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IES-2000
GATE-2016
In an orthogonal cutting test, the cutting force and
In an orthogonal cutting process the tool used has rake
thrust force were observed to be 1000N and 500 N
angle of zero degree. The measured cutting force and
respectively. If the rake angle of tool is zero, the
thrust force are 500 N and 250 N, respectively. The
coefficient of friction in chip-tool interface will be
coefficient of friction between the tool and the chip is
1 1
a 2 b 2 c d 2 ________________
2

IAS 1995 GATE-2016

In a single point turning operation with cemented carbide
In a single point turning operation with a cemented
tool and steel work piece, it is found that the Taylors
carbide and steel combination having a Taylor
exponent is 0.25. If the cutting speed is reduced by 50% then
exponent of 0.25, if the cutting speed is halved, then
the tool life changes by ______ times.
the tool life will become
(a) Half
(b) Two times
(c) Eight times
(d) Sixteen times

ESE-1999; IAS -2010 Conventional GATE-2016

The following equation for tool life was obtained for HSS The tool life equation for HSS tool is VT0.14 f 0.7 d0.4

tool. A 60 min tool life was obtained using the following

= C. The tool life (T) of 30 min is obtained using the
cutting condition VT0.13f0.6d0.3= C. v = 40 m/min, f = 0.25
following cutting conditions: V = 45 m/min, f = 0.35
mm, d = 2.0 mm. Calculate the effect on tool life if
mm, d = 2.0 mm. If speed (V), feed(f) and depth of
speed, feed and depth of cut are together increased by
cut (d) are increased individually by 25%, the tool
25% and also if they are increased individually by 25%;
life (in min) is
where f = feed, d = depth of cut, v = speed.
(a) 0.15 (b) 1.06 (c) 22.50 (d) 30.0

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IES - 1993 GATE-2016

Internal gear cutting operation can be performed by Internal gears are manufactured by

(a) Hobbing
(a) Milling
(b) Shaping with pinion cutter
(b) Shaping with rack cutter
(c) Shaping with rack cutter
(c) Shaping with pinion cutter
(d) Milling
(d) Hobbing

GATE-2007 GATE-2016
For an orthogonal cutting operation, tool material is
In orthogonal turning of a low carbon steel bar
of diameter 150 mm with uncoated carbide HSS, rake angle is 22o , chip thickness is 0.8 mm, speed
tool, the cutting velocity is 90 m/min. The feed is 48 m/min and feed is 0.4 mm/rev. The shear plane
is 0.24 mm/rev and the depth of cut is 2 mm.
angle (in degree) is
The chip thickness obtained is 0.48 mm. If the
orthogonal rake angle is zero and the principal
cutting edge angle is 90, the shear angle is
degree is
(a) 20.56 (b) 26.56
(c) 30.56 (d) 36.56

Example GATE-2016
How much machining time will be required to reduce The following data is applicable for a turning

the diameter of a cast iron rod from 120 mm to 116 mm operation. The length of job is 900 mm, diameter of

over a length of 100 mm by turning using a carbide job is 200 mm, feed rate is 0.25 mm/rev and

insert. Cutting velocity is 100 m/min and feed rate = 0.2 optimum cutting speed is 300 m/min. The

mm/rev. machining time (in min) in ________________

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GATE-1992, ISRO-2012, VS-2013 GATE-2016

The true strain for a low carbon steel bar which is The value of true strain produced in compressing a
doubled in length by forging is cylinder to half its original length is
(a) 0.307
(b) 0.5 (a) 0.69 (b) -0.69
(c) 0.693 (c) 0.5 (d) -0.5
(d) 1.0

GATE-2014 GATE-2016
The relationship between true strain (T ) and Engineering strain of a mild steel sample is
engineering strain (E ) in a uniaxial tension test is recorded as 0.100%. The true strain is
(a) E = ln(1 + T ) (b) E = ln(1 - T ) (a) 0.010 %
(c) T = ln(1 + E ) (d) T = ln(1 - E ) (b) 0.055 %

(c) 0.099 %

(d) 0.101 %

GATE-2013 (PI) GATE-2016

Circular blanks of 10 mm diameter are punched
from an aluminium sheet of 2 mm thickness. The
shear strength of aluminium is 80 MPa. The
minimum punching force required in kN is
(a) 2.57
In a sheet metal of 2 mm thickness a hole of 10 mm
diameter needs to be punched. The yield strength in
tension of the sheet material is 100 MPa and its ultimate
shear strength is 80 MPa. The force required to punch
the hole (in kN) is _______

