain refinement in hot
working.
Reason (R): In hot working physical properties are
generally improved.
Ans. (b)
Compiled By:SK Mondal Made Easy IESMadeEasy Compiled By:SK Mondal Made Easy
Page 31 of 79
7/24/2011
1
Rolling Rolling
BySKMondal
GATE2008
In a single pass rolling operation, a 20 mm thick
plate with plate width of 100 mm, is reduced to 18
mm. The roller radius is 250 mm and rotational
speed is 10 rpm. The average flow stress for the plate
material is 300 MPa. The power required for the material is 300 MPa. The power required for the
rolling operation in kW is closest to
(a) 15.2
(b) 18.2
(c) 30.4
(d) 45.6
Ans. (a)
GATE2007
The thickness of a metallic sheet is reduced from an
initial value of 16 mm to a final value of 10 mm in
one single pass rolling with a pair of cylindrical
rollers each of diameter of 400 mm. The bite angle
indegree will be indegree will be
(a) 5.936
(b) 7.936
(c) 8.936
(d) 9.936
Ans. (d)
GATE2004
In a rolling process, sheet of 25 mm thickness is
rolled to 20 mm thickness. Roll is of diameter 600
mm and it rotates at 100 rpm. The roll strip contact
length will be
(a) 5 mm (b) 39 mm (a) 5 mm (b) 39 mm
(c) 78 mm (d) 120 mm
Ans. (b)
GATE1998
A strip with a crosssection 150 mm x 4.5 mm is
being rolled with 20% reduction of area using 450
mm diameter rolls. The angle subtended by the
deformation zone at the roll centre is (in radian)
(a) 0 01 (b) 0 02 (a) 0.01 (b) 0.02
(c) 0.03 (d) 0.06
Ans. (d)
GATE2006
A 4 mm thick sheet is rolled with 300 mm diameter
rolls to reduce thickness without any charge in its
width. The friction coefficient at the workroll
interface is 0.1. The minimum possible thickness of
the sheet that can be produced in a single pass is the sheet that can be produced in a single pass is
(a) 1.0 mm (b) 1.5 mm
(c) 2.5 mm (d) 3.7 mm
Ans. (c)
Page 32 of 79
7/24/2011
2
IES 2003
Assertion (A): While rolling metal sheet in rolling
mill, the edges are sometimes not straight and flat
but are wavy.
Reason (R): Nonuniform mechanical properties of
the flat material rolled out result in waviness of the
edges.
(d) A is false but R is true [Ans. (c)]
IES 2002
In rolling a strip between two rolls, the position of
the neutral point in the arc of contact does not
depend on
(a) Amount of reduction (b) Diameter of the rolls
( ) C ffi i t f f i ti (d) M t i l f th ll (c) Coefficient of friction (d) Material of the rolls
Ans. (d)
IES 2001
Which of the following assumptions are correct for
cold rolling?
1. The material is plastic.
2. The arc of contact is circular with a radius greater than
the radius of the roll.
3. Coefficient of friction is constant over the arc of
contact and acts in one direction throughout the arc of
contact.
Codes:
(a) 1 and 2 (b) 1 and 3
(c) 2 and 3 (d) 1, 2 and 3 [Ans. (a)]
IES 2001
A strip is to be rolled from a thickness of 30 mm to
15 mm using a twohigh mill having rolls of
diameter 300 mm. The coefficient of friction for
unaided bite should nearly be
(a) 0 35 (b) 0 5 (a) 0.35 (b) 0.5
(c) 0.25 (d) 0.07
Ans. (a)
IES 2000
In the rolling process, roll separating force can be
decreased by
(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
Assertion(A):Inatwohighrollingmillthereisa
limittothepossiblereductioninthicknessinone
pass.
Reason(R):Thereductionpossibleinthesecond
passislessthanthatinthefirstpass passislessthanthatinthefirstpass.
(a) BothAandRareindividuallytrueandRisthe
(d) AisfalsebutRistrue [Ans.(b)]
Page 33 of 79
7/24/2011
3
IES 1993
In order to get uniform thickness of the plate by
rolling process, one provides
(a) Camber on the rolls
(b) Offset on the rolls
(c) Hardening of the rolls
(d) Antifriction bearings
Ans. (a)
IES 1993
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
Threadrollingisrestrictedto
(a) Ferrousmaterials
(b) Ductilematerials
(c) Hardmaterials
(d) Noneoftheabove
Ans.(b)
IAS 2004
Assertion (A): Rolling requires high friction which
increases forces and power consumption.
Reason (R): To prevent damage to the surface of the
rolled products, lubricants should be used.
IAS 2001
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
Rollingverythinstripsofmildsteelrequires
(a) Largediameterrolls
(b) Smalldiameterrolls
(c) Highspeedrolling
(d) Rollingwithoutalubricant
Ans.(b)
Page 34 of 79
7/24/2011
4
IAS 1998
Match List I (products) with List II (processes)
and select the correct answer using the codes given
belowthe lists:
List I List II
A M S l d h l W ldi A. M.S. angles and channels 1. Welding
B. Carburetors 2. Forging
C. Roof trusses 3. Casting
D. Gear wheels 4. Rolling [Ans. (d)]
(a) 1 2 3 4 (b) 4 3 2 1
(c) 1 2 4 3 (d) 4 3 1 2
IAS 2007
Match List I with List II and select the correct answer using
the code given belowthe Lists:
List I List II
(Type of Rolling Mill) (Characteristic)
A. Two high nonreversing mills 1. Middle roll rotates by friction
B Th hi h ill B ll ki ll 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 mills 4. Diameter of working roll is
very small [Ans. (d)]
(a) 3 4 2 1 (b) 2 1 3 4
(c) 2 4 3 1 (d) 3 1 2 4
IAS 2003
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
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.
(c) 1 and 3 only (d) 1, 2 and 3 [Ans. (c)]
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)
Page 35 of 79
Analysis of Rolling

Fig. Geometry of Rolling Process

Total reduction or draft taken in rolling.
e 1
h = h - h = 2 (R - R cos a) = D (1 - cos a)

Usually, the reduction in blooming mills is about 100 mm and in slabbing mills, about 50 to 60 mm.
The projected length if the arc of contact is,

= R.sin a l

2 2
or l = BC - CE
Now BC = R. h and CE = R (1 - cos a) (1 - cos a) = 0.5 h
( )
2
R. h l = - 0.5 h
P =
( )
2
Usually, 0.5 h is < R h
( )
1/2
l R h

Assumption in Rolling

`
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 material is rigid perfectly plastic (constant yield strength).
4. The co-efficient of friction is constant over the tool- work interface.

Fig.

Stress Equilibrium of an Element in Rolling

Considering the thickness of the element perpendicular to the plane of paper to be unity,
We get equilibrium equation in x-direction as,
Page 36 of 79

l
l l l P
- h + ( +d ) (h + dh) - 2 Rd sin +2 R d cos = 0
For sliding friction,
l
= p . Simplifying and neglecting second order terms, we get

( )
( ) ( )
( )
( ) ( )
x
'
x 0 0
'
0
'
0 '
0
' '
0 0 ' '
0 0
d h
2pR( )
d
2
p
3
d
h p 2pR
d
d p
h 1 2pR
d
d p p d
h 1 h 2pR
d d
=
= =

=

=

+ =

Due to cold rolling,
'
0
increases as h decreases, thus
'
0
h nearly a constant and its derivative zero.

( )
( )
( )
( )
( )
( )
=
= + = +
=
+
=
+ +
=

= = = =

+

= +

=

'
0
0
2
f f
'
0
2 '
f 0
'
0 2 2
f f
2
f
2 f
f
p/ d 2R

d p/ h
h h 2R 1 cos h R
d p /
2R
d
h R p/
Integrating both side
2Rd 2R
ln p / d
h R h R
I II
2Rd 2Rd 2d h
I ln
h R h h / R R
h
h / R
R
h d
2
d R
=
+
=
+
=
2
f
2
f
1
f f
2R
II d
h R
2
d
h / R
R R
2 . tan .
h h

( )

= +

=

=
=
=
= = =
=
' 1
0
f f
' H
0
1
f f
0
1
'
0
h R R
ln p / ln 2 . tan . lnC
R h h
h
p C e
R
R R
where H 2 . tan ..
h h
Now at entry,
Hence H H with replaced by inabove equation
At exit 0,H H 0
There for p

In the entry zone p =
o
H ' o
0
h
C. e
R

Page 37 of 79
( )
o
0
H
o
H H '
0
0
' H
0
f
R
C .e
h
h
p . e
h
In the exit zone
h
p .e
h
=
=

=

( )
( )
( )
=
=

=

=

=

= +
0 n n
0 n
H H H
n n
0 l
H 2H
o
f
0
n 0
f
1
f f
f f n
n
n f n
h h
. e . e
h h
h
or e
h
h 1 1
or H H ln
2 h
R R
from H 2 . tan ..
h h
h h H
. tan .
R R 2
h h 2R 1 cos

Maximum Draft. It has already been proved that if the strip is to enter the rolls unaided then, the
following relation has to be satisfied between the angle of bite and co-efficient of friction between the
roll and material surfaces.
> tan a
Now, from Fig. 13.12, the projected length of are of contact,

R. h, and
R h
tan
h
R h
R
2

l =
l
a = =
05
-

Since h, it can R > > 0.5 be written that

h
R
tan a =

Since
tan a
The maximum draft is given by

h
R

( )
2
max
or, h = R

Q.1. In rolling process, 25 mm thick plate is rolled to 20 mm in a four high mill. Determine the co-
efficient of friction if this is the maximum reduction possible. Roll diameter is 500 mm. Find neutral
Section, Back word and forward slip sad maximum pressure,
o
= 100
2
N/ mm for hot rolls of middle
steel at about 1100
o
C.
Solution:
(i).
2
h R =

( )
( )
( )
= = =
=
=
= =
0
25 20
h
or 0.142
R 250
and h 2R 1 cos
or 5 500 1 cos
8.11 0.1429

Page 38 of 79
(ii)

=

1
0
f f
R R
H 2 . tan .
h h

= =

=

= =

=

=

=
= +
1
0
n 0 e
f
e
f f n
n
n f
250 250
2. . tan 0.1429 3.306
20 20
h 1 1
H H log
2 h
1 1 25
3.306 .log 0.8678
2 0.142 20
h h H
. tan .
R R 2
250 20 0.8678
tan
20 250 2
0.0349 rad
h h 2R 1 cos ( )
( )
= +
= + =
n
2
f n
2
h R
20 250 0.0349 20.3mm

(iii) Backward slip =
r 0 0 n
r r 0
V V V h 20.3
1 1 1 18.8%
V V h 25
= = = =
Forward slip =
= = = =
f r f n
r r f
V V V h 20.3
1 1 1 1.5%
V V h 20

Vo Vr Vf
N

(iv)

= =
n
H
n
max n 0
f
h
p p .e
h

0.142 0.8678 2
2 20.3
.100 .e 132.4N / mm
20
3

= =

Q2. Sheet steel is reduced from 4.05 mm to 3.55 mm with 500 mm diameter rolls having a co-
efficient of fiction of 0.04. The mean flow stress in tension is 210 N/mm
2
. Neglect work
hardening and roll flattening.
(a) Calculate the roll pressure at the entrance to the rolls, the neutral plane, and the roll exit.
(b) If the co-efficient of friction is 0.40, determine the roll pressure at the neutral point.
(c) If 35 N/mm
2
front tensions are applied in the problem find the roll pressure at the neutral
point.
Solution:
Given h
o
=4.05 mm

f
h =3.55 mm
R =250 mm,
2
0
0.04, 210N / mm = =
Page 39 of 79
(a) The roll pressure at entry and exit,
p =
0
=
2
0
2
242.5N / mm
3
=
Now

=

1
0
f f
R R
H 2 . tan
h h

=

=

=

= =

=
n
1
0
o
n 0 e
f
e
H
n
n 0
f
250 250
H 2 . tan 0.0447
3.55 3.55
6.02
h 1 1
H H log
2 h
1 1 4.05
6.02 log 1.363
2 0.04 3.55
h
p . . e
h

Now

= = = =

f f 0 n
n
h h H 3.55 3.55
. tan . . tan 0.6815 0.009672 rad.
R R 2 250 25
0.554
0

And h =2R (1- cos)
(4.05-3.55) =2 250 (1- cos ) or =2.56
o
=0.0447 rad.

f
n
= +
n
h h 2R (1 cos )
=3.55 +2 250 (1- cos 0.554
o
)
=3.5734 mm
=
= =
n
H
n
n 0
f
0.04 1.363 2
h
p . .e
h
3.5734
242.5 e 257.78N/ mm
3.55

( ) ( )
( )
n
0
n e
n
2
n f n
2
H n
n 0
f
0.04 2.845 2
b H 6.02 earlier
0.4
1 1 4.05
then H 6.02 log 2.845
2 0.4 3.55
3.55 3.55
tan 1.4225 0.02rad
250 250
h h R
3.55 250 0.02 3.65mm
h
p . . e
h
3.65
242.5 e 777.9N / mm
3.55
=
=

= =

= =

= +
= + =
=
= =

( )
( )
=
= =
n
H
n
n 0 f
f
0.04 1.363 2
h
(c) p . . e
h
3.5734
242.5 35 e 220.57N/ mm
3.55

Q 3. A wide-strip is rolled to a final thickness of 6.35 mm will a reduction of 30 percent. The
roll radius is 50 cm and the co-efficient of friction is 0.2. Determine the neutral plane.
Solution:
Page 40 of 79
h
f
=6.35mm, R =50cm =500mm, =0.2
h
o
=h
f

100
9.07mm
70
=

( )
( )
= = =
=
=
= =
0 f
0
h h h 9.07 6.35 2.72mm
h 2R 1 cos
2.72 2 500 1 cos
or 4.23 0.0738rad.

Now

=

1
0
f f
R R
H 2. . tan .
h h

1
500 500
2 tan 0.0738
6.35 6.35
10.29.

=

=

= = =

0
n 0 e e
f
h 1 1 1 1 9.07
now H H log 10.29 log 4.26
2 h 2 0.2 6.35

=

= = =

f f n
n
0
h h H
. tan .
R R 2
6.35 6.35
tan 2.13 0.0273rad 1.55
500 500

Q.4. A metal strip is to be rolled from an initial wrought thickness of 3.5 mm to a final
rolled from an initial wrought thickness of 2.5 mm in a single pass rolling mill having rolls of
250 mm diameter. The strip is 450 mm wide. The average co-efficient of friction in the roll gap
is 0.08. Taking plain strain flow stress of 140 MPa, for the metal and assuming neglecting
spreading, estimate the roll separating force. [GATE-1997]
Solution Hint: We know p= =
m m
p l. b p
Use.

= + +

0 n
0
b
l n
h h
h
m
h
h h
1
p pdh pdh p.dh
h

Torque and Power
The power is spent principally in four ways
1) The energy needed to deform the metal.
2) The energy needed to overcome the frictional force.
3) The power lost in the pinions and power-transmission system.
4) Electrical losses in the various motors and generators.
Remarks: Losses in the windup reel and uncoiler must also be considered.

Page 41 of 79
The total rolling load is distributed
over the arc of contact in the typical
friction-hill pressure distribution.

However the total rolling load can be
assumed to be concentrated at a point
along the act of contact at a distance a
from the line of centres of the rolls.

The ratio of the moment arm a to the
projected length of the act of contact
Lp can be given as

P
a a
L
R h
= =

Where is 0.5 for hot-rolling and 0.45
for cold-rolling.

The torque MT is equal to the total
rolling load P multiplied by the
effective moment arm a. Since there
are two work rolls, the torque is given
by
T
M = 2Pa

During one revolution of the top roll the resultant rolling load P moves along the circumference of a
circle equal to 2a.
Since there are two work rolls, the work done W is equal to
Work = 2(2 a)P
Since power is defined as the rate of doing work, i.e., 1 W = 1 J s
-1
, the power (in watts) needed to
operated a pair of rolls revolving at N Hz (s
-1
) in deforming metal as it flows through the roll gap is
given by W = 4 aPN
Where P is in Newtons and a is in metre.

