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Comprehensive Examination
(EC-3 Regular)
Q.1 (a) Explain why the cutting force increases with increasing depth of cut and decreasing
rake angle. [2]
Q.1 (b) Under what conditions would you discourage the use of cutting fluids [2]
Q.1 (c) The accompanying illustration (Fig. 1) shows a part that is to be machined from a
rectangular blank. Suggest the type of operations required and their sequence, and
specify the machine tools that are needed. [2]
Q.1 (d) Explain the possible disadvantages of a machining operation if a discontinuous chip is
produced. [2]
Q.1 (e) What advantages does friction welding have observed are actually due to stress waves
in over the other joining methods? [2]
Q.1 (f) Discuss the factors that influence the strength of (i) a diffusion bonded component and
(ii) a cold welded component. [2]
Q.1 (g) Which materials can be friction stir welded, and which cannot? Explain your answer.
[2]
Q.1 (h) How does the weldability of steel change as the steel’s carbon content increases?
Why? [2]
Q.1 (i) What is the significance of some metals, such as lead and tin, having recrystallization
temperatures at about room temperature? [2]
Q.1 (j) List and briefly explain the three mechanisms by which metals shrink during casting.
[2]
Q.2. Figure 2 shows the final profile to be generated on a MS bar stock of diameter 5.0cm and
4.6 cm length by using a CNC turning center. Write CNC part program using G and M
codes [10]
Figure 1
Figure 2