2017 Metal Cutting Metal Forming Metrology PDF

Metal Cutting, Metal Forming & Metrology
Questions & Answers-For 2018 (All Questions are in Sequence)

IES-1992-2017 (26 Yrs.), GATE-1992-2017 (26 Yrs.), GATE (PI)-2000-2017 (18 Yrs.), IAS-1994-
2010 (17 Yrs.), some PSUs questions and conventional questions IES, IAS, IFS are added.
Section-I: Theory of Metal Cutting Questions Answer & Explanations
Chapter-1: Basics of Metal Cutting Page-1 Page-144
Chapter-2: Analysis of Metal Cutting Page-8 Page- 148
Chapter-3: Tool life, Tool Wear, Economics and Machinability Page-19 Page-159
Section-II: Metrology Questions Answer & Explanations

Chapter-4: Limit, Tolerance & Fits Page-37 Page-169
Chapter-5: Measurement of Lines & Surfaces Page-50 Page-176
Chapter-6: Miscellaneous of Metrology Page-62 Page-177
Section-III: Metal Forming Questions Answer & Explanations

Chapter-7: Cold Working, Recrystalization and Hot Working Page-67 Page-179
Chapter-8: Rolling Page-72 Page-180
Chapter-9: Forging Page-82 Page-183
Chapter-10: Extrusion & Drawing Page-92 Page-186
Chapter-11: Sheet Metal Operation Page-105 Page-190
Chapter-12: Powder Metallurgy Page-124 Page-194
Section-IV: Cutting Tool Materials Page-133 Page-195
For-2018 (IES, GATE & PSUs)

Manufacturing
g is a p
process of converting
g raw Orthogonal Machining
material in to finished product by using various
Theory of Metal Cutting processes, machines and energy, it is a narrow term.
Production is a p
process of converting
g inputs
p in to
b
outputs it is a broader term.
By S K Mondal
b
1 2 3
Speed feed
Speed, feed, and depth of cut IES‐2013 IES‐2001
Carbide tool is used to machine a 30 mm diameter For cutting of brass with single‐point cutting tool
steel
t l shaft
h ft att a spindle
i dl speed
d off 1000 revolutions
l ti per on a lathe, tool should have
minute The cutting speed of the above turning
minute.
(a) Negative rake angle
operation
p is:
(b) Positive rake angle
k l
(a) 1000 rpm
( ) Zero rake angle
(c) Z k l
(b) 1570 m/min
(d) Zero side relief angle
Z id li f l
(c) 94.2 m/min
Cutting speed, feed, and depth of cut for a turning operation (d) 47.1 m/min
4 5 6
IES‐1995 GATE‐1995; 2008 IES‐1993

Cutting power consumption in turning can be Assertion
A i (A):
(A) For
F a negative i rake
k tool,
l the
h specific
ifi
Single point thread cutting tool should ideally cutting pressure is smaller than for a positive rake
have: significantly reduced by
f l d db tool under otherwise identical conditions.
(a) Increasing rake angle of the tool Reason (R): The shear strain undergone by the chip
a) Zero rake in the case of negative rake tool is larger.
(b) Increasing the cutting angles of the tool ( ) Both
(a) h A and d R are individually
d d ll true and d R is the
h
b) Positive rake
(c) Widening the nose radius of the tool correct explanation of A
c) Negative rake (b) Both A and R are individually true but R is not the
(d) Increasing the clearance angle correct explanation of A
d) Normal rake
l k
(c) A is true but R is false
(d) A is false but R is true
7 8 9
For-2018 (IES,GATE & PSUs) Page 1 of 213 Rev.0
IES – 2005 IES‐2015 IES – 2002
Statement (I) : The ceramic tools used in machining of
Assertion
A i (A):
(A) Carbide
C bid tips i are generallyll given
i Assertion
A i (A):
(A) Negative
N i rakek is
i usuallyll provided
id d on
material have highly brittle tool tips.
negative rake angle. carbide tipped tools.
Statement (II) : Ceramic tools can be used on hard‐to hard to
Reason (R): Carbide tips are made from very hard machine work material. Reason (R): Carbide tools are weaker in
materials.
materials ( ) Both
(a) B th statement
t t t (I) and
d (II) are individually
i di id ll true
t andd compression.
compression
(a) Both A and R are individually true and R is the statement (II) is the correct explanation of statement (I) (a) Both A and R are individually true and R is the
correct explanation
l off A (b) Both statement (I) and statement(II) are individually correct explanation
l off A
(b) Both
ot A aand d R aaree individually
d v dua y ttrue
ue but R iss not
ot tthee true but statement(II)
( ) is not the correct explanation
p of (b) Both
d v dua y ttrue
ue but R iss not
ot tthee
correct explanation of A statement (I) correct explanation of A
( ) A is
(c) i true
t b t R is
but i false
f l (c) Statement (I) is true but Statement (II) is false ( ) A is
(c) i true
t b t R is
but i false
f l
(d) Statement (I) is false but statement (II) is true
(d) A is false but R is true (d) A is false but R is true
10 11 12
IES 2011 IAS – 1994

Which one of the following statement is NOT correct
GATE –
GATE – 2008 (PI)
2008 (PI) Consider the following characteristics
C id h f ll i h i i
g g g
1. The cutting edge is normal to the cutting velocity.y
with
h reference
f to the
h purposes and
d effects
ff off rake
k angle
l B ittl materials
Brittle t i l are machined
hi d with
ith tools
t l
2. The cutting forces occur in two directions only.
of a cutting tool? having zero or negative rake angle because it
3. The cutting edge is wider than the depth of cut.
Th i d i id h h d h f
(a) To guide the chip flow direction (a) results in lower cutting force pp g g
The characteristics applicable to orthogonal cutting
would include
(b) To reduce the friction between the tool flanks and ((b)) improves
p surface finish
( ) 1 and 2
(a) d (b) 1 and 3
d
the machined surface ((c)) p
provides adequate
q strength
g to cutting
g tool (c) 2 and 3 (d) 1, 2 and 3
(c) To add keenness or sharpness to the cutting edges.
(d) results in more accurate dimensions
(d) To provide better thermal efficiency.
13 14 15
IES ‐ 2014 IES ‐ 2012 IES‐2006

Which
Whi h one off theh following
f ll i statements is i correct about
b During orthogonal cutting, an increase in cutting speed
D i h l i i i i d
an oblique cutting? causes Which of the following is a single point cutting
(a) Direction of chip flow velocity is normal to the (a) An increase in longitudinal cutting force tool?
cutting edge of the tool (b) An increase in radial cutting force
(b) Only two components of cutting forces act on the (a) Hacksaw blade
(c) An increase in tangential cutting force
tooll (d) Cutting forces to remain unaffected (b) Milling cutter
(c) cutt
cutting
g edge oof tthee too
tool iss inclined
c ed at aan acute aangle
ge
to the direction of tool feed (c) Grinding wheel
(d) Cutting
C tti edged clears
l th width
the idth off the
th workpiece
k i (d) Parting tool
16 17 18
GATE‐2017(PI) IES ‐ 2012 IES‐2003
Statement (I): Negative rake angles are preferred on rigid set‐
St t t (I) N ti k l f d i id t The
Th angle l off inclination
i li i off the
h rake
k face
f with
ih
Turning, drilling, boring and milling are ups for interrupted cutting and difficult‐to machine respect to the tool base measured in a plane
commonly used machining operations.
operations Among materials.
materials
perpendicular to the base and parallel to the width
these, the operation(s) performed by a single Statement (II):Negative rake angle directs the chips on to the
machined surface of the tool is called
point cutting tool is (are) (a) Back rake angle
(a) Both Statement (I) and Statement (II) are individually
( ) turning
(a) t i t
true andd Statement
St t t (II) is
i the
th correctt explanation
l ti off (b) Side
S d rake
k angle l
Statement (I)
(b) drilling and milling only (b) Both
B h Statement
S (I) and
d Statement
S (II) are individually
i di id ll
(c) S
Side
de cutt
cuttingg edge aangle
ge
(c) turning and boring only true but Statement (II) is not the correct explanation of (d) End cutting edge angle
St t
Statement t (I)
(d) boring only (c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement (II) is true
19 20 21
IES‐2015 GATE(PI)‐1990 IAS – 1996

The tool life increases with the
Th l lif i i h h
The purpose of providing side rake angle in the cutting The diameter and rotational speed of a job are 100 mm and
((a)) Increase in side cutting edge angle
g g g
tool is 500 rpm respectively. The high spot (Chatter marks) are (b) Decrease in side rake angle
(a) avoid work from rubbing against tool f
found
d at a spacing off 30 deg
d on the
h job
b surface.
f The
h chatter
h ( ) Decrease in nose radius
(c) D i di
(b) Control chip flow
flo frequency is ((d)) Decrease in back rake angle
g
(c) Strengthen tool edge ((a)) 5 Hz ((b)) 12 Hz ((c)) 100 Hz ((d)) 5500 Hz
(d) Break chips

p
22 23 24
IAS – 1995 IES 2010 IES‐1995

Thrust force will increase with the increase in
Th f ill i i h h i i Consider
C id the
th following
f ll i statements:
t t t The angle between the face and the flank of the
((a)) Side cutting edge angle
g g g In an orthogonal, single
single‐point
point metal cutting, single point cutting tool is known as
(b) Tool nose radius as the side‐cutting edge angle is increased, a) Rake angle
( ) Rake angle
(c) R k l 1. The tangential force increases. b) Clearance angle
( )
(d) End cutting edge angle.
g g g 2 The longitudinal force drops.
2. drops c) Lip angle
d) Point angle.
33. The radial force increases.
Which of these statements are correct?
(a) 1 and 3 only (b) 1 and 2 only
( ) 2 and
(c) d 3 only
l (d) 1, 2 and
d3
25 26 27
IES‐2006 IES‐2002 IES ‐ 2012
Assertion (A): For drilling cast iron, the tool is Consider the following statements: Tool life increase with increase in
T l lif i i h i i
p
provided with a p point angle
g smaller than that The strength of a single point cutting tool depends ( )
(a) Cutting speed
g p
required for a ductile material. upon (b) Nose radius
Reason (R): Smaller point angle results in lower 1. Rake
R k angle l ( ) F d
(c) Feed
rake angle. 2. Clearance angleg ( ) p
(d) Depth of cut
(a) Both A and R are individually true and R is the 3. Lip angle
correct explanation
p of A
Which
hi h off these
h statements are correct?
(b) Both A and R are individually true but R is not the
correctt explanation
l ti off A (a) 1 aand
d3 ((b)) 2 aand
d3
(c) A is true but R is false (c) 1 and 2 (d) 1, 2 and 3
(d) A is false but R is true 28 29 30
IES‐2009 IES‐1995 IES‐1994

Consider
C id the
h following
f ll i statements about
b nose Tool geometry of a single point cutting tool is specified by
Consider the following statements with respect the following elements:
to the effects of a large g nose radius on the tool: radius
1
1. Back rake angle
1. It deteriorates surface finish. 1. It improves tool life 2. Side rake angle
2. It I increases
i the
h possibility
ibili off chatter.
h 2 It reduces the cutting force
2. 3. End d cutting edge
d angle l
33. It improves
p tool life. 3. It improves the surface finish. 4. Side cutting edge angle
Which of the above statements is/are correct? Select the correct answer using the codes given below: 5. Side relief angle
( ) 1 and
(a) d2 (b) 2 andd3 6. End relief angle
( ) 2 only
(a) l (b) 3 only
l
7. Nose radius
(c) 2 aandd3o onlyy (d) 1,, 2 aand
d3 (c) 1 and 3 (d) 1, 2 and 3
The correct sequence of these tool elements used for
correctly specifying the tool geometry is
( ) 1,2,3,6,5,4,7
(a) 6 (b) 1,2,6,5,3,4,7
6
31 32 (c) 1,2,5,6,3,4,7 (d) 1, 2, 6, 3, 5, 4,7 33
IES‐2009 IES‐1993
The following tool signature is specified for a single‐ In ASA System, if the tool nomenclature is 8‐6‐5‐5‐ ISRO‐2011
point cutting
p g tool in American system:
y 10‐15‐2‐mm,
5 , then the side rake angle
g will be A cutting tool having tool signature as 10,
10 9,
9 6,
6 6,
6 8,
8 8,
8
10, 12, 8, 6, 15, 20, 3 (a) 5° (b) 6° (c) 8° (d) 10°
g
2 will have side rake angle
Wh does
What d the
h angle l 12 represent??
((a)) Side cutting‐edge
g g angle g (a) 10o (b) 9o (c) 8o (d) 2o
(b) Side rake angle
( ) Back
(c) k rake
k anglel
(d) Side
de cclearance
ea a ce aangle
ge
34 35 36
GATE‐2008 GATE‐2001 GATE 2011
In
I a single
i l pointi turningi tool,
l the
h side
id rake
k anglel A single – point cutting tool with 12° rake angle is
During orthogonal cutting of mild steel with
and orthogonal rake angle are equal. Φ is the used to machine a steel work – p piece. The depth
p of
principal cutting edge angle and its range is a 10
10° rake angle tool,
tool the chip thickness ratio
cut, i.e. uncut thickness is 0.81 mm. The chip
0o ≤ φ ≤ 90o . The chip flows in the orthogonal plane.
plane
was obtained as 0.4. The shear angle (in thickness under orthogonal machining condition is
The value of Φ is closest to degrees) evaluated from this data is 1.8 mm. The shear angle is approximately
(a) 00 (b) 450 ( ) 6
(a) 6.53 (b)
(b) 20.22
( ) 22°°
(a)
(c) 600 (d) 900 (c) 22.94 (d) 50.00 ((b)) 26°
(c) 56°
(d) 76°
37 38 39
IES‐1994
GATE‐2017 The
Th following
f ll i parameterst determine
d t i the
th IES‐2014 Conventional
IES‐2014 Conventional
In an orthogonal machining with a tool of 90 model of continuous chip p formation: A bar of 70 mm diameter is being cut
orthogonal rake angle, the uncut chip 1. True feed orthogonally and is reduced to 68 mm by a
thickness
h k is 0.2 mm. Theh chip
h thickness
h k cutting tool.
tool In case mean length of the chip is
2. Cutting velocity
68.9 mm, find the cutting ratio. Determine
fluctuates between 0.25 mm and 0.4 mm. 3 Chip thickness
3. shear
h angle
l also
l if the
h rake
k angle i 10o
l is
The ratio of the maximum shear angle to the
4. Rake angle
4 g of the cutting g tool.
minimum
i i shear
h angle
l during
d i machining
hi i is i [10 Marks]
___________ The parameters which govern the value of shear
angle
l wouldld include
l d
Hint: length of uncut chip = πD
(a) 1,2
1 2 and 3 (b) 1,31 3 and 4
40
(c) 1,2 and 4 (d) 2,3 and 4 41 42
IAS 2015 Main

IAS‐2015 Main
GATE‐2014 IES ‐ 2004 In an orthogonal cutting operation, the tool has a
rake angle = 10o. The chip thickness before the cut
During
g p
pure orthogonal
g turning
g operation
p of a In a machining
g operation
p chip
p thickness ratio = 0.5
0 5 mm and the cut yields a deformed chip
hollow cylindrical pipe, it is found that the is 0.3 and the rake angle of the tool is 10°. What thickness = 1.125 mm.
thickness of the chip produced is 0.5 mm. The feed is the value of the shear strain? Calculate
given to the zero degree rake angle tool is 0.2 (i) shear
h plane
l angle,
l
(a) 0.31 (b) 0.13
mm/rev. The shear strain produced during the
(ii) shear strain for the operation.
operation
(c) 3.00 (d) 3.34
Derive the formulae that are to be used while
operation is ……………….
finding out the shear plane angle and shear
strain.
strain
For-2018 (IES,GATE & PSUs)
43
Page 5 of 213
44
[20‐Marks]
Rev.0
45
IES ‐ 2009 GATE (PI)‐1990
IES 2016
IES‐2016
During the formation of chips in machining with a
Minimum shear strain in A single point cutting tool with 120 rake angle is cutting tool, which one of the following relations
orthogonal
th l turning
t i with
ith a cutting
tti used for orthogonal machining of a ductile h ld good?
holds d
tool of zero rake angle
g is (a)
V V
= s = c
V
(b)
V V
= s = c
V
material.
i l Th
The shear
h plane
l angle
l f
for the
h cos (φ − α ) cos α sin α sin (φ − α ) cos α cos α
(a) 0.0
theoretically minimum possible shear strain to V V Vs
(b) 0.5 (c ) = c = (d ) V cos α = Vc sin α = Vs cos (α − φ )
cos α sin α sin (φ − α )
occur
( ) 1.0
(c)
(a) 51 (b) 45 where V is the cutting speed, Vc is the velocity of the
(d) 2.0
20 chip,
hi VsV is
i the
th velocity
l it att which
hi h shearing
h i t k place
takes l
(c) 30 (d) None of these along the shear plane, φ is the shear angle and α is the
rake angle.
46 47 48
GATE 2012
GATE ‐2012 IES‐2004 IES‐2006
Details pertaining to an orthogonal metal cutting Consider the following statements with respect to
C id h f ll i i h Consider the following statements:
C id h f ll i
process are given below. the relief angle of cutting tool: 1. A large rake angle means lower strength of the
g g g
Chip thickness ratio 0.4 1. This affects the direction of chip flow cutting edge.
Undeformed thickness 0 6 mm
0.6 2 This reduces excessive friction between the tool
2. This reduces excessive friction between the tool 2 Cutting torque decreases with rake angle.
2. Cutting torque decreases with rake angle
Rake angle +10° and work piece Which of the statements given above is/are correct?
Cutting speed 2.5 m/s 3. This affects tool life (a) Only 1 (b) Only 2
Mean thickness of primary shear zone 25 microns 4 This allows better access of coolant to the tool
4. This allows better access of coolant to the tool ( ) Both 1 and 2
(c) B th d (d) Neither 1 nor 2
N ith
The shear strain rate in s–1 during the process is work piece interface
(a) 0.1781×105 (b) 0.7754×105 Which of the statements given above are correct?
h h f h b
(c) 1.0104×10
1 0104×105 4 397×105
(d) 4.397×10 (a) 1 and 2 (b) 2 and 3
49 (c) 2 and 4 (d) 3 and 4 50 51
IES‐2004 IES‐2004, ISRO‐2009 IES‐2008

Match. List I with List II and select the correct answer
M h Li I i h Li II d l h Consider the following statements:
C id h f ll i
The rake angle of a cutting tool is 15°, shear angle 45°
using the codes given below the Lists: In an orthogonal cutting the cutting ratio is found to be
List I List II and
d cutting velocity
l 35 m/min. What
h is the
h velocity
l 0∙75. The cutting speed is 60 m/min and depth of cut 2∙4
A. Plan approach angle 1. Tool face mm. Which of the following are correct?
g
of chip along the tool face?
B. Rake angle 2. Tool flank 1. Chip velocity will be 45 m/min.
C Clearance angle
C. Cl l 3. T l f
Tool face and flank
d fl k (a) 28.5
28 5 m/min (b) 27 3 m/min
27.3 2 Chip velocity will be 80 m/min.
2. Chip velocity will be 80 m/min
D. Wedge angle
g g 4.
4 Cutting edge
g g 3. Chip thickness will be 1∙8 mm.
(c) 25.3
25 3 m/min (d) 23 5 m/min
23.5
5. Tool nose 4. Chip thickness will be 3∙2 mm.
A B C D A B C D Select the correct answer using the code given below:
(a) 1 4 2 5 (b) 4 1 3 2 (a) 1 and 3 (b) 1 and 4
(c) 4 1 2 3 (d) 1 4 3 5 ( ) 2 and 3
(c) d (d) 2 and 4d
52 53 54
IES ‐ 2014 IES‐2001 IES‐2003
In
I an orthogonal
h l turning
i process, the
h chip
hi thickness
hi k = If α is
i theh rake
k angle
l off the
h cutting
i tool,l φ isi the
h An
A orthogonal
h l cutting
i operation
i is
i being
b i
0.32 mm, feed = 0.2 mm/rev. then the cutting ratio will shear angle and V is the cutting velocity, then the carried out under the following conditions:
be velocity of chip sliding along the shear plane is cutting speed = 2 m/s, depth of cut = 0.5 mm,
(a) 2.6
26 given
i b
by chip
hi thickness
thi k = 0.6
6 mm. Then
Th th chip
the hi
(b) 3.2 velocityy is
(c) 1.6 V cos α V sin φ
(a) (b) (a) 2.0 m/s (b) 2.4 m/s
(d) 1.8
18 cos(φ − α ) cos (φ − α )
(c) 1.0 m/s (d) 1.66 m/s
V cos α V sin α
( )
(c) sin(φ − α )
(d) sin(φ − α )
55 56 57
IAS‐2003 IAS‐2002 IAS‐2000

In orthogonal cutting, shear angle is the angle between
( ) Shear plane and the cutting velocity
(a)
(b) Shear plane and the rake plane
Sh l d th k l
(c) Shear plane and the vertical direction
((d)) Shear plane and the direction of elongation of crystals in
p g y
the chip
58 59 60
IAS‐1998 IAS‐1995 GATE – 2009 (PI) Common Data S‐1

The cutting velocity in m/sec, for turning a work piece In
I an orthogonal
h l cutting,
i the
h depth
d h off cut is
i halved
h l d and
d An
A orthogonal
h l turning
i operation
i is
i carried
i d out at 20
the feed rate is double. If the chip thickness ratio is
off diameter
di t 100 mm att the
th spindle
i dl speed
d off 480
8 RPM is
i unaffected
ff d withh the
h changed
h d cutting conditions,
d the
h m/min cutting speed,
speed using a cutting tool of rake angle
actual chip thickness will be 155o. The chip
p thickness is 0.4
4 mm and the uncut chip
p
(a) 1.26
1 26 (b) 2 51
2.51 (c) 48 (d) 151
(a) Doubled (b) halved
thickness is 0.2 mm.
(c) Quadrupled (d) Unchanged.
Unchanged
The shear plane angle (in degrees) is
(a) 26.8 (b) 27.8 (c) 28.8 (d) 29.8
61 62 63
GATE – 2009 (PI) Common Data S‐2 GATE‐1995 IES 2007
An
A orthogonal
h l turning
i operation
i is
i carried
i d out at 20 During machining, excess metal is removed in the form
During machining excess metal is removed in the form
Plain milling of mild steel plate produces of chip as in the case of turning on a lathe. Which of the
m/min cutting speed,
speed using a cutting tool of rake angle following are correct?
(a) Irregular shaped discontinuous chips
Continuous ribbon like chip is formed when turning
155o. The chip
p thickness is 0.4
4 mm and the uncut chip
p (b) Regular shaped discontinuous chip 1
1. At a higher cutting speed
thickness is 0.2 mm. (c) Continuous chips without built up edge 2. At a lower cutting speed
(d) Joined chips 3. A brittle material
The chip velocity (in m/min) is 4. A ductile material
4
Select the correct answer using the code given below:
(a) 8 (b) 10 (c) 12 (d) 14
(a) 1 and 3 (b) 1 and 4
(c) 2 and 3 (d) 2 and 4
64 65 66
IES‐2015 IAS‐1997 GATE‐2002

Consider the following machining conditions: BUE will A built‐up‐edge is formed while machining
Coarse feed , low rake angle, low cutting speed and
f
form in
i
insufficient cooling help produce (a) Ductile materials at high speed
(a) Ductile material.
Ductile material (b) High cutting speed
High cutting speed.
(a) continuous chips in ductile materials (b) Ductile materials at low speed
(c) S
Small rake angle.
a a e a g e. (d) Small uncut chip thickness.
S a u cut c p t c ess.
(b) discontinuous chips in ductile materials ( )
(c) Brittle materials at high speed
(c)continuous chips with built
built‐up
up edges in ductile
(d) B i l
(d) Brittle materials at low speed
i l l d
materials
(d) discontinuous chips in brittle materials
67 68 69
GATE‐2009 IES‐1997
Friction at the tool‐chip interface can be reduced by Assertion (A): For high speed turning of cast iron
pistons, carbide tool bits are provided with chip
b k
breakers.
Analysis of Metal Cutting
(a) decreasing the rake angle
Reason (R): High speed turning may produce long,
ribbon type continuous chips which must be broken
(b) increasing the depth of cut into small lengths which otherwise would be
difficult to handle and may yp
prove hazardous.
( ) Decreasing the cutting speed
(c) (a) Both A and R are individually true and R is the
correct explanation
p of A
(d) increasing
i i the
h cutting
i speed
d (b) Both A and R are individually true but R is not the
correct explanation of A
B S K M d l
By S K Mondal
70 71 72
ESE ‐2000 (Conventional) Limitations of use of MCD GATE ‐2010 (PI) Linked S‐1
The following data from the orthogonal cutting test In
I orthogonal
h l turning
i off an engineering
i i alloy,
ll it
i has
h
1. MCD is valid only for orthogonal cutting. been observed that the friction force acting at the chip‐
is available. Rake angle = 100, chip thickness ratio =
0.35, uncut chip thickness = 0.51 mm, width of cut = 2. By the ratio F/N, the MCD gives apparent (not actual)
tool interface is 402.5 N and the friction force is also
3 mm,
mm yield shear stress of work material = 285 perpendicular
p p to the cuttingg velocityy vector. The feed
co‐efficient of friction. velocity is negligibly small with respect to the cutting
N/mm2, mean friction co‐efficient on tool face =
0.65,
6 D
Determinei velocity The ratio of friction force to normal force
velocity.
associated with the chip‐tool interface is 1. The uncut
((i)) Cutting
g force ((Fc)
chip
hi thickness
thi k i 0.2 mm and
is d the
th chip
hi thickness
thi k i 0.4
is
(ii) Radial force mm. The cutting velocity is 2 m/s.
(iii) Normal
N l force
f (N) on tooll and
d The shear force (in N) acting along the primary shear
((iv)) Shear force ((Fs )). plane is
73 74 (a) 180.0 (b) 240.0 (c) 360.5 (d) 402.5 75
GATE ‐2010 (PI) Linked S‐2 Linked Answer Questions GATE‐2013 S‐1 Linked Answer Questions GATE‐2013 S‐2

In
I orthogonal
th l turning
t i off an engineering
i i alloy,
ll it has
h
been observed that the friction force acting at the chip‐ In orthogonal turning of a bar of 100 mm diameter In orthogonal turning of a bar of 100 mm diameter
t l interface
tool i t f i 402.5 N and
is d the
th friction
f i ti f
force i also
is l with a feed of 0.25 mm/rev, depth of cut of 4 mm with a feed of 0.25 mm/rev, depth of cut of 4 mm
perpendicular to the cutting velocity vector. The feed
velocity
l it isi negligibly
li ibl small ll with
ith respectt to t the
th cutting
tti and
d cutting
tti velocity
l it off 90 m/min,
/ i it is
i observed
b d that
th t and
d cutting
tti velocity
l it off 90 m/min,
/ i it is
i observed
b d that
th t
velocity. The ratio of friction force to normal force
the main (tangential)cutting force is perpendicular the main (tangential)cutting force is perpendicular
associated
i t d with
ith the
th chip‐tool
hi t l interface
i t f i 1. The
is Th uncutt
chip thickness is 0.2 mm and the chip thickness is 0.4 to friction force acting at the chip‐tool interface. to friction force acting at the chip‐tool interface.
mm. The
Th cutting
i velocity
l i isi 2 m/s. /
The main (tangential) cutting force is 1500 N. The main (tangential) cutting force is 1500 N.
Assume that the energy gy expended
p during g machining g is
completely converted to heat. The rate of heat y The orthogonal rake angle of the cutting tool in degree is y The normal force acting at the chip‐tool interface in N is
generation (in W) at the p
g primaryy shear p plane is
(a) 180.5 (b) 200.5 (c) 302.5 (d) 402.5 (a) zero (b) 3.58 (c) 5 (d) 7.16 (a) 1000 (b) 1500 (c) 20oo (d) 2500
76 77 78
GATE 2015
GATE-2015 GATE 2017 (PI)
GATE‐2017 (PI)
The Merchant circle diagram g showingg various forces Merchant Theory or Analysis
A single point cutting tool with 0° rake angle is associated with a cutting process using a wedge ‐ shaped
tool is given in the Figure. Assumption
p
used in an orthogonal machining process. At a The coefficient of •The work material behaves like an ideal plastics.
cutting speed of 180 m/min, the thrust force is 490 friction can be
estimated from •The theory involves minimum energy principal.
N If the coefficient of friction between
N. bet een the tool the
h ratioi •τs and β are assumed to be constant, independent of φ
and the chip is 0.7, then the power consumption(in f f
(a) 1 (b) 3 I i b d i l h l h
•It is based on single shear plane theory.
kW) for the machining
g operation
p is _____ f2 f4
f5 f6
(c ) (d )
f6 f5
79 80 81
IAS – 1999
From Merchant Theory or Analysis
From Merchant Theory or Analysis
In an orthogonal cutting process, rake angle of the
π α β y Merchant
M h t theory
th gives
i hi h
higher shear
h plane
l tooll is 20° and
d friction
f angle
l is 25.5°. Using
φ= + − angle means smaller shear plane which means

lower shear force
Merchant'ss shear angle relationship,
Merchant relationship the value of
4 2 2 y Result: lower cutting forces, power, temperature,

shear angle will be
((a)) 39
39.5°
5 ((b)) 42.25°
4 5
all of which mean easier machining ((c)) 47
47.75°
75 ((d)) 550.5°
5
82 83 84
GATE‐1997 ESE‐2005 Conventional GATE 2008 (PI) Li k d S 1

GATE ‐2008 (PI) Linked S‐1
In an orthogonal cutting experiment,
experiment an HSS tool having
In a typical metal cutting operation, using a cutting Mild steel is being machined at a cutting speed of
200 m/min with a tool rake angle of 10. The width of the following
g tool signature
g in the orthogonal
g reference
tool of positive rake angle = 10°, it was observed cut and uncut thickness are 2 mm and 0.2 mm system (ORS) has been used: 0‐10‐7‐7‐10‐75‐1. Given
that the shear angle was 20°. The friction angle is respectively If the average value of co‐efficient
respectively. co efficient of
width of cut = 3.6 mm; shear strength of workpiece
friction between the tool and the chip is 0.5 and the
( ) 45°
(a) (b) 30° shear
h stress off the
h work
k material
i l is
i 400 N/mm
N/ 2, material
i l = 460 N/mm2; depth
6 N/ d h off cut = 0.25 mm;
( ) 60°
(c) 6 ° (d) 40°° Determine coefficient of friction at tool
tool‐chip
chip interface = 0.7.
07
(i) shear angle and Shear p

plane angle
g ((in degree)
g ) for minimum cutting
g force
((ii)) Cutting
g and thrust component
p of the force. is
85 86
(a) 20.5 (b) 24.5 (c) 28.5 (d) 32.5 87
GATE 2008 (PI) Li k d S 2

GATE ‐2008 (PI) Linked S‐2 GATE‐2014 GATE‐2014
In an orthogonal cutting experiment,
experiment an HSS tool having Which pair of following statements is correct for Better surface finish is obtained with a large rake
orthogonal cutting using a single‐point cutting angle because
the following
g tool signature
g in the orthogonal
g reference
t l?
tool? (a) the area of shear plane decreases resulting in the
system (ORS) has been used: 0‐10‐7‐7‐10‐75‐1. Given P. Reduction in friction angle
g increases cutting g force decrease in shear force and cuttingg force
width of cut = 3.6 mm; shear strength of workpiece Q. Reduction in friction angle decreases cutting force (b) the tool becomes thinner and the cutting force is
material
i l = 460 N/mm2; depth
6 N/ d h off cut = 0.25 mm; R Reduction
R. R d ti in i friction
f i ti anglel increases
i chip
hi thickness
thi k reduced
d d
coefficient of friction at tool
tool‐chip
chip interface = 0.7.
07 g decreases chip
S. Reduction in friction angle p thickness (c) less heat is accumulated in the cuttingg zone
(a) P and R (b) P and S (d) the friction between the chip and the tool is less
Minimum p
power requirement
q ((in kW)) at a cutting
g speed
p
( ) Q and
(c) dR (d) Q and
dS
of 150 m/min is
(a) 3.15 (b) 3.25 (c) 3.35 (d) 3.45 88 89 90
Modified Merchant Theory IES 2010 IES‐2005
The
Th relationship
l ti hi between
b t the
th shear
h angle
l Φ,
Φ
Which one of the following is the correct
τ s = τ so + kσ s g β and cutting
the friction angle g rake angle
g α
expression for the Merchant
Merchant'ss machinability
is given as
⎡ Fn ⎤ constant?
Wh
Where, σs is
i the
th normalstress
l t on shear
h plane
l ⎢σ s = ⎥ (a) 2φ + γ − α
⎣ As ⎦
(b) 2φ − γ + α
and then 2φ + β − α = cot (k )
−1
(c) 2φ − γ − α
((d)) φ + γ − α
(Where φ = shear angle,γ = friction angle
andα = rake angle)
91 92 93
IFS 2016
IFS‐2016 Other Relations
Theory of Lee and Shaffer In a slab milling g operation
p g teeth
with straight
•They applied the theory of plasticity for an cutter, the cutter has 15 teeth with 10o rake angle
and rotates at 200 rpm.rpm The diameter of the
ideal-rigid-plastic body.
cutter is 80 mm and table feed is 755 mm/min, the
•They also assumed that deformation occured depth of cut is 5 mm, the width of slab is 50 mm y By Stabler
on a thin-shear
thi h zone. and ultimate shear stress of work material is 420
N/mm2. Assuming the coefficient of friction
And derive between chip and cutter to be 0.7 and using Lee
π and Shaffer relation,
relation plot variation of resultant
φ= +α − β torque and cutter rotation, and estimate average
4
power consumption.i
94 95 96
The force relations (VIMP) IES‐2003 IES ‐ 2014

F = Fc sin α + Ft cos α In orthogonal cutting test, the cutting force = 900 N,
In
I an orthogonal
h l cutting
i operation
i shear
h anglel = 11.31o ,
cutting force = 900 N and thrust force = 810 N. Then the
the thrust force = 600 N and chip shear angle is 30o. shear force will be approximately ( given sin 11.31o = 0.2)
N = Fc cos α − Ft sin α Then the chip shear force is
(a) 650 N
(b) 720 N
Fn = Fc sin φ + Ft cos φ ( ) 1079.4 N

(a) (b) 969.6 N (c) 620 N
(d) 680 N
( ) 479.4 N
(c) (d) 6 6N
69.6
Fs = Fc cos φ − Ft sin φ
F
and μ = = tan β 97 98 99
N
IES‐2000 GATE – 2007 (PI) Common Data‐1
( )
GATE‐2016 In an orthogonal machining test, test the following
In an orthogonal cutting test, the cutting force and observations were made
In an orthogonal cutting process the tool used has rake
thrust force were observed to be 1000N and 500 N Cutting force 1200 N
angle
g of zero degree.
g The measured cutting
g force and Thrust force 500 N
respectively. If the rake angle of tool is zero, the
thrust force are 500 N and 250 N, respectively. The Tool rake angle zero
coefficient of friction in chip‐tool
chip tool interface will
ill be
coefficient of friction between the tool and the chip is Cutting speed 1 m/s
1 1 Depth of cut 0 8 mm
0.8
(a) 2 ( b) 2 ( c) ( d) 2
________________
2 Chip thickness 1.5 mm
Friction angle during machining will be
22 6o (b) 32.8
(a) 22.6 32 8o (c) 57.1
57 1o 67 4o
(d) 67.4
100 101 102
GATE – 2007 (PI) Common Data‐2
( ) G
GATE – 20 ( ) i k d S
2011 (PI) Linked S1 G
GATE – 20 ( ) i k d S2
2011 (PI) Linked S2
In an orthogonal machining test, test the following During orthogonal machining of a mild steel specimen During orthogonal machining of a mild steel specimen
observations were made with a cutting tool of zero rake angle, the following data with a cutting tool of zero rake angle, the following data
Cutting force 1200 N i obtained:
is bt i d i obtained:
is bt i d
Thrust force 500 N Uncut chip p thickness = 0.25 mm Uncut chipp thickness = 0.25 mm
Tool rake angle zero Chip thickness = 0.75 mm Chip thickness = 0.75 mm
Cutting speed 1 m/s Width off cutt = 2.5 mm Width off cutt = 2.5 mm
Depth of cut 0 8 mm
0.8 Normal force = 95 950 N Normal force = 95950 N
Chip thickness 1.5 mm Thrust force = 475 N Thrust force = 475 N
Th shear
The h angle
l andd shear
h f
force, respectively,
ti l are Th lti t h t
The ultimate shear stress (in N/mm
(i N/ 2) of the work
) f th k
Chip speed along the tool rake face will be
((a)) 771.565o
5 5 , 150.21
5 N ((b)) 18.435o
435 , 75
751.04
4N material is
(a) 0.83
0 83 m/s (b) 0.53
0 53 m/s
(c) 9.218o, 861.64 N (d) 23.157o , 686.66 N (a) 235 (b) 139 (c) 564 (d) 380
(c) 1.2 m/s (d) 1.88 m/s 103 104 105
IFS 2012
IFS‐2012
An orthogonal machining operation is being carried out GATE‐2006 Common Data Questions(1) GATE‐2006 Common Data Questions(2)
under the following conditions : In an orthogonal machining operation: In an orthogonal machining operation:
depth of cut = 0.1 mm, Uncut thickness 0 5 mm
Uncut thickness = 0.5 mm Uncut thickness 0 5 mm
Uncut thickness = 0.5 mm
chip thickness = 0.2 mm, Cutting speed = 20 m/min Rake angle = 15° Cutting speed = 20 m/min Rake angle = 15°
width of cut = 5 mm, Width of cut = 5 mm Chip thickness = 0.7 mm Width of cut = 5 mm Chip thickness = 0.7 mm
rake angle = 10o Thrust force 200 N
Thrust force = 200 N Cutting force 1200 N
Cutting force = 1200 N Thrust force 200 N
Cutting force = 1200 N
The force components along and normal to the direction Assume Merchant's theory. Assume Merchant's theory.
of cutting velocity are 500 N and 200 N respectively.
f i l i N d N i l
The coefficient of friction at the tool‐chip interface is The percentage of total energy dissipated due to
Determine
(a) 0 23
(a) 0.23 (b) 0 46
(b) 0.46 friction at the tool chip interface is
friction at the tool‐chip interface is
(i) The coefficient of friction between the tool and chip.
(c) 0.85 (d) 0.95 (a) 30% (b) 42%
(ii) Ultimate shear stress of the workpiece material [10]
(ii) Ultimate shear stress of the workpiece material. [10]
(c) 58% (d) 70%
106 107 108
GATE‐2006 Common Data Questions(3) T i O ti
Turning Operation y Fc or Fz or tangential component or primary cutting
force acting in the direction of the cutting velocity,
In an orthogonal machining operation: largest
l force
f andd accounts forf 99%% off the
h power
required by the process.
Uncut thickness 0 5 mm
Uncut thickness = 0.5 mm
y Fx or axial component or feed force acting in the
Cutting speed = 20 m/min Rake angle = 15°
direction of the tool feed.
feed This force is about 50% of
Width of cut = 5 mm Chip thickness = 0.7 mm Fc, but accounts for only a small percentage of the
Thrust force 200 N
Cutting force = 1200 N power required
i d because
b f d rates
feed t are usually
ll small
ll
Assume Merchant's theory. compared to cutting speeds.
The values of shear angle and shear strain, y Fy or radial force or thrust force in turning acting
respectively are
respectively, are perpendicular to the machined surface. This force is
(a) 30.3° and 1.98 (b) 30.3° and 4.23 about 50% of Fx i.e. 25% of Fc and contributes very
little to power requirements because velocity in the
(c) 40.2° and 2.97 (d) 40.2° and 1.65
109 110 radial direction is negligible. 111
IES‐1995 IES‐2001 IES‐1997

The primary tool force used in calculating the total Power consumption in metal cutting is Consider the following forces acting on a
mainly due to finish turning tool:
power consumption in machining is the
((a)) Tangential
g component
p of the force 1. Feed force
(a) Radial force (b) Tangential force
(b) Longitudinal component of the force 2. Thrust force
(c) Axial force (d) Frictional force. (c) Normal component of the force 3. Cutting force.
(d) Friction
F i ti att the
th metal‐tool
t l t l interface
i t f Th correctt sequence off the
The th decreasing
d i order
d off
the magnitudes
g of these forces is
(a) 1, 2, 3 (b) 2, 3, 1
(c) 3, 1, 2 (d) 3, 2, 1
112 113 114
IES‐1999 f d f d h
Determination of Un‐deformed chip
The radial force in single‐point tool during
Conversion Formula
Conversion Formula thickness in Turning: (VIMP)
thickness in Turning: (VIMP)
turning operation varies between We have to convert turning (3D) to Orthogonal For single point cutting tool
Cutting (2D)
((a)) 0.2 to 0.4
4 times the main cutting
g force t = f sin λ
(b) 0.4 to 0.6 times the main cutting force Fc = Fz
d
(c) 0.6 to 0.8 times the main cutting force F b=
Ft = Fxy =
Fx
= y = Fx2 + Fy2 Where sin λ
(d) 0.5 to
t 0.66 times
ti th main
the i cutting
tti force
f
sin λ cos λ t =Uncut chip thickness
f = feed
λ = 90 – Cs = approach angle
Cs = side cutting edge angle
side cutting edge angle
For-2018 (IES,GATE & PSUs)

115
Page 13 of 213
116 l =πD Rev.0
117
GATE‐2014 ESE‐2003‐ Conventional GATE – 1995 ‐Conventional
During turning a carbon steel rod of 160 mm diameter by a
A straight turning operation is carried out using a carbide tool of geometry; 0, 0, 10, 8, 15, 75, 0 (mm) at speed of While turning a C‐15 steel rod of 160 mm diameter at
400 rpm,
p , feed
eed o
of 0.3
0.32 mm/rev
/ ev aandd 4.0 mm deptdepth o
of cut, tthe
e 315 rpm, 2.5 mm depth of cut and feed of 0.16
single point cutting tool on an AISI 1020 steel rod. following observation were made. mm/rev by a tool of geometry 00, 100, 80, 90,150, 750,
Tangential component of the cutting force, Pz = 1200 N 0(mm) the following observations were made.
0(mm), made
The feed is 0.2 mm/rev and the depth of cut is 0.5
Axial component of the cutting force, Px = 800 N
Tangential component of the cutting force = 500 N
mm The tool has a side cutting edge angle of 60o.
mm. Chi thickness
Chip thi k t) α 2 = 0.8
( ft cut),
(after 0 8 mm
mm.
Axial component of the cutting force = 200 N
For the above machining condition determine the values of
The uncut chip thickness (in mm) is ………. Chip thickness = 0.48
0 48 mm
(i) Friction force, F and normal force, N acting at the chip tool
interface. Draw schematically the Merchant’s circle diagram
(ii) Yield shears strength of the work material under this for the cutting force in the present case.
machining condition.
(iii) Cutting power consumption in kW.
118 119 120
IAS‐2003 Main Examination Orthogonal Turning (λ = 90o) GATE‐2007

During turning process with 7 ‐ ‐ 6 – 6 – 8 – 30 – 1
(mm) ASA tool the undeformed chip thickness of
Fc = Fz In orthogonal turning of a low carbon steel bar
of diameter 150 5 mm with uncoated carbide
2.0 mm and width of cut of 2.5 mm were used. The tool, the cutting velocity is 90 m/min. The feed
F F
side rake angle of the tool was a chosen that the
Ft = x = x = Fx is 0.24
0 24 mm/rev and the depth of cut is 2 mm.mm
sin λ sin90
machining operation could be approximated to be The chip thickness obtained is 0.48 mm. If the
orthogonal
h l cutting.
i Th tangential
The i l cutting
i force
f and
d orthogonal rake angle is zero and the principal
thrust force were 1177 N and 560 N respectively.
Calculate: [30 marks]
t = f sin λ = f sin90 = f cutting edge angle is 90°, the shear angle is
d
degree i
is
(i) The side rake angle (a) 20.56
.5 ((b)) 26.56
.5
d d
(ii) Co‐efficient of friction at the rake face b= = =d (c) 30.56 (d) 36.56
(iii) The dynamic shear strength of the work material
121
i λ sin90
sin i 90 122 123
GATE 2015
GATE-2015 GATE 2015
GATE-2015 GATE 2016
GATE‐2016
Orthogonal turning of mild steel tube with a tool For an orthogonal cutting operation, tool material is
An
A orthogonal
h l turning
i operation
i isi carried
i d out under
d
rake angle of 10° is carried out at a feed of 0.14 HSS, rake angle is 22o , chip thickness is 0.8 mm, speed
the following conditions: rake angle = 55°, spindle
mm/rev. If the thickness of chip produced is 0.28 mm. is 48 m/min and feed is 0.4 mm/rev. The shear plane
rotational speed
p = 4
400 rpm,
p , axial feed = 0.4
4 m/min
/
The values of shear angle and shear strain is angle (in degree) is
and radial depth of cut = 5 mm. The chip thickness, tc
a) 28°20´ and 2.19
is found to be 3 mm . The shear angle (in degrees) in
b) ° ´ and
b)22°20 d 3.53
this turning process is _____
c) 24
24°20´
20 and 4.19
4 19
d)37°20´
37 and 55.19
9
124 125 126
GATE‐2007 GATE‐2003 Common Data Questions(1) GATE‐2003 Common Data Questions(2)
In orthogonal turning of low carbon steel pipe with A cylinder is turned on a lathe with orthogonal A cylinder is turned on a lathe with orthogonal
machining principle.
principle Spindle rotates at 200 rpm.
rpm The machining principle.
principle Spindle rotates at 200 rpm.
rpm The
principal cutting edge angle of 90°, the main cutting axial feed rate is 0.25 mm per revolution. Depth of cut is axial feed rate is 0.25 mm per revolution. Depth of cut is
force is 1000 N and the feed force is 800 N. The shear 0 4 mm.
0.4 mm The rake angle is 10 10°. In the analysis it is found 0 4 mm.
0.4 mm The rake angle is 10 10°. In the analysis it is found
that the shear angle is 27.75° that the shear angle is 27.75°
angle is 25°
2 ° and orthogonal rake angle is zero.
ero The thickness of the produced chip is In the above problem, the coefficient of friction at
Employing Merchant
Merchant’ss theory, the ratio of friction (a) 0 511 mm
(a) 0.511 mm (b) 0 528 mm
(b) 0.528 mm the chip tool interface obtained using Earnest and
p g
(c) 0.818 mm (d) 0.846 mm Merchant theory is
force to normal force acting
g on the cutting
g tool is
(a) 0 18
(a) 0.18 (b) 0 36
(b) 0.36
((a)) 1.56
5 ((b)) 1.255 ((c)) 0.80 ((d)) 0.64
4 (c) 0.71 (d) 0.98
127 128 129
GATE‐2008 Common Data Question (1) GATE‐2008 Common Data Question (2) Metal Removal Rate (MRR)

Orthogonal turning is performed on a cylindrical work Orthogonal turning is performed on a cylindrical work
piece with shear strength of 250 MPa.
MPa The following piece with shear strength of 250 MPa.MPa The following
M l
Metal removal rate (MRR) = A
l (MRR) Ac.V
V = b t V = fdV
b V fdV
conditions are used: cutting velocity is 180 m/min. feed conditions are used: cutting velocity is 180 m/min. feed
is 0.20
0 20 mm/rev.
mm/rev depth of cut is 3 mm.mm chip thickness is 0.20
0 20 mm/rev.
mm/rev depth of cut is 3 mm. mm chip thickness
ratio = 0.5. The orthogonal rake angle is 7o. Apply ratio = 0.5. The orthogonal rake angle is 7o. Apply Where
M h ' theory
Merchant's h f analysis.
for l i M h ' theory
Merchant's h f analysis.
for l i
Ac = cross‐section area of uncut chip (mm2)
p g ( g )
The shear plane angle (in degree) and the shear g , p y,
The cutting and Thrust forces, respectively, are
force respectively are (a) 568N; 387N (b) 565N; 381N
V = cutting speed = π DN , mm / min
(a) 52: 320 N (b) 52: 400N ( )
(c) 440N; 342N
N N (d)
(d) 480N; 356N
N N
(c) 28: 400N (d) 28:320N
130 131 132
IES ‐ 2004 GATE‐2013 IES 2016

IES‐2016
A 125 mm long, 10 mm diameter stainless steel rod is
A medium
di carbon
b steell workpiece
k i is
i turned
d on a A steell bar
b 200 mm in
i diameter
di is
i turned d at a feed
f d off
lathe at 50 m/min. cutting speed 0.8 mm/rev feed 0.25 mm/rev with a depth of cut of 4 mm. The being turned to 9 mm diameter, 0.5 mm depth of cut.
and 1.5 mm depth of cut. What is the rate of metal rotational speed of the workpiece is 160 rpm. The The spindle rotates at 360 rpm. With the tool traversing
removal? material removal rate in mm3/s is
at an axial speed of 175 mm/min, the metal removal rate
(a) 1000 mm3/min (a) 160 (b) 167.6 (c) 1600 (d) 1675.5
(b) 60,000 mm3/min
/ is nearly.
nearly
0,000 mm3//min
(c) 20,000 (a) 2200 mm3 / min (b) 2400 mm3 / min
3
(d) Can not be calculated with the given data (c) 2600 mm / min (d) 2800 mm3 / min
133 134 135

Power Consumed During Cutting Specific Energy Consumption GATE(PI)‐1991
Amount of energy consumption per unit volume of
Power (W ) Fc
e= = metal removal is maximum in
3
(
MRR mm / s 1000 fd ) (a) Turning (b) Milling
c (c) Reaming (d) Grinding
Where
Fc = cutting force (in N) Sometimes it is also known as specific power
πDN
V tti
V = cutting speed = , m/s
d / consumption.
consumption
60
136 137 138
GATE‐2007 GATE‐2016 (PI) GATE‐2013 (PI) Common Data Question

In orthogonal turning of medium carbon steel. The A disc
di off 200 mm outer and d 80
8 mm inner
i diameter
di is
i
A cylindrical bar of 100 mm diameter is orthogonally faced of 0.1 mm/rev with a depth of cut of 1 mm. The
specific machining energy is 2.0 J/mm3. The cutting
velocity, feed and depth of cut are 120 m/min, 0.2 straight turned with cutting velocity, feed and depth of facing operation is undertaken at a constant cutting
mm/rev and 2 mm respectively.
respectively The main cutting speed
p of 990 m/min
/ in a CNC lathe. The main
cut of 120 m/min, 0.25 mm/rev and 4 mm, respectively. (tangential) cutting force is 200 N.
force in N is
(a) 40 (b) 80 The specific cutting energy
energ of the work 103
ork material is 11×10 Neglecting the contribution of the feed force
towards cutting power, the specific cutting energy in
(c) 400 (d) 800 J/m3. Neglect the contribution of feed force towards
J/mm3 is
cutting
gppower. The main or tangential
g cutting
g force (in (a) 0.2 (b) 2 (c) 200 (d) 2000
N) is ________.
139 140 141
Example GATE‐2014
Specific Cutting Pressure
Specific Cutting Pressure The
Th main i cutting
i force
f acting
i on a tooll during
d i the
h
When the rake angle is zero during orthogonal cutting, turning (orthogonal cutting) operation of a metal is
show that The cutting force, Fc, divided by the cross section
area of the undeformed chip gives the nominal 400 N. The turning was performed using 2 mm
τs
=
(1 − μ r ) r cutting stress or the specific cutting pressure,
pressure pc depth
p of cut and 0.1 mm/rev/ feed rate. The specific
p
pc 1+ r2 cutting pressure is
Wh τs is
Where i the
h shear
h strengrhh off the
h material
i l Fc Fc (a) 1000
pc = specific
p ppower of cutting
g pc = = (b) 2000
r = chip thickness ratio bt fd
μ = coefficient of friction in tool chip interface
(c) 3000
(d) 4000
142 143 144
Friction in Metal Cutting
l GATE 1992 GATE‐1993
The effect of rake angle on the mean friction angle in The effect of rake angle on the mean friction angle in
machining can be explained by machining can be explained by
(A) sliding (Coulomb) model of friction (a) Sliding (coulomb) model of friction
(B) sticking and then sliding model of friction (b) sticking and then siding model of friction
((C)) sticking
g friction (c) Sticking friction
(D) Sliding and then sticking model of friction (d) sliding and then sticking model of friction
145 146 147
H Di ib i i M l C i
Heat Distribution in Metal Cutting
IES‐2000 IES‐2004
Assertion
A i (A):
(A) The
Th ratioi off uncut chip
hi thickness
hi k to
Assertion (A): In metal cutting, the normal actual chip thickness is always less than one and is
laws of sliding friction are not applicable.
applicable termed d as cutting ratio in orthogonal
h l cutting
Reason ((R): ) Very y highg temperature
p is Reason ((R): ) The frictional force is veryy high
g due to the
produced at the tool‐chip interface. occurrence of sticking friction rather than sliding
friction
( ) Both
d d ll true andd R is (a) Both A and R are individually true and R is the correct
the correct explanation of A explanation of A
(b) Both A and R are individually true but R is (b) Both A and R are individually true but R is not the
not the correct explanation of A correct explanation
l i off A
IES‐2002 IES‐1998 IAS – 2003

As the cutting speed increases
A h i d i
In a machining process, the percentage of In metal cutting operation, the approximate
heat carried away by the chips is typically ratio of heat distributed among chip,
chip tool ((a)) More heat is transmitted to the work piece and less
p
heat is transmitted to the tool
((a)) 55% ((b)) 25%
5 and work, in that order is
(b) More heat is carried away by the chip and less heat is
(c) 50% (d) 75% (a) 80: 10: 10 (b) 33: 33: 33 transmitted to the tool
( ) 20: 60: 10 (d) 10: 10: 80
(c) (c) More heat is transmitted to both the chip and the
too
tool
(d) More heat is transmitted to both the work piece and
th t l
the tool
151 152 153

For IES Only
Determination of cutting heat & temperature
E
Experimentally
i t ll
Mean Temperature in Turning HEAT
IAS – 2003
The
Th heat
h generatedd in
i metall cutting
i can
y Calorimetric method
conveniently be determined by
Mean temperature ∞ V f a b
TEMPERATURE
(a) Installing thermocouple on the job
y Decolourising
g agent
g
(b) Installing thermocouple on the tool
y Tool‐work thermocouple
Tool Material a b (c) Calorimetric set‐up
y Moving thermocouple technique
M i h l h i
HSS 0.5 0.375 (d) Using radiation pyrometer
y Embedded thermocouple technique
p q
Carbide 0.2 0.125
y Using compound tool
y Indirectly from Hardness and structural transformation
di l f d d l f i
y Photo‐cell technique
q
154
y Infra ray detection method 155 156
IES 2011 IES‐1993
Dynamometer The instrument or device used to measure the cutting A 'Dynamometer' is a device used for the
forces in machining is :
g
y Dynamometers are used for measuring Cutting forces.
forces measurement of
(a) Tachometer
y For Orthogonal Cutting use 2D dynamometer ((a)) Chip
p thickness ratio
(b) Comparator
(b) C
y For Oblique
q Cutting
g use 33D dynamometer
y ( ) y
(c) Dynamometer
(b) Forces during metal cutting
(d) Lactometer (c) Wear of the cutting tool
(d) Deflection
D fl ti off the
th cutting
tti tool
t l
157 158 159
IES‐1996 Types of Dynamometers Strain Gauge Dynamometers

Which of the following forces are measured directly by Strain
S i gauge type The
Th strain,
i ε induced
i d d by b the
h force
f changes
h the
h electrical
l i l
strain gauges or force dynamometers during metal Or resistance, R, of the strain gauges which are firmly
cutting ? pasted on the surface of the tool‐holding beam as
piezoelectric type
1. Force exerted byy the tool on the chip p acting
g normallyy to ΔR
ΔR
the tool face. = Gε
2. Horizontal cutting g force exerted byy the tool on the work R
piece. Strain
St i gauge type
t d
dynamometers
t are inexpensive
i i but
b t less
l where, G = gauge factor (around 2.0 for conductive
3. Frictional resistance of the tool against the chip flow accurate and consistent, whereas, the piezoelectric type gauges)
acting along the tool face. are highly accurate, reliable and consistent but very
The change in resistance of the gauges connected in a
4 Vertical force which helps in holding the tool in
4. expensive
p for highg material cost and stringent g
Wh t t
Wheatstone b id produces
bridge d voltage
lt output
t t ΔV,
ΔV through
th h
position. construction.
a strain measuring bridge (SMB)
(a) 1 and 3 (b) 2 and 4
(c) 1 and 4 (d) 2 and 3 160 161 162
IES‐1998 IAS‐2001
Assertion
A ti (A):
(A) Piezoelectric
Pi l t i transducers
t d and
d preferred
f d
The gauge factor of a resistive pick‐up of over strain gauge transducers in the dynamometers for
cutting force dynamometer is defined as the measurement of three‐dimensional
three dimensional cutting forces.
forces
ratio of Reason (R): In electric transducers there is a significant
leakage of signal from one axis to the other,
other such cross
(a) Applied strain to the resistance of the wire error is negligible in the case of piezoelectric
transducers.
transducers
(b) The
h proportionall change
h in resistance to the
h
(a) Both A and R are individually true and R is the correct
applied strain explanation of A
(c) The resistance to the applied strain (b) Both A and R are individually true but R is not the
l ti off A
(d) Change in resistance to the applied strain (c) A is true but R is false
163 164 165
Tool Failure
For PSU & IES
For PSU & IES Tool failure is two types
In strain gauge dynamometers the use of how y 1. Slow‐death: The g gradual or p
progressive
g wearingg
many active gauge makes the dynamometers more away of rake face (crater wear) or flank (flank wear) of
effective , ,
Tool Wear, Tool Life, Economics & the cuttingg tool or both.
y 2. Sudden‐death: Failures leading to premature end
(a) Four Machinability of the tool
(b) Three y The sudden‐death type of tool failure is difficult to
(c) Two predict. Tool failure mechanisms include plastic
deformation, brittle fracture, fatigue fracture or edge
(d) One pp g However it is difficult to p
chipping. predict which of
these processes will dominate and when tool failure
will occur.
By S K Mondal
166 167 168
IES 2010 IES – 2007, IES‐2016 IES ‐ 2014

Flank wear occurs on the Flank wear occurs mainly on which of the The
Th fatigue
f i failure
f il off a tooll is
i due
d to
((a)) abrasive friction,, cutting g fluid and chip
p breakage
g
( ) Relief face of the tool
(a) f ll i ?
following?
(b) Variable thermal stresses, chip breakage and variable
(b) Rake
R k face
f (a) Nose part and top face dimensions of cut
(b) Cutting edge only (c) Abrasive friction, chip breakage and variable
( ) Nose
(c) N off the
th tool
t l dimensions of cut
((c)) Nose p
part, front relief face, and side relief face of the (d) Chip breakage,
breakage variable thermal stresses and cutting
(d) Cutting edge
cutting tool fluid
(d) Face of the cutting tool at a short distance from

the cutting edge
169 170 171
Tool Wear l
Tool Wear IES – 1994
(a) Flank Wear Assertion (A): Tool wear is expressed in terms of
A i (A) T l i d i f
flank wear rather than crater wear.
(b) Crater Wear Reason (R): Measurement of flank wear is simple
and more accurate.
and more accurate
(c) Chipping off of the cutting edge
(a) Both A and R are individually true and R is the
l f
(b) Both A and R are individually true but R is not
ot a d R a e d v dua y t ue but R s ot tthe e
( ) A is true but R is false
(c) A i t b t R i f l
172 173 174
Flank Wear: (Wear land) GATE‐2014 Flank Wear: (Wear land)

Cutting
C i tooll is
i much h harder
h d than h the
h work‐piece.
k i
Reason Yet the tool wears out during the tool‐work
Effect
y Abrasion
Ab i b hard
by h d particles
i l and
d inclusions
i l i i the
in h work
k interaction, because y Flank
Fl k wear directly
di l affect
ff the
h component dimensions
di i
piece. produced.
(a) extra hardness is imparted to the work
work‐piece
piece due to
y Shearing off the micro welds between tool and work coolant used y Flank wear is usually the most common determinant of
material.
material tool life.
life
(b) oxide
d layers
l on the
h work‐piece
k surface
f impart extra
y Abrasion by fragments of built‐up‐edge ploughing hardness to it
against
i the
h clearance
l f
face off the
h tool.
l
(c) extra hardness is imparted to the work‐piece due to
y At low speed
p flank wear p
predominates. severe rate of strain
y If MRR increased flank wear increased. (d) vibration is induced in the machine tool
175 176 177
Flank Wear: (Wear land) Flank Wear: (Wear land)
Stages Primary wear
y Flank
Fl k Wear
W occurs in
i three
h stages off varying
i wear rates The region
Th i where
h the
h sharp
h cutting
i edge
d i quickly
is i kl
broken down and a finite wear land is established.
Secondary
y wear
The region where the wear progresses at a uniform rate.
178 179 180

Flank Wear: (Wear land) IES – 2004 GATE 2008 (PI)
GATE‐2008 (PI)
u g machining,
During ac g, tthee wea a d ((h)) has
wear land as bee
been p otted
plotted
Consider
C id theh following
f ll i statements:
Tertiary wear against machining time (T) as given in the following
During g the third stage g of tool‐wear,, rapid
p figure.
figure
The region
Th i where
h wear progresses at a gradually
d ll
deterioration of tool edge takes place because
increasing rate.
1 Flank wear is only marginal
1.
y In the tertiary region the wear of the cutting tool has
become sensitive to increased tool temperature due to 2. Flank wear is large
high wear land. 3. Temperature of the tool increases gradually
y Re‐grinding
R i di i recommended
is d d before
b f they
h enter this
hi 4. Temperature
T t off the
th tool
t l increases
i d ti ll
drastically
region. Which of the statements g given above are correct?
(a) 1 and 3 (b) 2 and 4 For a critical wear land of 1.8 mm, the cutting tool life (in
(
minute) is
( ) 1 and
(c) d4 (d) 2 and d3
181 182
(a) 52.00 (b) 51.67 (c) 51.50 (d) 50.00 183
Tool life criteria ISO Crater wear Crater wear Contd…..

(A certain width of flank wear (VB) is the most common
(A i id h f fl k (VB) i h y More common in ductile materials which produce y Crater depth exhibits linear increase with time.
criterion) y It increases with MRR.
MRR
y Uniform wear: 0.3 mm averaged over all past continuous chip.
h
y Localized wear: 0.6 mm on any individual past
Localized wear: 0 6 mm on any individual past y Crater
C wear occurs on the
h rake
k face.
f
y At very high
hi h speed
d crater
t wear predominates
d i t
y For crater wear temperature is main culprit and tool

defuse into the chip material & tool temperature is y Crater wear has little or no influence on cutting forces,
forces
maximum at some distance from the tool tip. work piece tolerance or surface finish.
184 185 186
IES – 2002 IAS – 2007 IES – 2000

Crater wear on tools always starts at some distance
C l l di Why does crater wear start at some distance from
Wh d di f Crater wear starts at some distance from the tool tip
C di f h l i
from the tool tip because at that point the tool tip? because
(a) Cutting fluid does not penetrate (a) Tool strength is minimum at that region (a) Cutting fluid cannot penetrate that region
(b) Normal stress on rake face is maximum (b) Cutting fluid cannot penetrate that region (b) Stress on rake face is maximum at that region
(c) Temperature is maximum (c) Tool temperature is maximum in that region (c) Tool strength is minimum at that region
(d) Tool strength is minimum (d) Stress on rake face is maximum at that region (d) Tool temperature is maximum at that region
187 188 189

IES – 1995 Wear Mechanism IAS – 2002
Crater wear is predominant in
C i d i i Consider
C id theh following
f ll i actions:i
1. Abrasion wear
((a)) Carbon steel tools 1. Mechanical abrasion 2. Diffusion
(b) Tungsten carbide tools 3. Plastic deformation 4. Oxidation
2. Adhesion wear
( ) High speed steel tools
(c) Hi h d l l Whi h off the
Which h above
b are the
h causes off tooll wear??
((d)) Ceramic tools 3 Diffusion wear
3. ((a)) 2 and 3 ((b)) 1 and 2
(c) 1, 2 and 4 (d) 1 and 3
4. Chemical or oxidation wear
190 191 192
IES – 1995 IAS – 1999 Why chipping off or fine cracks

Match List I with List II and select the correct
M h Li I i h Li II d l h
answer using the codes given below the lists:
The
Th type off wear that
h occurs due
d to the
h cutting
i
action of the particles in the cutting fluid is
developed at the cutting edge
d l d h d
List I (Wear type) List II (Associated mechanism) referred to as y Tool material is too brittle
A Abrasive wears
A. 1
1. Galvanic action (a) Attritions wear
B. Adhesive wears 2. Ploughing action (b) Diffusion wear y Weak design of tool, such as high positive rake angle
C. Electrolytic wear 3. Molecular transfer (c) Erosive wear
D Diffusion wears
D. Diff i 4. Pl ti d f
Plastic deformation
ti (d) Corrosive wear y As a result of crack that is already in the tool
5. Metallic bond
y Excessive
E i static
i or shock
h k loading
l di off the
h tool.
l
Code: A B C D A B C D
( ) 2
(a) 5 1 3 (b) 5 2 1 3
(c) 2 1 3 4 (d) 5 2 3 4193 194 195
IAS – 2003 Notch Wear IES – 1996

Consider
C id theh following
f ll i statements: y Notch wear on the trailing edge is to a great extent an Notch wear at the outside edge of the depth of cut is
N h h id d f h d h f i
pp g of a cutting
Chipping g tool is due to due to
oxidation
id ti wear mechanism
h i occurring
i where
h th cutting
the tti
1. Tool material being too brittle (a) Abrasive action of the work hardened chip material
edge leaves the machined workpiece material in the feed (b) Oxidation
2. Hot
H hardness
h d off the
h tooll material.
i l
33. High g ppositive rake angle
g of the tool. direction. (c) Slip‐stick action of the chip
Which of these statements are correct? (d) Chipping.
y But abrasion and adhesion wear in a combined effect can
( ) 1, 2 and
(a) d 3 (b) 1 and d3
contribute to the formation of one or several notches.
(c) 2 and 3 (d) 1 and 2
196 197 198

List the important properties of cutting tool IES 2015
IES‐2015 Tool Life Criteria
g statements are be correct for
Which of the following
materials and explain why each is important.
t i l d l i h hi i t t Tool life criteria can be defined as a predetermined
temperature rise in metal cutting operation?
y Hardness at high temperatures ‐ this provides longer numerical value of any type of tool deterioration which
life of the cutting tool and allows higher cutting speeds. 1. It adversely affects the properties of tool material can be measured.
y Toughness ‐ to provide the structural strength needed 2. It provides better accuracy during machining Some of the ways
to resist impacts and cutting forces 3. It
I causes dimensional
di i l changes
h i the
in h work‐piece
k i and
d y Actual cutting time to failure.
y Wear resistance ‐ to prolong usage before replacement
affects the accuracy of machining y Volume of metal removed.
Volume of metal removed
doesn’t chemically react ‐ another wear factor
4. It can distort the accuracyy of machine tool itself.
4 y Number of parts produced.
p p
y Formable/manufacturable ‐ can be manufactured in a
useful geometry (a) 1 and 2 (b) 2 and 3 y Cutting speed for a given time
(c) 3 and 4 only (d) 1, 3 and 4 y Length of work machined.