Page 42 of 79
7/24/2011
1
Forging
BySKMondal
GATE2007
In opendie forging, a disc of diameter 200 mm and
height 60 mm is compressed without any barreling
effect. The final diameter of the disc is 400 mm. The
true strain is
(a) 1 986 (b) 1 686 (a) 1.986 (b) 1.686
(c) 1.386 (d) 0.602
Ans. (c)
GATE1994
Match 4 correct pairs between List I and List II for
the questions List I gives a number of processes and
List II gives a number of products
List I List II
( ) I t t ti T bi t (a) Investment casting 1. Turbine rotors
(b) Die casting 2. Turbine blades
(c) Centrifugal casting 3. Connecting rods
(d) Drop forging 4. Galvanized iron pipe
(e) Extrusion 5. Cast iron pipes
(f ) Shell moulding 6. Carburettor body
Ans. (a) 2, (b) 6, (c) 5, (d) 3
GATE1998
List I List II
(A) Aluminium brake shoe (1) Deep drawing
(B) Plastic water bottle (2) Blow moulding
(C) Stainless steel cups (3) Sand casting
(D) Soft drink can (aluminium)
(4) Centrifugal casting
(5) Impact extrusion
(6) Upset forging
Ans. (A) 3, (B) 2, (C) 1, (D) 5
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)
IES 2006
Assertion (A): Forging dies are provided with taper
or draft angles on vertical surfaces.
Reason (R): It facilitates complete filling of die
cavity and favourable grain flow.
Ans. (c)
Page 43 of 79
7/24/2011
2
IES 2005
1. Forging reduces the grain size of the metal, which
results in a decrease in strengthand toughness.
2. Forged components can be provided with thin
ti ith t d i th t th sections, without reducing the strength.
Which of the statements givenabove is/are correct?
(a) Only 1 (b) Only 2
(c) Both 1 and 2 (d) Neither 1 nor 2
Ans. (b)
IES 1996
Which one of the following is an advantage of
forging?
(a) Good surface finish
(b) Lowtooling cost
(c) Close tolerance
(d) Improved physical property
Ans. (d)
IES 1993
Which one of the following manufacturing
processes requires the provisionof gutters?
(a) Closed die forging
(b) Centrifugal casting
(c) Investment casting
(d) Impact extrusion
Ans. (a)
IES 1997
Assertion (A): In drop forging besides the provision
for flash, provision is also to be made in the forging
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.
IES 2004
Match List I (Different systems) with List II
(Associated terminology) and select the correct
answer using the codes given below the Lists:
List I List II
A. Riveted Joints 1. Nipping J pp g
B. Welded joints 2. Angular movement
C. Leaf springs 3. Fullering
D. Knuckle joints 4. Fusion
A B C D A B C D
(a) 3 2 1 4 (b) 1 2 3 4
(c) 1 4 3 2 (d) 3 4 1 2
Ans. (d)
IES 2003
A forging method for reducing the diameter of a bar
and in the process making it longer is termed as
(a) Fullering (b) Punching
(c) Upsetting (d) Extruding
Ans. (a)
Page 44 of 79
7/24/2011
3
IES 2002
Consider the following steps involved in hammer
forging a connecting rod from bar stock:
1. Blocking 2. Trimming
3. Finishing 4. Fullering 5. Edging
Which of the following is the correct sequence of
operations?
(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 1999
Consider the following operations involved in
forging a hexagonal bolt from a round bar stock,
whose diameter is equal to the bolt diameter:
1. Flattening 2. Upsetting
S i C b i 3. Swaging 4. Cambering
The correct sequence of these operations is
(a) 1, 2, 3, 4 (b) 2, 3, 4, 1
(c) 2, 1, 3, 4 (d) 3, 2, 1, 4
Ans. (a)
IES 2003
Consider the following steps in forging a connecting
rod fromthe bar stock:
1. Blocking 2. Trimming
3. Finishing 4. Edging
Select the correct sequence of these operations using the
codes given below:
Codes:
(a) 1234 (b) 2341
(c) 3412 (d) 4132
Ans. (d)
IES 2005
The process of removing the burrs or flash from a
forged component in drop forging is called:
(a) Swaging (b) Perforating
(c) Trimming (d) Fettling
Ans. (c)
IES2011
Which of the following processes belong to forging
operation ?
1. Fullering
2. Swaging
3. Welding
(a) 1 and 2 only
(b) 2 and 3 only
(c) 1 and 3 only
(b) 1, 2 and 3 only [Ans. (a)]
IES 2008
The balls of the ball bearings are manufactured
fromsteel rods. The operations involved are:
1. Ground
2. Hot forged on hammers
3. Heat treated
4. Polished
What is the correct sequence of the above
operations fromstart?
(a) 3241 (b) 3214
(c) 2314 (d) 2341
Ans. (None) Correct sequence is 2 1 3 4
Page 45 of 79
7/24/2011
4
Video Video
IES 2001
Intheforgingoperation,fullering isdoneto
(a) Drawoutthematerial
(b) Bendthematerial
(c) Upsetthematerial
(d) Extrudingthematerial
Ans.(a)
IES2011
Consider the following statements :
1. Any metal will require some time to undergo complete
plastic deformation particularly if deforming metal has
to fill cavities and corners of small radii.
2. For larger work piece of metals that can retain
toughness at forging temperature it is preferable to use
forge press rather than forge hammer.
(a) 1 and 2 are correct and 2 is the reason for 1
(b) 1 and 2 are correct and 1 is the reason for 2
(c) 1 and 2 are correct but unrelated
(d) 1 only correct [Ans. (b)]
IES 1998
The bending force required for Vbending, U
bending and Edgebending 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)
IES 2005
Match List I (Type of Forging) with List II (Operation)
and select the correct answer using the code given
belowthe Lists:
List I List II
A. Drop Forging 1. Metal is gripped in the dies and
i li d h h d d pressure is applied on the heated end
B. Press Forging 2. Squeezing action
C. Upset Forging 3. Metal is placed between rollers and
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 the code
given belowthe lists:
ListI (Forging Technique) ListII (Process)
A. Smith Forging 1. Material is only upset to get the desired shape
B. Drop Forging 2. Carried out manually open dies
C. Press Forging 3. Done in closed impression dies by hammers in
blows
D. Machine Forging 4. Done in closed impression dies by continuous
squeezing force
Code: A B C D
(a) 2 3 4 1
(b) 4 3 2 1
(c) 2 1 4 3
(d) 4 1 2 3
Ans. (a)
Page 46 of 79
7/24/2011
5
IES 1998
Which one of the following processes is most
commonly used for the forging of bolt heads of
hexagonal shape?
(a) Closed die drop forging
(b) O di t f i (b) Open die upset forging
(c) Close die press forging
(d) Open die progressive forging
Ans. (c)
IES 1994
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)
IES 2009
Match ListI with ListII and select the correct answer using
the code given belowthe Lists:
ListI ListII
(Article) (Processing Method)
A. Disposable coffee cups 1. Rotomoulding
B. Large water tanks 2. Expandable bead moulding g p g
C. Plastic sheets 3. Thermoforming
D. Cushion pads 4. Blow moulding
5. Calendaring
Code:
(a) A B C D (b) A B C D
3 5 1 2 4 5 1 2
(c) A B C D (d) A B C D
4 3 3 1 3 1 5 2
Ans. (d)
IAS 2001
Match List I (Forging operations) with List II (Descriptions) and
select the correct answer using the codes given belowthe 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,
reducing thickness in middle and increasing reducing thickness in middle and increasing
length
C. Fullering 3. Rod is pulled through a die
D. Wire drawing 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
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
The forging defect due to hindrance to smooth flow
of metal in the component called 'Lap' occurs
because
(a) The corner radius provided is too large
(b) Th di id d i t ll (b) The corner radius provided is too small
(c) Draft is not provided
(d) The shrinkage allowance is inadequate
Ans. (b)
Page 47 of 79
7/24/2011
6
IAS1996
Compound die performs
(a) Two or more operations at one station in one stroke
(b) Two or more operations at different stations in one
stroke
(c) Only one operations and that too at one work station
(d) Two operations at two different work stations in the
same stroke
Ans. (a)
IAS 2002
Considerthefollowingstatementsrelatedto
forging:
1. Flashisexcessmaterialaddedtostockwhichflows
aroundpartingline.
Fl hh l i filli fthi ib db i 2. Flashhelpsinfillingofthinribsandbossesinupper
die.
3. Amountofflashdependsuponforgingforce.
Whichoftheabovestatementsarecorrect?
(a) 1,2and3 (b) 1and2
(c) 1and3 (d) 2and3 [Ans.(b)]
IES2011
Assertion (A) : Hot tears occur during forging
because of inclusions in the blank material
Reason (R) : Bonding between the inclusions and
the parent material is through physical and
chemical bonding.
(b) Both A and R are individually true but R is NOT the
Ans. (c)
IES 2006 Conventional
A certain disc of lead of radius 150 mm and thickness 50
mm is reduced to a thickness of 25 mm by open die
forging. If the coefficient of friction between the job and
die is 0.25, determine the maximum forging force. The
average shear yield stress of lead can be taken as 4 average shear yield stress of lead can be taken as 4
N/mm
2.
[10 Marks]
IES 2007Conventional
A cylinder of height 60 mm and diameter 100 mm is
forged at room temperature between two flat dies. Find
the die load at the end of compression to a height 30
mm, using slab method of analysis. The yield strength of
the work material is given as 120 N/mm
2
and the the work material is given as 120 N/mm and the
coefficient of friction is 0.05. Assume that volume is
constant after deformation. There is no sticking. Also
find mean die pressure. [20Marks]
Page 48 of 79
8/5/2011
1
Extrusion Extrusion
BySKMondal
Extrusion
The extrusion process is like squeezing toothpaste out of
a tube.
1Extrusion 2Diebacker 3Die
4Billet 5Dummyblock 6Pressingstem
7Containerliner 8Containerbody
DirectExtrusion
A solid ram drives the entire billet to and through a
stationary die and must provide additional power to
overcome the frictional resistance between the surface of the
moving billet and the confining chamber.
IndirectExtrusion
A hollow ram drives the die back through a stationary,
confined billet.
Since no relative motion, friction between the billet and
the chamber is eliminated.
Thebasicprinciplesofforwardandbackward
coldextrusionusingopenandcloseddies. Compiled By:SK Mondal Made Easy
ImpactExtrusion
Page 49 of 79
8/5/2011
4
JWM2010
Assertion (A) : Extrusion speed depends on work
material.
Reason (R) : High extrusion speed causes cracks in
the material.
Ans. (a)
GATE2006
In a wire drawing operation, diameter of a steel wire
is reduced from 10 mm to 8 mm. The mean flow
stress of the material is 400 MPa. The ideal force
required for drawing (ignoring friction and
redundant work) is redundant work) is
(a) 4.48 kN (b) 8.97 kN
(c) 20.11 kN (d) 31.41 kN
Ans. (b)
GATE2001
For rigid perfectlyplastic work material, negligible
interface friction and no redundant work, the
theoretically maximum possible reduction in the
wire drawing operation is
(a) 0 36 (b) 0 63 (a) 0.36 (b) 0.63
(c) 1.00 (d) 2.72
Ans. (b)
GATE2003
A brass billet is to be extruded from its initial
diameter of 100 mm to a final diameter of 50 mm.
The working temperature of 700C and the
extrusion constant is 250 MPa. The force required
for extrusion is for extrusion is
(a) 5.44 MN (b) 2.72 MN
(c) 1.36 MN (d) 0.36 MN
Ans. (b)
GATE1996
A wire of 0.1 mm diameter is drawn from a rod of 15
mm diameter. Dies giving reductions of 20%, 40%
and 80% are available. For minimum error in the
final size, the number of stages and reduction at
each stage respectively would be 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
(d) none of the above Ans. (b)
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)
Page 50 of 79
8/5/2011
5
IES 2007
statement?
(a) Extrusion is used for the manufacture of seamless
tubes.
(b) Extrusion is used for reducing the diameter of round ( ) g
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) Compiled By:SK Mondal Made Easy
IES 2007
Assertion (A): Greater force on the plunger is required
in case of direct extrusion than indirect one.
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.
explanation of A
Ans. (b)
IES 1993
Assertion (A): Direct extrusion requires larger force
than indirect extrusion.
Reason (R): In indirect extrusion of cold steel, zinc
phosphate coating is used.
Ans. (b)
IES 1994
Metal extrusion process is generally used for
producing
(a) Uniformsolid sections
(b) Uniform hollow sections
(c) Uniformsolid and hollow sections
(d) Varying solid and hollow sections.
Ans. (c)
IES 2009
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
t l h i d it metal having poor density
(c) As compared to roll forming, extruding speed is high
(d) Impact extrusion is quite similar to Hooker's process
including the flowof metal being in the same direction
Ans. ( c)
IES 1999
temperature range for hot extrusionof aluminium?
(a) 300340C (b) 350400C
(c) 430480C (d) 550650C
Ans. (c)
Page 51 of 79
8/5/2011
6
IES 2000
In forward extrusion process
1. The ram and the extruded product travel in the same
direction.
2. The ram and the extruded product travel in the opposite p pp
direction.
3. The speed of travel of the extruded product is same as that
of the ram.
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
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 2008
Which one of the following methods is used for the
manufacture of collapsible toothpaste tubes?
(a) Impact extrusion (b) Direct extrusion
(c) Deep drawing (d) Piercing
Ans. (a)
IES 2003
The extrusion process (s) used for the production of
toothpaste tube is/are
1. Tube extrusion
2. Forward extrusion
3. Impact extrusion
Codes:
(a) 1 only (b) 1 and 2
(c) 2 and 3 (d) 3 only
Ans. (d)
IES 2001
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.
3.The billet is inserted into the extrusion chamber and pressure p
is applied by a ram to extrude the billet through the die.
4. The billet is inserted into the extrusion chamber where it is
surrounded by a suitable liquid. The billet is extruded
through the die by applying pressure to the liquid.
Codes:
(a) 1 and 3 (b) 1 and 4
(c) 2 and 3 (d) 2 and 4 Ans. (d)
IES 2006
What does hydrostatic pressure in extrusion process
improve?
(a) Ductility (b) Compressive strength
(c) Brittleness (d) Tensile strength
Ans. (a)
Page 52 of 79
8/5/2011
7
IES2010
Assertion(A):Picklingandwashingofrolledrods
iscarriedoutbeforewiredrawing.
Reason(R):Theylubricatethesurfacetoreduce
frictionwhiledrawingwires.
Ans. (c)
IES 2009
Which one of the following stress is involved in the
wire drawing process?
(a) Compressive (b) Tensile
(c) Shear (d) Hydrostatic stress
Ans. (b)
IES 2000
Match List I (Components of a table fan) with List II
(Manufacturing processes) and select the correct
List I List II
A. Base with stand 1. Stamping and p g
pressing
B. Blade 2. Wire drawing
C. Armature coil wire 3. Turning
D. Armature shaft 4. Casting [ Ans. (d)]
(a) 4 3 2 1 (b) 2 1 4 3
(c) 2 3 4 1 (d) 4 1 2 3
IES 1999
Match ListI with ListII and select the correct
ListI ListII
A. Drawing 1. Soap solution
B Rolling 2 Camber B. Rolling 2. Camber
C. Wire drawing 3. Pilots
D. Sheet metal operations using 4. Crater
progressive dies 5. Ironing Ans. (d)
(a) 2 5 1 4 (b) 4 1 5 3
(c) 5 2 3 4 (d) 5 2 1 3
IES 1996
Match List I with List II and select the correct answer
List I (Metal/forming process) List II (Associated force)
A. Wire drawing 1. Shear force
B. Extrusion 2. Tensile force
C. Blanking 3. Compressive force
D. Bending 4. Spring back force
(a) 4 2 1 3 (b) 2 1 3 4
(c) 2 3 1 4 (d) 4 3 2 1
Ans. (c)
IES 1996
In wire drawing process, the bright shining surface
on the wire is obtained if one
(a) does not use a lubricant
(b) uses solid powdery lubricant.
(c) uses thick paste lubricant
(d) uses thin film lubricant
Ans. (d)
Page 53 of 79
8/5/2011
8
IES 1994
MatchListIwithListIIandselectthecorrectanswer
usingthecodesgivenbelowtheLists:
ListI(Metalfarmingprocess)ListII(Asimilarprocess)
A. Blanking 1. Wiredrawing
B C i i Pi i B. Coining 2. Piercing
C. Extrusion 3. Embossing
D. Cupdrawing 4. Rolling
5. Bending [Ans.(d)]
(a) 2 3 4 1 (b) 2 3 1 4
(c) 3 2 1 5 (d) 2 3 1 5 Compiled By:SK Mondal Made Easy
IES 1993
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. Malleability 1. Wire drawing
B Hardness 2 Impact loads B. Hardness 2. Impact loads
C. Resilience 3. Cold rolling
D. Isotropy 4. Indentation
5. Direction [Ans. (b)]
(a) 4 2 1 3 (b) 3 4 2 5
(c) 5 4 2 3 (d) 3 2 1 5
IES 2007
Which metal forming process is used for
manufacture of long steel wire?
(a) Deep drawing (b) Forging
(c) Drawing (d) Extrusion
Ans. (c)
IES 2005
Which of the following types of stresses is/are
involved in the wiredrawing operation?
(a) Tensile only
(b) Compressive only
(c) Acombination of tensile and compressive stresses
(d) A combination of tensile, compressive and shear
stresses
Ans. (a)
IES 2000
Which one of the following lubricants is most
suitable for drawing mild steel wires?
(a) Sodiumstearate (b) Water
(c) Limewater (d) Kerosene
Ans. (c)
IES 1998
Assertion (A): The first draw in deep drawing operation
can have up to 60% reduction, the second draw up to
40% reduction and, the third drawof about 30% only.
Reason (R): Due to strain hardening, the subsequent
draws in a deep drawing operation have reduced p g p
percentages.
explanation of A
Page 54 of 79
8/5/2011
9
IES 1993
A moving mandrel is used in
(a) Wire drawing
(b) Tube drawing
(c) Metal cutting
(d) Forging
Ans. (b)
IES 2002
answer:
List I (Parts) List II (Manufacturing processes)
A. Seamless tubes 1. Roll forming
B A d h b Sh i B. Accurate and smooth tubes 2. Shot peening
C. Surfaces having higher 3. Forging
hardness and fatigue strength4. Cold forming
Codes: A B C A B C
(a) 1 4 2 (b) 2 3 1
(c) 1 3 2 (d) 2 4 1
Ans. (a) Compiled By:SK Mondal Made Easy
IAS 2004
Assertion (A): Indirect extrusion operation can be
performed either by moving ram or by moving the
container.
Reason (R): Advantage in indirect extrusion is less
quantity of scrap compared to direct extrusion quantity of scrap compared to direct extrusion.
IAS 1995
The following operations are performed while
preparing the billets for extrusion process:
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
Match List I (Products) with List II (Suitable
processes) and select the correct answer using the
codes given below the Lists:
List I List II
A C ti d W ldi A. Connecting rods 1. Welding
B. Pressure vessels 2. Extrusion
C. Machine tool beds 3. Forging
D. Collapsible tubes 4. Casting Ans. (a)
(a) 3 1 4 2 (b) 4 1 3 2
(c) 3 2 4 1 (d) 4 2 3 1 Compiled By:SK Mondal Made Easy
IAS 1997
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)
Page 55 of 79
8/5/2011
10
IAS 2000
Assertion (A): Brittle materials such as grey cast
ironcannot be extruded by hydrostatic extrusion.
Reason(R): In hydrostatic extrusion, billet is
uniformly compressed fromall sides by the liquid.
IAS 2002
Assertion (A): In wiredrawing process, the rod
crosssection is reduced gradually by drawing it
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.
IES2011
MatchListIwithListIIandselectthecorrectanswerusing
thecodegivenbelowthelists:
ListI ListII
A.Connectingrods 1.Welding
Codes
A B C D A B C D
(a) 2 1 4 3 (b) 3 1 4 2
(c) 2 4 1 3 (d) 3 4 1 2
B.Pressurevessels 2.Extrusion
C.Machinetoolbeds 3.Forming
D.Collapsibletubes 4.Casting[Ans.(b)]
Compiled By:SK Mondal Made Easy Compiled By:SK Mondal Made Easy
Page 56 of 79
Analysis of Extrusion

For Tube
d
=
B
1
0
0
h 1 B
1
B h

+

But B =
1 2
tan tan
+

In the case of moving mandrel
B =
1 2
tan tan

Maximum reduction possible

max
B
1
0
h 1 B
1 1
B h

+
=

= = = =

=

0
1 2
1
0
max
if 0.05, 15 , 0
h
then 0.4275 43%
h

Extrusion
( )
2B
0 0
xo
f
1 B r
1
B r

+
=

Extrusion pressure (p
t
) = +
f
xo
p
Extension load =
2
t 0
p r
Real condition

=

o
o
f
A
P k.A ln
A

= where k extrusion constant

Reduction in Area (RA) =
2 2
2 2
0 1 1 1
2
1 0 0
r r r D
1 1
r D r

= =

Page 57 of 79

Analysis of wire/Rod Drawing

( ) ( )

+ + + + =

2
2
x x x x x
dx dx
d r dr r cos 2 r P .sin 2 r 0
cos cos

or + + + =
2
x x x x
2rdr d r 2r dx P .2rdxtan 0
or =
2
dx
cot , and devide both by r dr
dr

or ( )

+ + + =
x x
x x
d 2 2
P cot 0
dr r r

Vertical component of
x x
P P and that of
x
can be neglected due to small half die angles. There fore only
two principal stress
x
and
x
P
Trescas condition

( )
+ =
= =
x x 0
x x 0 x
P
P

Therefore ( )

+ + =
0 x
0 x
2 d 2
cot 0
dr r r

Taking cot =B
( )
x
x 0
d 2
B 1 B
dr r
+ +

Or
( )
x
x 0
d 2
dr
B 1 B r
=
+

Integration both side
( ) +

=
e x 0
e
log B 1 B
2log rC
B

or ( ) ( ) + = =

2B
e x 0 e
log B 1 B log rC where,C integretion constant
or ( ) ( ) + =
2B
x 0
B 1 B rC
at
0 x b
r r , = =
( ) ( ) + =
2B
b 0 0
B 1 B r C
or
( ) ( )
1
2B
x 0
0
B 1 B
C
r
+
=
or ( ) ( )

+ = +

2B
x 0 b 0
0
r
B 1 B B 1 B
r

or
( )
2B 2B
0
x b
0 0
1 B
r r
1
B r r

+
= +

Page 58 of 79
Drawing stress,
( )
2B 2B
0
1
d b
0 0
1 B
r r
1 .
B r r

+
= +

Now >
d 0
(in ideal case), therefore, maximum reduction can be found out,

Die Pressure

( )
B B
0
1 1
d b
0 0
1 B h h
1 .
B h h

+
= +

=

0
1
1
A
P A ln
A

Maximum Reduction or Draft per pass

d
0
1

For zero back stress, the condition will be

( )
( )
B
1 B
1 1 RA 1
B
+

=

In wire and rod drawing, co-efficient of friction of the order 0.1 are usually obtained (by the use of
proper lubrication)
Now B = cot

= =
= =
0.1 and 6
B 0.1 9.515 0.9515

From hence, we will get the limited maximum reduction RA=50.5%

Example: Calculate the drawing load required to obtain 30% reduction in area on a 12 mm
diameter copper wire. The following data is given
0
=240 N/mm
2
, 2 =12
0
, =0.10
Calculate the power of the electric motor if the drawing speed is 2.3 m/s. Take efficient of
motor is 98%.
Solution: RA = 0.30
B = = = cot 0.1 cot 0.95
( )
2B
0 1
d
0
1 B r
1
B r

+
=

( )
2
1
0
2
1
1
0
0.95
2
d 0
r
RA 1
r
r
0.7 or r 0.7 6 5.02mm
r
1.95
1 0.7 141.60N / mm
0.95

