Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
2 MARKS
1) Classify the process of metal shaping?
The process of metal shaping is classified into two types
Non cutting shaping process
Cutting shaping process
2) Explain the non cutting shaping process ?
The metal is shaped under the action of force , heating or both . Since there is no cutting of
metal , chip formation will so be there . So it is called as non cutting process.
Example: Forging , Drawing , Rolling etc.
3) Explain the cutting shaping process ?
The required shape of the metal is obtained by removing the unwanted material from the work
piece in form of chips is called as cutting process.
Example: Milling , Boring , Drilling etc.
4) Classify the relative motion between the work piece and cutting tool ?
13. What are all the conditions for using positive rake angle?
Ans.
15. Name the factors that contribute to poor surface finish in cutting?
Ans. a ) Cutting speed
b) Feed
c) Depth of cut
16 . Classify the types of metal cutting process?
Ans. The metal cutting processes are mainly classified into two types :
The sheared material begins to flow along the cutting tool face in the form of small pieces. The
compressive force applied to form the chip is called cutting force.
23. What is chip and mention its different types?
The sheared material to flow along the cutting tool face in the form of small pieces is called chip. Chips
are classified into three types:
a) Continuous chip.
b) Discontinuous chip.
c) Continuous chip with built up edge.
24. When will be continuous chip formed?
The following factors favour the formation of continuous chip.
i.
ii.
iii.
iv.
v.
vi.
vii.
Ductile material
Smaller depth of cut
High cutting speed
Large rake angle
Sharp cutting edge
Proper cutting fluid
Low friction between tool face and chips.
25. What will be the favourable factors for discontinuous chip formation?
a)
b)
c)
d)
e)
f)
26. What are the favourable factors for continuous chip with built up edge?
a)
b)
c)
d)
e)
k=
29. What is the function of chip breakers?
The chip breakers are used to break the chips into small pieces for removal, safety and to prevent both the
machine and work damage.
30. What are the difficulties involved due to long and continuous chip?
During machining, long and continuous chip that are formed at high cutting speed will affect machining.
It will spoil tool, work and machine. These chips are hard, sharp and hot. It will be difficult to remove
metal and also dangerous to safety.
31. Classify the different types of chip breakers?
Step type
Groove type
Clamp type
Feed force,Fx
Thrust force,Fy
Cutting force,Fz
35. What are the assumptions made in lee and shaffers theory?
The work ahead of the tool behaves as the ideal plastic mass
There exist a shear plane which seperates the chip and work piece
No hardening in the chip occurs
Cutting speed.
Feed and depth of cut.
Tool geometry.
Tool material
Cutting fluid
Work material
Rigidity of work, tool and ,machine
50. What are the factors considered for the selection of cutting speed?
Tool life
Properties of materials being machined.
Rate of feed
Depth of cut
Tool geometry
Cutting fluid used
Types of machining process
Surface finish to be obtained
51. What are the factors to be considered for the selection of tool material?
Volume of production
Tool design
Type of machining process
Physical and chemical properties
Rigidity and condition of machine.
52. What are the four important characteristics of materials used for cutting tools?
Hot hardness
Wear resistance
High thermal conductivity
Resistance to thermal shock
Easy to grind and sharpen.
Low mechanical and chemical affinity for the work material.
53. Name the various cutting tool materials.
Carbon tool steel
High speed steel
Cemented carbides
Ceramics
Diamonds
54. What are the functions of cutting fluids?
It is used to cool the cutting tool and work piece.
It lubricates the cutting tool and thus reduces the co-efficient of friction between tool and work.
It improves the surface finish as started earlier.
It causes the chips to break up into small parts.
It protects the finished surface from corrosion.
It washes away the chips from the tool. It prevents the tool from fouling.
55. What are the factors responsible for built-up edge in cutting tools?
During cutting process, the interface temperature and pressure are quite high and also high friction between tool
chip interfaces causes the chip material to weld itself to the tool face near the nose. This is called built up edge.
Sl.
no
1
2
Orthogonal cutting
Oblique cutting
Diamond is hardest material. It is used for machining very hard materials such as glass, plastics,
ceramics, etc.
62) What are the advantages of increasing nose radius?
If the nose radius increases, the strength of cutting tool is increased and it is used on castings and
cast iron, where the cuts are interrupted.
63) Give the equations of velocity of chip and velocity of shear in terms of cutting velocity, rake
angle and shear angle?
Velocity of chip, Vc =
Velocity of shear, Vs =
64) Calculate the power required for cutting a steel rod of 50mm in diameter at 200rpm. Assume
cutting force of 160kg.
Power required = Fc V
= Fc
= (160 9.81)
= 821.8 kW.
65) Write down the shear angle in terms of chip thickness and rake angle of the tool?
Shear angle, = tan-1
66) What is the composition of high speed steel?
High speed steel contains
Tungsten 18%, Vanadium 1%, Carbon 0.75%.
67) What are the causes of wear?
The tool is subjected to three important factors such as force, temperature and sliding action due
to relative motion between tool and the work piece. So, the tool is wear easily.