Introduction to Manufacturing and Machining

Objective
1. Machining is a
(a) Shaping process
(b) Removal process
(c) Regenerative process
(d) Joining process.

2. An object is machined to
(a) Fulfill its functional requirement
(b) Provide desirably good performance
(c) Render longer service life
(d) all of the above.

3. Feed rate is expressed in turning operation by

(a) mm/revolution
(b) mm/stroke
(c) mm per min
(d) none of the above.

4. Rapid prototyping is a
(a) Joining process
(b) removal process
(c) Regenerative manufacturing process
(d) Finishing process

Descriptive
1. What should be the aims and objectives in manufacturing of any product?
2. Justify “Machining is a value addition process”.
3. Why even a battery operated pencil sharpener cannot be accepted as a machine tool?
4. Why is making profit must for any industry?

Basic working principle, configuration, specification and

classification of machine tools
1. Show the tool-work motions and the Generatrix and Directrix in external thread cutting in
entre lathe. Also state how those ‘G’ & ‘D’ are obtained.
2. In which conventional machine tools flat surface can be produced ?
3. State the major differences between shaping machine and planing machine.
4. In which machine tools both the cutting motion & the feed motion are imparted to the tool ?
5. How is feed expressed in turning, shaping, drilling and milling ?
Geometry of single point cutting tools
1. Back rake of a turning tool is measured on its
(a) machine longitudinal plane
(b) machine transverse plane
(c) orthogonal plane
(d) normal plane

2. Normal rake and orthogonal rake of a turning tool will be same when its
(a) φ = 0
(b) φ = 0
1
(c) λ = 0
o
(d) φ = 90
1

3. Normal plane of a turning tool is always perpendicular to its

(a) π plane
X
(b) π plane
Y
(c) π plane
C
(d) none of them

4. Principal cutting edge angle of any turning tool is measured on its

(a) π
R
(b) π
Y
(c) π
X
(d) π
o
5. A cutting tool can never have its
(a) rake angle – positive
(b) rake angle – negative
(c) clearance angle – positive
(d) clearance angle – negative

6. Orthogonal clearance and side clearance of a turning tool will be same if

its perpendicular cutting edge angle is
o
(a) φ = 30
o
(b) φ = 45
o
(c) φ = 60
o
(d) φ = 90
7. Inclination angle of a turning tool is measured on its
(a) reference plane
(b) cutting plane
(c) orthogonal plane
(d) normal plane

8. Normal rake and side rake of a turning tool will be same if its
o o
(a) φ = 0 and λ = 0
o o
(b) φ = 90 and λ = 0
o o
(c) φ = 90 and λ = 90
o o
(d) φ = 0 and λ = 90

Conversion of tool angles from one system to another

Select the correct answer from the given four options
o o o o o o
1. The master line for the rake surface of the turning tool of geometry : - 10 , 0 , 8 , 6 , 15 , 30 ,
0.1 (inch)
(a) machine longitudinal plane
(b) Machine transverse plane
(c) Cutting plane
(d) Orthogonal plane
o
2. If the approach angle of a turning tool be 30 , the value of its principal cutting edge angle will
be
(a) O deg.
o
(b) 30 deg.
o
(c) 60 deg.
o
(d) 90 deg.
3. The value of side rake of the turning tool of geometry : -
o o o o o o
0 , 10 , 8 , 6 , 20 , 60 , 0 (mm) will be
o
(a) 0 deg.
o
(b) 10 deg.
o
(c) 8 deg.
o
(d) 6 deg.

4. The values of orthogonal clearance and normal clearance of a

turning tool will be same if,
(a) φ=0
(b) αX = αY
(c) λ = 0
(d) none of the above
5. The angle between orthogonal plane and normal plane of a turning
tool is
(a) γo
(b) φ
(c) γn
(d) λ

Problem
1. Determine the values of normal rake of the turning tool whose geometry is designated as :
o o o o o o
10 , - 10 , 8 , 6 , 15 , 30 , 0 (inch)?
o
2. Determine the value of side clearance of the turning tool whose geometry is specified as 0 , -
o o o o o
10 , 8 , 6 , 20 , 60 , 0 (mm) ?