=

= = =

= =

Drawing load =141.60
1
r
2
=11.21 kN
Power =
11.21 2.3 25.78
kW 26.31kW
0.98
= =

Page 59 of 79
8/1/2011
1
SheetMetalOperation p
BySKMondal
Piercing(Punching)andBlanking
PunchingPress
Punching
Blanking
Page 60 of 79
8/1/2011
2
Example
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 stress of the material is 450 N/mm
2
. Also
determine the work done if the percentage penetration is
25 percent of material thickness.
[Ans. 74.25 kN and 27.84 J]
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.
The ultimate shear strength of the sheet is 100 MPa and g
penetration to thickness ratio is 0.2. Neglect friction.
Assuming force vs displacement curve to be rectangular,
the work done (in J) is
(a) 100 (b) 200 (c) 250 (d) 300 [Ans. (a)]
S
400
GATE2010StatementLinked2
Statement for Linked Answer Questions:
In a shear cutting operation, a sheet of 5mm 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.
The ultimate shear strength of the sheet is 100 MPa and
penetration to thickness ratio is 0.2. Neglect friction.
A shear of 20 mm (S = 20 mm) is now provided on the
blade. Assuming force vs displacement curve to be
trapezoidal, the maximumforce (in kN) exerted is
(a) 5 (b) 10 (c) 20 (d) 40 [Ans. (b)]
S
400
Bolsterplate
Stripper
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3
Knockout
Knockout is a mechanism, usually connected to and
operated by the press ram, for freeing a work piece from
a die.
Dowelpin
GATE2011
The shear strength of a sheet metal is 300 MPa. The
blanking force required to produce a blank of 100
mmdiameter froma 1.5 mm thick sheet is close to
(a) 45 kN
(b) 70 kN
(c) 141 kN
(d) 3500 kN
Ans. (c)
GATE2007
The force requirement in a blanking operation of
low carbon steel sheet is 5.0 kN. The thickness of
the sheet is t and diameter of the blanked part is
d. For the same work material, if the diameter of
the blanked part is increased to 1.5 d and thickness the blanked part is increased to 1.5 d and thickness
is reduced to 0.4 t, the new blanking force in kN is
(a) 3.0 (b) 4.5
(c) 5.0 (d) 8.0
Ans. (a)
GATE2004
10 mm diameter holes are to be punched in a steel
sheet of 3 mm thickness. Shear strength of the
material is 400 N / mm
2
and penetration is 40%.
Shear provided on the punch is 2 mm. The blanking
force during the operation will be force during the operation will be
(a) 22.6 kN (b) 37.7 kN
(c) 61.6 kN (d) 94.3 kN
Ans. (a)
GATE2003
A metal disc of 20 mm diameter is to be punched
from a sheet of 2 mm thickness. The punch and the
die clearance is 3%. The required punch diameter is
(a) 19.88 mm (b) 19.94 mm
( ) 6 (d) (c) 20.06 mm (d) 20.12 mm
Ans. (a)
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4
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)
GATE2001
The cutting force in punching and blanking
operations mainly depends on
(a) The modulus of elasticity of metal
(b) The shear strength of metal
(c) The bulk modulus of metal
(d) The yield strength of metal
Ans. (b)
GATE1996
A 50 mm diameter disc is to be punched out from a
carbon steel sheet 1.0 mm thick. The diameter of
the punch should be
(a) 49.925 mm (b) 50.00 mm
( ) (d) f th b (c) 50.075 mm (d) none of the above
Ans. (d)
IES 1994
In sheet metal blanking, shear is provided on
punches and dies so that
(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
Consider the following statements related to
piercing and blanking:
1. Shear on the punch reduces the maximum cutting
force
Sh i th it f th d d 2. Shear increases the capacity of the press needed
3. Shear increases the life of the punch
4. The total energy needed to make the cut remains
unaltered due to provision of shear
(a) 1 and 2 (b) 1 and 4
(c) 2 and 3 (d) 3 and 4 [Ans. (b)]
IAS 1995
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)
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5
IES 2006
In which one of the following is a flywheel generally
employed?
(a) Lathe (b) Electric motor
(c) Punching machine (d) Gearbox
Ans. (c)
IES 2004
If the size of a flywheel in a punching machine is
increased
(a) Then the fluctuation of speed and fluctuation of
ill b th d energy will both decrease
(b) Then the fluctuation of speed will decrease and the
fluctuation of energy will increase
(c) Then the fluctuation of speed will increase and the
fluctuation of energy will decrease
(d) Then the fluctuation of speed and fluctuation of
energy both will increase [Ans. (a)]
IES 1999
A hole is to be punched in a 15 mm thick plate
having ultimate shear strength of 3Nmm
2
. If the
allowable crushing stress in the punch is 6 Nmm
2
,
the diameter of the smallest hole which can be
punched is equal to punched is equal to
(a) 15 mm (b) 30 mm
(c) 60 mm (d) 120 mm
Ans. (b)
IES 1997
For 50% penetration of work material, a punch with
single shear equal to thickness will
(a) Reduce the punch load to half the value
(b) Increase the punch load by half the value
(c) Maintain the same punch load
(d) Reduce the punch load to quarter load
Ans. (a)
IAS 2000
A blank of 30 mm diameter is to be produced out of
10 mm thick sheet on a simple die. If 6% clearance is
recommended, then the nominal diameters of pie
and punch are respectively
(a) 30 6 mmand 29 4 mm (a) 30.6 mmand 29.4 mm
(b) 30.6 mmand 30 mm
(c) 30 mmand 29.4 mm
(d) 30 mmand 28.8 mm
Ans. (d)
IAS 1994
In a blanking operation to produce steel washer, the
maximum punch load used in 2 x 10
5
N. The plate
thickness is 4 mm and percentage penetration is 25.
The work done during this shearing operation is
(a) 200J (b) 400J (a) 200J (b) 400J
(c) 600 J (d) 800 J
Ans. (a)
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6
IAS 2002
In deciding the clearance between punch and die in
press work in shearing, the following rule is helpful:
(a) Punch size controls hole size die size controls blank
size
(b) P h i t l b th h l i d bl k i (b) Punch size controls both hole size and blank size
(c) Die size controls both hole size and blank size
(d) Die size controls hole size, punch size controls blank
size
Ans. (a)
IAS 2007
For punching operation the clearance is provided
on which one of the following?
(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
Assertion (A): A flywheel is attached to a punching
press so as to reduce its speed fluctuations.
Reason(R): The flywheel stores energy when its
speed increase.
(d) A is false but R is true [Ans. (a)]
IES 2002
Which one is not a method of reducing cutting
forces to prevent the overloading of press?
(a) Providing shear on die
(b) Providing shear on punch
(c) Increasing die clearance
(d) Stepping punches
Ans. (c)
IAS 2003
Match List I (Presspart) with List II (Function) and select the
correct answer using the codes given belowthe lists:
ListI ListII
(Presspart) (Function)
(A) Punch plate 1. Assisting withdrawal of the punch
(B) Stripper 2. Advancing the workpiece through correct
di t distance
(C) Stopper 3. Ejection of the workpiece fromdie cavity
(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 2000
Best position of crank for blanking operation in a
mechanical press is
(a) Top dead centre
(b) 20 degrees below top dead centre
(c) 20 degrees before bottomdead centre
(d) Bottomdead centre
Ans. (b)
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7
IES 1999
Assertion (A): In sheet metal blanking operation,
clearance must be given to the die.
Reason (R): The blank should be of required
dimensions.
Ans. (d)
IAS 2003
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)
Drawing
IES 1997
A cup of 10 cm height and 5 cm diameter is to be
made from a sheet metal of 2 mm thickness. The
number of deductions necessary will be
(a) One
(b) T (b) Two
(c) Three
(d) Four
Ans. (c)
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9
Surfacescratches
Dieorpunchnothavingasmoothsurface,insufficient
lubrication
GATE2008
In the deep drawing of cups, blanks show a tendency to
wrinkle up around the periphery (flange).
The most likely cause and remedy of the phenomenon are,
respectively,
(A) Buckling due to circumferential compression; Increase (A) Buckling due to circumferential compression; Increase
blank holder pressure
(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) Buckling due to circumferential compression; decrease
blank holder pressure [Ans. (a)]
GATE1999
Identify the stress state in the FLANCE portion of a
PARTIALLYDRAWN CYLINDRICAL CUP when deep
drawing without a blank holder
(a) Tensile in all three directions
(b) N t i th fl t ll b th i (b) No stress in the flange at all, because there is no
blankholder
(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)]
GATE2003
A shell of 100 mm diameter and 100 mm height with
the corner radius of 0.4 mm is to be produced by
cup drawing. The required blank diameter is
(a) 118 mm (b) 161 mm
( ) (d) (c) 224 mm (d) 312 mm
Ans. (c)
GATE2006
Match the items in columns I and II.
Column I Column I
P. Wrinkling 1. Yield point elongation
Q. Orange peel 2. Anisotropy
R S h i L i i R. Stretcher strains 3. Large grain size
S. Earing 4. Insufficient blank holding
force [Ans. (d)]
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
(c) P 2, Q 5, R 3, S 4 (d) P 4, Q 3, R 1, S 2
IES 2008
A cylindrical vessel with flat bottom can be deep
drawn by
(a) Shallowdrawing
(b) Single action deep drawing
(c) Double action deep drawing
(d) Triple action deep drawing
Ans. (c)
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10
IES 1999
Consider the following statements: Earring in a
drawncup can be due to nonuniform
1. Speed of the press
2. Clearance between tools
3. Material properties
4. Blank holding
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1, 3 and 4 (d) 1, 2 and 4
Ans. (b)
IES 1993
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 1994
For obtaining a cup of diameter 25 mm and height 15
mm by drawing, the size of the round blank should
he approximately
(a) 42 mm (b) 44 mm
( ) 6 (d) 8 (c) 46 mm (d) 48 mm
Ans. (c)
IAS 2007
In drawing operation, proper lubrication is
essential for whichof the following reasons?
1. To improve die life
2. To reduce drawing forces
3. To reduce temperature
4. To improve surface finish
(a) 1 and 2 only (b) 1, 3 and 4 only
(c) 3 and 4 only (d) 1, 2, 3 and 4
Ans. (d)
IAS 1997
Which one of the following factor promotes the
tendency for wrinking in the process of drawing?
(a) Increase in the ratio of thickness to blank diameter
of work material
(b) D i th ti thi k t bl k di t f (b) Decrease in the ratio thickness to blank diameter of
work material
(c) Decrease in the holding force on the blank
(d) Use of solid lubricants
Ans. (c)
IAS 1994
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
(c) 2 and 4 (d) 1, 3 and 4 [Ans. (d)]
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11
Spinning
t
c
= t
b
sin

