QUESTION BANK

PR2201 - Basic Machining Processes

PART-A 1. What is the main function of Lathe? The main function of the lathe is to reduce the diameter and the length of the given work piece to the required dimension 2. List the various types of lathes? Engine lathe , tool room lathe, precision lathe , bench lathe, special purpose lathe, turret lathe, automatic lathe. 3. What is the function of a back gear? It doubles the number of speeds by providing the same number of slower speeds. 4. What is a mandrel? Why they are used in Lathe? It is hardened and tempered steel shaft that is mounted between centers 5. What are the operations that can be done on the Lathe? Centering, turning, taper turning , step turning, thread cutting, facing, knurling, polishing, filing, spinning, grooving, drilling , boring, reaming, counter boring, keyway cutting 6. Define taper. Name different methods of taper turning done on a centre lathe. A uniform increase in diameter of the workpiece along its length from one end to the other. 7. What are the functions of tailstock in Lathe? To hold the work piece which are very long, used in drilling, boring operations, it is used to do taper turning operation, 8. What is meant by burnishing on Lathe? It is a method of cold working metal surfaces to induce compressive residual stresses and enhance surface roughness qualities. The tooling typically consists of a hardened sphere or cylindrical roller 9. What are the functions of feed rod and lead screw in Lathe? It is used in thread cutting mechanism, and helps in automatic movement of carriage on the lathe bed.

10. What is the use of tumbler gear mechanism in Lathe. Tumbler gears are provided between the spindle and gear train along with a quadrant plate that enables a gear train of the correct ratio and direction to be introduced. This provides a constant relationship between the number of turns the spindle makes, to the number of turns the leadscrew makes. 11. Classify and list shapers. Standard shaper, universal shaper, crank shaper, geared shaper, hydraulic shaper, horizontal shaper, vertical shaper, vertical shaper, push cut shaper, draw cut shaper. 12. How the size of a shaper is specified? It is specified by the maximum length of stroke. 13. What is the difference between plain shaper and a universal shaper? Plain shaper has only vertical and horizontal movements but universal shaper has a swiveled axis which can be adjusted at any position. 14. What are the advantages of hydraulic shaper over crank shaper? More cutting force is exerted, hardened surfaces can be machined by this method,very efficient than the crank shaper, reduction of noise. 15. How you can adjust the length of stroke in a shaper? The length of the stroke can be adjusted by adjusting the distance between the crank and the rotating gear. 16. What is the fundamentals difference between a planner and a shaper? In a planner the work piece reciprocates on a fixed tool or tools, in a shaper the tool reciprocates on a fixed tool. 17. List different types of planers. Double housing planner, open side planner, pit type planner, edge or plate type planer Divided table planner. 18. What types of operations can be performed efficiently by a planer? Flat horizontal surfaces, vertical surfaces, angled surfaces, curved surfaces, helix, slots and grooves etc. 19. List various types of slotter. Puncher slotter, general purpose slotters, precissio tool room slotters, keyseater.

20. How a slotter is specified? Th length of stroke, the diameter of the work table, the maximum table travel, table feed per feed double stroke, principal movement motor power, overall dimensions of the slotter. 21. What is the difference between a vertical shaper and a slotter? The work table moves horizontally whereas in slotter the work table is rotating 22. Name different types of drilling machines. Portable drilling machine, bench type drilling, sensitive drilling, upright drilling, radial drilling, multiple spindke drilling, deep hole drilling, gang drilling, automatic drilling 23. How the size of a drilling machine is specified? Maximum diameter of the drill that can be held in the machine. 24. Name the various work holding devices of drilling machine. Machine vise, V- block, T bolts, strap clamp. Step block, angle plate, parallels, drill jig 25. What is trepanning? Cutting of a large hole in thin diameter material. 26. What is meant by counter boring? It has a guide that goes into the already existing hole and thus maintains the alignment of the counterboring tool. 27. What is meant by counter sinking? The countersinking operation bevels the mouth of a hole with a rotary tool called a counter sink. 28. What is a reamer? When it is used? It is a multiple cutting edge tool. It is used when the holes are extremely accurate and have an exceptionally fine finish. 29. Distinguish between gang drilling and multiple spindle drilling. In multiple , it drills no of holes simultaneously in work piece in gang drilling various drilling operations can be done simultaneously on the drilling machine. 30. How will you calculate the torque in drilling machine? The torque is given by 2180 f.0.78d1.8