199 200 201
IES – 1992 Taylor’s Tool Life Equation Values of Exponent ‘n’

Tool life is generally specified by
T l lif i ll ifi d b
based on Flank Wear n = 0.08 to 0.2 for HSS tool
((a)) Number of pieces machined
p Causes
(b) Volume of metal removed y Sliding of the tool along the machined surface
= 0.1 to 0.15 for Cast Alloys
( ) Actual cutting time
(c) A l i i y Temperature rise = 0.2 to 0.4 for
f carbide
bid tooll
VT n = C
((d)) Any of the above
y [IAS‐1999;
[IAS 1999; IES
IES‐2006]
2006]
= 0.55 to 0.77 for ceramic tool
Where, V = cutting speed (m/min) [NTPC‐2003]
T Time (min)
T = Time (min)
n = exponent depends on tool material
C = constant based on tool and work material and cutting
202 condition. 203 Reference: Kalpakjian 204
IES ‐ 2012 IES – 2008 IES – 2006

I T l ’ l lif i VTn
In Taylor’s tool life equation VT = C, the constants n
C h I T l ' l lif i i VTn
In Taylor's tool life equation is VT= constant.
Which
Whi h off the h following
f ll i values
l off index
i d n is
i
and C depend upon What is the value of n for ceramic tools? associated with carbide tools when Taylor's tool life
1. Work piece material (a) 0.15 to 0.25 (b) 0.4 to 0.55 equation, V.Tn = constant is applied?
2 Tool material
2. Tool material ( ) 0.6 to 0.75
(c) 6 (d) 0.8 to 0.9
(a) 0∙1 to 0∙15 (b) 0∙2 to 0∙4
3. Coolant (c) 0.45 to 0∙6 (d) 0∙65 to 0∙9
(a) 1, 2, and 3
(b) d l
(b) 1 and 2 only
(c) 2 and 3 only y
(d) 1 and 3 only
205 206 207

IES – 1999 IAS – 1998 IES 2016
IES‐2016
The
Th approximately
i l variation
i i off the
h tooll life
lif Match List ‐
M t h Li t I (Cutting tool material) with List ‐
I (C tti t l t i l) ith Li t II In a machining test,
test a cutting speed of 100 m/min
exponent 'n' of cemented carbide tools is (Typical value of tool life exponent 'n' in the Taylor's
equation V Tn = C) and select the correct answer using
equation V.T C) and select the correct answer using indicated the tool life as 16 min and a cutting speed
(a) 0.03 to 0.08 (b) 0.08 to 0.20 the codes given below the lists:
of 200 m/min indicated the tool life as 4 min. The
(c) 0.20
0 20 to 0.48
0 48 (d) 0.48
0 48 to 0.70
0 70 List I
List – List II
List –
A. HSS 1. 0.18 values of n and C are
B. Cast alloy 2. 0.12
(a) 0.5 and 200 (b) 0.25 and 200
C. Ceramic 33. 0.255
D. Sintered carbide 4. 0.5 (c) 0.5 and 400 (d) 0.25 and 400
Codes: A B C D A B C D
(a) 1 2 3 4 (b) 2 1 3 4
(c) 2 1 4 3 (d) 1 2 4 3
208 209 210
ISRO‐2011 GATE‐2004, IES‐2000
GATE ‐2009 (PI)
GATE ‐2009 (PI) A 50 mm diameter steel rod was turned at 284 rpm and
In
I a machining
hi i operation,
i doubling
d bli
1
the
h cutting
i
speed reduces the tool life to 8 th of the original
I an orthogonal
In th l machining
hi i operation,
ti th tool
the t l life
lif tool failure occurred in 10 minutes. The speed was value. The exponent n in Taylor's tool life equation
obtained is 10 min at a cutting speed of 100 m/min,
m/min VTn = C,, is
changed
h d to 232 rpm and
d the
h tooll failed
f il d in
i 60
6 minutes.
i
1 1 1 1
while at 75 m/min cutting
g speed,
p the tool life is 330 Assuming straight line relationship between cutting (a) (b) (c ) (d )
8 4 3 2
min. The value of index (n) in the Taylor’s tool life speed
p and tool life,, the value of Taylorian
y Exponent
p is
equation
(a) 0.21 (b) 0.133 (c) 0.11 (d) 0.233
(a) 0.262 (b) 0.323 (c) 0.423 (d) 0.521
211 212 213
IES – 1999, ISRO‐2013 GATE 2016

GATE‐2016 IAS – 1995
In a single point turning operation with cemented carbide
In a single‐point turning operation of steel with a In a single point turning operation with a cemented
tool and steel work piece, it is found that the Taylor’s
cemented
d carbide
b d tool,
l Taylor's
l ' tooll life
l f exponent is carbide
bid and
d steel
t l combination
bi ti h i
having a Taylor
T l
exponent is 0.25. If the cutting speed is reduced by 50% then
0 25 If the cutting speed is halved,
0.25. halved the tool life will exponent of 0.25, if the cutting speed is halved, then
the tool life changes by ______ times.
increase by the tool life will become
(a) Half
((a)) Two times ((b)) Four times
(b) Two times
((c)) Eight
g times ((d)) Sixteen times
(c) Eight times
(d) Sixteen times
214 215 216
GATE-2015
GATE 2015
Under certain cutting conditions, doubling the IAS – 2002 IES‐2015
cutting speed reduces the tool life to 1/16th of the Using the Taylor equation VTn = c, calculate the If n = 0.5 and C= 300 for the cutting speed and the tool
original. Taylor’s tool life index (n) for this tool‐ percentage increase in tooll life
l f when
h the
h cutting life relation, when cutting speed is reduced by 25% , if
workpiece combination will be _______ speed is reduced by 50% (n = 0∙5
0 5 and c = 400) the
h tooll life
lif is
i increased
i d by
b
(a) 300% (b) 400% a) 100%
(c) 100% (d) 50% b)95%

)95
c) 78%
d)50%
217 218 219
IES‐2013 IAS – 1997 IES – 2006 conventional

A carbide tool(having n = 0.25) with a mild steel In the Taylor's tool life equation, VTn = C, the value An HSS tool is used for turning operation. The tool life is
work‐piece
k i was found
f d to
t give
i lif off 1 hour
life h 21 off n = 0.5. The
h tooll has
h a life
l f off 180 minutes at a 1 hr.
h when
h turning is carried
d at 30 m/min. The
h tooll life
lf
minutes while cutting at 60 m/min.
m/min The value of C cutting speed of 18 m/min.
m/min If the tool life is reduced will be reduced to 2.0
2 0 min if the cutting speed is
in Taylor’s
y tool life equation
q would be equal
q to: to 45 minutes, then the cutting speed will be doubled. Find the suitable speed in RPM for turning 300
(a) 200 ((a)) 9 m/min
/ ((b)) 18 m/min
/ mm diameter so that tool life is 30 min.
(b) 180 ((c)) 336 m/min ((d)) 772 m/min

(c) 150
(d) 100 220 221 222
IFS‐2013
IFS 2013
GATE‐2009 Linked Answer Questions (1) GATE‐2009 Linked Answer Questions (2) In a metal cutting experiment, the tool life was
In a machining experiment, tool life was found to vary
I hi i i l lif f d In a machining experiment, tool life was found to vary
I hi i i l lif f d
with the cutting speed in the following manner: with the cutting speed in the following manner: found to vary with the cutting speed in the
Cutting speed (m/min) Tool life (minutes) Cutting speed (m/min) Tool life (minutes) following manner :
60 81 60 81 C i
Cutting speed, V (in m/min)
d V (i / i ) Tool life, T(in min)
T l lif T(i i )
90 36 90 36
100 120
The exponent (n) and constant (k) of the Taylor's What is the percentage increase in tool life when
tool life equation are the cutting speed is halved? 130 50
(a) n = 0.5 and k = 540 (b) n= 1 and k=4860 (a) 50% (b) 200% Derive Taylor's tool life equation for this operation
(c) n = ‐1 and k = 0.74 (d) n‐0.5 and k=1.15 (c) 300% (d) 400% and estimate the tool life at a speed of 2.5 m/s. Also
estimate the cutting speed for a tool life of 80 min.
223 224 225
GATE‐2010 GATE‐2013 GATE 2017
GATE‐2017
Two cutting tools with tool life equations given
For tool A, Taylor’s tool life exponent (n) is 0.45 and Two cutting tools are being compared for a
below are being compared:
constant (K)
( ) is 90. Similarly
l l for
f tooll B, n = 0.3 and
dK machining
hi i operation.
ti Th tool
The t l life
lif equations
ti are:
Tool 1: VT0.1 = 150
= 60.
60 The cutting speed (in m/min) above which tool Carbide tool: VT 1.6 = 3000 Tool 2: VT0.3
0 3 = 300
A will have a higher tool life than tool B is HSS tool: VT 0.6 = 200 Where V is cutting speed in m/minute and T is
tool life in minutes. The breakeven cutting speed
((a)) 26.77 ((b)) 4
42.55 ((c)) 80.77 ((d)) 142.9
4 9 Where V is the cutting
g speed
p in m/min and T is the
b
beyond d which
hi h Tool
T l 2 will
ill have
h a higher
hi h tool
t l life
lif is
i
tool life in min. The carbide tool will provide higher ____ m/minute.
tool life if the cutting speed in m/min exceeds
(a) 15.0 (b) 39.4 (c) 49.3 (d) 60.0
226 227 228
Example
p GATE 2003
GATE‐2003
The following data was obtained from the tool‐life g tools could p
A batch of 10 cutting produce 500 GATE‐2017
cutting test: During
D i the h turningi off a 20 mm‐diameter
di steell bar
b
components while working at 50 rpm with a tool
at a spindle speed of 400 rpm, a tool life of 20
Cutting Speed, m/min:49.74 49.23 48.67 45.76 42.58 feed of 0.25 mm/rev and depth of cut of 1 mm. A minute is obtained.
Tool life, min 2.94 3.90 4.77 9.87 28.27 similar batch of 10 tools of the same specification When the same bar is turned at 200 rpm, the tool
could
ld produce
d 122 components
t while
hil working
ki att 80
8 life becomes 60 minute. Assume that Taylor
Taylor’ss tool
Determine the constants of the Taylor tool life equation life equation is valid.
VTn = C
C rpm with a feed of 0.25
0 25 mm/rev and 1 mm depth of
When the bar is turned at 300 rpm, the tool life
cut. How many
y components
p can be p
produced with (in minute) is approximately
one cutting tool at 60 rpm? (a) 25 (b) 32 (c) 40 (d) 50
229 (a) 29 (b) 31 (c) 37 (d) 42 230 231
GATE‐1999 Extended or Modified Taylor’s equation IES 2010

What is approximate percentage change is the life, t, Tool life is affected mainly with
off a tooll with

h zero rake
k angle
l used
d in orthogonal
h l ( ) Feed
(a)
cutting when its clearance angle,
angle α,
α is changed from (b) Depth
D h off cut
10o to 7o?
( ) Coolant
(c) C l t
((Hint: Flank wear rate is p
proportional
p to cot α))
(d) Cutting speed
((a)) 330 % increase ((b)) 330%, decrease
(c) 70% increase (d) 70% decrease i.e Cutting speed has the greater effect followed by feed

g p g y
and depth of cut respectively.
232 233 234
IES – 1997 IES – 1994, 2007
ISRO‐2012 Consider the following elements: For increasing the material removal rate in turning,
What is the correct sequence of the following
1. Nose radius 2. Cutting speed without
h any constraints, what
h is the
h right
h sequence
parameters in order of their maximum to
minimum influence on tool life? to adjust the cutting parameters?
3. Depth of cut 4. Feed
1. Feed rate
The correct sequence of these elements in DECREASING 1
1. Speed 2
2. Feed 3
3. Depth of cut
2. Depth of cut
3 Cutting speed
3. order of their influence on tool life is Select the correct answer using the code given below:
Select the correct answer using the codes given (a) 11‐ 22‐ 3 (b) 22‐ 33‐ 1
(a) 2, 4, 3, 1
2 4 3 1 (b) 4 2 3 1
4, 2, 3, 1
below
(a) 1,
1 2,
2 3 (b) 3,
3 2,
2 1 (c) 2,
2 3,
3 1 (d) 3,
3 1,
1 2 (c) 2,4, 1, 3
2 4 1 3 (d) 4 2 I 3
4, 2, I, 3 ((c)) 33‐ 2‐ 1 ((d)) 1‐ 33‐ 2
235 236 237
IES – 2008 IAS – 1995 ESE‐1999; IAS ‐2010 Conventional

What are the reasons for reduction of tool life in a
Wh h f d i f l lif i Assertion
A i (A):
(A) An
A increase
i in
i depth
d h off cut shortens
h The following equation for tool life was obtained for HSS
machining operation? the tool life.
1. Temperature rise of cutting edge Reason(R): Increases in depth of cut gives rise to tool.
l A 60 min tooll life
l f was obtained
b d using the
h following
f ll
2 Chipping of tool edge due to mechanical impact
2. relatively small increase in tool temperature.
temperature cutting condition VT0.13
0 13f0.6
0 6d0.3
0 3= C.
C v = 40 m/min,
m/min f = 0.25
0 25
3. Gradual wears at tool point (a) Both A and R are individually true and R is the
mm, d = 2.0 mm. Calculate the effect on tool life if
4. Increase in feed of cut at constant cutting force correct explanation
l off A
(b) Both
d v dua y ttrue
ue but R iss not
ot tthee speed, feed and depth of cut are together increased by
S l t th
Select the correct answer using the code given
t i th d i
below: correct explanation of A 25% and also if they are increased individually by 25%;
(a) 1, 2 and 3 (b) 2, 3 and 4 ( ) A is
(c) i true
t b t R is
but i false
f l
where f = feed, d = depth of cut, v = speed.
(c) 1, 3 and 4
1 3 and 4 (d) 1, 2 and 4
1 2 and 4 (d) A is false but R is true
238 239 240
GATE‐2017 (PI)
( ) IES 2016 Conventional
IES‐2016 Conventional
GATE‐2016 In a machining operation with turning tool, the
Write the generalized Taylor's tool life
tool life (T) is related to cutting speed V (m/s),
(m/s)
The tool life equation for HSS tool is VT0.14 f 0.7 d0.4
feed f(mm) and depth of cut d (mm) as equation. Also write the simplified Taylor's
−2.5
2 5 −0 9 −0
0.9 0.15
15 tool life equation.
equation
= C. The tool life (T) of 30 min is obtained using the T = Cv f d During g machining g of low carbon steel with
Where, C is
Wh i a constant.
t t The
Th suggested t d values
l f
for
following cutting conditions: V = 45 m/min, f = 0.35 HSS tool, the following observations have
the cutting gp parameters are: V = 1.55 m/s,, f = 0.255
mm, d = 2.0 mm. If speed (V),
( ) feed(f)
( ) and depth of been made:
mm and d = 3 mm for normal rough turning. If Cutting speed, m/min 40 50
cut (d) are increased individually by 25%,
25% the tool the operation is performed at twice the cutting Tool Life min
Tool Life, min 40 10
life (in min) is speed and the other parameters remain
unchanged, the corresponding percentage change Derive the V‐T relationship.
((a)) 0.155 ((b)) 1.06 ((c)) 22.50
5 ((d)) 330.0 in tool life is_____________.
is
241 242 243
Tool Life Curve
l f IES 2010 Conventional IES 2010
y Draw tool life curves for cast alloy, High speed steel and
D l lif f ll Hi h d l d The above figure shows a typical
ceramic tools. [2 – Marks] relationship between tool life and
cutting speed for different
materials. Match the graphs for
Ans.
Ans HSS Carbide
HSS, C bid and d Ceramic
C i tooll
materials and select the correct
answer usingi th code
the d given
i
below the lists:
C d HSS
Code: SS Carbide
C bid C
Ceramici
(a) 1 2 3
(b) 3 2 1
(c) 1 3 2
1. HSS 2. Carbide 3. Ceramic 1. High speed steel 2. cast alloy and 3. ceramic tools. (d) 3 1 2
244 245 246
IAS – 2003 Cutting speed used for different Effect of Rake angle on tool life

The tool life curves for two tools A and B are shown in
Th l lif f l A d B h i
the figure and they follow the tool life equation VTn = C. tool materials
Consider the following statements:
d h f ll
1. Value of n for both the tools is same. HSS (min) 30 m/min < Cast alloyy < Carbide
2. Value of C for both the tools is same.
3
3. Value of C for tool A will be greater than that for the tool B
Value of C for tool A will be greater than that for the tool B. < Cemented carbide 150 m/min < Cermets
4. Value of C for tool B will be greater than that for the tool A. < Ceramics or sintered oxide (max) 600 m/min
Which of these statements is/are correct?
Whi h f th t t t i / t?
(a) 1 and 3 (b) 1 and 4
(c) 2 only (d) 4 only
247 248 249
For IES Only
Effect of Clearance angle on tool life IES ‐ 2014

Tool life Tests
Tool life Tests In
I accelerated
l d tooll life
lif tests, the
h three
h main
i types off
If clearance angle increased it reduces flank wear but
y Conventional test: Using empirical formula
g p quick and less costly tool life testing are
edge so best compromise is 80 for
weaken the cutting edge,
HSS and 50 for carbide tool. y Accelerated test: Estimate the tool life quickly (a) Extrapolation on the basis of steady wear;
E t
Extrapolating of steady wear rate
l ti f t d t conventional measurement of flank and crater wear;
Effect of work piece on tool life High speed test‐will take less time comparative performance against tool chipping
y With hard micro‐constituents in the matrix gives poor Variable speed test (b) Measurement off abrasive
b wear; multi
l –pass turning;
tool life. Multi pass turning conventional measurement of diffusion wear
y With larger grain size tool life is better. Taper turning (c) Extrapolating on the basis of steady wear, multi‐pass
turning; taper turning
(d) comparative performance against tool chipping;
taper turning; measurement of abrasive wear
250
Refer: B.L Juneja+Nitin Seth 251 252
Chip Equivalent • The SCEA alters the length of the engaged cutting edge IES‐1996
Engaged cutting edge length without affecting the area of cut. As a result, the chip Chip
Chi equivalent
i l is
i increased
i d byb
ChipEquivalent(q) =
Plan area of cut (a) An increases in side‐cutting edge angle of tool
equivalent changed. When the SCEA is increased, the
(b) An increase in nose radius and side cutting g
y It
I is
i used
d for
f controlling
lli the
h tooll temperature. chip
h equivalent
l is increased,
d without
h significantly
f l edge angle of tool
changing
h i the
th cutting
tti forces.
f ( ) Increasing
(c) I i the
th plant
l t area off cutt
• Increase
I i nose radius
in di also
l increases
i th value
the l off the
th (d) Increasing the depth of cut.
cut
chip equivalent and improve tool life.
life
253 254 255
E i f t l tti
Economics of metal cutting l
Formula
Vo Ton = C
Optimum tool life for minimum cost
⎛ C ⎞⎛ 1− n ⎞
To = ⎜ Tc + t ⎟ ⎜ ⎟ if Tc , Ct & Cm given
⎝ C m ⎠⎝ n ⎠
C ⎛ 1− n ⎞
= t ⎜ ⎟ if Ct & Cm ggiven
Cm ⎝ n ⎠
Optimum
p tool life for Maximum Productivity
y
(minimum production time)
⎛ 1− n ⎞
To = Tc ⎜ ⎟
256 257
⎝ n ⎠ 258
g g
Units:Tc – min (Tool changing time)
IES 2009 Conventional GATE‐2014
Determine
D i the
h optimumi cutting
i speed
d for
f an If the Taylor’s tool life exponent n is 0.2, and the
Ct – Rs./ servicing or replacement (Tooling
operation on a Lathe machine using the following
cost) tooll changing
h time is 1.5 min, then
h the
h tooll life
l f (in
(
information:
Cm – Rs/min (Machining cost)
Tool change time: 3 min min) for maximum production rate is ……………….
V – m/min (Cutting speed)
Tool regrinds time: 3 min
Machine running cost Rs.0.50 per min
Tooling cost (Ct) = tool regrind cost
Depreciation of tool regrinds Rs.
Rs 5.0
50
+ tool depreciation per service/ replacement
The constants in the tool life equation are 60 and
Machining cost (Cm) = labour cost + over head cost per
) labour cost + over head cost per 0.2
min
259 260 261

Example
p
ESE‐2001 Conventional A 600 mm long job of diameter 150 mm is turned with feed
In a certain machining operation with a cutting

IAS –
IAS – 2011 Main
2011 Main 0.255 mm/rev
/ p of cut 1.55 mm.
and depth
Data: Labour cost = Rs. 12.00/hr.
Determine the optimum
p speed
p for achievingg Machine overhead cost = Rs.Rs 40.00/hr.
40 00/hr
speed
d off 50 m/min, tooll life
l f off 45 minutes was maximum production rate in a machining Grinding cost = Rs. 15.00/hr.
observed When the cutting speed was increased to
observed. p
operation. The data is as follows :
G i di machine
Grinding hi overhead
h d = Rs.
R 50/hr.
/h
Machining time/job = 6 min.
100 m/min, the tool life decreased to 10 min. Idle time = 5 min
T l life
Tool lif = 90 min.
i Tool life constants are 0.22 and 475
Estimate the cutting speed for maximum Taylor's equation constants C = 100, n = 0.5 For tool: Initial cost = Rs. 60.00
Job handling time = 4 min./job Grinding time is 5 min/edge
productivity if tool change time is 2 minutes.
Tool changing time = 9 min.
min Tool change time 2 min
[10‐Marks] 9 grinds per tool before salvage.
Fi d minimum
Find i i production
d i cost
262 263 264
Answer Answer(Contd….)
( )
Tool change time (Tc ) = 2 min
Tool grinding cost = 5 x (15 + 50)/60 = Rs.
Rs 5.417/edge
5 417/edge
Machining time (Tm ) =
π DL
=
π × 150 × 600
1000 fV 1000 × 0.25 × 199.5
= 5.669 min GATE‐2016
Initial setuptime for a batch (ti ) For a certain job, the cost of metal cutting is Rs.
Tool will be used 10 times (Because first grinding not Total time (Ttotal ) = Idle time (to ) +
needed
d d 9 regrinding
i di needed)
d d) Number of parts produced per batch ( p )
18C/V and
d the
h cost off tooling
l is Rs. 270C/(TV),
( ) where
h
Tooling cost (Ct ) =
60 + 5.417 × 9
= Rs.10.875 / use of tool Machining time (Tm )
+ Machining time (Tm ) + Tool change time (Tc ) × C is a constant,
constant V is cutting speed in m/min and T is
10 Optimum tool life (To )
Machining cost (Cm ) = Labour cost +Overhead cost per min
5.669 the tool life in minutes. The Taylor
Taylor’ss tool life
=5 + 0 +5 669 + 2 ×
5.669 = 10
10.89min
89min
= (12+40)/60 = Rs. 0.8667/min 51.58
O i
Optimum
⎛ C ⎞⎛1 − n ⎞
life (To ) = ⎜ Tc + t ⎟ ⎜
tooll lif C t off O
Cost
⎛ t ⎞ T
ti = Cm ⎜ to + i + Tm ⎟ + (Ct + Tc × Cm ) × m
Operation equation is VT0.25 = 150. The cutting speed (in
⎝ Cm ⎠ ⎝ n ⎟⎠ ⎝ p ⎠ To
5.667
5 667 m/min)) for the minimum total cost is ________
⎛
= ⎜2 +
10 875 ⎞ ⎛ 1 − 0.22
10.875 0 22 ⎞
= 51.58min = 0.8667 × ( 5 + 0 + 5.667 ) + (10.875 + 2 × 0.8667 ) ×
⎝ 0.8667 ⎟⎠ ⎜⎝ 0.22 ⎟⎠ 51.58
= Rs.10.63 per piece
C 475
Optimum Speed (Vo ) = n = = 199.5m/min
To 51.580.22 265 266 267
C d
Contd………. F
From previous
i slide
lid
GATE‐2005 IAS – 2007 Contd…
A diagram
di related
l t d to
t machininghi i economics
i with ith
various cost components is given above. Match List I
(C t Element)
(Cost El t) with
ith List
Li t II (Appropriate
(A i t Curve)
C ) and d
select the correct answer using the code given below
th Lists:
the Li t
List I List II
(Cost Element) (Appropriate Curve)
A Machining cost
A. 1
1. Curve‐l
B. Tool cost 2. Curve‐2 Code:A B C D A B C D
C. Tool grinding cost
l d 3. Curve‐3 ( ) 3
(a) 2 4 5 ((b)) 4 1 3 2
D. Non‐productive cost
p 4.
4 Curve‐4
4 (c) 3 1 4 2 (d) 4 2 3 5
268
5. Curve‐5 269 270
IES 2011 Minimum Cost Vs Production Rate IES – 1999
The optimum cutting speed is one which should Consider
C id the
h following
f ll i approaches
h normally
ll
have: applied for the economic analysis of machining:
1. High metal removal rate 1. Maximum production rate
2. High
Hi h cutting
i tooll life
lif 2 Maximum profit criterion
2.
33. Balance the metal removal rate and cutting
g 3. Minimum cost criterion
tool life The correct sequence in ascending order of optimum
(a) 1,
1 2 and 3 cutting speed obtained by these approaches is
(b) 1 and 2 only (a) 1, 2, 3 (b) 1, 3, 2
(c) 2 and 3 only
Vmax.production > Vmax.profit > Vmin. cost (c) 3, 2, 1 (d) 3, 1, 2
(d) 3 onlyl
271 272 273
IES – 1998 IAS – 2002 IAS – 1997

The
Th variablei bl cost and d production
d i rate off a Optimum
O i cutting
i speed
d for
f minimum
i i cost (Vc min ) In turning, the ratio of the optimum cutting speed
I i h i f h i i d
machining process against cutting speed are shown and optimum cutting speed for maximum for minimum cost and optimum cutting speed for
in the given figure. For efficient machining, the production rate (Vr max ) have which one of the maximum rate of production is always
range
g of best cutting
g speed
p would be between following g relationships?
p (a) Equal to 1
(a) 1 and 3 (a) Vc min = Vr max (b) Vc min > Vr max (b) In the range of 0.6 to 1
(b) 1 andd5 ( ) Vc min < Vr max
(c) (d) V2c min = Vr max (c) In the range of 0.1 to 0.6
(c) 2 aand
d4 (d) Greater than 1
(d) 3 and 5
274 275 276
IES – 2000 IES – 2004 IES – 2002

The
Th magnitude
i d off theh cutting
i speed
d for
f maximum
i Consider
C id the
th following
f ll i statements:
t t t In economics of machining, which one of the
I i f hi i hi h f h
profit rate must be 1. As the cutting speed increases, the cost of production following costs remains constant?
i i i ll reduces,
initially d then
h after
f an optimum
i cutting
i speed
d iti
(a) In between the speeds for minimum cost and increases (a) Machining cost per piece
maximum production rate 2. As A the
h cuttingi speedd increases
i the
h cost off production
d i (b) Tool changing cost per piece
(b) Higher than the speed for maximum production rate also increases and after a critical value it reduces (c) Tool handling cost per piece
(c) Below the speed for minimum cost 3. Higher feed rate for the same cutting speed reduces cost (d) Tool cost per piece
of production
(d) Equal to the speed for minimum cost
4. Higher feed rate for the same cutting speed increases the
cost of production
Which of the statements given above is/are correct?
((a)) 1 and 3 ((b)) 2 and 3
277
(c) 1 and 4 (d) 3 only 278 279
IAS – 2007 IES 2010 Machinability‐Definition
Assertion
A i (A):
(A) The
Th optimumi cutting
i speed
d for
f theh With increasing
i i cutting
tti velocity,
l it the
th total
t t l Machinability
M hi bili can beb tentatively
i l defined
d fi d as ‘ability
‘ bili off
minimum cost of machining may not maximize the time for machining g a component
p being machined’ and more reasonably as ‘ease of
profit. machining’.
(a) Decreases
Reason (R): The profit also depends on rate of
(b) Increases Suchh ease off machining
h or machining
h characters
h
production.
of any
y tool‐work p
pair is to be jjudged
g by:
y
( ) Both
d d ll true and
d R is the
h (c) Remains unaffected
y Tool wear or tool life
correct explanation of A ((d)) First decreases and then increases
(b) Both A and R are individually true but R is not the y Magnitude of the cutting forces
correct explanation of A y Surface finish

(c) A is true but R is false y Magnitude
g of cuttingg temperature
p
280 281 y Chip forms. 282
For IES Only
Free Cutting steels Machinability Index IES ‐ 2012

The
Th usuall method h d off defining
d fi i machinability
hi bili off a
y Addition of lead in low carbon re‐sulphurised steels and
also in aluminium,
aluminium copper and their alloys help reduce
Or Machinability Rating material is by an index based on
their τs. The dispersed lead particles act as discontinuity The machinability index KM is defined by (a) Hardness of work material
and solid lubricants and thus improve machinability by KM = V606 /V60R
6 R (b) Production rate of machined parts
reducing friction, cutting forces and temperature, tool Where V60 is the cutting speed for the target material (c) Surface finish of machined surfaces
wear and d BUE formation.
f i that
h ensures tooll life
lif off 60
6 min,
i V60R is
i the
h same for
f the
h
(d) Tool life
y It contains less than 0.35%
35 lead byy weight
g . reference material.
y A free cutting steel contains If KM > 1, the machinability of the target material is
C
C‐0.07%,
% Si‐0.03%,
Si % Mn‐0.9%,
M % P‐0.04%,
P % S‐0.22%,
S % Pb‐0.15%
Pb % better that this of the reference material,
material and vice versa
283 284 285
For IES Only For IES Only
IAS – 1996 Machinability of Steel Machinability of Steel contd…

Assertion (A): The machinability of a material can
A i (A) Th hi bili f i l y Mainly
M i l sulfur
lf and
d lead
l d improve
i machinability
hi bili off y Leaded
L d d steel:
l Lead
L d is
i insoluble
i l bl and
d takes
k the
h form
f off
be measured as an absolute quantity. steel. dispersed fine particle and act as solid lubricants. At
Reason (R): Machinability index indicates the case y Resulfurized steel: Sulfur is added to steel only if high speed lead melts and acting as a liquid lubricants.
with which a material can be machined As lead is toxin and p
pollutant,, lead free steel is p
produced
th
there i sufficient
is ffi i t manganese in i it.
it Sulfur
S lf f
forms
(a) Both A and R are individually true and R is the using Bismuth and Tin.
manganese sulfide which exists as an isolated phase
l f y Rephosphorized steel: Phosphorus strengthens the
and act as internal lubrication and chip breaker.
ot a d R a e d v dua y t ue but R s ot tthe
e ferrite, causing increased hardness, result in better chip
y If insufficient manganese is there a low melting iron f
formation and
d surface
f f
finish.
h
correct explanation of A sulfide will formed around the austenite grain y Calcium
Calcium‐Deoxidized
Deoxidized steel: Oxide flakes of calcium
(c) A i t b t R i f l boundary. Such steel is very weak and brittle. silicates are formed. Reduce friction, tool temp, crater
(d) A is false but R is true y Tellurium and selenium is similar to sulfur.
sulfur wear specially at high speed.
speed
286 287 288
Machinability of Steel contd… Role of microstructure on Machinability IES – 1992

y Stainless
S i l Steel:
S l Difficult
Diffi l to machine
hi due
d to abrasion.
b i Coarse microstructure leads to lesser value of τ
C i l d l l f s. Tool life is generally better when
T l lif i ll b h
y Aluminum and Silicon in steel: Reduce machinability
y ((a)) Grain size of the metal is large
g
due to aluminum oxide and silicates formation, which Therefore, τs can be desirably reduced by (b) Grain size of the metal is small
are hard and abrasive.
abrasive y Proper heat treatment like annealing of steels
P h lik li f l ( ) Hard constituents are present in the microstructure
(c) H d i i h i
y Carbon and manganese in steel: Reduce of the tool material
y Controlled addition of materials like sulphur (S), lead
p ( ),
machinability
h b l due d to more carbide.
bd (Pb), Tellerium etc leading to free cutting of soft ductile (d) None of the above
y Nickel,
c e,C Chromium,
o u , molybdenum,
o ybde u , a and
d va
vanadium
ad u in metals and alloys.
metals and alloys
steel: Reduce machinability due to improved property.
y Effect
Eff t off boron
b i
is negligible.
li ibl O
Oxygen i
improve y Brittle materials are relatively more machinable.
machinability. Nitrogen and Hydrogen reduce
machinability.
289 290 291
ff
Effects off tooll rake
k angle(s)
l ( ) on IAS – 2000 Effects of Cutting Edge angle(s) on
machinability Consider the following statements:
C id h f ll i machinability
The tool life is increased byy
y The
Th variation
i ti ini the
th cutting
tti edge
d angles
l does
d nott affect
ff t
y As Rake angle increases machinability increases. 1. Built ‐up edge formation
cutting force or specific energy requirement for cutting.
cutting
2. Increasing cutting velocity
I i i l i
y But too much increase in rake weakens the cutting edge.
33. Increasing back rake angle up to certain value
g g p y Increase in SCEA and reduction in ECEA improves
Which of these statements are correct? surface finish sizeably in continuous chip formation
( ) 1 and 3
(a) d (b) 1 and 2
d
hence Machinability.
(c) 2 and 3 (d) 1, 2 and 3
292 293 294
Effects of clearance angle on machinability Effects of Nose Radius on machinability IES – 1992

Proper tool nose radiusing improves machinability to Ease of machining is primarily judged by
some extent through
(a) Life of cutting tool between sharpening
y increase in tool life by increasing mechanical strength
and
d reducing
d i temperature at the h tooll tip
i (b) Rigidity of work ‐piece
y reduction of surface roughness,
g , hmax
( ) Microstructure of tool material
(c)
2
f (d) Shape and dimensions of work
Sh d di i f k
Inadequate clearance angle reduces tool life and surface hmax =
finish by tool – work rubbing, and again too large
clearance reduces the tool strength
g and tool life hence
8R
8R
machinability.
295 296 297
IES – 2007, 2009 IES – 2003
Consider the following:
ISRO‐2007 Assertion
A ti (A):
(A) The
Th machinability
hi bilit off steels
t l improves
i
by adding sulphur to obtain so called 'Free
1. Tool life M hi bilit depends
Machinability d d on M hi i Steels‘.
Machining St l ‘
Reason (R): Sulphur in steel forms manganese
2. C tti f
Cutting forces (a) Microstructure,
Microstructure physical and mechanical sulphide inclusion which helps to produce thin
properties and composition of workpiece material. ribbon like continuous chip.
3
3. Surface finish
Which of the above is/are the machinability ((b)) Cutting
g forces correct
co ect eexplanation
p a at o oof A
criterion/criteria? (b) Both A and R are individually true but R is not the
((c)) Type
yp of chip
p correct explanation of A
(a) 1, 2 and 3 (b) 1 and 3 only (d) Tool life (c) A is true but R is false
( ) A is false but R is true
(d)
(c) 2 and 3 only (d) 2 only 298 299 300
IES – 2009 IES – 1998 IES – 1996

The elements which, added to steel, help in chip Consider the following criteria in evaluating
C id h f ll i i i i l i Which of the following indicate better
machinability:
f
formation d
during machining
h are machinability?
hi bilit ?
1. Surface finish 2. Type of chips
( ) Sulphur,
(a) S l h lead
l d and
d phosphorous
h h 3 Tool life
3. 4
4. Power consumption 1
1. Smaller shear angle
In modern high speed CNC machining with coated 2. Higher cutting forces
(b) Sulphur,
S l h lead
l d and
d cobalt
b lt carbide tools, the correct sequence of these criteria
in DECREASING order of their importance is
CR S G o de o t e po ta ce s 33. Longer
g tool life
(c) Aluminium,
Aluminium lead and copper
(a) 1, 2, 4, 3 (b) 2, 1, 4, 3 4. Better surface finish.
(d) Aluminium,
Aluminium titanium and copper ( ) 1, 2, 3, 4
(c) (d) 2, 1, 3, 4
(a) 1 and 3 (b) 2 and 4
301 302
(c) 1 and 2 (d) 3 and 4 303
For IES Only
IES – 1996 IES – 1995 Machinability of Titanium

Small amounts of which one of the following In low carbon steels, presence of small quantities y Titanium is very reactive and the chips tend to weld to
elements/pairs
l off elements
l is added
dd d to steell to sulphur improves
l h the
h tooll tip leading
l d to premature tooll failure
f l d to edge
due d
increase its machinability? ( ) Weldability
(a) W ld bili (b) F
Formability
bili chipping.
chipping
(a) Nickel (b) Sulphur and phosphorus ( ) Machinability

(c) M hi bilit (d) H d
Hardenability
bilit y Titanium and its alloys have poor thermal conductivity,
conductivity
(c) Silicon (d) Manganese and copper g high

causing g temperature
p rise and BUE.
y Almost all tool materials tend to react chemically

y with
titanium.
304 305 306

IES – 1992 IES ‐1995 Surface Roughness
Machining of titanium is difficult due to Consider the following work materials: y Ideal Surface ( Zero nose radius)
1 Titanium
1. 2
2. Mild steel f
(a) High thermal conductivity of titanium Peak to valley roughness (h) =
3. Stainless steel 4. Grey cast iron. tan SCEA + cot ECEA
(b) Chemical reaction between tool and work The correct sequence of these materials in terms of h f
and (Ra) = =
( ) Low tool‐chip contact area
(c)
increasing order of difficulty in machining is
4 4 ( tan SCEA + cot ECEA )
(a) 4, 2, 3, 1 (b) 4, 2, 1, 3 y Practical Surface ( with nose radius = R)
(d) None of the above
N f h b (c) 2, 4, 3, 1 (d) 2, 4, 1, 3 f2 f2
h= and Ra =
8R 18 3R
Change
g in feed ((f)) is more important
p than a change
g in nose radius
(R) and depth of cut has no effect on surface roughness.
307 308 309
IES ‐ 2002 IAS ‐ 1996 IES ‐ 1999

The
Th value
l off surface
f roughness
h 'h' obtained
b i d during
d i Given
Gi that
h In turning operation, the feed could be doubled to
the turning operating at a feed 'f' with a round nose /
S = feed in mm/rev. and
tool having radius 'r' is given as increase the
h metall removall rate. To keep
k the
h same
R = nose radius in mm,
the
h maximum i h i h off surface
height f roughness
h Hmax level of surface finish,
finish the nose radius of the tool
produced by a single‐point turning tool is given by should be
(a) S2/2R
((a)) Halved ((b)) Kept
p unchanged
g
(b) S2/4R
/ R
(c) S2/4R ((c)) doubled ((d)) Made four times
(d) S2/8R
310 311 312
GATE ‐ 1997 GATE – 2007 (PI)

( ) GATE ‐ 2005
A cutting tool has a radius of 1.8 mm. The feed rate A tool
t l with
ith Side
Sid Cutting
C tti Edge
Ed angle
l off 30o and
d Two
T tools
l P and d Q have
h signatures
i 5°‐5°‐6°‐6°‐8°‐30°‐
° ° 6° 6° 8° °
0 and 5°‐5°‐7°‐7°‐8°‐15°‐0 (both ASA) respectively.
f l f h f μ
for a theoretical surface roughness of is 5 m is
h End Cutting Edge angle of 10o is used for fine They are used to turn components under the same
turning with a feed of 1 mm/rev.
mm/rev Neglecting nose machining g conditions. If hp and hQ denote the p peak‐
( ) 0.268 mm/rev
(a) 68 /
to‐valley heights of surfaces produced by the tools P
(b) 0.187 mm/rev
8 / radius of the tool,
tool the maximum (peak to valley) and Q,
Q the ratio hp/hQ will be
(c) 0.036 mm/rev
0 036 mm/rev height of surface roughness produced will be tan 8o + cot15o tan15o + cot 8o
(a) (b)
(d) 0.0187 mm/rev
0 0187 mm/rev tan 8o + cot 30o tan 30o + cot 8o
(a) 0.16 mm (b) 0.26 mm
tan15o + cot7o tan7o + cot15o
(c ) (d )
313 (c) 0.32 mm (d) 0.48 mm 314
tan 30o + cot7o tan7o + cot 30o 315
IES – 1993, ISRO‐2008 IES ‐ 2006 GATE‐2014 (PI)
( )
For achieving a specific surface finish in single point In the selection of optimal cutting conditions, the A spindle
i dl speed d off 300 rpm and d a feed
f d off 0.3
mm/revolution are chosen for longitudinal turning
turning the
h most important factor
f to be
b controlled
ll d requirement off surface
f f
finish
h would
ld put a limit
l on operation on an engine lathe. In finishing pass,
is which of the following? roughness
g on the work surface can be reduced byy
(a) reducing the spindle speed
(a) Depth of cut (b) Cutting speed (a) The maximum feed (b) increasing the
h spindle
dl speedd
(c) Feed (d) Tool rake angle (b) The maximum depth of cut (c) reducing
educ g tthee feed
eed o
of too
tool
(d) increasing the feed of tool
(c) The maximum speed
((d)) The maximum number of p

passes
316 317 318
GATE ‐2010 (PI)
( ) Cutting fluid
Cutting fluid
GATE‐2017 y The cutting fluid acts primarily as a coolant and
During turning of a low carbon steel bar with TiN coated Assume
A that
th t the th surface
f roughness
h profile
fil is
i secondly
dl as a lubricant,
l bi t reducing
d i the th friction
f i ti effects
ff t att
carbide insert, one need to improve surface finish g
triangular as shown schematicallyy in the figure.
g If the tool‐chip interface and the work‐blank regions.
without sacrificing material removal rate. To achieve the peak to valley height is 20 μm, the central line y Cast Iron: Machined dry or compressed air, Soluble oil
average surface roughness Ra (in μm) is for high speed machining and grinding
improved surface finish, one should
y Brass: Machined dry or straight mineral oil with or
(a) decrease nose radius of the cutting tool and increase ((a)) 5 ((b)) 6.677 ((c)) 10 ((d)) 20
without
ih EPA
EPA.
depth of cut y Aluminium: Machined dry y or kerosene oil mixed with
(b) Increase nose radius of the cutting tool mineral oil or soluble oil
(c) Increase feed and decrease nose radius of the cutting y Stainless steel and Heat resistant alloy: High
performance soluble oil or neat oil with high
tool concentration
i with i h chlorinated
hl i d EP additive.
ddi i
(d) Increase depth of cut and increase feed 319 320 321
IAS 2009 Main

IAS ‐2009 Main IES ‐ 2001 IES ‐ 2012
y What are extreme pressure lubricants?
What are extreme‐pressure lubricants?
Dry
D and d compressed
d air
i is
i used
d as cutting
i fluid
fl id for
f The most important function of the cutting fluid is to
Th i f i f h i fl id i
[ 3 – marks] machining ( )
(a) Provide lubrication
Wh
Where hi h pressures and
high d rubbing
bbi action
i are
(a) Steel (b) Aluminium (b) Cool the tool and work piece
encountered, hydrodynamic lubrication cannot be
maintained;
i i d so Extreme
E P
Pressure (EP) additives
ddi i must be
b (c) Cast iron (d) Brass ( ) W h
(c) Wash away the chips
h hi
added to the lubricant. EP lubrication is provided by a ( ) p
(d) Improve surface finish
number
b off chemical
h i l components such h as boron,b
phosphorus, sulfur, chlorine, or combination of these.
Th compounds
The d are activated
i d by
b the
h higher
hi h temperature
resulting from extreme pressure. As the temperature
rises,
i EP molecules
l l b
become reactive
i and d release
l
derivatives such as iron chloride or iron sulfide and
f
forms a solid
lid protective
i coating.
i
322 323 324
Terminology
Metrology
y The
Th science
i off measurement.
t
y The purpose of this discipline is to establish means

t, o e a ce & ts
Limit, Tolerance & Fits of determining physical quantities, such as
dimensions, temperature, force, etc.
By S K Mondal 1 2 3
Terminology Terminology
Terminology C td
Contd....
Terminology
e o ogy Contd....
y Limits of sizes: There are two extreme permissible Unilateral Limits occurs when both maximum limit and
y No a ssize:
Nominal e: S
Sizee o
of a pa
partt spec ed in tthee d
specified aw g.
drawing.
It is used for general identification purpose. sizes for a dimension of the part. The largest minimum limit are either above or below the basic size.
permissible size for a dimension is called upper or high e.g. Ø25 +0.18
+0 18
y Basic size: Size of a part to which all limits of variation +0.10
(
(i.e. tolerances)) are applied.
pp Basic dimension is or maximum limit, whereas the smallest size is known
Basic Size = 25.00
25 00 mm
theoretical dimension. as lower or minimum limit. Upper Limit = 25.18 mm
y Tolerance Lower Limit = 25.10 mm
y Actual size: Actual measured dimension of the part. Tolerance = 0.08 mm
The difference between the basic size and the actual ¾The difference between the upper limit and lower
e g Ø25 -00.10
e.g. 10
size should not exceed a certain limit, otherwise it will limit. -0.20
interfere with the interchangeability of the mating ¾It is the maximum permissible variation in a Basic Size = 25.00 mm
Upper Limit = 24.90 mm
parts. dimension. Lower Limit = 24.80 mm
¾The tolerance may be unilateral or bilateral. Tolerance = 0.10 mm
4 5 6
Terminology
Terminology Contd
Contd....
For Unilateral Limits,

Limits a case may occur when one of the For PSU
For PSU ISRO‐2010
limits coincides with the basic size,
Tolerances are specified E
Expressing i as 25.3 ±0.05 mm is
i a dimension
di i the
th case
e.g. Ø25 +0.20 , Ø25 0 (a) To obtain desired fits
0 ‐0.10
0.10 of
(b) because it is not possible to manufacture a size
Bilateral Limits occur when the maximum limit is above exactlyy (a) Unilateral tolerance
and the minimum limit is below the basic size. (c) to obtain higher accuracy
((b)) Bilateral tolerance
(d) to have proper allowances
h ll
e.g. Ø25 ±0.04
Basic Size = 25.00
25 00 mm ((c)) Limiting
g dimensions
Upper Limit = 25.04 mm (d) All of the above
L
Lower Li it = 24.96
Limit 6 mm
Tolerance = 0.08 mm 7 8 9
Terminology
Terminology C td
Contd.... Terminology
Terminology C td
Contd....
GATE – 2010, ISRO‐2012
y Zero line: A straight
g line corresponding
p g to the basic
y Lower deviation: Is the algebraic difference between
−0.009
A shaft has a dimension,, φ35 mm
size. The deviations are measured from this line.
the minimum size and the basic size.
−0.025
0 025
y Deviation: Is the algebraic difference between a size The respective values of fundamental deviation and
y Mean deviation: Is the arithmetical mean of upper
pp tolerance are
(actual, max. etc.) and the corresponding basic size.
and lower deviations. ( ) − 0.025, ± 0.008
(a) ( ) − 0.025,0.016
(b)
y Actual deviation: Is the algebraic difference between (c) − 0.009, ± 0.008 (d) − 0.009,0.016
y Fundamental deviation: This is the deviation, either
an actuall size
i and
d the
h corresponding
di basic
b i size.
i
the upper or the lower deviation, which is nearest one
y Upper
U d i i
deviation: I the
Is h algebraic
l b i difference
diff b
between to zero line for either a hole or shaft.
the maximum size and the basic size.
size
10 11 12
GATE ‐ 1992 GATE ‐ 2004 IES ‐ 2005

Two shafts A and B have their diameters specified as
T h f A d B h h i di ifi d In
I an interchangeable
i h bl assembly,
bl shafts
h f off size
i The
Th tolerance
t l specified
ifi d by
b theth designer
d i for
f the
th
100 ± 0.1 mm and 0.1 ± 0.0001 mm respectively. diameter of a shaft is 20.00 ± 0.025 mm. The shafts
25.000
+0.040 +0.020 produced
d d by
b three
th diff
different t machines
hi A B and
A, d C
Which of the following statements is/are true? −0.0100 mm mate with holes of size 25.000
have mean diameters of 19∙99 mm, 20∙00 mm and
−0.000
(a) Tolerance in the dimension is greater in shaft A mm. 20.01 mm respectively,ti l with
ith same standard
t d d
(b) The relative error in the dimension is greater in shaft The maximum p possible clearance in the assembly
y deviation. What will be the percentage rejection for
A th shafts
the h ft produced
d d by
b machines
hi A B and
A, d C?
will be
(c) Tolerance in the dimension is greater in shaft B (a) Same for the machines A, Band C since the standard
( ) 10 microns
(a) i (b) 20 microns
i deviation is same for the three machines
(d) The relative error in the dimension is same for shaft (c) 30 microns (d) 60 microns (b) Least for machine A
A and shaft B
d h f
(c) Least for machine B
(d) Least
L t forf machine
hi C
13 14 15
Clearance Fits Use

Fit y Machine tools spindles
Hole
y Pistons of hydraulic machines
Fits: (assembly condition between “Hole” & “Shaft”) y Piston cylinder in IC engine
T l
Tolerance zones never meet

Max C
Hole – A feature engulfing a component Min C
y Inner and outer races of ball, roller and journal bearing
Shaft – A feature being engulfed by a Shaft y Clutch disks
Cl h di k
component
p y Sliding rod
y Crankshaft journals
y Bolts
Max. C = UL of hole - LL of shaft y Rivets
Min. C = LL of hole - UL of shaft y Pivots
y Latches
The clearance fits may be slide fit, easy sliding fit, running
Th l fit b lid fit lidi fit i
16 fit, slack running fit and loose running fit. 17
y Fits of parts exposed to corrosive effects 18
IES‐2015
GATE ‐ 2007 GATE 2015
GATE-2015 A hole and a shaft have a basic size of 25 mm and are to have a
clearance fit with a maximum clearance of 0.02 mm and a
0 .0 5 0 minimum clearance of 0.01 mm. The hole tolerance is to be 1.5
A hole is specified as 4 0 mm. The mating
0 .0 0 0 +0.040 times the shaft tolerance. The limits of both hole and shaft using
shaft
h f has
h a clearance
l f with
fit h minimum clearance
l off Holes of diameter 25 mm are assembled hole basis system will be
+0.020
a) low limit of hole = 25 mm, high limit of hole = 25.006 mm,
0 01 mm.
0.01 mm The tolerance on the shaft is 0.04
0 04 mm.
mm The +0.005 upper limit of shaft = 24.99 mm and low limit of shaft = 24‐
interchangeably with the pins of diameter 25 mm.
maximum clearance in mm between the hole and −0.008 986 mm
b) low limit of hole = 25 mm, high limit of hole = 25.026 mm,
the shaft is The minimum clearance in the assembly will be upper limit of shaft = 24.8 mm and low limit of shaft = 24.76
a) 0.048 mm b) 0.015 mm mm
(a) 0.04 (b) 0.05 c) low limit of hole = 24 mm, high limit of hole = 25.006 mm,
c) 0
0.005 mm
005 mm d) 0.008 mm
0 008 mm upper limit of shaft = 25 mm and low limit of shaft = 24.99 mm
(c) 0.10 (d) 0.11 d) low limit of hole = 25.006 mm, high Ch limit of hole = 25 mm,
upper limit of shaft = 24.99 mm and low limit of shaft = 25 mm
19 20 21
Transition Fits
IAS 2015 Main
IAS‐2015 Main Hole
IES 2015
IES‐2015
A 20 mm diameter shaft and bearing g are to be Consider the following statements
assembled with a clearance fit. The tolerance and Max C
Tolerance zones always
allowances are as under : overlap
In case of assemblyy of mating
gpparts
Shaft
Allowance = 0.002 mm Max I 1. The difference between hole size and shaft size is called
Tolerance on hole = 0.005 mm allowance.
T l
Tolerance on shaft
h f = 0.003 mm 2. In transition fit, small positive or negative clearance
Find the limits of size for the hole and shaft, if
b
between the
h shaft
h f and
d hole
h l member
b isi employable
l bl
(i) the hole basis system is used, Max. C = UL of hole - LL of shaft
Max. I = LL of hole - UL of shaft Which of the above statements is/are correct?
(ii) the shaft basis system is used.
The tolerances are disposed off unilaterally.
unilaterally The transition fits may be tight fit and push fit, wringing ((a)) 1 onlyy ((b)) Both 1 and 2
fit (Gear, pulley on shaft), press fit.
[10 –Marks] 22 23 (c) 2 only (d) Neither 1 nor 2 24
Interference Fits
Hole Tolerance zones never meet IES 2011 IES‐2013
but crosses each other
Max I Interference fit joints are provided for: Which of the following is a joint formed by
Shaft
i t f
interference fit ?
fits?
Min I (a) Assembling bush bearing in housing
(a) Joint of cycle axle and its bearing
(b) Mounting heavy duty gears on shafts
(b) Joint between I.C.
I C Engine piston and cylinder
(c) Mounting pulley on shafts
(c) Joint between a pulley and shaft transmitting power
(d) Assembly of flywheels on shafts
Max. I = LL of hole - UL of shaft
Min I = UL of hole - LL of shaft
Min. (d) Joint of lathe spindle and its bearing
The interference fits may be shrink fit, heavy drive fit and
The interference fits may be shrink fit heavy drive fit and
light drive fit. 25 26 27
IES
IES ‐ 2014
GATE ‐ 2005 Statement‐I: In interference fit, the outer diameter IES‐2015
of the inner cylinder will be more than the inner Statement
S (I) : In
I interference
i f fit,
fi the
h outer diameter
di off
In order to have interference fit, it is essential that diameter of the hollow outer cylinder the shaft is greater than the inner diameter of the hole.
the
h lower
l l
limit off the
h shaft
h f should
h ld be
b St t
Statement‐II:
t II These
Th fit are recommended
fits d d for
f two
t Statement (II) : The amount of clearance obtained from
parts frequently dismantled and assembled. the assemblyy of hole and shaft resulting g in interference fit
( ) Greater
(a) G than
h the
h upper limit
li i off the
h hole
h l (a) Both Statement (I) and Statement (II) are is called positive clearance.
individuallyy true and Statement (II) is the correct (a) Both statement (I) and (II) are individually true and
(b) Lesser
L th the
than th upper limit
li it off the
th hole
h l explanation of Statement (I)
statement (II) is the correct explanation of statement (I)
(c) Greater than the lower limit of the hole (b) Both Statement (I) and Statement (II) are (b) Both
B th statement
t t t (I) and
d statement(II)
t t t(II) are individually
i di id ll
individually true but Statement (II) is not the correct
true but statement(II) is not the correct explanation of
(d) Lesser than the lower limit of the hole explanation of Statement (I)
statement (I)
()
(c) Statement (I) is true but Statement (II) is false
(d) Statement
St t t (I) is
i false
f l but
b t Statement
St t t (II) is
i true
t (d) Statement (I) is false but statement (II) is true
28 29 30
IES‐2017
Statement (I): In sugarcane crushing rollers, the fit GATE 2011 GATE ‐2012 Same Q in GATE‐2012 (PI)
between the cast roll and the forged steel shaft is of +0.015
i t f
interference t
type. A hole is of dimension φ 9 +0
mm The
mm. In an interchangeable assembly,
assembly shafts of size 25+−0.04
0.01
+0.010
25++0.03
Statement (II): This helps in removing the roll from the
corresponding shaft is of dimension φ9 +0.001
mm. mm mate with holes of size 0 03
0.02
mm.
shaft whenever not needed. The resultingg assemblyy has
(a) Both statement (I) and (II) are individually true and (a) loose running fit The maximum interference (in microns) in the assembly
statement (II) is the correct explanation of statement (I)
(b) close
l running
i fit
fi is
(b) Both statement (I) and statement(II) are individually
true but statement(II) is not the correct explanation of (c) transition
a s o fit (a) 4
40 ((b)) 330 (c) 20 (d) 10
statement (I) (d) interference fit
(d) Statement (I) is false but statement (II) is true 31 32 33
IAS 2011 Main

IAS‐2011 Main IES ‐ 2007 ISRO 2011
ISRO‐2011
te e e ce asse
An interference b y, o
assembly, o a d
of nominal a ete 20
diameter 0 mm,, A shaft and hole pair is designated as 50H7d8. This
is of a unilateral holes and a shafts. The manufacturing
assembly constitutes
tolerances for the holes are twice that for the shaft.
shaft
Permitted interference values are 0.03 to 0.09 mm. (a) Interference fit
D t
Determinei th sizes,
the i with
ith limits,
li it for
f the
th two
t mating
ti
parts. [10‐Marks] (b) Transition fit
(c) Clearance fit
Hint: Use unilateral hole basis system.
34 35 36
IES ‐ 2006 IES ‐ 2009 IES ‐ 2008
Which of the following is an interference fit? Consider
C id the
h following
f ll i joints:
j i Consider
C id the h following
f ll i statements:
1. Railwayy carriageg wheel and axle g
1. The amount of interference needed to create a tight
(a) Push fit 2. IC engine cylinder and liner joint varies with diameter of the shaft.
(b) Running fit Whi h off the
Which h above
b j i
joints i /
is/are the
h result(s)
l ( ) off 2 An interference fit creates no stress state in the
2.
interference fit? shaft.
( ) Sliding fit
(c) (a) 1 only 3. The stress state in the hub is similar to a thick‐
(b) 2 only
l walled
a ed cy
cylinder
de witht internal
te a p pressure.
essu e.
(d) Shrink
Sh i k fit
fi
(c) Neither 1 nor 2 Which of the statements given above are correct?
(d) Both 1 and 2 ( ) 1, 2 and
(a) d3 (b) 1 and d 2 only
l
(c) 2 and 3 only (d) 1 and 3 only
37 38 39
IES 2015
IES‐2015 IES ‐ 2004 Allowance
y It is Minimum clearance or maximum interference. It is
In
I an interference
i f fit
fi between
b a shaft
h f and
d a hub,
h b the
h state Consider
C id theh following
f ll i fits:
fi the intentional difference between the basic
of stress in the shaft due to interference fit is 1. I.C. engine
g cylinder
y and p
piston dimensions of the mating
gpparts. The allowance mayy be
2. Ball bearing outer race and housing positive or negative.
a)) onlyy compressive
p radial stress
3. Ball
B ll bearing
b i inner
i race and
d shaft
h f
b)a tensile radial stress and a compressive tangential stress Which of the above fits are based on the interference
c) a tensile tangential stress and a compressive radial stress system?
( ) 1 and
(a) d2
d)a compressive tangential stress and a compressive radial
(b) 2 and 3
stress (c) 1 and 3
(d) 1, 2 and
d3
40 41 42
GATE ‐ 2001 GATE ‐ 1998 IES ‐ 2012

Allowance in limits and fits refers to In the specification of dimensions and fits, Clearance in a fit is the difference between
(a) Maximum clearance between shaft and hole (a) Allowance is equal to bilateral tolerance (a) Maximum hole size and minimum shaft size
(b) Minimum clearance between shaft and hole (b) Allowance is equal to unilateral tolerance (b) Minimum hole size and maximum shaft size
( ) Difference between maximum and minimum size of

(c) ( ) Allowance is independent of tolerance
(c) ( ) Maximum hole size and maximum shaft size
(c)
hole (d) Allowance
All i equall to the
is h difference
diff b
between (d) Minimum
Mi i h l size
hole i and
d minimum
i i shaft
h f size
i
(d) Difference between maximum and minimum size of maximum and minimum dimension specified by the
shaft tolerance.
43 44 45
Hole Basis System
ISRO‐2010
y For hole basis system,
y , H stands for dimensions of holes
Zero Line
+0.02 whose lower deviation is zero.
Dimension of the hole is 50 mm
−0.00
y The basic size of the hole is taken as the lower limit of
+0.02
0 02
and shaft is 50 mm. size of the hole ( Maximum metal condition).
+0.00
0.00
The minimum clearance is Hole basis system y The higher limit of size of the hole and two limits of size
(a) 0.02 mm (b) 0.00 mm y The hole is kept as a constant member (i.e. when the for the shaft are then selected to give desired fits.
lower deviation of the hole is zero))
(c) -0.02
0 02 mm (d) 0.01
0 01 mm y The actual size of hole is always more than basic size or
y Different fits are obtained by varying the shaft size then
the limit system is said to be on a hole basis.
basis equal to basic size
si e but never
ne er less than Basic size.
si e
46 47 48
For IES Only
Shaft Basis system
Why Hole Basis Systems are Preferred?
Why Hole Basis Systems are Preferred?
y For shaft basis system,
y , h stands for dimensions of shafts y Holes can be finished by
y tools like reamers,, drills,,
Zero Line whose upper deviation is zero. broaches, and their sizes are not adjustable. The shaft
y Basic size of the shaft is taken Upper limit for the shaft ( sizes can be easily obtained by external machining.
Maximum metal condition) y If shaft basis system is used considerable no of reamers
y Lower limit of the shaft and two limits of hole are

and other precision tools are required for producing
selected to give the desired fit. different classes of holes for one class of shaft for
Shaft basis system:
y When the shaft is kept as a constant member (i.e.
(i e when the obtaining different fits which increases cost of
upper deviation of the shaft is zero) y Actual size of shaft is always less than basic size or equal
production.
y Different fits are obtained by varying the hole size then the to basic size
si e but never
ne er more than basic size.
si e
limit system is said to be on a shaft basis. 49 50 y It is economical 51
IES ‐ 2005 IES ‐ 2005

ISRO‐2008 Assertion
A i (A):
(A) Hole
H l basisb i system isi generallyll Which
Whi h one off the h following
f ll i is i not correct in i hole
h l basis
b i
preferred to shaft basis system in tolerance design system of fits?
B i shaft
Basic h ft and
d basic
b i hole
h l are those
th whose
h upper for getting the required fits. (a) The hole size is kept constant.
deviations and lower deviations respectively are Reason (R): Hole has to be given a larger tolerance (b) The basic size of the hole is taken as the low limit of
band than the mating shaft. size of the hole.
(a) +ve, ‐ve
ve (b) ‐ve,
ve, +ve
( ) Both
d d ll true and
d R is the
h (c) The actual size of a hole that is within the tolerance
((c)) Zero,, Zero ((d)) None of the above correct explanation of A limitsts aalways
ays less
ess tthan
a tthee bas
basicc ssize.
e.
(b) Both A and R are individually true but R is not the (d) The high limit of the size of the hole and the two limits
correct explanation of A off size
i off the
th shaft
h ft are selected
l t d tot givei desired
d i d fit.
fit
52 53 54
Limits and Fits
Limits and Fits
µ
µm
Tolerance Zone y Limits and fits comprises 18 grades of fundamental Tolerance Designation (IS)
tolerances for both shaft and hole, designated as IT01, Tolerance on a shaft or a hole can be calculated by using
• It is defined graphically IT0 and IT1 to IT16. These are called standard table provided.
provided
55 tolerances. (IS‐919) But ISO 286 specify 20 grades upto
by the magnitude of the T = K ×i
Tolerance Zone tolerance and by its IT18
20 position in relation to the y There are 25 (IS 919) and 28 (ISO 286) types of Where, T is the tolerance (in µm)
zero line. fundamental deviations.
deviations Standard Tolerance unit or Fundamental tolerance unit
Hole: A, B, C, CD, D, E, EF, F, FG, G, H, J, JS, K, M, N, P,
i = 0.45 3 D + 0.001D in μ m
Basic Size R S,
R, S T,
T U,U V,
V X,
X Y,Y Z,
Z ZA,
ZA ZB,
ZB ZC.ZC
Shaft : a, b, c, cd, d, e, ef, f, fg, g, h, j, js, k, m, n, p, r, s, t, D = D1D2 (D1 and D2 are the nominal sizes marking
u, v, x, y, z, za, zb, zc. the beginning and the end of a range of
y A unilateral hole basis systemy is recommended but if sizes,, in mm))
necessary a unilateral or bilateral shaft basis system may K = is a constant [For IT6 to IT16]
55 56
also be used
Value of the Tolerance
Diameter Steps
Diameter Steps IT01 IT0 IT1 IT2
Above Upto and including 0.3 + 0.008D 0.5 + 0.012D 0.8 + 0.02D ar Grades of Tolerance
(mm)
( ) (mm)
( ) =a r = 101/5 y It is an indication of the level of accuracy.
‐ ‐ 3 IT3
3 IT4 IT5
5 IT6
6
3 ‐ 6 ar2 ar3 ar4 = 7i 10(1.6)(ITn -IT6) y IT01 to IT4 ‐ For production of gauges, plug gauges,
6 ‐
6 10 = 10i
measuring
i instruments
i
10 ‐ 18 IT7 IT8 IT9 IT10
188 ‐ 30 10(1.6)
( )(ITn -IT6) 10(1.6)
0( 6)(ITn -IT6) 10(1 6)((ITn -IT6))
10(1.6) 10(1 6)(ITn -IT6)
10(1.6) IT6)
y IT5
IT to
t IT 7 ‐ For
F fits
fit in
i precision
i i engineering
i i applications
li ti
30 ‐ 50 = 16i = 25i = 40i = 64i
550 ‐ 80
IT11 IT12 IT13 IT14 y IT8 to IT11 – For General Engineering
80 ‐ 120
10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6)
120 ‐ 180
180 ‐ 250 = 100i = 160i = 250i = 400i
y IT12 to IT14 – For Sheet metal working or press working
250 ‐ 315 IT15 IT16 y IT15 to IT16 – For processes like casting,
casting general cutting
315 ‐ 400 10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6)
400 ‐ 500 58
= 640i = 1000i 59
work 60
Fundamental Deviation
is chosen to locate the tolerance zone w.r.t. the zero line Shaft Fundamental Deviation
Calculation for Upper and Lower Deviation
a − (265 + 1.3D ) for D ≤ 120 mm
y For Shaft
Holes are designated by capital letter: − 3.5D for D > 120 mm
Letters A to G - oversized holes ei = es – IT
Letters P to ZC - undersized holes b − (140 + 0.85
0 85D ) for D ≤ 160 mm
es = ei + IT −1.8 D for D > 160 mm
y For Hole
F H l c − 52D 0.2 for D ≤ 40 mm
EI = ES – IT
− (95 + 0.8
0 8D ) f D > 40 mm
for
Shafts are designated by small letter: ES = EI + IT
Letters m to zc - oversized shafts d − 16 D 0.44
Letters a to g - undersized shafts
e − 11D 0.41
H is used for holes and h is used for shafts es = upper deviation of shaft
pp
whose fundamental deviation is zero
ei = lower deviation of shaft f − 5.5D 0.41
ES = upper deviation of hole g 2 5D 0.41
− 2.5
61 EI= lower deviation of hole 62 h 0 63
Shaft Fundamental Deviation
j5 to j8 −
k4 to
t k7 + 0.6
0 63 D
m + ( IT 7 − IT 6) y For hole, H stands for a dimension whose lower
n + 5D 0.34
0 34
deviation
d i ti refers
f t the
to th basic
b i size.
i TheTh hole
h l H for
f which
hi h
p + IT 7 + (0 − 5) the lower deviation is zero is called a basic hole.
r Geometric mean of values of
y Similarly, for shafts, h stands for a dimension whose Basic size Hole Tolerance Zone
ei for p and s
upper deviation refers to the basic size. The shaft h for
s IT 8 + 1 to 4 for D ≤ 50 mm Shaft Tolerance Zone
IT 7 + 0.4 D for D > 50 mm
which the upper deviation is zero is called a basic
t IT 7 + 0.63
0 63D
shaft.
u IT 7 + D y A fit is designated by its basic size followed by symbols
v IT 7 + 1.25D representing the limits of each of its two components,
F d
Fundamental Deviation
t l D i ti IT#
x IT 7 + 1.6 D the hole being quoted first.
y IT 7 + 2D y For example,
example 100 H6/g5 means basic size is 100 mm
z IT 7 + 2.5D
and the tolerance grade for the hole is 6 and for the
za IT 8 + 3.15D
shaft is 5.
5
zb IT 9 + 4 D
zc IT 10 + 5D 64 65 66
GATE 2014
GATE‐2014 IES ‐ 2008 IES‐2006 Conventional
g y 5 g p
For the given assembly: 25 H7/g8, match Group A with
Group B Consider
C id theh following
f ll i statements: Find
Fi d the
h limit
li i sizes,
i tolerances
l and
d allowances
ll for
f a
Group A
p Group B
p A nomenclature φ 550 H8/p8 /p denotes that 100 mm diameter shaft and hole pair designated by
1. Hole diameter is 50 mm. F8h10. Also specify the type of fit that the above pair
P. H I. Shaft Type belongsg to.
2. ItI is
i a shaft
h f base
b system.
Q. IT8 II. Hole Type Given: 100 mm diameter lies in the diameter step
33. 8 indicates fundamental deviation. range of 80‐120
80 120 mm.
mm The fundamental deviation for
R. IT7 III. Hole Tolerance Grade Which of the statements given above is/are incorrect? shaft designation ‘f’ is ‐5.5 D0.41
S
S. g IV Sh ft T l
IV. Shaft Tolerance Grade
G d ( ) 1, 2 and
(a) d3 The values of standard tolerances for grades of IT 8
P Q R S P Q R S (b) 1 and 2 only and IT 10 are 25i and 64i respectively.
(a) I III IV II (b) I IV III II (c) 1 and 3 only Also, indicate the limits and tolerance on a diagram.
( ) 3 only
(d) [ M k ]
[15‐Marks]
(c) II III IV I (d) II IV III I
67 68 69
IES‐2015 Conventional Selected Question IES ‐ 2002