GATE1992
Thethicknessoftheblankneededtoproduce,by
powerspinningamissileconeofthickness1.5mm
andhalfconeangle30,is
(a) 3.0mm (b) 2.5mm
( ) (d) (c) 2.0mm (d) 1.5mm
Ans.(a)
IES 1994
The mode of deformation of the metal during
spinning is
(a) Bending
(b) Stretching
(c) Rolling and stretching
(d) Bending and stretching.
Ans. (d)
IES 2006
Which one of the following is a continuous bending
process in which opposing rolls are used to produce
long sections of formed shapes from coil or strip
stock?
(a) Stretch forming (b) Roll forming (a) Stretch forming (b) Roll forming
(c) Roll bending (d) Spinning
Ans. ( b)
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12
HighEnergyRateForming(HERF)
UnderwaterExplosions
IES2011
High energy rate forming process used for forming
components from thin metal sheets or deform thin
tubes is:
(a) Petroforming
(b) Magnetic pulse forming
(c) Explosive forming
(d) electrohydraulic forming
Ans. (b)
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.
( ) B th A d R i di id ll t d R i th 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
Ans. (c) The workpiece has to be electrically conductive but
need not be magnetic.
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13
IES2010
Assertion (A) : In the high energy rate forming
method, the explosive forming has proved to be an
excellent method of utilizing energy at high rate and
utilizes both the high explosives and lowexplosives.
Reason (R): The gas pressure and rate of detonation ( ) g p
can be controlled for both types of explosives.
explanation of A
IES 2007
Which one of the following metal forming
processes is not a highenergy rate forming process?
(a) Electromechanical forming
(b) Rollforming
(c) Explosive forming
(d) Electrohydraulic forming
Ans. (b)
IES 2009
Which one of the following is a high energy rate
forming process?
(a) Roll forming
(b) Electrohydraulic forming
(c) Rotary forging
(d) Forward extrusion
Ans. (b)
IES 2005
Magnetic forming is an example of:
(a) Cold forming (b) Hot forming
(c) High energy rate forming (d) Roll forming
Ans. (c)
StretchFormingContd......
GATE2000
A 1.5 mm thick sheet is subject to unequal biaxial
stretching and the true strains in the directions of
stretching are 0.05 and 0.09. The final thickness of
the sheet in mm is
(a) 1 414 (b) 1 304 (a) 1.414 (b) 1.304
(c) 1 362 (d) 289
Ans. (b)
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14
IroningContd....
BendingForce
2
ut
Where l =Bend length =width of thestock, mm
=Ultimate tensilestrength, MPa (N/mm )
t bl k thi k
2
ut
Kl t
F
w
=
Condition V-Bending U-Bending Edge-Bending
W < 16t 1.33 2.67 0.67
W > = 16t 1.20 2.40 0.6
t =blank thickness, mm
w= width of die-opening, mm
K=die-openingfactor , (can be usedfollowin table)
ForUorchannelbendingforcerequiredisdoublethanV bending
ForedgebendingitwillbeaboutonehalfthatforV bending
Example
Calculate the bending force for a 45
o
bend in aluminium
blank. Blank thickness, 1.6 mm, bend length = 1200 mm,
Die opening = 8t, UTS = 455 MPa, Die opening factor =
1.33
Ans. (145.24 kN)
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
stretch factor is 0.5, the bend allowance is
(a) 99 mm (b) 100 mm
( ) (d) (c) 101 mm (d) 102 mm
Ans. (c)
2mm
1 radian
Page 72 of 79
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15
GATE2007
Match the correct combination for following metal
working processes.
Processes Associated state of stress
P. Blanking 1. Tension
Q Stretch Forming 2 Compression Q. Stretch Forming 2. Compression
R. Coining 3. Shear [Ans. (d)]
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
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. Blow moulding
6. Coining [Ans. (b)]
(a) P1 Q4 R6 S3 (b) P4 Q5 R2 S3
(c) P1 Q5 R3 S2 (d) P5 Q1 R2 S2
IAS 1999
Match List I (Process) with List II (Production of parts)
belowthe lists: [Ans. (d)]
ListI ListII
A. Rolling 1. Discrete parts
B. Forging 2. Rod and Wire
C. Extrusion 3. Wide variety of shapes with thin
walls
D. Drawing 4. Flat plates and sheets
5. Solid and hollowparts
(a) 2 5 3 4 (b) 1 2 5 4
(c) 4 1 3 2 (d) 4 1 5 2 Compiled by:SK Mondal Made Easy
IAS 1997
Match ListI (metal forming process) with ListII
(Associated feature) and select the correct answer
using the codes given belowthe Lists:
Listl List II [Ans. (c)]
A Bl ki Sh l A. Blanking 1. Shear angle
B. Flow forming 2. Coiled stock
C. Roll forming 3. Mandrel
D. Embossing 4. Closed matching dies
(a) 1 3 4 2 (b) 3 1 4 2
(c) 1 3 2 4 (d) 3 1 2 4 Compiled by:SK Mondal Made Easy
IES2010
The material properties which principally
determine howwell 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. [Ans. (d)]
(c) 1 only (d) 1, 2 and 3
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1
PowderMetallurgy gy
BySKMondal
Atomizationusingagasstream
Compacting
Metal powders are compacted by many methods, but
sintering is required to achieve which property? What
i h t i t ti i ? is hot isostatic pressing?
[2Marks]
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2
Whatisisostatic pressingofmetalpowders?
Whatareitsadvantage?
[2Marks]
OilimpregnatedPorousBronzeBearings
IES2010
Consider the following parts:
1. Grinding wheel
2. Brake lining
3 Selflubricating bearings 3. Self lubricating bearings
Which of these parts are made by powder
metallurgy technique?
(a) 1, 2 and 3 (b) 2 only
Ans. (c)
IES2010
Metallic powders can be produced by
(a) Atomization
(b) Pulverization
(c) Electrodeposition process (c) Electro deposition process
(d) All of the above
Ans. (d)
IES 2002
The rate of production of a powder metallurgy part
depends on
(a) Flowrate of powder
(b) Green strength of compact
(c) Apparent density of compact
(d) Compressibility of powder
Ans. (c)
IES 2001
Match ListI (Components) with ListII
(Manufacturing Processes) and select the correct
answer using the codes given belowthe lists:
List I List II
A C b d ( t l) M hi i A (d) A. Car body (metal) 1. Machining Ans. (d)
B. Clutch lining 2. Casting
C. Gears 3. Sheet metal pressing
D. Engine block 4. Powder metallurgy
(a) 3 4 2 1 (b) 4 3 1 2
(c) 4 3 2 1 (d) 3 4 1 2
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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
In powder metallurgy, the operation carried out to
improve the bearing property of a bush is called
(a) infiltration (b) impregnation
(c) plating (d) heat treatment
Ans. (b)
IES 1997
Which of the following components can be
manufactured by powder metallurgy methods?
1. Carbide tool tips 2. Bearings
3. Filters 4. Brake linings
(a) 1, 3 and 4 (b) 2 and 3
(c) 1, 2 and 4 (d) 1, 2, 3 and 4
Ans. (d)
IES 1999
The correct sequence of the given processes in
manufacturing by powder metallurgy is
(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
Carbidetipped cutting tools are manufactured by
powder metal technology process and have a
compositionof
(a) ZirconiumTungsten (35% 65%)
(b) T t bid C b lt ( % %) (b) Tungsten carbideCobalt (90% 10%)
(c) Aluminiumoxide Silica (70% 30%)
(d) NickelChromium Tungsten (30% 15% 55%)
Ans. (b)
IES 1999
Assertion (A): In atomization process of manufacture of
metal powder, the molten metal is forced through a
small orifice and broken up by a stream of compressed
air.
Reason (R): The metallic powder obtained by ( ) p y
atomization process is quite resistant to oxidation.
explanation of A
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4
IES 2007
What are the advantages of powder metallurgy?
1. Extreme purity product
2. Low labour cost
3. Lowequipment cost.
Select the correct answer using the code given below
(a) 1, 2 and 3 (b) 1 and 2 only
Ans. (b)
IES 2006
Which of the following are the limitations of
powder metallurgy?
1. High tooling and equipment costs.
2. Wastage of material.
3. It cannot be automated.
4. Expensive metallic powders.
(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
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)
IES 2009
Which of the following cutting tool bits are made by
powder metallurgy process?
(a) Carbon steel tool bits (b) Stellite tool bits
(c) Ceramic tool bits (d) HSS tool bits
Ans. (c)
IAS 2003
Which of the following are produced by powder
metallurgy process?
1. Cemented carbide dies
2. Porous bearings
3 Small magnets 3. Small magnets
4. Parts with intricate shapes
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
In parts produced by powder metallurgy process,
presintering is done to
(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)
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5
IAS 2000
Consider the following processes:
1. Mechanical pulverization
2. Atomization
3. Chemical reduction
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
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
uniformdensity of the metal powder uniformdensity of the metal powder.
explanation of A
Ans. (d)
IAS 1998
Throwaway tungsten carbide tip tools are
manufactured by
(a) Forging (b) Brazing
(c) Powder metallurgy (d) Extrusion
Ans. (c)
IAS 1996
Which one of the following processes is performed
in powder metallurgy to promote selflubricating
properties in sintered parts?
(a) Infiltration (b) Impregnation
( ) Pl ti (d) G hiti ti (c) Plating (d) Graphitization
Ans. (b)
IAS 2007
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
water cannot be used as a substitute for compressed
air.
IAS 2004
The following are the constituent steps in the
process of powder metallurgy:
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)
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6
IAS 2003
Assertion (A): Atomization method for production of
metal powders consists of mechanical disintegration of
molten streaminto fine particles.
Reason (R): Atomization method is an excellent means
of making powders from high temperature metals. g p g p
explanation of A
IAS 2007
Consider the following basic steps involved in the
productionof porous bearings:
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)
ConventionalQuestions
1. Explain why metal powders are blended. Describe what
happens during sintering. [IES2010, 2 Marks]
1. Discuss the terms fineness and particle size
distribution in powder metallurgy. [IES2010, 2 Marks]
Ans.
Fineness: Is the diameter of spherical shaped particle
and mean diameter of nonspherical shaped particle. p p p
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
define the particle size distribution.
Enumerate the steps involved in powder metallurgy
process. Discuss these steps. Name the materials used
in powder metallurgy. What are the limitations of
powder metallurgy? [IES2005, 10 Marks]
Page 79 of 79
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1
Lathe
BySKMondal
IES 2001
Thespindlespeedrangeinageneralpurposelathe
isdividedintostepswhichapproximatelyfollow
(a) Arithmeticprogression
(b) Geometricprogression
(c) Harmonicprogression
(d) Logarithmicprogression
Ans.(b)
IES 1992
Feedgearboxforascrewcuttinglatheisdesigned
onthebasisof
(a) Geometricprogression
(b) Arithmeticprogression
(c) Harmonicprogression
(d) None
Ans.(a)
Example
How much machining time will be required to reduce
the diameter of a cast iron rod from 120 mm to 116 mm
over a length of 100 mm by turning using a carbide
insert. Cutting velocity is 100 m/min and feed rate = 0.2
mm/rev.
IES2010
In turning a solid round bar, if the travel
of the cutting tool in the direction of
feed motion is 1000 mm, rotational
speed of the workpiece is 500 rpm, and p p 5 p ,
rate of feed is 0.2 mm/revolution, then
the machining time will be
(a) 10 seconds (b) 100 seconds
(c) 5 minutes (d) 10 minutes
Ans. (d)
IES 2003
The time taken to face a workpiece of 72 mm
diameter, if the spindle speed is 80 r.p.m. and cross
feed is 0.3 mm/rev, is
(a) 1.5 minutes (b) 3.0 minutes
( ) i t (d) 8 i t (c) 5.4 minutes(d) 8.5 minutes
Ans. (a)
Set-2
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2
IAS 2002
A 150 mm long, 12 mm diameter 304 stainless steel
rod is being reduced in diameter to 115 mm by
turning on a lathe. The spindle rotates at N = 400
rpm and the tool is travelling at an axial speed of
200 mm/min. The time taken for cutting is given by 200 mm/min. The time taken for cutting is given by
(a) 30 s (b) 36 s
(c) 1 minute (d) 45 s
Ans. (d)
IES 2004
A medium carbon steel workpiece is turned on a
lathe at 50 m/min. cutting speed 0.8 mm/rev feed
and 1.5 mm depth of cut. What is the rate of metal
removal?
(a) 1000 mm
3
/min (a) 1000 mm
3
/min
(b) 60,000 mm
3
/min
(c) 20,000 mm
3
/min
(d) Can not be calculated with the given data
Ans. (b)
IES 2006
For taper turning on centre lathes, the method of
swiveling the compound rest is preferred for:
(a) Long jobs with small taper angles
(b) Long jobs with steep taper angles
(c) Short jobs with small taper angles
(d) Short jobs with steep taper angles
Ans. (d)
Example
Find the angle at which the compound rest should
be set up to turn taper on the workpiece having a
length of 200 mm, larger diameter 45 mm and the
smaller 30 mm.
IES 1992
Tail stock set over method of taper turning is
preferred for
(a) Internal tapers
(b) Small tapers
(c) Long slender tapers
(d) Steep tapers
Ans. (c)
IAS 2002
The amount of offset of tail stock for turning taper
on full length of a job 300 mm long which is to have
its two diameters at 50 mmand 38 mmultimately is
(a) 6 mm (b) 12 mm
( ) (d) (c) 25 mm (d) 44 mm
Ans. (a)
Set-2
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3
IES 1998
A 400 mm long shaft has a 100 mm tapered step at
the middle with 4 included angle. The tailstock
offset required to produce this taper on a lathe
would be
(a) 400 sin 4 (b) 400 sin 2 (a) 400 sin 4 (b) 400 sin 2
(c) 100 sin 4 (d) 100 sin 2
Ans. (b)
IES2010
The effect of centering error
when the tool is set above the
center line as shown in the figure
results effectively in
1. Increase in rake angle.
R d i i k l 2. Reduction in rake angle.
3. Increase in clearance angle.
4. Reduction in clearance angle.
Which of these statements is/are
correct?
(a) 1 only (b) 1 and 4 only
(c) 2 and 4 only (d) 1, 2, 3 and 4
Ans. (b)
GATE 2002
A leadscrew with half nuts in a lathe, free to rotate
in both directions has
(a) Vthreads
(b) Whitworth threads
(c) Buttress threads
(d) ACME threads Ans. (d)
GATE 2008
The figure shows an incomplete schematic of a
conventional lathe to be used for cutting threads
with different pitches. The speed gear box U
v
, is
shown and the feed gear box U
s
, is to be placed. P, Q.
R and S denote locations and have no other R and S denote locations and have no other
significance. Changes in U
v
, should NOT affect the
pitch of the thread being cut and changes in U
s
,
should NOT affect the cutting speed.
Contd..
GATE2008Contd.
Ans.(c)
ThecorrectconnectionsandthecorrectplacementofU
s
are
givenby
(a) QandEareconnected. U
s
,isplacedbetweenPandQ.
(b) SandEareconnected.U
s
isplacedbetweenRandS.
(c) QandEareconnected.U
s
,isplacedbetweenQandE.
(d) SandEareconnected.U
s
,isplacedbetweenSandE.
GATE 2003
Qualityscrewthreadsareproducedby
(a) Threadmilling
(b) Threadchasing
(c) Threadcuttingwithsinglepointtool
(d) Threadcasting
Ans.(b)
Set-2
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4
IES2010
For producing both internal and external
screwthreads, the method used is
(a) Thread chasing with multiplerib chasers
(b) Thread milling and multiplethread cutters ( ) g p
(c) Thread tapping with taps
(d) Die threading with selfopening die heads
Ans. (b)
IES2011
External threads can be produced by :
1. Rolling
2. Grinding
3. Milling 3 g
(a) 1 and 3 only
(b) 1 and 2 only
(c) 2 and 3only
(d) 1, 2 and 3
Ans. (d)
IES 2004
Match List I (Cutting tools) with List II (Features)
belowthe Lists:
List I List II
A T i t l Chi l d
Ans.(c)
A. Turning tool 1. Chisel edge
B. Reamer 2. Flutes
C. Milling cutter 3. Axial relief
4. Side relief
Codes: A B C A B C
(a) 1 2 3 (b) 4 3 2
(c) 4 2 3 (d) 1 3 2
GATE1994
To get good surface finish on a turned job,
one should use a sharp tool with a ..feed
and speed of rotation of the job.
(a) Minimum, minimum ( )
(b) Minimum, maximum
(c) Maximum, maximum
(d) Maximum, minimum
Ans.(b)
IES 1996
Inturningofslenderrods,itisnecessarytokeep
thetransverseforceminimummainlyto
(a) Improvethesurfacefinish
(b) Increaseproductivity
(c) Improvecuttingefficiency
(d) Reducevibrationsandchatter.
Ans.(d)
IES 2009
Whatisthenumberofjawsinselfcentred chuck?
(a) Eight
(b) Six
(c) Four
(d) Three
Ans.(d)
Set-2
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5
IES 1999
Which one of the following sets of forces are
encountered by a lathe parting tool while groove
cutting?
(a) Tangential, radial and axial
(b) T ti l d di l (b) Tangential and radial
(c) Tangential and axial
(d) Radial and axial
Ans. (a)
IES 2009
Whichoneofthefollowingmethodsshouldbeused
forturninginternaltaperonly?
(a) Tailstockoffset
(b) Taperattachment
(c) Formtool
(d) Compoundrest
Ans.(d)
IES 1998
A single start thread of pitch 2 mm is to be produced
on a lathe having a lead screw with a double start
thread of pitch 4 mm. The ratio of speeds between
the spindle and lead screwfor this operation is
(a) 1 : 2 (b) 2: 1 (a) 1 : 2 (b) 2: 1
(c) 1: 4 (d) 4: 1
Ans. (d)
IES 1993
It is required to cut screw threads of 2 mm pitch on
a lathe. The lead screw has a pitch of 6 mm. If the
spindle speed is 60 rpm, then the speed of the lead
screwwill be
(a) 10 rpm (b) 20 rpm (a) 10 rpm (b) 20 rpm
(c) 120 rpm (d) 180 rpm
Ans. (b)
IES 1992
Whichofthefollowingstatementisincorrectwith
referenceoflathecuttingtools?
(a) Theflankofthetoolisthesurfacebelowand
adjacenttothecuttingedges
(b) Th i th h f j i i th id (b) Thenoseisthecorner,orchamferjoiningtheside
cuttingandtheendcuttingedges
(c) Theheelisthatpartofthewhichisshapedto
producethecuttingedgesandface
(d) Thebaseisthatsurfaceoftheshankwhichagainst
thesupportandtakestangent
Ans.(c)
IES 2006
It is required to cut screw threads with double start
and 2 mm pitch on a lathe having lead screw pitch
of 6 mm. What is the speed ratio between lathe
spindle and lead screw?
(a) 1 : 3 (b) 3: 1 (a) 1 : 3 (b) 3: 1
(c) 2 : 3 (d) 3: 2
Ans. (d)
Set-2
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6
IES 1997
Consider the following operations:
1. Under cutting 2. Plain turning
3. Taper turning 4. Thread cutting
The correct sequence of these operations in machining a
product is
(a) 2, 3, 4, 1 (b) 3, 2, 4, 1
(c) 2, 3, 1, 4 (d) 3, 2, 1, 4
Ans. (c)
IES 2009
A capstan lathe is used to massproduce, in batches
of 200, a particular component. The direct material
cost is Rs 4 per piece, the direct labour cost is Rs 3
per piece and the overhead costs are 400% of the
labour costs. What is the production cost per piece? labour costs. What is the production cost per piece?
(a) Rs 19 (b) Rs 23
(c) Rs 16 (d) Rs 15
Ans. (a)
IES 2007
Assertion (A): In a multispindle automatic lathe, the
turret tool holder is indexed to engage the cutting tools
one by one for successive machining operations.
Reason (R): Turret is a multiple tool holder so that for
successive machining operation, the tools need not be g p ,
changed.
explanation of A
IES 1995
1. Multiple operations can be performed
2. Operator's fatigue is greatly reduced.
3. Ideally suited for batch production
4 A break down in one machine does not affect the 4. A breakdown in one machine does not affect the
flowof products.
5. Can accommodate modifications in design of
components, within certain limits.
The characteristics which can be attributed to special
purpose machines would include
(a) 1, 3 and 4 (b) 1, 2 and 4
(c) 2, 3 and 5 (d) 1, 2 and 5 Ans. (c)
IES 1996
Assertion (A): Special purpose machine tools and
automatic machine tools are quite useful for job
shops
Reason (R): Special purpose machine tools can do
special types of machining work automatically special types of machining work automatically
IES 2003
Which one of the following mechanisms is
employed for indexing of turret in an automatic
lathe?
(a) Whitworth (b) Rack and pinion
( ) R t h t d l (d) G h l (c) Ratchet and pawl (d) Geneva wheel
Ans. (c)
Set-2
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7
IES 2009
For the manufacture of screw fasteners on a mass
scale, which is the most suitable machine tool?
(a) Capstan lathe
(b) Singlespindle automatic lathe
(c) CNC turning centre (lathe)
(d) CNC machining centre
Ans. (b)
IES 2001
The indexing of the turret in a singlespindle
automatic lathe is done using
(a) Geneva mechanism
(b) Ratchet and Pawl mechanism
(c) Rack and pinion mechanism
(d) Whitworth mechanism
Ans. (b)
IES 1995
Assertion (A): In a Swiss type automatic lathe, the
turret is given longitudinal feed for each tool in a
specific order with suitable indexing.
Reason (R): A turret is a multiple tool holder to
facilitate machining with each tool by indexing
without the need to change the tools.
IES 1992
Maximum production of small and slender parts is
done by
(a) Watch maker's lathe
(b) Sliding head stock automatic lathe
(c) Multispindle automatic lathe
(d) Capstan lathe
Ans. (c)
IES 2007
Screw threads are produced on solid rods by using
whichof the following?
(a) Dies (b) Punch
(c) Mandrel (d) Boring bar
Ans. (a)
IAS 2007
Which one of the following is the characteristic for
capstan lathe?
(a) Rate of production is low
(b) Labour cost is high
(c) Used for handling jobs of varying shapes and sizes
(d) Capstan head is mounted on a slide
Ans. (d)
Set-2
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8
IAS 2002
Consider the following statements related to Turret
lathe:
1. Turret is mounted directly on the saddle.
2. Turret is mounted on an auxiliary slide.
3. Much heavier and larger jobs than Capstan lathe can
be produced.
(a) 1 and 3 (b) 2 and 3
(c) 1 only (d) 2 only
Ans. (a)
IAS 1996
Apart from hexagonal turret, the elements (s) in a
turret lathe include (s)
(a) Crossslide tool post
(b) Crossslide tool post and rear tool post
(c) Crossslide tool post and tail stock
(d) Teal tool post and tail stock
Ans. (a)
IAS 2004
Swiss type screwmachines have
(a) Turrets (b) Radial slides
(c) Spindle carriers (d) Tool posts
Ans. (c)
IAS 2001
Consider the following operations and time
required on a multi spindle automatic machine to
produce a particular job
1. Turning 1.2 minutes
D illi 6 i t 2. Drilling 1.6 minutes
3. Forming 0.2 minute
4. Parting 0.6 minute
The time required to make one piece (cycle time) will be
(a) 0.6 minutes (b) 1.6 minutes
(c) 3.6 minutes (d) 0.9 minute Ans. (b)
IAS 1995
Assertion (A): In a multispindle automat, the turret
is indexed to engage each of the cutting tool
mounted on it.
Reason(R): Turret is a multiple tool holder so that
the machining can be continued with each tool
without the need to change the tool.
IAS 1994
A multispindle automat performs four operations
with times 50, 60, 65 and 75 seconds at each of its
work centers. The cycle time (time required to
manufacture one work piece) in seconds will be
(a) 50 + 60 + 65 + 75 (a) 50 + 60 + 65 + 75
(b) (50 + 60 + 65 + 75) /4
(c) 75/4
(d) 75
Ans. (d)
Set-2
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9
IAS 1998
Assertion (A): For thread cutting, the spindle speed
selected on a lathe, is very low.
Reason (R): The required feed rate is low in
threading operation.
IAS 1998
Consider the following statements associated with
the lathe accessories:
1. Steady rest is used for supporting a long job in
between head stock and tail stock.
M d l i d f t i ll li d i l j b 2. Mandrel is used for turning small cylindrical job.
3. Collects are used for turning discshaped job.
Of these statements:
(a) 1 and 2 are correct (b) 2 and 3 are correct
(c) 3 alone is correct (d) 1 alone is correct
Ans. (d)
IES2011
In Norton type feed gearbox for cutting Whitworth
standard threads with a standard TPI Leadscrew, power
flows from:
(a) Spindle to Tumbler gear to Norton cone to Meander
drive to Leadscrew
(b) Spindle to Norton cone to Tumbler geat to Meander
drive to Leadscrew
(c) Spindle t o Tumbler gear to Meander drive to Norton
cone to Leadscrew
(d) Spindle to Norton cone to Meander drive to Tumbler
gear to Leadscrew Ans. (a)
IAS 2000
Consider the following features:
1. All spindles operate simultaneously,
2. One piece is completed each time the tools are
withdrawn and the spindles are indexed
3. The tool slide indexes or revolves with the spindle
carrier
Which of these features are characteristics of a multi
spindle automatic machine used for bar work?
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3 Ans. (a)
Set-2
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Drilling
BySKMondal
IES 2004
The helical flute in a twist drill provides the necessary
1. Clearance angle for the cutting edge
2. Rake angle for the cutting edge
3. Space for the chip to come out during drilling
4. Guidance for the drill to enter into the workpiece
(a) 1 and 2 (b) 2 and 3
(c) 3 and 4 (d) 1 and 4 Ans. (b)
IES 2003
The purpose of helical grooves in a twist drill is to
1. Improve the stiffness
2. Save a tool material
3. Provide space for chip removal
4. Provide rake angle for the cutting edge
Codes:
(a) 1 and 2 (b) 2 and 3
(c) 3 and 4 (d) 1 and 4 Ans. (c)
GATE 1996
The rake angle in a drill
(a) Increases fromcentre to periphery
(b) decreases fromcentre to periphery
(c) Remains constant
(d) Is irrelevant to the drilling operation
Ans. (a)
IES 1997
The rake angle in a twist drill
(a) Varies from minimum near the dead centre to a
maximumvalue at the periphery
(b) Is maximum at the dead centre and zero at the
i h periphery
(c) Is constant at every point of the cutting edge
(d) Is a function of the size of the chisel edge.
Ans. (a)
IES 1992
A drill for drilling deep holes in aluminum should
have
(a) High helix angle (b) Taper shank
(c) Small point angle (d) No lip
Ans. (a)
Set-2
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2
GATE 1997
Helix angle of fast helix drill is normally
(a) 35
o
(b) 60
o
(c) 90
o
(d) 5
o
Ans. (a)
IES 1992
Low helix angle drills are preferred for drilling
holes in
(a) Plastics (b) Copper
(c) Cast steel (d) Carbon steel
Ans. (d)
Example
A hole with 40mm diameter and 50mm depth is to
be drilled in mild steel component. The cutting
speed can be taken as 65 m/min and the feed rate as
0.25 mm/rev. Calculate the machining time and the
material removal rate.
GATE 2002
The time taken to drill a hole through a 25 mm thick
plate with the drill rotating at 300 r.p.m. and
moving at a feed rate of 0.25 mm/revolution is
(a) 10 sec (b) 20 sec
( ) 6 (d) (c) 60 sec (d) 100 sec
Ans. (b)
GATE 2004
Through holes of 10 mm diameter are to be drilled
in a steel plate of 20 mm thickness. Drill spindle
speed is 300 rpm, feed 0.2 mm/ rev and drill point
angle is 120. Assuming drill over travel of 2 mm, the
time for producing a hole will be time for producing a hole will be
(a) 4 seconds (b) 25 seconds
(c) 100 seconds (d) 110 seconds
Ans. (b)
IES 2002
The arm of a radial drilling machine is being raised
at a speed of 3.9 m/min by single start square
threads of 6 mm pitch and 30 mm diameter. The
speed of the screw
(a) Is 650 rpm (a) Is 650 rpm
(b) Is 180 rpm
(c) Is 130 rpm
(d) Cannot be determined as the data is insufficient
Ans. (a)
Set-2
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IES 1994
The ratio between two consecutive spindle speeds
for a sixspeed drilling machine using drills of
diameter 6.25 to 25 mm size and at a cutting velocity
of 18 m/min is
(a) 1 02 (b) 1 32 (a) 1.02 (b) 1.32
(c) 1.62 (d) 1.82
Ans. (b)
IES 2009
What is the drilling time for producing a hole in an
MS sheet of 25 mm thickness using an HSS drill of
20 mm diameter? The cutting speed and feed for
drill are 20 m/min and 0.25 mm/revolution
respectively, Neglect time taken for setting up, respectively, Neglect time taken for setting up,
approaching and travelling of tools.
(a) 0.314 min (b) 0.236 min
(c) 0.438 min (d) 0.443 min
Ans. (a)
IES 2002
A 31.8 mm H.S.S. drill is used to drill a hole in a cast
iron block 100 mm thick at a cutting speed 20
m/min and feed 0.3 mm/rev. If the over travel of
drill is 4 mm and approach 9 mm, the time required
to drill the hole is to drill the hole is
(a) 1 min 40 s (b) 1 min 44 s
(c) 1 min 49 s (d) 1 min 53 s
Ans. (d)
IAS 1999
To drill a 10 mm diameter hole through a 20 mm
thick M.S. plate with a drill bit running at 300 rpm
and a feed of 0.25 mm per revolution, time taken
will be
(a) 8 s (b) 16 s (a) 8 s (b) 16 s
(c) 24 s (d) 32 s
Ans. (b)
IAS 1994
The time (in minutes) for drilling a hole is given by
where 'h' is the
RPM Feed
h hole the of Depth
t
+
=
(a) Length of the drill
(b) Drill diameter
(c) Flute length of the drill
(d) Cone height of the drill.
Ans. (d)
IES 1999
Match ListI (Drill bits) with ListII (Applications) and select the correct
answer using the codes given belowthe Lists:
ListI ListII
A. Core drill 1. To enlarge a hole to a certain depth so as to
accommodate the bolt head of a screw
B. Reamer 2. To drill and enlarge an already existing hole in a . ea e . o d a d e a ge a a eady e st g o e a
casting
C. Counter bore drill 3. To drill a hole before making internal
thread
D. Tap drill 4. To improve the surface finish and dimensional
accuracy of the already drilled hole
(a) 1 3 2 4 (b) 2 3 1 4
(c) 2 4 1 3 (d) 3 2 4 1
Ans. (c)
Set-2
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1
Reaming,Boring,Broaching
BySKMondal
IES 1999
Which one of the following processes results in the
best accuracy of the hole made?
(a) Drilling (b) Reaming
(c) Broaching (d) Boring
Ans. (b)
IES 1999
Consider the following statements regarding
reaming process:
1. Reaming generally produces a hole larger than its
own diameter
G ll k l t id d 2. Generally rake angles are not provided on reamers.
3. Even numbers of teeth are preferred in reamer
design.
(a) 1 and 2 (b) 2 and 3
(c) 1 and 3 (d) 1, 2 and 3 Ans. (b)
IES 1998
Match ListI with ListII and select the correct answer
using the codes given belowthe lists:
ListI ListII
A. Reaming 1. Smoothing and squaring surface
around the hole for proper seating around the hole for proper seating
B. Counterboring 2. Sizing and finishing the hole
C. Countersinking 3. Enlarging the end of the hole
D. Spot facing 4. Making a conical enlargement at the
end of the hole Ans. (d)
(a) 3 2 4 1 (b) 2 3 1 4
(c) 3 2 1 4 (d) 2 3 4 1
IES 1994
In reaming process
(a) Metal removal rate is high
(b) High surface finish is obtained.
(c) High formaccuracy is obtained
(d) High dimensional accuracy is obtained.
Ans. (d)
IES 1993
A hole of 30 mm diameter is to be produced by reaming.
The minimum diameter permissible is 30.00 mm while
the maximum diameter permissible is 30.05 mm. In this
regard, consider the following statements about the
reamer size:
1. The minimumdiameter of the reamer can be less than 30 mm.
2. The minimumdiameter of the reamer cannot be less than 30 mm.
3. The maximumdiameter of the reamer can be more than 30.05 mm.
4. The maximumdiameter of the reamer must be less than 30.05 mm.
Of these statements Ans. (d)
(a) 1 and 4 are correct (b) 1 and 3 are correct
(c) 2 and 3 are correct (d) 2 and 4 are correct
Set-2
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IES 1998
A component requires a hole which must be within
the two limits of 25.03 and 25.04 mm diameter.
Which of the following statements about the
reamer size are correct?
1 Reamer size cannot be below 25 03 mm 1. Reamer size cannot be below 25.03 mm.
2. Reamer size cannot be above 25.04 mm.
3. Reamer size can be 25.04 mm.
4. Reamer size can be 25.03 mm.
(a) 1 and 3 (b) 1 and 2 Ans. (b)
(c) 3 and 4 (d) 2 and 4
IAS 1999
For reaming operation of blind hole, the type of
reamer required is
(a) Straight flute reamer
(b) Right hand spiral fluted reamer
(c) Left hand spiral fluted reamer
(d) None of the above
Ans. (b)
IAS 2003
Match List I (Operation) with List II (Application) and select
the correct answer using the codes given below the lists:
ListI ListII Ans. (c)
(Operation) (Application)
(A) Reaming 1. Used for enlarging the end of a hole to give it a
i l h f h di conical shape for a short distance
(B) Boring 2. Used for enlarging only a limited portion of the
hole
(C) Counter boring 3. Used for finishing a hole
(D) Counter sinking 4. Used for enlarging a hole
(a) 3 2 4 1 (b) 1 4 2 3
(c) 3 4 2 1 (d) 1 2 4 3
IES 1992
Shell reamers are mounted on
(a) Tool holders (b) Amour plates
(c) Arbor (d) Shanks
Ans. (c)
IES 1993
The main purpose of boring operation, as compared
to drilling is to:
(a) Drill a hole
(b) Finish the drilled hole
(c) Correct the hole
(d) Enlarge the existing hole
Ans. (d)
IES 1994
Enlarging an existing circular hole with a rotating
single point tool is called
(a) Boring (b) Drilling
(c) Reaming (d) Internal turning.
Ans. (a)
Set-2
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IES 1992
Which of the machine tools can be used for boring
1. Lathe
2. Drilling machine
3. Vertical milling machine
4. Horizontal milling machine
(a) 1, 2, 3 (b) 1, 3, 4
(c) 2 and 4 (d) 1, 2, 3, 4
Ans. (a)
IES 2000
Which one of the following sets of tools or tools and
processes are normally employed for making large
diameter holes?
(a) Boring tool
(b) BTA t l (B i d t i i ti ) d (b) BTA tools (Boring and trepanning association) and
gun drill
(c) Gun drill and boring tool
(d) Boring tools and trepanning
Ans. (d)
IES 1996
Which of the following statements are correct?
1. A boring machine is suitable for a job shop.
2. A jig boring machine is designed specially for doing
more accurate work when compared to a vertical
illi hi milling machine.
3. A vertical precision boring machine is suitable for
boring holes in cylinder blocks and liners.
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
Ans. (a)
IES 1995
The effects of setting a boring tool above centre
height leads to a/an.
(a) Increase in the effective rake angle and a decrease in
the effective clearance angle.
(b) I i b th ff ti k l d ff ti (b) Increase in both effective rake angle and effective
clearance angle.
(c) Decrease in the effective rake angle and an increase
in the effective clearance angle.
(d) Decrease in both effective rank angle and effective
clearance angle. Ans. (c)
JWM2010
Considerthefollowingoperationsregardingboring
machines:
1.Counterboring
2.Countersinking
3.Trepanning
Whichoftheaboveoperationsis/arecorrect?
(a)1,2and3 (b)1and2only
(c)2and3only (d)1only
Ans.(a)
IES 2007
Among the following machining processes, which
can be used for machining flat surfaces?
1. Shaping 2. Milling 3. Broaching
(c) 2 and 3 only (d) 1, 2 and 3
Ans. (d)
Set-2
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IES 1993
Assertion (A): Soluble oils are employed with
broaching machine.
Reason (R): Soluble oils have excellent cooling
effect.
IES 1993,2001
Assertion (A): No separate feed motion is required
during broaching.
Reason (R): The broaching machines are generally
hydraulically operated.
IES 2001
The screw and nut in a broaching machine are
changed from square thread to ACME thread. The
power requirement of the machine at the same
r.p.m. will
(a) Remain same (a) Remain same
(b) Decrease
(c) Increase
(d) Depend on the operator
Ans. (c)
IAS 2004
Which one of the following is true for the last few
teeth of a broach which are meant for fine
finishing?
(a) They have equal diameter
(b) Th h i i di t (b) They have increasing diameter
(c) They have decreasing diameter
(d) They have alternately increasing and decreasing
diameter.
Ans. (a)
IES 2005
Match List I (Tool) with List II (Element of Tool) and
select the correct answer using the code given below the
Lists: Ans. (c)
List I List II
A Broach 1. Tang
B. Reamer 2. Pilot
C. Drill 3. Front taper
D. Carbide insert face mill 4. Bond
5. Sweeper tooth
(a) 2 5 1 3 (b) 1 3 4 5
(c) 2 3 1 5 (d) 1 5 4 3
IES 2002
Match List I with List II and select the correct answer:
List I (Machine tool) List II (Features)
A. Lathe 1. Push or pull tool
B. Drilling machine 2. Rachet and pawl
mechanism mechanism
C. Shaper 3. Dividing head
D. Broaching machine 4. Hollowtapered spindle
5. Face plate Ans. (d)
(a) 2 4 5 1 (b) 5 3 2 4
(c) 2 3 5 4 (d) 5 4 2 1
Set-2
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1
Milling
BySKMondal
Example
AC50steelflatsurfaceofdimensions100mm 250
mmistobeproducedonahorizontalaxismilling
machine.AnHSSslabmillwitha100mmdiameter
and150mmwidthistobeusedforthepurpose.The
millingcutterhas8teeth. millingcutterhas8teeth.
Calculatethemachiningtimeassumingthatentire
stockcanberemovedinonedepthof2mm.
Given,
Feed,f=0.13mm/tooth,
Cuttingspeed,V=20m/min.
Ans.4.11min
GATE 1995
ListI List II
(Manufacturing Processes) (Condition)
(A) Finish turning 1. Backlash eliminator
(B) Forming 2. Zero rake
(C) Thread cutting 3. Nose radius
(D) Down milling 4. Lowspeed
(a) 2 3 4 1 (b) 3 4 1 2
(c) 1 2 3 4 (d) 4 1 2 3
Ans. (a)
GATE 1993
A milling cutter having 8 teeth is rotating at 150
rpm. If the feed per tooth is 0.1, the table speed in
mmper minute is
(a) 120 (b) 187
( ) (d) (c) 125 (d) 70
Ans. (a)
IES 2003
In milling machine, the cutting tool is held in
position by
(a) Chuck (b) Spindle
(c) Arbor (d) Tool holder
Ans. (c)
IES 2009
The arbor of a milling machine is used to hold
whichone of the following?
(a) Spindle (b) Overarm
(c) Cutting tool (d) Mandrel
Ans. (c)
Set-2
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IES 1994
Consider the following operations:
1. Cutting key ways on shafts
2. Cutting external screw threads.
3. Cutting teeth of spur gears
4. Cutting external splines.
Those which can be performed with milling cutters
would include
(a) 1 and 2 (b) 2,3 and 4
(c) 1 and 3 (d) 1,2,3 and 4 .
Ans. (d)
IES 1992
A set of eight form relieved milling cutters for each
module is provided to enable cutting of gears of
different
(a) Materials
(b) T h li l t (b) Types e.g. spur, helical, etc.
(c) Number of teeth
(d) Width of gears
Ans. (c)
IES 2007
What is the process of removing metal by a milling
cutter which is rotated against the direction of
travel of the work piece, called?
(a) Down milling (b) Up milling
( ) E d illi (d) F illi (c) End milling (d) Face milling
Ans. (b)
GATE 1992
In horizontal milling process. (up/down)
milling provides better surface finish and..
(updown) milling provides longer tool life.
Ans. down, down
IES 1997
In Up milling process,
1. The cutter starts the cut from the machined surface and
proceeds upwards.
2. The cutter starts the cut from the top surface and p
proceeds downwards.
3. The job is fed in a direction opposite to that of cutter
rotation.
4. The job is fed in the same direction as that of cutter
rotation.
Of these statements correct are:
(a) 1 and 3 (b) 1 and 4
(c) 2 and 3 (d) 2 and 4 Ans. (a)
IES 1995
Assertion (A): Up milling or climb milling is
commonly used for machining castings and
forgings.
Reason (R): Up milling can be done on universal
milling machines milling machines.
Set-2
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IES 2005
In upmilling operation, the undeformed chip thickness,
a) Is zero at the start of the cut and increases to a
maximum value just before the tooth disengages the
k i workpiece.
b) Increases to the maximum value at the centre of the
travel and decreases towards the end of tooth
engagement.
c) Has a maximum value just after the cut is started and
drops to zero at the end of the cut.
d) Remains unchanged. Ans. (a)
IES 1993
Climb milling is chosen while machining because
(a) The chip thickness increases gradually
(b) It enables the cutter to dig in and depth of cut
(c) The specific power consumption is reduced
(d) Better surface finish can be obtained
Ans. (d)
IES2010
Assertion (A): Climb or down milling operation ensures
smoother operation of the machine tool and longer tool life
as compared to the conventional up milling operation.
Reason (R): In climb or down milling operation, the
rotational motion of the cutter as well as the feed motion of
the work piece are in the same direction and the depth of the workpiece are in the same direction, and the depth of
cut is maximum at the entry point as the cutter engages the
workpiece.
explanation of A
(b) Both A and R are individually true but R is NOT the correct
explanation of A
IES 2002
Assertion (A): Virtually all modern milling machines
are capable of doing downmilling.
Reason (R): In downmilling the cutter tends to push
the work along and lift it upward from the table. This
action tends to eliminate any effect in looseness in the
feed screw and nut of the milling machine table and feed screw and nut of the milling machine table and
results in smooth cut.
explanation of A
IES 2004
The cutting speed of a milling cutter while cutting
brass is:
(a) 45 to 60 m/min (b) 30 to 40 m/min
(c) 25 to 35 m/min (d) 15 to 20 m/min
Ans. (a)
IES 2006
Gang milling is a
(a) Milling process for generating hexagonal surfaces
(b) Process of cutting gears
(c) Process in which two or more cutters are used
simultaneously
(d) Milling operation combined with turning
Ans. (c)
Set-2
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IES 2009
For machining, which one of the following gang
milling operations is employed?
(a) Threads
(b) Bores
(c) Grooves
(d) Steps on prismatic parts
Ans. (d)
IES 1995
In a milling operation two side milling cutters are
mounted with a desired distance between them so
that both sides of a work piece can be milled
simultaneously. This set up is called.
(a) Gang milling (b) Straddle milling (a) Gang milling (b) Straddle milling
(c) String milling (d) Side milling.
Ans. (b)
IES 2004
One brand of milling machine has the following two
index plates supplied along with the indexing head:
Plate 1: 15, 16, 17, 18, 19, 20 hole circles
Plate 2: 21, 23, 27, 29, 31, 33 hole circles
It is proposed to mill a spur gear of 28 teeth using simple It is proposed to mill a spur gear of 28 teeth using simple
indexing method. Which one of the following combinations
of index plate and number of revolutions is correct?
(a) Plate 1: 1 revolution and 9 holes in 18 hole circles
(b) Plate 2: 1 revolution and 9 holes in 21 hole circles
(c) Plate 2: 1 revolution and 9 holes In 33 hole circles
(d) Plate 1: 1 revolution and 9 holes In 15 hole circles
Ans. (b)
IES 2000
One of the index plates of a milling machine
dividing head has the following hole circles: 15; 16;
17; 18; 19; 20
A gear wheel of 34 teeth has to be milled by simple
indexing method To machine each tooth the index indexing method. To machine each tooth, the index
crank has to be rotated through
(a) 17 holes in the 20hole circle
(b) 18 holes in the 20hole circle
(c) 1 revolution and 3 holes in 17hole circle
(d) 1 revolution and 2 holes in 18hole circle
Ans. (c)
IES 1999
A straight teeth slab milling cutter of 100 mm
diameter and 10 teeth rotating at 200 r.p.m. is used
to remove a layer of 3 mmthickness froma steel bar.
If the table feed is 400 mm/minute, the feed per
tooth in this operationwill be tooth in this operationwill be
(a) 0.2 mm (b) 0.4 mm
(c) 0.5 mm (d) 0.6 mm
Ans. (a)
IES 2002
A side and face cutter 125 mm diameter has 10 teeth.
It operates at a cutting speed of 14 m/min with a
table traverse 100 mm/min. The feed per tooth of
the cutter is
(a) 10 mm (b) 2 86 mm (a) 10 mm (b) 2.86 mm
(c) 0.286 mm (d) 0.8 mm
Ans. (c)
Set-2
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IES 2004
Match List I (Milling problem) with List II (Probable
causes) and select the correct answer using the codes
given belowthe Lists:
List I List II Ans. (b)
A. Chatter 1. Too high feed
B. Poor surface finish 2. Lack of rigidity in machine
fixtures, bar or workpiece
C. Loss of accuracy 3. High cutting load
D. Cutter burrs 4. Radial relief too great
5. Not enough lubricant
(a) 2 1 5 3 (b) 2 1 3 5
(c) 4 5 2 3 (d) 4 2 3 5
IAS 2001
Which one of the following statements are correct in respect of
upmilling and downmilling?
1. In upmilling the cutter rotates in a direction opposite to that of
workpiece travel whereas in downmilling the cutter rotates in a
direction similar to that of workpiece travel.
2. In downmilling chip will be thin at the beginning and increase to a
maximum at the end of the cut and reverse will be the case for a chip
f d b ll
p
formed by upmilling.
3. Downmilling is desirable with milling cutters having a high radial
rake angle when compared to upmilling.
4. Downmilling forces the workpiece against the milling table to
exert more pressure while upmilling tends to lift the workpiece from the
table.
Codes:
(a) 1, 2 and 3 (b) 1, 2 and 4
(c) 3 and 4 (d) 1, 3 and 4 Ans. (d)
IAS 1998
Which of the following statements are true of face
milling?
1. Face milling cutter is held on an arbor.
2. It has two rake angles axial rake and radial rake.
3 The maximum chip thickness equals the feed per 3. The maximum chip thickness equals the feed per
tooth.
4. The chip thickness varies from a minimum at the
start of cut to a maximumat the end of cut.
Codes :
(a) 1 and 2 (b) 2 and 3
(c) 2 and 4 (d) 3 and 4 Ans. (b)
IAS 2001
Which of the following mechanisms are suitable for
indexing the table of rotary transfer line?
1. Rack and pinion 2. Ratchet and pawl
3. Lead screw 4. Geneva mechanism
Select the correct answer by using the codes given below:
Codes:
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1, 3 and 4 (d) 1, 2 and 4 Ans. (d)
IAS 2000
Consider the following mechanisms:
1. Geneva gearing
2. Rack and pinion
3. Ratchet and pawl
Which of these mechanisms are used to index the work
table on a transfer machine?
(a) 1 and 2 (b) 2 and 3
(c) 1 and 3 (d) 1, 2 and 3
Ans. (d)
IAS 1994
A standard dividing head is equipped with the
following index plates
1. Plate with 12, 16, 17, 18, 19, 20 holes circles
2. Plate with 21, 23, 27, 29, 31, 33 holes circles
3. Plate with 37, 39, 41,43,47,49 holes circles
For obtaining 24 divisions on a work piece by simple
indexing
(a) Hole plate 2 alone can be used
(b) Hole plates 1 and 2 can be used
(c) Hole plates 1 and 3 can be used Ans. (d)
(d) Any of the three hole plates can be used
Set-2
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IAS 2003
A milling cutter of 70 mm diameter with 12 teeth is
operating at a cutting speed of 22 m/min and a feed
of 0.05 mm/tooth. The feed per minute is
(a) 110 m/min (b) 35 mm/min
(c) 6 mm/min (d) 60 mm/min
Ans (d)
IES1994
Whichoneofthefollowingoperationsiscarriedout
attheminimumcuttingvelocityifthemachinesare
equallyrigidandthetoolworkmaterialsarethe
same?
(a) Turning (a) Turning
(b) Grinding
(c) Boring
(d) Milling
Ans(d)
IES2011
MatchListIwithListIIandselectthecorrectanswerusing
thecodegivenbelowthelists: Ans(b)
ListI ListII
A.Lathe 1.Flute
Codes
A B C D A B C D
(a) 2 4 1 3 (b) 3 4 1 2
(c) 2 1 4 3 (d) 3 1 4 2
B.Shaper 2.Universalindexing
C.Drillingmachine 3.Leadscrew
D.Millingmachine 4.Rockerarm
IES 2002
answer:
List I (Machine tools) List II (Machine tool parts)
A. Lathe 1. Lead strew
B. Milling machine 2. Rocker arm
C. Shaper 3. Universal indexing
D. Drilling machine 4. Flute Ans (d)
(a) 4 2 3 1 (b) 1 3 2 4
(c) 4 3 2 1 (d) 1 2 3 4
Ch7:Milling
QNo Option Q.No Option
1 B 7 D
2 B 8 D
3 D 9 A
4 A 10 D
5 C 11 C
6 D 12 D
Set-2
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Shaper,Planner,Slotter Shaper,Planner,Slotter
BySKMondal
GATE 2005
A 600 mm x 30 mm flat surface of a plate is to be
finish machined on a shaper. The plate has been
fixed with the 600 mm side along the tool travel
direction. If the tool overtravel at each end of the
plate is 20 mm, average cutting speed is 8 m/min, plate is 20 mm, average cutting speed is 8 m/min,
feed rate is 0.3 mm/stroke and the ratio of return
time to cutting time of the tool is 1:2, the time
required for machining will be
(a) 8 minutes (b) 12 minutes
(c) 16 minutes (d) 20 minutes
Ans. (b)
IES 2004
Consider the following alignment tests on machine
tools
1. Straightness 2. Flatness
3. Run out 4. Parallelism
Which of the above alignment tests on machine tools are
common to both lathe and shaper?
(a) 1 and 2 (b) 2 and 3
(c) 3 and 4 (d) 1 and 4
Ans. (d)
IES 2001
In a shaper machine, the mechanism for tool feed is
(a) Geneva mechanism
(b) Whitworth mechanism
(c) Ratchet and Pawl mechanism
(d) Ward Leonard system
Ans. (c)
IES2010
Assertion (A): Longitudinal cutting motion of the
tool and crosswise feed motion of the job generates
flat surfaces in planning process.
Reason (R): Jobs used in planning machines are
generally long and heavy compared to shaping. generally long and heavy compared to shaping.
IES 1997
Which of the following are the advantages of a
hydraulic shaper over a mechanically drivenshaper?
1. More strokes per minute can be obtained at a given
cutting speed.
Th tti t k h d fi it t i i t 2. The cutting stroke has a definite stopping point.
3. It is simpler in construction.
4. Cutting speed is constant throughout most of the
cutting stroke.
(a) 1 and 2 (b) 1 and 4
(c) 2 and 4 (d) 1, 3 and 4 Ans. (b)
Set-2
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IES 1995
In a mechanical shaper, the length of stroke is
increased by
(a) Increasing the centre distance of bull gear and crank
pin
(b) D i th t di t f b ll d (b) Decreasing the centre distance of bull gear and
crank pin
(c) Increasing the length of the ram
(d) Decreasing the length of the slot in the slotted lever
Ans. (a)
IES 1994
Given that, average cutting speed = 9 m/min, the
return time to cutting time ratio is = 1 : 2, the feed
rate = 0.3 mm/stroke, the clearance at each end of
cut = 25 mm and that the plate is fixed with 700 mm
side along the direction of tool travel, the time side along the direction of tool travel, the time
required for finishing one flat surface of a plate of
size 700 x 30 mm in a shaper, will be
(a) 10 min (b) 12.5 min Ans. (b)
(c) 15 min (d) 20 min
IAS 1995
Size of a shaper is given by
(a) Stroke length (b) Motor power
(c) Weight of the machine (d) Table size
Ans. (a)
IAS 1994
Stroke of a shaping machine is 250 mm. It makes 30
double strokes per minute. Overall average speed of
operation is
(a) 3.75 m/min (b) 5.0 m/min
( ) / i (d) / i (c) 7.5 m/min (d) 15 m/min
Ans. (d)
Set-2
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GearManufacturing
BySKMondal
IES 1999
Consider the following processes for the
manufacture of gears:
1. Casting
2. Powder metallurgy
3. Machining from bar stock
4. Closed die forging
The correct sequence in increasing order of bending
strength of gear teeth is
(a) 1, 2, 3, 4 (b) 1, 2, 4, 3
(c) 2, 1, 4, 3 (d) 2, 1, 3, 4 Ans. (a)
IES 2006
Which of the following is/are used for cutting
internal gears?
1. Gear hobber 2. Gear shaper
3. Rack cutter 4. Jig borer
(a) Only 1 and 2 (b) Only 2 and 3
(c) Only 1 and 4 (d) Only 2
Ans. (d)
IES 2005
In helical milling, the ratio of the circumference of
the gear blank to the lead of the helix determines
the:
(a) Proper speed to use
(b) P f d d d th f t i d (b) Proper feed and depth of cut required
(c) Angle setting of the machine table
(d) Gear ratio for table screwand dividing head
Ans. (c)
IES2010
Match List I with List II and select the correct answer using
the code given belowthe lists: Ans. (d)
List I List II
(Type of work) (Manufacturing)
A. High rate production of worm Gears and 1. Gear shaving
wormwheel
B. Generating internal gears and Cluster gears 2. Gear milling
C. Finishing of gear tooth profiles 3. Gear hobbing
D. Repair and piece production of gears 4. Gear shaping
A B C D A B C D
(a) 2 1 4 3 (b) 3 1 4 2
(c) 2 4 1 3 (d) 3 4 1 2
IES 1996
Gear cutting on a milling machine using an involute
profile cutter is a
(a) Gear forming process
(b) Gear generating process.
(c) Gear shaping process
(d) Highly accurate gear producing process.
Ans. (a)
Set-2
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IES 2000
Which one of the following processes of gear
manufacture results in best accuracy of the involute
gear tooth profile?
(a) Milling
(b) H bbi (b) Hobbing
(c) Rotary gear shaper
(d) Rack type gear shaper
Ans. (b)
IES 2009
Assertion (A): Gears produced by employing form
cutting principle using gearmilling cutter on a milling
machine are not very accurate.
Reason (R): Production of the correct gear tooth profile
employing formcutting principle would require a
separate cutter for cutting different numbers of teeth separate cutter for cutting different numbers of teeth
even for the same module and also errors are associated
with inaccurate operation of indexing mechanism.
(a) Both A and R are true and R is the correct explanation of
A
(b) Both A and R are true but R is NOT the correct
explanation of A
IES 1996
Consider the following processes of gear
manufacture:
1. Milling with formcutter
2. Rack type gear shaper (gear planer)
3. Rotary gear shaper (gear shaper)
4. Gear hobbing
The correct sequence of these processes in increasing
order of accuracy of involute profile of the gear
(a) 3, 2, 4, 1 (b) 2, 3, 4, 1
(c) 3, 2, 1, 4 (d) 2, 3, 1, 4 Ans. (d)
IES 2009
By which one of the following machines the teeth of
an internal spur gear can be cut accurately?
(a) Milling machine
(b) Slotting machine
(c) Hobbing machine
(d) Gearshaping machine
Ans. (d)
IES 2004
Gear shaping is a process of manufacturing gears.
Which one of the following principles is employed by it?
(a) Formcutting with cutter
(b) Generating tooth formwith a reciprocating cutter
(c) Generating tooth form by a rotating cutter
(d) Generating form with a reciprocating and revolving
cutter
Ans. (d)
IES 1992
In gear hobbing
(a) Only hob rotates
(b) Only gear blank rotates
(c) Both hob and gear blank rotate
(d) Neither hob nor gear blank rotates
Ans. (c)
Set-2
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3
IES 2003
A spur gear of 40 teeth is machined in a gear
hobbing machine using a double start hob cutter.
The speed ratio between the hob and the blank is
(a) 1:20 (b) 1:40
( ) (d) (c) 40: 1 (d) 20: 1
Ans. (d)
IES 2008
Which machining processes are used for gear
manufacture?
1. Form milling 2. Broaching
3. Roll forming 4. Hobbing
(a) 1, 2 and 3 (b) 1, 3 and 4
(c) 1, 2 and 4 (d) 2, 3 and 4
Ans. (c)
IES 1999
A 60teeth gear when hobbed on a differential
hobber with a twostart hob, the index change gear
ratio is governed by which one of the following
kinematic balance equations?
(a) 1 revolution of gear blank = 1/60 of hob revolutions (a) 1 revolution of gear blank = 1/60 of hob revolutions
(b) 1 revolution of gear blank = 2/60 of hob revolutions
(c) 1 revolution of hob = 2/60 of blank revolutions
(d) 1 revolution of hob = 1/60 of blank revolutions
Ans. (c)
IES 1997
Which of the following motions are needed for spur
gear cutting with a hob?
1. Rotary motion of hob
2. Linear axial reciprocator motion of hob
3. Rotary motion of gear blank
4. Radial advancement of hob.
(a) 1, 2 and 3 (b) 1, 3 and 4
(c) 1, 2 and 4 (d) 2, 3 and 4
Ans. (a)
IES 2007
Which of the following methods are gear generating
processes?
1. Gear shaping
2. Gear hobbing
3. Gear milling
(a) 1, 2 and 3 (b) 1 and 2 only
Ans. (b)
IES 1993
Internal gear cutting operation can be performed by
(a) Milling
(b) Shaping with rack cutter
(c) Shaping with pinion cutter
(d) Hobbing
Ans. (c)
Set-2
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IAS 1998
Assertion (A): Internal gears are cut on a gear
shaper.
Reason (R): Hobbing is not suitable for cutting
internal gear.
Ans. (b)
IES 2006
Which of the following cannot be cut by hobbing
process?
(a) Helical gears (b) Bevel gears
(c) Wormgears (d) Spur gears
Ans. (b)
IES 1996
For the manufacture of full depth spur gear by
hobbing process, the number of teeth to be cut = 30,
module = 3 mm and pressure angle = 20. The radial
depth of cut to be employed should be equal to
(a) 3 75 mm (b) 4 50 mm (a) 3.75 mm (b) 4.50 mm
(c) 6.00 mm (d) 6.75 mm
Ans. (d)
IES 1995
While cutting helical gears on a nondifferential
gear hobber, the feed change gear ratio is
(a) Independent of index change gear ratio
(b) dependent on speed change gear ratio
(c) Interrelated to index change gear ratio
(d) Independent of speed and index change gear ratio
Ans. (c)
IES 1992
Gear burnishing process for
(a) Removing residual stresses from teeth roots
(b) Surface finishing
(c) Undercut gears
(d) Cycloidal gears
Ans. (b)
IAS 2003
Which one of the following is not a feature of gear
hobbing process?
(a) High rate of production
(b) Generation of helical gears
(c) Very accurate tooth profile
(d) Generation of internal gears
Ans. (d)
Set-2
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IAS 2001
Consider the following motions and setting in a
hobbing machine:
1. Hob rotation
2. Job rotation
3. Axial reciprocating hob rotation
4. Tilting of hob to its helix angle
Which of these motions and setting in a hobbing
machine are required to machine a spur gear?
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1, 2 and 4 (d) 1, 3 and 4 Ans. (c)
IES 1994
Consider the following machine tools:
1. Hobbing machine
2. Gear shaping machine
3. Broaching machine.
The teeth of internal spur gears can be cut in
(a) 1, 2 and 3 (b) 1 and 2
(c) 1 and 3 (d) 2 and 3
Set-2
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Grinding&Finishing Grinding&Finishing
BySKMondal
GATE 1995
Among the conventional machining processes,
maximumspecific energy is consumed in
(a) Turning (b) Drilling
(c) Planning (d) Grinding
Ans. (d)
GATE 1998
Ideal surface roughness, as measured by the
maximum height of unevenness, is best achieved
when, the material is removed by
(a) An end mill
(b) A i di h l (b) Agrinding wheel
(c) A tool with zero nose radius
(d) A ball mill
Ans. (b)
GATE 1998
In machining using abrasive material, increasing
abrasive grainsize
(a) Increases the material removal rate
(b) Decreases the material removal rate
(c) First decreases and then increases the material
removal rate
(d) First increases and then decreases the material
removal rate
Ans. (d)
GATE 2000
Abrasive material used in grinding wheel selected
for grinding ferrous alloys is
(a) Silicon carbide (b) Diamond
(c) Aluminiumoxide (d) Boron carbide
Ans. (c)
GATE 2002
The hardness of a grinding wheel is determined by
the
(a) Hardness of abrasive grains
(b) Ability of the bond to retain abrasives
(c) Hardness of the bond
(d) Ability of the grinding wheel to penetrate the work
piece
Ans. (b)
Set-2
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GATE 2004
Typical machining operations are to be performed on hard
tomachine materials by using the processes listed below.
Choose the best set of OperationProcess combinations
Operation Process
P. Debarring (internal surface) 1. Plasma Arc Machining
Q Die sinking 2 Abrasive Flow Machining Q. Die sinking 2. Abrasive Flow Machining
R. Fine hole drilling in thin sheets 3. Electric Discharge
Machining
S. Tool sharpening 4. Ultrasonic Machining
5. Laser beam Machining
Ans. (d) 6. Electrochemical Grinding
(a) P1 Q5 R3 S4 (b) P1 Q4 R1 S2
(c) P5 Q1 R2 S6 (d) P2 Q3 R5 S6
GATE 2006
If each abrasive grain is viewed as a cutting tool,
then which of the following represents the cutting
parameters in common grinding operations?
(a) Large negative rake angle, low shear angle and high
cutting speed cutting speed
(b) Large positive rake angle, low shear angle and high
cutting speed
(c) Large negative rake angle, high shear angle and low
cutting speed
(d) Zero rake angle, high shear angle and high cutting
speed Ans. (a)
GATE 1997
List I List II
(A) Grinding 1. Surface for oil retention
(B) Honing 2. Surface for max. load
capacity
(C) Superfinishing 3. Surface of limiting friction
D) Burnishing 4. Surface of matte finish
5. Surface for pressure sealing
6. Surface for interference fit.
Ans. (A) 3, (B) 1, (C)2, (D)5
IES 2005
Consider the following statements in respect of
grinding?
1. The pitch of the grit cutting edges is larger than the
pitch of the milling cutter.
Th tti l f th it h d 2. The cutting angles of the grits have a random
geometry.
3. The size of the chip cuts is very small for grinding.
(a) 1 and 2 (b) 2 and 3
(c) 1 and 3 (d) 1, 2 and 3 Ans. (d)
IES 2009
Which one of the following is NOT used as abrasive
material in grinding wheels?
(a) Aluminiumoxide
(b) Silicon carbide
(c) Cubic boron nitride
(d) Manganese oxide
Ans. (d)
IES 1997
Which one of the following materials is used as the
bonding material for grinding wheels?
(a) Silicon carbide
(b) Sodiumsilicate
(c) Boron carbide
(d) Aluminumoxide
Ans. (b)
Set-2
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IES 1996
Grinding wheel is said to be loaded when the
(a) Metal particles get embedded in the wheel surface
blocking the interspaces between cutting grains.
(b) Bonding material comes on the surface and the
h l b bl t wheel becomes blunt.
(c) Work piece being ground comes to a stop in
cylindrical grinding.
(d) Grinding wheel stops because of very large depth of
cut
Ans. (a)
IES 2001
Specific cutting energy is more in grinding process
compared to turning because
(a) Grinding (cutting) speed is higher
(b) The wheel has multiple cutting edges (grains)
(c) Plaguing force is significant due to small chip size
(d) Grinding wheel undergoes continuous wear
Ans. (b)
IES 1996
Specific energy requirements in a grinding process
are more than those in turning for the same metal
removal rate because of the
(a) Specific pressures between wheel and work being
high high.
(b) Size effect of the larger contact areas between wheel
and work.
(c) High cutting velocities
(d) High heat produced during grinding.