31. What is meant by spot facing? It provides a locally machined , flat seating around a holefor nuts or bolts being pulled down onto otherwise rough casting or forgings . 32. What is meant by tapping? Tapping is the process of creating a thread on a drilled hole. Usually the tap diameter is greater than that of the drilled hole diameter. 33. Differentiate between drilling and boring. Drilling is the process of making holes in object or in a given job is called drilling. Enlargement of a drilled hole to a higher diameter is called boring 34. What is meant by deep hole drilling? For drilling holes in rifle barrels connecting rods, and long spindles is called as deep hole drilling 35. How will you calculate machining time in drilling? Machining time for drilling is given by t= 60p/ Nf. 36. Classify milling machines and list them accordingly. column and knee type milling machine, planner milling machine, fixed bed milling machine, machining center machined, special types of milling machines. 37. Compare between plain and universal milling machine. A plain milling machine has a horizontal and vertical tool head, whereas the universal milling hasd the ability to swivel the tool head 38. What is meant by slab milling? Slab milling is otherwise known as plain milling. It produces plain horizontal surfaces. 39. Write short notes on straddle milling. Two side and face cutters, separated by spacing collars of the required dimensions , amy be used to produce parallel work in one cut. 40. What is meant by end milling? It is used to produce a flat surface which may be horizontal, vertical or at an angle with respect to the position of the table. The end mill is used to cut keyways and slots in a vertical milling machine.

41. What is meant by cam milling? cam milling machine consists of an eccentric projections on a revolving shafts shaped son that it can levers to a set position for a period and then return the lever to the original place. 42. What are the different methods of indexing? Rapid or direct indexing, simple or plain indexing, compound indexing, differential indexing, angular indexing 43. Why precision grinding is important? Precision grinding is principally associated with the removal of small amount of material to close tolerance 44. List various grinding machines. Cylindrical grinder, centerless grinder, internal grinder, surface grinder, tool and cutter grinder, special grinding machines, other grinding machines, Abrasive machining. 45. What is the function of grinding machine? How this function is similar or dissimilar with other machine tools? It can be applied nto any component which requires precision machining, especially if accuracy or surface finish required cannot be easily achieved by any other machining process. 46. What is meant by a universal grinder? How does it differ from a plain grinder? A universal cylindrical grinder differs from a plain cylindrical grinder in the sense that the wheel head can be swiveled on its base and can be fed to and from the table. 47. What is centre less grinding? In centerless grinder, the work piece is not held in centers; rather two wheels and a work rest support the work piece. The two wheels also help feed the work piece. 48. How the size of grinder is specified? The largest work piece which can be held on the grinder, the normal capacity of the grinder. The width of the table, the maximum traverse of the teable, wheel diameter, height of the grinding head. 49. Define grit, grade and structure.

the grain size of the abrasive material id called a grit, the grade referring to the hardness of the bond, structure of a grinding wheel refers to the grain spacing or the manner in which the abrasives grains are distributed. 50. List the various types of abrasives. Natural and synthetic, in natural, sandstone, emery, corundum, diamonds, garnet. Synthetic- silicon carbide, aluminum oxide, boron carbide, cubic boron nitride. 51. What is meant by bonding in grinding wheel? The bond is the material which cements or holds the abrasive grains together to form a grinding wheel. 52. What is meant by dressing? It removes metal or foreign matter which has lodges in and loaded the pores of the wheel. Fine grit wheels may load up quiet quickly. It removes dull grains wheels will burn the work and cause fine heat cracks 53. What is meant by truing? Truning of grinding wheels , just like dressing, is necessary. From time to time, to correct for the un even wear on the wheel face so as to obtain efficient cutting conditions. 54. What is meant by loading? It is welding of chips to the abrasives grains or mechanical trapping of chips in the pores of the grinding wheel. 55. Write short notes on glazing. Glazing of the wheel is a condition in which the abrasive particles in the wheel have become dull by attririous wear. 56. Why a grinding wheel is to be balanced? A un balanced wheel should never be used, because of the high rotative speeds involved, a slight unbalance will produce vibrations that will cause waviness in the work surface.