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Question Bank
During shaping like single point machining/turning) a steel plate at feed, 0.20 mm/stroke and
depth 4 mm by a tool of = = 0 and = 90 Fz and Fx were found (measured by
dynamometer) to be 800 N and 400 N respectively, chip thickness, a2 is 0.4 mm. From the
aforesaid conditions and using Merchants Circle Diagram determine the yield shear strength of
the work material in the machining condition?
Calculate the time taken to turn a brass component of 60 mm diameter by 84 mm long diameter
if the cutting speed is 50 m/min and the feed is 0.4 mm/rev. Only one cut has to be considered.
Neglect tool approach and tool travel
We have set up a lathe and are doing an orthogonal cut. The feed rate of the lathe is 0.1mm, and
the chip thickness after the cut is 0.2mm. The depth of the chip being cut is 5mm. The surface
cutting speed of the tool is 2m/s. The tool has a rake angle of 10deg. The tangential force is
measured as 200N, and the cutting force is 500N. a) Calculate the shear force and velocity. b)
Calculate the total energy produced in the cut, c) Calculate the energy used to shear d) Explain the
difference between the total and the shear energy.
What factors will affect surface finish? Derive the ideal surface finish equation for a turning process
17. a) Define machinability. b) What determines the machinability of a metal?
We are going to estimate the effects of feedrate on tool life. Some simple calculations yield the
Taylor tool life coefficients of n = 0.4 and a C = 400. Find the change in tool life (in %) when velocity
drops by a) 20% and b) 40%
What type of grinding is suited to the outside surfaces for the parts below?
Why are ceramic cutting tools generally designed with negative rake angles?
Explain the term carbon seeking and how it affects the PCD cutting tools
Explain the difference between the PVD and CVD coating process
Explain the relationship between the cutting force with cutting velocity for High speed
machining.
Write a short note about the spindle design requirement for High speed machining
What is lay pattern in a machined surface?. Indicate the lay pattern for
1. Surface Grinding
Taking a suitable example discuss how cutting tool wear can be mathematically modeled
using different approaches? What benefits can be achieved from such modelling?
(b) Write a note on 'tool life testing' and the success rate and reliability of the methods
used for the same.
(c) Discuss the following:
(i) Wear-Land wear.
(ii) Crater wear
A HSS tool requires regrinding after 2 hours and 45 minutes when machining steel at a
cutting speed of 35m/min: Calculate the tool Iife if the speed is increased to 70m/min.
How does metallurgy of the work material and the cutting tool affect the machinability in
any machining operation?
Discuss what different types of wear can take place in cutting tool. Explain any three of
them along with the mechanism involved
Taking the optimization variables as 'specific cost' and 'production rate', describe the
procedural steps that are involved in optimizing any machining operation? Support your
answer with a suitable example.
How brittle fracture is analyzed in tools using the fracture mechanics approach.
Discuss the mechanism of grinding in detail. Also describe the cutting action of the grit
and the effect of grit force on wheel wear.
(b) How grinding wheels are tested?
(c) Mention the procedural steps required in simulating any grinding process. What
advantages are associated with it?
Using the concept of dynamometry and theoretical considerations, explain how the
following can be measured during metal cutting
(i) Force measurement.
(ii) Heat measurement.
(iii) Temperature measurement.
Discuss in detail the force system in oblique cutting. How does it differ from orthogonal
cutting?
b. Discontinuous chips
d. Segmented chips
a. 20 degree to 40 degree
b. 40 degree to 60 degree
g) c. 60 degree to 80 degree
d. 80 degree to 90 degree
h) Consider the following statements in respect of a grinding wheel of specifications, 51A-36-L-7-R-23, using the standard alphanumeric codification:
i)
medium
j)
m) a. 1, 2 and 3
b. 1, 3 and 4
c. 2, 3 and 5
d. 1, 4 and 5
where V is the cutting speed in m/min and T is the tool life in min. The carbide tool will provide
higher tool life if the cutting speed in m/min exceeds
(A) 15.0 (B) 39.4 (C) 49.3 (D) 60.0
During plain turning mild steel by a tool of geometry, 0, 0, 8, 7, 15, 90, 0 (mm) at s0= 0.2
mm/rev, the chip thickness was found to be 0.5 mm. Determine the values of cutting ratio and
shear angle in the above case.
A TAP is a cutting tool used to create which one of the following geometries
A horizontal spindle surface grinder is cutting with t = 5 mm and U = 40 GPa. Estimate the
tangential force on the wheel if the wheel speed is 30 m.s-1, the cross-feed per stroke is 1.2
mm, the work speed is 0.3 m.s-1, and the wheel depth of cut is 0.05 mm.
What is flow stress in machining operation explain its importance for modeling of machining
process.
Select the process which corrects the following Errors in the cylinder bore
a) Curvature b) conicity c) barrel form d) lack of roundness e) taper f) waviness
Explain its operating principles.