Determine the fundamental deviation and tolerances and the In the tolerance specification 25 D 6, the letter D
A journal of nominal or basic size of 75 mm runs
li it f i f h l d h ft i i th fit
limits of size for hole and shaft pair in the fit: 25 mm H8d9.
H8d represents
The diameter steps are 18 mm and 30 mm. The fundamental
in a bearing with close running fit H8g7. Find the
( ) Grade
(a) G d off tolerance
l
deviation for d shaft is given as ‐16D0.44. The tolerance unit is, limits of shaft and bearing also find maximum
(b) Upper
U d i ti
deviation
i = 0.45 3 D + 0.001D and minimum clearance? 75 mm lies in the
(c) Lower deviation
The tolerance grade for number 8 quality is 25i and for 9 diameter steps of 50 to 80 mm. Fundamental
quality is 40i. (d) Type of fit
deviation for shaft g is ‐2.5 D0.34
[ M k ]
[10 Marks]
70 71 72
GATE ‐ 2009 GATE – 2008 (PI) GATE ‐ 2000
What
Wh t are the th upper and d lower
l limits
li it off the
th shaft
h ft Following data are given for calculating limits of
represented by 60 f8? A fit is specified as 25H8/e8. The tolerance value for
U the
Use h following
f ll i data: d di
dimensions
i and
d tolerances
t l f a hole:
for h l Tolerance
T l unit
it i (in
(i a nominall diameter
d off 25 mm in IT8 is 33 microns
Diameter 60 lies in the diameter step of 50‐80 mm.
F d
Fundamental l tolerance
l unit,
i
µm) = 0.45
0 45 ³√D
√D + 0.001D.
0 001D The unit of D is mm.
mm Diameter and fundamental deviation for the shaft is ‐ 40
i, in μ m= 0.45 D1/3 + 0.001D, where D is the step
p is 18‐30
3 mm. If the fundamental deviation for H microns. The maximum clearance of the fit in
representative size in mm;
Tolerance value for lT8 = 25i.
5 hole is zero and IT8 = 25 i, the maximum and minimum microns is
Fundamental deviation for 'f shaft = ‐5.5D0.41 limits of dimension for a 25 mm H8 hole (in mm) are (a) ‐7 (b) 7
(a) Lower limit = 59.924
59 924 mm,
mm Upper Limit = 59.970
59 970 mm
(b) Lower limit = 59.954 mm, Upper Limit = 60.000 mm (a) 24.984, 24.967 (b) 25.017, 24.984 (c) 73 (d) 106
(c) Lower
Lo er limit = 59.970
9 9 0 mm,
mm Upper Limit = 60.016
60 0 6 mm
(c) 25.033, 25.000 (d) 25.000, 24.967
(d) Lower limit = 60.000 mm, Upper Limit = 60.046 mm 73 74 75
GATE ‐ 2003 GATE‐2010 (PI) GATE‐2016 (PI)

The
Th dimensional
di i l limits
li i on a shaft
h f off 25h7
h are
A small bore is designated as 25H7. The lower The limits of a shaft designated as 100h5 are 100.000 mm
((a)) 25.000,
5 , 25.021
5 mm
(b) 25.000, 24.979 mm (minimum) and upper (maximum) limits of the bore and 100.014 mm. Similarly, the limits of a shaft
( ) 25.000, 25.007 mm
(c) are 25.000 mm and
d 25.021 mm, respectively.
ti l When
Wh the
th designated as 100h8 are 100.000 mm and 100.055 mm. If
((d)) 25.000,
5 , 24.993
4 993 mm bore is designated as 25H8, then the upper (maximum) a shaft is designated as 100h6,
100h6 the fundamental deviation
de iation
limit is 25.033 mm. When the bore is designated as
(in μm) for the same is
25H6, then the upper (maximum) limit of the bore (in
(a)‐22 (b) zero (c) 22 (d) 24
mm)) is
( ) 25.001 (b) 25.005 (c)
(a) ( ) 25.009 (d) 25.013
76 77 78
Recommended Selection of Fits GATE – 1996, IES‐2012 IES ‐ 2000

The
Th fit
fi on a hole‐shaft
h l h f system isi specified
ifi d as H7‐
H Which
f ll i tolerances
l set on inner
i
s6.The type of fit is diameter and outer diameter respectively of headed
(a) Clearance fit jig bush for press fit is correct?
(b) Running fit (sliding fit) (a) G7 h 6 (b) F7 n6
(c) Push fit (transition fit) (c) H 7h 6 (d) F7j6
(d) Force fit (interference fit)
79 80 81
Interchangeability
Selective Assembly y Interchangeability,
g y a maintainabilityy design
g factor, is
quite closely related to standardization and is realized
ISRO‐2008
y All the parts (hole & shaft) produced are measured
through standardization. I t h
Interchangeability
bilit can be
b achieved
hi d by
b
and graded into a range of dimensions within the
y If the variation of items are within certain limits, all
tolerance groups. (a) Standardization
parts of equivalent size will be equally fit for operating in
machines and mechanisms and the mating parts will (b) Better process planning
y Reduces
d the
h cost off production
d
give the required fitting.
(c) Simplification
Process capability y This facilitates to select at random from a large number
y No.of group =
Tolerance desired of parts for an assembly and results in a considerable (d) Better product planning
saving in the cost of production, reduce assembly time,
replacement and repair becomes very easy.
easy
82 83 84
Tolerance Sink GATE ‐ 2003 GATE ‐ 1997

Three
Th blocks
bl k B1 , B2 andd B3 are
y A design engineer keeps one section of the part blank to be inserted in a channel of
width S maintaining a
(without tolerance) so that production engineer can minimum gap of width T =
d
dump all
ll the
h tolerances
l on that
h section
i which
hi h becomes
b 0 125 mm,
0.125 mm as shown in Figure.
Figure
For P = 18. 75 ± 0.08;
most inaccurate dimension of the part.
part Q = 25.00 ± 0.12;
R = 28.125 ± 0.1 and
y Position of sink can be changing the reference point.
point
S = 72.35 + X, (where all
y Tolerance for the sink is the cumulative sum of all the dimensions are in mm), the
tolerance
l X is
tolerances and only like minded tolerances can be added ((a) + 0.38
) 3 ((b) ‐
) 0.38
3 ((c) + 0.05
) 5 ((d) ‐0.05
) 5
i.e. either equally bilateral or equally unilateral. 85 86 87
GATE 2015
GATE-2015 GATE 2007(PI)
GATE ‐2007(PI) GATE – 2007 (PI)
( )
In the assembly shown below, the part dimensions are:
The geometric tolerance that does NOT need a datum
±0.01
L 1 = 22.0 mm for its specification is Diameter of a hole after plating needs to be controlled
±0.005 between 30++0.050
0.010 mm. If the plating thickness varies
L2 = L3 = 10.0
10 0 mm ((a)) Concentricityy ((b)) Runout
between 10 - 15 microns, diameter of the hole before
Assuming normal distribution of part dimensions
Assuming normal distribution of part dimensions, ((c)) Perpendicularity
p y ((d)) Flatness
plating
l i should
h ld be
b
the dimension L4 in mm,
(a) 30++0.070
0.030 mm (b) 30++0.065
0.020 mm
a) 2.00±0.008 b) 2.00±0.012
c) 2.00
) ±0 016
±0.016
d) 2.00±0.020
d) ±0 020 (c) 30++0.080
0.030 mm (d) 30++0.070
0.040 mm
88 89 90
GATE‐2013 GATE ‐ 2017 GATE ‐ 2000
A cylindrical
li d i l pin
i off mm diameter
di is
i A slot
l isi to be
b milled
ill d centrally
ll on a block
bl k with
ih a
Cylindrical pins of 25++0.020
0.010 mm diameter are p
electroplated. Plating
g thickness is mm. dimension of 40 ± 0.05 mm. A milling cutter of 20
mm width is located with reference to the side of
electroplated in a shop. Thickness of the Neglecting the gauge tolerance, the diameter (in mm, up
to 3 decimal points accuracy) of the GO ring gauge to the block within ± 0.02 mm. The maximum offset in
plating is 30 ±2.0 micron. Neglecting gage inspect the plated pin is_________ mm between the centre lines of the slot and the
block is
tolerances, the size of the GO gage in mm (a) ± 0.070 (b) 0.070
tto iinspectt the
th plated
l t d components
t iis (c) ± 0.020 (d) 0.045
(a) 2525.042
042 (b) 25.052
25 052 (c) 25
25.074
074 (d) 25.084
25 084
91 92 93
GATE ‐ 2017 Limit Gauges

Limit Gauges
The
Th standard
d d deviation
d i i off linear
li dimensions
di i P
y Plug gauge: used to check the holes.
holes The GO plug gauge is
the size of the low limit of the hole while the NOT GO plug
ISRO‐2008
and Q are 3 μm and 4 μm, respectively. When gauge corresponds to the high limit of the hole.
hole Plug gauges are used to
assembled, the standard deviation (in μm ) of the y Snap, Gap or Ring gauge: used for gauging the shaft and (a) Measure the diameter of the workpieces
resulting
lti linear
li di
dimension
i (P + Q) is_________
i male
l components. The Th Go G snap gauge is i off a size
i (b) Measure the diameter of the holes in the
corresponding to the high (maximum) limit of the shaft, workpieces
p
while
hil theh NOT GO gauge corresponds d to theh low
l
(minimum limit). (c) Check the diameter of the holes in the
workpieces
(d) Check the length of holes in the workpieces
94 Fig. Plug gauge Fig. Ring and snap gauges 95 96
• Bilateral system: in this

Allocation of manufacturing tolerances
ll i f f i l Example system, the GO and NO GO
y Unilateral system: gauge tolerance
t l zone lies
li
Size of the hole to be checked 25 ± 0.02 mm
gauge tolerance zones are
entirely within the work tolerance zone. bisected by the high and
y work tolerance zone becomes smaller by the sum of the
H
Here, Hi
Higher
h limit
li it off hole
h l = 25.02
25 02 mm low limits off the work
gauge tolerance.
tolerance Lower limit of hole = 24.98
24 98 mm tolerance zone.
Work tolerance = 0.04 mm

∴ Gauge tolerance = 10% of work tolerance = 0.004 mm
Taking example as above:
+0.004 +0.002
∴ Dimension of 'GO' Plug gauge = 24.98 mm ∴ Dimension of 'GO' Plug gauge = 24.98 mm
−0.000
0 000 −0.002
0 002
+0.000
0.000 +0.002
+0.002
Dimension of 'NOT GO' Plug gauge = 25.02 mm Dimension of 'NOT GO' Plug gauge = 25.02 mm
97 −0.004 98 −0.002 99

• Taking example of above:
∴Wear Allowance = 5% of work tolerance = 0.002 mm GATE ‐ 2014
y Wear allowance: GO gauges which constantly rub
g g y
Nominal size of GO plug gauge = 24.98
24 98 + 0.002
0 002 mm A GO‐NOGO
GO NOGO plug l gauge isi to beb designed
d i d for
f
against the surface of the parts in the inspection are
subjected to wear and loose their initial size. +0.004 measuring a hole of nominal diameter 25 mm with a
∴ Dimension
Di i off 'GO' Plug
Pl gauge = 24.982
24 982 mm hole tolerance of ± 0.015 mm. Considering 10% of
y The size of go plug gauge is reduced while that of go −0.000 work tolerance to be the g gauge
g tolerance and no
snap gauge increases.
i
+0.000 wear condition, the dimension (in mm) of the GO
y To increase service life of gauges wear allowance is
g g g ggauge
Dimension of 'NOT GO' Plug g = 25.02 mm plug gauge as per the unilateral tolerance system is
added to the go gauge in the direction opposite to −0.004
0 004
+0.003 +0.000
wear. Wear allowance is usually taken as 5% of the
−0.003 −0.006
work tolerance. (a ) 24.985 (b) 25.015
y Wear allowance is applied to a nominal diameter
W ll i li d i l di +0.03 +0.003
before gauge tolerance is applied. −0.03 −0.000
(c) 24
24.985
985 (d ) 24
24.985
985
101
100 102
GATE ‐ 2004 GATE 2015

GATE-2015 GATE ‐ 1995
GO and d NO‐GO
NO GO plug
l gages are to be
b designed
d i d for
f a Which one of the following statements is TRUE? Checking
Ch ki the
h diameter
di off a hole
h l using
i GO‐NO‐GO
GO NO GO
0.05
hole 200.01 gauges is an, example of inspection by
g tolerances can be taken as 10%
0 01 mm. Gage a) The ‘GO’
GO gage controls the upper limit of a hole
of the hole tolerance. Following ISO system of gage …..(variables/attributes)
design sizes of GO and NO
design, NO‐GO
GO gage will be b)The ‘NO GO’ gage controls the lower limit of a shaft The above statement is
respectively c) The ‘GO’ gage controls the lower limit of a hole (a) Variables
( ) 20.010 mm and
(a) d 20.050 mm d)The ‘NO GO’ gage controls the upper limit of a hole (b) Attributes
(b) 20.014
0.0 4 mm aand
d 20.046
0.046 mm (c) Cant say
(c) 20.006 mm and 20.054 mm (d) Insufficient data
(d) 20.014 mm and d 20.054 mm
103 104 105
For IES Only
GATE – 2006, VS‐2012 T l ’ Pi i l
Taylor’s Principle Limit Gauges
A ringi gauge is i used d to measure This principle states that the GO gauge should always be Gauge For Measuring
((a)) Outside diameter but not roundness Snap Gauge External Dimensions
so designed
d d that
h it will
ll cover the
h maximum metall
(b) Roundness but not outside diameter
Plug Gauge
g g Internal Dimensions
( ) Both
(c) B h outside
id diameter
di and
d roundness
d condition (MMC) of as many dimensions as possible in
Taper Plug Gauge Taper hole
((d)) Onlyy external threads the same limit gauges, whereas a NOT GO gauges to
Ring Gauge External Diameter
cover the minimum metal condition of one dimension
G G
Gap Gauge G d G
Gaps and Grooves
only.
Radius Gauge Gauging radius
Thread pitch Gauge
p g External Thread
106 107 108
Feeler Gauge GATE‐2016
PSU Match the following:
A f l
A feeler gauge is used to check the
i d t h k th P. Feeler gauge
P Feeler gauge II. Radius of an object
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
S C li d i l l IV I id di
IV. Inside diameter of
t f straight
t i ht
(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
109 110
(c) P‐IV, Q‐II, R‐I, S‐III (d) P‐IV, Q‐I, R‐II, S‐III 111
Why is a unilateral tolerance
Why is a unilateral tolerance Preferred Number
Preferred Number Preferred Number Contd.
Preferred Number ….. C td
y A designed product needs standardization. y These are named as Renard series.
preferred over bilateral tolerance ?
preferred over bilateral tolerance ? y Motor speed, engine power, machine tool speed and y Many other derived series are formed by multiplying or
y This system is preferred for Interchangeable manufacturing.
manufacturing feed, all follows a definite pattern or series. dividing the basic series by 10, 100 etc.
y This also helps in interchangeability of products. y Typical values of the common ratio for four basic G.P.
y It is easy and simple to determine deviations.
deviations series
i are given
i b l
below.
y It has been observed that if the sizes are put in the form
y It helps
p standardize the GO g
gauge
g end of ggeometric p progression,
g
with a definite sequence.
, then wide ranges
g are covered R5 : 11.58
58 :1
:1.0,1.6,
0 1 6 2.5,...
25 ( 10
5
10, 100 5
1000 ) 5
100, 1000,....
:1 0 1 25 1 6 ( 10, 1000 )
y Helpful for operator because he has to machine the upper 10 10 10
y These numbers are called preferred numbers having R10 : 1.26
1 26 :1.0,1.25,1.6,... 10 100,
100 1000,....
limit of the shaft and the lower limit of the hole knowing common ratios as,
fully well that still some margin is left for machining before 5
10 ≈ 1.58, 10
10 ≈ 1.26, 20
10 ≈ 1.12 and 40 10 1.06 R 20 : 1.12 :1 0 1 12 1 4 ( 10
1 12 :1.0,1.12,1.4,... 20 20
10, 100, 1000,....)
100 1000 20
the part is rejected.

rejected y Depending on the common ratio,
ratio four basic series are R 40 : 1.06 1 0 1 06 1 12 ( 10
1 06 :1.0,1.06,1.12,... 40
10, 100 1000,....)
40
100, 1000 40
112
formed; these are R5 , R10 , R20 and R40 113 114
Accuracy & Precision

Accuracy & Precision
y Accuracy ‐ The ability of a measurement to match the actual
(true) value of the quantity being measured. The expected
ability for a system to discriminate between two settings.settings
Smaller the bias more accurate the data.
y P i i
Precision ‐ The
Th precision
i i off an instrument
i i di
indicates i
its
Measurement of Lines & Surfaces ability to reproduce a certain reading with a given accuracy
‘OR’ it
i is
i the
h degree
d off agreement between
b repeated d results.
l
y Precision data have small dispersion
p ( spread
p or scatter ) but
may be far from the true value.
y A measurement can be accurate but not precise,
precise precise but
not accurate, neither, or both.
y A measurementt system
t i called
is ll d valid
lid if it is
i both
b th accurate t
By S K Mondal 115 and precise. 116 117
GATE‐2017 (PI) Repeatability Reliability of measurement
Reliability of measurement
y It is a quantitative characteristic which implies
Accuracy
A off a measuringi instrument
i is
i y It is the ability of a measuring system to reproduce confidence in the measured results depending on
output readings when the same input is applied to it whether or not the frequency
q y distribution
expressed as
consecutively,
i l underd the
h same conditions,
di i andd in
i the
h characteristics of their deviations from the true values
(a) true value – measured value same direction. of the corresponding
p g q
quantities are known. It is the
(b) measured value ‐ true value y Imperfections in mechanical systems can mean that probability that the results will be predicted.
t
true value-measured
l d value
l during a Mechanical cycle,
cycle a process does not stop at the
(c) 1- same location, or move through the same spot each time.
true value
Th variation
The i ti range is
i referred
f d to
t as repeatability.
t bilit
true value-measured value
(d)1+
true value Which of these targets represents A change in one variable, such as wind,
accurate shooting? Precise alters the results as shown. Dose this
shooting?
h ti ? Reliable
R li bl shooting?
h ti ? show
h which
hi h shooting
h ti was the
th mostt
reliable?
118 119 120
Calibration y Drift: It is a slow change of a metrological characteristics of a Errors

y It
I is
i the
h setting
i or correcting
i off a measuring
i device
d i measuring instruments y Systematic
S i errors or fixed
fi d errors (Bias):
(Bi ) Due
D to faulty
f l
usually by adjusting it to match or conform to a y Resolution: It is the smallest change of the measured
quantity
tit which
hi h changes
h th indication
the i di ti off a measuring
i or improperly calibrated instruments.
instruments These may be
dependably known value or act of checking.
instruments
y Calibration determines the performance characteristics reduced or eliminated byy correct choice of instruments.
y Sensitivity: The smallest change in the value of the
of an instrument, system or reference material. It is
measured variable to which the instrument respond is Eg.
g calibration errors, Errors of technique
q etc.
usuall achieved
usually achie ed by
b means of a direct comparison against sensitivity. It denotes the maximum changes in an input
measurement standards or certified reference materials. signal
g that will not initiate a response
p on the output.
p y Random errors: Random errors are due to non‐specific
y It is very widely used in industries. y Rule of 10 or Ten‐to one rule: That the discrimination cause like natural disturbances that may occur during
y A calibration certificate is issued and,
and mostly,
mostly a sticker is (resolutions) of the measuring instrument should divide the
provided for the instrument. tolerance of the characteristic to be measured into ten parts. the experiment. These cannot be eliminated.
In other words,
words the gauge or measuring instrument should be Eg. Errors stemming from environmental variations, Due
E E i f i l i i D
10 times as accurate as the characteristic to be measured. 122
121
to Insufficient sensitivity of measuring system 123
Linear measurements Vernier Caliper

Vernier Caliper
y A vernier scale is an auxiliary scale that slides along the main
Some
S off the
h instruments
i used
d for
f the
h linear
li scale.
measurements are: y The vernier scale is that a certain number n of divisions on
y Rules (Scale) the vernier scale is equal in length to a different number
y Vernier (usually one less) of main
main‐scale
scale divisions.
divisions
y Micrometer (Most widely used, Working Standard) nV = (n −1)S
where
h n = number
b off divisions
d on the
h vernier scale
l
y Height gauge
V = The length
g of one division on the vernier scale
y Bore
B gauge
and S = Length of the smallest main‐scale division
y Dial indicator
y Least count is applied to the smallest value that can be read
y Slip gauges or gauge blocks (Most accurate, End directly by use of a vernier scale.
Standard) y Least count = S − V = 1 S
n Vernier Caliper
124 125 126
ISRO‐2010 M t i Mi t
Metric Micrometer
The
Th vernier
i reading
di should
h ld not be
b taken
k at its
i face
f ISRO‐2008 y A micrometer allows a measurement of the size of a
value before an actual check has been taken for Th least

The l t countt off a metric
t i vernier
i caliper
li body. It is one of the most accurate mechanical devices
(a) Zero error having 25 divisions on vernier scale, matching in common use.
(b) Its calibration with 24

4 divisions of main scale (1 main scale y It consists a main scale and a thimble
divisions = 0.5 mm) is Method of Measurement

((c)) Flatness of measuring
g jjaws
(a) 0.005 mm (b) 0.01 mm Step‐I: Find the whole number of mm in the barrel
((d)) Temperature
p equalization
q
(c) 0.02 mm (d) 0.005mm Step‐I: Find the reading of barrel and multiply by 0.01
127 128
Step‐III: Add the value in Step‐I and Step‐II 129
y Bore Gauge: used for measuring bores of different

ISRO‐2009, 2011
ISRO‐2009 2011 g g from small‐to‐large
sizes ranging g sizes.
y Provided with various extension arms that can be
I a simple
In i l micrometer
i t with
ith screw pitch
it h 0.5 added for different sizes.
sizes
mm and divisions on thimble 50, the reading
corresponding
p g to 5 divisions on barrel and 12
divisions on thimble is
(a) 2.620 mm (b) 2.512 mm

Micrometer (c) 2.120 mm (d) 5.012 mm
130 131 132
y Dial indicator: Converts a linear GATE – 2008 S‐1

displacement into a radial pp cat o s o d a d cato c ude:
Applications of dial indicator include:
A displacement
di l sensor (a
( dial
di l indicator)
i di ) measures the
h
movement to measure over a y centering workpices to machine tool spindles lateral displacement of a mandrel mounted on the taper
small
ll range off movement for
f theh hole inside a drill spindle. The mandrel axis is an
plunger. y offsetting lathe tail stocks extension of the drill spindle
p taper
p hole axis and the
y The typical least count that can be protruding portion of the mandrel surface is perfectly
y aligning a vice on a milling machine
obtained with suitable gearing cylindrical Measurements are taken with the sensor
cylindrical.
dial indicators is 0.01 mm to 0.001 y checking dimensions placed at two positions P and Q as shown in the figure.
mm.
mm Th readings
The di are recorded
d d as Rx = maximum
i d fl ti
deflection
y It is possible to use the dial minus minimum deflection, corresponding to sensor
indicator as a comparator by position at X, over one rotation.
mounting g it on a stand at anyy
suitable height. Principle of a dial indicator
133 134 135
GATE – 2008 contd… from S‐2
d f GATE – 2014(PI) S‐1
( ) GATE – 2014(PI) S‐2
( )
If Rp= RQ>0, >0 which one of the The
Th alignment
li test This
Thi test inspects
i whether
h h the h
following would be consistent with the
observation? “Spindle square with ((a)) spindle
p vertical feed axis is p perpendicular
p to the base
(A) The drill spindle rotational axis is base plate” is applied plate
coincident with the drill spindle
p taper
p to the radial drilling g
hole axis (b) axis of symmetry of the cylindrical spindle is
machine. A dial perpendicular to the base plate
(B) The drill spindle rotational axis
i
intersects the
h drill
d ill spindle
i dl taper hole
h l indicator is fixed to
the cylindrical spindle (c) axis of symmetry, the rotational axis and the vertical
axis at point P
and
d the
th spindle
i dl is i feed
eed aaxiss o
of tthee sp
spindle
d e aaree aall co
coincident
c de t
(C) The
Th drill
d ill spindle
i dl rotational
t ti l axis
i is
i
parallel to the drill spindle taper hole rotated to make the (d) spindle rotational axis is perpendicular to the base
axis plate
l t
indicator
d touch h the
h
(D) The drill spindle rotational axis
intersects the drill spindle taper hole base p
plate at different
axis at point Q points
136 137 138
Slip Gauges or Gauge blocks y Come in sets with different number of pieces in a given To make up a Slip Gauge pile to 41.125 mm
y These
Th are small
ll blocks
bl k off alloy
ll steel.
l sett to
t suit it the
th requirements
i t off measurements. t y A Slip
Sli Gauge
G pile
il is
i sett up with
ith the
th use off simple
i l
y Used in the manufacturing
g shops
p as length
g standards. y A typical
yp set consisting
g of 88 p
pieces for metric units is maths.
y Not to be used for regular and continuous shown in.
y Decide what height
g y you want to set up,
p in this
measurement.
measurement y To
T build
b ild any giveni di
dimension,
i it is
i necessary to t
y Rectangular blocks with thickness representing the identifyy a set of blocks,, which are to be p put together.
g case 41.125mm.
dimension of the block. The cross‐section of the block y Number of blocks used should always be the smallest. y Take away the thickness of the two wear gauges,
iss usua
usuallyy 332 mm x 9 mm..
y Generally
G ll theh top and d bottom
b Sli Gauges
Slip G i the
in h pile
il and then use the gauges in the set to remove
y Are hardened and finished to size. The measuring
are 2 mm wear g gauges.
g This is so that theyy will be the
surfaces
f off the
th gauge blocks
bl k are finished
fi i h d to
t a very high
hi h each place of decimal in turn,
turn starting with the
degree of finish, flatness and accuracy. only ones that will wear down, and it is much cheaper
lowest.
to replace
l two gauges than
h a whole
h l set.
139 140 141
To make up a Slip Gauge pile to 41.125 mm A M t i li t (88 Pi )

A Metric slip gauge set (88 Pieces)
41.125
-4.000 Slip gauges size or Increment, mm
Increment mm Number of
______
37.125 range, mm Pieces
-1.005
1 00
_______ 1.005 ‐ 1
36.120 1.001 to 1.009 0.001 9
-1.020
1 020
_______ 1.010 to 1.490 0.010 49
35.100
-1.100
1 100 0 500 to 9.500
0.500 to 9 500 0 500
0.500 19
_______
34.000 10 to 100 10.000 10
-4.000
4 000
_______
30.000
-30.000
30 000
_______
0.000
142 143 144

ISRO‐2010 Comparators
A master gauge is ISRO‐2008 y Comparator is another form of linear measuring
method, which is quick and more convenient for
(a) A new gauge St d d to
Standards t be
b used
d for
f reference
f purposes in
i checking
h ki largel number
b off identical
id ti l dimensions.
di i
(b) An international
te at o a reference
e e e ce sta
standard
da d laboratories and workshops are termed as y Duringg the measurement, a comparator
p is able to g
give
the deviation of the dimension from the set dimension.
(c) A standard gauge for checking accuracy of (a) Primary standards y Cannot measure absolute dimension but can only
gauges used on shop floors
compare two dimensions.
(d) A gauge used by experienced technicians ((b)) Secondaryy standards
y Highly reliable.
((c)) Tertiaryy standards y To magnify the deviation, a number of principles are
used such as mechanical, optical, pneumatic and
(d) Working standards
electrical.
electrical
145 146 147
GATE – 2007 (PI)
( ) Mechanical Comparators
Mechanical Comparators
y The Mikrokator principle
Which one of the following instruments is a
greatly magnifies any
comparator
t ? d i ti
deviation i size
in i so that
th t
even small deviations
(a) Tool Maker
Maker’ss Microscope produce
d l
large d fl
deflections off
the p
pointer over the scale.
(b) GO/NO GO gauge
(c) Optical Interferometer
(d) Dial Gauge
Fig. Principle of a comparator 148 149 150
Sigma Mechanical Comparator
The Sigma Mechanical Comparator uses a partially
y The Eden‐Rolt Reed system
y uses a
wrapped
d band
b d wrapped
d about
b a driving
d d
drum to turn a
pointer attached to the end of two
pointer needle.
needle The assembly provides a frictionless
reeds. One reed is pushed by a
movement with a resistant pressure provided by the
plunger, while the other is fixed. As
springs.
one reed
d moves relative
l ti tot the
th other,
th
the pointer that they are commonly
attached to will deflect.
Sigma Mechanical Comparator
151 152 153
Optical Comparators Pneumatic Comparators
y These
Th devices
d i use a plunger
l to rotate a mirror.
i A light
li h y Flow type:
beam is reflected off that mirror, and simply by the In this system, Mechanical amplification
virtue of distance, the small rotation of the mirror can = 20 /1 , y The float height is essentially proportional to the air
be converted to a significant
g translation with little
A d O i l
And, Optical amplification
lifi i that
h escapes from
f the
h gauge head
h d
friction.
50 /1 x 2
y Master
M t gauges are used
d to
t find
fi d calibration
lib ti points
i t on
It is multiplied by 2, because if mirror
is tilted by an angle δθ then image
is tilted by an angle δθ, then image the scales
will be tilted by 2 x δθ. Thus overall
y The input pressure is regulated to allow
magnification of this system
= 2 x (20/1) ( 50/1 =2000 units)
2 x (20/1) ( 50/1 2000 units) magnification adjustment
154 155 156
Pneumatic Comparators Angular Measurement Bevel Protractor

This involves the measurement of angles of tapers and y Is part of the machinist's combination square.
similar
l surfaces.
f The
h most common angular
l measuring y The flat base of the protractor helps in setting it firmly
tools are: on the
h workpiece
k i and
d then
h byb rotating
i the
h rule,
l iti is
i
y Bevel protractor possible to measure the angle.
angle It will typically have a
y Sine bar discrimination of one degree.

g
157 158 159
Sine Bar
Sine Bar
y When a reference for a non‐square angle is required, a sine bar
can be used.
y Basically a sine bar is a bar of known length.
length When gauge blocks
are placed under one end, the sine bar will tilt to a specific
angle.
y Knowing the height differential of the two rollers in alignment
with the workpiece ,the angle can be calculated using the sine
formula.
y A sine bar is specified by the distance between the centre of the
two rollers, i.e. 100 mm, 200 mm, & 300 mm. the various part of
sine bar are hardened before grinding & lapping. H
A Bevel Protractor s in θ =
160 161
L 162
( )
GATE ‐2012 (PI) Dis‐advantages
ISRO‐2011 y 1. Sine bars cannot be used for conveniently for
A sine bar has a length of 250 mm. Each roller has
A sine
i bar
b is
i specified
ifi d by
b measuring angles h 60o because
l more than b off slip
l gauge
a diameter of 20 mm. During taper angle
(a) Its total length adjustment problems.
problems
measurement of a component, the height from the
(b) The size of the rollers surface
f plate
l to the
h centre off a roller
ll isi 100 mm. y 2.
2 Misalignment of workpiece with sine bar may
(c) The centre distance between the two rollers sometimes introduce considerable errors.
Th calculated
The l l t d taper
t angle
l (in
(i degrees)
d ) is
i
(d) The distance between rollers and upper surface ( ) 21.1
(a) (b) 22.8
8 ( ) 23.6
(c) 6 (d) 68.9
68
163 164 165
Thread Measurements y The parameters that are normally measured are: Three-Wire Method

y Threads are normally specified by the major diameter.
Th d ll ifi d b h j di y Major diameter
y Though there are a large variety of threads used in
g g y y Three wires of equal diameter placed in thread, two
y Micrometer
engineering, the most common thread encountered is on one side and one on other side
y Pitch diameter
the metric V thread shown in Fig.
the metric V‐thread shown in Fig
y Floating Carriage micrometer y Standard micrometer used to measure distance over
y Wire method (Three wire and two wire)
wires (M)
y Pitch
y Screw pitch gauge y Different sizes and pitches of threads require
y Pitch measuring machine diff
different
t sizes
i off wires
i
y Thread form
y Optical projector
166 167 168
The Three-Wire Method of Measuring Threads y Distance W over the outer edge
⎛ α⎞ p α
W = D p + d ⎜1 + cosec ⎟ − cot
⎝ 2⎠ 2 2
For ISO metric thread,, α = 60 and D p = D − 0.6496 p
W = D + 3d − 1.5156 p
y Best wire size
p α
d= sec
2 2
For ISO metric thread, α = 60
D p = pitch diameter or Effective diameter
d = 0.5774 p
169 p = pitch of thread , and α = thread angle 170 171
y Pitch
Pit h Diameter
Di t or Eff
Effective
ti Di
Dia.
Two-Wire Method Dp = T + P
p ⎛α ⎞ ⎛ α ⎞
GATE –
GATE – 2011 (PI)
2011 (PI)
y Two wires of equal diameter placed in thread, two on =T + cot ⎜ ⎟ − d ⎜ cosec − 1⎟
2 ⎝2⎠ ⎝ 2 ⎠ The best wire size (in mm) for measuring
one side and one on other side T = Dimensions under the wire = D + ( Dm − Ds ) effective diameter of a metric thread
D=D Diameter
i t off master
t or standard
t d d cylinder
li d (included angle is 60o) of 20 mm diameter and
Dm = Micrometer reading over standard cylinder with two wire 2.5 mm pitch using two wire method is
D s = Micrometer reading over the plug screw gauge with the wire (a) 1.443
P = Pitch value (b) 0.723
0 723
y Best wire size (c) 2.886
p α (d) 2.086
d= sec
2 2
172 173 174
GATE‐2013 IES‐2017 (Pre)
( )
A metric thread of pitch 2 mm and thread A metric thread of pitch 2 mm and thread
GATE –
GATE – 2011 (PI)
2011 (PI)
To measure the effective diameter of an external
angle 60 inspected for its pitch diameter angle 60o is inspected for its pitch diameter metric thread (included angle is 60o) of 3.5 mm
pitch,, a cylindrical
p y standard of 330.55 mm diameter
using 3‐wire method. The diameter of the using the 3‐wire method. The indicated and two wires of 2 mm diameter each are used.
The micrometer readings over the standard and
best size wire in mm is diameter of the wire will be nearly over the wires are 16.532 mm and 15.398 mm,
respectively. The effective diameter (in mm) of the
(a) 0.866 (b) 1.000 (c) 1.154 (d) 2.000 (a) 0.85 mm (b) 1.05 mm thread is
(a) 33.366
33 366 (b) 30.397
30 397
(c) 1.15 mm (d) 2.05 mm (c) 29.366 (d) 26.397
175 176 177
Surfaces y Surface geometry can be quantified a few different
ways.
ways
y No surface is perfectly smooth, but the better the
surface
f quality,
l the
h longer
l a product
d generally
ll lasts,
l
and the better is performs.
performs
Measurement of Surfaces
fS f y Surface texture can be difficult to analyse
q
quantitatively.
y y Real surfaces are rarely so flat, or smooth, but most
Real surfaces are rarely so flat or smooth but most
commonly a combination of the two.
y Two surfaces may
y be entirelyy different, yyet still p
provide
the same CLA (Ra) value.
178 179 180

y Roughness
g g
height: is the p
parameter with which
generally the surface finish is indicated. It is specified
either as arithmetic average value or the root mean
square value.
y Roughness
R h width:
idth isi the
th distance
di t parallel
ll l to
t the
th
nominal part surface within which the peaks and
valleys, which constitutes the predominant pattern of
the roughness.
g
y Roughness width cut‐off: is the maximum width of
the surface that is included in the calculation of the
roughness height.
181 182 183
Lay Lay Contd..
y Waviness: refers to those surface irregularities that have Diagram Symbol Description Diagram Symbol Description
a greater spacing than that of roughness width.
width Parallel lay: Lay parallel to Multidirectional lay: Lay
y Determined by the height of the waviness and its the Surface. Surface is multidirectional. Surface is
width. produced
d d b
by shaping,
h i produced
d d by b grinding,
i di
y The greater the width,
width the smoother is the surface and planning etc. lapping, super finishing.
thus is more desirable. Perpendicular lay: Lay Circular lay:
y Lay
L di
direction:
i i the
is h direction
di i off the
h predominant
d i perpendicular to the Approximately circular
surface pattern produced on the workpiece by the tool Surface. Surface is produced relative to the center.
marks. b shaping
by h i and d planning
l i S f
Surface i produced
is d d by b
Crossed lay: Lay angular in
y y g facing.
y Flaw: are surface irregularities that are present which are
random and therefore will not be considered. both directions. Radial lay: Approximately
Surface is produced by radial relative to the center
184
knurling, honing. 185
of the nominal surface. 186
IES‐2012 Representation of Surface Roughness GATE‐2017 (PI)

In
I connection i with
i h surface
f texture define
d fi A machined
hi d surface
f with
ith standard
t d d symbols
b l
((a)) waviness indicatingg the surface texture is shown in the
(b) flaws, and Figure. (All dimensions in the Figure are in
( ) lay.
(c) l micrometer).
micrometer)
List three defects found on surfaces. The waviness height g ((in micrometer)) of the
[2 marks] surface is
( )1
(a) (b) 50
(c) 60 (d) 120
187 188 189

Roughness Roughness Grade Roughness Symbol
Ra (μm) Number
50 N12 ‐ IES ‐ 1992
25
2 N11
∇
IES‐2016 conventional
IES‐2016 conventional Which
Whi h grade
d symbol
b l represents surface
f rough
h off
12.5 N10 broaching?
Show in a figure location of the surface
6.3 N9 (a) N12 (b) N8
texture details when used with
32
3.2 N8 ∇∇ machining
h symbols.
b l (c) N4 (d) N1
1.6 N7
[4 Marks]
0.8 N6
04
0.4 N5 ∇∇∇
0.2 N4
0.1 N3
0 05
0.05 N2 ∇∇∇∇
0.025 N1 190 191 192
y Waviness height ‐ the distance from a peak to a valley Evaluation of Surface Roughness Determination of Mean Line

y Waviness width ‐ the distance between peaks or y M‐System: After plotting the characteristic of any
1. Centre line average (CLA) or arithmetic mean
valleys
y surface a horizontal line is drawn by joining two points.
points
y Roughness width cutoff ‐ a value greater than the deviation denoted as Ra. This line is shifts up and down in such a way that 50%
maximum roughness width that is the largest area is above the line and 50% area is below the line
2. Root mean square value (Rg) : rms value
separation of surface irregularities included in the
measurements. Typical
T i l values
l are (0.003”,
( ” 0.010”,” 3. Maximum peak to valley roughness (hmax)
0.030”, 0.100”, 0.300”)
y Lay ‐ the direction the roughness pattern should 4. The average of the five highest peak and five deepst
follow valleys
ll i the
in th sample.
l
y Stylus travel is perpendicular to the lay specified.
5 The average or leveling depth of the profile.
5. profile
193 194 195
Determination of Mean Line Arithmetical Average: GATE 2016 (PI)

GATE‐2016 (PI)
The roughness profile of a surface is depicted below.
y Measured
M d for
f a specified
ifi d area and
d the
h figures
fi are added
dd d
y E‐System: (Envelop System) A sphere of 25 mm
diameter is rolled over the surface and the locus of its together and the total is then divided by the number of
centre is being traced out called envelope. This envelope measurements taken to obtain the mean or
is shifted in downward direction till the area above the arithmetical average
g ((AA).)
line is equal to the area below the line. This is called y It is also sometimes called the centre line average or
mean envelope
l and
d the
h system off datum
d i called
is ll d E‐
E CLA value.
value This in equation form is given by
system.
L
1 1
Ra = ∫ y ( x) dx ≅
L0 N
∑y i
196 197 The surface roughness parameter Ra (in μm) is _______ 198
y The other parameter that is used sometimes is the root
IES ‐ 2006
mean square value of the deviation in place of the ISRO‐2011 The M and E‐system in metrology are related to
arithmetic average , This in expression form is
g p
CLA value and RMS values are used for measurement measurement of:
f
1
RRMS =
N
∑y 2
i
of
(a) Metal hardness
( ) Screw
(a) S threads
h d (b) Fl
Flatness
( ) Angularity
(c) A l it (d) S f
Surface fi i h
finish
(b) Sharpness of tool edge
(c) Surface dimensions
(d) Surface roughness
Fig. Surface roughness parameters 199 200 201
IES ‐ 2007 IES ‐ 2008 IES 2010

What is the dominant direction of the tool marks or What term is used to designate the direction of the Match List I with List II and select the correct answer
using the code given below the lists:
scratches
h in a surface
f texture having
h a directional
d l predominant
d surface
f pattern produced
d d b
by List I List II
(Symbols for direction of lay) (Surface texture)
quality called?
quality, machining operation?
(a) Primary texture (b) Secondary texture (a) Roughness (b) Lay
(c) Lay (d) Flaw (c) Waviness (d) Cut off
A B C D A B C D
(a) 4 2 1 3 (b) 3 2 1 4
202 203 (c) 4 1 2 3 (d) 3 1 2 4204
IES ‐ 2008 Methods of measuring Surface Roughness

h d f i S f h
ISRO‐2010 There are a number of useful techniques for measuring
Surface roughness on a drawing is represented by
surface roughness:
(a) Triangles
y Observation and touch ‐ the human finger
g is veryy
(b) Circles
perceptive to surface roughness
(c) Squares
y stylus based equipment ‐ very common
(d) Rectangles
y Interferometry ‐ uses light wave interference patterns
(discussed later)
205 206 207

Observation Methods Stylus Equipment
y Human perception is highly relative. y uses a stylus
l that
h tracks
k small
ll changes
h in
i surface
f
height, and a skid that follows large changes in surface
y To give the human tester a reference for what they are height.
touching,
hi commercial
i l sets off standards
d d are available.
il bl y The relative motion between the skid and the stylus is
measured with a magnetic circuit and induction coils.
y Comparison
C i should
h ld b
be made
d against
i t matched
t h d y One
O example l off this
h is the
h Brown & Sharpe
Sh S f
Surfcom
identical processes.
processes unit.
y One method of note is the finger nail assessment of

roughness and touch method.
208 209 210
Profilometer Contact profilometers
y A diamond stylus is moved vertically in contact with a
A di d l i d i ll i i h
y Measuring instrument used to measure a surface's sample and then moved laterally across the sample for
profile, in order to quantify its roughness. a specified distance and specified contact force.
y A profilometer can measure small surface variations in
y Vertical resolution is usually in the nanometre level, vertical stylus displacement as a function of position.
though
h h lateral
l l resolution
l is usually
ll poorer. y The radius of diamond stylus ranges from 20
h d fd d l f
nanometres to 25 μm.
211 212 213
Non‐contact Profilometers Advantages of optical Profilometers Optical Flats

y Optical‐grade
O ti l d clear
l fused
f d quartz
t or glass
l structures
t t
y Because the non‐contact profilometer does not touch
y An optical profilometer is a non‐contact method for lapped and polished to be extremely flat on one or
the
h surface
f the
h scan speeds
d are dictated
d d by
b the
h light
l h b th sides.
both id
providing much of the same information as a stylus
y Used with a monochromatic light to determine the
reflected from the surface and the speed of the flatness of other optical surfaces by interference.
based profilometer.
acquisition electronics. y When a flat surface of another optic p is p placed on the
y There are many different techniques which are optical flat, interference fringes are seen due to
y Optical
p profilometers do not touch the surface and
p te e e ce in tthee ttinyy gap bet
interference between
ee tthee ttwoo su
surfaces.
aces.
currently
tl being
b i employed,
l d such
h as laser
l ti
triangulation
l ti
therefore cannot be damaged by surface wear or y The spacing between the fringes is smaller where the
(triangulation sensor),
sensor) confocal microscopy and digital gap is changing more rapidly,
rapidly indicating a departure
careless operators. from flatness in one of the two surfaces, in a similar
holography.
g p y way to the contour lines on a map.
map
214 215 216
217 218 219
For IES Only
GATE 2016
GATE‐2016
y 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 anglel θ as shown
h in
i the
th figure.
fi Monochromatic
M h ti light
li ht
is incident vertically.
surface is perfectly flat.
flat
y For convex surface the fringes curve around the point of
contact.
y For concave surface the fringes curve away from the point
of contact.
λ
The distance of air gap between two successive fringes is given by =
2
nλ If the wavelength of light used to get a fringe
Distance of air ggap g of n order is =
p of interference fringe th
2 spacing of 1 mm is 450 nm,nm the wavelength of light

220 (in nm) to get a fringe spacing of 1.5 mm is _______221 222
For IES Only
IES – 2012 Conventionall Optical flat as a comparator

Optical flat as a comparator
nλ l
Write in short about optical flat. Two fringe patterns Δh =
are supplied for two completely different surfaces using 2
optical
ti l flat,
fl t name the
th types
t off surfaces,
f and
d draw
d if Wh l = separation of edges
Where
required n = number of fringes / cm
Δh = The difference of height between gauges
λ = wevlength of monochomatic light
Fig. Fringe patterns for two completely different types
of surfaces. 223 224 225

GATE ‐ 2003 Parallelism Error
Parallelism Error
y In case of large‐length
g g slip
p g g
gauges, the p
parallelism of
Two
T slip
li gauges off 10 mm width
id h measuringi 1.000 mm surfaces can also be measured by placing the gauge on a
and 1.002 mm are kept side by side in contact with each NPL Flatness rotary table in a specific position and reading number 1
other lengthwise. An optical flat is kept resting on the
slip
pggauges
g as shown in the figure.
g Monochromatic light
g Interferometer can be taken.
y The
Th number b off fringes
fi obtained
bt i d is
i the
th result
lt off the
th angle
l
of wavelength 0.0058928 mm is used in the inspection.
that the gauge surface makes with the optical flat. (n1)
The total number of straight fringes that can be observed
on both slip gauges is y Then the table is turned through 180o and reading
number 2 can be taken. (n2)
(a) 2 (b) 6 y The change in distance between the gauge and optical
(c) 8 (d) 13 fl = λ/2
flat λ/
Parallelism Error =
( n2 − n1 ) × λ
4
226 227 228
GATE – 2011 (PI) Talysurf

Observation of a slip gauge on a flatness y It
I is
i based
b d upon measuring
i the
h generated
d noise
i due
d to
interferometer produced fringe counts numbering dry friction of a metallic blade which travels over the
10 and 14 for two readings. The second reading is surface under consideration.
set up by 180o. Assume that
taken by rotating the set‐up y If the frictional force is made small enough to excite
both faces of the slip gauge are flat and the the blade, and not the entire system, then the noise Miscellaneous of Metrology
wavelength
l h off the
h radiation
di i i 0.5086
is 86 µm. The
Th will
ill be proportional to surface roughness,
roughness and
parallelism error (in µm) between the two faces of independent of the measured specimen size and
the slip gauge is material.
l
(a) 0.2543
0 2543 (b) 1.172
1 172 y The specimen surface roughness was measured by a
(c) 0.5086 (d) 0.1272 widely used commercial instrument (Talysurf 10), and
the prototype transducer.
transducer
229 230 By S K Mondal 231
Cli t
Clinometer Clinometer A t lli t
Autocollimator
y An opt ca instrument
optical st u e t for
o non‐contact
o co tact measurement
easu e e t o
of
y An
A optical
i l device
d i for
f measuring
i elevation
l i angles
l above
b
small angles or small angular tilts of a reflecting surface.
horizontal.
y Used
U d to t align
li components t and d measure deflections
d fl ti i
in
y Compass clinometers are fundamentally just magnetic
optical or mechanical systems.
compasses held with their plane vertical so that a
plummet or its equivalent can point to the elevation of y An autocollimator works by projecting an image onto a
the sight line.
line target mirror, and measuring the deflection of the
returned image against a scale, either visually or by
y The clinometer can read easily and accurately angles of
means of an electronic detector.
detector
elevation that would be very difficult to measure in any
other simple and inexpensive way. y A visual autocollimator can measure angles as small as
0.5 arcsecond, while an electronic autocollimator can be
y A fairly common use of a clinometer is to measure the
up
p to 100 times more accurate.
h i ht off trees.
height t
232 233 234
y Visual autocollimators are used for lining up laser rod Autocollimator GATE ‐ 1998
ends
d andd checking
h ki the
th face
f parallelism
ll li off optical
ti l Auto
A collimator
lli is
i used
d to check
h k
windows and wedges. ((a)) Roughness
g
y Electronic and digital autocollimators are used as (b) Flatness
angle
l measurementt standards,
t d d for f monitoring
it i angular l ( ) Angle
(c) A l
movement over long periods of time and for checking ((d)) Automobile balance.
angular position repeatability in mechanical systems.
y Servo
S autocollimators
t lli t are specialized
i li d compactt forms
f off
electronic autocollimators that are used in high speed
servo feedback loops for stable platform applications.
235 236 237
Optical Square
GATE –
GATE – 2009 (PI)
2009 (PI) GATE –
GATE – 2014 y An
A Optical
O ti l square consists
i t off a small
ll cylindrical
li d i l metal
t l box,
b
about 5 cm in diameter and 12.5 cm deep, in which two
A autocollimator
An t lli t is i used
d to
t Th flatness
The fl t off a machine
hi b d can be
bed b mirrors are placed at an angle of 45o to each other and at
right angles to the plane of the instrument.
(a) measure small angular displacements on flat measured using y One mirror(horizon glass) is half silvered and other(index
glass) is wholly silvered.
surface (a) Vernier calipers y Th optical
The ti l square belongs
b l t a reflecting
to fl ti instruments
i t t which
hi h
measure angles by reflection. Angle between the first
((b)) compare
p known and unknown dimensions ((b)) Auto collimator incident ray and the last reflected ray is 90o
((c)) measure the flatness error ((c)) Height
g g gauge
g y Used to find out the foot of the perpendicular from a given
point
i t to
t a line.
li
(d) measure roundness error between centers (d) Tool maker’s microscope y Used to set out right angles at a given point on a line in the
fi ld
field.
238 239 y Two mirrors may be replaced by two prisms. 240
ISRO‐2010 Laser Scanning Micrometer
Optical
O i l square is i y The LSM features a high scanning rate which allows
((a)) Engineer's
g square
q having 90o
g stock and blade set at 9 inspection
p of small workpiece
p even if theyy are fragile,
g ,
(b) A constant deviation prism having the angle of at a high temperature, in motion or vibrating.
deviation between the incident ray and reflected ray, ray y Applications :
equal to 90o y Measurement of outer dia. And roundness of
(c) A constant deviation prism having the angle of cylinder,
deviation
dev at o bet
between
ee tthee incident
c de t ray
ay aand
d reflected
e ected ray,
ay, y Measurement of thickness of film and sheets,
sheets
equal to 45o y Measurement of spacing if IC chips,
(d) Used
U d tot produce
d i t f
interference fi
fringes y Measurement of forms,
y Measurement of gap between rollers.
rollers
An Optical Square 241 242 243
IES ‐ 1998 Laser interferometer
Laser interferometer
Match List‐I
List I with List‐II
List II and select the correct answer using the y Laser interferometers represent the ultimate feedback
codes given below the lists: device for high‐precision motion control application.
List‐I List‐II
(Measuring Device) (Parameter Measured) y The
h combination
b off high
h h resolution
l and
d outstanding
d
A. Diffraction grating 1. Small angular deviations on long accuracyy has made it the ideal transducer for wafer
flat surfaces
B. Optical flat 2. On‐line measurement of moving steppers, flat panel inspection, and high‐accuracy laser
p
parts micromachining.
C. Auto collimators 3. Measurement of gear pitch
D. Laser scan micrometer4. Surface texture using interferometer y A laser interferometer system employs a highly stabilized
5. Measurement off very smallll li ht source and
light d precision
i i optics
ti to
t accurately
t l measure
displacements
distances.
(a) 5 4 2 1 (b) 3 5 1 2 y An additional advantage is that interferometers measure
((c)) 3 5 4 1 ((d)) 5 4 1 2 distances directly at the workpiece.
244 245 246
GATE‐2014 McLeod gauge
y Used
d to measure vacuum by
b application
l off the
h
Which one of the following instruments is widely
principle of Boyle's law.
used to check and calibrate geometric features of
y Works on the principle, "Compression of known
machine tools during their assembly?
volume of low p pressure ggas to higher
g pressure and
p
(a) Ultrasonic probe measuring resulting volume & pressure, one can
calculate initial p
pressure usingg Boyle's
y Law equation."
q
(b) Coordinate Measuring Machine (CMM) y Pressure of gases containing vapours cannot normally
measured with a McLeod gauge, gauge for the reason that
( ) Laser interferometer
(c) f
compression will cause condensation .
(d) Vernier calipers y A pressure from
f 0.01 micron
i t 50 mm Hg
to H can beb
measured. Generally McLeod gauge is used for
calibration
lib ti purpose.
247 248 249
Planimeter LVDT
y A device used for measuring the area of any plane y Acronym for Linear Variable Differential Transformer,
surface by tracing the boundary of the area.
y g y a common type yp of electromechanical transducer that
can convert the rectilinear motion of an object to
which it is coupled mechanically into a corresponding
electrical signal.
y LVDT linear
li position
i i sensors are readily
dil available
il bl that
h
can measure movements as small as a few millionths of
an inch up to several inches, but are also capable of
measuring
easu g pos positions
o s up to
o ±20 inches
c es ((±0.5
.5 m).
).
y A rotary variable differential transformer (RVDT)
i a type
is t off electrical
l t i l transformer
t f used d for
f measuring i
250 251 angular displacement. 252
LVDT GATE ‐ 1992 Tool Maker’s Microscope
Match
M t h the
th instruments
i t t with
ith the
th physical
h i l quantities
titi they
th An essential part of engineering inspection,
measure:
measurement and calibration in metrology gy labs.
I
Instrument M
Measurement
Hence is used to the following:
(A) Pilot‐tube (1) R.P.M. of a shaft
y Examination of form tools,tools plate and template
(B) McLeod Gauge (2) Displacement
((C)) Planimeter (3) Flow velocityy
gauges, punches and dies, annular grooved and
(D) LVDT (4) Vacuum
threaded
h d d hobs
h b etc.
(5) Surface finish y Measurement of g glass ggraticules and other surface
(6) Area marked parts.
C d A
Codes:A B C D A B C D y Elements
El t off external
t l thread
th d forms
f off screw plug
l
(a) 4 1 2 3 (b) 3 4 6 2 gauges, taps, worms and similar components.
(c) 4 2 1 3 (d) 3 1 2 4 y Shallow bores and recesses.
253 254 255
GATE ‐ 2004 Telescopic Gauges

Telescopic Gauges
y Used to measure
easu e a bo e s ssize,
bore's e, by ttransferring
a se g tthee
Match
M h the h following
f ll i
internal dimension to a remote measuring tool.
Feature to be inspected Instrument
y They
Th are a direct
di t equivalent
i l t off inside
i id callipers
lli and
d
P Pitch and Angle errors of screw thread 1. Auto Collimator
require the operator to develop the correct feel to
Q Flatness error of a surface plate 2.
2 Optical Interferometer obtain repeatable results.
R Alignment error of a machine slide way 3. Dividing Head
andd Dial
Di l Gauge
G
S Profile of a cam 4. Spirit
p Level
5. Sine bar
6 Tool maker
6. maker'ss Microscope
(a) P‐6 Q‐2 R‐4 S‐6 (b) P‐5 Q‐2 R‐1 S‐6
(c) P‐6 Q‐4 R‐1 S‐3 (d) P‐1 Q‐4 R‐4 S‐2
256 257 258
GATE ‐ 1995 C di t M i M hi
Coordinate Measuring Machine
g ,
Advantages,
List
Li I List
Li II (CMM)
y can automate inspection process
((Measuring g instruments)) ((Application)
pp ) y An instrument that locates point coordinates on three
st u e t t at ocates po t coo d ates o t ee
y less prone to careless errors
l l
(A) Talysurf 1. T‐slots dimensional structures mainly used for quality control
applications
applications. y allows direct feedback into computer system
p y
(B) Telescopic
Tl i gauge 2. Fl
Flatness
y The highly sensitive machine measures parts down to Disadvantages,
((C)) Transfer callipers
p 33. Internal diameter
the fraction of an inch. y Costly
C l
(D) Autocollimator 4. Roughness
y Specifically, a CMM contains many highly sensitive air y fixturing is critical
g
Codes:A
d B C D A B C D
bearings on which the measuring arm floats. y requires a very good tolerance model
(a) 4 1 2 3 (b) 4 3 1 2
(c) 4 2 1 3 (d) 3 1 2 4
259 260 261

GATE ‐ 2010 GATE 2008 (PI)
GATE ‐2008 (PI)
An experimental setup is planned to determine the taper of
A taper hole
h l is
i inspected
i d using
i a CMM,
CMM with i h a probe
b
workpiece as shown in the figure. If the two precision rollers
of 2 mm diameter. At a height, Z = 10 mm from the
have radii 8 mm and 5 mm and the total thickness of slip
bottom, 5 points are touched and a diameter of gauges inserted between the rollers is 15.54 mm, the taper
circle ((not compensated
p for p
probe size)) is obtained angle θ is
as 20 mm. Similarly, a 40 mm diameter is obtained
(a) 6 degree
at a height Z = 40 mm.
mm the smaller diameter (in mm)
(b) 10 degree
of hole at Z = 0 is
(c) 11 degree
( ) 13.334
(a)
(d) 12 degree
(b) 15.334
(c) 15.442
( ) 15.542
(d)
262 263 264
GATE 2014
GATE ‐2014
The diameter of a recessed ring was measured by using two GATE‐2016
spherical
h i l balls
b ll off diameter
di d2 = 60
6 mm andd 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 + r2 + R2
mm and d1 Diameter
H1 = 20.55 C
(b) H = (R + r) + (D + r)
mm. Th
The
diameter (D, H (c) H = (R + r) + D2 − R2
A B
i mm)) off the
in th R (d) H = (R + r) + 2D(R + r) − D2
ring gauge is
………….
Recessed Ring
D
265 266
d2 Diameter

Four Important forming techniques are:
Four Important forming techniques are: Terminology
Semi‐finished product
y Rolling:
g The pprocess of pplasticallyy deformingg metal byy
y Ingot:
I is
i the
h first
fi solid
lid form
f off steel.
l
passing it between rolls.
y Bloom: is the p product of first breakdown of ingot
g has square
q
y Forging: The workpiece is compressed between two cross section 6 x 6 in. or larger
g
Metal Forming opposing dies so that the die shapes are imparted to the
work.
y
y
Billet: is hot rolled from a bloom and is square,
side or larger.
Sl b is
Slab: i the
th hot
h t rolled
ll d ingot
i t or bloom
bl
square 1.5
1 5 in.
rectangular
t
in on a
l cross
y Extrusion: The work material is forced to flow section 10 in. or more wide and 1.5 in. or more thick.
through a die opening taking its shape
y Drawing: The diameter of a wire or bar is reduced by

pulling it through a die opening (bar drawing) or a series
By S K Mondal off die
di openings
i ( i drawing)
(wire d i )
Ingot Bloom Billet
1 2 slab 3
Terminology Plastic Deformation Bulk Deformation Processes

Mill product y Deformation beyond elastic limits. y These processes involve large amount of plastic
deformation.
deformation
y Plate is the product with thickness > 5 mm y Due to slip, grain fragmentation, movement of
y The cross‐section of workpiece
p changes
g without
y Sheet is the product with thickness < 5 mm and width > atoms and lattice distortion. volume change.
600 mm y The ratio cross‐section area/volume is small.
y Strip is the product with a thickness < 5 mm and width y For

F mostt operations,
ti h t or warm working
hot ki
conditions are preferred although some operations
< 600
6 mm are carried out at room temperature.
4 5 6
Sheet‐Forming Processes
y In
I sheet
h metall working
ki operations,
i the
h cross‐section
i off Strain Hardening
Strain Hardening GATE‐1995
workpiece does not change—the material is only
y When metal is formed in cold state,
state there is no A test
t t specimen
i i stressed
is t d slightly
li htl beyond
b d the
th
subjected to shape changes.
recrystalization
y of g
grains and thus recoveryy from yield point and then unloaded.
unloaded Its yield strength
y The
Th ratio
i cross‐section
i area/volume
/ l i very high.
is hi h
grain distortion or fragmentation does not take
y Sheet metalworking operations are performed on thin (a) Decreases
(less than 5 mm) sheets, strips or coils of metal by means place.
((b)) Increases
off a set off tools
l called
ll d punch
h and
d die
di on machine
hi toolsl y As grain deformation proceeds, greater resistance
called stamping presses. ((c)) Remains same
t this
to thi action
ti results
lt in
i increased
i d hardness
h d and
d
y They are always performed as cold working operations. (d) Become equal to UTS
strength i.e. strain hardening.
7 8 9
IES‐2013
Statement (I): At higher strain rate and lower y Rx temp.
temp depends on the amount of cold work a material
temperature structural steel tends to become brittle. Recrystallisation Temperature (Rx temp.) has already received. The higher the cold work, the lower
Statement (II): At higher strain rate and lower y “The
“Th minimum
i i temperature at which
hi h the
h completed
l d would
ld be
b the
h RxR temp.
temperature
p the yyield strength
g of structural steel tends recrystallisation of a cold worked metal occurs within a y Rx temp.
temp varies between 1/3 to ½ melting paint.
paint
to increase. specified period of approximately one hour”.
y For Pure metal Rx temp. = 0.3 x Melting temp.
( ) Both
(a) B th Statement
St t t (I) and
d Statement
St t t (II) are individually
i di id ll y Rx temp.
temp decreases strength and increases ductility.
ductility (Kelvin).
true and Statement (II) is the correct explanation of y If working
g above Rx temp.,
p , hot‐working
g p
process
Statement (I)
() y For Alloy Rx temp.
temp = 0.5
0 5 x Melting temp.
temp (Kelvin).
(Kelvin)
whereas working below are cold‐working process.
(b) Both Statement (I) and Statement (II) are individually y Rx temp.
p of lead and Tin is below room temp.
p
y It
I involves
i l replacement
l off cold‐worked
ld k d structure by
b a
true but Statement (II) is not the correct explanation of y Rx temp. of Cadmium and Zinc is room temp.
new set of strain‐free, approximately equi‐axed grains to
Statement (I)
replace all the deformed crystals. Contd. y Rx temp. of Iron is 450oC and for steels around 1000°C
(d) Statement (I) is false but Statement (II) is true y Finer
Fi i the
is h initial
i i i l grain
i size;
i lower
l will
ill be
b the
h Rx
R temp
10 11 12
IES 2016
IES‐2016 Grain growth
h Malleability
ll b l
The recrystallization behaviour of a particular metal
y Grain growth follows complete crystallization if the materials y Malleability is the property of a material whereby it can
alloy is specified in terms of recrystallization
left at elevated temperatures.
p
temperature, which is typically 1/3rd of the absolute b shaped
be h d when
h cold
ld by
b hammering
h or rolling.
ll
y Grain growth does not need to be preceded by recovery and
melting temperature of a metal or an alloy and depends recrystallization; it may occur in all polycrystalline materials.
ll ll l ll l y A malleable
ll bl material
i l is
i capable
bl off undergoing
d i plastic
l i
on several factors including
g the amount of y In contrary to recovery and recrystallization, driving force deformation without fracture.
fracture
1. cold working and purity of the metal and alloy for this process is reduction in grain boundary energy.
y A malleable material should be plastic but it is not
2. hot working and purity of the metal and alloy y In practical applications, grain growth is not desirable.
Which of the above is/are correct? y Incorporation of impurity atoms and insoluble second phase essential to be so strong.
g
(a) 1 only (b) 2 only particles are effective in retarding grain growth. y Lead, soft steel, wrought iron, copper and aluminium are
(c) Both 1 and 2 (d) Neither 1 nor 2 y Grain growth is very strongly dependent on temperature.
13 14 some materials in order of diminishing malleability. 15
Advantages of Cold Working
d f ld k
1. Better accuracy, closer tolerances
y Working below recrystalization temp.
2. Better surface finish
g
Cold Working 3. Strain hardening increases strength and hardness
4. Grain flow during deformation can cause desirable

directional properties in product
5 No heating of work required (less total energy)

5.
16 17 18
Disadvantages of Cold Working
d f ld k
1. Equipment of higher forces and power required
2. Surfaces of starting work piece must be free of scale and
S f f t ti k i t b f f l d
dirt
3. Ductility and strain hardening limit the amount of forming
that can be done
4. In some operations, metal must be annealed to allow
H t W ki g
Hot Working
further deformation
55. Some metals are simply not ductile enough to be cold
py g
worked. 19 20 21
Advantages of Hot Working Dis‐advantages of Hot Working
1. The porosity of the metal is largely eliminated. 1. It requires expensive tools.
y Working above recrystalization temp. 2 The grain structure of the metal is refined.
2. refined 2 It produces poor surface finish,
2. finish due to the rapid
3. The impurities like slag are squeezed into fibers and oxidation and scale formation on the metal surface.
di ib d throughout
distributed h h the
h metal.l 3. Due
D to the
h poor surface
f fi i h close
finish, l tolerance
l
4. The mechanical p
4 properties
p such as toughness,
g , cannot be maintained.
percentage elongation, percentage reduction in area, and
resistance to shock and vibration are improved due to
the refinement of grains.
22 23 24
Annealing
g
Micro‐Structural Changes in a Hot
Mi St t l Ch i H t IES 2016
IES‐2016 •Annealing relieves the stresses from cold working – three
Statement (I) : Pursuant to p
plastic deformation of
Working Process (Rolling)
Working Process (Rolling) metals, the mechanical properties of the metals get
stages: recovery,
recovery recrystallization and grain growth.
growth
•During recovery, physical properties of the cold‐worked
changed.
material
i l are restored
d without
ih any observable
b bl change
h i
in
Statement (II) : Mechanical properties of metals microstructure.
d
depend d on grain
i size
i also
l which
hi h gets
t changed
h d by
b
plastic deformation.
(a) Both Statement (I) and Statement (II) are individually true and
Statement ((II)) is the correct explanation
p of Statement ((I).
)
(b) Both Statement (I) and Statement (II) are individually true but
Statement (II) is not the correct explanation of Statement (I).
(c) Statement (I) is true but Statement (II) is false.
(d) Statement
St t t (I) is
i false
f l but
b t Statement
St t t (II) is
i true
t
25 26 27
W F i
Warm Forming Isothermal Forming
h l
y Deformation produced at temperatures intermediate to IES 2011
hot and cold forming is known as warm forming. y During hot forming, cooler surfaces surround a hotter Assertion (A): Lead, Zinc and Tin are always hot
y Compared to cold forming,
forming it reduces loads,
loads increase interior and the variations in strength can result in non‐
interior, non worked.
material ductility. uniform deformation and cracking of the surface.
Reason (R) : If they are worked in cold state
they cannot retain their mechanical properties.
properties
y Compared to hot forming, it produce less scaling and
y For temp.‐sensitive materials deformation is performed (a) Both A and R are individually true and R is the
decarburization, better dimensional precision and
smoother surfaces. under isothermal conditions. correct explanation of A
y Warm forming
f i i a precision
is i i f i
forging operation
i carried
i d y The
Th dies
di or tooling
li must be
b heated
h d to the
h workpiece
k i (b) Both A and R are individually true but R is NOT
out at a temperature range between 550–950°C. It is the correct explanation of A
temperature,
p , sacrificing
g die life for p
product q
quality.
y
useful for forging of details with intricate shapes, with ( ) A is true but
(c) b R is false
f l
desirable grain flow, good surface finish and tighter y Close tolerances, low residual stresses and uniform metal (d) A is false but R is true
dimensional tolerances. 28
flow.
29 30
GATE‐2003 GATE‐2002, ISRO‐2012 ISRO 2010

ISRO‐2010
Cold
C ld working
ki off steell is i defined
d fi d as working
ki Hot
H rolling
lli off mildild steell is
i carried
i d out Materials
M t i l after
ft cold
ld working
ki are subjected
bj t d to
t
((a)) At its recrystallisation
y temperature
p ((a)) At recrystallisation
y temperature
p
follo ing process to relieve
following relie e stresses
(b) Above its recrystallisation temperature (b) Between 100°C to 150°C
( ) Below
(c) B l itsi recrystallisation
lli i temperature ( ) Below
(c) B l recrystallisation
lli i temperature ( ) Hot
(a) H working
ki
((d)) At two thirds of the melting g temperature
p of the ((d)) Above recrystallisation
y temperature
p
metal (b) Tempering
(c) Normalizing
(d) Annealing
31 32 33
IES – 2006 IES – 2004 IES – 2009

Which
f ll i is
i the
h process to refine
fi Consider
C id theh following
f ll i statements: Consider
C id theh following
f ll i characteristics:
h i i
the grains of metal after it has been distorted by p
In comparison to hot working,
g, in cold working,
g, 1. Porosityy in the metal is largely
g y eliminated.
hammering or cold working? 1. Higher forces are required 2. Strength is decreased.
(a) Annealing (b) Softening 2. NoN heating
h i is i required
i d 3. Close
Cl tolerances
l cannot be
b maintained.
i i d
(c) Re‐crystallizing (d) Normalizing 33. Less ductilityy is required
q Which of the above characteristics of hot working
g is/are
/
4. Better surface finish is obtained correct?
Which
h h off the
h statements given above
b are correct? ( ) 1 only
(a) l (b) 3 only
l
(a) 1, 2 and 3 (b) 1, 2 and 4 (c) 2 and 3 (d) 1 and 3
(c) 1 and 3 (d) 2, 3 and 4
34 35 36
IES – 2008 IES – 2008 IES – 2004
Consider
f ll i statements: Cold
C ld forging
f i results
l ini improved
i d quality
li dued to Assertion
A i (A):
(A) Cold
C ld workingki off metals
l resultsl in i
1. Metal forming g decreases harmful effects of which of the following? increase of strength and hardness
impurities and improves mechanical strength. 1. Better mechanical properties of the process. Reason (R): Cold working reduces the total number
2 Metal working process is a plastic deformation
2. 2 Unbroken grain flow.
2. flow of dislocations per unit volume of the material
process. 3. Smoother finishes. (a) Both A and R are individually true and R is the
3. Very intricate shapes can be produced by forging 4. High pressure. correct explanation
l off A
process
p ocess as co
compared
pa ed to cast
casting
gpprocess.
ocess. S l t the
Select th correctt answer using
i the
th code
d given
i b l
below: (b) Both
d v dua y ttrue
ue but R iss not
ot tthee
Which of the statements given above are correct? correct explanation of A
(a) 1, 2 and 3 (b) 1, 2 and 4
( ) 1, 2 and
(a) d3 (b) 1 and d 2 only
l ( ) A is
(c) i true
t b t R is
but i false
f l
(c) 2, 3 and 4 (d) 1, 3 and 4
(c) 2 and 3 only (d) 1 and 3 only (d) A is false but R is true
37 38 39
IES – 2003 IES – 2000