Ans. (d)
IES 1994
The ratio of thrust force to cutting force is nearly 2.5
in
(a) Turning (b) Broaching
(c) Grinding (d) Plain milling
Ans. (c)
IES 1992
Assertion (A): Vitrified bond is preferred for thin
grinding wheels.
Reason (R): Vitrified bond is hard brittle.
t l ti f A correct explanation of A
Ans. (a)
IES 2000
Assertion (A): The ratio of cutting force to thrust force is
very high in grinding process as compared to other
machining processes.
Reason (R): Random orientation and effective negative
rake angles of abrasive grains increase the cutting force
and adversely affect the cutting action and promote and adversely affect the cutting action and promote
rubbing action.
explanation of A
Set-2
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IES 1995
Soft materials cannot be economically grind due to
(a) The high temperatures involved
(b) Frequent wheel clogging
(c) Rapid wheel wear
(d) Lowwork piece stiffness
Ans. (b)
IES2010
In relation to the peripheral or surface
speeds of the grinding wheel and that of the
workpiece in cylindrical grinding of alloy
steel workpieces, the grinding wheel speed is
(a) Less than the speed of the workpiece
(b) Same as the speed of the workpiece
(c) Double the speed of the workpiece
(d) 65 to 75 times the speed of the workpiece.
Ans. (d)
IES 2009
Given that the peripheral speed of the grinding
wheel of 100 mm diameter for cylindrical grinding
of a steel work piece is 30 m/s, what will be the
estimated rotational speed of the grinding wheel in
revolutionper minute (r.p.m.)? revolutionper minute (r.p.m.)?
(a) 11460 (b) 5730
(c) 2865 (d) 95
Ans. (b)
IES 2002
Which of the following materials are used in
grinding wheel?
1. Aluminiumoxide
2. Cubic boron nitride
3. Silicon carbide
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
Ans. (a)
IES 2001
The marking on a grinding wheel is '51 A 36 L 5 V 93'.
The code '36' represents the
(a) Structure
(b) Grade
(c) Grain size
(d) Manufacturer's number
Ans. (c)
IES 2000
The sequence of markings "S 14 K 14 S" on a grinding
wheel represents respectively
(a) Bond type, structure, grade, grain size and abrasive
type
(b) Ab i t i i d t t d b d (b) Abrasive type, grain size, grade, structure and bond
type
(c) Bond type, grade, structure, grain size and abrasive
type
(d) Abrasive type, structure, grade, grain size and bond
type
Ans. (b)
Set-2
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IES 1995
In the grinding wheel of A 60 G 7 B 23, B stands for
(a) Resinoid bond (b) Rubber bond
(c) Shellac bond (d) Silicate bond
Ans. (a)
IES 1993
Tool life in the case of a grinding wheel is the time
(a) Between two successive regrinds of the wheel
(b) Taken for the wheel to be balanced
(c) Taken between two successive wheel dressings
(d) Taken for a wear of 1mmon its diameter
Ans. (c)
IES 2001
Assertion (A): Hard wheels are chosen for grinding
hard metals.
Reason (R): In hard wheels only the abrasive grains
are retained for long time.
Ans. (d)
IES 1994
grinding of high carbonsteel:
1. Grinding at high speed results in the reduction of
chip thickness and cutting forces per grit.
Al i i id h l l d 2. Aluminiumoxide wheels are employed.
3. The grinding wheel has to be of open structure.
Of these statements
(a) 1, 2 and 3 are correct (b) 1 and 2 are correct
Ans. (b)
IES 1999
Consider the following reasons:
1. Grinding wheel is soft
2. RPMof grinding wheel is too low
3. Cut is very fine
4. An improper cutting fluid is used
A grinding wheel may become loaded due to reasons
stated at
(a) 1 and 4 (b) 1 and 3
(c) 2 and 4 (d) 2 and 3
Ans. (c)
IES 1993
In centre less grinding, the work piece centre will be
(a) Above the line joining the two wheel centres
(b) Belowthe line joining the two wheel centres
(c) On the line joining the two wheel centres
(d) At the intersection of the line joining the wheel
centres with the work plate plane.
Ans. (a)
Set-2
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IES 2000
Consider the following advantages:
1. Rapid process
2. Work with keyways can be ground
3. No work holding device is required.
Which of these are the advantages of centre less
grinding?
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
Ans. (d)
IES 1996
A grinding wheel of 150 mm diameter is rotating at
3000 rpm. The grinding speed is
Ans. (a)
IES 1993
Consider the following parameters:
1. Grinding wheel diameter.
2. Regulating wheel diameter.
3. Speed of the grinding wheel.
4. Speed of the regulating wheel.
5. Angle between the axes of grinding and regulating
wheels.
Among these parameters, those which influence the
axial feed rate in centreless grinding would include
(a) 2, 4 and 5 (b) 1, 2 and 3
(c) 1, 4 and 5 (d) 3, 4 and 5 Ans. (a)
IES 2007
Honing Process gives surface finishof what order?
(a) 10 m (CLA) (b) 1.0 m (CLA)
(c) 0.1 m (CLA) (d) 0.01 m (CLA)
Ans. (c)
IES 1992
CLAvalue for Honing process is
(a) 6 (b) 0.05 3.0
(c) 0.05 1.0 (d) 0.025 0.1
Ans. (c)
IES 2001
Match ListI (Cutting Tools) with ListII (Applications)
belowthe lists:
List I List II
A. Trepanning tool 1. For surface finishing by
h i honing
B. Side milling cutter 2. For machining gears
C. Hob cutter 3. For cutting keyways in shafts
D. Abrasive sticks 4. For drilling large diameter
holes Ans. (b)
(a) 1 3 2 4 (b) 4 3 2 1
(c) 1 2 3 4 (d) 4 2 3 1
Set-2
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IES 1992
A surface finish of 0.025 0.1 micrometer CLA values
is to be produced. Which machining process would
you recommend?
(a) Grinding (b) Rough turning
( ) L i (d) H i (c) Lapping (d) Honing
Ans. (c)
IES 1992
Buffing wheels are mode of
(a) Softer metals (b) Cotton fabric
(c) Carbon (d) Graphite
Ans. (b)
IAS 2004
The size effect refers to the increase in specific
cutting energy at low values of undeformed chip
thickness. It is due to which one of the following?
(a) Existence of ploughing force
(b) W k h d i (b) Work hardening
(c) High strain rate
(d) Presence of high friction at chiptool interface.
Ans. (a)
IAS 2000
Consider the following statements in respect of a
grinding wheel of specification, 51A 36L7R23,
using the standard alphanumeric codification:
1. Abrasive used in the wheel is aluminumoxide
Th i i f b i i di 2. The grain size of abrasive is medium
3. The wheel grade is medium hard
4. It has an open structure
5. It has resinoid as bonding agent
Which (If these statements are correct?
(a) 1, 2 and 3 (b) 1, 3 and 4
(c) 2, 3 and 5 (d) 1, 4 and 5 Ans. (a)
IAS 1999
Assertion (A): The grade of a grinding wheel is a
measure of hardness of the abrasive used for the
wheel.
Reason (R): Grading is necessary for making right
selection of the wheel for a particular work selection of the wheel for a particular work.
IAS 2001
The setup for internal centreless grinding consists of a
regulating wheel, a pressure roll and a support roll, between
which the tubular workpiece is supported with the grinding
wheel within the tube, wherein
1.The grinding wheel, workpiece and regulating wheel centers
must lie on one line must lie on one line
2.The directions of rotation of workpiece and grinding wheel are
same
3.The directions of rotation of pressure roll, support roll and
regulating wheel are same
4.The directions of rotation of grinding wheel and regulating
wheel are same
(a) 1, 2 and 3 (b) 1, 3 and 4
(c) 2 and 3 (d) 3 and 4 Ans. (a)
Set-2
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IAS 1997
Which of the following pairs are correctly matched?
1. Drill press : Trepanning
2. Centreless grinding: Through feeding
3. Capstan lathe: Ram type turret
Codes:
(a) 1 and 2 (b) 1, 2 and 3
(c) 1 and 3 (d) 2 and 3
Ans. (b)
IAS 2007
using the code given belowthe Lists:
List I List II
(Machine Tool/ Cutting Tool) (Part/ Characteristics)
A. Screwcutting lathe1. Self locking taper g g p
B. Drill 2. Chasing dial
C. End mill 3. Wiper insert
D. Grinding wheel 4. Self releasing taper
5. Balance weights Ans. (b)
(a) 4 5 3 1 (b) 2 1 4 5
(c) 4 1 3 5 (d) 2 5 4 1
IAS 1999
Which one of the following processing sequences
will give the best accuracy as well as surface finish?
(a) Drilling, reaming and grinding
(b) Drilling, boring and grinding
(c) Drilling, reaming and lapping
(d) Drilling, reaming and electroplating
Ans. (c)
IAS 2001
Which one of the following grinding wheels (with
Grade, Grit and Bond) is suitable for cutter
grinding?
(a) K 60 vitrified (b) K 320 vitrified
( ) T 6 i id (d) T i id (c) T 60 resinoid (d) T 320 resinoid
Ans.(a)
Set-2
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NTMM NTMM
BySKMondal
GATE 2006
Arrange the processes in the increasing order of
their maximum material removal rate.
Electrochemical Machining (ECM)
Ultrasonic Machining (USM)
Electron Beam Machining (EBM) Electron Beam Machining (EBM)
Laser Beam Machining (LBM) and
Electric Discharge Machining (EDM)
(a) USM, LBM, EBM, EDM, ECM
(b) EBM, LBM, USM, ECM, EDM
(c) LBM, EBM, USM, ECM, EDM
(d) LBM, EBM, USM, EDM, ECM Ans. (d)
IES 2007
Consider the following statements in relation to the
unconventional machining processes:
1. Different forms of energy directly applied to the
piece to have shape transformation or material removal
fromwork surface fromwork surface.
2. Relative motion between the work and the tool is
essential.
3. Cutting tool is not in physical contact with work
piece.
(a) 1 and 2 only (b) 1, 2 and 3 only
(c) 2 and 3 only (d) 1 and 3 only Ans. (d)
IES 2009
Which one of the following statements is correct in
respect of unconventional machining processes?
(a) The cutting tool is in direct contact with the job
(b) The tool material needs to be harder than the job
t i l material
(c) The tool is never in contact with the job
(d) There has to be a relative motion between the tool
and the job
Ans. (c)
IAS 2002
Match List I (Processes) with List II (Tolerances
obtained) and select the correct answer using the codes
List I List II
(Processes) (Tolerances obtained)
A. Plasma Arc machining 1. 75 microns
B. Laser Beam machining 2. 25 microns
C. Abrasive Jet machining 3. 50 microns
D. Ultrasonic machining 4. 125 microns Ans. (c)
(a) 4 1 3 2 (b) 3 2 4 1
(c) 4 2 3 1 (d) 3 1 4 2
PSU
ECMcannotbeundertakenfor
(a)steel
(b)Nickelbasedsuperalloy
(c)Al2O3 (c)Al2O3
(d)Titaniumalloy
Ans.(c)
Set-2
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PSU
Commercial ECM is carried out at a combination
of
(a) lowvoltage high current
(b) lowcurrent lowvoltage
(c) high current high voltage
(d) lowcurrent lowvoltage
Ans. (a)
Example
UsingECMremove5cm
3
/minfromanironworkpiece,
whatcurrentisrequired?
Atomicweightofiron56,density7.8g/cm
3
valency,2
Example
Calculate the material removal rate and the
electrode feed rate in the electrochemical
machining of an iron surface that is 25 mm 25 mm
in crosssection using NaCl in water as electrolyte.
The gap between the tool and the workpiece is 0.25 The gap between the tool and the workpiece is 0.25
mm. The supply voltage is 12 V DC. The specific
resistance of the electrolyte is
For iron, Valency, Z = 2
Atomic weight, A = 55.85
Density, =
3 cm
3
7860 kg / m
Example(GATE2009)
Electrochemicalmachiningisperformedtoremove
materialfromanironsurfaceof20mmx20mmunder
thefollowingconditions:
Interelectrodegap = 0.2mm
S l V lt (DC) V SupplyVoltage(DC) = 12V
Specificresistanceofelectrolyte =2cm
AtomicweightofIron = 55.85
Valency ofIron = 2
Faraday'sconstant = 96540Coulombs
Thematerialremovalrate(ing/s)is
Example
Composition of a Nickel superalloy is as follows:
Ni = 70.0%, Cr = 20.0%, Fe = 5.0% and rest Titanium
Calculate rate of dissolution if the area of the tool is 1500
mm
2
and a current of 1000 A is being passed through the
cell Assume dissolution to take place at lowest valancy cell. Assume dissolution to take place at lowest valancy
of the elements.
Example
The electrochemical machining of an iron surface that is
25 mm 25 mm in crosssection using NaCl in water as
electrolyte. The gap between the tool and the workpiece
is 0.25 mm. The supply voltage is 12 V DC. The specific
resistance of the electrolyte is 3 cm. resistance of the electrolyte is 3 cm.
Estimate the electrolyte flow rate. Specific heat of the
electrolyte is given as 0.997 cal/gC. The ambient
temperature is 35C and the electrolyte boiling
temperature, is 95C.
Density, = 7860 kg/m
3
Set-2
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Example
In ECM operation of pure iron an equilibrium gap of 2
mm is to be kept. Determine supply voltage, if the total
overvoltage is 2.5 V. The resistivity of the electrolyte is 50
mmand the set feed rate is 0.25 mm/min.
IES 2000
In electrochemical grinding,
1. A rubber bonded alumina grinding wheel acts as the
cathode and the workplace as the anode.
2 A copper bonded alumina grinding wheel acts as the 2. A copper bonded alumina grinding wheel acts as the
cathode and the work piece as the anode.
3. Metal removal takes place due to the pressure
applied by the grinding wheel.
4. Metal removal takes place due to electrolysis.
(a) 1 and 3 (b) 2 and 4
(c) 2 and 3 (d) 1 and 3 Ans. (b)
GATE 2008
A researcher conducts electrochemical machining
(ECM) on a binary alloy (density 6000 kg/m
3
) of iron
(atomic weight 56, valency 2) and metal P (atomic
weight 24, valency 4). Faraday's constant = 96500
coulomb/mole. Volumetric material removal rate of
the alloy is 50 mm
3
/s at a current of 2000 A. The
percentage of the metal P in the alloy is closest to
(a) 40 (b) 25 (c) 15 (d) 79 Ans. (b)
GATE 2001
In ECM, the material removal is due to
(a) Corrosion
(b) Erosion
(c) Fusion
(d) Ion displacement
Ans. (d)
GATE 1997
Selection electrolyte for ECM is as follows:
(a) Nonpassivating electrolyte for stock removal and
passivating electrolyte for finish control
(b) Passivating electrolyte for stock removal and non
i ti l t l t f fi i h t l passivating electrolyte for finish control
(c) Selection of electrolyte is dependent on current
density
(d) Electrolyte selection is based on tool work
electrodes
Ans. (d)
GATE 1992
The two main criteria for selecting the electrolyte in
Electrochemical Machining (ECM) is that the
electrolyte should
(a) Be chemically stable
(b) N t ll di l ti f th d t i l (b) Not allowdissolution of cathode material
(c) Not allowdissolution of anode material
(d) Have high electrical conductivity
Ans. (a, d)
Set-2
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GATE 1997
Inter electrode gap in ECG is controlled by
(a) Controlling the pressure of electrolyte flow
(b) Controlling the applied static load
(c) Controlling the size of diamond particle in the wheel
(d) Controlling the texture of the work piece
Ans. (c)
IES 2002
Assertion (A): In ECM, the shape of the cavity is the
mirror image of the tool, but unlike EDM, the tool
wear in ECM is less.
Reason (R): The tool in ECM is a cathode.
IES 1997
Which one of the following processes does not
cause tool wear?
(a) Ultrasonic machining
(b) Electrochemical machining
(c) Electric discharge machining
(d) Anode mechanical machining
Ans. (b)
IES2011Conventional
Discuss the effects of insufficient dielectric and
electrolyte circulation in the interelectrode gap on the
Electric Discharge machining and Electro Chemical
Machining process respectively. [5 Marks]
IES2009Conventional
i. What is the principle of metal removal in EDM
process?
ii. Describe the process with the help of sketch.
iii. List advantages and limitations of the system.
[15marks]
GATE 1994
Electric discharge machining is more efficient
process than Electrochemical machining for
producing large noncircular holes.
The above statement is
( ) T (a) True
(b) False
(c) Cant say
(d) Insufficient data
Ans. (a)
Set-2
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GATE 2004
The mechanism of material removal in EDM
process is
(a) Melting and Evaporation
(b) Melting and Corrosion
(c) Erosion and Cavitation
(d) Cavitation and Evaporation
Ans. (a)
GATE 2003
As tool and work are not in contact in EDMprocess
(a) No relative motion occurs between them
(b) No wear of tool occurs
(c) No power is consumed during metal cutting
(d) No force between tool and work occurs
Ans. (d)
GATE 1999
In ElectroDischarge Machining (EDM), the tool is
made of
(a) Copper (b) High Speed Steel
(c) Cast Iron (d) Plain Carbon Steel
Ans. (a)
GATE 2007
In electro discharge machining (EDM), if the
thermal conductivity of tool is high and the specific
heat of work piece is low, then the tool wear rate
and material removal rate are expected to be
respectively respectively
(a) High and high (b) Lowand low
(c) High and low (d) Lowand high
Ans. (d)
GATE 2005
A zigzag cavity in a block of
high strength alloy is to be
finish machined. This can be
carried out by using
(a) Electricdischargemachining (a) Electricdischargemachining
(b) Electrochemicalmachining
(c) Laserbeammachining
(d) Abrasiveflowmachining
Ans.(a)
IES 2005
Which of the following is/are used as low wearing
tool material(s) in electric discharge machining?
(a) Copper and brass
(b) Aluminiumand graphite
(c) Silver tungsten and copper tungsten
(d) Cast iron
Ans. (c)
Set-2
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GATE 2000
Deep hole drilling of small diameter, say 0.2 mm is
done with EDM by selecting the tool material as
(a) Copper wire (b) Tungsten wire
(c) Brass wire (d) Tungsten carbide
Ans. (b)
GATE 1994
Ultrasonic machining is about the best process for
making holes in glass which are comparable in size
with the thickness of the sheet.
( ) T (a) True
(b) False
(c) Cant say
(d) Insufficient data
Ans. (a)
IES2011
USM has good machining performance for :
(a) Al
(b) Steel
(c) Super alloys ( ) p y
(d) Refractory material
Ans. (d)
GATE 1993
In ultrasonic machining process, the material
removal rate will be higher for materials with
(a) Higher toughness (b) Higher ductility
(c) Lower toughness (d) Higher fracture strain
Ans. (c)
GATE 1992
In Ultrasonic Machining (USM) the material
removal rate would
(a) Increase
(b) Decrease
(c) Increase and then decrease
(d) decrease and then increase
with increasing mean grain diameter of the abrasive
material.
Ans. (c)
IES 2009
By which one of the following processes the
metering holes in injector nozzles of diesel engines
can be suitably made?
(a) Ultrasonic machining
(b) Ab i j t hi i (b) Abrasive jet machining
(c) Electron beam machining
(d) Chemical machining
Ans. (b)
Set-2
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IES 2006
During ultrasonic machining, the metal removal is
achieved by
(a) High frequency eddy currents
(b) high frequency sound waves
(c) Hammering action of abrasive particles
(d) Rubbing action between tool and workpiece
Ans. (c)
IAS 1996
During ultrasonic machining, the metal removal is
affected by the
(a) Hammering action of abrasive particles
(b) Rubbing action between tool and workpiece
(c) High frequency sound waves
(d) High frequency eddy currents
Ans. (c)
GATE 1992
Match the following components with the appropriate
machining processes:
Component Process
(A) Square hole in a high strength alloy (1) Milling
(B) Square hole in a ceramic component (2) Drilling ( ) q p ( ) g
(C) Blind holes in a die (3) ECM
(D) Turbine blade profile on high strength alloy(4) Jig boring
Ans. (b) (5) EDM
(6) USM
(a) 4 1 2 3 (b) 5 6 1 3
(c) 4 2 1 3 (d) 3 1 2 4
GATE2011
Match the following non traditional machining
processes with the corresponding material removal
mechanism:
Machiningprocess Mechanismofmaterialremoval
P.Chemicalmachining 1.Erosion
QElectro chemical 2 Corrosivereaction
(a)P 2,Q 3,R 4,S 1(b)P 2,Q 4,R 3,S 1
(c)P 3,Q 2,R 4,S 1(d)P 2,Q 3,R 1,S 4
Ans.(a)
Q.Electro chemical
machining
2.Corrosivereaction
R.Electro discharge
machining
3.Iondisplacement
S.Ultrasonicmachining 4.Fusionandvaporization
GATE 2007
Matchthemostsuitablemanufacturingprocessesforthe
followingparts.
Parts ManufacturingProcesses
P. Computerchip 1. ElectrochemicalMachining
Q. Metalformingdiesandmoulds g
2. UltrasonicMachining
R. Turbineblade 3. Electrodischarge
Machining Ans.(a)
S. Glass 4. PhotochemicalMachining
Codes:P Q R S P Q R S
(a) 4 3 1 2 (b) 4 3 2 1
(c) 3 1 4 2 (d) 1 2 4 3
GATE 1998
List I List II
(A) ECM (1) Plastic shear
(B) EDM (2) Erosion/Brittle fracture
(C) USM (3) Corrosive reaction
(D) LBM (4) Melting and vaporization
(5) Ion displacement Ans. (b)
(6) Plastic shear and ion displacement
(a) 4 1 2 3 (b) 5 4 2 4
(c) 4 2 1 3 (d) 3 1 2 4
Set-2
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IES 2008
using the code given belowthe lists:
ListI ListII Ans. (a)
(Unconventional machining process) (Basic process)
A Electro polishing 1 Thermal A. Electro polishing 1. Thermal
B. Electrochemical machining 2. Mechanical
C. Abrasive jet machining 3. Electrochemical
D. Electrical discharge machining 4. Chemical
(a) 4 3 2 1 (b) 2 1 4 3
(c) 4 1 2 3 (d) 2 3 4 1
IES 1998
Match ListI (Machining process) with ListII
(Associated medium) and select the correct answer
ListI ListII Ans. (b)
A Ult i hi i K A. Ultrasonic machining 1. Kerosene
B. EDM 2. Abrasive slurry
C. ECM 3. Vacuum
D. EBM 4. Salt solution
(a) 2 3 4 1 (b) 2 1 4 3
(c) 4 1 2 3 (d) 4 3 2 1
IES 2005
Match List I (Machining Process) with List II
(Application) and select the correct answer using the
code given belowthe Lists:
List I List II
A. EDM 1. Holes & cavities in hard & brittle materials
B LBM 2 Microdrilling & microwelding of B. LBM 2. Micro drilling & micro welding of
materials
C. USM 3. Shaping of hard metals or reshaping of
cemented carbide tools
D. ECM 4. Shaping of cemented carbide dies and
punches Ans. (c)
(a) 4 1 2 3 (b) 3 2 1 4
(c) 4 2 1 3 (d) 3 1 2 4
IES 2003
Match List I (Materials) with List II (Machining) and
select the correct answer using the codes given below
the Lists: Ans. (d)
List I List II
(Materials) (Machining)
A. Machining of conducting materials 1. ECM
B. Ruby rod 2. EDM
C. Electrolyte 3. USM
D. Abrasive slurry 4. LBM
(a) 4 2 1 3 (b) 4 2 3 1
(c) 2 4 3 1 (d) 2 4 1 3
IES 2003
Assertion (A): Water jet machining uses high
pressure and high velocity water stream which acts
like a sawand cuts a narrowgroove in the material.
Reason (R): The force required for cutting is
generated from sudden change in the momentum
of the water stream.
IAS 2002
Which one of the following pairs is NOT correctly
matched?
(Unconventional (Application)
machining method)
(a) Electric discharge : Machining of electrically
conductive materials
(b) Laser beam : Micromachining
(c) Plasma arc : Faster cutting of hard materials
(d) Electron beam : Faster metal removal rate
Ans. (d)
Set-2
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IAS 1999
Match List I (Unconventional machining process) with
List II (Typical application) and select the correct
List I List II Ans. (d)
A Electro discharge machining 1 Drilling micro holes in A. Electro discharge machining 1. Drilling micro holes in
very hard metals
B. Electro chemical machining 2. Drilling holes in glass
C. Ultrasonic machining 3. Die sinking
D. Laser beam machining 4. Machining contours
(a) 4 2 3 1 (b) 3 4 1 2
(c) 4 3 2 1 (d) 3 4 2 1
IES 2004
Match List I (Machining processes) with List II
(Operating media) and select the correct answer using
the codes given belowthe Lists:
List I List II
A. Abrasive jet machining 1. Dielectric
B. Electron beam machining 2. Electrolyte
C. Electrochemical machining 3. Abrasive slurry
D. Electrodischarge machining 4. Vacuum
5. Air Ans. (a)
(a) 5 4 2 1 (b) 4 5 2 1
(c) 4 2 3 5 (d) 2 5 3 4
IES 1999
using the codes given belowthe Lists:
ListI ListII
A. Die sinking 1. Abrasive jet machining
B. Debarring 2. Laser beam machining g g
C. Fine hole drilling (thin materials) 3. EDM
D. Cutting/sharpening hard materials
4. Ultrasonic machining
Ans. (c) 5. Electrochemical grinding
(a) 3 5 4 1 (b) 2 4 1 3
(c) 3 1 2 5 (d) 4 5 1 3
GATE 2004
Typical machining operations are to be performed on hard
tomachine materials by using the processes listed below.
Choose the best set of OperationProcess combinations
Operation Process
P. Debarring (internal surface) 1. Plasma Arc Machining
Q Die sinking 2 Abrasive Flow Machining Q. Die sinking 2. Abrasive Flow Machining
R. Fine hole drilling in thin sheets 3. Electric Discharge
Machining
S. Tool sharpening 4. Ultrasonic Machining
5. Laser beam Machining
6. Electrochemical Grinding
(a) P1 Q5 R3 S4 (b) P1 Q4 R1 S2
(c) P5 Q1 R2 S6 (d) P2 Q3 R5 S6
Ans. (d)
Ch10:NonConventionalMachiningOperation
Q.No Option Q.No Option
1 D 8 D
2 B 9 A 9
3 B 10 B
4 D 11 D
5 D 12 A
6 B 13 A
7 A 14 B
Set-2
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NC,CNC&Robotics
BySKMondal
IAS 1996
Assertion (A): The temperature control of an
electric iron is an example of servomechanism.
Reason (R): It is an automatic control system.
t l ti f A correct explanation of A
Ans. (d)
GATE 1994
CNC machines are more accurate than conventional
machines because they have a high resolution
encoder and digital readouts for positioning.
T f l ? True or false?
Ans. True
IES 1999
numerically controlled machine tools:
1. They reduce nonproductive time
2. They reduce fixturing
3. They reduce maintenance cost
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
Ans. (b)
IES 1995
Consider the following characteristics of
production jobs:
1. Processing of parts frequently in small lots
2. Need to accommodate design changes of products.
3. Lowrate of metal removal
4. Need for holding close tolerances
The characteristics which favour the choice of
numerically controlled machines would include
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1, 3 and 4 (d) 1, 2 and 4 Ans. (d)
IES 2009
In which of the following machining manual part
programming is done?
(a) CNC machining (b) NC machining
(c) DNC machining (d) FMS machining
Ans. (b)
Set-2
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GATE 1993
With reference to NC machine, which of the
following statement is wrong?
(a) Both closedloop and openloop control systems are
used
(b) P t fl t d tt d f (b) Paper tapes, floppy tapes and cassettes are used for
data storage
(c) Digitizers may be used as interactive input devices
(d) Post processor is an itemof hardware
Ans. (c)
IES 2007
What are the main components of an NC machine?
1. Part program
2. Machine Control Unit
3. Servo motor
(a) 1, 2 and 3 (b) 1 and 2 only
Ans. (a)
JWM2010
Consider the following components regarding numerical
control system :
1. Programme of instructions
2. Machine control unit
P i i 3. Processing equipment
Which of these are correct ?
(a) 1, 2 and 3 (b) 1 and 2 only
Ans. (a)
IES 2009
What is the purpose of satellite computers in
Distributed Numerical Control machines?
(a) To act as standby systems
(b) To share the processing of largesize NC programs
(c) To serve a group of NC machines
(d) To network with another DNC setup
Ans. (c)
IES 1999
Consider the following components:
1. Adedicated computer
2. Bulk memory
3. Telecommunication lines
Which of these components are required for a DNC
system?
(a) 2 and 3 (b) 1 and 2
(c) 1, 2 and 3 (d) 1 and 3
Ans. (c)
JWM2010
ConsiderthefollowingadvantagesofDNCsystems:
1.Timesharing
2.Greatercomputationalcapability
3.Remotecomputerlocation
Whichoftheaboveis/arecorrect?
(a)1and2only (b)2and3only
(c)2only (d)1,2and3
And.(d)
Set-2
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IES 2002S1
answer:
List I List II
(NC machine tool systems) (Features)
A NC system 1 It has an integrated automatic tool A. NC system 1. It has an integrated automatic tool
changing unit and a component
indexing device
B. CNC system 2. A number of machine tools are
controlled by a computer. No tape
reader, the part program is
transmitted directly to the
machine tool from the
computer memory
IES 2002Contd..FromS1
C. DNC system 3. The controller consists of
softwired computer and
hard wired logic Graphic
display of tool path is
also possible
D. Machining centre 4. The instructions on tape is
prepared in binary
decimal form and operated by
a series of coded
instructions Ans. (c)
(a) 4 2 3 1 (b) 1 3 2 4
(c) 4 3 2 1 (d) 1 2 3 4
GATE 2007
WhichtypeofmotorisNOTusedinaxisorspindle
drivesofCNCmachinetools?
(a) Inductionmotor (b) DCservomotor
(c) Steppermotor (d) Linearservomotor
Ans.(a)
IES 1994
Feed drives in CNC milling machines are provided
by
(a) Synchronous motors
(b) Induction motors
(c) Stepper motors
(d) Servomotors.
Ans. (d)
IES 2002
In a CNC machine tool, encoder is used to sense and
control
(a) Table position
(b) Table velocity
(c) Spindle speed
(d) Coolant flow
Ans. (b)
Example
A DC servomotor is coupled directly to a leadscrew
which drives the table of an NC machine tool. A
digital encoder, which emits 500 pulses per
revolution, is mounted on the other end of the
leadscrew If the leadscrew pitch is 5 mm and the leadscrew. If the leadscrew pitch is 5 mm and the
motor rotates at 600 rpm, calculate
(a) The linear velocity of the table
(b) The BLU of the NC system
(c) The frequency of pulses transmitted by the encoder.
Set-2
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IES2011Conventional
The table of a CNC machine is driven by a Lead screw which
is rotated by a DC servomotor. A digital encoder which emits
1000 pulses per second is mounted on the lead screw as a
feedback device. If the lead screw pitch is 6 mm and motor p
rotates at 500 rpm, find
1. Basic length Units of the system
2. Linear velocity of the table.
3. Frequency of pulses generated by the feedback device.
[5 Marks]
StatementforLinkedAnswersquestions:S1
In the feed drive of a PointtoPoint open loop CNC
drive, a stepper motor rotating at 200 steps/rev drives a
table through a gear box and lead screwnut mechanism
(pitch = 4 mm, number of starts = 1).
The gear ratio = is given by U =
speed rotational Output
1
The gear ratio = is given by U =
The stepper motor (driven by voltage pulses from a pulse
generator) executes 1 step/pulse of the pulse generator.
The frequency of the pulse train from the pulse
generator is f = 10,000 pulses per minute.
speed rotational Input
4
GATE 2008Q1 (StatementinS1)
The Basic Length Unit (BLU), i.e., the table
movement corresponding to 1 pulse of the pulse
generator, is
(a) 0.5 microns (b) 5 microns
( ) i (d) i (c) 50 microns (d) 500 microns
Ans. (b)
GATE 2008Q2 (StatementinS1)
A customer insists on a modification to change the BLU
of the CNC drive to 10 microns without changing the
table speed. The modification can be accomplished by
Ans. (a)
GATE 1997
In a point to point control NC machine, the slides
are positioned by an integrally mounted stepper
motor drive. If the specification of the motor is
1
o
/pulse, and the pitch of the lead screw is 3.6 mm,
what is the expected positioning accuracy? what is the expected positioning accuracy?
Ans. (b)