(b) 3.29
(c) 5.03
(d) 6.33

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GATE-2016
Maximum Draft Possible
A 300 mm thick slab is being cold rolled using
roll of 600 mm diameter. If the coefficient of

h max = 2R friction is 0.08,

reduction (in mm) is ____________
the maximum possible

Formula GATE-2016
Vo To Cn For a certain job, the cost of metal cutting is Rs.
18C/V and the cost of tooling is Rs. 270C/(TV), where
Optimum tool life for minimum cost
C 1 n C is a constant, V is cutting speed in m/min and T is
To Tc t if Tc , Ct & Cm given
C m n the tool life in minutes. The Taylors tool life
C 1 n
t if Ct & Cm given equation is VT0.25 = 150. The cutting speed (in
Cm n
Optimum tool life for Maximum Productivity m/min) for the minimum total cost is ________
(minimum production time)
1 n
To Tc
n

GATE -2014
The diameter of a recessed ring was measured by using two GATE-2016
spherical balls of diameter d2 = 60 mm and d1 = 40 mm as For the situation shown in the figure below the
shown in the figure. expression for H in terms of r, R and D is
The distance
H2 = 35.55 H2 H1 ( a ) H D r 2 R2
mm and d1 Diameter
H1 = 20.55 C
(b) H ( R r ) ( D r )
mm. The
diameter (D, H (c ) H ( R r ) D 2 R2
A B
in mm) of the R ( d ) H ( R r ) 2 D( R r ) D 2
ring gauge is
.
Recessed Ring
D

d2 Diameter

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Limit Gauges Feeler Gauge

Gauge For Measuring
Snap Gauge External Dimensions
Plug Gauge Internal Dimensions
Taper Plug Gauge Taper hole
Ring Gauge External Diameter
Gap Gauge Gaps and Grooves
Radius Gauge Gauging radius
Thread pitch Gauge External Thread

GATE-2016
PSU Match the following:
A feeler gauge is used to check the P. Feeler gauge I. Radius of an object
Q. Fillet gauge II. Diameter within limits by
(a) Pitch of the screw comparison
(b) Surface roughness R. Snap gauge III. Clearance or gap between
components
(c) Thickness of clearance S. Cylindrical plug IV. Inside diameter of straight
(d) Flatness of a surface gauge hole
(a) P-III, Q-I, R-II, S-IV (b) P-III, Q-II, R-I, S-IV
(c) P-IV, Q-II, R-I, S-III (d) P-IV, Q-I, R-II, S-III

GATE-2002, Conventional GATE-2016

The arc length-voltage characteristic of a DC arc is given
by the equation: V = 24 + 4L, where V is voltage in volts
and L is arc length in mm. The static volt-ampere
characteristic of the power source is approximated by a
straight line with a no load voltage of 80 V and a short
circuit current of 600A. Determine the optimum arc
length for maximum power.
The voltage-length characteristic of a direct current arc
in an arc welding process is V = (100 + 40 l ), where l is
the length of the arc in mm and V is arc voltage in volts.
During a welding operation, the arc length varies
between 1 and 2 mm and the welding current is in the
range 200 250 A. Assuming a linear power source, the
short circuit current is _______ A.

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GATE-2009 (PI) Linked S-1
Resistance spot welding of two steel sheets is carried out in
lap joint configuration by using a welding current of 3 kA and
a weld time of 0.2 S. A molten weld nugget of volume 20 mm3
is obtained. The effective contact resistance is 200
(micro-ohms). The material properties of steel are given as:
(i) latent heat of melting: 1400 kJ/kg, (ii) density: 8000
kg/m3, (iii) melting temperature: 1520oC, (iv) specific heat:
0.5 kJ/kgoC. The ambient temperature is 20oC.
Heat (in Joules) used for producing weld nugget will be
(assuming 100% heat transfer efficiency)
(a) 324 (b) 334 (c) 344 (d) 354
GATE-2016
Spot welding of two steel sheets each 2 mm thick is
carried out successfully by passing 4 KA of current
for 0.2 seconds through the electrodes. The
resulting weld nugget formed between the sheets is
5 mm in diameter. Assuming cylindrical shape for
the nugget, the thickness of the nugget is ________
mm.
Latent heat of fusion for steel 1400 kJ/kg
Effective resistance of the weld joint 200
Density of steel 8000 kg/m3