Cold
C ld working
ki produces
d the
h following
f ll i effects:
ff Assertion
A i (A):
(A) To
T obtain
b i large
l deformations
d f i by
b coldld ISRO‐2009
p in the metal
1. Stresses are set up working intermediate annealing is not required. In the metal forming process, the stresses
2. Grain structure gets distorted Reason (R): Cold working is performed below the encountered are
3. Strength
S h and
d hardness
h d off the
h metall are decreased
d d recrystallisation temperature of the work material.
material ( ) Greater
(a) G than
h yield
i ld strength
h but
b l
less than
h
4. Surface finish is reduced
4 (a) Both A and R are individually true and R is the ultimate strength
correct explanation
l off A (b) Less than yield strength of the material
(b) Both
d v dua y ttrue
ue but R iss not
ot tthee (c) Greater than the ultimate strength of the
( ) 1and
(a) d2 (b) 1, 2 and d3 correct explanation of A material
(c) 3 and 4 (d) 1 and 4 ( ) A is
(c) i true
t b t R is
but i false
f l (d) Less than the elastic limit
40 41 42
IES – 1997 IES – 1996 IES – 2006

In metals subjected to cold working, strain
I l bj d ld ki i Consider the following statements:
C id h f ll i Assertion
A i (A):
(A) InI case off hot
h workingki off metals,
l the
h
hardening effect is due to y
When a metal or alloy is cold worked temperature at which the process is finally stopped
should
h ld not be b above
b the
h recrystallisation
ll temperature.
(a) Slip mechanism 1. It is worked below room temperature.
Reason ((R): ) If the p process is stopped
pp above the
(b) Twining mechanism 2. It is worked below recrystallisation temperature.
I i k d b l lli i recrystallisation temperature, grain growth will take
(c) Dislocation mechanism 33. Its hardness and strength increase.
g place again
p g and spoil
p the attained structure.
(d) Fracture mechanism 4. Its hardness increases but strength does not (a) Both A and R are individually true and R is the correct
increase. explanation of A
Of these correct statements are (b) Both A and R are individually true but R is not the
correct explanation
l i off A
(a) 1 and 4 (b) 1 and 3
( ) 2 and 3
(c) d (d) 2 and 4
d
43 44 45
IES – 1992 IAS – 1996 IAS – 2004
Specify
S if the
h sequence correctly l For
F mild ild steel,
l the
h hot
h forging
f i temperature range is
i Assertion (A): Hot working does not produce strain
A i (A) H ki d d i
((a)) Grain ggrowth,, recrystallisation,
y , stress relief ((a)) 44000C to 6000C hardening.
(b) Stress relief, grain growth, recrystallisation (b) 7000C to 9000C Reason (R): Hot working is done above the re‐
( ) Stress
(c) S relief,
li f recrystallisation,
lli i grain
i growth h ( ) 10000C to 12000C
(c) crystallization temperature.
crystallization temperature
((d)) Grain g
growth,, stress relief,, recrystallisation
y 3 0Cto 1500
((d)) 1300 5 0C (a) Both A and R are individually true and R is the
l f
ot a d R a e d v dua y t ue but R s ot tthe
e
(c) A i t b t R i f l
46 47 48
IAS‐2002 IES‐2008
Assertion
A i (A):(A) There
Th is
i good d grain
i refinement
fi in
i hot
h Which one of the following is correct?
GATE‐2017
working.
It is desired to make a product having TT‐
Reason (R): In hot working physical properties are Malleability is the property by which a metal or
shaped cross‐section from a rectangular
generally improved.
improved alloy
ll can be
b plastically
l i ll deformed
d f d by
b applying
l i aluminium
l bl k Which
block. h h one off theh
( ) Tensile
(a) T il stress
t (b) B di stress
Bending t following processes is expected to provide
correct explanation
l off A
the highest strength of the product?
(b) Both
d v dua y ttrue
ue but R iss not
ot tthee (c) Shear stress (d) Compressive stress
correct explanation of A (a) Welding (b) Casting
( ) A is
(c) i true
t b t R is
but i false
f l (c) Metal forming (d) Machining
49 50 51
Rolling
y Definition: The process of plastically deforming GATE‐2013
metal by passing it between rolls. In a rolling process, the state of stress of the
y Most widely used, high production and close material undergoing deformation is
g
Rolling tolerance. (a) pure compression
y Friction between the rolls and the metal surface (b) pure shear
produces high compressive stress. (c) compression and shear
y Hot‐working (unless mentioned cold rolling.) (d) tension and shear
By S K Mondal
52 y Metal will undergo bi‐axial compression. 53 54
Hot Rolling
y Done above the recrystallization temp.
y Results fine grained structure.
y Surface quality and final dimensions are less accurate.
y Breakdown of ingots into blooms and billets is done by

h
hot‐rolling.
ll This
h is followed
f ll d by
b further
f h hot‐rolling
h ll into
plate sheet,
plate, sheet rod,
rod bar,
bar pipe,
pipe rail.
rail
y Hot rolling is terminated when the temp.

temp falls to
about (50 to 100
100°C)
C) above the recrystallization temp.
temp
55 56 57
Ch
Change in grains structure in Hot‐rolling
i i t t i H t lli IAS – 2001 Cold Rolling
Consider
C id the
h following
f ll i characteristics
h i i off rolling
lli
y Done below the recrystallization temp..
process:
1. Shows work hardening effect y Products are sheet, strip, foil etc. with good
2 Surface finish is not good
2.
3. Heavy reduction in areas can be obtained
surface finish and increased mechanical strength
Which of these characteristics are associated with hot with close product dimensions.
rolling?
(a) 1 and 2 (b) 1 and 3 y Performed on four‐high or cluster‐type rolling
Hot rolling is an effective way to reduce grain size in (c) 2 and 3 (d) 1, 2 and 3 mills. (Due to high force and power)
metals for improved
p strength
g and ductility.
y
58 59 60
Ring Rolling
ISRO‐2006 y Ring rolls are used for tube rolling, ring rolling.
Whi h off the
Which th following
f ll i processes would
ld y As the rolls squeeze and rotate, the wall thickness is
produce strongest components? reduced
d d and
d the
h diameter
di off the
h ring
i increases.
i
(a) Hot rolling y Shaped
Sh d rolls
ll can be
b used
d to
t produce
d a wide
id variety
i t off
((b)) Extrusion cross‐section
cross section profiles.
profiles
((c)) Cold rolling
g y Ring rolls are made of spheroidized graphite bainitic and
(d) Forging pearlitic matrix or alloy cast steel base.
61 62 63
Sheet rolling
ISRO‐2009 y In sheet rolling we are only attempting to reduce the
Ring rolling is used cross section thickness
h k off a material.
l
(a) To decrease the thickness and increase
diameter
(b) To
T increase
i th thickness
the thi k off a ring
i
(c) For producing a seamless tube
(d) For producing large cylinder
64 65 66
Roll Forming Roll Bending
y A continuous form of three‐point bending is roll
bending, where plates, sheets, and rolled shapes can
be bent to a desired curvature on forming rolls.
y Upper roll being adjustable to control the degree of

curvature.
t
67 68 69
IES – 2006 Shape rolling Pack rolling

Which one of the following is a continuous bending y Pack rolling involves hot rolling multiple sheets of
process in which
h h opposing rolls
ll are used
d to produce
d materiall at once, such
h as aluminium
l f l
foil.
long sections of formed shapes from coil or strip y Improved
I d productivity
d i i
stock? y Aluminum sheets (aluminum foil)
y Matte, satin side – foil‐to‐foil contact
((a)) Stretch forming
g ((b)) Roll forming
g
y Shiny,
h b h side
bright d – foil‐to‐roll
f l ll contact due
d to high
h h contact
((c)) Roll bending
g ((d)) Spinning
p g stresses with polished rolls
y A thin surface oxide film prevents their welding
70 71 72
Thread rolling Thread rolling contd….
y Used to produce threads in substantial quantities. y Major diameter is always greater than the diameter of the
y This is a cold‐forming process in which the threads are bl k

blank.
f
formed
d by
b rolling
lli a thread
h d blank
bl k between
b h d
hardened
d dies
di y Blank
Bl k diameter
di i little
is li l larger
l (
(0.002 i h) than
inch) h the
h pitch
i h
that cause the metal to flow radially into the desired diameter of the thread.
thread
shape.
p y Restricted to ductile materials.
materials
y No metal is removed, g
greater strength,
g smoother, harder,
and more wear‐resistant surface than cut threads.
73 74 75
IES – 1992, GATE‐1992(PI) IES – 1993, GATE‐1989(PI)

Thread rolling is restricted to The blank diameter used in thread rolling will be
(a) Ferrous materials (a) Equal to minor diameter of the thread
(b) Ductile materials (b) Equal to pitch diameter of the thread
( ) Hard materials
(c) ( ) A little large than the minor diameter of the thread
(c)
N f h b (d) A little
li l larger
l than
h the
h pitch
i h diameter
di off the
h thread
h d
76 77 78
Manufacture of gears by rolling
y The straight and helical teeth of disc or rod type external
steell gears off small
ll to medium
d d
diameter and
d module
d l are
generated by cold rolling.
rolling
y High accuracy and surface integrity.

integrity
y Employed for high productivity and high quality.

quality (costly
machine))
y Larger size gears are formed by hot rolling and then

finished by machining. 79 Fig. Gear rolling between three gear roll tools 80 81
Roll piercing
Roll piercing y It is a variation of rolling called roll piercing.
y The billet or round stock is rolled between two rolls,,
both of them rotating in the same direction with their
axes at an angle of 4.5 to 6.5 degree.
y These rolls have a central cylindrical portion with the
sides tapering slightly.
slightly There are two small side rolls,
rolls
which help in guiding the metal.
y Because of the angle at which the roll meets the metal,
it gets in addition to a rotary motion, an additional
axial advance, which brings the metal into the rolls.
y This cross‐rolling
g action makes the metal friable at the
centre which is then easily pierced and given a
cylindrical shape by the central
central‐piercing
piercing mandrel.
82 83 84
IAS – 2007 IAS – 2003 IAS – 2000

Match
M t h List
Li t I with
ith List
Li t II and
d select
l t the
th correctt answer using i
the code given below the Lists: In one setting of rolls in a 3‐high rolling mill, one Rolling very thin strips of mild steel requires
List I List II gets
(Type of Rolling Mill) (Characteristic)
(a) Large diameter rolls
A Two
A. T high
hi h non‐reversing
i mills
ill 1. Middle
Middl roll ll rotates
t t byb friction
f i ti ( ) One
(a) O reduction
d i in i thickness
hi k (b) Small diameter rolls
B. Three high mills 2. By small working roll, power
for rolling is reduced (b) Two
T reductions
d ti i thickness
in thi k ( ) High speed rolling
(c)
C. Four high mills 3. Rolls of equal size are
rotated only in one direction (c) Three reductions in thickness (d) Rolling without a lubricant
R lli i h l b i
D. Cluster mills 4. Diameter of working roll is
very small (d) Two or three reductions in thickness depending
Code:A B C D A B C D
(a) 3 4 2 1 (b) 2 1 3 4 upon
p the setting
g
(c) 2 4 3 1 (d) 3 1 2 4 85 86 87
Planetary mill Camber
y Consist of a pair of heavy backing rolls surrounded by a large
number of planetary rolls.
y Each planetary roll gives an almost constant reduction to the
slab as it sweeps out a circular path between the backing rolls
and the slab.
y As each pair of planetary rolls ceases to have contact with the
work piece, another pair of rolls makes contact and repeat
that
h reduction.
d i
y The overall reduction is the summation of a series of small
reductions
d ti b each
by h pair
i off rolls.
ll Therefore,
Th f th planetary
the l t mill
ill
can reduce a slab directly to strip in one pass through the
mill.
mill
y The operation requires feed rolls to introduce the slab into
the mill, and a pair of planishing rolls on the exit to improve
the surface finish. y Camber can be used to correct the roll deflection (at only
88 89 one value of the roll force). 90
IES – 1993 Lubrication for Rolling IAS – 2004
In order to get uniform thickness of the plate by y Hot rolling of ferrous metals is done without a lubricant. Assertion
A i (A):
(A) Rolling
R lli requires
i high
hi h friction
f i i which
hi h
increases forces and power consumption.
rolling
ll process, one provides
d y Hot rolling of non‐ferrous metals a wide variety of Reason (R): To prevent damage to the surface of the
( ) Camber
(a) C b on the
h rolls
ll compounded
d d oils,
il emulsions
l i and
d fatty
f acids
id are used.
d rolled products,
products lubricants should be used. used
(b) Offset
Off t on the
th rolls
ll y Cold
C ld rolling
lli l bi
lubricants
t are water‐soluble
t l bl oils,
il low‐
l correct explanation
l off A
(c) Hardening of the rolls viscosity lubricants,
lubricants such as mineral oils,
oils emulsions,
emulsions (b) Both
d v dua y ttrue
ue but R iss not
ot tthee
(d) Antifriction bearings paraffin and fattyy acids.
p
( ) A is
(c) i true
t b t R is
but i false
f l
91 92 93
Defects in Rolling Defects in Rolling
Defects What is Cause Anisotropy
Surface Scale, rust, Inclusions and
Material develops anisotropy during cold rolling of sheet
•Material develops anisotropy during cold rolling of sheet GATE –
GATE – 2009 (PI)
2009 (PI)
metal
Defects scratches,, impurities
p in the
Three principal true strain A i t
Anisotropy i rolled
in ll d components
t is
i caused
d by
b
pits, cracks materials
⎛L ⎞ (a) changes in dimensions
Wavy edges Strip is Due to roll Inlengthdirection, ε l = ln ⎜ f ⎟
⎝ Lo ⎠
thinner along g bendingg edges
g (b) scale formation
⎛W ⎞
its edges than elongates more Inwidthdirection, ε w = ln ⎜ f ⎟
at its centre.
centre and buckle.
buckle ⎝ Wo ⎠ (c) closure of defects
⎛t ⎞
Inthethicknessdirection, ε t = ln ⎜ f ⎟
Alligatoring Edge breaks Non uniform
Non‐uniform ⎝ to ⎠
(d) grain orientation
deformation For isotropicmaterials,ε w = ε t but in a cold rolled sheet ε w ≠ ε t
εw
Anisotropyratio ( r ) =
94 εt 95 96
Example
A rectangular block 100 mm x 20 mm x 2 mm IES‐2003
A
Assertion
ti (A):
(A) While
Whil rolling
lli metal
t l sheet
h t in
i rolling
lli
is elongated to 130 mm. If the anisotropy
mill the edges are sometimes not straight and flat
mill,
ratio = 2,, find true strain in all directions. but are wavy.
y Formula in Rolling
Reason (R) : Non uniform mechanical properties
of the flat material rolled out result in waviness of
the edges.
97 98 99
Geometry of Rolling Process Draft GATE‐2007
y Total
T l reduction
d i or “draft”
“d f ” taken
k ini rolling.
lli The thickness of a metallic sheet is reduced from an
Δh=h0 - hf =2(R- Rcos α) =D(1- cos α) initiall value

l off 16 mm to a final
f l value
l off 10 mm in
one single pass rolling with a pair of cylindrical
y Usually,
y, the reduction in blooming
g mills is about 100 rollers each of diameter of 400 mm. The bite angle
mm and in slabbing mills, about 50 to 60 mm.
in degree will be
(a) 5.936 (b) 7.936
(c) 8.936 (d) 9.936
100 101 102
GATE – 2012 Same Q in GATE – 2012 (PI) GATE 2017 (PI)

GATE‐2017 (PI) GATE‐1998
A metallic strip having a thickness of 12 mm is to
be rolled using two steel rolls, each of 800 mm A strip with a cross‐section 150 mm x 4.5 mm is
In a single pass rolling process using 410 mm
diameter steel rollers, a strip of width 140 mm and di
diameter. I is
It i assumed d that
h there
h i no change
is h i
in b
being rolled
ll d with
h 20%
% reduction
d off area using 450
width of the strip p duringg rolling.
g In order to mm diameter rolls.
rolls The angle subtended by the
thickness
h k 8 mm undergoes
d 10%
% reduction
d off
achieve 10% reduction in cross‐sectional area of
thickness The angle of bite in radians is
thickness. deformation zone at the roll centre is (in radian)
th strip
the t i after
ft rolling,
lli th angle
the l subtended
bt d d (in
(i
((a)) 0.006 ((b)) 0.031
3 g
degrees) ) byy the deformation zone at the center of ((a)) 0.01 ((b)) 0.02
the roll is
(c) 0.062 (d) 0.600 ((c)) 0.033 ((d)) 0.06
( ) 1.84
(a) 8 (b) 3.14 (c)
( ) 6.84
68 (d) 8.23
8
103 104 105
Roll strip contact length

Roll strip contact length
GATE‐2004 For Unaided entry
y Roll strip contact length
R ll i l h In a rolling process, sheet of 25 mm thickness is
L = R α
[ α must be in radian]
rolled
ll d to 20 mm thickness.
h k Roll
mm and it rotates at 100 rpm.
ll is off diameter
d 600
rpm The roll strip contact
μ ≥ tan α
length will be
((a)) 5 mm ((b)) 39 mm
((c)) 778 mm ((d)) 120 mm
106 107 108

Maximum Draft Possible GATE 2011 GATE 2014
In a rolling process,
process the maximum possible draft,draft
The maximum possible draft in cold rolling of defined as the difference between the initial and
sheet increases with the th final
the fi l thickness
thi k off the
th metal t l sheet,
h t mainly
i l
( Δh )max 2 depends on which pair of the following parameters?

=μ R (a) increase in coefficient of friction P: Strain
(b) decrease
d in coefficient
ff off friction
f Q: Strength of the work material
R: Roll diameter
( ) decrease
(c) d i roll
in ll radius
di S: Roll velocity
(d) increase
i i roll
in ll velocity
l it T: Coefficient of friction between roll and work
(a) Q, S (b) R, T
(c) S, T (d) P, R
109 110 111
GATE 2016
GATE-2016 GATE 2015
GATE-2015 GATE 2015
GATE-2015
A 300 mm thick slab is being cold rolled using In a rolling operation using rolls of diameter In
I a slab
l b rolling
lli operation
i , the
h maximum
i
roll
ll off 600
6 mm diameter.
di t If the
th coefficient
ffi i t off 500 mm , if a 25 mm thick
thi k plate
l t cannott be
b thickness reduction(∆h)max is given by ∆hmax = µ
µ²R
R,
friction is 0 08,
0.08, the maximum possible reduced to less than 20 mm in one pass, the where R is the radius of the roll and µ is the co‐
reduction (in mm) is ____________ coefficient of friction between the roll and the efficient of friction between the roll and the sheet.
plate is _______ If µ = 0.1, the maximum angle subtended by the

deformation zone at the centre of the roll (bite
angle
l in degrees)
d ) is _____
112 113 114
IES – 1999 Minimum Possible Thickness (h f min ) GATE‐2006

Assertion
A i (A):
(A) InI a two high
hi h rolling
lli mill
ill there
h is
i a A 4 mm thick sheet is rolled with 300 mm diameter
ho − h f min = μ 2 R
limit to the possible reduction in thickness in one
pass. rolls
ll to reduce
d thickness
h k without
h any change
h in its
Reason (R): The reduction possible in the second width The friction coefficient at the work‐roll
width. work roll
pass is less than that in the first pass.
interface is 0.1. The minimum possible thickness of
( ) Both
h
correct explanation of A the sheet that can be produced in a single pass is
(a) 1.0 mm (b) 1.5 mm
(c) A is true but R is false (c) 2.5 mm (d) 3.7 mm
115 116 117
Number of pass needed G
GATE – 20 ( )
2011 (PI) IES – 2001
The
Th thickness
hi k off a plate
l is
i reduced
d d from
f 30 mm to 10 A strip is to be rolled from a thickness of 30 mm to
Δhrequired mm by successive cold rolling passes using identical 15 mm using a two‐high

h h mill
ll having
h rolls
ll off
n=
q rolls of diameter 600 mm. Assume that there is no diameter 300 mm.
mm The coefficient of friction for
Δhmax
change in width. If the coefficient of friction unaided bite should nearly be
between the rolls and the work piece is 0.1, the
((a)) 0.35
35 ((b)) 0.55
minimum number of passes required is
((c)) 0.255 ((d)) 0.077
(a) 3 (b) 4 (c) 6 (d) 7
118 119 120
Neutral Point and Neutral Plane
The point
Th i where
h roll
ll velocity
l i equals
l
GATE‐2014(PI) work velocity is known as the no‐slip V0 = input velocity
A 80
8 mm thick
hi k steell plate
l with
i h 400 mm width
id h is
i point
i t or the
th neutral
t l point.
i t Vf = final or output velocity GATE‐1990 (PI)
GATE‐1990 (PI)
rolled to 40 mm thickness in 4 passes with equal R roll radius
R = roll radius
reduction in each pass, by using rolls of 800 mm Whil rolling
While lli a strip
t i the
th peripheral
i h l velocity
l it off
ho = back height
diameter. Assuming g the pplane‐strain deformation,, the roll is ….A…..than
A than the entry velocity of the
hf =output or final
fi l
what is the minimum coefficient of friction
thickness strip
p and is ……B …..the exit velocity
y of the
required for unaided rolling to be possible?
α = angle of bite
(a) 0.111 (b) 0.158 (c) 0.223 (d) 0.316 strip.
N N neutral point or no
N‐N = neutral point or no‐
slip point (a) less than/greater less
Vr − Vo
Backward slip = × 100% To the left of the Neutral Point:
Vr (b) Greater than/less than
Velocity of the strip < Velocity of the roll
V f − Vr
Forward slip = ×100% To the right of the Neutral Point:
121 Vr Velocity of the strip > Velocity of the roll
122 123
IES 2014
IES ‐ IES – 2002
In the process of metal rolling operation, along the arc GATE ‐2008(PI)
off contact ini the
h roll ll gap there
h is
i a pointi called
ll d the
h In a rolling process, thickness of a strip is reduced In rolling a strip between two rolls, the position of
neutral point, because
(a) On one side of this point, the work material is in tension f
from 4 mm to 3 mm using 300 mm diameter
d rolls
ll the
h neutrall point in the
h arc off contact does
d not
and on the other side,, the work material is in compression
p
rotating at 100 rpm.
rpm The velocity of the strip in depend on
(b) On one side of this point, the work material has velocity
greater than that of the roll and on the other side,
side it has (m/s) at the neutral point is (a) Amount of reduction (b) Diameter of the rolls
velocity lesser than that of the roll
((a)) 1.57
57 ((b)) 33.14
4 ((c)) 47
47.10 ((d)) 94
94.20 (c) Coefficient of friction (d) Material of the rolls
( ) On
(c) O one side id off this
thi point,
i t the
th work k material
t i l has
h rough h
surface finish and on the other side, the work material has
very fine
fi finish
fi i h
(d) At this ppoint there is no increase in material width, but
on either side of neutral point, the material width increases
124 125 126
Selected Questions C ti it E
Continuity Equation
ti GATE‐2014
y Generally rolling increases the
The effect of friction on the rolling mill is work width from an initial value A mild steel plate has to be rolled in one pass such
of bo to a final one of bf and this
(a) always bad since it retards exit of reduced metal is called spreading. that the final plate thickness is 2/3rd of the initial
(b) always good since it drags metal into the gap between y The
Th inlet
i l and
d outlet
l volume
l thickness,
hi k with
i h the
h entrance speed
d off 10 m/min
/ i
rates of material flow must be
th rolls
the ll the
h same, thath is,
i and roll diameter of 500 mm.
mm If the plate widens
byy 2% during
g rolling,
g, the exit velocityy ((in m/min)
/ )
(c) advantageous before the neutral point hobovo = hf bfvf
where vo and vf are the entering
g is ……………
(d) disadvantageous after the neutral point
and exiting velocities of the
work.
127 128 129
Force, Torque and Power
Elongation Factor or Elongation Co‐efficient GATE‐1992(PI)
L1 Ao If the elongation factor during rolling of an
E= = for single pass ingot is 1.22. The minimum number of passes
Lo A1
needed
d d to produce
d a section
i 250 mm x 250 mm
L A
En = n = o f n − pass
for from an ingot of 750 mm x 750 mm are
Lo An (a) 8 (b) 9
(c) 10 (d) 12
Will b
be
discussed
130 131 in class 132
Projected length ( L p ) = R sin α = RΔh , mm

Projected
j Area ( Ap ) = Lp × b , mm 2 GATE‐2016 (PI) GATE‐2008
In
I a single
i l pass rolling
lli operation,
i a 20 mm thick
hi k
g Force ( F ) = σ o × L p × b , N
RollSeparating
p In a single‐pass rolling operation, a 200 mm wide plate with plate width of 100 mm, is reduced to 18
metallic strip is rolled from a thickness 10 mm to a mm. The roller radius is 250 mm and rotational
[σ o in N / mm 2 i.e. MPa ] speed
p is 10 rpm.
p The averageg flow stress for the p
plate
thickness 6 mm. The roll radius is 100 mm and it rotates material is 300 MPa. The power required for the
e gt ( a in mm ) = 0.5 Lp for
Arm length o hot
ot rolling
o g at 200 rpm.
rpm The roll‐strip
roll strip contact length is a function of rolling operation in kW is closest to
= 0.45 Lp for cold rolling roll radius and,
and initial and final thickness of the strip.
strip If
(a) 15.2
(b) 18.2
a the average
g flow stress in p
plane strain of the strip
p
T
Torque ll (T ) = F ×
per roller , Nm
N (c) 30.4
30 4
1000 material in the roll gap is 500 MPa, the roll separating (d) 45.6
Total power for two roller ( P ) = 2T ω , inW 133
force (in kN) is _______. 134 135
GATE‐2017 IES – 2000, GATE‐2010(PI) IAS – 2007
A strip
i off 120 mm width
id h andd 8 mm thickness
hi k is
i In the rolling process, roll separating force can be Consider
C id theh following
f ll i statements:
rolled between two 300 mm ‐ diameter rolls to get g can be reduced byy
Roll forces in rolling
d
decreased
d by
b
a strip of 120 mm width and 7.2 mm thickness. 1. Reducing friction
Th speed
The d off the
th strip
t i att the
th exit
it is
i 30 m/min.
/ i ( ) Reducing
(a) R d i theh roll
ll diameter
di 2. Using
Ui l
large di
diameter rolls
ll to increase
i the
h contact
There is no front or back tension. Assuming g area.
(b) Increasing
I i the
th roll
ll diameter
di t
uniform roll pressure of 200 MPa in the roll bite 3. Taking smaller reductions per pass to reduce the
and 100% mechanical efficiency,
efficiency the minimum (c) Providing back‐up
back up rolls contact area.
area
total power (in kW) required to drive the two Which of the statements given above are correct?
(d) Increasing the friction between the rolls and the
rolls is___________ (a) 1 and 2 only (b) 2 and 3 only
metal (c) 1 and 3 only (d) 1, 1 2 and 3
136 137 138
IES – 2001 IAS ‐2012 Main IAS – 1998

Which
Whi h off the
th following
f ll i assumptions
ti are correctt for
f Match
M h ListLi ‐ I (products)
( d ) with
i h List
Li ‐ II (processes)
( )
cold rolling? and select the correct answer using the codes given
What is friction hill ?
What is "friction hill" ?
1. The material is plastic. below the lists:
2. The arc of contact is circular with a radius g greater than List – I List ‐II
II
the radius of the roll.
A. M.S. angles and channels 1. Welding
3 Coefficient of friction is constant over the arc of
3.
contact and acts in one direction throughout the arc of B. Carburetors 2. Forging
contact.
contact C Roof trusses
C. 3
3. Casting
Select the correct answer using the codes given below: D. Gear wheels 4. Rolling
Codes:
d Codes: A B C D A B C D
((a)) 1 and 2 ((b)) 1 and 3 (a) 1 2 3 4(b) 4 3 2 1
(c) 2 and 3 (d) 1, 2 and 3 139 140 (c) 1 2 4 3(d) 4 3 1 2 141
Forging Closed Die forging
g g
y Forging
g g p g p
process is a metal working process byy which
metals or alloys are plastically deformed to the desired
Forging shapes by a compressive force applied with the help of a

pair of dies.
y Because
B off the
th manipulative
i l ti ability
bilit off the
th forging
f i
process, it is possible to closely control the grain flow in
the specific direction, such that the best mechanical
properties
p p can be obtained based on the specific p
application.
By S K Mondal
y
142 143 144
IES‐2013
IES‐2016 Statement (I): The dies used in the forging process are Open and Closed die forging
d l dd f
made in pair.
pair y Depending
D di upon complexity
l i off the
h part forging
f i is
i
Statement (II): The material is pressed between two carried out as open die forging and closed die forging.
Ill
Illustrate the
h difference
diff b
between surfaces and the compression force applied, gives it a
shape.
p y In open die forging, the metal is compressed by repeated
(i) open die forging and bl
blows b a mechanical
by h i l h
hammer and
d shape
h i
is
(a) Both Statement (I) and Statement (II) are individually manipulated manually.
true and Statement (II) is the correct explanation of
(ii) closed die forging with appropriate Statement (I) y In closed die forging, the desired configuration is
sketches (b) Both Statement (I) and Statement (II) are individually obtained
b i d byb squeezing i the
h workpiece
k i b
between two
true but Statement ((II)) is not the correct explanation
p of shaped and closed dies.
[4 Marks] Statement (I)
145
(d) Statement (I) is false but Statement (II) is true 146 147
Advantages of Forging
d f Disadvantages of Forging
d f IES – 1996
y Discrete
Di shape
h off product
d can be
b produced.
d d y Costly
C l Which one of the following is an advantage of
y Mechanical properties and reliability of the materials y Poor dimensional accuracy and surface finish.
finish forging?
increases due to improve in crystal structure.
y Forging operations are limited to simple shapes and has
( ) Good
(a) G d surface
f fi i h
finish
y In forging favorable grain orientation of metal is limitations for parts having undercuts, re‐entrant
obtained that strengthen the component but forging surfaces etc
surfaces, (b) Low
L tooling
t li costt
distorts the previously created uni‐directional fibre.
(c) Close tolerance
y Forging reduces the grain size of the metal, which
increases strength and toughness.
toughness (d) Improved physical property.
property
y Fatigue and creep strength increases.
148 149 150
IES‐2013 IES 2005

IES – IES ‐ 2012
Consider the following statements: Statement (I): It is difficult to maintain close
In the forging process:
I h f i
tolerance in normal forging operation.
1. The metal structure is refined
Th t l t t i fi d 1. Forging reduces the grain size of the metal, which Statement (II): Forging is workable for simple
results in a decrease in strength
g and toughness.
g shapes and has limitation for parts having
2 Original unidirectional fibers are distorted
2. Original unidirectional fibers are distorted. undercuts.
undercuts
2. Forged components can be provided with thin (a) Both Statement (I) and Statement (II) are
3 Poor reliability as flaws are always there due to intense
3. Poor reliability, as flaws are always there due to intense i di id ll true and
individually d Statement
S (II) is
i theh correct
sections, without reducing the strength. explanation of Statement (I)
working
g
Which of the statements given above is/are correct? (b) Both Statement (I) and Statement (II) are
4
4. Part are shaped by plastic deformation of material
p yp individuallyy true but Statement ((II)) is not the correct
(a) Only 1 (b) Only 2 explanation of Statement (I)
(a) 1, 2 and 3 (b) 1, 3 and 4 (c) Statement (I) is true but Statement (II) is false
(c) Both 1 and 2 (d) Neither 1 nor 2 (d) Statement (I) is false but Statement (II) is true 153
(c) 1, 2 and 4 (d) 2, 3 and 4 151 152
IES 2016
IES‐2016 ISRO‐2013 Forgeability
bl
Consider the following g statements about forging
g g:
Which
f ll i processes induce
i d more y The
Th forgeability
f bili off a metall can be
b defined
d fi d as its
i
1. Forgings have high strength and ductility.
stress in the metal? capability to undergo deformation by forging without
2. Forgings
F i offer
ff greatt resistance
i t t impact
to i t and
d cracking.
fatigue loads. (a) Hot rolling
3. Forging assures uniformity in density as well as y Metal
M l which
hi h can be
b formed
f d easily
il without
ih cracking,
ki with
ih
(b) Forging
dimensions of the forged parts. low force has good forgeability.
(c) Swaging
Which of the above statements are correct? y Upsetting test and Hot‐twist test are used to determine
(a) 1 and 2 only (b) 1 and 3 only ( ) Turning
(d) f
forgeability.
bili
(c) 2 and 3 only (d) 1,
1 2 and 3 y Forgeability increases with temperature.
temperature
154 155 156
IES ‐ 2012 Draft

f IES – 2006
Which
f ll i statements is i correct for
f y The
Th draft
d f provided
id d on the
h sides
id for
f withdrawal
i hd l off the
h Assertion
A i (A):
(A) Forging
F i dies
di are provided id d with
i h taper
forging? forging. or draft angles on vertical surfaces.
(a) Forgeability is property of forging tool, by which y Adequate draft should be provided‐at least 3o for Reason (R): It facilitates complete filling of die
forging can be done easily.
easily aluminum
l i d 5 to 7o for
and f steel.
l cavity and favourable grain flow.flow
(b) Forgeability decreases with temperature upto lower (a) Both A and R are individually true and R is the
criticall temperature. y Internal surfaces require more draft than external correct explanation
l off A
surfaces. During cooling, forging tends to shrink towards
(c) Ce
Certain
ta mechanical
ec a ca p properties
ope t es o
of tthee material
ate a aaree (b) Both
d v dua y ttrue
ue but R iss not
ot tthee
i centre and
its d as a result,
l the
h externall surfaces
f are likely
lik l
influenced by forging. correct explanation of A
to be separated, whereas the internal surfaces tend to
(d) Pure
P metals
t l have
h good d malleability,
ll bilit therefore,
th f poor cling to the die more strongly. ( ) A is
(c) i true
t b t R is
but i false
f l
forging properties. (d) A is false but R is true
157 158 159
Flash
l h Flash
l h Contd… IES ‐ 2014
The
Th excess metall added
dd d to the
h stockk to ensure complete
l y A flash
fl h acts as a cushion
hi for
f impact
i blows
bl from
f the
h In
I hot
h die di forging,
f i thin
hi layer
l off material
i l all
ll around
d
filling of the die cavity in the finishing impression is finishing impression and also helps to restrict the the forging is
called Flash. outward flow of metal, thus helping in filling of thin ribs (a) Gutter space, which fills up hot gases
and bosses in the upper
pp die. (b) Flash,
Flash the width of it is an indicator of the pressure
y The amount of flash depends on the forging size and developed in the cavity
may vary from 10 to 50 per cent. (c) Coining, which indicates the quality of the forging
y The
Th forging
f i l d can be
load b decreased
d d by
b increasing
i i the
h (d) Cavity,
Cavity which is filled with hot impurities in the
flash thickness. material
160 161 162

IES‐2016
Statement (I) : In drop forging, the excess metal IAS – 2002 Gutter
added to the stock for complete filling of the die Consider the following statements related to
C id h f ll i l d y In
I addition
ddi i to the
h flash,
fl h provision
i i should
h ld be
b made
d in
i the
h
cavity is called flash. forging: die for additional space so that any excess metal can flow
Statement (II) : Flash acts as a cushion against 1. Flash is excess material added to stock which flows and help in the complete closing of the die. This is called
impact
p blows attributable to the finishing g around parting line.
around parting line g
gutter.
impression.
2. Flash helps in filling of thin ribs and bosses in upper
(a) Both Statement (I) and Statement (II) are individually true and die.
Statement (II) is the correct explanation of Statement (I).
3. Amount of flash depends upon forging force.
ou t o as depe ds upo o g g o ce.
Which of the above statements are correct?
Statement ((II)) is not the correct explanation
)
( ) 1, 2 and 3
(a) d (b) 1 and 2d
(c) Statement (I) is true but Statement (II) is false.
(c) 1 and 3 (d) 2 and 3
163 164 165
Gutter Contd…. IES – 1993, GATE‐1994(PI) IES – 1997

Assertion
A ti (A):
(A) In
I drop
d forging
f i besides
b id theth provision
i i
y Without a gutter, a flash may become excessively thick, Which one of the following manufacturing
for flash, provision is also to be made in the forging
not allowing
ll the
h dies
d to close
l completely.
l l processes requires the
h provision off ‘gutters’?
‘ ’ di for
die f additional
dditi l space called
ll d gutter.
tt
Reason (R): The gutter helps to restrict the outward
y Gutter
G d h and
depth d width
id h should
h ld be
b sufficient
ffi i to ( ) Closed
(a) Cl d die
di forging
f i flow of metal thereby helping to fill thin ribs and
bases in the upper die.
accommodate the extra,
extra material.
material (b) Centrifugal
C t if l casting
ti
(c) Investment casting correct
co ect eexplanation
p a at o o of A
(d) Impact extrusion correct explanation of A
(d)
166 167 168
IES‐2015 Sequential steps involved in closed die forging
Fullering or Reducing cross section and making it longer.
Which of the following statements apply to provision swaging
GATE‐1989(PI) of flash gutter and flash land around the parts to be Edging or rolling Preform shape. Gathers the material as
required in the final forging.
At th l t h
At the last hammer stroke the excess material from
t k th t i l f forged? Bending Required for those parts which have a bent
the finishing cavity of a forging die is pushed 1. Small cavities are provided which are directly outside shape
p
the die impression. Drawing or cogging Like fullering but c/s of only one end is
into…………….. 2 The volume of flash land and flash gutter should be
2. reduced
about 20%‐25% of the volume of forging. Flattening Flatten the stock so that it fits properly into
3. Gutter
G tt is i provided
id d to
t ensure completel t closing
l i off the
th the finishing impression.
the finishing impression
die. Blocking Semi‐finishing impression, Imparts to the
(a) 1 and 2 only (b) 1 and 3 only f i it’
forging it’s general but not exact or final shape.
l b t t t fi l h
((c)) 1,, 2 and 3 ((d)) 2 and 3 onlyy Finishing Final impression, Flash land and Gutter
provided to the die.
169 170
Trimming or cut off Removal of flash present around forging 171
Example
l IES – 1998 IES – 2001
Which one of the following processes is most In the forging operation, fullering is done to
commonly
l used
d for
f the
h forging
f off bolt
b l heads
h d off (a) Draw out the material
hexagonal shape? (b) Bend the material
(a) Closed die drop forging ( ) Upset the material
(c)
(b) Open die upset forging (d) Extruding the material
E di h i l
(c) Close die press forging
((d)) Open
p die p
progressive
g forging
g g
172 173 174
IES – 2003 IES 2011 IES – 2005

A forging method for reducing the diameter of a bar Which of the following processes belong to forging The process of removing the burrs or flash from a
operation
p ?
and
d in the
h process making
k it longer
l is termed
d as f
forged
d component in drop
d f
forging is called:
ll d
1. Fullering
( ) Fullering
(a) F ll i (b) P
Punching
hi 2. Swaging
S i ( ) Swaging
(a) S i (b) P f
Perforating
i
33. Welding g
( ) Upsetting
(c) U tti (d) E t di
Extruding ( ) Trimming
(c) Ti i (d) F ttli
Fettling
(a) 1 and 2 only
(b) 2 and d 3 only
l
(c) 1 aand
d3o onlyy
(b) 1, 2 and 3 only
175 176 177
IES – 2002 IES – 2003 IAS – 2001

Consider
f ll i steps involved
i l d in
i hammer
h Consider
C id theh following
f ll i steps in i forging
f i a connecting i Match List I (Forging operations) with List II (Descriptions)
and select the correct answer using the codes given below
forging a connecting rod from bar stock: rod from the bar stock: the Lists:
1. Blocking 2. Trimming 1. Blocking 2. Trimming List I List II
A. Flattening 1. Thickness is reduced continuously at
3 Finishing 4.
3. 4 Fullering 5 Edging
5. 3 Finishing 4.
3. 4 Edging diff
different sections
i along
l l
length
h
Which of the following is the correct sequence of Select the correct sequence of these operations using the B. Drawing 2. Metal is displaced away from centre,
reducing thickness in middle and
operations? codes given below: increasing length
(a) 1,
1 4,
4 3,
3 2 and 5 Codes: C. Fullering g 33. Rod is p
pulled through
g a die
D. Wire drawing 4. Pressure a workpiece between two flat
(b) 4, 5, 1, 3 and 2 (a) 1‐2‐3‐4 (b) 2‐3‐4‐1 dies
(c) 5, 4, 3, 2 and 1 (c) 3‐4‐1‐2 (d) 4‐1‐3‐2 Codes:A B C D A B C D
(a) 3 2 1 4 (b) 4 1 2 3
(d) 5,
5 1,
1 4,
4 2 and 3 ( ) 3
(c) 1 2 4 ( )
(d) 4 2 1 3
178 179 180
IES‐2012 Conventionall IAS – 2003 Drop Forging
In
I forging
f i define
d fi the
h terms Match
M h List Li I (Forging
(F i Operation)
O i ) withi h List
Li II (View
(Vi off the h
y The drop forging die consists of two halves. The lower
Forging Operation) and select the correct answer using the
((i)) Edging
g g codes
d given
i b l
below th lists:
the li t h lf off the
half h die
d is fixed
f d to the
h anvill off the
h machine,
h while
hl
(ii) Fullering List‐I List‐II
and d (iii) Flash
Fl h (Forging Operation) (View of the Forging Operation) the upper half is fixed to the ram.
ram The heated stock is
g g
(A) Edging 1
1. kept in the lower die while the ram delivers four to five
2.
(B) Fullering
(C) Drawing
blows on the metal, in quick succession so that the metal
3. 4.
(D) Swaging spreads and completely fills the die cavity. When the two
C d A B
Codes:A C D A B C D
die halves close, the complete cavity is formed.
(a) 4 3 2 1 (b) 2 1 4 3
(c) 4 1 2 3 (d) 2 3 4 1 y Drop forging is used to produce small components.
181 182 183
Click to see file Page 4 – 5 ‐6
IES – 1994, ISRO‐2010 IAS – 2000

InI drop
d forging,
f i forging
f i isi done
d by
b dropping
d i Drop
D forging
f i isi used
d to produce
d
((a)) The work ppiece at high
g velocityy ((a)) Small components
p
(b) The hammer at high velocity. (b) Large components
( ) The
(c) Th die
di with
i h hammer
h at high
hi h velocity
l i ( ) Identical
(c) Id i l Components
C i large
in l numbers
b
((d)) a weight
g on hammer to p produce the requisite
q ((d)) Medium‐size components
p
impact.
184 185 186
Press Forging
g g IES 2011
IES 2011
y Metal is squeezed gradually by a hydraulic or mechanical Advantages of Press Forging over Drop Forging Consider the following statements :
press and component is produced in a single closing of 1. Any metal will require some time to undergo
y Press forging is faster than drop forging
die, hence the dimensional accuracy is much better than complete
p plastic deformation p
p particularly
y if
d
drop f i
forging. y Alignment of the two die halves can be more easily deforming metal has to fill cavities and corners of
small radii.
maintained
i i d than
h with
i h hammering.
h i
2. For larger work piece of metals that can retain
y Structural
St t l quality
lit off the
th product
d t is
i superior
i tot drop
d toughness
h at forging
f i temperature it i is
i preferable
f bl to
forging.
forging use forge press rather than forge hammer.
(a) 1 and 2 are correct and 2 is the reason for 1
y With ejectors in the top and bottom dies, it is possible to (b) 1 and 2 are correct and 1 is the reason for 2
handle reduced die drafts. (c) 1 and 2 are correct but unrelated
(d) 1 only correct
187 188 189
Machine Forging
h Upset Forging Roll Forging
ll
y Unlike the drop or press forging where the material is y Increasing the diameter of a material by compressing its y When the rolls are in the open position, the heated stock
d
drawn out, in machine
h f
forging, the
h materiall is only
l upset l
length.
h is advanced
d d up to a stop. As the
h rolls
ll rotate, they
h grip and
d
to get the desired shape.
shape y Employs
E l split
li dies
di that
h contain
i multiple
l i l positions
ii or roll down the stock.
stock The stock is transferred to a second
cavities.
cavities set of grooves. The rolls turn again and so on until the
piece is finished.
190 191 192
Roll Forging
ll Contd….
Skew Rolling Smith Forging
h
y A rapid
id process. y Skew rolling produces y Blacksmith
Bl k i h uses this
hi forging
f i method
h d
metal ball y Quality of the product depends on the skill of the
y Round stock is fed operator.
continuously to two y Not used in industry.
p y
specially designed
g
opposing rolls.
y Metal is forged by each

of the grooves in the rolls
and emerges from the
end as a metal ball.
ball
193 194 195
For IES Only
IES – 2008
IES Hi h V l it F i (HVF)
High Velocity Forming (HVF)
IES – 2005 Match List‐I with List‐II and select the correct answer using
Match
M t h List
Li t I (Type
(T off Forging)
F i ) withith List
Li t II (Operation)
(O ti ) the code given below the lists: y The
ep ocess de
process o s metals
deforms eta s by us g ve
using veryy high
g ve oc t es,
velocities,
and select the correct answer using the code given List‐I (Forging Technique) List‐II (Process) provided on the movements of rams and dies.
below the Lists: A Smith Forging
A. Smith Forging 11. Material is only upset to get the y As K.E ∞ V2, high energy is delivered to the metal with
List I List II desired shape relativelyy small weights
g ((ram and die).
)
A Drop
A. D F i
Forging 1. M l is
Metal i gripped
i d in
i theh dies
di andd B. Drop Forging 2.Carried out manually open dies
pressure is applied on the heated end y Cost and size of machine low.
B. Press Forging 2. Squeezing action C Press Forging
C. Press Forging 3 Done in closed impression dies by
3.
p Forging
C. Upset g g 33. Metal is p placed between rollers and
hammers in blows y Ram strokes short (due to high acceleration)
pushed D. Machine Forging 4. Done in closed impression dies by
y Productivity high, overall production cost low
D. Roll Forging
g g 4 4. Repeated
p hammer blows continuous squeezing
q g force
A B C D A B C D Code: A B C D A B C D y Used for Alloy steel, titanium, Al, Mg, to fabricate one
(a) 4 1 2 3 (b) 3 2 1 4 (a) 2 3 4 1 (b) 4 3 2 1 piece complex components of smaller size like valve,
(c) 4 2 1 3 (d) 3 1 2 4196 (c) 2 1 4 3 (d) 4 1 2 3 197 rocket component. 198
For IES Only
IES‐2013 Flashless forging

Statement (I): In high velocity forming process, high
gy can be transferred to metal with relativelyy small
energy y The work material is completely surrounded by the die IES – 2008
weight. cavity during compression and no flash is formed. The
Th balls
b ll off the
h ball
b ll bearings
b i are manufactured
f d
y Most important requirement in flashless forging is that from steel rods. The operations involved are:
Statement (II): The kinetic energy is the function of
mass and velocity. the work volume must equal the space in the die cavity to 1. Ground
a very close tolerance.
tolerance 2 Hot forged on hammers
2.
true and Statement ((II)) is the correct explanation
p of 3. Heat treated
Statement (I) 4. Polished
(b) Both
B th Statement
St t t (I) and
d Statement
St t t (II) are individually
i di id ll Wh t is
What i the
th correctt sequence off the th above
b
true but Statement (II) is not the correct explanation of operations from start?
Statement (I)
() (a) 3‐2‐4‐1 (b) 3‐2‐1‐4
(c) Statement (I) is true but Statement (II) is false (c) 2‐3‐1‐4 (d) 2‐3‐4‐1
(d) Statement (I) is false but Statement (II) is true 199 200 201
Lubrication for Forging
b f Forging Defects
f Forging Defects
f Contd….
y Lubricants influence: friction, wear, deforming forces y Unfilled Sections: Die cavity is not y Scale
S l Pits:
Pi Irregular
I l depressions
d i on the
h surface
f due
d to
improper cleaning of the stock.
and
d flow
fl off materiall in die‐cavities,
d non‐sticking,
k completely
l l filled,
f ll d due
d to improper y Die Shift: Due to Misalignment of the two die halves or
thermal barrier.
barrier design of die making the two halves of the forging to be of improper
shape.
y For hot forging: graphite,
graphite MoS2 and sometimes molten y Cold Shut or fold: A small crack at y Flakes:
l k Internall ruptures caused d by
b the
h improper
g
glass. the corners and at right
g angles
g to cooling.
y Improper Grain Flow: This is caused by the improper
y For cold forging:
g g mineral oil and soaps.
p the forged surface. Cause: improper
design of the die,
die which makes the flow of metal not
y In hot forging, the lubricant is applied to the dies, but in
design of the die flowing the final intended directions.
cold forging, it is applied to the workpiece. 202 203 204
Forging Defects
f Contd…. IAS – 1998 IES 2011
y Forging Laps: These are folds of metal squeezed The
Th forging
f i defect
d f due
d to hindrance
hi d to smooth
h flow
fl Assertion (A) ( ) : Hot tears occur during
d forging
f
of metal in the component called 'Lap' occurs because of inclusions in the blank material
together
h during
d f
forging. They
h have
h irregular
l contours because Reason (R) : Bonding between the inclusions
and occur at right angles to the direction of metal flow.
flow (a) The corner radius provided is too large and the p parent material is through
g p physical
y
and chemical bonding.
(b) The corner radius provided is too small
y Hot tears and thermal cracking: These are surface (a) Both A and R are individually true and R is the
(c) Draft is not provided correct explanation of A
cracks occurring
g due to non‐uniform cooling
g from the (d) The shrinkage allowance is inadequate (b) Both A and R are individually true but R is NOT
forging stage or during heat treatment. the correct explanation of A
( ) A is true but
(c) b R is false
f l
((d)) A is false but R is true
205 206 207
IES‐2013
B lli
Barrelling Consider
C id the
h following
f ll i statements pertaining i i to the h
open‐die forging of a cylindrical specimen between
GATE ‐2008 (PI)
GATE ‐2008 (PI) two flat dies:
Match the following
1 Lubricated specimens show more surface movement
1.
Group ‐1 Group‐2 than un‐lubricated ones.
P Wrinkling
P . 1 Upsetting
1. Upsetting 2. Lubricated
b d specimens show
h l
less surface
f movement
Q. Centre burst 2. Deep drawing than un‐lubricated ones.
R. Barrelling 3. Extrusion 3. Lubricated specimens show more barrelling than un‐
S C ld h t
S. Cold shut 4. Closed die forging
Cl d di f i lubricated ones.
ones
4. Lubricated specimens shows less barrelling than un‐
(a) P – 2, Q – 3, R – 4, S‐1 (b) P – 3, Q – 4, R – 1, S‐2 lubricated ones.
(c) P – 2, Q
(c) P 2 Q – 3, R
3 R – 1, S
1 S‐4
4 (d) P – 2, Q
(d) P 2 Q – 4, R
4 R – 3, S
3 S‐1
1 Which of these statements are correct?
Inhomogeneous deformation with barreling of the workpiece (a) 1 and 3 (b) 1 and 4 (c) 2 and 3 (d) 2 and 4210
208 209
For IES Only
Die Materials Should have
l h ld h GATE ‐2010 (PI)
y Good hardness, toughness and ductility at low and
Good hardness toughness and ductility at low and
Hot die steel, used for large solid dies in drop forging,
elevated temperatures
p
should
h ld necessarily
l have
h
y Adequate fatigue resistance
( ) high
(a) hi h strength
h and
d high
hi h copper content
y Sufficient hardenability
y Low thermal conductivity (b) high
hi h hardness
h d and
d low
l hardenability
h d bilit
y Amenability to weld repair
A bili ld i (c) high toughness and low thermal conductivity
y Good machinability (d) high hardness and high thermal conductivity

Material: Cr‐Mo‐V‐alloyed tool steel and Cr‐Ni‐Mo‐
y
alloyed tool steel. 211 212 213
For IES Only
IES‐2013
IES 2013
Statement (I): In power forging energy is provided by True Stress & True Strain
compressed d air
i or oil
il pressure or gravity.
it
Statement ((II):) The capacity
p y of the hammer is g given byy
True stress (σ T ) = σ (1 + ε )
the total weight, which the falling pans weigh. ⎛ L ⎞ ⎛ Ao ⎞ ⎛ do ⎞
True strain (ε T ) = ln(1
( + ε ) = ln ⎜ ⎟ = ln ⎜ ⎟ = 2 ln ⎜ d ⎟
⎝ Lo ⎠ ⎝ A ⎠ ⎝ ⎠
true and Statement (II) is the correct explanation of
S
Statement (I)
((b)) Both Statement ((I)) and Statement ((II)) are individuallyy
true but Statement (II) is not the correct explanation of
Statement (I)
214 215 216
GATE‐2014 GATE‐1992, ISRO‐2012, VS‐2013 GATE‐2016
The relationship between true strain (εT ) and Engineering strain of a mild steel sample is
The true strain for a low carbon steel bar
engineering strain (ε
( E ) in a uniaxiall tension test is
which is doubled in length by forging is recorded as 0.100%. The true strain is
( ) E = ln(1 + ε
(a) ε l ( T ) (b) E = ln(1 ‐
(b) ε l ( εT )
((a)) 0.307
3 7 (a) 0.010 %
( ) εT = ln(1 + ε
(c) l ( E ) (d) T = ln(1 ‐
(d) ε l ( εE )
(b) 0.5 (b) 0.055 %
(c) 0.693
0 693 ((c)) 0.099
99 %
(d) 1.0
10 (d) 0.
0.101
0 %
217 218 219
GATE‐2007 GATE‐2016
In open‐die forging, a disc of diameter 200
GATE‐2017 (PI)
GATE‐2017 (PI) The value of true strain produced in
mm and height 60 mm is compressed A steell wire
i off 2 mm diameter
di i to be
is b drawn
d compressing a cylinder to half its original
without any barreling effect. The final f
from a wire
i off 5 mm diameter.
di t TheTh value
l off length is
diameter of the disc is 400 mm. The true true strain developed
de eloped is _____________(up
(up
(a) 0.69 (b) ‐0.69
strain is to three decimal places).
places)
(c) 0.5 (d) ‐0.5
(a) 1.986 (b) 1.686
(c) 1.386 (d) 0.602 220 221 222
Strain Hardening & Flow Stress
GATE 2017
GATE‐2017 y In the plastic region,
region the material behaviour is expressed
by the flow curve: Average Flow Stress
A rod of length 20 mm is stretched to make a rod σ = Kε n
Where K is strength coefficient and n is strain‐hardening y Average (mean) flow stress is not on the basis of
of length 40 mm. Subsequently, it is compressed (or work‐hardening)
work hardening) exponent and at UTS,
UTS ε = n instantaneous flow stress,
stress but on an average value over
the stress – strain curve from the beginning of strain to
to make a rod of final length 10 mm. Consider the the final (maximum) value that occurs during
longitudinal
g tensile strain as p
positive and deformation.
K ε nf
compressive
p strain as negative.
g The total true g flow stress (σ o ) =
Average
longitudinal
g strain in the rod is
1+ n
Here εf is the maximum strain value during deformation.
((a)) ‐0.55 ((b)) ‐0.69
9 ((c)) ‐0.75
75 ((d)) ‐1.0
223 224 225
St i
Strain rate effects
t ff t GATE 2015
GATE-2015
GATE‐2006
y Strain rate effect (hot Working) The ultimate tensile strength of a material is 400
The strain hardening exponent n of stainless
σ o = Cε m
MPa and the elongation up to maximum load is
35%.
% If the
h materiali l obeys
b power law
l off hardening,
h d i steall SS 304 with
h distinct
d yield
ld and
d UTS values
l
1 dh v Platen Velocity then the true stress‐true strain relation (stress in
ε = = = undergoing plastic deformation is
h dt h Instantaneous height MPa) in the plastic deformation range is:
(a) σ = 540 ε0.30 (b) σ = 775 ε0.30
0 30 a) n<0
(c) σ = 540 ε0.35 (d) σ = 775 ε0.35 b)n=0
c) 0<n<1
d)n=1
226 227 228
GATE‐2012 Same Q GATE ‐2012 (PI) GATE‐2016 (PI)
GATE‐2017 A solid cylinder of diameter 100 mm and height 50 mm Two solid cylinders of equal diameter have different
The Poisson
Poisson’ss ratio for a perfectly is forged between two frictionless flat dies to a height of
f db f l fl d h h f
incompressible linear elastic material is heights. They are compressed plastically by a pair of rigid
25 mm The percentage change in diameter is
25 mm. The percentage change in diameter is dies to create the same percentage reduction in their
(a) 1 (b) 0.5
( )0
(c) (d) Infinite
I fi it (a) 0 (b) 2 07
(b) 2.07 (c) 20 7
(c) 20.7 (d) 41 4
(d) 41.4 respecti e heights.
respective heights Consider that the die‐workpiece
die orkpiece
interface friction is negligible.
negligible The ratio of the final
diameter of the shorter cylinder
y to that of the longer
g
cylinder is __________.
229 230 231
GATE‐2015 GATE 2000 (PI)

GATE‐2000 (PI) Extrusion & Drawing
The
Th flow
fl stress (in
(i MPa)
MP ) off a material
i l is
i given
i by
b A cylindrical billet of 100 mm diameter is forged from 50
mm height to 40 mm at 1000
1000°C.
C. The material has
σ = 500ε 0.1
01
constant flow stress of 80 MPa. Find the work of

Where ε is true strain.
strain The Young
Young’ss modulus of
elasticity of the material is 200 GPa. A block of deformation. If a 10 KN drop hammer is used to
thickness 100 mm made of this material is
compressed to 95 mm thickness and then the load complete the reduction in one blow. What will be the
i removed.
is d The
Th final
fi l dimension
di i off the
th block
bl k (in
(i height of fall?
mm) is _________
By S K Mondal
232 233 234
Extrusion y Steels, stainless steels, and nickel‐based alloys are
y The extrusion process is like squeezing toothpaste out of
y Metal is compressed and forced to flow through a difficult to extrude. (high yield strengths, welding with
a tube.
suitably
bl shaped
h d die
d to form
f a product
d with
h reduced
d d but
b wall). Use phosphate‐based and molten glass
constant cross section.
section lubricants .
y Metal will undergo tri‐axial compression.
compression
y Hot extrusion is commonly employed.

employed
y Lead, copper, aluminum, magnesium, and alloys of these

metals are commonly extruded.
235 236 237
IES – 2007 Extrusion Ratio DRDO‐2008

Which
Whi h one off the th following
f ll i is
i theth correctt
y Ratio of the cross‐sectional area of the billet to the cross‐ If the extrusion ratio is 20, the percentage reduction
statement?
(a) Extrusion is used for the manufacture of seamless sectionall area off the
h product.
d in the
h cross‐sectionall area off the
h billet
b ll after
f the
h
tubes.
y about
b 40: 1 for
f hot
h extrusion
i off steell extrusion will be
(b) Extrusion is used for reducing the diameter of round
bars and tubes byy rotating g dies which open
p and close (a) 98% (b) 95% (c) 20% (d) 5%
y 400: 1 for
f aluminium
l i i
rapidly on the work?
(c) Extrusion is used to improve fatigue resistance of the
metal by setting up compressive stresses on its surface
(d) Extrusion
E t i comprises
i pressing
i th metal
the t l inside
i id a
chamber to force it out by high pressure through an
orifice
ifi which
hi h is
i shaped
h d to
t provide
id the
th desired
d i d from
f off the
th
finished part. 238 239 240
Advantages of Extrusion
d f IES ‐ 2012 IES – 2009
y Any cross‐sectional shape can be extruded from the Extrusion
E i process can effectively
ff i l reduce
d the
h cost off Which
Whi h one off the
h following
f ll i statements is i correct??
product through ((a)) In extrusion p
process,, thicker walls can be obtained
nonferrous
f metals.
t l
(a) Material saving by increasing the forming pressure
y Many shapes (than rolling) (b) process time saving (b) Extrusion is an ideal process for obtaining rods from
y No
oddraft
at (c) Saving in tooling cost metal having poor density
(d) saving in administrative cost (c) As compared to roll forming, extruding speed is high
y Huge reduction in cross section.
(d) Impact extrusion is quite similar to Hooker
Hooker'ss process
y Conversion from one product to another requires only a including the flow of metal being in the same direction
single die change
y Good dimensional precision.