( ) 1 ( ) 10
( ) 50 ( ) 100
a m b m
c m d m
GATE 1992
In a pointtopoint type of NC system
(a) Control of position and velocity of the tool is
essential
(b) Control of only position of the tool is sufficient
(c) Control of only velocity of the tool is sufficient
(d) Neither position nor velocity need be controlled
Ans. (b)
Set-2
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GATE 2006
NCcontouring is an example of
(a) Continuous path positioning
(b) Pointtopoint positioning
(c) Absolute positioning
(d) Incremental positioning
Ans. (a)
GATE2005
WhichamongtheNCoperationsgivenbeloware
continuouspathoperations?
ArcWelding(AW) Milling(M)
Drilling(D) PunchingisSheetMetal(P)
L C i fSh M l(LC)S W ldi (SW) LaserCuttingofSheetMetal(LC)SpotWelding(SW)
(a) AW,LCandM (b)AW,D,LCandM
(c) D,LC,PandSW (d)D,LC,andSW
Ans.(a)
IES 2000
Assertion (A): The axis of an NC drilling machine
spindle is denoted as zaxis.
Reason (R): In NC machine tool, the axis
perpendicular to both x and yaxis is designated as
z axis zaxis
IES 1996
Assertion (A): Numerically controlled machines
having more than three axes do not exist.
Reason (R): There are only three Cartesian
coordinates namely xyz.
IES 2003S1
While part programming
in CNC machines, the
input of dimensional
information for the tool
path can be given in the path can be given in the
absolute coordinate
system or in incremental
coordinate system. The
above figure shows the
route to be followed by the
tool from O to C, i.e., O A
B C.
IES 2003Contd..FromS1
If incremental coordinates system is used, the co
ordinates of each point A, B and C are
(a) A: X 5.0, Y 10.0 (b) A: X 5.0, Y 10.0
B: X 20.0, Y5.0 B: X 25, Y 15.0
C: X 10.0, Y 10.0 C: X 35, Y 5.0
(c) A: X 10.0, Y 5.0 (d) A: X 10.0, Y 5.0
B: X 15.0, Y 25.0 B: X 5.0, Y 20.0
C: X 15.0, Y 35.0 C: X 10.0, Y 10.0
Ans. (a)
Set-2
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GATE 2004
During the execution of a CNC part programblock
N020 G02 X45.0 Y25.0 R5.0 the type of tool motion will
be
(a) Circular Interpolation clockwise
(b) Circular Interpolation counter clockwise
(c) Linear Interpolation
(d) Rapid feed
Ans. (a)
GATE 2010
In a CNC program block, N002 G02 G91 X40 Z40,
G02 and G91 refer to
(a) Circular interpolation in counterclockwise direction
and incremental dimension
(b) Ci l i t l ti i t l k i di ti (b) Circular interpolation in counterclockwise direction
and absolute dimension
(c) Circular interpolation in clockwise direction and
incremental dimension
(d) Circular interpolation in clockwise direction and
absolute dimension
IES 2009
Interpolation in the controller refers to control of
whichone of the following in a CNC machine?
(a) Loading/unloading of jobs on machine
(b) Loading/unloading of tools from the tool changer
(c) Axes of machine for contouring
(d) Coolant and miscellaneous functions on machine
Ans. (c)
GATE 2001
In an NC machining operation, the tool has to be
moved from point (5, 4) to point (7, 2) along a
circular path with centre at (5, 2). Before starting the
operation, the tool is at (5, 4). The correct G and M
code for this motion is code for this motion is
(a) N010 G03 X7.0 Y2.0 I5.0 J2.0
(b) N010 G02 X7.0 Y2.0 I5.0 J2.0
(c) N010 G01 X7.0 Y2.0 I5.0 J2.0
(d) N010 G00 X7.0 Y2.0 I5.0 J2.0
Ans. (b)
GATE 2005
The tool of an NC machine has to move along a
circular arc from (5, 5) to (10,10) while performing an
operation. The centre of the arc is at (10, 5). Which
one of the following NC tool path commands
performs the above mentioned operation? performs the above mentioned operation?
(a) N010G02 X10 Y10 X5 Y5 R5
(b) N010G03 X10 Y10 X5 Y5 R5
(c) N010G01 X5 Y5 X10 Y10 R5
(d) N010G02 X5 Y5 X10 Y10 R5
Ans. (d)
GATE 2000
In finish machining of an island on a casting with
CNC milling machine, an end mill with 10 mm
diameter is employed. The corner points of the
island are represented by (0, 0), (0, 30), (50, 30), and
(50, 0). By applying cutter radius right (50, 0). By applying cutter radius right
compensation, the trajectory of the cutter will be
(a) (5, 0), (5, 35), (55, 35), (55, 5), (5, 5)
(b) (0, 5), (55, 5), (55, 35), (5, 35), (5, 5)
(c) (5, 5), (5, 25), (45, 25), (45, 5), (5, 5)
(d) (5, 5), (45, 5), (45, 25), (5, 25), (5, 5)
Ans. (b)
Set-2
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GATE 2009
Ans. (c)
IES 1993
A 'block' of information in N.C. machine program
means
(a) One rowon tape
(b) Aword comprising several rows on tape
(c) One complete instruction
(d) One complete program for a job
Ans. (c)
IES 1996
In manual programming and tape preparation for a
NC drilling machine, the spindle speed was coded
as S 684 (using the magicthree code). The spindle
speed in rpmwill be
(a) 684 (a) 684
(b) 68.4
(c) 840
(d) 6840
Ans. (a)
IES 1995
List I List II
(A function connected (Associated parameter)
with NC m/c tool)
A Interpolation 1 Tape preparation A. Interpolation 1. Tape preparation
B. Parity check 2. Canned cycle
C. Preparatory function 3. Drilling
D. Point to point control 4. Contouring
5. Turning
(a) 4 1 2 3 (b) 4 1 2 5
(c) 5 1 3 2 (d) 1 4 3 2
Ans. (a)
IES 1998
Which of the following are the rules of
programming NC machine tools in APT language?
1. Only capital letters are used
2. A period is placed at the end of each statement
3. Insertion of space does not affect the APT word
(a) 1 and 2 (b) 2 and 3
(c) 1 and 3 (d) 1 alone
Ans. (d)
IES2008
Name the four types of statements in a complete APT
part program. Prepare part program for geometry
description of the contour shown in the figure below:
[15Marks]
20
30 40
Y
R
2
0
R
2
0
135
L3
L2
20
L
1
80
L5
L
4
C
2
P
1
P
2
X
C
1
Set-2
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IES2007
Prepare part using APT language for milling the contour
shown in Fig. in a single pass. [20Marks]
110
R30
Q
B
D
C
+
+
+
+
40
40
120
100
A F
P
E
110
R40
8 mm
Material : M S.
IES2006
Prepare part program to machine the contour shown in
the figure using APTon CNC milling machine.
[15Marks]
R20
R30
80
100 mm
200 mm
60
50
Material: MS Thickness: 8.0 mm
IES2011Conventional
State the method of defining line segment of
cutter motion using APT program format.
[5 Marks]
IES 1997
Which of the following are valid statements for
point to point motion of the tool in APT language?
1. GO/TO/............
2. GO DLTA/............
3. GO/TO, .
(a) 1 and 2 (b) 2 and 3
(c) 1 and 3 (d) 1, 2 and 3
Ans. (c)
IES 1995
In APT language, the cutter motion in incremental
coordinate mode is addressed as
(a) GO/TO/.....
(b) GO/TO.....
(c) GO DLTA/....
(d) GO FWD/...
Ans. (c)
IES2011
Trajectoryofarobotmean:
(a)Pathtracedbytheendeffectors
(b)KinematicsofRobot
(c)Robotjoints ( ) j
(d)Robotprogramming
Ans.(a)
Set-2
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IES2010
Good dynamic performance is usually difficult to achieve
in robots which contain a rotary base because
1. Position, speed and acceleration of the other joints cause
variations in the reflected torque and moment of inertia.
2. The moment of inertia reflected at the base depends upon the
weight of the object being carried.
3. The moment of inertia reflected at the base also depends upon
the distance between the base axis and the manipulated object.
(a) 1, 2 and 3 (b) 2 and 3 only
(c) 1 only (d) 1 and 3 only Ans. (b)
IES 2006
Which one of the following is the third basic
component of robots besides power supply and
control (memory) console?
(a) Software (b) Coaxial cable
( ) M h i l it (d) Mi t (c) Mechanical unit arm (d) Microcomputer
Ans. (c)
IES 2000
Consider the following characteristics of a robot:
1. The tip of the robot arm moves from one point to
another with its inbetween path not being defined.
2. It can be used for drilling holes at difference points in a
workpiece workpiece.
3. It can be used for V butt joint welding between two
points.
4. The memory capacity required for its control unit is low.
Which of these are the characteristics associated with a point
to point robot?
(a) 1 and 2 (b) 1, 3 and 4
(c) 1, 2 and 4 (d) 2, 3 and 4 Ans. (c)
IES 2006
Which item best describes a CAM technology?
(a) Geometric modeling (b) Documentation
(c) Drafting (d) Numerical control
Ans. (d)
IES 1996
Whichofthefollowingpairsarecorrectlymatched?
1. CNCmachinePostprocessor
2. Machiningcentre.Toolmagazine
3. DNC.FMS
(a) 1,2and3 (b) 1and2
(c) 1and3 (d)2and3
Ans.(a)
IES 2006
Flexible manufacturing allows for:
(a) Tool design and production
(b) Automated design
(c) Quick and inexpensive product change
(d) Quality control
Ans. (c)
Set-2
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IES 2004
1. Single machine tool
2. Manual materials handling system
3. Computer control
4. Randomsequencing of parts to machines
Which of the above characteristics are associated with
flexible manufacturing system?
(a) 1, 2 and 3 (b) 1 and 2
(c) 3 and 4 (d) 2, 3 and 4
Ans. (a)
Set-2
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Limit Tolerance&Fits Limit,Tolerance&Fits
BySKMondal
GATE 2001
Allowance in limits and fits refers to
(a) Maximumclearance between shaft and hole
(b) Minimumclearance 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
In the specificationof 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)
GATE 2010
Ashaft has a dimension,
The respective values of fundamental deviation and
tolerance are
0.009
0.025
35