Mechanism of chip formation

1.In turning mild steel the value of ζ will be
(a) > 1.0
(b) < 1.0
(c) = 1.0
(d) none of the above
2.The value of shear angle, βo depends upon
(a) tool rake angle
(b) friction at chip-tool interface
(c) built – up – edge formation
(d) all of the above
3.Shaping grey cast iron block will produce
(a) Continuous chip with BUE
(b) Continuous chip without BUE
(c) Discontinuous chip of irregular size & shape
(d) Discontinuous chip of regular size & shape

4.The value of chip reduction coefficient, ζ does not depend upon

(a) cutting velocity
(b) depth of cut
(c) cutting tool material
(d) tool rake angle

1.During plain turning mild steel by a tool of geometry, 0o, 0o, 8o, 7o, 15o, 90o, 0 (mm) at so=
0.2 mm/rev, the chip thickness was found to be 0.5 mm. Determine the values of ζ and βo in the
above case
Orthogonal and oblique cutting
1.Cutting will be called orthogonal when
(a) λ = 0
(b) λ = 0 and φ= 90o
(c) chip flows along πo plane
(d) λ = 0 and r (nose radius) = 0
2.In turning, chip will flow along πo only when
(a) RCE is absent
(b) nose radius is zero
(c) λ = 0
(d) all of the above conditions
3.Deviation of chip flow from po ( ? )does not depend upon
(a) cutting velocity
(b) feed
(c) depth of cut
(d) nose radius
4.Effective rake in any turning process is measured on
(a) πX
(b) πo
(c) πn
(d) none of the above

Use of chip breaker in machining

Machining forces and Merchant’s Circle Diagram (MCD)

Analytical and Experimental determination of cutting forces

Dynamometers for measuring cutting forces
Control of cutting temperature and cutting fluid application
1. Cutting fluid is employed in machining for
(a) cooling the tool and the job
(b) lubricate at the rubbing surfaces
(c) cleaning the machining zone
(d) all of the above

2. For same tool-work materials and speed, feed and depth of cut, the average cutting
temperature will decrease
(a) with the increase in principal cutting edge angle (φ)
(b) with the decrease in principal cutting edge angle (φ)
(c) with the increase in auxiliary cutting edge angle (φ1)
(d) with the decrease in the auxiliary cutting edge angle (φ1)

3. The work material, which is machined by HSS tool generally in dry condition, is
(a) grey cast iron
(b) mild steel
(c) stainless steel
(d) low alloy steel

4. Extreme pressure additive (EPA) is mixed with cutting fluid for improving its power of
(a) cooling
(b) lubrication
(c) cleaning of the cutting zone
(d) protection of the machined surface
5. More lubricating type cutting fluid should be used while machining
(a) easily machinable material at high speed
(b) grey cast iron at low speed
(c) high alloy steels at low speed
(d) aluminium at high speed

6. In Z-Z method of cooling in surface grinding, the cutting fluid is employed

(a) in the form of flood under gravity
(b) in the form of jet at the grinding zone
(c) drop by drop
(d) none of the above

7. In machining copper under heavy cut one should use

(a) light soluble oil
(b) active type chemical fluid

(c) inactive type chemical fluid

(d) compound oil
Failure of cutting tools and tool life

1. In high speed machining of steels the teeth of milling cutters may fail by
(a) mechanical breakage
(b) plastic deformation
(c) wear
(d) all of the above
2. Tool life in turning will decrease by maximum extent if we double the
(a) depth of cut
(b) feed
(c) cutting velocity
(d) tool rake angle
3. In cutting tools, crater wear develops at
(a) the rake surface
(b) the principal flank
(c) the auxiliary flank
(d) the tool nose
4. To prevent plastic deformation at the cutting edge, the tool material should possess
(a) high fracture toughness
(b) high hot hardness
(c) chemical stability
(d) adhesion resistance