241 242 243
Limitation of Extrusion
f Application
l IES – 1994
y Cross section must be uniform for the entire length of y Working of poorly plastic and non ferrous metals and Metal
M l extrusion i process isi generally
ll used
d for
f
producing
the
h product.
d alloys.
ll (a) Uniform solid sections
y Manufacture
M f off sections
i and
d pipes
i off complex
l (b) Uniform hollow sections
(c) Uniform solid and hollow sections
configuration.
configuration
(d) Varying solid and hollow sections.
y Medium and small batch production.
production
y Manufacture of parts of high dimensional accuracy.
244 245 246
GATE‐1994 IES – 1999

The
Th process off hot
h extrusioni is i usedd to produce
d E t i
Extrusion Which
f ll i is
i theh correct
((a)) Curtain rods made of aluminium temperature range for hot extrusion of aluminium?
(b) Steel pipes/or domestic water supply (a) 300‐340°C (b) 350‐400°C
Hot Cold
( ) Stainless
(c) S i l steell tubes
b used d in
i furniture
f i (c) 430‐480°C
430 480°C (d) 550‐650°C
550 650°C
((d)) Large
g shape
p ppipes
p used in cityy water mains
Direct Indirect Forward Backward
Cold Impact
Hydrostatic Extrusion Extrusion
Forging
247 248 249
Hot Extrusion Process IES – 2009 Direct Extrusion

What
Wh is i the
h major
j problem
bl in
i hot
h extrusion?
i ? y A solid
lid ram drives
di the
h entire
i billet
bill to and
d through
h h a
y The temperature range for hot extrusion of aluminum is
((a)) Design
g of p
punch ((b)) Design
g of die stationary die and must provide additional power to
430‐480°C overcome the
h frictional
f l resistance between
b the
h surface
f off the
h
(c) Wear and tear of die (d) Wear of punch moving billet and the confining chamber.
y Used
U d to produce
d curtain
i rods
d made
d off aluminum.
l i
y Design
D i off die
di is
i a problem.
bl
y Either direct or indirect method used.

used
250 251 252

IES – 1993 IES – 2000 Indirect Extrusion
d
Assertion
A i (A):
(A) Direct
Di extrusion
i requiresi larger
l force
f Consider
C id theth following
f ll i statements:
t t t y A hollow
h ll ram drives
di the
th die
di back
b k through
th h a stationary,
t ti
than indirect extrusion. In forward extrusion process confined billet.
Reason (R): In indirect extrusion of cold steel, zinc 1. The ram and the extruded product travel in the same y Since no relative motion, friction between the billet and
direction. the chamber is eliminated.
phosphate coating is used. used
2. The ram and the extruded product travel in the opposite
(a) Both A and R are individually true and R is the direction.
correct explanation
l off A 3. The speed of travel of the extruded product is same as that
(b) Both
d v dua y ttrue
ue but R iss not
ot tthee of the ram.
correct explanation of A 4. The speed of travel of the extruded product is greater than
that of the ram.
( ) A is
(c) i true
t b t R is
but i false
f l
Which of these Statements are correct?
(d) A is false but R is true (a) 1 and 3 (b) 2 and 3
253
(c) 1 and 4 (d) 2 and 4 254 255
Indirect Extrusion
d Contd… IES ‐ 2012 IES – 2007
Which
f ll i are correct for
f an indirect
i di hot
h Assertion
A i (A):
(A) Greater
G force
f on the
h plunger
l is
i required
i d
y Required force is lower (25 to 30% less)
extrusion process? in case of direct extrusion than indirect one.
y Low process waste. 1. Billet remains stationary Reason (R): In case of direct extrusion, the direction of
the force applied
pp on the p plunger
g and the direction of
2 There is no friction force between billet and container
2.
the movement of the extruded metal are the same.
walls.
3. The force required on the punch is more in explanation of A
comparison
co pa so to d direct
ect eextrusion.
t us o . (b) Both
B th A and d R are individually
i di id ll true
t b t R is
but i nott the
th
4. Extrusion parts have to be provided a support. correct explanation of A
( ) 1, 2, 3 and
(a) d4 (b) 1, 2 and
d 3 only
l (c) A is true but R is false
(c) 1, 2 and 4 only (d) 2, 3 and 4 only ((d)) A is false but R is true
256 257 258
IES‐2016
IAS – 2004 Statement (I): Employing the extrusion process is not Cold Extrusion
ld
Assertion
A i (A):
(A) Indirect
I di extrusion
i operation
i can be
b economical in case of large billets.
billets
y Used with low‐strength metals such as lead, tin, zinc,
performed either by moving ram or by moving the Statement (II): A significant part of the press capacity is lost
container. overcoming
i f i i
frictional
l resistance
i b
between workpiece
k i and
d and
d aluminum
l to produce
d collapsible
ll bl tubes
b f
for
cylinder wall during the extrusion process.
Reason (R): Advantage in indirect extrusion is less toothpaste medications,
toothpaste, medications and other creams; small "cans"
cans
quantity of scrap compared to direct extrusion.
Statement ((II)) is the correct explanation
) for shielding electronic components and larger cans for
( ) Both
h
correct explanation of A food and beverages.
St t
Statementt (II) is
i nott the
th correctt explanation
l ti off Statement
St t t (I).
(I)
(c) Statement (I) is true but Statement (II) is false. y Now‐a‐days also been used for forming mild steel parts.
259 260 261
Backward cold extrusion
k d ld Impact Extrusion IES – 2008, GATE‐1989(PI)
y The metal is extruded through the gap between the Which one of the following methods is used for the
punch
h and
d die
d opposite to the
h punch
h movement. manufacture
f off collapsible
ll bl tooth‐paste
h tubes?
b
y For
F softer
f materials
i l such
h as aluminium
l i i and
d its
i alloys.
ll ( ) Impact
(a) I extrusion
i (b) Di
Direct extrusion
i
y Used
U d for
f making
ki collapsible
ll ibl tubes,
t b cans for
f liquids
li id and
d ( ) Deep
(c) D d
drawing
i (d) Pi i
Piercing
similar articles.
articles
y The extruded parts are stripped by the use of a stripper

262 plate, because they tend to stick to the punch. 263 264
IES – 2003 IES ‐ 2014 Hooker Method

k h d
The
Th extrusioni process (s)( ) usedd for
f the
h production
d i off A toothpaste
h tube
b can be
b produced
d d by
b
toothpaste tube is/are ((a)) Solid forward extrusion
1. Tube extrusion (b) Solid backward extrusion
2 Forward extrusion
2. ( ) Hollow
(c) H ll backward
b k d extrusion
i
3. Impact extrusion ((d)) Hollow forward extrusion
Select the correct answer using the codes given below:
C d
Codes:
(a) 1 onlyy (b) 1 and 2
(c) 2 and 3 (d) 3 only
265 266 267
Hooker Method
k h d Hydrostatic Extrusion
d Hydrostatic Extrusion
d Contd….
y The
Th ram/punch
/ h has
h a shoulder
h ld and d acts
t as a mandrel.
d l
y Another type of cold extrusion process.
y A flat blank of specified diameter and thickness is placed in a
suitable
i bl die
di and d is
i forced
f d through
h h the
h opening
i off the
h die
di with
ih y High‐pressure fluid applies the force to the workpiece
the punch
y when
h the
h punch h starts downward
d d movement. Pressure
P i
is through
h h a die.
di
exerted by the shoulder of the punch, the metal being forced
t flow
to fl th
through h the
th restricted
t i t d annular
l space between
b t th
the y It i forward
is f d extrusion,
t i b t the
but th fluid
fl id pressure
punch and the opening in the bottom of the die.
y I place
In l off a flat
fl solid
lid blank,
bl k a hollow
h ll slug
l can also
l beb used.
d surrounding the billet prevents upsetting.
upsetting
y If the tube sticks to the punch on its upward stroke, a y Billet
Billet‐chamber
chamber friction is eliminated, and the
stripper willll strip it from
f the
h punch.h
y Small copper tubes and cartridge cases are extruded by this pressurized fluid acts as a lubricant between the billet
method.
268 and the die. 269 270
Hydrostatic Extrusion
d Contd…. IAS – 2000
y Temperature
T is
i limited
li i d since
i the
h fluid
fl id acts as a heat
h sink
i k Application Assertion
A i (A):
(A) Brittle
B i l materials i l such h as grey cast
and the common fluids (light hydrocarbons and oils) iron cannot be extruded by hydrostatic extrusion.
burn or decomposes at moderately low temperatures. y Extrusion of nuclear reactor fuel rod
E t i f l t f l d
Reason(R): In hydrostatic extrusion, billet is
y The metal deformation is performed in a high high‐ y Cladding of metals uniformly compressed from all sides by the liquid. liquid
compression environment. Crack formation is (a) Both A and R are individually true and R is the
suppressed leading to a phenomenon known
suppressed, kno n as y Making wires for less ductile materials correct explanation
l off A
pressure‐induced ductility. (b) Both
d v dua y ttrue
ue but R iss not
ot tthee
y Relatively brittle materials like cast iron, stainless steel, correct explanation of A
molybdenum, tungsten and various inter inter‐metallic
metallic ( ) A is
(c) i true
t b t R is
but i false
f l
compounds can be plastically deformed without
fracture and materials with limited ductility become
fracture, (d) A is false but R is true
highly plastic. 271 272 273
IES – 2006 IES – 2001

What
Wh does
d hydrostatic
h d i pressure in
i extrusion
i process GATE‐1990(PI) Which
Whi h off the th following
f ll i statements
t t t are the
th salient
li t
improve? features of hydrostatic extrusion?
S i brittle
Semi b ittl materials
t i l can be
b extruded
t d d by
b 1. It
I is
i suitable
i bl for
f soft f and
d ductile
d il material.
i l
(a) Ductility (b) Compressive strength
2. It is suitable for high‐strength super‐alloys.
(c) Brittleness (d) Tensile strength (a) Impact extrusion 3.The billet is inserted into the extrusion chamber and pressure
is applied by a ram to extrude the billet through the die.
(b) Closed cavity extrusion
4. The billet is inserted into the extrusion chamber where it is
(c) Hydrostatic extrusion surrounded byy a suitable liquid.q The billet is extruded
through the die by applying pressure to the liquid.
(d) Backward extrusion Select the correct answer using g the codes g
given below:
Codes:
(a) 1 and 3 (b) 1 and 4
274 275
(c) 2 and 3 (d) 2 and 4 276
For IES Only
Lubrication for Extrusion
b f IES 2009 Conventional
y For
F hot
h extrusion
i glass
l is
i an excellent
ll lubricant
l bi with
ih Explain the processes of extrusion given below.
Process variables in Extrusion
Process variables in Extrusion
steels, stainless steels and high temperature metals and 1. Experimental
p studies of flow
alloys. Indicate one typical product made through each of these 2. Temperature and Metallurgy: Variations in temperature
y For cold extrusion,
extrusion lubrication is critical,
critical especially with processes:
during extrusion seem to influence flow behaviour in
steels, because of the possibility of sticking (seizure) number of ways. As indicated, flow patterns may be
changed
g considerablyy byy rendering g the temperature
p
bet een the workpiece
between orkpiece and the tooling if the lubrication (i) Direct
Di t Extrusion
E t i
distribution in the container. It is known that the extrusion
breaks down. Most effective lubricant is a phosphate pressure mayy be lowered if either the temperature
p p of the
conversion coating on the h workpiece.
k (ii) Indirect Extrusion
billet or the velocity of the stem is increased, and that there
are certain limitations, because the material starts melting g
(iii) Hydrostatic Extrusion
or cracking if it is leaves the die with too high temperature.
(iv) Impact Extrusion
277 278 279
IES
IES ‐ 2014 Extrusion Defects
Extrusion Defects IES 2016
IES‐2016
Statement‐I: For high extrusion pressure, the initial
y Surface crack due to high
g temperature,
p g speed,
high p Surface cracking occurring at low temperature in
temperature of billet should be high. high
high friction etc.
Statement‐II: As the speed of hot extrusion is hydrostatic extrusion is know as
i
increased,
d it may lead l d to t melting
lti off alloy
ll y Bamboo defects at low temperature due to sticking of
constituents metals in die land. (a) Fluid Defect (b) Bamboo Defect
(a) Both Statement (I) and Statement (II) are y Pipe defects or tail pipe or fishtailing, during
(c) Fishtailing (d) Arrowhead Fracture
individuallyy true and Statement (II) is the correct extrusion surface oxides and impurities p are driven
explanation of Statement (I) towards the centre of the billet, like funnel called pipe.
(b) Both Statement (I) and Statement (II) are y Centre Burst or Chevron defect are attributed to a
individually true but Statement (II) is not the correct state of hydrostatic tensile stress at the centreline in the
explanation of Statement (I)
d f
deformation
i zone in
i the
h die.
di Tendency
T d i
increases with
ih
(c) Statement (I) is true but Statement (II) is false increasing die angle and amount of impurities. Tendency
(d) Statement
St t t (I) is
i false
f l but
b t Statement
St t t (II) is
i true
t decrease with increasing extrusion ratio and friction.
280 281 282
GATE‐2014
With respect to metal working,
working match Group A with Group B
JWM 2010 Group A Group B
Wire Drawing
Assertion (A) : Extrusion speed depends on work P: Defect in extrusion I: alligatoring y A cold working process to obtain wires from rods of
material.
Q: Defect in rolling II: scab
Reason (R) : High extrusion speed causes cracks in b
bigger d
diameters through
h h a die.
d
R: Product of skew III: fish tail
the material. rolling
lli y Same
S process as bar
b drawing
d i except that
h iti involves
i l
(a) Both A and R are individually true and R is the S: Product of rolling IV: seamless tube
l ti off A smaller‐diameter material.
material
through cluster mill
(b) Both A and R are individuallyy true but R is not the V: thin sheet with tight tolerance y At the start of wire drawing, the end of the rod or wire to
correct explanation of A VI: semi‐finished balls of ball bearing be drawn is pointed to make for an easier entrance of
(c) A is true but R is false wire into the die. This pointing is done by means of
P Q R S P Q R S rotary swaging or by simple hammering.
(d) A is false but R is true (a) II III VI V (b) III I VI V
283
(c) III I IV VI (d) I II V VI
284 285
Wire Drawing Contd…. Wire Drawing Contd…. IES – 2007

y Wire getting continuously wound on the reel. Which metal forming process is used for
y For
F fine
fi wire,
i theth material
t i l may be
b passed
d through
th h a number
b manufacture
f off long
l steell wire?
of dies,, receiving
g successive reductions in diameter,, before
( ) Deep
(a) D d
drawing
i (b) F i
Forging
being coiled and known as Tandem Drawing.
( ) Drawing
(c) D i (d) E t i
Extrusion
y The wire is subjected to tension only. But when it is in
contact with
i h dies
di then
h a combination
bi i off tensile,
il compressive
i
and shear stresses will be there in that p
portion only.
y
y Wire drawing is always a cold‐working process, need
sufficient ductility, may be annealed before drawing.
286 287 288
IES – 2009 IES – 2005
Which one of the following stress is involved in the Which
Whi h off theh following
f ll i types off stresses is/are
i / GATE‐1987
involved in the wire‐drawing operation?
wire drawing
d process? F i d
For wire drawing operation, the work material
i ti th k t i l
(a) Tensile only
( ) Compressive
(a) C i (b) T il
Tensile (b) Compressive only should essentially be
(c) A combination of tensile and compressive stresses (a) Ductile (b) Tough
( ) Shear
(c) Sh (d) H d t ti stress
Hydrostatic t
(d) A combination of tensile, compressive and shear
stresses ((c) Hard
) ((d) Malleable
)
289 290 291
IES‐2016
Statement (I) : In wire‐drawing, the end of the stock Cleaning and Lubrication in wire Drawing IES 2010
is made ‘pointed’
pointed to make for easier entrance of the y Cleaning is done to remove scale and rust by acid pickling.
Cleaning is done to remove scale and rust by acid pickling Assertion (A): Pickling and washing of rolled rods
wire into the die. y Lubrication boxes precede the individual dies to help reduce is carried out before wire drawing.
Statement (II) : The pointing of the wire is done friction drag and prevent wear of the dies. Reason (R): They lubricate the surface to reduce
exclusivelyy by
y rotaryy swaging
g g and not by y simple
p friction while drawing g wires.
hammering. y Sulling: The wire is coated with a thin coat of ferrous
(a) Both Statement (I) and Statement (II) are individually true and hydroxide which when combined with lime acts as filler for correctt explanation
l ti off A
Statement (II) is the correct explanation of Statement (I). the lubricant. (b) Both A and R are individuallyy true but R is NOT the
(b) Both Statement (I) and Statement (II) are individually true but y Phosphating: A thin film of Mn, Fe or Zn phosphate is correct explanation of A
( ) p ()
Statement (II) is not the correct explanation of Statement (I). applied on the wire.
wire (c) A is true but R is false
(c) Statement (I) is true but Statement (II) is false. (d) A is false but R is true
y Electrolytic
y coating:
g For veryy thin wires,, electrolytic
y coating
g
292
of copper is used to reduce friction. 293 294
IES – 2000 IAS – 1995 IES – 1996

Which
f ll i lubricants
l b i is
i most The
Th following
f ll i operations
i are performed
f d while
hil In
I wire
i drawing
d i process, the
h bright
b i h shining
hi i surface
f
suitable for drawing mild steel wires? preparing the billets for extrusion process: on the wire is obtained if one
(a) Sodium stearate (b) Water 1. Alkaline cleaning (a) does not use a lubricant
(c) Lime‐water
Lime water (d) Kerosene 2 Phosphate coating
2. (b) uses solid powdery lubricant.
lubricant
3. Pickling (c) uses thick paste lubricant
4. Lubricating with reactive soap. (d) uses thin film lubricant
Th correctt sequence off these
The th operations
ti i
is
(a) 3, 1, 4, 2 (b) 1, 3, 2, 4
(c) 1, 3. 4, 2 (d) 3, 1, 2, 4
295 296 297

IES
IES ‐ 2014
Statement‐I: In drawing process, cross‐section of Wire Drawing Die
Bundle Drawing
Bundle Drawing round d wire
i is
i reduced
d d by
b pulling
lli it through
th h a die
di
Statement‐II: Bundle drawing g p
produces wires that
In this process,
process many wires (as much as several
are polygonal in cross‐section rather than round
thousand)) are drawn simultaneouslyy as a bundle. To (a) Both Statement (I) and Statement (II) are
prevent sticking, the wires are separated from each individually true and Statement (II) is the correct
explanation
l i off Statement
S (I)
other by a suitable material. The cross‐section of the
((b)) Both Statement ((I)) and Statement ((II)) are
wires is somewhat
h polygonal.
l l individually true but Statement (II) is not the correct
explanation of Statement (I)
(d) Statement (I) is false but Statement (II) is true y Die materials: tool steels or tungsten carbides or
298 299 polycrystalline diamond (for fine wire) 300
Rod and Tube Drawing
d d b Rod and Tube Drawing
d d b Contd…
y Rod
R d drawing
d i isi similar
i il to wire
i drawing
d i except for
f the
h fact
f
that the dies are bigger because of the rod size being
larger than the wire.
y The tubes are also first pointed and then entered
through the die where the point is gripped in a similar
way
a as the bar drawing
dra ing and pulled through in the form Tube Sinking Fixed Plug Drawing
desired along a straight line.
y When the final size is obtained, the tube may be
annealed and straightened.
y The practice of drawing tubes without the help of an Back
i t
internall mandrel
d l is
i called
ll d tube
t b sinking.
i ki
301 302 Floating plug Drawing Moving Mandrel 303
Swaging or kneading
k d
IES‐1993; GATE‐1994(PI), 2014(PI)
IES 1993; GATE 1994(PI) 2014(PI) IAS‐2006 y The hammering of a rod or tube to reduce its diameter
A moving mandrel is used in Which one of the following processes necessarily where
h the
h die
d itself
lf acts as the
h hammer.
h
(a) Wire drawing (b) Tube drawing requires
q mandrel of requisite
q diameter to form the
y Repeated
R d blows
bl are delivered
d li d from
f various
i angles,
l
((c)) Metal Cutting
g ((d)) Forging
g g internal hole?
causing the metal to flow inward and assume the shape
(a) Hydrostatic Extrusion
of the die.
(b) Tube drawing
y It is cold working.
g The term swaging
g g is also applied
pp to
(c) Swaging
processes where material is forced into a confining die to
(d) Wire
Wi Drawing
D i
304 305
reduce its diameter. 306
Swaging or kneading
k d Contd… IES‐2015 IES – 1993
Tandem
T d drawing
d i off wires
i andd tubes
b is i necessary
Rotary swaging is a process for shaping
because
a) Round bars and tubes (a) It is not possible to reduce at one stage
b)Billets
b)Bill (b) Annealing is needed between stages
(c) Accuracy in dimensions is not possible otherwise
c) Dies
(d) Surface finish improves after every drawing stage
d)Rectangular
) g blocks
307 308 309
IES – 2000 IES – 1999 IES – 1996

Match
M t h List
Li t I (Components
(C t off a table
t bl fan)
f ) withith List
Li t II Match
M t h List‐I
Li t I with
ith List‐II
Li t II and
d select
l t the
th correctt Match List I with List II and select the correct answer
(Manufacturing processes) and select the correct answer using the codes given below the Lists: List I (Metal/forming process) List II (Associated force)
answer using i the
th codesd given
i b l
below th Lists:
the Li t List‐I List‐II A. Wire drawing 1. Shear force
List I List II A. Drawing g 1. Soapp solution
B Extrusion
B. E t i 2. T il force
Tensile f
A. Base with stand 1. Stamping and B. Rolling 2. Camber
p
pressingg g
C. Blanking 3. Compressive
p force
C Wire drawing
C. dra ing 3
3. Pilots
B. Blade 2. Wire drawing D. Bending 4. Spring back force
D. Sheet metal operations using 4. Crater
C Armature
C. A t coil
il wire
i 3. T i
Turning progressive dies 5. Ironing C d A B
Codes:A C D A B C D
D. Armature shaft 4. Casting Code:A B C D A B C D (a) 4 2 1 3 (b) 2 1 3 4
Codes:A B C D A B C D (a) 2 5 1 4 (b) 4 1 5 3 (c) 2 3 1 4 (d) 4 3 2 1
(a) 4 3 2 1 (b) 2 1 4 3 ( ) 5
(c) 2 3 4 (d) 5 2 1 3
(c) 2 3 4 1 (d) 4 1 2 3310 311 312
IES – 1994 IES – 1993, ISRO‐2010 IES – 2002

Match List I with List II and select the correct answer
M h Li I i h Li II d l h Match
M t h List
Li t I with
ith List
Li t II and
d select
l t the
th correctt Match
M h List
Li I with
i h List
Li II and
d select
l the
h correct
using the codes given below the Lists: answer using the codes given below the lists: answer:
List I (Metal farming process) List II (A similar process) List I (Mechanical property) List II (Related to) List I (Parts) List II (Manufacturing processes)
A.
A Blanking 11. Wire drawing A. Malleabilityy 1. Wire drawing g A. Seamless tubes
A 1 Roll forming
1.
B. Coining 2. Piercing B. Hardness 2. Impact loads B. Accurate and smooth tubes 2. Shot peening
C Resilience
C. 3
3. Cold rolling
C. Extrusion 3. Embossing C. Surfaces having higher 3. Forging
D. Isotropy 4. Indentation
D
D. Cup drawing 4
4. Rolling hardness and fatigue strength4.
strength4 Cold forming
5. Direction
5. Bending Codes: A B C A B C
Codes:A B C D A B C D
Codes:A B C D A B C D (a) 4 2 1 3 (b) 3 4 2 5 (a) 1 4 2 (b) 2 3 1
(a) 2 3 4 1 (b) 2 3 1 4 ( ) 5
(c) 4 2 3 (d) 3 2 1 5 (c) 1 3 2 (d) 2 4 1
(c) 3 2 1 5 (d) 2 3 1 5 313 314 315
GATE 2015
GATE-2015
IAS – 2001 Match the followingg pproducts with p
preferred
IAS – 2002
Match
M h List Li I (Products)
(P d ) with
i h List
Li II (Suitable
(S i bl manufacturing processes: Assertion
A ti (A):
(A) InI wire‐drawing
i d i process, the
th rod d
processes) and select the correct answer using the cross‐section is reduced gradually by drawing it
codes given below the Lists: Product Process severall times
ti i successively
in i l reduced
d d diameter
di t dies.
di
List I List II P Rails 1 Blow molding Reason (R): Since each drawing reduces ductility of
Q Engine Crankshaft 2 Extrusion the wire, so after final drawing the wire is
A. Connecting rods 1. Welding normalized.
B. Pressure vessels 2. Extrusion R Al i i
Aluminium Ch
Channels
l 3 F i
Forging
C Machine tool beds
C. 3
3. Forging S PET water bottles 4 Rolling
g correct
co ect eexplanation
p a at o o
of A
D. Collapsible tubes 4. Casting (b) Both A and R are individually true but R is not the
a ) P -4
4 ,Q
Q -3
3 ,R
R -1
1 ,S
S -2
2 b ) P -4
4 ,Q
Q -3
3 ,R
R -22 ,S
S -1
1 correct explanation of A
c ) P -2 ,Q -4 ,R -3 ,S -1 d ) P -3 ,Q -4 ,R -2 ,S -1 (c) A is true but R is false
(a) 3 1 4 2 (b) 4 1 3 2 ( ) A is false but R is true
(d)
(c) 3 2 4 1 (d) 4 2 3 1 316 317 318
IES 2011
IES 2011 IAS 1994
g
Match List –I with List –II and select the correct answer using
the code given below the lists : Seamless tube Manufacturing
Seamless tube Manufacturing Which of the following methods can be used for
manufacturing 2 meter long seamless metallic
List I
List –I List II
List –II 1 Rolling
1. Rolling tubes?
b
A Connecting rods
A. Connecting rods 1 Welding
1. Welding 2 Extrusion 1. Drawing g 2. Extrusion
3. Rolling 4. Spinning
B. Pressure vessels 2. Extrusion 3
3. Tube Drawing
g
Select
l the
h correct answer using the
h codes
d given below
b l
C. Machine tool beds 3. Forming 4. Spinning Codes:
D. Collapsible tubes 4. Casting (a) 1 and 3 (b) 2 and 3
Codes
A B C D A B C D ( ) 1, 3 and 4
(c) ( ) 2, 3 and 4
(d)
(a) 2 1 4 3 (b) 3 1 4 2
(c) 2 4 1 3 (d) 3 4 1 2319 320 321
Extrusion Load Extrusion Stress Force required in Wire or Tube drawing

y Approximate
A i method
h d (Uniform
(U if deformation,
d f i no y Approximate
A i method
h d (Uniform
(U if deformation,
d f i no y Approximate method (Uniform deformation,
deformation no
friction) “work – formula” friction) “work – formula” friction) “work – formula”
⎛A ⎞ πd2 ⎛d ⎞ π d o2 P ⎛A ⎞ ⎛d ⎞ ⎛A ⎞ π d 2f ⎛d ⎞
P = Aoσ o ln ⎜ o ⎟⎟ = 2 × o × σ o × ln ⎜⎜ o ⎟⎟ = × σ o × ln ( R ) σE = = σ o ln ⎜ o ⎟⎟ = 2 × σ o × ln ⎜⎜ o ⎟⎟ = σ o × ln ( R ) P = Af σ o ln ⎜ o ⎟⎟ = 2 × × σ o × ln ⎜ o ⎟⎟
⎜A 4 4 ⎜A ⎜A 4 ⎜d
⎝ f ⎠ ⎝ df ⎠ A0 ⎝ f ⎠ ⎝ df ⎠ ⎝ f ⎠ ⎝ f ⎠
y For real conditions y For real conditions Drawing Stress
⎛A ⎞ πd
2 ⎛d ⎞ P ⎛A ⎞ ⎛d ⎞ ⎛A ⎞ ⎛d ⎞
P = KAo ln ⎜ o ⎟⎟ = 2 × o
× K × ln ⎜ o ⎟⎟ σE = = K ln ⎜ o ⎟⎟ = 2 × K × ln ⎜⎜ o ⎟⎟ σd =
P
= σ o ln ⎜ o
⎜A 4 ⎜ ⎜
⎜A ⎟⎟ = 2 × σ o × ln ⎜⎜ o ⎟⎟
⎝ f ⎠ ⎝ df ⎠ A0 ⎝ Af ⎠ ⎝ df ⎠ Af ⎝ f ⎠ ⎝ df ⎠
K = extrusion
t i constant.
t t K = extrusion
t i constant.
t t
322 323 324
GATE‐2003 GATE – 2009 (PI) GATE‐2006
A brass billet is to be extruded from its initial Using direct extrusion process, a round billet of 100 In a wire drawing operation, diameter of a steel wire
d
diameter off 100 mm to a final
f l diameter
d off 50 mm. mm length
l h and
d 50 mm diameter
d is extruded.
d d is reduced
d d from
f 10 mm to 8 mm. The
h mean flow
fl
The working temperature of 700°C
700 C and the Considering an ideal deformation process (no stress of the material is 400 MPa.
MPa The ideal force
extrusion constant is 250 MPa. The force required friction and no redundant work), extrusion ratio 4, required for drawing (ignoring friction and
for extrusion is and average flow stress of material 300 MPa, the redundant work) is
(a) 5.44 MN (b) 2.72 MN pressure (in MPa) on the ram will be (a) 4.48 kN (b) 8.97 kN
(c) 1.36 MN (d) 0.36 MN (a) 416 (b) 624 (c) 700 (d) 832 (c) 20.11 kN (d) 31.41 kN
325 326 327
GATE 2008 (PI) Linked S 1

GATE ‐2008 (PI) Linked S‐1 GATE 2008 (PI) Linked S 2
GATE ‐2008 (PI) Linked S‐2 IES‐2014 Conventional
A 10 mm diameter annealed steel wire is drawn A 10 mm diameter annealed steel wire is drawn
(i) What kind of products are manufactured by wire
through
g a die at a speed
p of 0.55 m/s to reduce the through
g a die at a speed
p of 0.55 m/s to reduce the
drawing process?
diameter by 20%. The yield stress of the material is diameter by 20%. The yield stress of the material is
(ii) How
H much
h force
f will
ill approximately
i l be
b required
i d
800 MPa. 800 MPa.
to draw a wire from 1.5
1 5 mm diameter steel wire to 1.0
10
Neglecting friction and strain hardening, the stress The power required for the drawing process (in kW)
mm diameter wire if the average
g yyield strength
g of
required for drawing (in MPa) is is
the work material is 300 MPa?
(a) 178.5 (b) 357.0 (c) 1287.5 (d) 2575.0 (a) 8.97 (b) 14.0 (c) 17.95 (d) 28.0
[10 Marks]
328 329 330
GATE‐2001, GATE ‐2007 (PI) IES ‐ 2014 GATE‐1996

For rigid perfectly‐plastic work material, negligible In
I wire‐drawing
i d i operation,
i the
h maximum
i A wire
i off 0.1 mm diameter
di is
i drawn
d from
f a rod
d off 15
reduction per pass for perfectly plastic material in mm diameter. Dies giving reductions of 20%, 40%
interface
f f
friction and
d no redundant
d d work,
k the
h ideal condition is and 80% are available. For minimum error in the
theoretically maximum possible reduction in the (a) 68 % (b) 63 % final size,, the number of stages g and reduction at
(c) 58 % (d) 50% each stage respectively would be
wire drawing operation is (a) 3 stages and 80% reduction for all three stages
((a)) 0.36
3 ((b)) 0.633 (b) 4 stages and 80% reduction for first three stages
followed by a finishing stage of 20% reduction
((c)) 1.00 ((d)) 2.72
7 (c) 5 stages and reduction of 80%,
80% 80%.40%,
80% 40% 40%,
40% 20%
in a sequence
( ) none of the above
(d)
331 332 333
GATE 2015
GATE-2015 Wire Drawing
Wire Drawing
Maximum Reduction per pass
σ o (1 + B ) ⎡ ⎛r ⎞ ⎤ ⎛r ⎞
2B 2B
In a two stage wire drawing operation , the
σd = ⎢1 − ⎜ f ⎟ ⎥ + ⎜ f ⎟ .σ b With back stress, σ b
f ti
fractional
l reduction
d ti ( ti off change
(ratio h i cross –
in B ⎢⎣ ⎝ ro ⎠ ⎥⎦ ⎝ ro ⎠
σ o (1 + B ) ⎡ ⎛ rf min ⎞ ⎤ ⎛ rf min ⎞
2B 2B
sectional area to initial cross

cross‐sectional
sectional area) in the σo = ⎢1 − ⎜ ⎟ ⎥+⎜ ⎟ .σ b
B ⎢⎣ ⎝ ro ⎠ ⎥⎦ ⎝ ro ⎠
first stage
g is 0.4.
4 The fractional reduction in the
second stage is 0.3. The overall fractional
stress σ b
Without back stress,
reduction is _____
σ o (1 + B ) ⎡ ⎞ ⎤
2B
⎛r
(a) 0.24 (b) 0.58 (c) 0.60 (d) 1.0 σo = ⎢1 − ⎜ f min ⎟ ⎥
f
B ⎢⎣ ⎝ ro ⎠ ⎥⎦
334 335 336
IFS 2016
IFS‐2016 G
GATE – 20 ( ) C S
2011 (PI) Common Data‐S1
IES – 2011 Conventional
A 12.5 mm diameter
d rod
d is to be
b reduced
d d to 10 mm A round rod of annealed brass 70‐30 is being In a multi pass drawing operation,
multi‐pass operation a round bar of 10 mm
diameter by drawing in a single pass at a speed of 100 diameter and 100 mm length is reduced in cross‐section
drawn from a diameter of 6 mm to 3 mm at a b drawing
by d i it successively
i l through
th h a series
i off seven dies
di
m/min. Assuming a semi die angle of 5o and coefficient
of friction between the die and steel rod as 0.15, speed
p of 0.6 m/s. Assume that the frictional and of decreasing exit diameter. During each of these
calculate: d
drawing operations, the
h reduction
d in cross‐sectionall area
((i)) The p
power required
q in drawing
g redundant work together constitutes 35% of the is 35
35%. The yyield strength
g of the material is 200 MPa.
(ii) Maximum possible reduction in diameter of the rod Ignore strain hardening.
ideal work of deformation.
(iii) If the rod is subjected to a back pressure of 50 The total true strain applied and the final length (in
N/mm2 , what would be the draw stress and maximum Calculate (i) power required in this operation and mm), respectively, are
possible
ibl reduction
d ti ? (a) 2.45 and 8 17 (b) 2.45 and 345
Take stress of the work material as 400 N/mm2 . (ii) die pressure at the exit of the die. [10‐Marks]
(c) 3.02 and 2043 (d) 3.02 and 3330
[15 Marks] Hint: K =895 MPa and n = 0.49
337 338 339
G
GATE – 20 ( ) C S2
2011 (PI) Common Data‐S2 GATE – 2014 IAS – 1997
In a multi pass drawing operation,
multi‐pass operation a round bar of 10 mm Extrusion
E i force
f DOES NOT depend
d d upon the
h
diameter and 100 mm length is reduced in cross‐section A metal rod of initial length is subjected to a
((a)) Extrusion ratio
b drawing
by d i it successively
i l through
th h a series
i off seven dies
di d
drawing process. The
h length
l h off the
h rod
d at any
of decreasing exit diameter. During each of these (b) Type of extrusion process
d
drawing operations, the
h reduction
d in cross‐sectionall area expression L(t) = Lo(1 + t2)
instant is given by the expression, ( ) Material
(c) M i l off the
h die
di
is 35
35%. The yyield strength
g of the material is 200 MPa. where t is the time in minutes. The true strain rate ((d)) Workingg temperature
p
Ignore strain hardening.
at the end of one minute is ………..
Neglecting friction and redundant work the force (in
Neglecting friction and redundant work, the force (in
kN) required for drawing the bar through the first die, is
(a) 15.71 (b) 10.21
(c) 6.77 (d) 4.39
340 341 342
IES – 2012 The Degree of Drawing or Reduction factor IAS – 2006
Write
W i theh process variables
i bl in
i wire
i drawing.
d i in Cross Sectional area
in Cross Sectional area In
I drawing
d i operationi if Di = initial
i i i l diameter
di and
d Do
Ans. = Outgoing diameter, then what is the degree of
1. Reduction in cross sectional area
drawing equal to?
2. Die
Di anglel Ao − Af Do2 − D 2f Di − Do Do − Di Di2 − Do2 Di2 − Do2
D= = (a) (b) (c ) (d )
33. Friction Ao Do2 Di Do Di2 Di2
⎛A ⎞ ⎛ 1 ⎞
ThereforeTrue strain ( ε ) = ln ⎜ o ⎟⎟ = ln ⎜ ⎟
⎜A ⎝ 1− D ⎠
⎝ f ⎠
343 344 345
Piercing (Punching) and Blanking
( h ) d l k
Sheet Metal
y Product has light weight and versatile shape as y Piercing and blanking are shearing operations.
compared to forging/casting
y In blanking, the piece being punched out becomes
Sheet Metal Operation y Most commonly used
strength, formability)
– low carbon steel sheet (cost,
the
h workpiece
k i and
d any major
j burrs
b or undesirable
d i bl
y Aluminium and titanium for aircraft and aerospace features should be left on the remaining strip.
strip
y Sheet metal has become a significant material for,
y In piercing (Punching),
(Punching) the punch
punch‐out
out is the scrap
‐ automotive bodies and frames,
‐ office furniture and the remaining
g strip
p is the workpiece.
p
frames for home appliances
By S K Mondal
y ‐ y Both done on some form of mechanical press.
346 347 348
Piercing (Punching) and Blanking
Clearance (VIMP)
Clearance (VIMP)
y Die opening must be larger than punch and known as
clearance.
‘clearance’
y Punching
Punch = size of hole
Die = punch size +2 clearance
y Remember: In punching punch is correct size.
y Blanking
Di = size
Die i off product
d
Punch = Die size ‐2 clearance
y Remember: In blanking die size will be correct.
y Note: In pu
punching
c g cclearance
ea a ce iss p
provided
ov ded o
on Die
e
349 350
In Blanking clearance is provided on punch 351
Clearance
Clearance Contd
Contd….
y The clearance is determined with g

following
Clearance in %
Clearance in %
equation
y If the
th allowance
ll f the
for th material
t i l is
i a = 0.075 given
i th
then
C = 0.0032t τ C = 0.075
0 075 x thickness of the sheet
y Where τ is the shear strength of the material in y If clearance is 1% given then
N/mm2(MPa) C = 0.01
0 01 x thickness of the sheet
y Total clearance between punch and die size will be

Punching Blanking
twice these ‘C’ i.e. 2C
352 353 354
Example
l GATE‐2003 Punching Force and Blanking Force
h d l k
Determine
D i the
h die
di andd punchh sizes
i for
f blanking
bl ki a circular
i l
Fm ax = Ltτ
A metal disc of 20 mm diameter is to be punched
disc of 20‐mm diameter from a sheet whose thickness is 1.5
mm. f
from a sheet
h off 2 mm thickness.
h k The
h punch
h and
d the
h
die clearance is 3%.
3% The required punch diameter is
Shear strength of sheet material = 294 MPa
(a) 19.88
19 88 mm (b) 19 94 mm
19.94
Also determine the die and punch sizes for punching a The punching force for holes which are smaller than the stock
(c) 20.06
20 06 mm (d) 20 12 mm
20.12 thi k
thickness may be estimated as follows:
b ti t d f ll
circular hole of 20‐mm diameter from a sheet whose
thickness is 1.5 mm. π dtσ
Fmax =
3
d
355 356 t 357
Capacity of Press for Punching and Blanking Example
l
Estimate the blanking force to cut a blank 25 mm wide
GATE‐2014
A rectangular hole of size 100 mm × 50 mm is to be
Press capacity will be = Fmax ×C and
d 30 mm long
l f
from a 1.5 mm thick
h k metall strip, iff the
ultimate shear strength of the material is 450 N/mm2.
h
made on a 5 mm thick sheet of steel having
ultimate tensile strength and shear strength of 500
MPa and 300 MPa, respectively. The hole is made
Also determine the work done if the percentage
b punching
by hi process. Neglecting
N l i the
h effect
ff off
[Where C is a constant and equal to 1.1 to 1.75 depending penetration is 25 percent of material thickness. clearance, the punching force (in kN) is
upon the profile]
th fil ]
(a) 300 (b) 450
(c) 600 (d) 750
358 359 360

GATE‐2016 (PI) Minimum Diameter of Piercing
f
IAS‐2011 Main
IAS‐2011 Main The ratio of press force required to punch a square hole
For punching a 10 mm circular hole, and cutting a off 30 mm side
id in
i a 1 mm thick
thi k aluminium
l i i sheet
h t to
t that
th t π
rectangular blank of 50 x 200 mm from a sheet of 1 τs πd.t
Piercing pressure, = Strength of punch, σc × d 2
4
mm thickness (mild steel,
steel shear stress = 240 needed to punch a square hole of 60 mm side in a 2 mm
N/mm2), Calculate, in each case : thick aluminium sheet is__________________
(i) Size of punch
(ii) Size of die
(iii) Force required. [10‐Marks]
361 362 363
IES – 1999 IES ‐ 2014 ISRO‐2008, 2011

A hole is to be punched in a 15 mm thick plate A hole
h l off diameter
di 35 mm is
i to be
b punched
h d in
i a With a punch for which the maximum crushing
sheet metal of thickness t and ultimate shear
h
having ultimate
l shear
h h off 3N‐mm‐2. Iff the
strength h strength 400 MPa, using punching force of 44 kN. stress is 4 times the
h maximum shearing
h stress off the
h
allowable crushing stress in the punch is 6 N mm‐22,
N‐mm The maximum value of t is plate the biggest hole that can be punched in the
plate,
(a) 0.5 mm
the diameter of the smallest hole which can be plate would be of diameter equal to
(b) 10 mm
1
punched is equal to (c) 1 mm (a) × Thickness of plate
4
(a) 15 mm (b) 30 mm (d) 2 mm 1
(b) × Thickness of plate
2
(c) 60 mm (d) 120 mm
(c) Plate thickness
364 365 (d) 2 × Plate thickness 366
IES‐2013 Energy and Power for Punching and Blanking Shear on Punch

h h
A hole of diameter d is to be punched in a plate of Id l Energy
Ideal E i J) = maximum
(E in i force
f h travell = Fmax × ( p × t )
x punch
y To reduce shearing force, shear is ground on the face of
(Unit:Fmax
a in kN and t in mm othrwise use Fmax
a in N and t in m)
thi k
thickness t For
t. F the
th plate
l t material,
t i l the
th maximum
i the
h die
d or punch.
h
Where p is percentage penetration required for rupture
crushing stress is 4 times the maximum allowable E×N
Ideal power in press ( P inW ) = y It distribute the cutting action over a period of time.
60
shearing
g stress. For p
punching
g the biggest
gg hole, the
[Where N = actual number of stroke per minute]
ratio of diameter of hole to plate thickness should Actual Energy ( E in J ) = Fmax × ( p × t ) × C y Shear only reduces the maximum force to be applied but
be equal to: Where C is a constant and equal to 1.1 to 1.75 depending upon the profile total work done remains same.
1 E×N
1 A
Actual
l power in W)=
i press ( P iinW
(a) (b) 2 60 ×η
4
WhereE is actual energy and η is efficiency of the press
(c) 1 (d) 2
367 368 369
Force required with shear on Punch
Force required with shear on Punch
Example
F × ptt [for
[f circular
i l hole
h l and
d other
h searing
i
F = max y A hole, 100 mm diameter, is to be punched in steel plate
S + pt operations]
5.6 mm thick. The ultimate shear stress is 550 N/mm2 .
Fmax × pt With normal clearance on the tools, cutting is complete

F=
S [For Shear cutting, or if force Vs at 40 per cent penetration
i off the
h punch.
h Give
Gi suitable
i bl
displacement curve trapezoidal mentioned shear angle for the punch to bring the work within the
in the question.]
capacity
capac ty o
of a 30
30T p
press.
ess.
Wh
Where p = penetration
i off punch h as a fraction
f i
S = shear on the punch or die, mm
370 371 372
Example
l GATE‐2010 Statement Linked 1 GATE‐2010 Statement Linked 2
A washer
h with
i h a 12.7 mm internal
i l hole
h l and d an outside
id Statement
S for
f Linked
Li k d Answer
A Questions:
Q i Statement for Linked Answer Questions:
diameter of 25.4 mm is to be made from 1.5 mm thick In a shear cutting operation, a sheet of 5 mm thickness In a shear cutting operation, a sheet of 5mm thickness
strip. The
h ultimate
l shearing
h strengthh off the
h materiall off is cut along a length of 200 mm.
mm The cutting blade is 400
is cut along a length of 200 mm. The cutting blade is 400 mm long and zero‐shear (S = 0) is provided on the edge.
the washer is 280 N/mm2. mm long g and zero‐shear ((S = 0)) is p
provided on the edge.
g The ultimate shear strength
g of the sheet is 100 MPa and
(a) Find the total cutting force if both punches act at The ultimate shear strength of the sheet is 100 MPa and penetration to thickness ratio is 0.2. Neglect friction.
the same time and no shear is applied
pp to either p
punch penetration to thickness ratio is 0.2. Neglect
p g friction. 400
400
or the die.
(b) What will be the cutting force if the punches are
staggered, so that only one punch acts at a time. S
S
( ) Taking
(c) T ki 6 % penetration
60% i andd shear
h on punchh off 1 Assuming force vs displacement curve to be rectangular, A shear of 20 mm (S = 20 mm) is now provided on the
mm, what will be the cutting force if both punches act the work done ((in J) is blade. Assuming g force vs displacement curve to be
together.
h trapezoidal,
d l the
h maximum force
f ( kN)
(in k ) exerted
d is
(a) 100 (b) 200 (c) 250 (d) 300
373 374 (a) 5 (b) 10 (c) 20 (d) 40 375
Fine Blanking
l k y Slitting ‐ moving rollers trace out complex paths during y Trimming ‐ Cutting unwanted excess material from the
Fine
Fi Blanking
Bl ki ‐ dies
di are designed
d i d that
h have
h small
ll periphery of a previously formed component.
clearances and pressure pads that hold the material cutting (like a can opener).
while it is sheared. The final result is blanks that have y Shaving
h ‐ Accurate dimensions
d off the
h part are obtained
b d by
b
y Perforating: Multiple holes which are very small and
extremelyy close tolerances. removing a thin strip of metal along the edges.
edges
close together are cut in flat work material.
y Notching: Metal pieces are cut from the edge of a sheet,

strip
t i or blank.
bl k
376 377 378

y Lancing – A hole is partially cut and then one side is bent Dinking
k
down to form a sort of tab or louver. No metal removal, no y Used
U d to blank
bl k shapes
h from
f low‐strength
l h materials,
i l such
h as
y Steel Rules ‐ soft materials are cut with a steel strip
rubber, fiber, or cloth.
scrap. shaped
h d so that
h the
h edge
d is the
h pattern to be
b cut. y The shank of a die is either struck with a hammer or mallet or
the entire die is driven downward byy some form of
y Nibbling
Nibbli ‐ a single
i l punch
h is
i moved
d up and
d down
d rapidly,
idl mechanical press.
each time cutting off a small amount of material.
material This
allows a simple
p die to cut complex
p slots.
y Squeezing ‐ Metal is caused to flow to all portions of a die
cavity under the action of compressive forces.
379 380 381
Elastic recovery or spring back
l b k Elastic recovery or spring back
l b k Contd.. IAS – 2003
y Total deformation = elastic deformation + plastic y More important in cold working. The
Th 'spring
' i back'
b k' effect
ff in
i press working
ki is i
((a)) Elastic recoveryy of the sheet metal after removal of
d f
deformation. the load
y It depends
d d on the
th yield
i ld strength.
t th Higher
Hi h the
th yield
i ld (b) Regaining the original shape of the sheet metal
strength, greater spring back. (c) Release of stored energy in the sheet metal
y At the
th end
d off a metal
t l working
ki operation,
ti when
h th
the
(d) Partial recovery of the sheet metal
pressure is released,
released there is an elastic recovery and the
total deformation will g
get reduced a little. This y To compensate this, the cold deformation be carried
phenomenon is called as "spring back". beyond the desired limit by an amount equal to the
spring back.
382 383 384
ISR0– 2013 Punch and Die material Punching Press

h
Spring back in metal forming depends on
y Commonly used – tool steel
(a) Modulus of Elasticity
y For high production ‐ carbides
(b) Load Applied
(c) Strain Rate
(d) None
N off these
h
385 386 387

Bolster plate
l l Bolster plate
l l Contd.... Punch plate
h l
y When many dies are to run in the same press at different y Used to locate and hold the
times, the
h wear occurring on the
h press bed
b d is high.
h h The
h punch
h in position.
bolster plate is incorporated to take this wear.
wear y This
Thi is
i a useful
f l way off
y Relatively cheap and easy to replace.
replace mounting
mounting, especially for
y Attached to the press bed and the die shoe is then small punches.
p
attached to it.
388 389 390
Stripper Stripper Contd.... Knockout

k
y The stripper removes the stock from the punch after a y Knockout
K k is
i a mechanism,
h i usually
ll connected
d to and
d
piercing or blanking operation. operated by the press ram, for freeing a work piece from
Ps = KLt a die.
Where Ps = stripping force, kN
stripping force kN
L = perimeter of cut, mm
t = stock thickness, mm
k hi k
K = stripping constant,
= 0.0103 for low‐ carbon steels thinner than 1.5 mm with
the cut at the edge or near a preceding cut
= 0.0145 for same materials but for other cuts
f i l b f h
= 0.0207 for low‐ carbon steels above 1.5‐mm thickness
= 0.0241 for harder materials
f h d l
391 392 393
Pitman Dowel pin
l GATE 2011
y It is a connecting rod which is used to transmit motion The shear strength of a sheet metal is 300 MPa. The
blanking g force required
q to p
produce a blank of 100
f
from the
h main drive
d shaft
h f to the
h press slide.
ld mm diameter from a 1.5 mm thick sheet is close to
(a) 45 kN
(b) 70 kN
(c) 141 kN
(d) 3500 kN
394 395 396

GATE‐2016 GATE‐2013 (PI)
( )
In a sheet metal of 2 mm thickness a hole of 10 mm
GATE –
GATE – 2009 (PI)
2009 (PI) Circular blanks of 10 mm diameter are punched
diameter needs to be punched. The yield strength in A disk
di k off 200 mm diameter
di t isi blanked
bl k d from
f a strip
ti f
from an aluminium
l i i sheet
h t off 2 mm thickness.
thi k Th
The
tension of the sheet material is 100 MPa and its ultimate of an aluminum alloy of thickness 3.2
3 2 mm.
mm The shear strength of aluminium is 80 MPa. The
shear strength is 80 MPa. The force required to punch material shear strength
g to fracture is 150
5 MPa. The minimum punching force required in kN is
the hole (in kN) is _______ blanking force (in kN) is (a) 2.57
(a) 291 (b) 301 (c) 311 (d) 321 (b) 3.29
(c) 5.03
(d) 6.33
397 398 399
ISRO‐2009 GATE‐2007 GATE‐2004

The
Th force
f requirement
i in
i a blanking
bl ki operation
i off 10 mm diameter
di holes
h l are to be
b punched
h d in
i a steell
The force required to punch a 25 mm hole in a low carbon steel sheet is 5.0 kN. The thickness of sheet of 3 mm thickness. Shear strength of the
mild steel plate 10 mm thick, when ultimate shear the sheet is ‘t’ and diameter of the blanked part is material is 400 N / mm2 and penetration is 40%.
‘d’. For the same work material,, if the diameter of Shear pprovided on the ppunch is 2 mm. The blanking
g
stress of the plate is 500 N/mm2 will be nearly the blanked part is increased to 1.5 d and thickness force during the operation will be
is reduced to 0.4
0 4 t,
t the new blanking force in kN is (a) 22.6
22 6 kN (b) 37.7
3 kN
(a) 78 kN (b) 393 kN (c) 98 kN (d) 158 kN (a) 3.0 (b) 4.5 (c) 61.6 kN (d) 94.3 kN
(c) 5.0 (d) 8.0
400 401 402
GATE‐2002
GATE ‐
GATE ‐ 2012 GATE‐2008(PI) In
I a blanking
bl ki operation,
i the
h clearance
l is
i provided
id d
Calculate the p punch size in mm,, for a circular on
A blank of 50 mm diameter is to be sheared from a
blanking operation for which details are given (a) The die
below. sheet of 2.5 mm thickness. The required radial
(b) Both the die and the punch equally
Size of the blank 25 mm clearance between the die and the punch is 6% of
(c) The punch
Thi k
Thickness off the
th sheet
h t 2 mm sheet thickness. The punch and die diameters (in mm) (d) Brittle the punch nor the die
Radial clearance between punch and die 0.06 mm for this blanking operation,
operation respectively,
respectively are
Die allowance 0.05 mm
(a) 24.83
24 83 (b) 24.89
24 89 (a) 50.00 and 50.30 (b) 50.00 and 50.15
(c) 25.01 (d) 25.17 (c) 49.70 and 50.00 (d) 49.85 and 50.00
403 404 405

GATE‐2001 GATE‐1996 IES – 1994
The
Th cutting i force
f in
i punching
hi and
d blanking
bl ki A 50 mm diameter
di disc
di isi to be
b punched
h d out from
f a In
I sheet
h metall blanking,
bl ki shear
h is
i provided
id d on
operations mainly depends on carbon steel sheet 1.0 mm thick. The diameter of punches and dies so that
(a) The modulus of elasticity of metal the punch should be (a) Press load is reduced
(b) The shear strength of metal (a) 49.925
49 925 mm (b) 50.00
50 00 mm (b) Good cut edge is obtained.
obtained
(c) The bulk modulus of metal (c) 50.075 mm (d) none of the above (c) Warping of sheet is minimized
(d) The yield strength of metal (d) Cut blanks are straight.
406 407 408
IES – 2002 IAS – 1995 IES – 2006

Consider
C id the
h following
f ll i statements related
l d to InI blanking
bl ki operation i the h clearance
l provided
id d is
i In
I which
hi h one off the
h following
f ll i isi a flywheel
fl h l generally
ll
piercing and blanking: ((a)) 550% on ppunch and 550% on die employed?
1. Shear on the punch reduces the maximum cutting (b) On die (a) Lathe (b) Electric motor
force ( ) On
(c) O punch h (c) Punching machine (d) Gearbox
2. Shear increases the capacity of the press needed ((d)) On die or p
punch depending
p g upon
p designer’s
g choice
3. Shear increases the life of the punch
4 The total energy needed to make the cut remains
4.
unaltered due to provision of shear
Which
h h off these
h statements are correct?
(a) 1 and 2 (b) 1 and 4
(c) 2 and 3 (d) 3 and 4 409 410 411
IES – 2004 IES – 1997 IAS – 2000

Which
f ll i statements is i correct?? For
F 50% % penetration
i off work k material,
i l a punch
h with
ih A blank
bl k off 30 mm diameter
di is
i to be
b produced
d d out off
If the size of a flywheel
y in a ppunching
g machine is single shear equal to thickness will 10 mm thick sheet on a simple die. If 6% clearance is
increased (a) Reduce the punch load to half the value recommended, then the nominal diameters of die
(a) Then the fluctuation of speed and fluctuation of (b) Increase the punch load by half the value and p
punch are respectively
p y
energy will both decrease (c) Maintain the same punch load (a) 30.6 mm and 29.4 mm
(b) Then the fluctuation of speed will decrease and the (d) Reduce the punch load to quarter load (b) 30.6 mm andd 30 mm
fluctuation
uctuat o oof eenergy
e gy will increase
c ease (c) 30 mm aand
d 29.4
9.4 mm
(c) Then the fluctuation of speed will increase and the (d) 30 mm and 28.8 mm
fl t ti off energy will
fluctuation ill decrease
d
(d) Then the fluctuation of speed p and fluctuation of
energy both will increase
412 413 414
GATE – 2007 (PI)
( ) IAS – 1994 IAS – 2002
Circular
Ci l blanks
bl k off 35 mm diameter
di t are punched
h d In
I a blanking
bl ki operationi to produce
d steell washer,
h theh In
I deciding
d idi the h clearance
l between
b punchh andd die
di in
i
from a steel sheet of 2 mm thickness. If the maximum punch load used in 2 x 105 N. The plate press work in shearing, the following rule is helpful:
clearance per side between the punch and die is thickness is 4 mm and percentage penetration is 25. (a) Punch size controls hole size die size controls blank
to be kept as 40 microns,
microns the sizes of punch and The work done duringg this shearing
g operation
p is size
die should respectively be (a) 200J (b) 400J (b) Punch size controls both hole size and blank size
( ) 600 J
(c) (d) 800 J (c) Die size controls both hole size and blank size
(a) 35+0.00 and 35+0.040 (b) 35‐0.040 and 35‐0.080
(d) Die size controls hole size,
size punch size controls blank
(c) 35‐0.080 and 35+0.00 (d) 35+0.040 and 35‐0.080 size
415 416 417
IAS – 2007 IAS – 1995 IES – 2002, GATE(PI)‐2003

For
F punchinghi operation
i the
h clearance
l is
i provided
id d Assertion
A i (A):
(A) A flywheel
fl h l isi attached
h d to a punching
hi Which
Whi h one is i not a method h d off reducing
d i cutting
i
on which one of the following? press so as to reduce its speed fluctuations. forces to prevent the overloading of press?
(a) The punch Reason(R): The flywheel stores energy when its (a) Providing shear on die
(b) The die speed
p increase. (b) Providing shear on punch
(c) 50% on the punch and 50% on the die (a) Both A and R are individually true and R is the (c) Increasing die clearance
correct explanation
e planation of A
(d) 1/3rd on the punch and 2/3rd on the die (d) Stepping punches
418 419 420
IAS – 2003 IES – 2000 IES – 1999

Match List I (Press‐part)
(Press part) with List II (Function) and select the Best
B position
ii off crank
k for
f blanking
bl ki operation
i in
i a Assertion
A i (A):
(A) In
I sheet
h metall blanking
bl ki operation,
i
correct answer using the codes given below the lists:
List‐I List‐II mechanical press is clearance must be given to the die.
(Press‐part) (Function) (a) Top dead centre Reason (R): The blank should be of required
(A) Punch plate 1. Assisting withdrawal of the punch
(B) Stripper
S i 2. Ad
Advancing
i theh work‐piece
k i through
h h correct (b) 20 degrees below top dead centre dimensions.
dimensions
distance (a) Both A and R are individually true and R is the
(c) 20 degrees before bottom dead centre
(C) Stopper 3
3. Ejection of the work‐piece
work piece from die cavity
(d) Bottom dead centre correct explanation
l off A
(D) Knockout 4. Holding the small punch in the proper
position (b) Both
d v dua y ttrue
ue but R iss not
ot tthee
Codes: A B C D A B C D
(a) 4 3 2 1 (b) 2 1 4 3
( ) 4
(c) 1 2 3 (d) 2 3 4 1 ( ) A is
(c) i true
t b t R is
but i false
f l
421 422 423
Drawing
y Drawing is a plastic deformation process in which a flat
sheet
h or plate
l is formed
f d into a three‐dimensional
h d l part
with a depth more than several times the thickness of
the metal.
y As a p
punch descends into a mating
g die,, the metal
Drawing assumes the desired configuration.
424 425 426
Drawing Blank Size

Blank Size IES – 1994
y Hot drawing is used for thick‐walled parts of simple D = d + 4dh 2 When d > 20r For obtaining a cup of diameter 25 mm and height 15
geometries, thinning
h takes
k place.
l mm by
b drawing,
d the
h size off the
h round
d blank
bl k should
h ld
D = d 2 + 4dh − 0.5r when15r ≤ d ≤ 20r
y Cold
C ld drawing
d i uses relatively
l i l thin
hi metal,
l changes
h the
h be approximately
( d − 2r ) + 4d ( h − r ) + 2π r ( d − 0.7 r )
2
D= when d < 10r
thickness very little or not at all,
all and produces parts in a (a) 42 mm (b) 44 mm
wide varietyy of shapes.
p (c) 46 mm (d) 48 mm
427 428 429
GATE‐2003 GATE‐2017
A shell of 100 mm diameter and 100 mm height with
ISRO‐2011
A 10 mm deep cylindrical cup with diameter of 15
the
h corner radius
d off 0.4 mm is to be
b produced
d d by
b The initial blank diameter required to form
mm is drawn from a circular blank. Neglecting a cylindrical cup of outside diameter 'd‘ and
cup drawing.
drawing The required blank diameter is totall height
h h 'h' having
h a corner radius
d ' ' is
'r'
the variation in the sheet thickness, the diameter
(a) 118 mm (b) 161 mm obtained using the formula
(up to 2 decimal points accuracy) of the blank is
(c) 224 mm (d) 312 mm (a ) Do = d 2 + 4dh − 0.5r
______ mm. (b) Do = d + 2h + 2r
(c) Do = d 2 + 2h 2 + 2r
430 431 (d ) Do = d 2 + 4dh − 0.5r 432
y Drawing Force IAS – 2013 Main
⎡D ⎤ A cup, of 50 mm diameter and 100 mm height, is to be
P = π dtσ ⎢ − C ⎥
⎣d ⎦ d
drawn f
from l
low carbon
b steell sheet.
h Neglecting
l the
h
y Blank Holding Force
influence of thickness and corner radii:
Blank holding force required depends on the
wrinkling
i kli t d
tendency off the
th cup. The
Th maximum
i (i) Calculate the blank diameter
limit is g
generallyy to be one‐third of the drawing
g (ii) Decide whether it can be drawn in a single draw,
draw if
force.
maximum reduction p
permitted is 4
40%.
y Draw
D Cl
Clearance
Punch diameter = Die opening diameter – 2.5 25t [10 marks]
433 434 435
IFS‐2013 Deep drawing
d IES – 2008
y Drawing when cup height is more than half the diameter is A cylindrical
li d i l vessell with
i h flat
fl bottom
b can be
b deep
d
A symmetrical cup of circular cross section with
termed deep
p drawing.
g drawn by
d
diameter 40 mm and
d height
h h 60 mm with
h a corner (a) Shallow drawing
y Easy with ductile materials.
radius of 2 mm is to be obtained in C20 steel of 0.6
06 (b) Single action deep drawing
y Due to the radial flow of material, the side walls increase in (c) Double action deep drawing
mm thickness. Calculate the blank size for the
thickness as the height is increased. (d) Triple action deep drawing
drawn cup. Will it be possible to draw the cup in
y A cylindrical vessel with flat bottom can be deep drawn by
single step?
double action deep drawing.
drawing
[10 Marks]
y Deep drawing ‐ is a combination of drawing and stretching.
436 437 438
Deep Drawability
bl Limiting Drawing Ratio (LDR)
Stresses on Deep Drawing
Stresses on Deep Drawing y The ratio of the maximum blank diameter to the y The average reduction in deep drawing
y In flange of blank: d
= 0.5
05
d
diameter off the
h cup drawn
d . i.e. D/d.
d
Bi‐axial tension and D
compression y There
Th i a limiting
is li i i drawing
d i ratio
i (LDR),
(LDR) after
f which
hi h the
h ⎛ d ⎞
Reduction = ⎜ 1 − ⎟ × 100% = 50%
⎝ D ⎠
punch will pierce a hole in the blank instead of drawing.
drawing Th b rule:
Thumb l
y In wall of the cup:
First draw:Reduction = 50 %
simple uni‐axial
uni axial y This ratio depends upon material,
material amount of friction
tension Second draw:Reduction = 30 %
present, etc.
p Third draw:Reduction = 25 %
y Limiting drawing ratio (LDR) is 1.6 to 2.3 Fourth draw:Reduction = 16 %
Fifth draw:Reduction = 13 %
439 440 441
For IES Only
IES – 1997 IES – 1998 Die Design

Assertion
A i (A):
(A) The
Th first
fi draw
d in
i deep
d drawing
d i operationi
A cup of 10 cm height and 5 cm diameter is to be y Progressive dies
can have up to 60% reduction, the second draw up to
made
d from
f a sheet
h metall off 2 mm thickness.
h k The
h 40%% reduction
d and,
d theh third
h d draw
d off about
b 30%
% only.
l
y Compound dies
Reason ((R): ) Due to strain hardening, g, the subsequent
q
number of deductions necessary will be
draws in a deep drawing operation have reduced
p
percentages.
g y Combination dies
(a) One
(b) Two explanation of A
(c) Three correct explanation
l i off A
((d)) Four (c) A is true but R is false
442 443 444
For IES Only For IES Only For IES Only
Progressive dies Progressive piercing and blanking die for Method for making a simple washer in a compound piercing and

Perform two or more operations simultaneously in a single blanking die. Part is blanked (a) and subsequently pierced
stroke
k off a punchh press, so that
h a complete
l component is making a simple washer.
making a simple washer (b) The blanking punch contains the die for piercing.
obtained for each stroke.
Compound dies
All the necessary operations are carried out at a single
station, in a single stroke of the ram. To do more than one set
of operations, a compound die consists of the necessary sets
off punches
h and d dies.
di
Combination
C bi i dies
di
A combination die is same as that of a compound die with
th main
the i difference
diff th t here
that h non‐cutting
tti operations
ti such
h as
bending and forming are also included as part of the
operation.
operation
445 Back
446 Back
447
For IES Only
IAS‐1996 Lubrication
b IAS – 2007
Compound die performs In
I drawing
d i operation,
i proper lubrication
l b i i is
i
y In drawing operation, proper lubrication is essential for
essential for which of the following reasons?
(a) Two or more operations at one station in one stroke 1. To improve die life. 1. To improve die life
(b) Two or more operations at different stations in one 2 To reduce drawing forces
2.
2. To reduce drawing forces. 3. To reduce temperature
stroke
t k
3. To reduce temperature. 4. To improve surface finish
(c) high frequency sound wave S l t the
i the
th code
d given
i b l
below:
4. To improve surface finish. (a) 1 and 2 onlyy (b) 1, 3 and 4 onlyy
(d) High frequency eddy current
(c) 3 and 4 only (d) 1, 2, 3 and 4
448 449 450

Defects in Drawing ‐
f wrinkle
kl Defects in Drawing ‐
f Fracture Defects in Drawing ‐earing
f
y An
A insufficient
i ffi i blank
bl k holder
h ld pressure causes wrinkles
i kl to y Further,
F h too much
h off a blank
bl k holder
h ld pressure and
d friction
fi i y While
Whil drawing
d i a rolled
ll d stock,
k ears or lobes
l b tend
d to occur
develop on the flange, which may also extend to the wall may cause a thinning of the walls and a fracture at the because of the anisotropy induced by the rolling
of the cup. flange, bottom, and the corners (if any). operation.
Flange Wrinkle Wall Wrinkle 451 452 453
IES‐1999 Defects in Drawing –
f miss strike
k Defects in Drawing –
f Orange peel l
y Due
D to the
h misplacement
i l off the
h stock,
k unsymmetrical
i l y A surface
f roughening
h i (defect)
(d f ) encountered
d in
i forming
f i
flanges may result. This defect is known as miss strike. products from metal stock that has a coarse grain size.
E i in a drawn cup can be due non‐uniform
Earing i d b d if
y It is due to uneven flow or to the appearance of the
1. Speed of the press
p p overly large grains usually the result of annealing at too
2. Clearance between tools high a temperature.
3. Material properties
M i l i
4. Blank holding
4 g
( ) 1, 2 and 3
(a) d (b) d
(b) 2, 3 and 4
((c) 1, 3 and 4
) ,3 4 ((d) 1, 2 and 4
) , 4
454 455 456
St t h t i (lik L d Lines)
Stretcher strains (like Luders Li ) GATE‐2008
y Caused
C d by
b plastic
l ti deformation
d f ti due
d to
t inhomogeneous
i h Surface scratches
Surface scratches In
I the
h deep
d drawing
d i off cups, blanks
bl k show
h a tendency
d to
wrinkle up around the periphery (flange).
yielding. y Die or punch not having a smooth surface, insufficient
lubrication The most likely cause and remedy of the phenomenon are,
y These lines can criss‐cross the surface of the workpiece
p and respectively,
p y,
may be visibly objectionable. (A) Buckling due to circumferential compression; Increase
blank holder pressure
y Low carbon steel and aluminium shows more stretcher (B) High blank holder pressure and high friction; Reduce
strains. bl k holder
blank h ld pressure and d apply
l lubricant
l bi t
(C) High temperature causing increase in circumferential
length: Apply coolant to blank
((D)) Buckling g due to circumferential compression;
p ; decrease
blank holder pressure
457 458 459
IAS – 1997 GATE‐1999 GATE‐2006
Which
f ll i factor
f promotes the
h Identify
Id if the
h stress ‐ state ini the
h FLANCE portion i off a Match
M h the h items
i in
i columns
l I and
d II.
II
tendency for wrinking in the process of drawing? PARTIALLYDRAWN CYLINDRICAL CUP when deep ‐ Column I Column II
(a) Increase in the ratio of thickness to blank diameter drawing without a blank holder P. Wrinkling 1. Yield point elongation
of work material (a) Tensile in all three directions Q Orange peel
Q. 2
2. Anisotropy
(b) Decrease in the ratio thickness to blank diameter of (b) No stress in the flange at all, because there is no R. Stretcher strains 3. Large grain size
workk materiall bl k h ld
blank‐holder S. Earing 4. Insufficient blank holding
(c) Decrease
ec ease in tthee holding
o d g force
o ce o
on tthee b
blank
a (c) Tensile
e s e st
stress
ess in oonee d
direction
ect o aand
d co
compressive
p ess ve in force
(d) Use of solid lubricants the one other direction 5. Fine grain size
(d) Compressive
C i in i two
t di ti
directions and
d tensile
t il ini the
th 6
6. Excessive blank holding force
third direction (a) P – 6, Q – 3, R – 1, S – 2 (b) P – 4, Q – 5, R – 6, S – 1
(c) P – 2, Q – 5, R – 3, S – 4 (d) P – 4, Q – 3, R – 1, S – 2
460 461 462
IES – 1999 IAS – 1994 Spinning

Consider
C id the
h following
f ll i statements: Earring
E i in
i a Consider
f ll i factors
f
drawn cup can be due to non‐uniform 1. Clearance between the p punch and the die is too
1. Speed of the press small.
2 Clearance between tools
2. 2 The finish at the corners of the punch is poor.
2. poor
3. Material properties 3. The finish at the corners of the die is poor.
4. Blank holding 4. The punch and die alignment is not proper.
Whi h off these
Which th statements
t t t are correct?
t? Th factors
The f t responsible
ibl for
f the
th vertical
ti l lines
li parallel
ll l tot
(a) 1, 2 and 3 (b) 2, 3 and 4 the axis noticed on the outside of a drawn cylindrical cup
(c) 1, 3 and 4 (d) 1, 2 and 4 wouldld include.
l d
(a) 2, 3 and 4 (b) 1 and 2
463 (c) 2 and 4 (d) 1, 3 and 4 464 465
Spinning Spinning
1. A mandrel
d l (or( die
di for
f internal
i l pieces)
i ) is
i placed
l d on a
rotating axis (like a turning center).
y Spinning
S i i i a cold‐forming
is ld f i operation
ti i which
in hi h a
2. A blank or tube is held to the face of the mandrel.
rotating disk of sheet metal is shaped over a male 3 A roller is pushed against the material near the
3.
form, or mandrel. center of rotation, and slowly moved outwards, pushing
the
h blank
bl k against the h mandrel.
d l
y Localized pressure is applied through a simple 4. Thee pa
partt co
conforms
o s to tthee sshape
ape oof tthee mandrel
a d e ((with
t
round‐ended wooden or metal tool or small roller, some springback).
5. The
Th process is i stopped,
t d and d the
th partt is i removed d andd
which traverses the entire surface of the part
trimmed.
466 467 468

GATE‐1992 IES – 1994
The thickness of the blank needed to produce, by The mode of deformation of the metal during
power spinning a missile cone of thickness 1.5 mm
l f h k spinning is
tc = tb sinα and half cone angle 30°, is
and half cone angle 30 is ( ) Bending
(a) B di
(a) 3.0 mm
3 0 mm (b) 2 5 mm
2.5 mm (b) Stretching
St t hi
(c) 2.0 mm
2 0 mm (d) 1 5 mm
1.5 mm (c) Rolling and stretching
(d) Bending and stretching.

stretching
469 470 471
Underwater
HERF explosions.
y High Energy Rate Forming, also known as HERF or explosive

f
forming
i can be
b utilised
tili d to
t form
f a wide
id variety
i t off metals,
t l from
f Electro‐magnetic
Electro magnetic
(the use of Underwater spark
g gy g( )
High Energy Rate Forming(HERF) aluminum to high strength alloys. rapidly formed discharge (electro‐
discharge (electro
magnetic fields). HERF hydraulic).
y Applied a large amount of energy in a very sort time interval.
y HERF makes it possible to form large work pieces and

difficult‐to‐form metals with less‐expensive equipment and
Internal
tooling required. Pneumatic‐
P i
combustion of
mechanical
gaseous
g
y No
N springback
i b k means
mixtures.
472 473 474
U d
Underwater Explosions
E l i U d
Underwater explosions
l i Electro‐hydraulic Forming
l h d l
y A shock wave in the fluid medium (normally water ) is y An operation using electric discharge in the form of
sparks to generate a shock wave in a fluid is called
generated
d by
b detonating
d an explosive
l charge.
h
electrohydrulic forming.
y TNT and
d dynamite
d i for
f higher
hi h energy and
d gun powder
d for
f
y A capacitor bank is charged through the charging circuit,
lower energy is used.
used subsequently,
b tl a switch
it h is
i closed,
l d resulting
lti i a spark
in k
y Used for parts of thick materials.
materials within the electrode g
gap
p to discharge
g the capacitors.
p
y Employed in Aerospace, aircraft industries and y Energy level and peak pressure is lower than underwater
explosions but easier and safer.
automobile related components.
y Used for bulging operations in small parts.
475 476 477
Electromagnetic or Magnetic Pulse Forming
y Based
B d on the
h principle
i i l that
h the
h electromagnetic
l i field
fi ld off
an induced current always opposes the electromagnetic
field of the inducing current.
y A large capacitor bank is discharged, producing a current

surge through
h h a coiled
l d conductor.
d
y If the coil has been placed within a conductive cylinder,

around d a cylinder,
li d or adjacent
dj t the
th flat
fl t sheet
h t off metal,
t l the
th
discharge induces a secondary current in the workpiece,
causing it to be repelled from the coil and conformed to
478
a die or mating workpiece. 479 480
For IES Only
Electromagnetic or Magnetic Pulse Forming Petro ‐ Forging or Petro ‐ Forge Forming

y The
Th process is
i very rapid
id and
d is
i used
d primarily
i il to expand
d y In
I this
hi process, the
h stored
d chemical
h i l energy off a hydrocarbon,
h d b
or contract tubing, or to permanently assemble like petrol or diesel is utilized to move the dies at very high
component parts. velocity.
l The
h principlel off working
k off a Petro‐forge
f h
hammer is
just similar to I.C. engine.
y This process is most effective for relatively thin materials
y It is a piston‐cylinder arrangement and a piston drives a ram
(0.25 to 1.25 mm thick).
(piston rod)) and a die.
(p
y The workpiece must be electrically conductive but need y After air‐fuel mixture is ignited in the combustion chamber
not be magnetic.
magnetic pressure increases by 5 to 7 times which breaks the seal and
y Short life of the coil is the major problem. the high pressure gases act on the top face of the piston.
y The
Th piston,
i ram and d die
di are accelerated
l d at a very rapid
id rate
and strike upto 250 m/s.
481 482 483
IES 2016
Consider the following in case of high energy forming
IES 2011 JWM 2010
p
processes:
Assertion (A) : In magnetic pulse‐forming
pulse forming method,
method
1. The evacuation between die and blank in explosive High energy rate forming process used for magnetic field produced by eddy currents is used to
forming forming is done by a vacuum pump.
pump create force
f b
between coil
il and
d workpiece.
k i
forming components from thin metal sheets or
2. The pressure waves produced in water in explosive
Reason ((R)) : It is necessary y for the workpiece
p
f
forming d f
deform the
h blank
bl k to the
h die
d shape.
h d f
deform thin
hi tubes
b is:
i
material to have magnetic properties.
33. The electrohydraulic
y formingg makes use of discharge g of
large amount of electrical energy used in a capacitor bank.
( ) Petro‐forming
(a) P t f i ( ) Both
(a) B th A and d R are individually
i di id ll true
t and
d R is
i the
th
4
4. In Petroforge,
Petroforge the piston is moved by combustion of fuel (b) Magnetic pulse forming
moving at the rate of 150 – 200 m/s. (b) Both A and R are individually true but R is NOT the
Whi h off the
Which th above
b are correct?
t? (c) Explosive forming correct explanation of A
(a) 1, 2, 3 and 4 (b) 1, 2 and 3 only (c) A is true but R is false
(d) electro
electro‐hydraulic
hydraulic forming
(c) 3 and 4 only (d) 1, 2 and 4 only (d) A is false but R is true
484 485 486
IES 2010 IES – 2007 IES – 2009
Assertion (A) : In the high energy rate forming
method, the explosive forming has proved to be an
Which one of the following metal forming Which one of the following is a high energy rate
excellent
ll method
h d off utilizing
ili i energy at high
hi h rate and d processes is not a high
h h energy rate forming
f process? forming process?
utilizes both the high explosives and low explosives.
Reason (R): The gas pressure and rate of detonation ( ) Electro‐mechanical
(a) El h i l forming
f i ( ) Roll
(a) R ll forming
f i
can be controlled for both types yp of explosives.
p
(b) Roll‐forming
R ll f i (b) Electro‐hydraulic
El t h d li forming
f i
explanation of A (c) Explosive forming (c) Rotary forging
(b) Both A and R are individually true but R is NOT the
(d) Electro‐hydraulic
Electro hydraulic forming (d) Forward extrusion
IES – 2005 Stretch Forming

h Stretch Forming
h Contd......
y Produce
P d large
l sheet
h t metal
t l parts
t in
i low
l or limited
li it d
Magnetic forming is an example of: y Popular in the aircraft industry and is frequently used to
quantities.
(a) Cold forming (b) Hot forming y A sheet of metal is gripped by two or more sets of jaws f
form aluminum
l and
d stainless
l steell
that stretch it and wrap it around a single form block.
(c) High energy rate forming (d) Roll forming y Because most of the deformation is induced by the y Low‐carbon
L b steell can be
b stretch
h formed
f d to produce
d l
large
g, the forces on the form block are far
tensile stretching, panels for the automotive and truck industry.
industry
less than those normally encountered in bending or
o
forming.g.
y There is very little springback, and the workpiece
conforms very closely to the shape of the tool.
tool
y Because the forces are so low, the form blocks can often
b made
be d off wood, d low‐melting‐point
l lti i t metal,
t l or even
490 plastic. 491 492
Stretch Forming
h Contd...... Stretch Forming
h Contd...... GATE‐2000
A 1.5 mm thick
hi k sheet
h is
i subject
bj to unequall biaxial
bi i l
stretching and the true strains in the directions of
stretching are 0.05 and 0.09. The final thickness of
the sheet in mm is
(a) 1.414 (b) 1.304
( ) 1.362
(c) (d) 289
493 494 495