(a) 0.025, 0.008 (b) 0.025,0.016

(c) 0.009, 0.008 (d) 0.009,0.016

Ans.(d)
GATE 1992
TwoshaftsAandBhavetheirdiametersspecifiedas
100 0.1mmand0.1 0.0001mmrespectively.
Whichofthefollowingstatementsis/aretrue?
(a) ToleranceinthedimensionisgreaterinshaftA
(b) Therelativeerrorinthedimensionisgreaterinshaft
A
(c) ToleranceinthedimensionisgreaterinshaftB
(d) Therelativeerrorinthedimensionissameforshaft
AandshaftB
Ans.(a)
GATE 2004
In an interchangeable assembly, shafts of size
mm mate with holes of size mm.
The maximum possible clearance in the assembly
will be
( ) i
0.040
0.0100
25.000
+
0.020
0.000
25.000
+
(a) 10 microns
(b) 20 microns
(c) 30 microns
(d) 60 microns
Ans. (c)
Set-2
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GATE 2007
A hole is specified as mm. The mating
shaft has a clearance fit with minimum clearance of
0.01 mm. The tolerance on the shaft is 0.04 mm. The
maximum clearance in mm between the hole and
the shaft is
0 . 0 5 0
0 . 0 0 0
4 0
the shaft is
(a) 0.04
(b) 0.05
(c) 0.10
(d) 0.11
Ans. (c)
IES 2005
The tolerance specified by the designer for the
diameter of a shaft is 20.00 0.025 mm. The shafts
produced by three different machines A, B and C
have mean diameters of 1999 mm, 2000 mm and
20.01 mm respectively, with same standard
d i ti Wh t ill b th t j ti f deviation. What will be the percentage rejection for
the shafts produced by machines A, B and C?
(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)
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 ( ) g p y
(d) Assembly of flywheels on shafts
Ans. (a)
GATE 2005
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)
GATE2011
A hole is of dimension mm. The
corresponding shaft is of dimension mm.
0.010
0.001
9
+
+
0.015
0
9
+
+
p g
The resulting assembly has
(a) loose running fit
(b) close running fit
(c) transition fit
(d) interference fit
Ans. (c)
IES 2007
Ans.(a)
Set-2
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IES 2006
Which of the following is an interference fit?
(a) Push fit
(b) Running fit
(c) Sliding fit
(d) Shrink fit
Ans. (d)
IES 2009
Consider the following joints:
1. Railway carriage wheel and axle
2. IC engine cylinder and liner
Which of the above joints is/are the result(s) of
interference fit?
(a) 1 only
(b) 2 only
(c) Neither 1 nor 2
(d) Both 1 and 2
Ans. (d)
IES 2008
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
h ft shaft.
3. The stress state in the hub is similar to a thick
walled cylinder with internal pressure.
(a) 1, 2 and 3 (b) 1 and 2 only
Ans. (d)
IES 2004
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
Match ListI (Phenomenon) with ListII (Significant
Parameters/Phenomenon) and select the correct
answer using the codes given belowthe 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. Lubricating of bearings 4. Induced compressive
stress [ Ans. (b)]
(a) 3 4 1 2 (b) 4 3 2 1
(c) 3 4 2 1 (d) 4 3 1 2
IES 2005
Assertion (A): Hole basis system is generally
preferred to shaft basis system in tolerance design
for getting the required fits.
Reason (R): Hole has to be given a larger tolerance
band than the mating shaft band than the mating shaft.
Set-2
Page 59 of 70
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4
IES2006Conventional
Find the limit sizes, tolerances and allowances for a
100 mm diameter shaft and hole pair designated by
F
8
h
10
. Also specify the type of fit that the above pair
belongs to. Given: 100 mm diameter lies in the
diameter step range of 80120 mm. The fundamental diameter step range of 80 120 mm. The fundamental
deviation for shaft designation f is 5.5 D
0.41
The values of standard tolerances for grades of IT 8
and IT 10 are 25i and 64i respectively.
Also, indicate the limits and tolerance on a diagram.
[15Marks]
IES 2008
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 correct?
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 1 and 3 only
(d) 3 only [Ans. (None)]
IES 2002
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
What are the upper and lower limits of the shaft
represented by 60 f
8
?
Use the following data:
Diameter 60 lies in the diameter step of 5080 mm.
Fundamental tolerance unit,
i, in m= 0.45 D
1/3
+ 0.001D, where D is the
representative size in mm; [Ans. (a)]
Tolerance value for lT8 = 25i.
Fundamental deviation for 'f shaft = 5.5D
0.41
(a) Lower limit = 59.924 mm, Upper Limit = 59.970 mm
(b) Lower limit = 59.954 mm, Upper Limit = 60.000 mm
(c) Lower limit = 59.970 mm, Upper Limit = 60.016 mm
(d) Lower limit = 60.000 mm, Upper Limit = 60.046 mm
GATE 2000
A fit is specified as 25H8/e8. The tolerance value for
a nominal diameter of 25 mm in IT8 is 33 microns
and fundamental deviation for the shaft is 40
microns. The maximum clearance of the fit in
microns is microns is
(a) 7
(b) 7
(c) 73
(d) 106
[Ans. (d)]
GATE 1996
The fit on a holeshaft system is specified as H7
s6.The type of fit is
(a) Clearance fit
(b) Running fit (sliding fit)
(c) Push fit (transition fit)
(d) Force fit (interference fit)
[Ans. (d)]
Set-2
Page 60 of 70
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5
GATE 2003
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 2003
[Ans.(b)]
GATE 1997
Three blocks B
1
, B
2
and B
3
are
to be inserted in a channel of
width S maintaining a
minimum gap of width T =
0.125 mm, as shown in Figure.
For P 18 75 0 08; For P = 18. 75 0.08;
Q = 25.00 0.12;
R = 28.125 0.1 and
S = 72.35 + X, (where all
dimensions are in mm), the
tolerance X is
(a) +0.38 (b) 0.38 (c)+0.05 (d)0.05
[Ans.(d)]
IES 2000
Which one of the following tolerances set on inner
diameter and outer diameter respectively of headed
jig bush for press fit is correct?
(a) G7 h 6 (b) F7 n6
( ) H h 6 (d) F j6 (c) H 7h 6 (d) F7j6
[Ans. (b)]
GATE 2004
GOand NOGO plug gages are to be designed for a
hole mm. Gage tolerances can be taken as 10%
of the hole tolerance. Following ISO system of gage
design, sizes of GO and NOGO gage will be
respectively
0.05
0.01
20
respectively
(a) 20.010 mmand 20.050 mm
(b) 20.014 mmand 20.046 mm
(c) 20.006 mmand 20.054 mm
(d) 20.014 mmand 20.054 mm [Ans. (b)]
GATE 1995
Checking the diameter of a hole using GONOGO
gauges is an, example of inspection by
..(variables/attributes)
( ) V i bl (a) Variables
(b) Attributes
(c) Cant say
(d) Insufficient data [Ans. (b)]
Set-2
Page 61 of 70
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6
GATE 2006
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)]
Set-2
Page 62 of 70
9/30/2011
1
MeasurementofLines&Surfaces MeasurementofLines&Surfaces
BySKMondal
GATE 2008 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
protruding portion of the mandrel surface is perfectly protruding portion of the mandrel surface is perfectly
cylindrical. Measurements are taken with the sensor
placed at two positions P and Q as shown in the figure.
The readings are recorded as R
x
= maximum deflection
minus minimum deflection, corresponding to sensor
position at X, over one rotation.
GATE 2008contdfromS1
If R
p
= R
Q
>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 to the drill spindle taper hole
axis
(D) The drill spindle rotational axis
intersects the drill spindle taper hole
axis at point Q [Ans. (c)]
IES 2006
The M and Esystem in metrology are related to
measurement of:
(a) Screwthreads (b) Flatness
(c) Angularity (d) Surface finish
[Ans. (d)]
IES 2007
What is the dominant direction of the tool marks or
scratches in a surface texture having a directional
quality, called?
(a) Primary texture (b) Secondary texture
( ) L (d) Fl (c) Lay (d) Flaw
[Ans. (c)]
IES 2008
What term is used to designate the direction of the
predominant surface pattern produced by
machining operation?
(a) Roughness (b) Lay
( ) W i (d) C t ff (c) Waviness (d) Cut off
[Ans. (b)]
Set-2
Page 63 of 70
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2
IES2010
using the code given belowthe lists:
List I List II
(Symbols for direction of lay) (Surface texture)
A B C D A B C D
(a) 4 2 1 3 (b) 3 2 1 4
(c) 4 1 2 3 (d) 3 1 2 4
[Ans.(b)]
IES 2008
[Ans.(b)]
GATE 1997
List I List II
(A) Surface profilometer 1. Calibration
(B) Light Section Microscope 2. Form tester
(C) Microkater 3. Filmthickness
measurement measurement
(D) Interferometer 4. Centre line average
5. Comparator [Ans. (b)]
6. Surface lay measurement
(a) 4 1 2 3 (b) 4 3 5 1
(c) 4 2 1 3 (d) 3 1 2 4
GATE 2003
Two slip gauges of 10 mm width measuring 1.000 mm
and 1.002 mm are kept side by side in contact with each
other lengthwise. An optical flat is kept resting on the
slip gauges as shown in the figure. Monochromatic light
of wavelength 0.0058928 mm is used in the inspection. of wavelength 0.0058928 mm is used in the inspection.
The total number of straight fringes that can be observed
on both slip gauges is
(a)2 (b)6
(c)8 (d)13
[Ans.(a)]
Set-2
Page 64 of 70
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1
MiscellaneousofMetrology MiscellaneousofMetrology
BySKMondal
GATE 1998
Auto collimator is used to check
(a) Roughness
(b) Flatness
(c) Angle
(d) Automobile balance.
[Ans. (c)]
IES 1998
Match ListI with ListII and select the correct answer using the
codes given belowthe lists:
ListI ListII
(Measuring Device) (Parameter Measured)
A. Diffraction grating 1. Small angular deviations on long
flat surfaces
B Optical flat 2 Online measurement of moving B. Optical flat 2. Online measurement of moving
parts
C. Auto collimators 3. Measurement of gear pitch
D. Laser scan micrometer4. Surface texture using interferometer
5. Measurement of very small
displacements
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
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 g p
(C) Planimeter (3) Flowvelocity
(D) LVDT (4) Vacuum
(5) Surface finish
(6) Area [Ans. (b)]
(a) 4 1 2 3 (b) 3 4 6 2
(c) 4 2 1 3 (d) 3 1 2 4
GATE 2004
Match the following
Feature to be inspected Instrument
P Pitch and Angle errors of screw thread 1. Auto Collimator
Q Flatness error of a surface plate 2. Optical Interferometer
R Ali f hi lid Di idi H d R Alignment error of a machine slide way 3. Dividing Head
and Dial Gauge
S Profile of a cam 4. Spirit Level
5. Sine bar [Ans. (b)]
6. Tool maker's Microscope
(a) P6 Q2 R4 S6 (b) P5 Q2 R1 S6
(c) P6 Q4 R1 S3 (d) P1 Q4 R4 S2
GATE 1995
List I List II
(Measuring instruments) (Application)
(A) Talysurf 1. Tslots
(B) Telescopic gauge 2. Flatness
(C) Transfer callipers 3. Internal diameter
(D) Autocollimator 4. Roughness
(a) 4 1 2 3 (b) 4 3 1 2
(c) 4 2 1 3 (d) 3 1 2 4
[Ans. (b)]
Set-2
Page 65 of 70
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2
GATE 2010
A taper hole is inspected using a CMM, with a probe
of 2 mm diameter. At a height, Z = 10 mm from the
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 as 20 mm. Similarly, a 40 mm diameter is obtained
at a height Z = 40 mm. the smaller diameter (in mm)
of hole at Z = 0 is
(a) 13.334
(b) 15.334
(c) 15.442
(d) 15.542
[Ans.(a)]
IAS 2001
For transporting materials over long distances with
greater speed, which one of the following devices is
most suitable?
(a) Motor vehicle
(b) I d t i l hi l (b) Industrial vehicle
(c) Belt conveyor
(d) Roller conveyor
[Ans. (b)]
IAS 1995
For moving materials is varying paths, the material
handling equipments that is not suitable is
(a) Crane
(b) Conveyor
(c) Truck
(d) Hand trolley
[Ans. (b)]
IAS 1994
Consider the following situations
1. Loads are uniform
2. Materials move relatively continuously
3. Movement rate is variable
4. Routes do not vary
For material transportation, conveyors are used when
the prevailing conditions include
(a) 1, 3, and 4 (b) 1, 2, and 3
(c) 1, 2, and 4 (d) 2, 3 and 4
[Ans. (c)]
IES 2001
During manufacture of cement, the handling of
limestone is done by
(a) Belt conveyor
(b) Bucket conveyor
(c) Overhead crane
(d) Forklift crane
[Ans. (b)]
IAS 1998
Match ListI (Material handling equipments) with List
II (Application in a foundry) and select the correct
List I ListII
A. Belt conveyor 1. To move the compacted mould
boxes
B. Monorail conveyor 2. To move the prepared
moulding sand
C. Apron conveyor 3. To move the rough casting to
the fettling station
D. Roller conveyor 4. To transfer he molten metal
ladle [Ans. (d)]
(a) 1 2 3 4 (b) 2 1 3 4
(c) 2 4 1 3 (d) 2 4 3 1
Set-2
Page 66 of 70
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3
IAS 1997
Elevators are used for moving materials
(a) Along fixed and horizontal paths
(b) In a vertical direction along a fixed path
(c) Along a horizontal path to any distance
(d) In both the planes
[Ans. (b)]
IES 1994
Killed steels
(a) Have minimum impurity level
(b) Have almost zero percentage of phosphorus and
sulphur
(c) Are produced by LD process
(d) Are free fromoxygen
[Ans. (d)]
IES 1992
Dye penetration method is generally used to locate
(a) Core defects
(b) Surface defects
(c) Superficial defects
(d) Temporary defects
[Ans. (b)]
IES 1999
Transfer machines can be defined as
(a) Material processing machines
(b) Material handling machines
(c) Material processing and material handling machines
(d) Component feeders for automatic assembly
[Ans. (c)]
IES 2000
AscrewthreadspecifiedbyM20x2.5CasperBIS
threadsystemmeans
(a) Metricthreadof20mmnominaldiameterand2.5
mmpitchhavingcoarsetolerance
(b) M t i th d f tdi t d (b) Metricthreadof20mmrootdiameterand2.5mm
pitchhavingcoarsetolerance
(c) Metricthreadoffineclasshaving20mmroot
diameterand2.5mmpitch
(d) Metricthreadof20mmshankdiameterand2.5mm
threaddepthwithcoarsetolerance [Ans.(c)]
Ch13:Metrology
Q.No Option Q.No Option
1 C 10 D
2 C 11 D
3 A 12 B
4 C 13 B 4 C 13 B
5 C 14 D
6 B 15 B
7 C 16 C
8 B 17 B
9 B
Set-2
Page 67 of 70
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1
JigsandFixtures JigsandFixtures
BySKMondal
GATE 1999
Choosethecorrectstatement:
(a) Afixtureisusedtoguidethetoolaswellastolocate
andclamptheworkpiece
(b) AJigisusedtoguidethetoolaswellastolocateand
l th k i clamptheworkpiece
(c) JigsarcusedonCNCmachinestolocateandclamp
theworkpieceandalsotoguidethetool
(d) Noarrangementtoguidethetoolisprovidedinajig.
[Ans.(b)]
IES 2007
According to the principle of location in jigs and
fixtures, how many degrees of freedom are to be
eliminated to have a body fixed in space?
(a) 3
(b) (b) 4
(c) 5
(d) 6
[Ans. (d)]
GATE 2005
When 321 principle is used to support and locate a
three dimensional workpiece during machining,
the number of degrees of freedom that are
restricted is
(a) 7 (a) 7
(b) 8
(c) 9
(d) 10
[Ans. (c)]
GATE 2001
321 method of location in a jig or fixture would
collectively restrict the workpiece in n degrees of
freedom, where the value of n is
(a) 6
(b) 8 (b) 8
(c) 9
(d) 12
[Ans. (c)]
IES2011
Inthe321principleoffixture3referstonumberof
:
(a)Setupspossible
(b)Clampsrequired
(c)Positionsonprimaryface
(d)Locatingpositions
[Ans.(d)]
Set-2
Page 68 of 70
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2
IES 1998,1999
Diamond pin location is used in a fixture because
(a) It does not wear out
(b) It takes care of any variation in centre distance
between two holes
(c) It is easy to clamp the part on diamond pins
(d) It is easy to manufacture
[Ans. (b)]
IES 2009
A lever having two precisely drilled holes, one
smaller than the other, has to be located in a fixture
using hardened and ground plugs for further
machining in relation to the holes. Select the
correct method of locating the lever from the given
lt ti alternatives.
(a) Using two hardened and ground plugs, the smaller
one having flats machined on each side
(b) Using two hardened and ground plugs
(c) Using one hardened and ground plug and one V
block
(d) Using two Vblocks [Ans. (a)]
IES 1995
If the diameter of the hole is subject to considerable
variation, then for locating in jigs and fixtures, the
pressure type of locator used is
(a) Conical locator
(b) Cylindrical locator
(c) Diamond pin locator
(d) Vee locator [Ans. (a)]
IES 2005
Match List I (An Element of Jigs and Fixtures) with List
II (Associating System) and select the correct answer
using the code given belowthe Lists:
List I List II
A Bush 1. Milling fixture
B. Setting block 2. Turning fixture
C. Diamond pin 3. Radial location
D. Vblock 4. Cylindrical location
5. Drill jigs [Ans. (c)]
(a) 5 4 3 1 (b) 3 1 2 4
(c) 5 1 3 4 (d) 3 4 2 1
IES 2000
Match List I (Components used in jigs and fixtures) with List II
(Their functions) and select the correct answer using the codes
List I List II
A. Jack pin 1. To guide the drill bit during machining
B. Vlocator 2. For easy removal of the work piece from the y p
jig or fixture after the machining operation
is over
C. Bushes 3. To locate the circular or
semicircular objects in a jig or fixture
D. Ejectors 4. To locate work piece whose dimensions are
subject to variations [Ans. (b)]
(a) 3 4 1 2 (b) 4 3 1 2
(c) 3 4 2 1 (d) 4 3 2 1
IES 1995
Match List I with List Ii and select the correct answer using the
codes given belowthe lists:
List I (Task) List II (Recommendation)
A. Three components in a straight 1. Clamp with a
floating pad.
line should worked in one loading
B. Unloading of clamp element from jig is essential
2. Quick action nut
C. Clamping of rough surfaces 3. Camclamp
D. Need for heavy clamping force 4. Equalising clamp
5. Strap clamp
(a) 5 2 3 4 (b) 4 2 1 5
(c) 1 4 2 3 (d) 4 1 5 3
[Ans. (d)]
Set-2
Page 69 of 70
9/30/2011
3
IES 2005
Which one of the following is the most significant
property to be considered in the selection of
material for the manufacture of locating pins and
drill jig buses used in jigs and fixtures?
(a) Wearresistance (b) Elasticity (a) Wearresistance (b) Elasticity
(c) Shearstrength (d) Tensilestrength
[Ans.(a)]
IES 1996
Assertion (A): A workpiece with rough unmachined
surface can be located in a jig or fixture on three
supporting points.
Reason (R): Indexing is made accurate by
supporting on three points supporting on three points.
IES 1996
The cutter setting block in a milling fixture
1. Sets the cutting tool with respect of two of its surfaces.
2. Limits the total travel required by the cutter during
machining.
3. Takes location from the location scheme of the
component.
(a) 1,2 and 3 are correct (b) 1 and 2 are correct
[Ans. (d)]
IES 1993
The floating position of the holding fixture in a
rotary transfer device is used to
(a) Improve the accuracy of location
(b) Reduce the tendency to over index
(c) Reduce the cycle time
(d) Improve upon the acceleration and deceleration
characteristics
[Ans. (d)]
JigsandFixtures
Q. No Opt i on Q. No Opt i on
1 C 6 C
2 D 7 D 2 D 7 D
3 B 8 D
4 B 9 C
5 C
Set-2
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Compiled By:SK Mondal Made Easy

Compiled by:SK Mondal Made Easy

Compiled by:SK Mondal Made Easy

(a) 0.025, 0.008 (b) 0.025,0.016

3. 8 indicates fundamental deviation.

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