IES-2006
GATE-2016
In which of the following welding processes, flux
is used in the form of granules? The welding process which uses a blanket of
fusible granular flux is
(a) AC arc welding
(a) Tungsten inert gas welding
(b) Submerged arc welding
(b) Submerged arc welding
(c) Argon arc welding
(c) Electroslag welding
(d) DC arc welding
(d) Thermit welding

GATE - 2009 GATE-2016

Match the following part programming codes with their
respective functions.
Part Programming Functions
Codes
P. G01 I. Spindle Stop
Q. G03 II. Spindle rotation, clockwise
R. M03 III. Circular interpolation,
anticlockwise
S. M05 IV. Linear interpolation
(a)P-II, Q-I, R-IV, S-III (b) P-IV, Q-II, R-III, S-I
(c) P-IV, Q-III, R-II, S-I (d) P-III, Q-IV, R-II, S-I

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GATE-2013 GATE-2016
A point P(1, 3, -5) is translated by 2 + 3 - 4k and then
In a CAD package, mirror image of a 2D point
rotated counter clockwise by 90o about the z-axis. The
P(5,10) is to be obtained about a line which passes
new position of the point is
through the origin and makes an angle of 45o
(a) (-6, 3, -9)
counterclockwise with the X-axis. The coordinates
(b) (-6, -3, -9)
of the transformed point will be
(c) (6, 3, -9)
(a) (7.5, 5) (b) (10, 5) (c) (7.5, -5) (d) (10, -5)
(d) (6, 3, 9)

GATE-2014 GATE-2016
The figure below represents a triangle PQR with initial
A robot arm PQ with end coordinates P(0, 0) and Q(2, 5)
coordinates of the vertices as P(1,3), Q(4,5) and R(5,3.5).
rotates counter clockwise about P in the XY plane by 90o. The triangle is rotated in the X-Y plane about the vertex
P by angle in clockwise direction. If sin = 0.6 and cos
The new coordinate pair of the end point Q is = 0.8, the new coordinates of the vertex Q are
(a) (2, 5) (b) (5, 2) (a) (4.6, 2.8)
(b) (3.2, 4.6)
(c) (5, 2) (d) (2, 5) (c) (7.9, 5.5)
(d) (5.5, 7.9)

Example GATE-2016
The surface irregularities of electrodes used in an
Calculate the material removal rate and the electrochemical machining (ECM) process are 3 m and 6
electrode feed rate in the electrochemical m as shown in the figure. If the work-piece is of pure iron
machining of an iron surface that is 25 mm 25 mm and 12V DC is applied between the electrodes, the largest
feed rate is ______________________ mm/min.
in cross-section using NaCl in water as electrolyte.
The gap between the tool and the workpiece is 0.25 Conductivity of the electrolyte 0.02 ohm-1 mm-1
mm. The supply voltage is 12 V DC. The specific Over-potential voltage 1.5 V
resistance of the electrolyte is 3 cm
Density of iron 7860 kg/m3
For iron, Valency, Z = 2
Atomic weight of iron 55.85 gm
Atomic weight, A = 55.85
Density, = 7860 kg / m3 Assume the iron to be dissolved as Fe+2 and the Faraday
constant to be 96500 Coulomb

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Example
In ECM operation of pure iron an equilibrium gap of 2
mm is to be kept. Determine supply voltage, if the total
overvoltage is 2.5 V. The resistivity of the electrolyte is 50
-mm and the set feed rate is 0.25 mm/min.

GATE-2016
When the fringes are perfectly straight and same fringe Two optically flat plates of glass are kept at a small
width for dark and bright band we conclude that the angle as shown in the figure. Monochromatic light
is incident vertically.
surface is perfectly flat.
For convex surface the fringes curve around the point of
contact.
For concave surface the fringes curve away from the
point of contact.