For IES Only
Ironing Ironing Contd.... Ironing Force

y The process of thinning the walls of a drawn cylinder by y Neglecting
N l i the h friction
f i i andd shape
h off the
h die,
di the
h ironing
i i
force can be estimated using the following equation.
passing it between
b a punch
h and
d die
d whose
h separation is
less than the original wall thickness.
thickness
⎛t ⎞
y The walls are thinned and lengthened,
lengthened while the
F = π dt ttσ av ln
l ⎜ o⎟
thickness of the base remains unchanged.
g
⎝ tt ⎠
y Examples
p of ironed p
products include brass cartridge
g
cases and the thin‐walled beverage can.
496 497 498
Embossing
b Coining Bending
y After basic shearing operation, we can bend a part to give it some
shape.
h
y It is a very shallow drawing operation where the depth of y Coining is essentially a cold‐forging operation except for
y Bending parts depends upon material properties at the location of
the
h draw
d is limited
l d to one to three
h times the
h thickness
h k off the
h fact
f that
h the
h flow
fl off the
h metall occurs only
l at the
h top the bend.
h b d
y At bend, bi‐axial compression and bi‐axial tension is there.
the metal,
metal and the material thickness remains largely layers and not the entire volume.
volume
unchanged. y Coining is used for making coins,
coins medals and similar
articles.
499 500 501
For IES Only
Bending Bending Bending Force

Bending Force
Klσ ut t 2
Bend allowance, y The strain on the outermost fibers of the bend is
F=
Lb = α(R+kt)
α(R+kt)
ε=
1 w
Where l =Bend length = width of the stock, mm
where 2R
+1
+ 1 σ ut = Ultimate
Ulti t tensile
t il strength,
t th MPa
MP (N/mm
(N/ 2
)
R = bend radius t t = blank thickness, mm
k
k = constant (stretch factor)
( h f ) w = width
idth off die-opening,
di i mm
For R > 2t k = 0.5 K = die-opening factor , (can be used followin table)
For R < 2t k = 0.33 Condition V-Bending U-Bending Edge-Bending

W < 16t 1.33 2.67 0.67
t = thickness of material
hi k f i l W > = 16t 1.20 2.40 0.6
α = bend angle (
g (in radian) For U or channel bending force required is double than V bending
For U or channel bending force required is double than V –
For edge bending it will be about one‐half that for V ‐ bending
502 503 504
IES 1998
IES‐1998 Example
l GATE‐2005
The bending force required for V‐bending, U‐ y Calculate the bending force for a 45o bend in aluminium A 2 mm thick
hi k metall sheet
h is
i to be
b bent
b at an angle
l off
blank. Blank thickness, 1.6 mm, bend length = 1200 mm, one radian with a bend radius of 100 mm. If the
b di and
bending d Edge
Ed bending
b di will
ill be
b in
i the
th ratio
ti Di opening
Die i = 8t, UTS = 455 MPa,
MP DieDi opening
i factor
f = stretch factor is 0.5, the bend allowance is
of 1.33 (a) 99 mm (b) 100 mm
(c) 101 mm (d) 102 mm
(a) 1 : 2 : 0.5 (b) 2: 1 : 0.5
2mm
((c)) 1: 2 : 1 ((d)) 1: 1 : 1
1 radian
505 506 507
For IES Only
Spanking
k GATE‐2007
Match
M t h the
th correctt combination
bi ti for
f following
f ll i metal
t l
y During bending, the area of the sheet under the punch
working processes.
h a tendency
has d to flow
fl and
d form
f a bulge
b l on the
h outer Processes Associated state of stress
surface.
surface P. Blankingg 1. Tension
Q. Stretch Forming 2. Compression
y The lower die should be provided with mating surfaces,
surfaces R Coining
R. 3
3. Shear
so that when the p
punch and die are completely
p y closed on S. Deep Drawing 4. Tension and Compression
5. Tension and Shear
the blank, any bulging developed earlier will be
Codes:P Q R S P Q R S
completely presses or “spanked” out. (a) 2 1 3 4 (b) 3 4 1 5
( ) 5
(c) 4 3 1 (d) 3 1 2 4
508 509 510
GATE ‐2012 Same Q in GATE‐2012 (PI) GATE‐2004 IAS – 1999

Match the following metal forming processes with their Match
M h the h following
f ll i Match
M t h List
Li t I (Process)
(P ) with
ith List
Li t II (Production
(P d ti off parts)
t )
and select the correct answer using the codes given
associated stresses in the workpiece.
p Product Process below the lists:
Metal forming process Type of stress P. Moulded luggage 1. Injection moulding List‐I List‐II
1. Coining P. Tensile Q Packaging
Q. P k i containers i f liquid
for li id 2. H rolling
Hot lli A Rolling
A. R lli 1. Di
Discrete parts
2 Wire Drawing
2. Wire Drawing Q Shear
Q. Shear R. Longg structural shapes
p 33. Impact
p extrusion B. Forging 2. Rod and Wire
C. Extrusion 3. Wide variety of shapes with thin
3. Blanking R. Tensile and S. Collapsible tubes 4. Transfer moulding
walls
compressivei 5. Blow
l moulding
ld D. Drawing 4. Flat plates and sheets
4
4. Deep Drawing
p g S. Compressive
p 6. Coining 5
5. Solid and hollow parts
(a) 1‐S, 2‐P, 3‐Q, 4‐R (b) 1‐S, 2‐P, 3‐R, 4‐Q (a) P‐1 Q‐4 R‐6 S‐3 (b) P‐4 Q‐5 R‐2 S‐3 Codes:A B C D A B C D
( ) 1‐P, 2‐Q, 3‐S, 4‐R
(c) (d) 1‐P, 2‐R, 3‐Q, 4‐S ( ) P‐1 Q‐5 R‐3 S‐2
(c) ( ) P‐5 Q‐1 R‐2 S‐2
(d) (a) 2 5 3 4 (b) 1 2 5 4
511 512 (c) 4 1 3 2 (d) 4 1 5 2513
IAS – 1997 IES 2010
Match
M h List‐I
Li I (metal
( l forming
f i process)) with
i h List‐II
Li II Consider the following
follo ing statements:
statements
(Associated feature) and select the correct answer The material p properties
p which p principally
p y
using the codes given below the Lists: determine how well a metal may be drawn are
List‐ll
List
A. Blanking
List‐ II
List
1. Shear angle
1. Ratio
R ti off yield
i ld stress
t t ultimate
to lti t stress.
t Powder Metallurgy
2.Rate of increase of yyield stress relative to
B. Flow forming 2. Coiled stock progressive amounts of cold work.
C Roll forming
C. 3
3. Mandrel 3. Rate
R off workk hardening.
h d i
D. Embossing 4. Closed matching dies
Which of the above statements is/are correct?
(a) 1 and 2 only (b) 2 and 3 only
(a) 1 3 4 2 (b) 3 1 4 2
(c) 1 only (d) 1, 2 and 3
(c) 1 3 2 4 (d) 3 1 2 4514 515 By S K Mondal 516
Manufacturing of Powder
Atomization using a gas stream IAS – 2003
Powder Metallurgy
Powder Metallurgy Assertion
A i (A):
(A) Atomization
A i i method
h d for
f production
d i off
Molten metal is metal powders consists of mechanical disintegration of
y Powder metallurgy is the name given to the f
forcedd through
th h a molten
l stream into fine
f particles.
l
small orifice and
process byy which fine p
p powdered materials are Reason ((R): ) Atomization method is an excellent means
is disintegrated by
a jet of
of making powders from high temperature metals.
blended, pressed into a desired shape
compressed air, air (a) Both A and R are individually true and R is the correct
(compacted), and then heated (sintered) in a inert gas or water explanation of A
jet It is used for
jet,. (b) Both
B th A and d R are individually
i di id ll true
t b t R is
but i nott the
th
controlled
ll d atmosphere
h to bond
b d the
h contacting
low melting point correct explanation of A
surfaces of the particles and establish the desired materials brass,
materials, brass
bronze, Zn, Tn, (c) A is true but R is false
p p
properties. Al, Pb etc. ((d)) A is false but R is true
517 518 519
IES‐2016
IAS – 2007 Statement (I) : Metal powders can be produced by IES – 1999
Assertion
A ti (A):
(A) Mechanical
M h i l disintegration
di i t ti off a atomization process.
process Assertion
A i (A):
(A) In
I atomization
i i process off manufacture
f off
molten metal stream into fine particles by means of Statement (II) : In case of metals with low melting metal powder, the molten metal is forced through a
a jet
j t off compressed d air
i is
i known
k as atomization.
t i ti point, the size of particles cannot be controlled and smallll orifice
f andd broken
b k up by b a stream off compressedd
Reason (R): In atomization process inert‐gas or the shapep of the p particles remains regular
g in air.
water cannot be used as a substitute for compressed atomization. Reason (R): The metallic powder obtained by
air. atomization p process is q
quite resistant to oxidation.
(a) Both A and R are individually true and R is the (a) Both A and R are individually true and R is the correct
Statement (II) is the correct explanation of Statement (I).
correct
co ect eexplanation
p a at o oof A explanation of A
(b) Both A and R are individually true but R is not the (b) Both A and R are individually true but R is not the
correct explanation of A Statement ((II)) is not the correct explanation
)
correct explanation
l i off A
(c) A is true but R is false (c) Statement (I) is true but Statement (II) is false.
(d) (d) Statement (I) is false but Statement (II) is true (d) A is false but R is true
520 521 522
GATE 2017(PI)
GATE‐2017(PI) Manufacturing of Powder
Reduction
In powder
d metallurgy,
ll the
h process 'atomization'
' ' GATE ‐2011 (PI)
GATE ‐2011 (PI)
y Metal oxides are turned to pure metal powder when
refers
f to a method
h d off Whi h off
Which th
the f ll i
following powder
d production
d ti
exposed to below melting point gases results in a
methods produces spongy and porous particles?
(a) Producing powders product of cake of sponge metal.
(a) Atomization
(b) compaction of powders y The
h irregular
i l sponge‐like
lik particles
i l are soft,
f readily
dil
compressible and give compacts of good pre‐sinter
compressible, ((b)) Reduction of metal oxides
(c) sintering of powder compacts
(“green”)
g strength
g ((c)) Electrolytic
y deposition
p
(d) blending of metal powders y Used for iron, Cu, tungsten, molybdenum, Ni and (d) Pulverization
523
Cobalt. 524 525
Only for IES
Manufacturing of Powder Manufacturing of Powder
Manufacturing of Powder Manufacturing of Powder
Electrolytic Deposition
Comminution
C i i y Used for iron, copper, silver
Grinding
g
y Granular
G l material,
t i l which
hi h may be
b coarsely
l atomized
t i d y Process is similar to electroplating.
electroplating
This metallic powder is nothing but the unburnt tiny p
powder,, is fed in a stream of ggas under p
pressure through
g y For making copper powder, copper plates are placed as
chips formed during the process of grinding. a venturi and is cooled and thereby embrittled by the anode in the tank of electrolyte, whereas the aluminium
adiabatic
di b i expansion i off the
h gas before
b f i i i
impinging on a plates
l t are placed
l d in i the
th electrolyte
l t l t to t actt as cathode.
th d
g on which the g
target granules shatters When DC current is p passed, the copper
pp ggets deposited
p
y Process is used for production of very fine powders such on cathode. The cathode plated are taken out and
as are required for injection moulding . Brittle materials powder
d is
i scrappedd off.
ff The
Th powderd isi washed,
h d dried
d i d and d
such as inter
inter‐metallic
metallic compounds,
compounds ferro
ferro‐alloys
alloys ‐ ferro
ferro‐ pulverized to the desired g
p grain size.
526 chromium, ferro‐silicon are produces 527
y The cost of manufacturing is high. 528
IES ‐ 2012 Manufacturing of Powder GATE‐2014 (PI)

In
I electrolysis
l l i Granulations ‐ as metals are cooled they are stirred rapidly Which
f ll i methods
h d is
i NOT used
d
((a)) For making g copper
pp p powder,, copper
pp p plate is made for producing metal powders?
Machining ‐ coarse powders such as magnesium
cathode in electrolyte tank (a) Atomization
Milling
g ‐ crushers and rollers to break down metals. Used for
(b) For making aluminum powder,
powder aluminum plate is (b) Compaction
made anode brittle materials.
(c) Machining and grinding
(c) High amperage produces powdery deposit of cathode Shooting ‐ drops of molten metal are dropped in water, used (d) Electrolysis
metal
eta oon aanode
ode for low melting point materials.
materials
(d) Atomization process is more suitable for low melting Condensation – Metals are boiled to produce metal vapours
point
i t metals
t l
and then condensed to obtain metal powders. Used for Zn,
Mg Cd.
Mg, Cd
529 530 531
IAS – 2000 IES 2010
Consider
C id theh following
f ll i processes: Metallic
M t lli powders d can be
b produced
d d by
b Characteristics
Ch i i off metall powder: d
1. Mechanical pulverization
p (a) Atomization y Fineness: refers to p particle size of p powder,, can be
2. Atomization determined either by pouring the powder through a sieve or
(b) Pulverization
3. Chemical
Ch i l reduction
d i by microscopic testing.
testing A standard sieves with mesh size
(c) Electro‐deposition process varies between (100) and (325) are used to determine
4. Sintering
4 g
(d) All off the
h above
b particle
ti l size
i and d particle
ti l size
i distribution
di t ib ti off powder
d ini a
Which of these processes are used for powder certain range.
preparation
ti in
i powder
d metallurgy?
t ll ?
y Particle size distribution: refers to amount of each particle
(a) 2, 3 and 4 (b) 1, 2 and 3 size in the powder and have a great effect in determining
(c) 1, 3 and 4 (d) 1, 2 and 4 flowability, apparent density and final porosity of product.
532 533 534
Conventional Questions IES – 1999

y Discuss
Di the
h terms fineness
fi and d particle
i l size
i The
Th correct sequence off the h given
i processes in
i
distribution in powder metallurgy. [IES‐2010, 2 Marks] manufacturing by powder metallurgy is
Ans. (a) Blending, compacting, sintering and sizing
Fineness: Is the diameter of spherical shaped particle and (b) Blending,
Blending compacting,
compacting sizing and sintering
mean diameter of non‐spherical shaped particle.
(c) Compacting, sizing, blending and sintering
Particle size distribution: Geometric standard deviation (d) Compacting, blending, sizing and sintering
((a measure for the bredth or width of a distribution),), is the
ratio of particle size diameters taken at 84.1 and 50% of the
cumulative undersized weight plot, respectively and mean
mass diameter define the particle size distribution.
535 536 537
Blending
l d Compacting
y Blending
Bl di or mixing
i i operations
ti can be
b done
d either
ith dry
d or wet.
t
y Powder is pressed into a “green compact”
y Lubricants such as graphite or stearic acid improve the flow
characteristics and compressibility at the expense of reduced y 40 to 1650 MPa pressure (Depends on materials,
strength. product complexity)

y Binders produce the reverse effect of lubricants. y Still very porous, ~70% density
Thermoplastics or a water
water‐soluble
soluble methylcellulose binder is
y May be done cold or warm (higher density)
used.
y Most lubricants or binders are not wanted in the final
product and are removed ( volatilized or burned off)
538 539 540
C ti
Compacting Sintering GATE‐2016 (PI)
y Controlled atmosphere: no oxygen In powder metallurgy, sintering of the component
y Heat to 0.75*T melt
(a) increases density and reduces ductility
y Particles bind together, diffusion, recrystalization
P ti l bi d t th diff i t li ti
(b) increases porosity and reduces density
and grain growth takes place.
g g p
y Part shrinks in size (c) increases density and reduces porosity
y Density increases, up to 95% (d) increases porosity and reduces brittleness.
y Strength increases, Brittleness reduces, Porosity
St th i B ittl d P it
decreases. Toughness increases.
g
541 542 543
IES – 2002 Cold Isostatic

ld Pressing (CIP)
( )
GATE ‐2010 (PI)
GATE ‐2010 (PI) The
Th rate off production
d i off a powder
d metallurgy
ll part y The powder is contained in a flexible mould made of
depends on
I powder
In d metallurgy,
t ll sintering
i t i off a componentt rubber
bb or some other
h elastomer
l materiall
(a) Flow rate of powder
(a) Improves strength and reduces hardness (b) Green strength of compact y The
Th flexible
fl ibl mould
ld is
i then
h pressurized
i d by
b means off
(c) Apparent density of compact
(b) Reduces brittleness and improves strength high‐pressure water or oil.
oil (same pressure in all
(d) Compressibility of powder
(c) Improves hardness and reduces toughness directions))
(d) Reduces porosity and increases brittleness y No lubricant is needed
y High and uniform density can be achieved
544 545 546
H t I t ti Pressing (HIP)
Hot Isostatic P i (HIP)
Cold Isostatic Pressingg y Is carried out at high
g temperature
p and p
pressure using
ga
gas such as argon.
y The flexible mould is made of sheet metal. (Due to high
temperature)
y Compaction
C i and
d sintering
i i are completed
l d
simultaneously.
simultaneously
yU
Used in the p
production of billets of super‐alloys,
p y , high‐
g
speed steels, titanium, ceramics, etc, where the integrity
547
of the materials is a prime consideration 548 549
IAS – 1997 S
Spray Deposition
D iti Metal Injection Moulding
Metal Injection Moulding
Assertion
A ti (A):
(A) Close
Cl dimensional
di i l tolerances
t l are y Spray
S deposition
d iti isi a shape‐generation
h ti process. y Fine metal powders are blended with an organic binder such
NOT possible with isostatic pressing of metal as a polymer or a wax‐based binder.
powder
d in i powder
d metallurgy
t ll t h i
technique. y Basic components of a spray deposition process
y The powder‐polymer mixture is then injected into split dies,
Reason (R): In the process of isostatic pressing, the (a) Atomiser preheated to remove the binder and, finally, sintered.
pressure is equal in all directions which permits (b) Spray chamber with inert atmosphere
uniform density of the metal powder. y Volumetric shrinkage during sintering is very high.
(c) Mould for producing preforms.
preforms
(a) Both A and R are individually true and R is the y Complex shapes that are impossible with conventional
correct
co ect eexplanation
p a at o oof A y After the metal is atomised,, it is deposited
p into a cooler
compaction.
ti
(b) Both A and R are individually true but R is not the preformed mould.
correct explanation of A y Good dimensional accuracy.
(c) A is true but R is false y Achieve density above 99%, fine grain structure,
y High production rate.
(d) mechanical
h i l properties
ti same as wrought
ht product
d t
550 551 y Good mechanical properties. 552
R ll C
Roll Compaction
ti l
Explosive Compaction
y Powders are compacted by passing between two rolls y High Energy Rate Forming (HERF) or Explosive Forming
rotating in opposite direction. of the metal powders at rather higher velocities 3500 m/s
y The powders are put in a container and are forced by a than
h thath off the
h usuall speedd off compaction
i during
d i the h
ram between two rotating rolls,
rolls and is compacted into a ordinary die compacting.
continuous strip at speeds of up to 0.5 m/s. y Higher green densities
y Sheet metal for electrical and electronic components and y Higher sintered strength
for coins can be made by this process.
process
y More uniform density distribution
y The rolling
g p
processes can be carried out at room or at
elevated temperature.
553 554 555
For IES Only
ISRO 2013
ISRO ‐2013 Features of PM products
f d
Liquid Phase Sintering
y During sintering a liquid phase, from the lower MP Following is a process used to form powder metal to y For
F high
hi h tolerance
l parts, a sintering
i i part is
i put back
b k into
i
component,
p , mayy exist a die and repressed. In general this makes the part more
shape
h accurate with a better surface finish.
y Alloying may take place at the particle‐particle interface
y Molten
M l component may surround d the
h particle
i l that
h hash ( ) Sintering
(a) Si i y A part has many voids that can be impregnated.
impregnated One
not melted method is to use an oil bath. Another method uses
(b) Explosive
E l i Compacting
C ti vacuum
acuum first,
first then impregnation.
impregnation
y High compact density can be quickly attained
y A part surface can be infiltrated with a low melting point
y Important variables: (c) Isostatic Molding
metal to increase density, strength, hardness, ductility
y Nature of alloy, molten component/particle wetting, and impact resistance.
(d) All of these
capillary action of the liquid
y Plating, heat treating and machining operations can also
b used.
be d
556 557 558
Production of magnets
d f Advantages
d Advantages
d Contd….
y 50:50 Fe‐Al alloys is used for magnetic parts
F Al ll i d f i y Good tolerances and surface finish
G d l d f fi i h y Physical properties can be controlled
y Al‐Ni‐Fe is used for permanent magnets
p g y Highly complex shapes made quickly
g y p p q y
y Variation from part to part is low
y Sintering is done in a wire coil to align the magnetic y Can produce porous parts and hard to manufacture
poles of the material materials (e g cemented oxides)
materials (e.g. cemented oxides) y Hard to machine metals can be used easily
H d t hi t l b d il
y H2 is used to rapidly cool the part (to maintain magnetic y Pores in the metal can be filled with other
y No molten metals
alignment) materials/metals
y Total shrinkage is approximately 3‐7% (for accurate parts y Surfaces can have high wear resistance y No need for many/any finishing operations
an extra sintering step may be added before magnetic y Porosity can be controlled y Permits high volume production of complex shapes
g p p p
alignment)
li t) y Low waste
y The sintering temperature is 600°C in H
g p y Allows non‐traditional alloy combinations
2 y Automation is easy
559 560 y Good control of final density 561
IES – 2007 Disadvantages

d
GATE –
GATE – 2009 (PI)
2009 (PI) What
Wh are the h advantages
d off powder
d metallurgy?
ll ? y Metal powders deteriorate quickly when stored
M l d d i i kl h d
1. Extreme p purityy p
product improperly
Whi h off the
Which th following
f ll i process is
i used
d to
t
2. Low labour cost y Fixed and setup costs are high
manufacture products with controlled porosity? y Part size is limited by the press, and compression of the
Part size is limited by the press and compression of the
3. Low
L equipmenti cost.
Select the correct answer using g the code g
given below powder used.
(a) Casting
y Sharp corners and varying thickness can be hard to
(a) 1, 2 and 3 (b) 1 and 2 only
((b)) welding
g p oduce
produce
( ) 2 and
(c) d 3 only
l (d) 1 and d 3 only
l
y Non‐moldable features are impossible to produce.
((c)) formation
(d) Powder metallurgy

562 563 564
IES ‐ 2012 IES – 2006 IES – 2004

Statement
St t t (I):
(I) Parts
P t made d by
b powder
d metallurgy
t ll do
d nott Which
f ll i are the
h limitations
li i i off Consider
C id theh following
f ll i factors:
f
have as good physical properties as parts casted. powder metallurgy? 1. Size and shapep that can be p
produced economicallyy
Statement (II): Particle shape in powder metallurgy 1. High tooling and equipment costs.
influences the flow characteristic of the powder. 2. Porosity of the parts produced
2 Wastage of material.
2. material 3. Available
A il bl press capacity
i
(a) Both Statement (I) and Statement (II) are
individuallyy true and Statement ((II)) is the correct 3. It cannot be automated. 4. High
4 g densityy
explanation of Statement (I) 4. Expensive metallic powders. Which of the above are limitations of powder
(b) Both Statement (I) and Statement (II) are S l t the
i the
th codes
d given
i b l
below: metallurgy?
t ll ?
individually true but Statement (II) is not the correct
explanation of Statement (I) (a) Onlyy 1 and 2 (b) Onlyy 3 and 4 (a) 1, 3 and 4 (b) 2 and 3
(c) Statement (I) is true but Statement (II) is false (c) Only 1 and 4 (d) Only 1, 2 and 4 (c) 1, 2 and 3 (d) 1 and 2
( ) Statement (I)
(d) ( ) is false but Statement (II)
( ) is true
565 566 567
A li ti
Applications IES 2010 IAS – 1998
y Oil impregnated bearings made from either iron or
Oil‐impregnated Consider
C id theth following
f ll i parts: t Throwaway
Th tungsten carbide
bid tip
i tools
l are
copper alloys for home appliance and automotive manufactured by
applications
li ti 1. Grinding wheel
(a) Forging (b) Brazing
y P/M filters can be made with p pores of almost anyy size. 2. Brake lining
(c) Powder metallurgy (d) Extrusion
y Pressure or flow regulators. 3. Self‐lubricating bearings
y Small
S ll gears, cams etc.t Whi h off these
Which h parts are made d by
b powder
d
y Products where the combined p properties
p of two or more metallurgy gy technique?
q
metals (or both metals and nonmetals) are desired.
(a) 1, 2 and 3 (b) 2 only
y Cemented carbides are produced by the cold‐
Cemented carbides are produced by the cold
compaction of tungsten carbide powder in a binder, such (c) 2 and 3 only (d) 1 and 2 only
as cobalt ( 5 to 12%), followed by liquid‐phase sintering.
b lt ( t %) f ll d b li id h i t i
568 569 570
IES – 2009 IAS – 2003

Which of the following cutting tool bits are made by
GATE –
GATE – 2011 (PI)
2011 (PI) Which
f ll i are produced
d d by
b powder
d
The binding material used in cemented carbide metallurgy process?
powder
d metallurgy
ll process? 1. Cemented carbide dies
cutting tools is
( ) Carbon
(a) C b steell tooll bits
bi (b) S lli tooll bits
Stellite bi ( ) graphite
(a) hi 2 Porous bearings
2.
((b)) tungsten
g 3. Small magnets
( ) Ceramic
(c) C i tool
t l bits
bit (d) HSS tool
t l bits
bit
(c) nickel 4. Parts with intricate shapes
(d) cobalt
b l S l t the
i the
th codes
d given
i b l
below:
Codes:
(a) 1, 2 and 3 (b) 1, 2 and 4
( ) 2, 3 and
(c) d 4 (d) 1, 3 and d4
571 572 573
IES‐2015
IES – 1997 IES – 2001 Consider the following statements regarding powder
metallurgy :
Which
f ll i components can be b Carbide‐tipped
C bid i d cutting
i tools
l are manufactured
f d by
b
1. Refractory materials made of tungsten can be
manufactured by powder metallurgy methods? powder‐ metal technology process and have a
manufactured easily.
easily
1. Carbide tool tips 2. Bearings composition of
2. In metal powder, control of grain size results in
3 Filters
3. 4
4. Brake linings (a) Zirconium
Zirconium‐Tungsten
Tungsten (35% ‐65%)
65%) relatively
l i l much h uniform
if structure
Select the correct answer using the codes given below: (b) Tungsten carbide‐Cobalt (90% ‐ 10%) 3. The powder heated in die or mould at high temperature
(a) 1, 3 and 4 (b) 2 and 3 (c) Aluminium oxide‐ Silica (70% ‐ 30%) is then pressed and compacted to get desired shape and
(d) Nickel‐Chromium‐ Tungsten (30% ‐ 15% ‐ 55%) strength.
g
( ) 1, 2 and
(c) d 4 (d) 1, 2, 3 and d4
4. In sintering the metal powder is gradually heated
resulting in coherent bond.
bond
Which of the above statements are correct?
( ) 1, 2 and
(a) d 3 only
l (b) 1, 2 andd 4 only
l
574 575 (c) 2, 3 and 4 only (d) 1, 2, 3 and 4 576
Pre ‐ Sintering IAS – 2003 Repressing
y If a part made by PM needs some machining, it will be In
I parts produced
d d by
b powder d metallurgy
ll process, y Repressing is performed to increase the density and
pre‐sintering is done to
rather
h very difficult
d ff l iff the
h materiall is very hard
h d and
d (a) Increase the toughness of the component improve the
h mechanical
h l properties.
strong These machining operations are made easier by
strong. (b) Increase the density of the component y Further
F h improvement
i i achieved
is hi d byb re‐sintering.
i i
the pre
pre‐sintering
sintering operation which is done before (c) Facilitate bonding of non‐metallic particles
(d) Facilitate machining of the part
sintering operation.
577 578 579
Infiltration
fl Impregnation Oil‐impregnated Porous Bronze Bearings
y Component is dipped into a low melting‐temperature y Impregnation
I i isi similar
i il to infiltration
i fil i
y PM component
p is kept
p in an oil bath. The oil p
penetrates
alloy
ll liquid
l d into the voids by capillary forces and remains there.
y The
Th liquid
li id would
ld flow
fl i
into the
h voids
id simply
i l byb capillary
ill y The oil is used for lubrication of the component when
necessary. During the actual service conditions, the oil is
action thereby decreasing the porosity and improving
action, released
l d slowly
l l to provide
d the
h necessary lubrication.
l b
the strength
g of the component.
p y The e co
components
po e ts ca
can abso
absorb
b bet
between
ee 12%% aand
d 30% o
oil by
volume.
y The p
process is used q
quite extensivelyy with ferrous p
parts
y It is
i being
b i used
d on P/M self‐lubricating
lf l b i ti b
bearing
i
using copper as an infiltrate but to avoid erosion, an alloy components since the late 1920's.
of copper containing iron and manganese is often used.
580 581 582
GATE 2011 IAS – 1996 IES – 1998

Which
f ll i processes is
i performed
f d In
I powderd metallurgy,
ll the
h operation
i carried
i d out to
The operation in which oil is permeated into the
in powder metallurgy to promote self‐lubricating improve the bearing property of a bush is called
pores of a powder metallurgy product is known properties in sintered parts? (a) infiltration (b) impregnation
as (a) Infiltration (b) Impregnation (c) plating (d) heat treatment
(c) Plating (d) Graphitization
( ) mixing
(a) i i
(b) sintering
(c) impregnation
(d) Infiltration
583 584 585
IES ‐ 2014 IAS – 2007 IAS – 2004
The
Th process off impregnation
i i in
i powder d metallurgy
ll Consider
C id theh following
f ll i basic
b i steps involved
i l d in
i theh The
Th following
f ll i are the
h constituent
i steps in
i the h
technique is best described by which of the following? production of porous bearings: process of powder metallurgy:
(a) After sintering operation of powder metallurgy, rapid 1. Sintering 1. Powder conditioning
cooling is performed to avoid thermal stresses. stresses 2 Mixing
2. 2 Sintering
2.
(b) Low melting point metal is filled in the pores of a 3. Repressing 3. Production of metallic powder
sintered
d powder
d metallurgyll product
d 4. Impregnation 4. Pressing or compacting into the desired shape
(c) Liquid
qu d ooil oor g
grease
ease iss filled
ed in tthee po
pores
es o
of a ssintered
te ed 5. Cold‐die‐compaction
C ld di ti I d tif the
Indentify th correctt order
d ini which
hi h they
th have
h t be
to b
powder metallurgy product performed and select the correct answer using the codes
g is the correct sequence
Which one of the following q of the
(d) During
D i sintering
i t i operation
ti off powderd metallurgy,
t ll above steps? given below:
b l
rapid heating is performed to avoid sudden produce of (a) 11‐2‐3‐4
234 (b) 33‐1‐4‐2
142
high internal pressure due to volatilization of lubricant
586 587 (c) 2‐4‐1‐3 (d) 4‐3‐2‐1 588
IES – 2001 GATE 2008 (PI)

GATE ‐2008 (PI)
Matc t e o ow g
Match the following
Match
M h List‐I
Li I (Components)
(C ) with
ih List‐II
Li II
(Manufacturing Processes) and select the correct Group – 1 Group ‐2
answer using the codes given below the lists: P. Mulling 1. Powder metallurgy
List I List II Q Impregnation
Q. Impregnation 2 Injection moulding
2. Injection
A. Car body (metal) 1. Machining R. Flash trimming 3. Processing of FRP composites
B. Clutch lining 2. Casting S. Curing 4. Sand casting
C Gears
C. 3
3. Sheet metal pressing
D. Engine block 4. Powder metallurgy (a) P – 4, Q – 3, R – 2, S – 1 (b) P – 2, Q – 4, R – 3, S ‐ 1
Codes:A B C D A B C D (c) P – 2, Q – 1, R – 4, S – 3 (d) P – 4, Q – 1, R – 2, S ‐ 3
(a) 3 4 2 1 (b) 4 3 1 2
(c) 4 3 2 1 (d) 3 4 1 2589 590 591
You have to grow

from the inside out.
N
None can tteach
h you,
There is no other teacher
But your own soul.
‐Swami Vivekananda
Swami Vivekananda
592
Introduction y Cemented carbides,
y Cast carbides,
y Success in metal cutting depends on selection of the
proper cutting tool (material and geometry) for a given y Coated carbides,
work material. y Coated high speed steels,
y A wide range of cutting tool materials is available with y Ceramics,
Cutt g oo ate a s
Cutting Tool Materials a varietyy of p
cost.
properties,
p , p
performance capabilities,
p , and y Cermets,
Cermets
y Whisker reinforced ceramics,
y These include: y Sialons,
y High carbon Steels and low/medium alloy steels,
y Sintered polycrystalline cubic boron nitride (CBN),
Sintered polycrystalline cubic boron nitride (CBN)
y High‐speed steels,
y Sintered polycrystalline diamond, and single‐crystal
y Cast cobalt alloys,
alloys natural diamond.
l di d
By S K Mondal 1 Contd…
2 3
Carbon Steels
Carbon Steels
y Limited tool life. Therefore,, not suited to mass
production.
y Can be formed into complex shapes for small production
runs
y Low cost
y Suited to hand tools, and wood working
y Carbon content about 0.9 to 1.35% with a hardness
ABOUT 62 C Rockwell
y Maximum cutting speeds about 8 m/min. dry and used
upto 250oC
y The hot hardness value is low. This is the major factor in
FIGURE: Improvements in cutting tool materials have reduced
tool life.
life
Fig. Productivity raised by cutting tool materials
machining time. 4 5 6
IAS – 1997 High speed steel

Assertion
A i (A):
(A) Cutting
C i tools
l made
d off high
hi h carbon
b y These steels are used for cutting metals at a much
steel have shorter tool life. higher cutting speed than ordinary carbon tool steels.
steels
Reason(R): During machining, the tip of the cutting y The high speed steels have the valuable property of
tool is heated to 600/700
600/700°C C which cause the tool tip retaining
i i their
h i hardness
h d even when
h heated
h d to red
d heat.
h
to lose its hardness.
y Most of the high
g speed
p steels contain tungsten
g as the
( ) Both
h chief alloying element, but other elements like cobalt,
correct explanation of A chromium vanadium,
chromium, vanadium etc.
etc may be present in some
(b) Both A and R are individually true but R is not the proportion.
7 8 Contd…
9
y With time the effectiveness and efficiency of HSS
IES‐2013 IAS‐1997
(tools) and their application range were gradually
(t l ) d th i li ti d ll Vanadium in high speed steels: Which of the following processes can be used for
enhanced by improving its properties and surface production thin, hard, heat resistant coating at TiN,
condition through ‐
diti th h ( ) Has a tendency to promote decarburization
(a) on HSS?
y Refinement of microstructure y p
1. Physical vapour deposition.
p
y Addition of large amount of cobalt and Vanadium to (b) Form
F very hard
h d carbides
bid and
d thereby
h b increases
i the
h 2. Sintering under reducing atmosphere.
increase hot hardness and wear resistance wear resistance of the tool 3 Chemical vapour deposition with post treatment
3.
respectively 4. Plasma spraying.
y Manufacture by powder metallurgical process (c) Helps in achieving high hot hardness S l t th
Select the correct answer using the codes given below:
t i th d i b l
y Surface coating with heat and wear resistive Codes:
materials like TiC
t i l lik TiC , TiN
TiN , etc by Chemical Vapour
t b Ch i l V (d) Has a tendency to promote retention of Austenite
(a) 1 and 3 (b) 2 and 3
Deposition (CVD) or Physical Vapour Deposition ((c)) 2 and 4
4 ((d)) 1 and 44
(PVD)
10 11 12
18‐4‐1 High speed steel IES‐2003 IES 2007

y This steel contains 18 per cent tungsten, 4 per cent The correct sequence of elements of 18‐4‐1 HSS Cutting tool material 18‐4‐1 HSS has which one of
chromium and 1 per cent vanadium.
vanadium tool is the following compositions?
y It is considered to be one of the best of all purpose tool (a) W, Cr, V (a) 18% W, 4% Cr, 1% V (b) 18% Cr, 4% W, 1% V
steels.
l (b) Mo, Cr, V (c) 18% W, 4% Ni, 1% V (d) 18% Cr, 4% Ni, 1% V
y It is widelyy used for drills,, lathe,, p
planer and shaper
p (c) Cr, Ni, C
Cr Ni C
tools, milling cutters, reamers, broaches, threading (d) Cu, Zn, Sn
dies punches,
dies, punches etc.
etc
13 14 15
IES‐1993 Molybdenum high speed steel Super high speed steel

The blade of a power saw is made of y This steel contains 6 per cent tungsten, 6 per cent y This steel is also called cobalt high speed steel
(a) Boron steel molybdenum, 4 per cent chromium and 2 per cent
molybdenum because cobalt is added from 2 to 15 per cent,
cent in order
(b) High speed steel vanadium. to increase the cutting efficiency especially at high
y It
I has
h excellent
ll toughness
h andd cutting
i ability.
bili temperatures.
temperatures
(c) Stainless steel
y The molybdenum
y high
g speed
p steels are better and y This steel contains 20 per cent tungsten, 4 per cent
(d) Malleable cast iron chromium, 2 per cent vanadium and 12 per cent cobalt.
cheaper than other types of steels.
y It is particularly used for drilling and tapping
operations.
16 17 18
IES‐1995 IES‐2000 IES‐1992
The compositions of some of the alloy steels are as Percentage of various alloying elements present The main alloying elements in high speed Steel in
under: in different steel materials are given below: order of increasing proportion are
1. 18 W 4 Cr 1 V 1. 18% W; 4% Cr; 1% V; 5% Co; 0.7% C (a) Vanadium, chromium, tungsten
2 12 Mo 1 W 4 Cr 1 V
2. 2. 8% Mo; 4% Cr; 2% V; 6% W; 0.7% C (b) Tungsten, titanium, vanadium
3. 6 Mo 6 W 4 Cr 1 V
3 27% Cr; 3% Ni; 5% Mo; 0.25% C
3. 27% Cr; 3% Ni; 5% Mo; 0 25% C (c) Chromium, titanium, vanadium
Chromium titanium vanadium
4. 18 W 8 Cr 1 V
4. 18% Cr; 8% Ni; 0.15% C (d) Tungsten, chromium, titanium
The compositions of commonly used high speed steels
would include Which of these relate to that of high speed steel?
(a) 1 and 2 (b) 2 and 3 (a) 1 and 3 (b) 1 and 2
(c) 1 and 4 (d) 1 and 3 (c) 2 and 3 (d) 2 and 4
19 20 21
IAS‐2001 IAS 1994
Assertion (A): For high‐speed turning of magnesium Assertion (A): The characteristic feature of High IAS –
IAS – 2013 Main
2013 Main
alloys, the coolant or cutting fluid preferred is water‐ speed Steel is its red hardness.
miscible mineral fatty oil.
i ibl i l f il Compare HSS and ceramic tools with regard to their
Reason (R): Chromium and cobalt in High Speed
Reason (R): As a rule, water‐based oils are recommended promote martensite formation when the tool is cold
p application in high speed machining.
pp g p g
f hi h
for high‐speed operations in which high temperatures are
d ti i hi h hi h t t worked.
generated due to high frictional heat. Water being a good
coolant the heat dissipation is efficient
coolant, the heat dissipation is efficient. ((a)) Both A and R are individually true and R is the correct
y
(a) Both A and R are individually true and R is the correct explanation of A
explanation of A (b) Both A and R are individually true but R is not the
(b) Both A and R are individually true but R is not the correct correct explanation of A
e p a at o o
explanation of A (c) A is true but R is false
(c) A is true but R is false (d) A is false but R is true
22 23 24
Cast cobalt alloys/Stellite y Other elements added include V, B, Ni, and Ta.

y Tools of cast cobalt alloys are generally cast to shape and
IES 2011
y Cast cobalt alloys are cobalt‐rich, chromium‐tungsten‐ carbon finished to size by grinding. Stellite is a non‐ferrous cast alloy composed of:
cast alloys
y having g p properties
p and applications
pp in the (a) Cobalt,
Cobalt chromium and tungsten
y They are available only in simple shapes,
shapes such as single‐
single
intermediate range between high‐speed steel and cemented
carbides. point tools and saw blades, because of limitations in the (b) Tungsten, vanadium and chromium
casting process and expense involved in the final shaping
y Although comparable in room‐temperature hardness to high‐ (c) Molybdenum, tungsten and chromium
speed steel tools, cast cobalt alloy tools retain their hardness to
(grinding). The high cost of fabrication is due primarily to
a much higher temperature.
temperature Consequently,
Consequently they can be used at the high hardness of the material in the asas‐cast
cast condition. (d)Tungsten molybdenum,
(d)Tungsten, molybdenum chromium and vanadium
higher cutting speeds (25% higher) than HSS tools. y Materials machinable with this tool material include plain‐
y Cutting speed of up to 80‐100
80 100 fpm can be used on mild steels.
steels carbon steels, alloy steels, nonferrous alloys, and cast iron.
y Cast cobalt alloys are hard as cast and cannot be softened or y Cast cobalt alloys are currently being phased out for
heat treated.
treated cutting‐tool
cutting tool applications because of increasing costs, costs
y Cast cobalt alloys contain a primary phase of Co‐rich solid shortages of strategic raw materials (Co, W, and Cr), and
solution strengthened by Cr and W and dispersion hardened by the development of other, superior tool materials at lower
complex hard, refractory carbides of W and Cr. cost.
Contd…
25 26 27
Cemented Carbide y Cemented carbide tool materials based on TiC have
IAS –
IAS – 2013 Main
2013 Main y Carbides, which are nonferrous alloys, are also called,
been developed,
b d l d primarily
i il f
for auto
t i d t
industry
sintered ((or cemented)) carbides because theyy are
applications using predominantly Ni and Mo as a
What are the desirable properties while selecting a tool bi d
binder. Th
These are used d for
f hi h
higher‐speedd (>
( 1000
manufactured by powder metallurgy techniques.
material for metal‐cutting applications?
g pp ft/min) finish machining of steels and some malleable
y Most carbide tools in use today are either straight
tungsten carbide (WC) or multicarbides of W‐Ti or W‐
castt irons.
i
Ti‐Ta,, depending
p g on the work material to be machined. y Cemented carbide tools are available in insert form in
y Cobalt is the binder. many different shapes; squares, triangles, diamonds,
y These tool materials are much harder,
harder are chemically more and rounds.
stable, have better hot hardness, high stiffness, and lower y Compressive strength is high compared to tensile
friction, and operate at higher cutting speeds than do HSS. strength, therefore the bits are often brazed to steel
y They are more brittle and more expensive and use strategic shanks, or used as inserts in holders.
metals (W,
(W Ta,
Ta Co) more extensively.
extensively y These inserts may often have negative rake angles.
angles
28 Contd…
29 Contd…
30
IES‐1995
y Speeds
S d up to 300 fpm
f are common on mild
ild steels
l
The straight grades of cemented carbide cutting
y Hot hardness p
properties
p are veryy g
good tool materials contain
y Coolants and lubricants can be used to increase tool (a) Tungsten carbide only
life, but are not required.
life required
(b) Tungsten carbide and titanium carbide
y Special alloys are needed to cut steel
(c) Tungsten carbide and cobalt
(d) Tungsten carbide and cobalt carbide
Contd…
31 32 33
IAS – 1994 The standards developed by ISO for grouping of carbide tools Table below shows detail grouping of cemented carbide tools

pp g g
and their application ranges are given in Table below.
Assertion
A i (A):
(A) Cemented
C d carbide
bid tooll tips
i are ISO Material
M t i l Process
P
Application
produced by powder metallurgy. ISO Code Colour Code Application group
Reason (R): Carbides cannot be melted and cast. P01 Steel, Steel castings Precision and finish machining, high speed
P For machining long chip forming
(a) Both A and R are individually true and R is the common materials like plain carbon
P10 Steel Steel castings
Steel, Turning, threading,
Turning threading and milling high speed
speed,
small chips
correct explanation of A and low alloy steels P20 Steel, steel castings, Turning, milling, medium speed with small chip
malleable cast iron section
(b) Both A and R are individually true but R is not the M For machining long or short chip
correct
co ect eexplanation
p a at o oof A formingg ferrous materials like P30 Steel, steel castings, Turning, milling, medium speed with small chip
malleable
ll bl cast iiron section
i
Stainless steel
(c) A is true but R is false P40 Steel and steel casting Turning, planning, low cutting speed, large chip
K For machining short chipping,
chipping with
ith sand
d iinclusions
l i section
ti
(d) A is false
f l but
b R is true
ferrous and nonferrous material P50 Steel and steel castings Operations requiring high toughness turning,
and non – metals like Cast Iron,
Iron off medium
di or llow ttensile
il planning,
l i shaping
h i att llow cutting
tti speeds
d
Brass etc. strength
34 35 36
K01 Hard grey C.l., chilled casting,
Al.
Al alloys with high silicon
Turning, precision turning and boring, milling,
scraping
IES‐1999 Ceramics
K10 Grey C.l. hardness > 220 HB.
Malleable C.l., Al. alloys
Turning, milling, boring, reaming, broaching,
scraping
Match List‐I (ISO classification of carbide tools) with List‐ y Ceramics are essentially alumina ( Al2O3 ) based high
containing Si
II (Applications) and select the correct answer using the
pp g refractory materials introduced specifically for high
K20 Grey C.l. hardness up to 220 Turning, milling, broaching, requiring high codes given below the Lists: speed machining of difficult to machine materials and
HB toughness
List‐I List‐II cast iron.
iron
K30 Soft grey C.l.
C l Low tensile Turning reaming under favourable conditions
Turning,
strength steel A. P‐10 1. Non‐ferrous, roughing cut
K40 Soft non-ferrous metals Turning milling etc. y These can withstand very high temperatures, are
B. P‐505 2. Non‐ferrous, finishing cut
, g
M10 Steel steel castings
Steel, castings, Turning, milling,
Turning milling medium cutting speed and medium chemically more stable,
stable and have higher wear
manganese steel, grey C.l. chip section C. K‐10 3. Ferrous material, roughing cut
M20 Steel casting, austentic steel, Turning, milling, medium cutting speed and medium resistance than the other cutting tool materials.
manganese steelsteel, chip section D.. K‐50
5 4. Ferrous material, finishing cut
e ous a e a , s g cu
spherodized C.l., Malleable y In
I view
i off their
h i ability
bili to withstand
ih d high
hi h temperatures,
C.l. they can be used for machining at very high speeds of
M30 Steel austenitic steel,
Steel, steel Turning milling,
Turning, milling planning,
planning medium cutting speed,
speed (a) 4 3 1 2 (b) 3 4 2 1
spherodized C.l. heat medium or large chip section the
h order
d off 10 m/s.
/
resisting alloys
(c) 4 3 2 1 (d) 3 4 1 2
M40 Free cutting steel
steel, low tensile Turning profile turning
Turning, turning, specially in automatic
y They can be operated at from two to three times the
y p
strength steel, brass and light machines. cutting speeds of tungsten carbide.
alloy 37 38 Contd…
39
y Itt iss poss b e to get mirror

possible o finish
s oon cast iron
o us g
using y Through last few years remarkable improvements in
ceramic turning. strength and toughness and hence overall performance
of ceramic tools could have been p possible byy several
y The
Th main i problems
bl off ceramic
i tools
t l are their
th i low
l
means which include;
strength, poor thermal characteristics, and the
y Sinterability,
Sinterability microstructure
microstructure, strength and
tendency to chipping.
toughness of Al2O3 ceramics were improved to
y They are not suitable for intermittent cutting or for low
some extent byb adding
ddi TiO2
TiO and d MgO,
M O
cutting speeds.
y Transformation toughening
g g byy addingg appropriate
pp p
y Very
V hi h hot
high h t hardness
h d properties
ti
amount of partially or fully stabilised zirconia in
y Often used as inserts in special
p holders. Al2O3 powder,
powder
y Isostatic and hot isostatic pressing (HIP) – these are
very effective
ff i but b expensivei route.
Comparison of important properties of ceramic and tungsten carbide tools 40 Contd…
41 Contd…
42
y Introducing nitride ceramic (Si3N4) with proper sintering

IES 2016
IES‐2016
y Cutting
g fluid, if applied
pp g with
should in flooding Statement (I): Ceramics withstand very high
technique – this material is very tough but prone to built‐up‐
built up
copious quantity of fluid, to thoroughly wet the entire temperatures that range from 1000°C to 1600°C.
edge formation in machining steels
y Developing SIALON – deriving beneficial effects of Al2O3 machining zone, since ceramics have very poor Statement ((II):
) Silicon carbide is an exceptionp from
and Si3N4 thermal shock resistance. Else, it can be machined among ceramics that cam withstand high
with no coolant.
coolant p
temperatures.
y Addi
Adding carbide
bid like
lik TiC (5
( ~ 15%)
%) in
i Al2O3
Al O powder d – to t
impart toughness and thermal conductivity y Ceramic tools are used for machining work pieces,
(a) Both Statement (I) and Statement (II) are
y Reinforcing
f oxide
d or nitride
d ceramics by
b SiC whiskers,
h k which
h h individually true and Statement (II) is the correct
which have high hardness, such as hard castings, case explanation of Statement (I).
enhanced strength, toughness and life of the tool and thus hardened and hardened steel.
productivity
d i i spectacularly.
l l (b) Both Statement (I) and Statement (II) are
y Toughening Al2O3 ceramic by adding suitable metal like
y Typical products can be machined are brake discs, individually true but Statement (II) is not the correct
silver which also impart thermal conductivity and self brake drums,
drums cylinder liners and flywheels.
flywheels explanation
l ti off Statement
St t t (I).
(I)
lubricating property; this novel and inexpensive tool is still (c) Statement (I) is true but Statement (II) is false.
i experimental
in i l stage. (d) Statement (I) is false but Statement (II) is true
Contd…
43 44 45
High Performance ceramics (HPC) IES‐2013 IES 2010
Sialon ceramic is used as: Constituents
C tit t off ceramics i are oxides
id off
different materials, which are
( )
(a) Cutting tool material
(a) Cold mixed to make ceramic pallets
(b) C
(b) Creep resistant
i (b) Ground, sintered and palleted to make ready
( ) F
(c) Furnace linens
li ceramics
(c) Ground, washed with acid, heated and cooled
Silicon Nitride
Sili Nit id Alumina toughned
Al i t h d byb (d) High strength
(i) Plain (i) Zirconia
(d) Ground, sintered, palleted and after calcining
(ii) SIALON (ii) SiC whiskers cooled
l d in
i oxygen
(iii) Whisker toughened (iii) Metal (Silver etc)
46 47 48
IAS‐1996 IES‐1997 IES‐1996

Match List I with List II and select the correct answer Assertion (A): Ceramic tools are used only for light,
using the codes given below the lists: A machinist desires to turn a round steel stock of
g p
smooth and continuous cuts at high speeds. outside diameter 100 mm at 1000 rpm The
outside diameter 100 mm at 1000 rpm. The
List I (Cutting tools)
( l ) List II (Major constituent)
( )
Reason (R): Ceramics have a high wear resistance and material has tensile strength of 75 kg/mm2. The
A. Stellite l. Tungsten high temperature resistance.
B. H.S.S. 2. Cobalt d
depth of cut chosen is 3 mm at a feed rate of 0.3
h f h i f d f
C. Ceramic 3. Alumina correct explanation of A
mm/rev. Which one of the following tool
D. DCON 4. Columbium materials will be suitable for machining the
55. Titanium correct explanation of A component under the specified cutting
p p g
Codes: A B C D A B C D conditions?
((a)) 5 1 33 4 ((b)) 2 1 4 3
A i f l b R i (a) Sintered carbides (b) Ceramic
(c) 2 1 3 4 (d) 2 5 3 4
(c) HSS (d) Diamond
49 50 51
IES 2007 IAS‐2000 IAS‐2003

Which one of the following is not a ceramic? Consider the following cutting tool materials used for At room temperature, which one of the following
g p
metal‐cutting operation at is the correct sequence of increasing hardness of
( ) Alumina
(a) Al i
high speed: the tool materials?
((b)) Porcelain 1
1. Tungsten carbide
(c) Whisker (a) Cast alloy‐HSS‐Ceramic‐Carbide
2. Cemented titanium carbide
(d) Pyrosil
P il 3. High‐speed steel
Hi h d l (b) HH
HH‐Cast alloy‐Ceramic‐Carbide
Cast alloy Ceramic Carbide
4. Ceramic (c) HSS‐Cast alloy‐Carbide‐Ceramic
The correct sequence in increasing order of the range of (d) Cast alloy‐HSS‐Carbide‐Ceramic
cutting speeds for optimum use of these materials is
(a) 3,1,4,2 (b) 1,3,2,4
(c) 3,1,2,4 (d) 1,3,4,2
52 53 54
Coated Carbide Tools y The coatings
g must be fine g
grained, & free of binders y The most successful combinations are
y Coated tools are becoming the norm in the metalworking and porosity. TiN/TiC/TiCN/TiN and TiN/TiC/ Al2O3 .
industry because coating , can consistently improve,
improve tool y Naturally,
Naturally the coatings must be metallurgically bonded y Chemical
h l vapour deposition
d (
(CVD)
) is the
h technique
h
life 200 or 300% or more. to the substrate. used to coat carbides.
y In
I cutting
tti tools,
t l material
t i l requirements
i t att the
th surface
f off the
th y Interface coatings are graded to match the properties
tool need to be abrasion resistant, hard, and chemically of the coating
g and the substrate.
i
inert to prevent the
h tooll and d the
h work k material
i l from
f
interacting chemically with each other during cutting. y The coatings must be thick enough to prolong tool life
but thin enough to prevent brittleness.
brittleness
y A thin, chemically stable, hard refractory coating of TiC,
TiN,, or Al2O3 accomplishes
p this objective.
j y Coatings should have a low coefficient of friction so
y The bulk of the tool is a tough, shock‐resistant carbide that that the chips do not adhere to the rake face.
can withstand high
high‐temperature
temperature plastic deformation and y Multiple coatings are used,
used with each layer imparting
resist breakage.
Contd…
55
its own characteristic to the tool. Contd…
56 Contd…
57
IAS‐1999 TiN‐Coated High‐Speed Steel
The coating materials for coated carbide tools, y Coated high‐speed steel (HSS) does not routinely
includes provide as dramatic improvements in cutting speeds as
(a) TiC, TiN and NaCN (b) TiC and TiN do coated carbides, with increases of 10 to 20% being
(c) TiN and NaCN (d) TiC and NaCN typical.
i l
y In addition to hobs,, ggear‐shaper
p cutters,, and drills,,
HSS tooling coated by TiN now includes reamers, taps,
chasers spade
chasers, spade‐drill
drill blades,
blades broaches,
broaches bandsaw and
circular saw blades, insert tooling, form tools, end
mills and an assortment of other milling cutters.
mills, cutters
58 59 Contd…
60
C t
Cermets IES 2010
y Physical
y p
vapour p
deposition (PVD) has p
proved to be the y These sintered hard inserts are made by combining ‘cer’
cer from
best process for coating HSS, primarily because it is a ceramics like TiC, TiN or TiCN and ‘met’ from metal (binder) The
Th cutting
tti tool
t l material
t i l required
i d to
t
relatively low temperature process that does not likee Ni,, Ni‐Co,
Co, Fee etc. sustain high temperature is
exceed the tempering point of HSS. y Harder, more chemically stable and hence more wear resistant
y More brittle and less thermal shock resistant
((a)) High
g carbon steel alloys
y
y Therefore,
Th f no subsequent
b t heat
h t treatment
t t t off the
th
cutting tool is required. y Wt% of binder metal varies from 10 to 20%. (b) Composite of lead and steel
y The advantage of TiN‐coated HSS tooling is reduced y Cutting edge sharpness is retained unlike in coated carbide
inserts (c) Cermet
tool wear.
y Can machine steels at higher cutting velocity than that used for (d) Alloy of steel, zinc and tungsten
y Less tool wear results in less stock removal during tool tungsten carbide, even coated carbides in case of light cuts.
regrinding,
i di thus
h allowing
ll i i di id l tools
individual l to be b y Modern cermets with rounded cutting edges are suitable for
reground more times. finishing and semi‐finishing of steels at higher speeds, stainless
steels but are not suitable for jerky interrupted machining and
61 machining of aluminium and similar materials. 62 63
IES‐2000 IES – 2003 Di d
Diamonds
y Diamond is the hardest of all the cutting
g tool materials.
The
Th correct sequence off cutting i tools
l ini theh y Diamond has the following properties:
Cermets are
ascending order of their wear resistance is y extreme hardness,
hardness
( ) Metals for high temperature use with ceramic like
(a) M l f hi h i h i lik
(a) HSS‐Cast non‐ferrous alloy (Stellite)‐Carbide‐ y low thermal expansion,
properties
Nitride y high
hi h heat
h conductivity,
d i i and d
(b) Ceramics with metallic strength and luster
(b) Cast non‐ferrous alloy (Stellite)‐HSS‐Carbide‐ y a very low co‐efficient of friction.
(c) Coated tool materials Nitride
d y This is used when good surface finish and dimensional accuracy
(d) Metal‐ceramic composites (c) HSS‐Cast
SS Cast non‐ferrous
o e ous aalloy oy (Ste
(Stellite)‐Nitride‐
te) t de are desired.
Carbide y The work‐materials on which diamonds are successfully employed
are the non‐ferrous one, such as copper,
pp brass, zinc, aluminium
(d) Cast
C t non‐ferrous
f alloy
ll (St llit ) C bid Nit id
(Stellite)‐Carbide‐Nitride‐ and magnesium alloys.
HSS y On ferrous materials,, diamonds are not suitable because of the
diffusion of carbon atoms from diamond to the work‐piece
64 65 66
material. Contd…
y Diamond tools have the applications in single point turning and y Diamond tools offer dramatic performance
GATE –
GATE – 2009 (PI)
2009 (PI) boring
b i tools,
t l milling
illi cutters,
tt reamers, grinding
i di wheels,
h l honing
h i improvements over carbides. Tool life is often greatly
tools, lapping powder and for grinding wheel dressing.
improved, as is control over part size, finish, and
p p
Di
Diamond
d cutting
tti t l are nott recommended
tools d d for
f y Due
D to their
h i brittle
b i l nature, the h diamond
di d toolsl have
h poor
surface integrity.
resistance to shock and so, should be loaded lightly.
machining of ferrous metals due to y Positive rake tooling is recommended for the vast
y Polycrystalline diamond (PCD) tools consist of a thin layer (0.5
to 1.5 mm) of'fine grain‐ size diamond particles sintered majority of diamond tooling applications.
(a) high tool hardness
together
h and d metallurgically
ll ll bonded
b d d to a cemented d carbide
bd y If BUE is a problem, increasing cutting speed and the
substrate. use of more positive rake angles may eliminate it.
p g y
((b)) high
g thermal conductivityy of work material
y The main advantages of sintered polycrystalline tools over
natural single‐crystal tools are better quality, greater toughness,
y Oxidation of diamond starts at about 450oC and
((c)) p
poor tool toughness
g
and improved wear resistance, resulting from the random thereafter it can even crack For this reason the
thereafter it can even crack. For this reason the
(d) chemical affinity of tool material with iron orientation of the diamond grains and the lack of large cleavage diamond tool is kept flooded by the coolant during
planes.
l cutting, and light feeds are used.
i d li h f d d
67 Contd…
68 69
IES‐1995 IES‐2001 IES – 1999

Assertion (A): Non‐ferrous materials are best Assertion (A): Diamond tools can be used at high
C id h f ll i
machined with diamond tools. p
speeds. p g y,
For precision machining of non‐ferrous alloys, diamond
Reason (R): Diamond tools are suitable for high speed Reason (R): Diamond tools have very low coefficient is preferred because it has
machining. of friction. 1 Low coefficient of thermal expansion
1.
(a) Both A and R are individually true and R is the (a) Both A and R are individually true and R is the
correct explanation of A correct explanation of A 2. High wear resistance
(b) Both A and R are individually true but R is not the (b) Both A and R are individually true but R is not the 3. High compression strength
correct explanation of A correct explanation of A 4. Low fracture toughness
L f t t h
(c) A is true but R is false (c) A is true but R is false Which of these statements are correct?
A i f l b R i (d) A is false but R is true
A i f l b R i
(a) 1 and 2 (b) 1 and 4
( ) 2 and 3
(c) d (d) 3 and 4
d
70 71 72
IES‐1992 IAS – 1999 Cubic boron nitride/Borazon
Assertion (A): During cutting, the diamond tool is
A i (A) D i i h di d l i
Which of the following given the correct order of y Next to diamond, cubic boron nitride is the hardest
kept flooded with coolant.
increasing hot hardness of cutting tool material? material presently available.
available
Reason (R): The oxidation of diamond starts at
(a) Diamond, Carbide, HSS y It is made by bonding a 0.5 – 1 mm layer of
about 4500C
(b) Carbide, Diamond, HSS polycrystalline cubic boron nitride to cobalt based
(a) Both A and R are individually true and R is the carbide substrate at veryy high g temperature
p and
(c) HSS, carbide, Diamond
HSS carbide Diamond correct explanation of A
l f pressure.
(d) HSS, Diamond, Carbide (b) Both A and R are individually true but R is not
ot a d R a e d v dua y t ue but R s ot tthe e y It remains inert and retains high hardness and fracture
correct explanation of A toughness at elevated machining speeds.
(c) A i t b t R i f l y It shows excellent performance in grinding any
(d) A is false but R is true material of high
g hardness and strength.
g
73 74 Contd…
75
y The operative speed range for cBN when machining IES‐1994

grey castt iron
i is
i 300 ~400 m/min/ i
y CBN is less reactive with such materials as hardened Consider the following tool materials:
y Speed
p ranges
g for other materials are as follows: steels, hard‐chill cast iron, and nickel‐
steels hard chill cast iron and nickel and cobalt‐
and cobalt 1. Carbide
C bid 2. C
Cermet
y Hard cast iron (> 400 BHN) : 80 – 300 m/min based superalloys. 33. Ceramic 4.
4 Borazon.
y Superalloys
S ll ( 35 RC) : 80
(> 8 – 140 m/min
/ i y CBN can be used efficiently and economically to
Correct sequence of these tool materials in increasing
y Hardened steels ((> 45 RC) : 100 – 3 300 m/min machine these difficult‐to‐machine materials at higher
g order of their ability to retain their hot hardness is
y It is best to use cBN tools with a honed or chamfered speeds (fivefold) and with a higher removal rate
(fivefold) than cemented carbide and with superior
(fivefold) than cemented carbide, and with superior (a) 1,2,3,4 (b) 1,2,4,3
edge preparation,
preparation especially for interrupted cuts.
cuts Like
ceramics, cBN tools are also available only in the form accuracy, finish, and surface integrity. (c) 2, 1, 3, 4 (d) 2, 1, 4, 3
off indexable
i d bl inserts.
i
y The only y limitation of it is its high
g cost.
Contd…
76 77 78
IES‐2002 IES‐1996 IES‐1994

Which one of the following is the hardest cutting Cubic boron nitride Cubic boron nitride is used
tool material next only to diamond? ( ) Has a very high hardness which is comparable to
(a) H hi h h d hi h i bl ( ) As lining material in induction furnace
(a) A li i i l i i d i f
(a) Cemented carbides that of diamond. ((b)) For making optical quality glass.
g p q yg
(b) Ceramics (b) Has a hardness which is slightly more than that of (c) For heat treatment
(c) Silicon HSS (d) For none of the above.
F f h b
(d) Cubic boron nitride (c) Is used for making cylinder blocks of aircraft
engines
i
((d)) Is used for making optical glasses.
g p g
79 80 81
IAS‐1998 C it
Coronite IES‐1993
y Coronite is made basically by combining HSS for strength and
Which of the following tool materials have cobalt toughness and tungsten carbides for heat and wear resistance. Match List I with List IT and select the correct answer using the
codes given below the lists:
as a constituent element? y Microfine TiCN particles are uniformly dispersed into the matrix.
matrix Li I (Cutting tool Material)
List ‐ I (C i l M i l) List ‐
Li I I(Major
I I(M j
y Unlike a solid carbide, the coronite based tool is made of three characteristic constituent)
1. Cemented carbide 2. CBN A. High speed steel 1. Carbon
layers;
3. Stellite 4. UCON y the central HSS or spring steel core
B. Stellite 2. Molybdenum
C. Diamond 3. Nitride
Select the correct answer using the codes given below: y a layer of coronite of thickness around 15% of the tool D. Coated carbide tool 4. Columbium
Codes: diameter 5. Cobalt
y a thin (2 to 5 μm) PVD coating of TiCN C d A
Codes: B C D A B C D
(a) 1 and 2 (b) 1 and 3 (a) 2 1 3 5 (b) 2 5 1 3
y The coronite tools made by y hot extrusion followed byy PVD‐ (c) 5 2 4 3 (d) 5 4 2 3
(c) 1 and 4 (d) 2 and 3 coating of TiN or TiCN outperformed HSS tools in respect of
cuttingg forces, tool life and surface finish.
82 83 84
IES‐2003 IES‐2000 IES‐1999

Which one of the following is not a synthetic Consider the following tool materials: Match List‐I with List‐II and select the correct answer
using the codes given below the Lists:
abrasive material? 1. HSS 2. C
Cemented carbide
d bid List I List II
(a) Silicon Carbide (b) Aluminium Oxide 33. Ceramics 4.
4 Diamond (Materials) (Applications)
A Tungsten carbide
A. bid 1. Ab i h l
Abrasive wheels
(c) Titanium Nitride (d) Cubic Boron Nitride The correct sequence of these materials in decreasing B. Silicon nitride 2. Heating elements
order of their cutting speed is C Aluminium
C. Al i i oxide
id 3. Pi f
Pipes for conveying
i
liquid metals
(a) 4, 3, 1, 2 (b) 4, 3, 2, 1
D Silicon carbide
D. 4
4. Drawing dies
(c) 3, 4, 2, 1 (d) 3, 4, 1, 2 Code: A B C D A B C D
(a) 3 4 1 2 (b) 4 3 2 1
(c) 3 4 2 1 (d) 4 3 1 2
85 86 87
IAS‐2001 Attrition wear IES‐1996

