Assignment-1

Malaviya National Institute of Technology, Jaipur

Mechanical Engineering Department
Course Name: Machining Science and Machine Tools (B.Tech 4th Semester)

1) What are the different types of tool specification system? Explain the geometry of a single
point cutting tool with the help of a neat diagram as per ASA system.
2) Discuss the effect of following cutting parameters on tool life and surface finish
a) Back Rake angle
b) Side cutting edge angle
c) End cutting edge angle
d) Nose Radius
3) Differentiate between:
a) Orthogonal and Oblique cutting
b) Continuous chip and continuous chips with BUE
4) Explain in detail the various desirable properties of a cutting tool material. What are the most
commonly used cutting tool materials.
5) Write short note on:
a) Chip breakers
b) Tools having unusual geometry(anti chatter tools)
 Assignment-2
Malaviya National Institute of Technology, Jaipur
Mechanical Engineering Department
Course Name: Machining Science and Machine Tools (B.Tech 4th Semester)

6) Derive the following relation for the shear angle (φ ):

r cos α
tan φ = 1−r sin α

Where r=chip thickness ratio and α= back rake angle.

7) During orthogonal machining with a cutting tool having a 12o rake angle, the chip thickness
is measured to be 0.44mm, uncut chip thickness being 0.18mm.Determine:
a) Shear plane angle
b) Shear strain.
8) The following data from the orthogonal cutting test is available:
Rake angle = 10o, Chip thickness ratio=0.35, uncut chip thickness=0.51, width of cut=3mm,
yield shear stress of work material=285N/mm2, mean friction coefficient on tool face=0.65.
Determine the following:
a) Cutting force
b) Radial force
c) Normal force on tool
d) Shear force on tool
4) The following observations were made during an orthogonal cutting operation:
Depth of cut=0.3mm, Chip thickness=0.6mm, rake angle=20o, cutting velocity=102m/min,
cutting force=300N, feed force=120 N,
Determine the following:
a) Shear angle
b) Shear strain
c) Velocity of chip along the tool face
d) Work done in shear.
5) Mild steel is being machined at a cutting speed of 200m/min with a tool rake angle of 10o, the
width of cut and uncut chip thickness are 2mm and 0.2 mm respectively. If the average value
of coefficient of friction between tool and chip is 0.5 and shear strength of work material is
400N/mm2.
Determine the following:
a) Shear angle
b) Cutting and thrust component of machining forces.
Use the Lee Shaffer condition of metal cutting.
6) Explain merchant circle in metal cutting with the help of a neat diagram. Also describe
various techniques of measurement of cutting forces involved.
 Assignment-3
Malaviya National Institute of Technology, Jaipur
Mechanical Engineering Department
Course Name: Machining Science and Machine Tools (B.Tech 4th Semester)

1) Explain the various factors which cause excessive heat generation during metal cutting.
2) Describe the various properties of a cutting fluid. Explain with reason the type of cutting
fluid to be used while machining: cast iron, steel, aluminum, brass and bronze
3) Explain with the help of a neat diagram various deformation zones formed during metal
cutting. Also describe the distribution of heat within these deformation zones.
4) Explain the following techniques of tool temperature measurement with the help of a neat
diagram:
a) Tool-work piece thermocouple technique.
b) Embedded thermocouple technique.
c) Infrared photographic technique.
5) Give a broad classification of various types of cutting fluids. Explain with the help of a
diagram the following methods of cutting fluid application.
a) Flood method
b) Mist method
6) Describe at least 5 additives for coolants and give their functions. How to choose the best
coolant for machining a particular metal.
 Assignment-4
Malaviya National Institute of Technology, Jaipur
Mechanical Engineering Department
Course Name: Machining Science and Machine Tools (B.Tech 4th Semester)
1) Explain the following types of tool wear mechanisms:
a) Diffusion wear.
b) Adhesion wear.
c) Abrasion wear.
2) Following is the data available on cutting speed and tool life:
V=150m/min T=60 min
V=200m/min T=23 min
Determine the Taylor’s constant and tool life exponent.
3)
Spindle Feed(f) Components
Speed (N)
250 0.1 311
250 0.125 249
300 0.125 144

This is the record of number of identical components produced at different speeds and feeds.
Estimate the number of components that can be produced at a spindle speed of 310 rpm and
feed of 0.15mm per revolution.
4) A turning tool with sharp corner and major cutting edge angle of 60 o is to be used at a
feed of 0.05mm.What minor cutting edge angle should be provided to obtain a
arithmetical mean surface roughness of 3μm under ideal conditions?
5) Define the term ‘Machinability’. Explain the various factors which affect machinability.
6) Write short notes on:
a) Flank wear
b) Crater wear
c) Chipping
7) Discuss the causes of variability of the constants n and c of Taylor’s tool life equation.
Also explain the relationship between tool temperature and tool life.
 Assignment-5
Malaviya National Institute of Technology, Jaipur
Mechanical Engineering Department
Course Name: Machining Science and Machine Tools (B.Tech 4th Semester)
1) Define retrofitting and state its objectives. Write down its procedure and benefits.
2) Describe the following in details:
a) Drive mechanisms in CNC
b) ATC
3) What are the various aspects an engineer should keep in mind before introducing CNC
machine tool at its workplace?
4) What is a backlash error in CNC. Describe the various methods of compensating it.
5) Define feedback system of a CNC machine tool and its principle with the help of a neat
diagram
6) Explain the different types of maintenance system used for a CNC machine tool
7) In a cutting operation with a cutting speed of 50m/min, a tool life of 45 mins was observed.
When the cutting speed was increased to 100 m/min tool life decreases to 10 min. Estimate the
cutting for maximum productivity if tool change time is 2 mins.
8) Discuss the effect of variations in cutting speed on various cost factors with the help of a
graph.
9) Prepare a part program to position the tool (say a drill) successively at points A, B, C and D
in incremental mode. The position of A, B, C and D are shown in figure below:
10) It is desired to turn a bar of 50mm dia to 46 mm dia over a length of 30mm.Write a part
program for it