The distance of air gap between two successive fringes is given by
2
n If the wavelength of light used to get a fringe
Distance of air gap of interference fringe of n order is
th

2 spacing of 1 mm is 450 nm, the wavelength of light

(in nm) to get a fringe spacing of 1.5 mm is _______

Brazing and Soldering Soldering

Brazing is the joining of metals through the use of heat
and a filler metal whose melting temperature is above By definition, soldering is a brazing type of operation
450C; but below the melting point of the metals being
joined. where the filler metal has a melting temperature
Comparison with welding and the brazing process
below 450C.
1. The composition of the brazing alloy is significantly
different from that of the base metal.
Strength of the filler metal is low.
2. The strength of the brazing alloy is substantially lower
than that of the base metal.
Soldering is used for a neat leak-proof joint or a low
3. The melting point of the brazing alloy is lower than that
of the base metal, so the base metal is not melted. resistance electrical joint.
4. Capillary action or capillary attraction draws the
molten filler metal into the joint, even against the flow of Not suitable for high-temp. application.
gravity.
Contd

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IAS-1996 GATE -2016

Match List I with List II and select the correct answer using Under optional conditions of the process the
the codes given below the lists
List I List-II temperatures experienced by a copper work
(Filler rod material) (Joining process) piece in fusion welding, brazing and soldering
A. Mild steel 1. MIG welding are such that
B. Bronze 2. Soldering
C. Brass 3. Brazing ( a ) Twelding Tsoldering Tbrazing
D. Lead and tin alloy 4. Thermit welding
5. Braze welding (b) Tsoldering Twelding Tbrazing
Codes:A B C D A B C D
(a) 1 5 3 2 (b) 4 3 2 5 (c ) Tbrazing Twelding Tsoldering
(c) 4 3 5 2 (d) 1 3 5 4
(d ) Twelding Tbrazing Tsoldering

GATE-2016
Conventional Question IES-2008 A cylindrical job with diameter of 200 mm and
Calculate the size of a cylindrical riser (height and diameter height of 100 mm is to be cast using modulus
equal) necessary to feed a steel slab casting of dimensions method of riser design. Assume that the bottom
30 x 30 x 6 cm with a side riser, casting poured horizontally
surface of cylindrical riser does not contribute as
into the mould.
cooling surface. If the diameter of the riser is equal
[Use Modulus Method]
to its height, then the height of the riser (in mm) is
[10 - Marks]
(a) 150 (b) 200 (c) 100 (d) 125

GATE-2016
Cooling Curve Heat is removed from a molten metal of mass 2 kg at a
constant rate of 10 kW till it is completely solidified. The
cooling curve is shown in the figure.
Assuming uniform
temperature
throughout the
volume of the metal
during solidification,
the latent heat of
fusion of the metal
(in KJ/kg) is
__________

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GATE-2016
GATE 2010 (PI) Equal amount of a liquid metal at the same temperature
Solidification time of a metallic alloy casting is are poured into three moulds made of steel, copper and
aluminium. The shape of the cavity is a cylinder with 15
(a) Directly proportional to its surface area mm diameter. The size of the moulds are such that the
outside temperature of the moulds do not increase
(b) Directly proportional to the specific heat of the appreciably beyond the atmospheric temperature during
solidification. The sequence of solidification in the
cast material mould from the fastest to slowest is
(c) Directly proportional to the thermal diffusivity of (Thermal conductivities of steel, copper and aluminium
are 60.5, 401 and 237 W/m-K, respectively.
the molten metal Specific heats of steel, copper and aluminium are 434,
385 and 903 J/kg-K, respectively.
(d)Inversely proportional to the pouring
Densities of steel, copper and aluminium are 7854, 8933
temperature. and 2700 kg/m3, respectively.)

GATE-2016 contd....
Densities of steel, copper and aluminium are 7854, 8933
and 2700 kg/m3, respectively.)
(a) Copper Steel Aluminium
(b) Aluminium Steel Copper
(c) Copper aluminium Steel
Contd........
(d) Steel Copper Aluminium

GATE-2004 GATE-2016
Gray cast iron blocks 200 x 100 x 10 mm are to be Gray cast iron blocks of size 100 mm x 50 mm x
cast in sand moulds. Shrinkage allowance for 10 mm with a central spherical cavity of
pattern making is 1%. The ratio of the volume of diameter 4 mm are sand cast. The shrinkage
pattern to that of the casting will be allowance for the pattern is 3%. The ratio of
the volume of the pattern to volume of the
(a) 0.97 (b) 0.99 (c) 1.01 (d) 1.03 casting is ____________

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Expression for choke area

m
GATE-2016
CA mm2
ct 2gH The part of a gating system which regulates
the rate of pouring of molten metal is
Where m = mass of the casting, kg
= Density of metal, kg / m3 (a) Pouring basin (b) runner
t = pouring time (c) Choke (d) ingate
c = Efficiency factor and is the function of gate
system used
H = Effective head of liquid metal
= h for top gate

Contd

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