Match. List I (Cutting tool materials) with List II y The strong bonding between the chip and tool material at The limit to the maximum hardness of a work
(Manufacturing methods) and select the correct answer high temperature is conducive for adhesive wear.
using the codes given below the Lists:
i th d i b l th Li t material which can be machined with HSS tools
y The adhesive wear in the rough region is called attrition
List I List II wear . even at low speeds is set by which one of the
A HSS
A. 1
1. Casting y In the rough region, some parts of the worn surface are still following tool failure mechanisms?
B. Stellite 2. Forging covered by molten chip and the irregular attrition wear (a) Attrition
C Cemented carbide
C. 3
3. Rolling occurs in this region .
D. UCON 4. Extrusion y The irregular attrition wear is due to the intermittent (b) Abrasion
5
5. Powder metallurgy adhesion during interrupted cutting which makes a (c) Diffusion
Codes:A B C D A B C D periodic attachment and detachment of the work material
(a) 3 1 5 2 (b) 2 5 4 3 on the tool surface. (d) Plastic deformation under compression.
(c) 3 5 4 2 (d) 2 1 5 3 y Therefore, when the seizure between workpiece to tool is
broken, the small fragments of tool material are plucked
andd brought
b h away byb the
h chip.
h
88 89 90
IES‐2005
Consider the following statements: An increase in
the cobalt content in the straight carbide grades
g g
of carbide tools
1 Increases the hardness.
1. Increases the hardness
2. Decreases the hardness.
3. Increases the transverse rupture strength
I h h
4. Lowers the transverse rupture strength.
4 p g
Which of the statements given above are correct?
(a) 1 and 3 (b) 2 and 4
(c) 1 and 4 (d) 2 and 3
91 92

Ch-1 Basics of Metal Cutting: Answers with Explanations
IES-2013 Page No.1 SlideNo.5 Ans.(c)
π DN π × 30 ×1000
Speed (V ) = m / min = m / min = 94.2 m / min
1000 1000
IES-2001 Page No.1 Slide No.6 Ans. (c) For cutting brass recommended rake angle is -5 to +5
degree.
IES-1995 Page No.1 Slide No.7 Ans. (a) It is true form-cutting procedure, no rake should be
ground on the tool, and the top of the tool must be horizontal and be set exactly in line with the axis of
rotation of the work; otherwise, the resulting thread profile will not be correct. An obvious disadvantage
of this method is that the absence of side and back rake results in poor cutting (except on cast iron or
brass). The surface finish on steel usually will be poor.
GATE-1995;2008 Page No.1 Slide No.8 Ans. (a) Increasing rake angle reduces the cutting force
on the tool and thus power consumption is reduced.
IES-1993 Page No.1 Slide No.9 Ans. (d) Negative rake angle increases the cutting force i.e.
Cutting force
specific pressure. Specific pressure =
feed×depth of cut
IES-2005 Page No.2 Slide No.10 Ans.(b) Carbide tips are generally given negative rake angle it
is very hard and very brittle material. Negative rake is used as carbides are brittle not due to hardness.
Hardness and brittleness is different property
IES-2015 Page No. 2 Slide No.11 Ans.(b)
IES-2002 Page No.2 Slide No.12 Ans.(c) Carbide tools are stronger in compression.
IES-2011 Page No.2 Slide No.13 Ans. (b) The rake angle does not have any effect on flank but
clearance anglehas to reduce the friction between the tool flank and the machined surface.
GATE-2008(PI) Page No.2 Slide No.14 Ans. (c) Brittle workpiece materials are hard and needs
stronger tool. Tools having zero or negative rake angle provides adequate strength to cutting tool due to
large lip angle.
IAS-1994 Page No.2 Slide No.15 Ans. (d)
IES-2014 Page No.2 Slide No.16 Ans. (c)
IES-2012 Page No.2 Slide No.17 Ans.(d) When cutting velocity is increased, it will lead to
increase in power and temperature, and cutting force will be slightly reduce so we take as cutting forces will not
be affected by the cutting velocity. Common sense will say force will increase, but if you think deeply
there is no reason for increasing the force, same material same hardness, same tool same sharpness.
Therefore the force will remain unaffected. But in actual practice it will reduce due to high
temperature. As velocity increases power consumption will increase and temperature will increase.
IES-2006 Page No.2 Slide No.18 Ans. (d) All other tools are multi-point.
GATE-2017(PI) Page No.3 Slide No.19 Ans. (c)

IES-2012 Page No.3 Slide No.20 Ans. (b) Both are correct. We have used negative rake angles
for different purpose but not for the direction of chip. In turning positive back rake angle takes the chips away
from the machined surface, Whereas negative back rake angle directs the chip on to the machined surface.
IES-2003 Page No.3 Slide No.21 Ans. (b)
GATE(PI)-1990 Page No.3 Slide No.23 Ans. (c)

No of chattering per cycle 360/30 = 12
No of cycle per second = 500 /60
Therefore chattering frequency is 12 x 500/60 = 100 Hz
IAS-1996 Page No.3 Slide No.24 Ans. (a)
IAS-1995 Page No.3 Slide No.25 Ans. (a) Fy = Ft cos λ = Ft sin CS
IES-2010 Page No.3 Slide No.26 Ans. (c) Fy ↑= Ft cos λ = Ft sin CS ↑ (radial force)
Fx ↓= Ft sin λ = Ft cos CS ↑ (axial force)and SCEA has no influence on cutting force i.e. tangential force. But
this question is not for Orthogonal Cutting it should be turning.
IES-2006 Page No.4 Slide No.28 Ans.(c) Smaller point angle results in higher rake angle.
IES-2002 Page No.4 Slide No.29 Ans. (d)Strength of a single point cutting tool depends on lip
angle but lip angle also depends on rake and clearance angle.
IES-2009 Page No.4 Slide No.31 Ans. (c)Large nose radius improves tool life. A sharp point on the
end of a tool is highly stressed, short lived and leaves a groove in the path of cut. There is an
improvement in surface finish and permissible cutting speed as nose radius is increases from zero value.
But too large a nose radius will induce chatter.
IES-1995 Page No.4 Slide No.32 Ans. (c) It will increase tool cutting force.
IES-1993 Page No.4 Slide No.35 Ans. (b)The second item is the side rake angle. Thus 6° is
the side rake angle.
ISRO-2011 Page No. 4 Slide No.36 Ans. (b)
GATE-2008 Page No. 5 Slide No.37 Ans.(d) We may use principal cutting edge angle or approach
angle = 90 - CS . When, principal cutting edge angle =90;then α S = α . Don’t confuse with side cutting
edge angle. Side cutting edge angle is not principal cutting edge angle.
r cos α 0.4 cos10

GATE-2001Page No.5 Slide No.38 Ans.(c) φ = tan −1 = tan −1 = 22.944
1 − r sin α 1 − 0.4sin10
t 0.81
GATE-2011Page No.5 Slide No.39 Ans. (b) r = = = 0.45
tc 1.8
r cos α 0.45cos12o
φ = tan −1 = tan −1 = 25.90o
1 − r sin α 1 − 0.45sin12o

GATE-2017Page No.5 Slide No.40 Ans. 1.494
IES-1994 Page No.5 Slide No.41 Ans. (b) Shear angle does not depends on velocity.
lc 68.9 r cos α
IES-2014 Conventional Page No. 5 Slide No. 42 Ans. 18.3o r = = and tan φ =
l π × 69 1 − r sin α
GATE-2014 Page No.5 Slide No.43 Ans. 2.8 to 3.0
t f sin λ 0.2 × sin 90o

r= = (for turning) = = 0.4
tc tc 0.5
r cos α r cos 0
φ = tan −1 = tan −1 = tan −1 r = tan −1 0.4
1 − r sin α 1 − r sin 0
φ = 21.80o
Shear strain(ε )= cot φ + tan (φ − α ) = cot 21.80o + tan(21.80 − 0)o = 2.9
IES-2004 Page No.5 Slide No.44 Ans.(d)

r cos α 0.3cos10
r = 0.3, α = 10 ∴ φ = tan −1 = tan −1 = 17.31o
1 − r sin α 1 − 0.3sin10
shear strain (ε ) = cot φ + tan (φ − α ) = cot17.31o + tan (17.31 − 10 ) = 3.34
o
Without using calculator we can’t solve this question.
IAS-2015 Main Page No.5 Slide No.45
α = 10o
t = 0.5 mm
tc = 1.125 mm
t 0.5
r= = = 0.444
tc 1.125
r cos α 0.444 cos10
tan φ = =
1 − r sin α 1 − 0.444 sin10
φ = 25.35o
γ = cot φ + tan(φ − α ) = cot 25.35o + tan(25.35o − 10o ) = 2.385
IES-2009 Page No.6 Slide No.46 Ans. (d)as rake angle is zero. shear strain (ε ) = cot φ + tan φ
GATE-1990(PI)Page No.6 Slide No.47 Ans. (a)
ε = cot φ + tan (φ − 12 )
dε
= − cos ec 2φ + sec 2 (φ − 12 ) = 0 gives φ = 51o
dφ
V Vs V
IES-2016 Page No.6 Slide No.48 Ans. (a) = = c
cos (φ − α ) cos α sin φ
GATE-2012 Page No. 6 Slide No.49 Ans. (c)

r = 0.4; α = 10
r cos α 0.4 cos10
φ = tan −1 = tan −1 = 22.94
1 − r sin α 1 − 0.4sin10
from the velocity triangle;
V VS
=
sin ( 90 − φ + α ) sin ( 90 − α )
2.5 VS
=
sin ( 90 − 22.94 + 10 ) sin ( 90 − 10 )
VS = 2.526m / s
VS 2.526 m / s
Shear strain rate(ε i ) = = = 1.0104 ×105 / s
tS 25 × 10−6 m
IES-2004 Page No.6 Slide No.50 Ans. (b) actually 2, 3 and 4 are correct. But best choice is (b)
IES-2006 Page No.6 Slide No.51 Ans. (c) Cutting torque decreases with increase in rake angle.
IES-2004,ISRO-2009 Page No.6 Slide No.53 Ans. (a)
VC V
=
sin φ sin ( 90 + α − φ )
35 × sin 45
VC = = 28.577m / min
sin ( 90 + 15 − 45 )
Cutting ratio means chip thickness ratio, r = 0.75; V = 60 m / min

t 2.4
r= ⇒ tC = = 3.2 mm
tC 0.75
VC sinφ
= = r = 0.75
V sin(90 + α − φ )
VC = 0.75 × 60 = 45 m / min
IES-2014 Page No.7 Slide No.55 Ans. (c)f = f sinλ = 0.2 sin 90 = 0.2 mm ; tc= 0.32 mm;
cutting ratio = chip thickness ratio = t / tc = 0.2/0.32 = 0.625 But examiner has given reciprocal value = 1.6
IES-2001 Page No.7 Slide No.56 Ans. (a) Most of the students get confused in this question.
Velocity of chip sliding along the shear plane is shear velocity (Vs) and velocity of chip along rake
face is chip velocity (Vc ).
IES-2003 Page No.7 Slide No.57 Ans. (d)

VC t 0.5
t = 0.5 mm , tc = 0.6 mm, =r= =
V tc 0.6
2 × 0.5
or VC = = 1.66 m / s
0.6

IAS-1998Page No.7 Slide No.61 Ans. (b)

π DN π ×100
1 × 480
V= m/s = m / s = 2.51 m / s
1000 × 60 10000 × 60
IASS-1995 Page e No.7 Slide No.62

N Anss. (b) It is orthogonal cutting meeans depth of cut equa al to
uncuut chip thick
kness. As d
depth of cut halved, unccut chip thicckness is alsso halved an
nd hence chiip thicknesss will
be halved.
h
GAT
TE-2009 (PI -common
n data S-1) Page No.7 Slide No.63 Ans.(c))
m ; tc = 0.44 mm; α = 155°
t = 0.2 mm
t r cos α 0.5cos15°
∴r = = 0.5; φ = tan
t −1 = tan −1 = 29.02°
tc 1 − r sin α 1 − 0.5sin155°
Nearesst option is ( c )
GAT
TE-2009 (PI- common
n data S-2) Page No.8 Slide No.64 Ans. (b
b)
V
V = 20 m / min; C = r = 0.5 orrVC = 10 m / min
V
GATTE-1995 Pa age No.8 Slide No.65

N Anss. (b)It is multi-point
m cu
utter and m
mild steel is ductile
d mateerial.
Ducctile materia
al with multiipoint cutterr will producce regular sh
haped disconntinuous chip.
IES
S-2007 Pag
ge No.8 Slide No.66
N Anss. (b)
IES
S-2015 Pag
ge No.8 Slide No.67
N Anss. (c)
IAS
S-1997 Pag
ge No.8 Slide No.68
N Anss. (a)
GATTE-2002 Pa age No.8 Slide No.69

N Anss. (b)Low cuutting speed means long
g chip tool co
ontact time. And
long
g contact tim
me will sufficcient to form
m bond betweeen chip and
d tool.
GAT TE-2009 Pa age No.8 Slide No.70

N Anss. (d)Low cu utting speed d means long
g chip tool co
ontact time. And
long
g contact tim
me will suffficient to foorm bond beetween chip p and tool. This
T micro-weld have to break du ue to
rela
ative motion between chiip and tool. It will increease co-efficient of frictioon.
IESS-1997Page No.8 Slide No.71

N ans brittle material and will form
Anss. (d)Cast iron mea
disccontinuous chip. So chip breaker is not
n needed.
Ch
h-2: An
nalysis of Mettal Cuttting: Answer
A rs with
h Expla
anation
ns
ESE
E-2000(co
onvention
nal) Pag
ge No.9 Slide No
o.73
Ans.

α = 10°, r = 0.35, t = 0.51 mm, b=3mm,
τ y = 285 N / mm 2 , μ = 0.65
r cos α 0.35 × cos10
tan φ = = = 0.3669
1 − r sin α 1 − 0.35sin10
φ = tan −1 0.3669 = 20.152°
bt 3 mm × 0.51 mm
FS = τ y = 285 N / mm 2
sin φ sin 20.152°
= 1265.7 N
μ = tan β , ∴ β = tan −1 μ = tan −1 0.65 = 33.023°
From Merchant Circle:
∴ Fs = R cos (φ + β − α )
FS
⇒R= = 1735.6 N
cos (φ + β − α )
(i) Cutting force (Fc ): Fc = R cos ( β − α ) = 1597.3 N
(ii) Radial force (Fy ) =0 [This force is present in turning but it is orthogonal cutting]
(iii) Normal force on tool (N): N = R cos β = 1455.2 N
(iv)Shear force (Fs ):1265.7 N
Note : Shear force on tool face is friction force ( F ) = R sin β = 945.86 N
GATE-2010 (PI) linked S-1 Page No.9 Slide No.75 Ans.(a)
∵ Friction force is perpendicular to the

cutting velocity vector that means α = 0°
F
F = 402.5 N ; and = μ = 1( given) ∴ N = 402.5 N
N
t 0.2
t = 0.2 mm; tc = 0.4mm, r = = = 0.5
tc 0.4
r cos α r cos 0
tan φ = = = r = 0.5.......(∵α = 0°)
1 − r sin α 1 − r sin 0
or φ = tan −1 r = tan −1 0.5 = 26.565°
tan β = μ = 1; β = 45°
From merchant circle:

F = R sin β or R = 402.5 N = 569.22 N
sin 45°
In FS and FC triangle:
Fs =Rcos ( β − α + φ ) = 569.22 × cos ( 45 − 0 + 26.565 ) N = 180.0 N
GATE-2010 (PI) linked S-2 Page No.9 Slide No.76 Ans. (d)

V = 2m ;
s
From the velocity triangle , applying sine rule;
V VS
=
sin {90 − (φ − α )} sin ( 90 − α )
2 V
= S
sin ( 90 − 26.565 ) sin 90
VS = 2.2361 m
s
∴ Heat generation at the primary shear zone
will be because of shear velocity and shear force
Heat =FS × VS = 180.0 N × 2.2361 m / s = 402.5W
GATE-2013 linked question S-1 Page No.9 Slide No.77 Ans. (a)
From Merchant Circle if cutting force ( FC ) is perpendicular to the friction force ( F ) then the rake
angle will be zero
GATE-2013 linked question S-2 Page No.9 Slide No.78 Ans. (b)
From merchant circle;
∵ α = 0, then F, N, FC , Ft will form a rectangle.
Fc = N = 1500 N
Ft = F
GATE-2015 Page No.9 Slide No.79 Ans. 2.1
IAS-1999 Page No.10 Slide No.84 Ans. (b)
α β
φ =45° + −
2 2
20° 25.5°
φ = 45° + − = 42.25°
2 2
GATE-1997 Page No.10 Slide No.85 Ans. (c)
Using Merchant Analysis:
α β
φ = 45° + −
2
2
10° β °
20° = 45° + − ⇒ β = 60°
2 2
ESE-2005(conventional) Page No.10 Slide No.86 Ans.
μ = 0.5; ∴ β = tan −1 μ = tan −1 0.5 = 26.565°
using Merchant Analysis:
α β
φ = 45° + −
2 2
26.565°
or φ = 45° + 5° − = 36.717°
2

bt 2 mm × 0.22 mm
FS = τ y = 400 N / mm
m2 = 267
7.61 N
sin φ sin 36.717°
Froom merchant circle:
Fs = R cos (φ + β -α )
or 267.61
2 5° − 10° )
N = R cos(36.717° + 26.565
or R = 447.6 N
andd Fc = R cos ( β -α )
1 ° ) = 429.002 N
FC = 447.6 cos(26.565° − 10
0° ) = 127.61N
Ft = 447.6sin(226.565° − 10
GA
ATE-2008 (PI) Link
ked S-1 Page No..10 Slide No.87 Ans. ((d)
Forr minimum cutting
c forcee we have too use mercha
ant Theory
α = 10° , μ = 0.7 = tan β or β = tan −1 μ = 34.99°
Using Merchant
M A
Analysis
α β
φ = 45° +
−
2 2
10° 34.99°
φ = 45° + − = 32.5°
2 2
GA
ATE-2008 (PI) Link ked S-2 Page No..10 Slide No.88 Ans. ((b)
b = 3.6 mm
Calculaating shear force
f Fs :
bt 3.6 mm × 0.25
0 mm
Fs = τ y × 60 ( N / mm 2 )
= 46 = 770.52
7 N
sin φ sin 322.5°
Using Merchant
M C
Circle:
In trianngle formed by Fs , Fn an
nd R;
c (φ + β − α )
Fs = R cos
or 770.52 N = R ( N ) × cos(32.5° + 34.99° − 10° ) ⇒ R = 1433.7 N
In trianngle formed by Ft , Fc an
nd R;
Fc =Rcoos ( β − α ) = 1433.7 × co
os(34.99° − 110° ) = 1299.5 N
1500
=FC iV = 129
Power= 48.8W ≈ 3.2
m / s = 324
99.5 N × 25 KW
60
GA
ATE-2014 Pagge No.10 Slide No.89 Ans. (d)
α β↓
Using Merchant Analysis, φ ↑= 45° + −
2 2
As shear anglee increases cutting force will decrease and lengtth of shear p
plane decrea
ased results chip
thicckness decreease.
GA
ATE-2014 Pag
ge No.10 Slide No.90 Ans. (a)
α β↓
Ussing Merchaant Analysiss, φ ↑= 45° + −
2 2
As shear anglee increases area
a of the shear plane e decreased,, it results ccutting force
e hence imp
prove
surrface finish. Here option
n (b) is also correct
c but best
b one is op
ption (a).
IES
S-2010 Page No..11 Slide No.92 Ans. (b) Mercha ant Analyssis
IES
S-2005 Page No..11 Slide No.93 Ans. (a)
IES
S-2003 Page No..11 Slide No.98 Ans.(c c)
Fs = Fc cos φ − Ft sin φ = 900
9 cos 30 − 600sin 30 = 479.4N
IES
S-2014 Page No..11 Slide No.99 Ans. (b)(

Fs = Fc cos ϕ − Ft sin ϕ = 900 cos11.31° − 810sin11.31° = 723 N
But we have to calculate without using calculator
sin11.31° = 0.2 given ∴ cos 11.31° = 1 − sin 2 11.31° = 1 − 0.22 = 0.98
900 cos11.31° − 810sin11.31° = 900 × 0.98 − 810 × 0.2 = 720 N
IES-2000 Page No.12 Slide No.100 Ans. (a)
F = Fc sin α + Ft cos α
N = Fc cos α − Ft sin α
∵ α = 0;
. so F= F = 500 N
t
N = Fc = 1000 N
F 500 1
μ = = =
N 1000 2
IES-2016 Page No.12 Slide No.101 Ans. 0.5
F Fc sin α + Ft cos α 500 sin 0 + 250 cos 0
μ= = = = 0.5
N Fc cos α − Ft sin α 500 cos0 − 250sin 0
GATE-2007 (PI) Linked S-1 Page No.12 Slide No.102 Ans. (a)
FC = 1200 N ; Ft = 500 N ;α = 0 °
Using the relations:

F = FC sin α + Ft cos α = 1200sin 0 + 500 cos 0 = 500 N
N = FC cos α − Ft sin α = 1200 cos 0 − 500sin 0 = 1200 N
F 500
μ = tan β = =
N 1200
500
∴ β = tan −1 = 22.6°
1200
GATE-2007 (PI) Linked S-2 Page No.12 Slide No.103 Ans. (b)
Orthogonal machining, t = depth of cut = 0.8 mm,
t c =1.5 mm, V =1m/s
t 0.8 Vc Vc
r= = = =
tc 1.5 V 1
⇒ Vc = 0.53 m / s
GATE-2011 (PI) linked S-1 Page No.12 Slide No.104 Ans. (b)
t = 0.25 mm; tc = 0.75 mm; α = 0°; b = 2.5 mm; N = 950 N ; Ft = 475 N
t 0.25
r= = = 0.33333
tc 0.75
r cos α r cos 0
tan φ = = = r = 0.33333
1 − r sin α 1 − r sin 0
φ ⇒ 18.435°
To calculate shear force;
as α = 0, N = Fc = 950 N
Fs = Fc cos φ − Ft sin φ = 950 cos18.435° − 475sin18.435° = 751.04 N
GATE-2011 (PI) linked S-2 Page No.12 Slide No.105 Ans. (d)

bt
We know, FS = τ y ;
sin φ
2.5 mm × 0.25 mm
751.04 N = τ y ( N / mm 2 )
sin18.435°
⇒ τ y = 379.90 N
mm 2
IFS-2012 Page No.12 Slide No.106 Ans.
d = t = 0.1 mm, tc = 0.2mm, b = 5 mm, Fc = 500 N , Ft = 200 N , α = 10°
To calculate co-efficient of friction:
Using relations:
F = Fc sin α + Ft cos α = 500sin10° + 200 cos10° = 283.79 N
N = Fc cos α − Ft sin α = 500 cos10° − 200sin10° = 457.67 N
F 283.79
μ= = = 0.62
N 457.67
To calculate shear strength;
t 0.1 mm
r= = = 0.5
tc 0.2 mm
r cos α 0.5cos10
φ = tan −1 = tan −1 = 28.334°
1 − r sin α 1 − 0.5sin10
Using relation;
Fs = Fc cos φ − Ft sin φ = 500 cos 28.334° − 200sin 28.334° = 345.18 N
⎛ bt ⎞
Shear force(FS ) = shear strength(τ y ) × shear area ⎜ ⎟
⎝ sin φ ⎠
bt 5 × 0.1
Fs = τ y ⇒ 345.18 = τ y ×
sin φ sin 28.334°
τ y = 327.65 N / mm 2
GATE-2006 common data Q-1 Page No.12 Slide No.107 Ans. (b)
α = 15; t = 0.5mm; tc = 0.7mm; Fc = 1200 N ; Ft = 200 N
t 0.5
r= = = 0.7142
tc 0.7
r cos α 0.7142 cos15°
φ = tan −1 = tan −1 = 40.24°
1 − r sin α 1 − 0.7142sin15°
F = Fc sin α + Ft cos α =1200sin15° + 200 cos15° = 503.77 N
N = Fc cos α − Ft sin α = 1200 cos15° − 200sin15° = 1107.3 N
F 503.77
∴μ = = = 0.455 ≈ 0.46
N 1107.3
Alternatively
Using Merchant Theory:
α β
φ = 45° + −
2 2
15°
β = 45° + − 40.24° = 24.5°
2
μ = tan β = tan 24.5° = 0.456 ≈ 0.46
GATE-2006 common data Q-2 Page No.12 Slide No.108 Ans.(a)

V = 20m / min; Fc = 1200 N ; Ft = 200 N ( given)
Vc t Vc 0.5
=r= or =
V tc 20 m / min 0.7
orVC = 14.286 m / min
20
Total power = Fc × V = 1200 N × m / s = 400 W
60
14.286
Frictional power=F × VC = 503.77 N × m / s = 119.95W
60
Percentage of total energy dissipated as frictional power is
F × VC 119.95
⇒ × 100% = × 100% = 29.988% ≈ 30%
Fc × V 400
GATE-2006 common data Q-3 Page No.13 Slide No.109 Ans. (d)
ε = cot φ + tan(φ − α ) = cot 40.24 + tan(40.24 − 15 ) = 1.653
° ° °
IES-1995 Page No.13 Slide No.112 Ans. (b) Tangential force accounts for 99% of
the power consumption.
GATE-2014 Page No.14 Slide No.118 Ans. 0.08 to 0.12
t = f sin λ
λ = 90° − CS = 90° − 60° = 30°
t = 0.2sin 30° = 0.1 mm
ESE-2003(conventional) Page No.14 Slide No.119 Ans.

α = 0;f = 0.2mm / rev, d = 4mm, tc = 0.8mm, dia ( D) = 160mm, speed = 400rpm
∵ it is a turning operation,
Fc = 1200 N
Fx 800
Ft = = = 828.22 N
sin λ sin 75°
(i) Using the force relations
F=FC sin α + Ft cos α = 1200sin 0 + 828.22 cos 0 = 828.22 N
N = Fc cos α − Ft sin α = 1200 cos 0 − 828.22sin 0 = 1200 N
(ii ) ∵ it is a turning operation,
t = f sin λ = 0.32sin 75° = 0.3091 mm
d 4
b= = = 4.1411 mm,
sin λ sin 75°
t 0.3091 mm
Now , r = = = 0.38638
tc 0.8 mm
r cos α r cos 0
φ = tan −1 = tan −1 = tan −1 r = tan −1 0.38638 = 21.13°
1 − r sin α 1 − r sin 0
Fs = Fc cos φ − Ft sin φ = 1200 cos 21.13 − 828.22sin 21.13 = 820.76 N
bt
Fs = τ y ×
sin φ
F 820.76
or τ y = s = = 230.93 N / mm 2
bt 4.1411× 0.3091
sin φ sin 21.13
π DN π × 0.160 × 400
(iii ) V = = = 3.351 m / s
60 60
Power consumption(P)=Fc × V = 1200 × 3.351W = 4.021kW
GATE-1995(conventional) Page No.14 Slide No.120 Ans.
Given : α =100 t = f sin λ = 0.15455mm
t
λ = 750 r= = 0.32197
tc
r cosα
t c = 0.48 mm tanφ = = 0.33586
1 − r sinα
f = 0.16 mm/rev or φ =18.5650
Fc = 500N
Fx 200
Ft = = = 207N
sin λ sin75
F = Fc sin α + Ft cos α = 500 sin10 + 207 cos10 = 290.68 N
N = Fc cos α − Ft sin α = 500 cos10 − 207sin10 = 456.56N
F 290.68
μ= = = 0.63667
N 456.56
β = tan −1 μ = 32.484 o
Fn = Fc sin φ + Ft cos φ = 500 sin18.565 + 207 cos18.565 = 355.42N
Fs = Fc cos φ − Ft sin φ = 500 cos18.565 − 207 sin18.565 = 408.08 N
IAS-2003(main exam) Page No.14 Slide No.121 Ans.

Givven :
α b = 7; CS = 300;∴ λ = 90° − 30° = 60°
t = 2mm; b = 2.5mm; Fc = 1177
1 N ; Ft = 560 N
Usiing relationss:
tan α = tan α s sin λ + taan α b cos λ
t α = tan α s sin 60° + tan 7° cos 60°...........(i )
or tan
tan α b = tann α cos λ + siin λ tan i
t 7° = tan α cos 60° + sin 60° tan 0°
or tan
or α = 13.79°
Froom (i ) α s = 12°
1
Usiing force relaations
F = FC sin α + Ft cos α
= 1177 sin13.79 + 560 coss13.79 = 8224.44 N
N = FC cos α − Ft sin α = 1177
1 cos13.779 − 560sinn13.79 = 10009.6 N
F 824.444
μ= = = 0.816 ⇒ β = tann −1 μ = tan −1 0.816 = 39..214°
N 1009..6
Usiing Merchannt Theory
α β 3.79° 39.2214°
13
φ = 45°+ − = 45° + − = 32.288°
2 2 2 2
Usiing force rellation:
Fs = Fc cos φ − Ft sin φ = 1177
1 cos 32..288° − 560 sin 32.288° = 695.87 N
Fs 6695.87
Sheear strength (τ y ) = = = 74.34 N / mm 2
bt 2 × 2.55
sinn φ sin 32.288
GA
ATE-2007 Pag ge No.14 Slide No.123 3 An
ns. (b)
λ = 90° ; α = 0°
t = f sinn λ = f sin 90
9 ° = 0.24 mm
m
tc = 0.448 mm
t 0.24 mm
r= = = 0.5
tc 0.48 mm
r cos α r cos 0
φ = tan −1 = tan −1 = tann −1 r = tan −1 0.5 = 26.566°
1 − r sin α 1 − r sin 0
GA
ATE-2015 Pag
ge No.14 Slide No.124
4 An
ns. 18.88
GA
ATE-2015 Pag
5 An
ns. (a)
GA
ATE-2016 Pag
6 Anss. (b)

For an Orthogonal Turning (Orthogonal Cutting)
This question is somehow confusing,datagiven
for orthogonal turning but written orthogonal cutting
Principal cutting edge angle λ = 90o
t = f sin λ or t = 0.4 sin 90o = 0.4 mm
tc = 0.8 mm
t 0.4
r= = = 0.5
tc 0.8
r cos α 0.5cos 22
Now,tan φ = = or φ = 29.7o
1 − r sin α 1 − 0.5sin 22
GATE-2007 Page No.15 Slide No.127 Ans.(c)
λ = 90 ; α = 0 ;φ = 25 ; Fc = 1000 N
° ° °
Fx 800
We know; Ft = = = 800 N
sin λ sin 90°
Using relations:
F = Fc sin α + Ft cos α = 1000sin 0 + 800 cos 0 = 800 N
N = Fc cos α − Ft sin α = 1000 cos 0 − 800sin 0 = 1000 N
F 800
μ= = = 0.8
N 1000
GATE-2003(common data)S-1 Page No.15 Slide No.128 Ans. (a)
f = 0.25 mm / rev, d = 0.4 mm, α = 10°, φ = 27.75°
t = f sin λ = 0.25sin 90° = 0.25 mm
r cos α r cos10°
tan φ = =
1 − r sin α 1 − r sin10°
r cos10°
tan 27.75° =
1 − r sin10°
t 0.25
r = 0.4888 = =
tc tc
⇒ tc = 0.51138 mm
GATE-2003(common data)S-2Page No.15 Slide No.129 Ans. (d)
using Merchant Analysis;
α β
φ =45°+ −
2 2
10° β
27.75° = 45° + − ⇒ β = 44.5°
2 2
μ = tan β = tan 44.5° = 0.9826
GATE-2008(common data)S-1 Page No.15 Slide No.130 Ans. (d)
τ y = 250 MPa;V = 180 m / min;
f = 0.20 mm / rev; d = 3 mm; r = 0.5; α = 7°
r cos α 0.5cos 7°
φ = tan −1 = tan −1 = 27.85° ≈ 28°
1 − r sin α 1 − 0.5sin 7°
We know;
d = b sin λ ⎤
.........(λ = 90); d = b & t = f
t = f sin λ ⎥⎦
bt 0.20 × 3
Fs = τ y = 250 × = 321.09 N ≈ 320 N
sin φ sin 27.85°

GATE-2008(common data)S-2 Page No.15 Slide No.131 Ans. (b)
Using Merchant Theory:
7 β 7° β
φ = 45° + − ⇒ 28° = 45° + − = 41°
2 2 2 2
Using Merchant Circle:
Fs = R cos (φ + β − α )
320 = R cos(28° + 41° − 7°) ⇒ R = 681.62 N
Fc = R × cos ( β − α ) = 681.62 cos(41 − 7) = 565.09 N
Ft = R × sin ( β − α ) = 681.62sin(41 − 7) = 381.16 N
IES-2004 Page No.15 Slide No.133 Ans.(b)
MRR = Vfd
( )
= 50 × 103 × 0.8 × 1.5mm3 / min
= 60000mm3 / min
GATE-2013 Page No.15 Slide No.134 Ans.(d)
π DN π × 200 ×160
MRR = fdV = fd × mm / s = 0.25mm × 4 mm × mm / s = 1675.5mm3 / s
60 60
MRR = Cross Section × AxialVelocity
π
=
4
(D 1
2
)
− D22 × F
π
=
4
(10 2
)
− 92 × 175 mm3 / min = 2611.45 mm3 / min
Or MRR = fdV = fd (π DN ) = π dDaverage ( fN ) = π dDaverage F

= π × 0.5 × 9.5 × 175 mm3 / min = 1611.45 mm3 / min
GATE(PI)-1991 Page No.16 Slide No.138 Ans. (d)
GATE-2007 Page No.16 Slide No.139 Ans. (d)
The energy consumption per unit volume of material removal, commonly known as specific energy.
Power (W ) Fc
e= =
3
(
MRR mm / s 1000 fd )
Fc
or 2.0 = ⇒ Fc = 800 N
1000 × 0.2 × 2
GATE-2016(PI) Page No.16 Slide No.140 Ans. 0.001
GATE-2013(PI) common data question Page No.16 Slide No.141 Ans. (b)
FC 200
Specific cutting energy = J / mm3 = = 2 J / mm3
1000 fd 1000 × 0.1× 1
GATE-2014 Page No.16 Slide No.144 Ans. (b)
FC FC 400
Specific pressure = = = = 2000 N / mm 2
bt fd 2 × 0.1
chip : work piece : tool = 80 : 10 : 10
IAS-2003 Page No.18 Slide No.156 Ans. (c)

IES- 1996 Page No.18 Slide No.160 Ans. (b)
ΔR
IES- 1998 Page No.19 Slide No.164 Ans. (b) = Gε
R
IAS- 2001 Page No.19 Slide No.165 Ans. (c)
FOR PSU & IES Page No.19 Slide No.166 Ans.(a) For higher sensitivity, two
gauges are used for tensile strain, while two others are for compressive strain, total of which adds up to four
gauges. All the four gauges in each bridge are active gauges, and the bridge fully compensates for temperature
changes. For 3-D lathe dynamometer total 12 strain gauge is needed, 4 for main cutting force, 4 for Radial force
and 4 for feed force.
Ch‐3 Tool Life: Answers with Explanation

IES-2010 Page No.19 Slide No.169 Ans.(a)
IES-2007 Page No.19 Slide No.170 Ans.(c)
IES-2014 Page No.19 Slide No.171 Ans. (b) Think only the parameters which can produce cyclic
stress on tool material.
IES-1994 Page No.20 Slide No.174 Ans.(b) Flank wear directly affect the component dimensions.
GATE-2014 Page No.20 Slide No.176 Ans.(c) Strain hardening don’t confuse with oxide layers because
if workpiece is clean then also tool will wear.
GATE-2008(PI) Page No.21 Slide No.183 Ans.(b)
Solving using straight line equation:
y2 − y1
y − y1 = i( x − x1 )
x2 − x1
2 − 0.8
1.8 − 0.8 =
60 − 10
( x − 10 )
x = 51.666
IES-2002 Page No.21 Slide No.187 Ans.(c)For crater wear temperature is main culprit and tool
defuse into the chip material & tool temperature is maximum at some distance from the tool tip that so
why crater wear start at some distance from tip.
IAS-2007 Page No.21 Slide No.188 Ans.(c)
IES-1995 Page No.22 Slide No.190 Ans.(b)Crater wear occurs due to temperature mainly. And high
carbon tool steel withstands least temperature 250oC. 250oC is too low for diffusion. HSS will withstand
600oC it is also low for diffusion. WC (Tungsten Carbide) tool contains cobalt as binder which can diffuse
as temperature is 800oC to 900oC. Ceramics are carbide or oxides of metal it will not diffuse.
IAS-1999 Page No.22 Slide No.194 Ans.(c)Chemical reaction between abrasive and workpiece
material at elevated temperature and in the presence of grinding fluid.
IAS-2003 Page No.22 Slide No.196 Ans.(b)
In Taylor’s tool life equation is
n = 0.08 – 0.20 → for H.S.S.
n = 0.20 – 0.60 → for Carbides.
n = 0.60 – 0.80 → for Ceramics.
IAS-1998 Page No.24 Slide No.209 Ans.(d)
GATE-2009(PI) Page No.24 Slide No.211 Ans.(a)

Using Taylor's Tool Life Equation VT n = C
V1T1n = V2T2 n
or 100 × 10n = 75 × 30n
or n = 0.2616 ( can be solved using solve function on calculator )
ISRO-2011 Page No.24 Slide No.212 Ans.(c)
D = 50mm;
π D × 284
N1 = 284rpm; T1 = 10 min;V1 = m / min
1000
π D × 232
N 2 = 232rpm; T2 = 60 min;V2 = m / min
1000
Using Taylor's Tool Life Equation, VT n = C
V1T1n = V2T2 n
π D × 284 π D × 232
or ×10n = × 60n or n = 0.1128
1000 1000
In the question straight line relation is mentioned which is wrong.
GATE-2004, IES-2000 Page No.24 Slide No.213 Ans.(c)

V1T1n = V2T2 n
n
⎛T ⎞ 1
or V × T = 2V × ⎜ ⎟ or 8n = 2 or n =
n
⎝8⎠ 3
IES-1999, ISRO-2013 Page No.24 Slide No.214 Ans.(d)

V1T1n = V2T2 n
⎛V ⎞
or V1T10.25 = ⎜ 1 ⎟ T2 0.25
⎝2⎠
⎛ 1 ⎞
⎜ ⎟
or T2 = 2⎝ 0.25 ⎠ T1 = 16T1

V
V1T1n = V2T2 n or n = 0.25;V2 = 1
2
V
or V1 × T10.25 = 1 × T20.25 or T2 = 16T1
2
GATE-2015 Page No.25 Slide No.217 Ans.0.25
IAS-2002 Page No.25 Slide No.218 Ans.(a)

⎡ V1 ⎤
V1T1n = V2T2 n ⎢Where, n = 0.5;V2 = 2 ⎥
⎣ ⎦
⎛V ⎞
or V1T10.5 = ⎜ 1 ⎟ T20.5
⎝2⎠

or T2 = 20.5 T1 = 4T1
T2 − T1 4T − T
%change = ×100% = 1 1 × 100% = 300%
T1 T1

n = 0.25;V = 60m / min; T = 1 hr 21min = 81min
60 × 810.25 = C = 180

V1T1n = V2T2 n
n = 0.5; V1 = 18 m / min; T1 = 180 min; T2 = 45 min;V2 = ?
Putting in equation:
or 18 ×1800.5 = V2 × 450.5
or V2 = 36m / min
IES-2006 (conventional) Page No.25 Slide No.222 Ans.
Given: V1 = 30 m/min; T1 = 1 hr = 60 min, V2 = 2V1, T2 = 2 min, T3 = 30 min,
Taylor tool life equation gives
VTn = C
or V1 T1n = V2 T2n
n
⎛ T1 ⎞ ⎛ V2 ⎞
or ⎜ ⎟ =⎜ ⎟
T
⎝ 2⎠ ⎝ V1 ⎠
taking log on both side we get
⎛T ⎞ ⎛ V2 ⎞
n ln ⎜ 1⎟ = ln ⎜ ⎟
⎝ T2
⎠ ⎝ V1 ⎠
⎛V ⎞ ⎛ 2V ⎞
ln ⎜ 2 ⎟ ln ⎜ 1 ⎟
or n = ⎝ V1 ⎠ = ⎝ V1 ⎠ = 0.204
⎛T ⎞ ⎛ 60 ⎞
In ⎜ 1 ⎟ ln ⎜ ⎟
⎝ T2 ⎠ ⎝ 2 ⎠
Now for = T3 = 30 min, V3 = ?
Here V1 T1n = V3 T3n
n 0.204
V1 T1n ⎛T ⎞ ⎛ 60 ⎞
or V3 = = V1 x ⎜ 1 ⎟ = 30 × ⎜ ⎟ = 34.55 m/min
T3n T
⎝ 3⎠ ⎝ 30 ⎠
V3 = πdN
V3 34.55
or N = = =36.66 rpm
πd π×0.3
GATE-2009 Linked Q-1 Page No.25 Slide No.223 Ans.(a)
VTn = C V1 T1n = V2 T2n
60 × 81n = 90 × 36n
n
⎛ 81 ⎞ 90
or ⎜ ⎟ = = 1.5
⎝ 36 ⎠ 60
In1.5
n= ⇒ n = 0.5
⎛ 81 ⎞
In ⎜ ⎟
⎝ 36 ⎠
C =60 × 810.5 = 90 × 360.5 = 540 = K

GATE-2009 Linked Q-2 Page No.25 Slide No.224 Ans.(c)
V1 60
Now, according to the given question V = = = 30m / min;
2 2
1/n
⎛C⎞
T1 = ⎜ ⎟
⎝ V1 ⎠
1/n
⎛ C⎞
T2 = ⎜ ⎟
⎝ V2 ⎠
T2 − T1 ⎛ V1 ⎞
1/n
−1 = ( 2)
1/0.5
=⎜ ⎟ − 1 = 300%
T1 ⎝ V2 ⎠
IFS-2013 Page No.25 Slide No.225 Ans.
Using Taylor's Tool Life Equation:
V1T1n = V2T2 n
or 100 ×120n = 130 × 50n
or n = 0.2997 ≈ 0.3
NowC = 100 ×1200.3 = 420.49
Tool life when cutting speed is 2.5 m/s = 2.5 × 60 m/min
( 2.5 × 60 ) T 0.3 = 420.49
or T = 31.06 min
Velocity when tool life is 80 min
V × 800.3 = 420.49
or V = 112.94 m / min
GATE-2010 Page No.26 Slide No.226 Ans.(a)
for Carbide → n1 = 1.6, K 1 = 90
for HSS → n2 = 0.6, K 2 = 60
Using Taylor's Tool Life Equation:VT n =C
let cutting speed is x m/min
1
⎛ 90 ⎞ 0.45
x×TA 0.45
=90 ⇒ TA = ⎜ ⎟
⎝ x ⎠
1
⎛ 60 ⎞ 0.30
and x×TB 0.3
= 60 ⇒ TB = ⎜ ⎟
⎝ x ⎠
for TA >TB
1 1
⎛ 90 ⎞ 0.45 ⎛ 60 ⎞ 0.30
⎜ x ⎟ >⎜ ⎟
⎝ ⎠ ⎝ x ⎠
Solve for x using calculator, x = 26.7 m/min
GATE-2013 Page No.26 Slide No.227 Ans.(b)
for A → n1 = 0.45, K1 = 3000
for B → n2 = 0.3, K 2 = 200
Using Taylor's Tool Life Equation:VT n =C
let cutting speed is x m/min
1
⎛ 3000 ⎞ 1.6
x×Tc
1.6
=3000 ⇒ Tc = ⎜ ⎟
⎝ x ⎠
1
⎛ 200 ⎞ 0.6
and x×TH 0.6
= 200 ⇒ TH = ⎜ ⎟
⎝ x ⎠

for Tc >TH
1 1
⎛ 3000 ⎞ 1.6 ⎛ 200 ⎞ 0.60
⎜ x ⎟ >⎜ x ⎟
⎝ ⎠ ⎝ ⎠
Solve for x using calculator, x = 39.389 m/min
Ans. 106.066
Let us assume the speed is x m/min.
1
⎛ 150 ⎞ 0.1
xT10.1 = 150 ⇒ T1 = ⎜ ⎟
⎝ x ⎠
1
⎛ 300 ⎞ 0.3
and xT 2
0.3
= 300 ⇒ T2 = ⎜ ⎟
⎝ x ⎠
NowT2 > T1
1 1
⎛ 300 ⎞ 0.3 ⎛ 150 ⎞ 0.1
or ⎜ ⎟ >⎜ ⎟
⎝ x ⎠ ⎝ x ⎠
For solving inequality
1 1
⎛ 300 ⎞ 0.3 ⎛ 150 ⎞ 0.1
⎜ ⎟ =⎜ ⎟
⎝ x ⎠ ⎝ x ⎠
0.1 0.3
⎛ 300 ⎞ ⎛ 150 ⎞
or ⎜ ⎟ =⎜ ⎟
⎝ x ⎠ ⎝ x ⎠
x 0.3 1500.3
or 0.1 =
x 3000.1
or x = 106.066 m / min
EXAMPLE Page No.26 Slide No. 229 Ans.
This can be solved using regression analysis:
Using Taylor's Tool Life Equation:VT n = C
taking log on both sides: log V + n log T = log C
or log V = log C − n log T
On comparing with straight line equation,in Casio Calculator:
y = A + Bx
y = log V ; x = log T ; A = log C ; B = − n
T V X=logT Y=logV
2.94 49.74 X1= log2.94 Y1= log49.47
3.90 49.23 X2= log3.90 Y2= log49.23
4.77 48.67 X3= log4.77 Y3= log48.67
9.87 45.76 X4= log9.87 Y4= log45.76
28.27 42.58 X5= log28.27 Y5= log42.58
Now on calculator,
Press mode – 2 times-then press ‘2’ (Reg-2)
Then select the type – (lin-1)
Then start entering the values as below;
x1 ,y1 i.e. log2.94, log49.47 then press DT(M+) it will display n =1 then press AC
After entering all values then press shift then S-VAR(on number 2),then press the right arrow 2 times
then A (1) press 1 then = it will give A = 1.732
Again press the right arrow 2 times then B(2) press 2 and = it will give B = -0.07

From y = A + Bx; A = log C ⇒ C = 10 A = 54
B = − n = −0.07 ⇒ n = 0.07
∴ equation becomes:VT n = C ⇒ VT 0.07 = 54
10 cutting tools produce 500 components
Therefore, 1 cutting tool will produce 50 components
we know : V = π DNm / min
For the 1st case:
N = 50rpm, f = 0.25mm / rev
L
Let t1 be the time to produce 1 component in 1st case,t1 = min
fN
L
Tool life(T1 ) = 50components × t1 = 50 × min
f × 50
10 cutting tools produce 122 components
Therefore, 1 cutting tool will produce 12.2 components
For the 2nd case:
N = 80rpm, f = 0.25mm / rev
L
Let t2 be the time to produce 1 component in 2nd case,t 2 = min
fN
L
Tool life(T2 ) = 12.2components × t2 = 12.2 × min
f × 80
Using Taylor's Tool Life Equation:VT n = C ⇒ V1T1n = V2T2 n
n n
⎛ L ⎞ ⎛ L ⎞
or π D × 50 × ⎜ 50 × ⎟ = π D × 80 × ⎜ 12.2 ×
⎝ 0.25 × 50 ⎠ ⎝ 0.25 × 80 ⎟⎠
or n = 0.2499 ≈ 0.25
For 3rd case : N = 60rpm, f = 0.25mm / rev
L
Let t3 be the time to produce 1 component in 3rd case,t 3 = min
fN
L
Tool life(T3 ) = ( x )components × t2 = x × min
f × 60
now, V1T10.25 = V3T30.25
0.25 0.25
⎛ L ⎞ ⎛ L ⎞
or π D × 50 × ⎜ 50 × = π D × 60 × ⎜ x ×
⎝ 0.25 × 50 ⎟⎠ ⎝ 0.25 × 60 ⎟⎠
0.25
⎛ x ⎞
or 50 = 60 × ⎜ ⎟
⎝ 60 ⎠
or x = 28.926 ≈ 29components
GATE-2017 Page No. 26 Slide No. 231 Ans. (b)

V1 = π D × 400 m / min, T1 = 20 min
V2 = π D × 200 m / min, T2 = 60 min
Now using Taylor's equation
V1 T1n = V2T2n
π D × 400 × ( 20 ) = π D × 200 × 60n
n
or
or n = 0.6309
And , V3 = π D × 300 m / min, T3 = ?
V1 T1n = V2T2n = V3 T3n
π D × 400 × ( 20 ) = π D × 300 × T30.6309
0.6309
∴T3 = 31.55 min ≈ 32 min

∵ flank wear ∝ cot α
∴ tool life ∝ tan α
tan α 2 − tan α1 tan 7 − tan10
% change in life = × 100% = × 100% = −30%
tan α1 tan10
∴ % change in life = 30% decrease
ISRO-2012 Page No.27 Slide No.235 Ans.(d)
IES-1994,2007 Page No.27 Slide No.237 Ans.(c)
We know that cutting speed has the greatest effect on tool life followed by feed and depth of cut
respectively. For maximizing tool life we will adjust 3- 2- 1 respectively.
IES-2008 Page No.27 Slide No.238 Ans.(a) If we increase feed rate it must increase cutting force and
temperature. Therefore statement ‘4’ is wrong.
IAS-1995 Page No.27 Slide No.239 Ans. (a) It is comparing, if we increase speed it will increase maximum
temperature and depth of cut increase temperature least. That so why tool life affected mostly by velocity
and least by depth of cut.
ESE-1991, IAS-2010(conventional) Page No.27 Slide No.240 Ans.
given;VT 0.3 f 0.6 d 0.3 = C
V = 40m / min; T = 60 min; f = 0.25mm / rev; d = 2mm
Putting in equation : 40 × 600.3 × 0.250.6 × 20.3 = C ⇒ C = 36.49
When speed, feed & depth of cut are together increased by 25%; tool life will be
Now when V, f and d are increased by 25%
New V,f and d are:V = 40 + 0.25 × 40 = 50 m / min
f = 0.25 + 0.25 × 0.25 = 0.3125mm / rev
d = 2 + 0.25 × 2 = 2.5mm
putting in given equation:VT 0.13 f 0.6 d 0.3 = 36.49
50 × T 0.13 × 0.31250.6 × 2.50.3 = 34.99
T = 2.29 min
When only speed is increased by 25%, rest parameters remain same; then
Now when V is increased by 25%
New V,f and d are:V = 40 + 0.25 × 40 = 50m / min, f = 0.25mm / rev, d = 2mm
putting in given equation: VT 0.13 f 0.6 d 0.3 = 34.99
or 50 × T 0.13 × 0.250.6 × 20.3 = 34.99
or T = 10.779 min
When only feed is increased by 25% , rest parameters remain same; then tool life

Now when f is increased by 25%
New V,f and d are:V = 40m / min, f = 0.25 + 0.25 × 0.25 = 0.3125mm / rev, d = 2mm
or 40 × T 0.13 × 0.31250.6 × 20.3 = 36.49
or T = 21.41min
When only depth of cut is increased by 25%, rest parameters remain same; then
Now when d is increased by 25%
New V,f and d are:V = 40m / min, f = 0.25mm / rev, d = 2 + 0.25 × 2 = 2.5mm
or 40 × T 0.13 × 0.250.6 × 2.50.3 = 36.49
or T = 35.844 min
0.14 0.7 0.4
45 × 30 × 0.35 ×2 = C = 45.84
V1 = 45 × 1.25 = 56.25 m / min
T1 = ?
f1 = 0.35 × 1.25 = 0.4375 mm
d1 = 2.0 × 1.25 = 2.5 mm
45.84
T10.14 = = 1.007538
56.25 × 0.43750.7 × 2.50.4
T1 = 1.055 ≈ 1.06
GATE-2017(PI) Page No.27 Slide No. 242 Ans. Range (80 to 84)
IES-2016 Conventional Page No.27 Slide No. 243 Ans. n = 0.160964, C = 72.43

IES-2014 Page No.28 Slide No.252 Ans.
IES-2009(conventional) Page No.29 Slide No.260 Ans.
Tc = 3min, Tool regrind time(Tr ) = 3min, Cm = Rs.0.50 / min
Depriciation cost = Rs.5.0, n = 0.2; C = 60
Using the equation for optimum tool life for minimum cost
⎛ C ⎞⎛ 1 − n ⎞
To = ⎜ Tc + t ⎟ ⎜
⎝ Cm ⎠ ⎝ n ⎟⎠
Ct = Cm × Tr + Depriciation cost
Ct = Rs.0.50 / min× 3min + Rs.5.0 = Rs.6.5 / regrind
Putting in equation:
⎛ 6.5 ⎞ ⎛ 1 − 0.2 ⎞
To = ⎜ 3 + ⎟ ⎜ 0.2 ⎟ = 64 min
⎝ 0.50 ⎠⎝ ⎠
Using Taylor's Tool Life Equation:VoTon = C
Vo ( 64 )
0.2
= 60 orVo = 26.11 m / min
GATE-2014 Page No.29 Slide No.261 Ans. 5.9 to 6.1min
Tc = 1.5 min; n = 0.2
Using optimum tool life equation for maximum productivity:
⎛ 1− n ⎞ ⎛ 1 − 0.2 ⎞
To = Tc ⎜ ⎟ or To = 1.5 ⎜ 0.2 ⎟ = 6 min
⎝ n ⎠ ⎝ ⎠
ESE-2001(conventional) Page No.30 Slide No.262

V1 = 50m / min; T1 = 45 min;V2 = 100m / min; T2 = 10 min; Tc = 2 min
Using Taylor's Tool Life Equation:VT n = C ⇒ V1T1n = V2T2 n
50 × 45n = 100 ×10n or n = 0.46, C = 50 × 450.46 = 288
Using equation of optimum tool life:
⎛ 1− n ⎞ ⎛ 1 − 0.46 ⎞
To = Tc ⎜ ⎟ = 2⎜ ⎟ = 2.34
⎝ n ⎠ ⎝ 0.46 ⎠
Again Using Taylor's Tool Life Equation:VoTon = C
Vo × 2.340.46 = 288 orVo = 195m / min
IAS-2011(main) Page No.30 Slide No.263 Ans.
Tc = 9 min; n = 0.5; C = 100
Using optimum tool life equation for max productivity:
⎛ 1− n ⎞ ⎛ 1 − 0.5 ⎞
To = Tc ⎜ ⎟ or To = 9 ⎜ ⎟ = 9 min
⎝ n ⎠ ⎝ 0.5 ⎠
Using Taylor's Tool Life Equation:VoTon = C , Vo × 90.5 = 100 orVo = 33.33 m / min
GATE-2016 Page No.30 Slide No.267 Ans. 57.91 m/min
TotalCost (Ct ) = MetalCutting Cost (Cm ) + Tooling Cost (Ct )
18C 270C ⎡ ⎛ 150 ⎞ 0.25 ⎛ 150 ⎞ ⎤

1 4
Ct = + ⎢ Now T = ⎜ ⎟ =⎜ ⎟ ⎥
V VT ⎢⎣ ⎝ V ⎠ ⎝ V ⎠ ⎥⎦
18C 270C
Ct = + 4
V ⎛ 150 ⎞
V⎜ ⎟
⎝ V ⎠
dCt 18C 270C × 3V 2
=− 2 + =0 orV = 57.91 m / min
(150 )
4
dV V
IAS-2007 Page No.30 Slide No.269-270 Ans.(b)
The minimum cost criterion will give a lower cutting speed i.e. lower prodeuction rate, while the
maximum production rate criteria will result higher cutting speed i.e. higher cost per piece as it reduces
tool life.
IAS-1997 Page No.31 Slide No.276 Ans.(b) it is less than one but very close to each other so 0.1 is not
possible.
IES-2004 Page No.31 Slide No.278 Ans.(a) To improve MRR = fdv i.e. productivity we can increase
velocity or feed. but increase in velocity will reduce the tool drastically so will increase cost more than
feed.
IAS-2007 Page No.32 Slide No.280 Ans.(a)At optimum cutting speed for the minimum cost of
machining gives low production rate.
IES-2010 Page No.32 Slide No.281 Ans.(d) After some time cutting speed will be so that tool
changing time will be significant.
IAS-1996 Page No.32 Slide No.286 Ans.(d) Machinability is a comparative measure not absolute.
IES-1992 Page No.33 Slide No.291 Ans.(a) large grain means soft workpiece material.
IAS-2000 Page No.33 Slide No.293 Ans.(a)Built up edge protects the cutting edge of the tool from
wear, So tool life increased but it changes the geometry of the cutting.
IES-2007,2009 Page No.34 Slide No.298 Ans.(a)Machinability: Machinability can be tentatively defined as
‘ability of being machined’ and more reasonably as ‘ease of machining’.
Such ease of machining or machining characters of any tool-work pair is to be judged by:
• Magnitude of the cutting forces
• Tool wear or tool life

• Surface finish
• Magnitude of cutting temperature
• Chip forms
ISRO-2007 Page No.34 Slide No.299 Ans.(a)But All of the above are machinability criteria. We have to
select best option that so why chosen (a)
IES-2003 Page No.34 Slide No.300 Ans.(c)Free-machining steels are basically carbon steels that
have been modified by an alloy addition to enhance machinability. Sulfur, lead, bismuth, selenium,
tellurium, and phosphorus have all been added to enhance machinability. Sulfur (0.08 to 0.33%)
combines with manganese (0.7 to 1.6%) to form soft manganese sulfide inclusions. These act as
discontinuities in the structure which serve as sites to form broken chips. The inclusions also provide a
built-in lubricant that prevents formation of a built-up edge on the cutting tool and imparts an altered
cutting geometry.
IES-2009 Page No.34 Slide No.301 Ans.(a) Sulphur, Lead and Phosphorous are added to steel which
when added to Manganese forms Manganese sulphide etc. which has low shear strength.
IES-1998 Page No.34 Slide No.302 Ans.(c) It is CNC machine, dimensional accuracy and surface
finish are prime factor.
IES-1996 Page No.34 Slide No.303 Ans.(d) smaller shear angle means higher force.
IES-1992 Page No.35 Slide No.307 Ans. (b) Titanium is very reactive and the chips tend to weld to
the tool tip leading to premature tool failure due to edge chipping. Almost all tool materials tend to react
chemically with titanium.
Titanium’s work-hardening characteristics are such that titanium alloys demonstrate a complete absence
of “built-up edge”. Because of the lack of a stationary mass of metal (BUE) ahead of the cutting tool, a
high shearing angle is formed. This causes a thin chip to contact a relatively small area on the cutting
tool face and results in high loads per unit area. These high forces, coupled with the friction developed by
the chip as it passes over the cutting area, result in a great increase in heat on a very localized portion of
the cutting tool. All this heat (which the titanium is slow to conduct away), and pressure, means that tool
life can be short, especially as titanium has a tendency to gall and weld to the tool surface.
IES-1995 Page No.35 Slide No.308 Ans. (a) Titanium high cost and need 10 times much energy than
steel to produce. Light weight, strong, corrosion resistant, properties between steel and aluminium.
f2
we know : hc =
8R
f2 f2 f2 4f
When f1 = 2 f , and hc remains the same; = 1 or = ⇒ R1 = 4 R
8 R 8 R1 8 R 8 R1
GATE-1997 Page No.35 Slide No.313 Ans. (a)
h = 5μ m = 5 ×10 m; R = 1.8mm = 1.8 ×10−3 m
−6
f2 f2
we know : h = or 5 ×10−6 = or f = 2.68 ×10−4 m / rev = 0.268mm / rev
8R 8 ×1.8 ×10−3
f = 1mm / rev; SCEA = 30°; ECEA = 10°
f 1
Using formula: h = = = 0.16mm
tan SCEA + cot ECEA tan 30 + cot10
f
Using formula:h =
tan SCEA + cot ECEA
f f
hP = and hQ =
tan 30 + cot 8 tan15 + cot 8
h
∴ P =
( tan15 + cot 8)
hQ ( tan 30 + cot 8 )
IES-1993, ISRO-2008 Page No.36 Slide No.316 Ans. (c) Surface roughness is directly dependent on
square of feed. Slow cutting results in formation of built-up edge, but after certain speed the finish
remains same. Rake angle has noticeable effect at slow speeds, but its effect is small at speeds, used for
finish machining. So f has maximum effect.
IES-2006 Page No.36 Slide No.317 Ans. (a) refer previous question

GATE-2014(PI) Page No.36 Slide No.318 Ans.
GATE-2010(PI) Page No.36 Slide No.319 Ans. (b)
For increasing surface finish means reduce roughness we have to increase nose radius and reduce feed.
Here MRR remains same therefore feed remains same only nose radius can be changed.
For triangular surface profile
h 20
Ra = = = 5 μm
4 4
Ch-4: Limit, Tolerance & Fit: Answers with Explanations

For PSU PageNo.37 Slide No.8 Ans.(b)
ISRO-2010 Page No.37 Slide No.9 Ans.(b)
GATE-2010, ISRO-2012 Page No.38 Slide No.12 Ans.(d)
upper limit = 35-0.009 = 34.991mm
lower limit = 35-0.025 = 34.975 mm

Fundamental Deviation = basic size-nearer limit = 35-34.991= 0.009 mm
Tolerance = upper limit-lower limit = 34.991 - 34.975 = 0.016 mm
Tolerance of shaft A=100.1-99.9=0.2
Tolerance of shaft B=0.1001-0.0999=0.0002
So, tolerance of shaft A > tolerance of shaft B
Never confused with relative errors because we even don’t know the actual dimensions of all product. we
can’t calculate error.
Maximum clearance = Higher limit of hole – lower limit of shaft
= 25.020-24.990 = 0.03 mm = 30 microns
Since basic size is 20 mm so, minimum rejection will be of the batch having mean diameter 20 mm. Due
to natural variations dimensions of the component will increase and decrease same from basic size.
max clearance = upper limit of hole - lower limit of shaft = 40.50-39.95 = 0.1 mm
GATE-2015 Page No.39 Slide No.20 Ans.(b)This being an clearance fit , so minimum clearance will
be
Min C= LL of hole –UL of Shaft
Min C = 25.020-25.005 mm = 0.015 mm

IES-2015 Page No.39 Slide No.24 Ans.(c) Allowance is the minimum clearance between shaft and hole.

GATE -2012 Same Q in GATE-2012 (PI) Page No.40 Slide No.33 Ans.(c)
Maximum Interference = Maximum size of shaft – Minimum size of hole
= (25 + 0.04) – (25 + 0.02) mm = 20 µm
IAS-2011(main) Page No.40 Slide No.34 Ans.

Using unilateral hole base system;
Min clearance = 0.03mm; Max clearance = 0.09 mm; Basic size = 20 mm
Refering the figure:2 x + 0.03 + x = 0.09 or x = 0.02 mm
∴ size of hole: lower limit = 20 mm
upper limit =20+2x = 20+2 × 0.02=20.04 mm
size of shaft:Lower limit = 20.04+0.03= 20.07 mm
upper limit = 20.07+ x =20.07+0.02=20.09 mm
For clearance fit Maximum metal condition of shaft will be smaller than minimum metal condition of the
hole. (a) Smax=50.000, Hmin=50.005 so Smax<Hmin
An interference fit creates stress state in the shaft therefore “2” is wrong.
It is thick cylinder under external pressure.
Distribution of radial and circumferential stresses within the
cylinder wall when only external pressure acts

It is transition fit, Using formula of minimum clearance
Min clearance = upper limit of shaft - lower limit of hole = -0.02 mm
Here Minimum clearance is negative i.e. maximum inteference occur.
Actually in transition fit no min clearance is there. Theoretically minimum clearance is negative of
maximum interference.
IES-2008 Page No.44 Slide No.68 Ans.(a) All statements are wrong. 50 mm is not hole diameter it
is basic size. And examiner ask INCORRECT not correct options. Therefore all options are incorrect.
Basic size =100 mm; D = D1 × D2
= 80 × 120 = 97.97 mm
Fundamental deviation of shaft
= − 5.5D 0.41 = −36 μ m
∴ Fundamental deviation of hole = +36 μ m
1
i = 0.45 D 3 + 0.001D = 2.1711μ m
IT 8 = 25i = 25 × 2.17 μ m = 54μ m
IT 10 = 64i = 64 × 2.17 μ m = 139 μ m
Allowance = min clearance = 36 µm

Geometric mean diameter(D) = 1830  23.238mm

Standard tolerance unit (i) = 0.453 D 0.001D 1.3074m
Tolerance of hole = 25i = 33m 0.033mm
Tolerance of shaft = 40i = 52m 0.052mm
Fundamental deviation of shaft d = -16D0.44 64m0.064mm
Fundamental deviation of hole H= zero
LL of hole = BS =25mm
UL of hole = BS + Tolerance = 25.033mm
UL of shaft = BS +FD= 25- 0.064mm= 24.936mm
LLof shaft = UL - tolerance = 24.936-0.052 = 24.884 mm
Selected Question Page No.44 Slide No.71 Ans.

Geometric mean diameter (D) = 50 × 80 = 63 mm
3 3
Standard tolerance unit (i) = 0.45 𝐷 + 0.001𝐷 = 0.45 63 + 0.001 × 63 = 1.853 𝜇𝑚
Tolerance for hole H8 (IT8) = 25 i = 25 × 1.853 𝜇𝑚 = 46𝜇𝑚 = 0.046 𝑚𝑚
Tolerance for shaft g7 (IT7) = 16 i = 16 × 1.853 𝜇𝑚 = 30𝜇𝑚 = 0.030 𝑚𝑚
Fundamental deviation of shaft „g‟ is=−2.5 𝐷0.34 = −2.5 × 630.34 𝜇𝑚 = −0.010 𝑚𝑚
Lower limit of hole = Basic size = 75 mm

Upper limit of hole = LL of hole + Tolerance of hole = 75 + 0.046 mm =75.046 mm
Upper limit of shaft = Basic size – fundamental deviation = 75 – 0.01 =74.99 mm
Lower limit of shaft = UL of shaft – Tolerance of shaft = 74.99 – 0.03 = 74.96 mm
Maximum clearance = UL of hole – LL of shaft = 75.046 – 74.96 mm = 0.086 mm
Minimum clearance = LL of hole – UL of shaft = 75 – 74.99 = 0.01 mm
As minimum clearance is positive it is a clearance fit.

60 mm diameter lies in the diameter step of 50-80mm. Therefore
Geometric mean diameter,D = Dmin ×Dmax = 50 × 80 = 63.246 mm
Fundamental tolerance unit ( i ) = (0.45D1/3 +0.001D) μm
= [0.45(63.246)1/3 + 0.001(63.246)] = 1.859 μm = 0.00186 mm
For IT8 = 25i = 25 × 0.00186 = 0.04646 mm
Fundamental deviation for 'f'shaft, = −5.5D0.41 = −5.5[63.246]0.41 = −0.030115mm
GATE-2008(PI) Page No.45 Slide No.74 Ans.(c)Without calculating we can choose option (c) as
fundamental deviation is zero therefore LL = Basic size = 25.000 mm
But proper calculation is
D = D1 × D2 = 18 × 30 = 23.23 mm
1
i = 0.45 D 3 + 0.001D = 1.3076 μ m = 1.3076 × 10−3 mm
For IT 8 = 25i = 0.0326mm
upper limit of hole = basic size + tolerance = 25+0.0326=25.032mm
∵ hole base system so, lower limit = basic size=25mm
Hole: Lower limit = Basic size = 25 mm
Higher limit = lower limit + tolerance = 25 + 0.033 = 25.033 mm
Shaft: Higher limit = basic size – fundamental deviation = 25 – 0.04 = 24.96 mm
Lower limit = Higher limit – tolerance = 24.96 – 0.033 = 24.927 mm
Therefore Maximum clearance = Higher limit of hole – lower limit of shaft
= 25.033 – 24.927 = 0.106 mm = 106 microns
∵ diametric steps are not given we take given dia as the basic diameter only.
i = 0.45 3 D + 0.001D = 1.34 μ m = 1.34 × 10−3 mm
For IT 7 = 16i = 16 × 1.34 × 10−3 = 0.021 mm
∵ it is a shaft base system:
Upper limit = basic size=25.00 mm
Lower limit = Upper limit − tolerance = 25.00 - 0.021=24.978 mm
GATE-2010(PI) Page No.45 Slide No.77 Ans.(d)
Fundamental deviation of all the bore is zero.
For IT7, Tolerance = 16i = 0.021 mm
Therefore i = 0.021/16 mm = 0.033/25 mm
ITn − IT6
Use formula 10 × 1.6
GATE-2016(PI) Page No.45 Slide No.78 Ans. (b) All are shaft basis system.
GATE-1996,IES-2012 Page No.45 Slide No.80 Ans.(d)
Remember
H7 with p6, s6: Interference fit
H7 with k6, n6: Transition fit
All other fits are clearance fit.
ISRO-2008 Page No.46 Slide No.84 Ans.(a)
GATE-2003 Page No.46 Slide No. 86 Ans.(b)

P = 35+0.08mm
Q = 12.00+0.02mm
R = 13.0 +−0.04
0.02 = 13.01 ± 0.03
Now all have same bilateral tolerance, so

P =Q+W+R
Considering dimension
⇒ 35 = 12 + W + 13.01
w = 9.99mm
Tolerance are probabilities and not the absolute value on any part, at
least one section must be there that treated as sink, and tolerance of
sink will be cumulative sum of all tolerances.
∴ Tolerance = 0.08 + 0.02 + 0.03 = 0.13
GATE-1997 Page No.46 Slide No. 87 Ans.(d)
S = P +Q + R +T or T = S − P − Q − R or Tmin = Smin − Pmax − Qmax − Rmax
LL of L4 = LL of L1 –UL of L2 –UL of L3
= 21.99-10.005-10.005=1.98mm
UL of L4 = UL of L1 –LL of L2 –LL of L3
= 22.01-9.995-9.995=2.02mm
GATE-2007(PI) Page No.46 Slide No.89 Ans.(a) It requires centre.
Before plating the hole size will be bigger ,
Maximum limit will correspond to min thickness;so,
min thickness = 2 × (10 × 10−3 ) mm = 0.02mm
Max limit = max size of hole + min thickness = 30.050+0.02=30.07 mm
Minimum limit will correspond to max thickness;so,
max thickness = 2 × (15 × 10−3 ) mm = 0.03mm
Min limit = min size of hole + max thickness = 30.010+0.03=30.04 mm

Upper limit of pin = 25.020 mm
Lower limit of pin = 25.010 mm
Max thickness of plating =2 × 0.032=0.064 mm
Min thickness of plating =2 × 0.028=0.056 mm
Minimum size will correspond to max thickness
Size of GO-Guage = Lower limit of pin + Max thickness of plating
Size of GO-Guage = 25.020+ 2x0.032 = 25.084 mm
GATE-2017 Page No.47 Slide No.92 Ans. 29.030
GO ring gauge will inspect maximum metal conditions i.e. UL of shaft i.e. Largest size after platting.
UL after platting = 25.02 + 2.005 + 2.005 mm = 29.030 mm

GATE-2000 Page No.47 Slide No.93 Ans.(a) It is a case of tolerance sink. Final product will be
tolerance sink because due to the errors in the block and due to the errors in the cutter locations both
errors will affect.
GATE-2017 Page No.47 Slide No.94 Ans.5
According to Root Sum Square or RSS model

Lower limit of hole = 25-0.015=24.958 mm
lower limit of GO-Guage = 24.985 mm
Work tolerance = 10% of guage tolerance = 10% of (2 × 0.015) = 0.003mm
Upper limit of GO- Guage = 24.9850+0.003 mm
GATE-2004 Page No.48 Slide No.103 Ans. (None)
Higher limit of hole = 20.05 mm
Lower limit of hole = 20.01 mm
Work tolerance = 20.05 – 20.01 = 0.04 mm
Gauge tolerance = 10% of work tolerance = 0.004 mm

0.004
Therefore, Dimension of ‘GO’ gauge = 20.01 mm
0
0.004
Dimension of ‘NOT GO’ gauge = 20.05 mm
0
GATE-2015 Page No.48 Slide No.104 Ans.(b, c and d are correct.)
GATE – 2006, VS-2012 Page No.48 Slide No.106 Ans.(c)
PSU Page No.49 Slide No.110 Ans.(c)
Ch-5 Measurement of Lines & Surface: Answers with Explanations

ISRO-2010 Page No.51 Slide No.137 Ans.(a) The vernier reading should not be taken at its face value
before an actual check has been taken for zero.
ISRO-2008 Page No.51 Slide No.138 Ans.(c) Least count = 0.5/25 = 0.02 mm
ISRO-2009, 2011 Page No.51 Slide No.131 Ans.(a)
Pitch
Total dimension= pitch × No.of div + × reading
No.of div in thimble
0.5x5 + (0.5/50) x 12 = 2.62 mm
GATE-2008 Page No.51,52 Slide No.135,136 Ans.(c) If there is axial intersection Rp
must not equal to RQ
GATE-2014(PI) Page No.52 Slide No.137,138 Ans. (d)
ISRO-2010 Page No.53 Slide No.145 Ans.(c) A measuring device of a standard size that is used
to calibrate other measuring instruments.
ISRO-2008 Page No.53 Slide No.146 Ans.(d) Primary standards are used for calibration only.
In workshop it has no use.
GATE-2007(PI) Page No.53 Slide No.149 Ans.(d) During the measurement, a comparator is able to
give the deviation of the dimension from the set dimension. Cannot measure absolute dimension but can only
compare two dimensions. (Rest all the options will give reading of the dimension measured it will not compare)
ISRO-2011 Page No.55 Slide No.163 Ans.(c) A sine bar is specified by the distance between the centre
of the two rollers
L = 250 mm; H + r = 100 mm ;( Diameter d = 20 mm or r = 10 mm) or H = 90 mm

⎛H⎞ −1 ⎛
90 ⎞
θ = sin −1 ⎜ ⎟ = sin ⎜ 250 ⎟ = 21.1
o
⎝ ⎠
L ⎝ ⎠
p α 2.5 ⎛ 60 ⎞
Best Wire Size : d = sec = sec ⎜ ⎟ = 1.443 mm
2 2 2 ⎝ 2 ⎠
GATE-2013 Page No.56 Slide No.175 Ans.(none) refer formula
IES-2017(Pre) Page No.56 Slide No.176 Ans(c)
GATE-2011(PI) Page No.56 Slide No.177 Ans.(c)
Difference between the readings of micrometers= 16.532-15.398=1.134mm
Diameter of cylindrical standard = 30.5mm
∴ Effective diameter= 30.5-1.134=29.366mm
IES-2012 Page No.57 Slide No.187 Ans. Refer slides for theory

GATE-2016(PI) Page No.58 Slide No.198 Ans. Ans. 2 μm (Range 2.0 to 2.0)
ISRO-2011 Page No.59 Slide No.200 Ans.(d)
IES-2007 Page No.59 Slide No.202 Ans.(c)Lay direction: is the direction of the predominant surface
pattern produced on the workpiece by the tool marks.
IES-2008 Page No.59 Slide No.203 Ans.(b)Lay – directional of predominant surface texture produced
by machining operation is called Lay.

GATE-2016 Page No.61 Slide No.221 Ans.675
The distance of air gap between two successive
nλ
fringes is given by =
2
For1mm fringe gap we need 450 nm
∴For1.5 mm fringe gap we need 450×1.5 nm = 675 nm
nλ l
Δh =
2
n × 0.0058928 × 10−1 cm × 10−1 cm
(1.002 − 1.000) × 10−1 cm =
2
n = 0.678 / cm
So for both fringes=2 × n = 1.357 ≈ 2 fringes
GATE-2011(PI) Page No.62 Slide No.229 Ans.(c)
Parallelism Error =
(14 − 10 ) × 0.5086 μm = 0.5086 μm
4
Ch-6 Miscellaneous of Metrology: Answers with Explanations
GATE-1998 Page No.63 Slide No.237 Ans. (c) Autocollimator isan optical instrument for non-contact
measurement of small angles or small angular tilts of a reflecting surface
GATE-2009(PI) Page No.63 Slide No.238 Ans. (a)
GATE-2014 Page No.63 Slide No. 239 Ans. (b) Autocollimator is also measure flatness.
ISRO-2010 Page No.63 Slide No. 242 Ans. (b) In optical square two mirrors are placed at an angle of
45o to each other and at right angles to the plane of the instrument. Angle between the first incident ray and
the last reflected ray is 90o.Two mirrors may be replaced by two prisms.
GATE-2014 Page No.64 Slide No. 248 Ans. (c) Laser interferometer is widely used to check and
calibrate geometric features of machine tools during their assembly
GATE-1992 Page No.65 Slide No. 254 Ans. (b)

10
tan θ =
30
θ = 18.434
Also,
x
tan θ =
10
x
tan18.434 =
10
x = 3.334
∴ diameter at z = 0 is (20 − 2 x)
∴ diameter = (20 − 2 × 3.334) = 13.336
GATE-2008(PI) Page No.66 Slide No. 264 Ans. (d)
θ C2 A 3
tan = =
2 5 + 15.54 + 8 28.54
θ
= 6.006
2
θ = 12.001
GATE-2014 Page No.66 Slide No. 265
BC = (H2 + d2/2) – ( H1
+ d1/2) = 35.55 + 60/2 -
20.55 – 40/2 = 25 mm
AC = 60/2 + 40/2 = 50
mm
AB = ( 50 2
)
− 252 = 43.3
D = 60/2 + 43.30 + 40/2

= 93.30 mm

AB = ( R + r )2 − ( D − R − r )2
= ( R + r + D − R − r )( R + r − D + R + r )
= 2D( R + r ) − D 2
H = R + AB + r
= R + r + 2D( R + r ) − D 2
Ch-7 Metal Forming: Answers with Explanations

GATE-1995 Page No. 67 Slide No.9 Ans. (b)If the specimen is stressed slightly beyond the yield point
and unloaded then the phenomena of strain hardening takes place as a result of which strength
increases.
IES-2013 Page No.68 Slide No. 10 Ans. (b)
IES-2016 Page No.68 Slide No. 13 Ans. (a)
Mechanical properties of the material is depends on grain size.
Due to plastic deformation grain gets elongated.
IES-2011 Page No.70 Slide No. 30 Ans. (b) If cold worked it will improve mechanical properties.
GATE-2003 Page No.70 Slide No. 31 Ans. (c) If working below Rx temp then it is cold-working process
GATE-2002, ISRO-2012 Page No. 70 Slide No. 32 Ans. (d)
ISRO-2010 Page No. 70 Slide No. 33 Ans. (d) Annealing is used to induce ductility,
soften material, relieve internal stresses, refine the structure by making it homogeneous, and
improve cold working properties.Normalization is an annealing process in which a metal is cooled in
air after heating.
IES-2006 Page No.70 Slide No.34 Ans. (c) When a metal is heated & deformed under mechanical
force, an energy level will reached when the old grain structure (which is coarse due to previous cold
working) starts disintegrating. Simultaneously, an entirely new grain structure (equi-axed, stress free)
with reduced grain size Starts forming. This phenomenon is known as “recrystallisation”. Never be
confused with Annealing because in the last stage of annealing grain growth takes place. So no reduction
in grain size.
IES-2004 Page No. 70 Slide No. 35 Ans. (b) For cold working metal should have high ductility.
IES-2009 Page No. 70 Slide No.36 Ans. (d) Strength increases due to grain refinement.
IES-2008 Page No. 71 Slide No. 37 Ans. (b)
IES-2008 Page No. 71 Slide No. 38 Ans. (a)
Advantages of Cold Forming vs. Hot Working:
• Better accuracy, closer tolerances
• Better surface finish
• Strain hardening increases strength and hardness
• Grain flow during deformation can cause desirable directional properties in product
• No heating of work required (less total energy)
Dis-advantages of Cold Forming
• Equipment of higher forces and power required
• Surfaces of starting work piece must be free of scale and dirt
• Ductility and strain hardening limit the amount of forming that can be done
• In some operations, metal must be annealed to allow further deformation
• In other cases, metal is simply not ductile enough to be cold worked
IES-2004 Page No. 71 Slide No. 39 Ans. (c) During deformation, a portion of the deformation energy
becomes stored within the material in the form of additional dislocations and increased grain boundary
surface area.
IES-2003 Page No. 71 Slide No. 40 Ans. (a)
IES-2000 Page No. 71 Slide No. 41 Ans. (d) Annealing required.
ISRO-2009 Page No. 71 Slide No. 42 Ans. (a)

IES-1997 Page No. 71 Slide No. 43 Ans. (c)
• Phenomenon where ductile metals become stronger and harder when they are deformed plastically is
called strain hardening or work hardening.
• During plastic deformation, dislocation density increases. And thus their interaction with each other
resulting in increase in yield stress.
IES-1996 Page No. 71 Slide No. 44 Ans. (c)Cold working increases the strength and hardness of the
material due to strain hardening. Strength, fatigue, and wear properties are improved through strain
hardening.
IES-2006 Page No. 71 Slide No. 45 Ans. (d) Should be above the recrystallisation temperature.
IES-1992 Page No. 72 Slide No. 46 Ans. (c)
• Annealing relieves the stresses from cold working – three stages: recovery, recrystallization and grain
growth.
• During recovery, physical properties of the cold-worked material are restored without any observable
change in microstructure.
• Grain growth follows complete crystallization if the material is left at elevated temperatures.
• Grain growth does not need to be preceded by recovery and recrystallization; it may occur in all
polycrystalline materials.
IAS-1996 Page No. 72 Slide No. 47 Ans. (c) For Mild Steel, recrystallisation temp is of the order of
10000C
IAS-2004 Page No. 72 Slide No. 48 Ans. (a)
IAS-2002 Page No. 72 Slide No. 49 Ans. (b) Ulta hai. Assertion reason me hona chahiye.
IES-2008 Page No. 72 Slide No. 50 Ans. (d)Malleability- It is a special case of ductility which permits
materials to be rolled or hammered into thin sheets. A malleable material should be plastic but it is not
essential to be so strong. Lead, soft steel, wrought iron, copper and aluminium are some materials in
order of diminishing malleability.
GATE -2017 Page No.72 Slide No.51 Ans.(c)In metal forming mechanical properties of materials will
increase due to improvement in grain.
Ch-8 Rolling: Answers with Explanations

GATE -2013 Page No.72 Slide No.54 Ans.(c)Bi axial compression and frictional force between roller
and workpiece produces shear stress
IAS-2001 Page No.73 Slide No.59 Ans.(c)Rolling means hot working it will not show work
hardening
ISRO-2006 Page No.73 Slide No.62 Ans.(c) You may confused with Forging but forging is hot
working, but Cold rolling (cold working) is mentioned therefore answer will be (c). In cold working
product will be stronger. If we compare cold forging and cold rolling then cold forging produce stronger
components.
IES-2006 Page No.74 Slide No.70 Ans.(c) A continuous form of three-point bending is roll bending,
where plates, sheets, and rolled shapes can be bent to a desired curvature on forming rolls.
IES – 1992, GATE-1992(PI) Page No.75 Slide No.77 Ans.(b)Since brittle materials cannot handle
plastic deformation.
IES – 1993, GATE-1989(PI) Page No.75 Slide No.78 Ans.(d)
• Thread rolling is used to produce threads in substantial quantities. This is a cold-forming process
operation in which the threads are formed by rolling a thread blank between hardened dies that cause
the metal to flow radially into the desired shape. Because no metal is removed in the form of chips, less
material is required, resulting in substantial savings. In addition, because of cold working, the threads
have greater strength than cut threads, and a smoother, harder, and more wear-resistant surface is
obtained.
• One obvious characteristic of a rolled thread is that its major diameter always is greater than the
diameter of the blank. When an accurate class of fit is desired, the diameter of the blank is made about
0.002 inch larger than the thread-pitch diameter. If it is desired to have the body of a bolt larger than the
outside diameter of the rolled thread, the blank for the thread is made smaller than the body.
IAS -2003 Page No.76 Slide No.86 Ans.(b)
IAS-2000 Page No.76 Slide No.87 Ans.(b)Rolling with smaller diagram rolls requires lower force.
IES-1993 Page No.77 Slide No.91 Ans.(a)In order to get uniform thickness of the plate by rolling
process, one provides camber on the rolls to take care of unavoidable tool bending. Cylindrical rollers
would result in production of plate with convex surface. Because of the limitations in the equipment and
workability of the metal, rolling is accomplished progressively in many steps. Plate, sheet and strip are
rolled between rolls having a smooth, cylindrical, slightly cambered (convex) or concave working surface.

IAS-2004 Page No.77 Slide No.93 Ans.(c) Rolling means hot rolling where no lubricant is used.
GATE -2009(PI) Page No.77 Slide No.96 Ans.(d) Due to directional granule deformation.
IES-2003 Page No.77 Slide No.98 Ans. (c) Wavy edges due to roller deflection.
GATE -2007 Page No.78 Slide No.102 Ans.(d)
ho = 16 mm ; h f = 10 mm ;D = 400 mm;R=200 mm∴Δh = 6 mm;
Δh = D(1 − cos α )
6 = 400(1 − cos α ) ⇒ α = 9.936°
GATE – 2012 Same Q in GATE – 2012 (PI) Page No.78 Slide No.103 Ans.(c)
ho = 8 mm ; h f = 8 x (1 – 0.1) = 7.2 mm; D = 410 mm;
Δh = 10% of 8 mm = 0.8 mm ⎡⎣ alternative : ho − h f = 8 − 7.2 = 0.8 mm ⎤⎦
We know that, Δh = D(1 − cos α ) or 0.8 = 410 (1 − cos α )
π
or α = 3.58o = 3.58 × rad = 0.062 rad
180
GATE -2017 Page No.78 Slide No.104 Ans.(b)
GATE -1998 Page No.78 Slide No.105 Ans.(d) For strip rolling sheet rolling width remains same.
Initial thickness (h1) = 4.5 mm.
As width constant therefore 20% reduction in area means 20% reduction in thickness also.
Final thickness (h2 = 0.8 x 4.5 = 3.6 mm
Δh = D (1 − cos θ ) or ( 4.5 − 3.6 ) = 450 (1 − cos θ ) or θ = 3.62° = 0.063 radian
GATE -2004 Page No.78 Slide No.107 Ans.(b)
Roll strip contact length, L = R α
Δh = D (1 − cos α ) or ( 25 − 20 ) = 600 (1 − cos α ) or α = 7.402° = 0.129 rad
Therefore L = R α = 300 x 0.129 = 38.76 mm ≈ 39 mm
GATE -2011 Page No.79 Slide No.110 Ans.(a) Maximum possible draft. Δhmax = μ2R
GATE -2014 Page No.79 Slide No.111 Ans.(b) Maximum possible draft. Δhmax = μ2R
GATE -2016 Page No.79 Slide No.112 Ans. 1.92
R = 300 mm, and Δhmax = μ 2 R = 0.082 × 300 = 1.92 mm
GATE -2015 Page No.79 Slide No.113 Ans.0.1414
GATE -2015 Page No.79 Slide No.114 Ans. 5.71
IES-1999 Page No.79 Slide No.115 Ans.(b) Actually metal will get hardened in every pass due to
strain hardening. Therefore in actual practice the reduction in second pass is less than in the first pass.
( Δh )max = ho − h f ,min = μ 2 R = 0.12 ×150 mm =1.5 mm
or 4 − h f ,min = 1.5 or h f ,min = 2.5 mm
GATE – 2011 (PI) Page No.80 Slide No.119 Ans.(d)
( Δh )max = μ R = ( 0.1) × 300 mm = 3 mm
2 2
Therefore we cannot reduce more than 3 mm in a single pass but we have

to reduce total, 30 mm -10 mm = 20 mm
20
∴ Number of pass needed = ≈7
3
R = 150 mm; ho = 30 mm; h f = 15 mm
Δh 15 1 1
Δh = μ 2 R or μ = = = ≈ ≈ 0.3something
R 150 10 3.something
In IESobjective exam calculators are not allowed, we have to use above apporx.calculation
GATE-2014(PI) Page No.80 Slide No.121 Ans.(b) same as above

The velocity at neutral point is equal to the velocity of roller, as there is no slip occur
π DN π × 0.300m × 100rpm
V= = = 1.57 m / s
60 60
Selected Questions Page No.81 Slide No.127 Ans.(c & d)
GATE-2014 Page No.81 Slide No.129 Ans.14.6 to 14.8 m/min
The inlet and outlet volume rates of material flow must be the same, that is,
h o bo vo = h f b f v f
2
hf = h ; b = 1.02bo ; vo = 10m / min
3 o f
2
h o bo ×10 = h o × 1.02bo v f ⇒ v f = 14.706 m / min
3
A
Elongation factor = E = o = 1.22...........( given)
A1
Ao 750 × 750
En = or 1.22n = or 11.04
An 250 × 250
GATE-2016(PI) Page No.81 Slide No.134 Ans. 2000 (Range 1990 to 2010)
F = σ o L p b = σ o × R Δh × b
= 500 × 100 × 4 × 200 N = 2000 KN
Δh = 20 mm −18 mm = 2mm = 0.002m
R = 250mm = 0.250m
Pr ojected Length (L p ) = RΔh = 0.250 × 0.002 = 0.02236 m
Arm length (a) = λ RΔh = 0.5 0.250 × 0.002 = 0.01118 m
( )
Force(F) = Pr essure × Pr ojected area = σ o × (L p × b) = 300 × 106 × 0.02236 × 0.1 = 670.8 kN
Torque(T) = F × a [Force F on both roller]
( 3
)
= 670.8 × 10 × 0.01118 = 7.5 kNm
2π N 2π × 10
Total Power for both roller (P) = 2 × T × ω = 2 × T ×
60
( )
= 2 × 7.5 × 103 ×
60
= 15.7 KW
GATE-2017 Page No.82 Slide No.136 Ans.
This question is wrong. For proper calculation we need velocity of neutral plane or velocity of roller. But in this
question velocity of exit is given. From velocity of exit we may assume the velocity of neutral plane but can’t
calculate correctly.
After IITs’ answer we will challenge and confirm the answer. I have given best answer for this question.
Projected length ( Lp ) = R sin α ≈ RΔh , mm = 150 × (8 − 7.2) = 10.954 mm

Projected Area ( Ap ) = Lp × b , mm 2 = 10.954 ×120 = 1314.48 mm 2
RollSeparating Force ( F ) = σ o × Lp × b , N = 200 ×1314.48 N = 262.9 KN
[σ o in N / mm 2 i.e. MPa]
Arm length ( a in mm ) = 0.5 L p for hot rolling = 0.5 ×10.954 mm =5.477 mm
= 0.45 L p for cold rolling
a
Torque per roller (T ) = F × , Nm =262.9 KN × 5.477 mm = 1439.9 Nm
1000
2π N
Total power for two roller ( P ) = 2T ω , inW = 2T ×
60

For the calculation of N we need velocity of neutral plane( Jugaad )
Continuity equation
h o bo vo = h f bf vf
8 ×120 × vo = 7.2 ×120 × 30
orVo = 27 m / min
Assuming velocity of neutral plane
= average velocity ( V ) =
V +V
o f
=
27 + 30
= 28.5 m / min
2 2
Now,V = π DN
or 28.5 = π × 0.300 × N
or N = 30.24 rpm
∴ Total power for two roller ( P )
2π N 2 × π × 30.24
= 2T × = 2 × 1439.9 × , W = 9.1195 KW ≈ 9.12 KW
60 60
IES – 2000, GATE-2010(PI) Page No.82 Slide No.137 Ans.(a)The roll-separating force which separates
the two rolls apart can be obtained by multiplying the average roll pressure with the total contact area.
The average roll pressure can be decreased by reducing the maximum pressure, which is a function of
the contact length. Smaller contact lengths means lesser friction forces acting. Thus, by reducing the
contact length, it is possible to decrease the roll-separating force. This in turn, can be achieved by
reducing the roll diameter, since; smaller rolls would have less contact length than larger rolls for the
same reduction.
IAS-2007 Page No.82 Slide No.138 Ans.(c)Use small dia rolls to reduce Roll force.
IES-2001 Page No.82 Slide No.139 Ans.(a)Coefficient of friction is constant over the arc of contact
and But does not acts in one direction throughout the arc of contact.
Ch-9 Forging: Answers with Explanations

IES-2013 Page No.83 Slide No. 146 Ans.(a)
IES-1996 Page No.83 Slide No. 150 Ans.(d)
IES-2013 Page No.83 Slide No. 151 Ans.(c) Forging components poses high reliability i.e. point3. is
wrong, means (a), (b) and (d) wrong.
IES-2005 Page No.83 Slide No. 152 Ans.(b)
IES-2012 Page No.83 Slide No. 153 Ans.(b) If undercut is present it is not moldable means can’t be
withdrawn from die.
• Forging means hot working it will increases strength and ductility both.
• Hot working reduced or eliminates porosity of the metal and increase resistance to shock and vibrating.
• Forging pressure is not uniform so it can’t guarantee uniformly and forging has poor dimensional accuracy and
surface finish.
ISRO-2013 Page No.84 Slide No. 155 Ans.(b)
IES-2012 Page No.84 Slide No. 157 Ans.(c)
IES-2006 Page No.84 Slide No. 159 Ans.(c) The draft provided on the sides for withdrawal of the
forging.
IAS-2002 Page No.85 Slide No. 164 Ans.(b)Amount of flash depends on the forging size not on forging
force.
IES – 1993, GATE-1994(PI) Page No.85 Slide No.167 Ans.(a)Closed die forging requires the provision of
gutters to provide space for excess material and ensure complete closure of die and defect free forged
part.
IES-1997 Page No.85 Slide No.168 Ans.(c) The provision of gutters to provide space for excess
material and ensure complete closure of die and defect free forged part.

GATE-1989(PI) Page No.85 Slide No. 169 Ans. Gutter
IAS-2001 Page No.86 Slide No. 180 Ans.(b)
IES-2012 Conventional Page No.87 Slide No. 181 Ans. refer theory slides
IAS-2003 Page No.87 Slide No. 182 Ans.(a) The term swaging is also applied to processes where
material is forced into a confining die to reduce its diameter.
IES – 1994, ISRO-2010 Page No.87 Slide No. 185 Ans.(c)The drop forging die consists of two halves.
The lower half of the die is fixed to the anvil of the machine, while the upper half is fixed to the ram. The heated
stock is kept in the lower die while the ram delivers four to five blows on the metal, in quick succession so that
the metal spreads and completely fills the die cavity. When the two die halves close, the complete cavity is
formed.
IAS-2000 Page No.87 Slide No. 186 Ans.(a) Due to low toughness.
IES-2013 Page No.89 Slide No. 199 Ans.(a) As K.E ∞ V2, high energy is delivered to the metal with
relatively small weights (ram and die).
IES-2008 Page No.89 Slide No. 201 Ans.(None) Correct sequence is 2 – 1 – 3 - 4
IAS-1998 Page No.89 Slide No. 206 Ans.(b)
IES-2011 Page No.89 Slide No. 207 Ans.(c) Bonding between the inclusions and the parent material is
through physical bonding no chemical bonding possible.
GATE-2008(PI) Page No.90 Slide No. 208 Ans.(c)
GATE-2010(PI) Page No.90 Slide No. 212 Ans.(c)Low thermal conductivity because low heat loss
from workpiece.
GATE-2014 Page No.91 Slide No. 217 Ans.(c)
elongation
Engineering strain or Conventional Strain(ε E ) =
original length
elongation
True Strain(ε T ) =
instantaneous length
If suppose x is the length; dx is the elongation which is infinitely small
L dx L
εT = ∫ = ln
Lo x Lo
L Lo + ΔL ΔL
as = = 1+ = 1+ ε E
Lo Lo Lo
ε T = ln (1 + ε E )
∵ volume change will not be there so,Ao Lo = AL
L Ao (π / 4 ) d o 2
= =
Lo A (π / 4 ) d 2
L A d
ln = ln o = 2 ln o
Lo A d
GATE-1992, ISRO-2012, VS-2013 Page No.91 Slide No. 218 Ans.(c)
⎛ L⎞ ⎛ 2 L0 ⎞
ε T = ln ⎜ ⎟ = ln ⎜ ⎟ = ln 2 = 0.693
⎝ Lo ⎠ ⎝ Lo ⎠
⎛ 0.100 ⎞
ε T = ln(1 + ε ) = ln ⎜1 + × 100% = 0.09995
⎝ 100 ⎟⎠

GAT
TE-2007 Page No.91
1 Slide No. N 220 Anss.(c)
L
dx ⎛ L⎞ ⎛A ⎞ ⎛D ⎞ ⎛ 200 ⎞⎟
True strain (∈T ) = ∫ = ln ⎜⎜⎜ ⎟⎟⎟ = ln ⎜⎜ o ⎟⎟⎟ = 2 ln ⎜⎜ o ⎟⎟⎟ = 2 ln ⎜⎜ ⎟ = −1.386
x ⎝⎜ Lo ⎠⎟ ⎝⎜ A ⎠⎟ ⎜⎝ D ⎠⎟ ⎜⎝ 400 ⎠⎟
Lo
ve sign indica
negativ ates compresssive strain.
GAT
TE-2017(PII) Pagge No.91 Slide No. 221 2 Ans. 1.8
833 Range (1.80 to 1.8
85)
GAT
TE-2016 Page No.91
1 Slide No.
N 222 Anss.(b)
⎛ L ⎞ ⎛ Lo / 2 ⎞
ε T = ln ⎜ ⎟ = ln ⎜ ⎟ = − ln 2 = −0.69
⎝ Lo ⎠ ⎝ L o ⎠
TE-2017
GAT Page No.91
1 Slide No.
N 223 Anss.(b)
For calculating true strain we have to know

k initiall and final le
ength only.
Initiial length ( Lo ) = 20 mm
m
al length ( L ) =10 mm
Fina
⎛L⎞ ⎛A ⎞ ⎛d ⎞
Truee strain (ε T ) = ln(1 + ε ) = ln ⎜ ⎟ = ln ⎜ o ⎟ = 2 ln ⎜ o ⎟
⎝ Lo ⎠ ⎝ A ⎠ ⎝d⎠
⎛L⎞ ⎛ 10 ⎞
Truee strain (ε T ) = ln ⎜ ⎟ = ln ⎜ ⎟ = −0.693
⎝ Lo ⎠ ⎝ 20 ⎠
TE-2006
GAT Page No.92
2 Slide No.
N 227 Anss.(b)

TE-2015 Page No.92

GAT 2 Slide No.
N 228 Anss.(c)
GAT
TE-2017 Page No.922 Slide No.
N 229 Anss.(b)
GAT
TE-2012 Sa
ame Q GATE -2012 (PII) Pag
ge No.92 Slide No. 230
2 Ans.(d))
Volumee of materiaal will remainn same due to
t incompressibility
π d12 π d 22
× h1 = × h2
4 4
h1 50
d 2 = d1 = 100 × = 1411.42 mm
h2 25
d 2 − d1
Percenttage change in diameterr = × 100% = 41..42%
d1
GAT
TE-2016(PII) Pagge No.92 Slide No. 231
2 Ans. 1.0
0 (Range 1.0
0 to 1.0)
GAT
TE-2015 Page No.92
2 Slide No.232
N Anss. 95.19 mmm

100
True strain = ln = 0.5129
95
σ = 500 × (0.5129)0.1 = 371.51
Upto elastic limits using Hooke's Law
σ ×l 371.51 × 106 × 100
E= or 200 × 109 =
Δl Δl
Δl = 0.18575mm (considering this for elastic recovery)
This is elastic component and after release of the compressive load this
amount of recovery takes place.
This will be added to 95mm. Therefore, final dimension = 95.18575mm
GATE-2000(PI) Page No.92 Slide No.233 Ans. 7068 J , 0.6968 m
πdo2 πd 2f
× ho = × hf
4 4
π×1002 × 50 π× d f × 40
2
or = or d f = 111.8 mm
4 4
πdo2 π× 1002
Initial Force( Po ) = × σo = × 80 = 628.3 KN
4 4
πd 2f π× 111.82
Final Force( Pf ) = × σo = × 80 = 785.35 KN
4 4
Po + Pf 628.3 + 785.35
AverageForce( Pavg ) = = = 706.8 KN
2 2
( )
Workdone(W ) = Pavg × ho − h f = 706.8 × (50 − 40) J = 7068 J
mg(h + x ) = W [ x = ho − h f ]
10 × 103 ( h + 0.010 ) = 7068 or h = 0.6968 m
Ch-10 Extrusion and Drawing: Answers with Explanations

IES-2007 Page No.93 Slide No. 238 Ans. (d)
The equipment consists of a cylinder or container into which the heated metal billet is loaded.
On one end of the container, the die plate with the necessary opening is fixed. From the other end, a plunger or
ram compresses the metal billet against the container walls and the die plate, thus forcing it to flow through the
die opening, and acquiring the shape of the opening. The extruded metal is then carried by the metal-handling
system as it comes out of the die.
DRDO-2008 Page No.93 Slide No. 240 Ans.(b)
Advantages: 1. Material saving 2. Process time saving 3. Saving in tooling cost
All are correct but only a die change can change the product therefore (c) is most appropriate.
IES-1994 Page No.94 Slide No. 246 Ans.(c)Metal extrusion process is generally used for producing
constant solid and hollow sections over any length.
GATE-1994 Page No.94 Slide No. 247 Ans. (a)
IES-1993 Page No.95 Slide No. 253 Ans. (b) Both A and R are true but R is not correct explanation of
A.
Zinc phosphate coating is used to prevent metal contact.In direct extrusion, friction with the chamber opposes
forward motion of the billet. For indirect extrusion, there is no friction, since there is no relative motion.
IES-2000 Page No.95 Slide No.254 Ans.(c)As diameter decreases therefore for same mass flow rate
the speed of travel of the extruded product must be greater than that of the ram.
IES-2012 Page No.95 Slide No. 257 Ans.(c) The force required on the punch is less in comparison to
direct extrusion.
IES-2007 Page No.95 Slide No. 258 Ans. (b)In direct extrusion, friction with the chamber opposes
forward motion of the billet.

IAS-2004 Page No.95 Slide No. 259 Ans. (d) Only ram movement is there.
IES-2016 Page No.95 Slide No. 260 Ans. (a) In the direct extrusion a significant amount of energy is
used to overcome frictional resistance between workpiece and cylinder wall.
IES – 2008, GATE-1989(PI) Page No.96 Slide No.264 Ans. (a) Impact Extrusion is used for
manufacture of collapsible toothpaste tubes
IAS-2000 Page No.97 Slide No. 273 Ans. (d)Hydrostatic extrusion suppresses crack formation by
pressure induced ductility. Relative brittle materials can be plastically deformed without fracture. And materials
with limited ductility become highly plastic.
IES-2006 Page No.97 Slide No.274 Ans. (a) It is pressure induced ductility.
IES-2009(conventional) Page No. 97 Slide No. 278 Ans.
For sketches refer slides.
(i)Direct Extrusion-curtain rods
(ii) Indirect Extrusion-
(iii) Hydrostatic Extrusion-Cladding of metals, Extrusion of nuclear fuel reactor fuel rod
(iv) Impact Extrusion-Collapsible tubes for toothpastes, creams etc.
IES-2014 Page No.98 Slide No.280 Ans. (d) For high extrusion pressure, the initial temperature of
billet should be low.
IES-2016 Page No.98 Slide No.282 Ans. (b) Bamboo defects at low temperature due to
sticking of metals in die land.
JWM-2010 Page No.98 Slide No. 283 Ans. (a)
IES-2009 Page No.99 Slide No. 289 Ans. (b)The wire is subjected to tension only. But when it is in
contact with dies then a combination of tensile, compressive and shear stresses will be there in that portion only.
GATE-1987 Page No.99 Slide No. 291 Ans. (a)
Cleaning is done to remove scale and rust by acid pickling.
Lubrication boxes precede the individual dies to help reduce friction drag and prevent wear of the dies.
It is done by sulling, phosphating, electroplating.
IAS-1995 Page No.99 Slide No. 296 Ans. (d)The correct sequence for preparing a billet for extrusion
process is pickling, alkaline cleaning, phosphate coating, and lubricating with reactive soap.
IES-2014 Page No. 100 Slide No.299 Ans. (b)
IES-1993; GATE-1994(PI), 2014(PI) Page No. 100 Slide No. 304 Ans. (b)
IAS-2006 Page No.100 Slide No. 305 Ans. (b)
IES-1993 Page No.101 Slide No. 309 Ans. (a) Tandem drawing of wires and tubes is necessary because
it is not possible to reduce at one stage.
IES-1993, ISRO-2010, Page No. 101 Slide No. 314 Ans. (b)since malleability is related to cold rolling,
hardness to indentation, resilience to impact loads, and isotropy to direction.
IAS-2001 Page No.102 Slide No. 316 Ans. (a)
IAS-2002 Page No.102 Slide No. 318 Ans. (b)
IAS-1994 Page No.102 Slide No.321 Ans. (b) Extrusion and skew rolling produce seamless metallic
tubes.

Extrusion constant ( k ) = 250MPa
π do 2 πdf 2
Initial area ( A o ) = and Final area ( A f ) =
4 4
Force required for extrusion:
⎛A ⎞ π ⎛ π / 4 × 0.12 ⎞
P = kA0 ln ⎜ o ⎟⎟ = 250 × × 0.1 ln ⎜
2
2 ⎟
= 2.72219 MN
⎜ ⎝ π / 4 × 0.05 ⎠
⎝ Af ⎠ 4
⎛A ⎞
Pressure (σ ) = σ o ln ⎜ o ⎟⎟ = σ o ln r = 300 ln 4 = 416 MPa
⎜A
⎝ f ⎠
Given : Do = 10 mm; Df = 8 mm; σ 0 = 400 MPa; Ignore friction and redundant work means
⎛r ⎞ π × 82 ⎛ 5 ⎞
Ideal Force = 2σ 0 A f ln ⎜ o ⎟ = 2 × 400 × ln ⎜ ⎟ = 8.97 kN
⎝ rf ⎠ 4 ⎝4⎠
GATE -2008 (PI) Linked S-1 Page No. 103 Slide No.328 Ans. (b)
d o = 10 mm, d f = (1 − 0.2) × d o = (1 − 0.2) × 10 = 8 mm
⎛A ⎞ ⎛d ⎞ ⎛ 10 ⎞
Stress (σ d ) = σ o ln ⎜ o ⎟⎟ = 2 × σ o × ln ⎜⎜ o = 2 × 800 × ln ⎜ ⎟ = 357 MPa
⎜A ⎟⎟ ⎝8⎠
⎝ f ⎠ ⎝ df ⎠
GATE -2008 (PI) Linked S-2 Page No.103 Slide No. 329 Ans. (a)
Power = Drawing force × Velocity
= Stress (σ d ) × area ( Af ) ×Velocity
π × 82
= 357 × × 0.5W = 8.97 KW
4
IES-2014 Conv. Page No.103 Slide No.330 Ans. 190 N
GATE-2001, GATE -2007 (PI) Page No.103 Slide No. 331 Ans. (b)
⎛ Ao ⎞
σ d = σ o ln ⎜ ⎟ For Maximum reduction,σ d = σ o
⎝ Af ⎠
⎛A ⎞ A A − Af ⎛ 1⎞
σ o = σ o ln ⎜ o ⎟ or o = e = 2.71828 ∴ o × 100 = ⎜1 − ⎟ × 100 = 63%
A
⎝ f⎠ A f A o ⎝ e⎠
Case(a ) : 3 − stage reduction final dia =15 × (1 − 0.8 ) × (1 − 0.8 ) × (1 − 0.8 ) = 0.12 mm ∴ error = 0.02mm
(b) 4 − stage reduction final dia =15 × (1 − 0.8 ) × (1 − 0.8 ) × (1 − 0.8 ) × (1 − 0.2 ) = 0.096mm ∴ error = 0.004mm
(c) 5 − stage reduction final dia
=15 × (1 − 0.8 ) × (1 − 0.8 ) × (1 − 0.4 ) × (1 − 0.4 ) × (1 − 0.2 ) = 0.1728mm∴ error = 0.0728mm
IES-2011(conventional) Page No. 104 Slide No.337 Ans.
d o = 12.5mm; d f = 10mm;V = 100m / min; α = 5°; μ = 0.15; σ o = 400MPa
B = μ cot α = 0.15cot 5 = 1.7145
σ o (1 + B ) ⎡ ⎛ rf ⎞ ⎤
2B
σd = ⎢1 − ⎜ ⎟ ⎥
B ⎢⎣ ⎝ ro ⎠ ⎥⎦

400(1 + 1.7145) ⎡ ⎛ 5 ⎞ ⎤
2×1.7145
σd = ⎢ ⎜
1 − ⎟ ⎥ = 338.653MPa
1.7145 ⎢⎣ ⎝ 6.25 ⎠ ⎥⎦
π
Force ( P ) = 338.653 × 102 N
4
π 100
Power = P × V = 338.653 × 102 × m / s = 44.329 kW
4 60
Maximum possible reduction;σ o = σ d
σ o (1 + B ) ⎡
⎛ rf min ⎞ ⎤ 400(1 + 1.7145) ⎡ ⎛ rf min ⎞ ⎤
2B 2×1.7145
σo = ⎢1 − ⎜ ⎟ ⎥ or 400 = ⎢ 1 − ⎜ ⎟ ⎥ or rf min = 4.67 mm

B ⎢⎣ ⎝ ro ⎠ ⎥⎦ 1.7145 ⎢⎣ ⎝ ro ⎠ ⎥⎦
d − d f min r −r
Max possible reduction in dia = o ×100% = o f min ×100% = 25.3%
do ro
If the rod is subjected to a back pressure of 50 N/mm2
σ o (1 + B ) ⎡ ⎛ r f ⎞ ⎤ ⎛ rf ⎞
2B 2B
σd = ⎢1 − ⎜ ⎟ ⎥ + ⎜ ⎟ .σ b
B ⎢⎣ ⎝ ro ⎠ ⎥⎦ ⎝ ro ⎠
2×1.7145
400(1 + 1.7145) ⎡ ⎛ 5 ⎞ ⎤ ⎛ 5 ⎞
2×1.7145
σd = ⎢1 − ⎜ ⎟ ⎥+⎜ ⎟ × 50 = 361.26MPa
1.7145 ⎣⎢ ⎝ 6.25 ⎠ ⎦⎥ ⎝ 6.25 ⎠
For maximum possible reduction;σ o = σ d
σ o (1 + B ) ⎡ ⎛ rf min ⎞ ⎤ ⎛ rf min ⎞
2B 2B
σo = ⎢1 − ⎜ ⎟ ⎥+⎜ ⎟ .σ b
B ⎢⎣ ⎝ ro ⎠ ⎥⎦ ⎝ ro ⎠
2×1.7145
400(1 + 1.7145) ⎡ ⎛ rf min ⎞ ⎤ ⎛ rf min ⎞

2×1.7145
400 = ⎢1 − ⎜ ⎟ ⎥ +⎜ ⎟ × 50 ⇒ rf min = 4.78 mm

1.7145 ⎢⎣ ⎝ 6.25 ⎠ ⎥⎦ ⎝ 6.25 ⎠
d − d f min
Max possible % reduction in diameter = o × 100% = 23.5%
do
Ao − Af min
Max possible % reduction in area = × 100% = 41.5%
Ao
IFS-2016 Page No. 104 Slide No. 338 Ans (i) 5.594 KW and (ii) 73.24 MPa
GATE – 2011 (PI) Common Data-S1 Page No. 104 Slide No. 339 Ans.(c)
πd 2
π ×10 2
Initial area ( A o ) = o
= mm 2 = 78.54 mm 2
4 4
After first pass area ( A1 ) = (1 − 0.35 ) Ao = (1 − 0.35 ) × 78.54 mm 2 = 51 mm 2
After second pass area ( A 2 ) = (1 − 0.35) Ao and then ........
2
After 7th pass area ( A 7 ) = (1 − 0.35 ) Ao = (1 − 0.35 ) × 78.54 mm 2 = 3.85 mm 2

7 7
⎛ L⎞ ⎛A ⎞ ⎛ 78.54 ⎞
True strain = ln ⎜ ⎟ = ln ⎜ o ⎟ = ln ⎜ ⎟ = 3.02
⎝ Lo ⎠ ⎝ A⎠ ⎝ 3.85 ⎠
and Ao Lo = A7 L7 or 78.54 × 100 = 3.85 × L7 ⇒ L7 = 2040 mm
GATE – 2011 (PI) Common Data-S-2 Page No. 104 Slide No. 340 Ans. (d)
⎛A ⎞ ⎛A ⎞ ⎛ 78.54 ⎞
P = σ o Af ln ⎜ o ⎟⎟ = σ o A1 ln ⎜ o ⎟ = 200 × 51× ln ⎜ ⎟ N = 4.40 KN
⎜ ⎝ ⎠
⎝ Af ⎠ ⎝ A1 ⎠ 51

GATE-2014 Page No.104 Slide No. 341 Ans. = 0.9 to 1.1
t
dL dL 2tdt
True strain at any instant t ( ε T ) = ∫ =∫ =∫ = ln ⎡⎣1 + t 2 ⎤⎦
L (
L0 1 + t 2
)0 1+ t
2
( )
( )
as, L = L0 1 + t 2 ,∴ dL = L0 2tdt
dεT 2t 2 ×1
εT = = = = 1.0
dt 1+ t (
2
1 + 12)
IAS-1997 Page No.104 Slide No. 342 Ans.(c)
IES-2012 Page No.105 Slide No. 343 Ans. Refer slides
IAS-2006 Page No.105 Slide No. 345 Ans. (c)
Ch-11 Sheet Metal Operation: Answers with Explanations

Example Page No.106 Slide No. 355 Ans.
The clearance to be provided is given by, C = 0.0032 × t × √τ
Shear strength of annealed C20 steel = 294 MPa
Hence, C = 0.0032 ×1.5 × 294 = 0.0823 mm
Since it is a blanking operation,
Die size = blank size = 20 mm
Punch size = blank size – 2 C = 20 – 2 × 0.0823 = 19.83 mm
Now when it is punching operation,
Punch size= size of hole = 20 mm
Die size = Punch size +2 C = 20 +2 × 0.0823 = 20.1646 mm
It is blanking operation
Therefore Diameter of die = metal disc diameter = 20 mm
3% clearance (c) = 0.06 mm on both side of the die (of sheet thickness)
Therefore Diameter of punch = 20 – 2c = 20 – 2 x 0.06 = 19.88 mm
Example Page No.106 Slide No. 359 Ans.

Punching Force(F) = Ltτ
F = 2(a + b)tτ = 2(100 + 50) × 5 × 300 = 450 kN
IAS-2011(main) Page No.107 Slide No. 361 Ans.
For punching operation 10 mm circular hole
d = 10 mm; t = 1 mm;τ = 240 MPa
(i) Punch size = size of hole = 10 mm
( ii ) Die size = Punch size + 2 C = 10 + 2(0.0032t τ )=10 + 2(0.0032 ×1× 240)= 10.09914 mm
(iii) Punching Force(F) = Ltτ = π dtτ = π ×10 × 1× 240 N = 7.54 KN

For blanking 50×200 mm rectangular blank
(i) Punch size = size -2C
Length will be = 200-2C =200 - 2(0.0032 ×1× 240) =199.90 mm
Width will be = 50 -2C =50 - 2(0.0032 × 1× 240) = 49.90 mm
( ii ) Die size = correct size
Length will be = 200 mm
Width will be = 50 mm
(iii ) F = 2(a + b)tτ = 2(200 + 50) × 1× 240 = 120 kN
GATE-2016(PI) Page No.107 Slide No. 362 Ans. 0.25 (Range 0.24 to 0.26)

f 3
IES-1999 Page No.107 Slide No.364 Ans.(b) min dia =4t s = 4 × 20 × = 30 mm
fc 6
πd2 4tτ 4tτ
ISRO-2008, 2011 Page No.107 Slide No. 366 Ans.(c) π dtτ ≤ σ c × or d ≥ = =t
4 σc 4τ
IES-2013 Page No.107 Slide No. 367 Ans.(c)same as previous question
Maximum force without shear = 550 x 100 x π x 5.6 N = 968 kN
Capacity of press, F = 30 T = 30 x 9.81 KN = 294 KN
Fmax × pt 968 × 0.4 × 5.6
F= or 294 = or s = 5.13mm
s + pt s + 0.4 × 5.6
Angle of shear, tanθ = 5.13/100 or θ = 2.9o

d1 = 25.4 mm; d 2 = 12.7 mm; t = 1.5 mm;τ = 280 N / mm 2
Total cutting force when both punches act at the same time and no shear is
applied to either the die or punch;
F = π d1tτ + π d 2tτ = π × 25.4 × 1.5 × 280 + π × 12.7 × 1.5 × 280 = 50.27 KN
The cutting force if the punches are staggered, so that only one punch acts at a time:
Fmax = π d outsidetτ = π × 25.4 × 1.5 × 280 = 33.515 kN
Taking 60% penetration and shear on punch of 1 mm,
The cutting force if both punches act together;
F=
(π d1tτ + π d 2tτ ) × pt = (π 25.4 ×1.5 × 280 + π ×12.7 ×1.5 × 280 ) × 0.6 ×1.5 = 23.81KN
S + pt 1 + 0.6 × 1.5
GATE-2010 Statement Linked 1 Page No.108 Slide No. 374 Ans.(a)
p
t = 5 mm; L = 200 mm;τ = 100MPa; = 0.2
t
Fmax = Ltτ = 200 × 5 × 100 = 100 kN
Work Done = Fmax × ( pt ) = 100 × (0.2 × 5) = 100 J
GATE-2010 Statement Linked 2 Page No.108 Slide No. 375 Ans.(b)

For 400mm length shear is 20mm; therefore for
200mm length it becomes10mm. Only 200 mm length
is effective.
Fmax ( pt )
F=
S
100
F= = 10kN
10

IAS-2003 Page No.109 Slide No. 384 Ans.(a)
ISRO-2013 Page No.109 Slide No. 385 Ans.(a) Higher the modulus of elasticity higher will be the spring
back.
Blanking Force(F) = Ltτ = π dtτ = π × 100 × 1.5 × 300 = 141.371kN
GATE-2016 Page No.111 Slide No. 397 Ans. 5.026 KN
F = π dtτ = π × 10 × 2 × 80 = 5026 N = 5.026 KN
Blanking Force(F) = Ltτ = π dtτ = π × 200 × 3.2 × 150 = 301.592kN
Blanking Force(F) = Ltτ = π dtτ = π × 10 × 2 × 80 = 5.026kN
ISRO-2009 Page No.111 Slide No. 400 Ans.(b)
Blanking Force(F) = Ltτ = π dtτ = π × 25 × 10 × 500 = 392.69kN
GATE-2007 Page No.111 Slide No. 401 Ans.(a)
Blanking Force(F) = Ltτ = π dtτ
F1 = 5 = π dtτ and F2 = π × 1.5d × 0.4t × τ
F1 π dtτ 5 1
= or = or F2 = 3
F2 π × 1.5d × 0.4t × τ F2 1.5 × 0.4
The blanking force (Fmax ) =π dtτ = π × 10 × 3 × 400 = 37.7 kN
Fmax × pt 37.7 × 0.40 × 3
F= = = 22.6 kN
S 2
GATE_2012 Page No.111 Slide No. 403 Ans.(a)
Punch size without allowance = Die size – 2 x radial clearance = 25 – 2 x 0.06 = 24.88 mm
We need another gap (die allowance ) i.e. final punch size will be = 24.88 – 0.05 = 24.83 mm
C = 6% of t = 0.06×2.5 mm = 0.15 mm
Punch size = die size - 2C = 50 - 2×0.15 mm = 49.70 mm
Die size = 50.00 mm
GATE-1996 Page No.112 Slide No. 407 Ans.(d) Clearance only on punch for Blanking operation. Due to
insufficient data we cant calculate.
IAS-2000 Page No.112 Slide No. 414 Ans.(d)
It is blanking operation so clearance must be provided on punch.
Therefore, Die size = blank size = 30 mm
Punch size = blank size – 2C = 30 -2 x 0.06 x t = 30 – 2 x 0.06 x 10 = 28.8 mm
C = 40 microns = 0.040 mm; 2C = 0.08 mm
It is blanking operation : Punch size = 35 − 0.080 mm and Die size = 35 mm
IAS-1994 Page No.113 Slide No. 416 Ans.(a)
Work done = Fmax × pt = 200 kN × 0.25 × 4 = 200 J [2 × 105 N = 200kN ]
IAS-2002 Page No.113 Slide No. 417 Ans.(a) In punching usable part is sheet so punch size is
Correct and clearance on die. In blanking usable part is punched out circular part so die size is correct
and clearance on punch
IAS-2007 Page No.113 Slide No. 418 Ans.(b)In punching useable part is punched sheet so size of hole
must be accurate i.e. size of punch must be accurate. Clearance have be given on Die only.
IAS-1995 Page No.113 Slide No. 419 Ans.(a)Both A and R are true and R is the correct explanation of A
IES-2002, GATE(PI)-2003 Page No.113 Slide No. 420 Ans.(c)

IES-1999 Page No.113 Slide No. 423 Ans.(d) In blanking operation clearance is always given on the
punch . Die size is always the exact dimension
d = 25mm; h = 15mm;We know ( D ) = d 2 + 4dh = 252 + 4 × 25 ×15 = 46 mm
d 100
Here = = 250 For d ≥ 20r ; D = d 2 + 4dh = 1002 + 4 × 100 × 100 = 224 mm
r 0.4
GATE-2017 Page No.114 Slide No. 431 Ans.(28.723mm)

ISRO-2011 Page No.114 Slide No. 432 Ans.(a)
IAS-2013(mains) Page No.115 Slide No. 435 Ans.
d = 50 mm; h = 100 mm; BlankDia ( D ) = d 2 + 4dh = 502 + 4 × 50 × 100 = 150 mm
d d
Reduction = 1 − ; 1st Reduction; 0.4 = 1 − ⇒ d = 90 mm
D 150
So, it can't be draw in a single draw.
IFS-2013 Page No.115 Slide No. 436 Ans.
d = 40 mm; h = 60 mm; r = 2 mm
D = d 2 + 4dh = 402 + 4 × 40 × 60 = 105.83mm
First draw 50% reduction, d1 = 0.5D=52.415mm
Second draw 30% reduction, d 2 = 0.6d1 = 31.44mm (possible)
It is not possible to draw the cup in single step.we have to use double step.
IES-2008 Page No.115 Slide No. 438 Ans.(c) A cylindrical vessel with flat bottom can be deep drawn
by double action deep drawing
D = d + 4dh = 15 cm
2
First draw 50% reduction, d1 = 7.5 cm

Second draw 30% reduction, d2 = 5.25 cm
Third draw 25% reduction, d3 = 3.94 cm possible
d ⎛ d⎞
= 0.5; Reduction = ⎜1 − ⎟ ×100% = 50%
D ⎝ D⎠
Thumb rule:
First draw:Reduction = 50 %
Second draw:Reduction = 30 %
Third draw:Reduction = 25%
Fourth draw:Reduction =16 %
Fifth draw:Reduction = 13%
IAS-2007 Page No.116 Slide No. 450 Ans.(d) In drawing operation, proper lubrication is essential for
1. To improve die life.
2. To reduce drawing forces.
3. To reduce temperature.
4. To improve surface finish.
GATE-2008 Page No.117 Slide No. 459 Ans.(a)An insufficient blank holder pressure causes wrinkles to
develop on the flange, which may also extend to the wall of the cup.
GATE-1999 Page No.118 Slide No. 461 Ans.(b)It is without a blank holder, so no stress.
GATE-1992 Page No.119 Slide No. 470 Ans.(a)
tc = 1.5mm; α = 30° now ( tc ) = tb sin α ; or 1.5 = tb sin 30 ⇒ tb = 3 mm

IES-1994 Page No.119 Slide No. 471 Ans.(d)Mode of deformation of metal during spinning is bending
and stretching.
Option (b) Magnetic pulse forming and (d) Eletro-hydraulic formingboth are High Energy Rate
Forming (HERF). But Question is "usedfor forming components form thin metal sheets or deform
thin tubes"it is done by Magnetic pulse forming only.
JWM-2010 Page No.120 Slide No. 486 Ans.(c)
High-Energy-Rate-Forming is metal forming through the application of large amount of energy in a very sort
time interval.
High energy-release rate can be obtained by five distinct methods:
(i) Underwater explosions.
(ii) Underwater spark discharge (electro-hydraulic).
(iii)Pneumatic-mechanical means.
(iv)Internal combustion of gaseous mixtures.
(v) Electro-magnetic (the use of rapidly formed magnetic fields)
li1 l
For bi-axial strectching of sheets: ε1 = ln and ε 2 = ln i 2
lo1 lo 2
initial thickness (t )
Final thickness =
e ε1 × e ε 2
1.5
t = 1.5mm; ε1 = 0.05; ε 2 = 0.09 ∴Final thickness = = 1.304 mm
e0.05 × e0.09
EXAMPLE Page No. 123 Slide No. 506 Ans.
Klσ ut t 2
F=
w
1.33 ×1200 × 455 ×1.62
= N = 145.24 kN
12.8
α = 1 radian; R = 100mm; k = 0.5; t = 2mm

Lb = α (R + kt) = 1(100 + 0.5 × 2) = 101 mm
GATE -2012 Same Q in GATE-2012 (PI) Page No.123 Slide No.511 Ans.(a)
Ch-12 Powder Metallurgy: Answers with Explanations

IAS-2003 Page No.124 Slide No.519 Ans. (c)It is for low melting point temperature metals.
IAS-2007 Page No.124 Slide No.520 Ans. (c)In atomization process inert gas or water may be used as
a substitute for compressed air.
• Molten metal is forced through a small orifice and is disintegrated by a jet of compressed air, inert gas or
water jet.
• In atomization, the particles shape is determined largely by the rate of solidification and varies from
spherical, if a low-heat-capacity gas is employed, to highly irregular if water is used. By varying the
design and configurations of the jets pressure and volume of the atomizing fluid, thickness of the stream
of metal, etc, it is possible to control the particle size distribution over a wild range.
IES-1999 Page No.124 Slide No.522 Ans. (c)An oxide film is formed in the case of air atomization and
that film can be avoided by using an inert gas.
GATE-2011(PI) Page No.125 Slide No.525 Ans. (b)In reduction Metal oxides are turned to pure
metal powder when exposed to below melting point gases results in a product of cake of sponge metal.

GATE -2014 (PI) Page No.125 Slide No.531 Ans. (b) Compaction is used for making product.
IAS-2000 Page No.126 Slide No.532 Ans. (b)Sintering used for making bond
IES-2013(conventional) Page No.129 Slide No.544 Ans. Lubricants such as graphite or stearic acid
improve the flow characteristics and compressibility at the expense of reduced strength.
GATE-2016(PI) Page No.127 Slide No.543 Ans. (c)
GATE-2010(PI) Page No.127 Slide No.544 Ans. (b)Due to formation of bonding brittleness reduces.
IAS-1997 Page No.128 Slide No.550 Ans. (d)A is false. Closed dimensional tolerances are possible
with iso-static pressing of metal power in powder metallurgy technique.
ISRO-2013 Page No.128 Slide No.567 Ans. (b& c) Best choice will be ( c)
GATE-2009(PI) Page No.129 Slide No.562 Ans. (d)
IES-2007 Page No.129 Slide No.563 Ans. (b)Disadvantage of PM is relatively high die cost.
IES-2006 Page No.129 Slide No.566 Ans. (c)No wastage of material.It may be automated though it is
difficult for automation. this is not true
IAS-1998 Page No.130 Slide No.570 Ans. (c)
GATE-2011(PI) Page No130 Slide No.572 Ans. (d)
GATE-2008(PI) Page No.132 Slide No.590 Ans. (d)
Ch-xx Tool Materials: Answers with Explanations

IAS-1997 Page No.133 Slide No.7 Ans.(a)Carbon steel tools have Limited tool life. Maximum
cutting speeds about 8 m/min. dry and used upto 250oC
IES-2013 Page No.134 Slide No.11 Ans.(b) Addition of large amount of cobalt and Vanadium to
increase hot hardness and wear resistance respectively
IAS-1997 Page No.134 Slide No.12 Ans.(a)Coating if TiC and TiN on HSS is done by by Chemical
Vapour Deposition (CVD) or Physical Vapour Deposition (PVD)
IES-2003 Page No.134 Slide No.14 Ans.(a)18-4-1 High speed steel- contains 18 per cent tungsten, 4
per cent chromium and 1 per cent vanadium
IES-1993 Page No.134 Slide No.16 Ans.(b)The blade of a power saw is made of high speed steel.
• 18-4-1 High speed steel- contains 18 per cent tungsten, 4 per cent chromium and 1 per cent vanadium
• Molybdenum high speed steel contains 6 per cent tungsten, 6 per cent molybdenum, 4 per cent
chromium and 2 per cent vanadium.

Creamics tool is sued upto 1300°C SiC can with stand upto 2700°C that so why we
can use it for furnace part also. But statement-I and statement-II has no relation.
IES-2010 Page No.138 Slide No.48 Ans.(b)Constituents of ceramics are oxides of different materials,
which areGround, sintered and palleted to make ready ceramics
IES-1997 Page No.138 Slide No.50 Ans.(b)Ceramic tools are used only for light, smooth and
continuous cuts at high speeds.This is because of low strength of ceramics
π D(mm) N π ×100 ×1000
V= m / min = = 314.15m / min
1000 1000
Cutting speed in this case is 314 m / min, at which ceramic is suited.
H.S.S < Cast alloy < Carbide < Cemented carbide < Cermets < ceramics
IES-2000 Page No.140 Slide No.64 Ans.(d)Cermets are Metal-ceramic composites
GATE-2009(PI) Page No.140 Slide No.67 Ans.(d)On ferrous materials, diamonds are not suitable
because of the diffusion of carbon atoms from diamond to the work-piece material.
IES-1995 Page No.140 Slide No.70 Ans.(b)Nonferrous materials are best to work with diamond
because ferrous materials have affinity towards diamond and diffusion of carbon atoms takes place.
IAS-1999 Page No.141 Slide No.74 Ans.(a)“Oxidation of diamond starts at about 450oC and
thereafter it can even crack. For this reason the diamond tool is kept flooded by the coolant during cutting, and
light feeds are used.” - Book B L Juneja and Nitin seth page 88
IES-1996 Page No.141 Slide No.80 Ans.(a)Hardness of CBN is comparable to diamond
IES-1994 Page No.141 Slide No.81 Ans.(d)None of the uses is true for CBN.
High speed steel, in addition to W, Cr & V, has Mo as the most influencing constituent. Thus A matches with 2.
Non ferrous alloys (stellites) are high in cobalt. Thus B matches with 5.
The major constituent of diamond is carbon. Thus C matches with 1.
Coated carbide tools are treated by nitriding. Thus D matches with 3
IES-2003 Page No.142 Slide No.85 Ans.(b)This is one of the natural abrasives found, and is also
called corundum and emery. However, the natural abrasives generally have impurities and, as a result, their
performance is inconsistent. Hence the abrasive used in grinding wheels is generally manufactured from the
aluminium ore, bauxite, Silicon carbide (SiC) Silicon carbide is made from silica sand and coke with small
amounts of common salt.
IES-2000 Page No.142 Slide No.86 Ans.(b)Cutting speed of diamond is very high but small feed rate
with low depth of cut. Degarmo and Kalpakjian both book written this.
IES-1999 Page No.142 Slide No.87 Ans.(d)WC is used for drawing dies, silicone nitride for pipes to
carry liquid metal, Al2O3 for abrasive wheels, and silicon carbide for heating elements.

Equationo ofFlowCurvve
Ana
alysis
s of Forg
ging (a)Withsttrainhardening
Vo K(T )n
e.g. Vo 0 (T )0.3
1000

True stress and Trrue Strrain Here ı o iss flow stresss but it is truee stress and İ T is truestraain.
Th
he true strress is defiined as thee ratio of th
he load to the cross section are
ea at any (b)Withou
utstrainhard
dening:
lload V o V y
nstant. TT

in T 1 F
Instanta
aneous area
a
W
Where T annd F is thee engineering stress and
a engineeering strain
n respective
ely.
Trrue strain
L
Elongation
E dxx L¬ A ¬ d ¬
FT
¨ ln ln 1 F
ln o 2 ln o
Instan
ntaneouslennght L x Lo ® A ® d ®
o
ng strain ( F ) = e FT -1
orr engineerin
The volume of the specimen

s iss assumed to
t be consta
ant during plastic defformation.
[ ' Ao Lo AL ] It is valid
v till th
he neck form
mation.
Wewillannalyzeonlyoopendieforgingusingsllabmethodofanalysisffor
(1)RectanngularBarforging,and
Flow Stress
s (2)AxiͲsym
mmetricforgging
Whenam
materialdeformsplasticalllystrainharrdeningoccurs. 1. Rec
ctangu
ular Bar Forgiing

Beforeforging Afterfforging (lenggth n height p)
B B
h
h1
2L
2L1
x Here we are using plane

p strain n i.e. width won’t increease.
n condition
x At the en
nd of the forging,
f forrce will be maximum m because oof the area involved
between the die and
d the workp piece is ma
aximum.
x Geometry should bee taken at end
e of forgiing
P
dx
B Wx
x
Forgingoccursinplassticzonei.einbetween V y and Vult (Vx+d Vx)
h x
V y –YieldStress x =0
V o – For forging,
f we need flow stress
s and fllow stress iss not constaant and depends on stress of the 2L
L Wx
P
workpiecee.
Vult –Ultimmatetensilestresshereneckformationstarts. x 0 , is the point at
a which thhe material does not move
m in any
y direction.
Take an element dxx at a distance of x (en
nlarged view
w):


As 2 0 (' Plane stra
ain conditioon)
V2 QV1 QV3
0
E E E
V2 Q( V1 V3 )
Fig. FBD
F of Elements orr V2 Q( Vx P)
§ 1·
Now elem
ment will loook like a slab
s and hence its nam
me slab metthod of ana
alysis. Note: In theories off plasticity ¨ Poisson's ratio,ǎ
r = ¸ as volume change nott occur.
© 2¹
x On left sidee (stress x area) = Force V x u Bh and on other side force e will be
1
V x dV x Bh
B .
Therefore, V2 V P
2 x
x Upper die will
U w give preessure on upper
u surface and lower surface will get pre
essure by From Vo
on-Mises theory:
t
2
= P × area = (P × B× dx)
loower die. Soo on upper side force= d & similarly on low wer side = 1 ½ 1 ½ 2
®V x ( V x P) ¾ ® ( V x P) P ¾ ( P V x ) 2V02
P B dx )
(P ¯ 2 ¿ ¯2 ¿
x As metal is moving ou utwards soo friction force
f will act
a in oppoosite directtion, this ( V x P)2 ( V x P)2
or ( V x P)2 2V20
frriction force is shear force and d will causse shear sttress on th
he surface equal to 4 4
(WWx B dx ) in lo
ower and upper
u surface. 3
or ( V x P))2 2 V20
2
At the en
nd of forgin
ng the systeem must bee in equilibrrium; thereefore net reesultant forrce in any 4 2
or ( V x P)2 V0
direction
n is zero. 3
? 6 Fx 0; Gives 2
or ( V x P) V0
( Vx d Vx ) B h Vx . B h 2Wx . B dx 0 3
or d Vx B h 2Wx B dx 0 V0
or Vx P 2 K ….(2)) [where K = flow shear strress]
or d Vx . h 2Wx dx 0 3
dV x 2W x resca’s th
From Tr heory :
0 (1
1) V1 V3 V0
dx h
Here theere are thrree variablees Vx , Wx and x so we reduce
r it in
nto two va
ariables by applying or Vx P V0
condition
n. V0
or Vx P 2 K ….(2)) [where K = flow
w shear strress]
2
For a ducctile materrial there arre two the
eories of plasticity.
Differenttiating equation (2)
1. Von-M ory: (V1 V2 )2 ( V2 V3 )2 ( V3 V1 )2
Mises Theo 2 V02
2. Tresca’s Theory
y: V1 V3 V0

dV x d P 2P
0 (L x )
dx dxx
or P 2K . e h
.... (5) (Pressure
( d
distribution
n equation)
dVx d P
or ....(3) 2P
(L)
dx dxx At x = 0, Pmax K eh
2K
Condition-1: 2P
(0)
At x = L, Pmin K eh
2K 2K
dering sliding fric
Consid ction all over the
e surface ( Wx PP )
dx
PBd
W × Bdx
F = ǍN
N
or dF = ǍdN
Ǎ
Wx B dx P . PB dx
Wx PP
From equ
uation (1) and
a (3)
d V x 2W x
0
dx h
d P 2P P Elementa
al force, dF
F = P.B.dx
or 0 2P
(L x )
dx x h dF = 2K e h . B.dx
dP 2P
or ³ P h ³ dxx L 2P
. (L x ) § L L
·
Integratiing, F 2 u ³ (2 K . e h
. B . dx ) ¨¨' ³ gives half we use 2³ ¸¸
h portion F so for 2L w
2P 0 © 0 0 ¹
or ln P x C ......(4) L 2P
h (L x )
F 4 KB .³ e h . dx
0
Condition-2:
Consid
dering sticking frriction all over the surfac
ce ( Wx Wy K )
Shear faiilure will occur at each and everry point.
Boundary condition ns, at x = L, V x 0 (because

( no
o force is applied soo no stresss on that
surface) and Vx P 2K gives P = 2 K
2P
or ln 2 K LC
h
2P From equ
uation (1) and
a (3)
or C ln 2 K .L
h dV x W
2 x 0
Putting the
t values of
o C in equ
uation (4) dx h
2P 2P dPP 2K
ln P l 2 K
x ln .L or 0
h h dxx h
§ P · 2P 2K
or ln ¨ ¸ L x)
(L or ³ d P h ³ dxx
© 2K ¹ h
2P 2K
§ P · or P x C .......(6)
or ln ¨ ¸ L x)
(L h
© 2K ¹ h

Boundary condition ns, at x = L, V x 0 (because
( no
o force is applied soo no stresss on that d P 2P P
or 0
surface) and Vx P 2K gives P = 2 K dx h
2K L dP 2P
So, 2K C or ³ P h ³ dx
h
2K 2P
or C 2K .L or ln P x C ......(4)
h h
Putting in
i equation
n (6) Boundary conditions, at x = L, V x 0 (because no force is applied so no stress on that
2K 2K surface) and Vx P 2 K gives P = 2 K
P .x 2
2K .L
h h 2P
or ln 2 K LC
2K
2 h
P 2K (L x ) …..... (7) {Presssure distriibution equ
uation} or C ln 2 K
2P
.L
h h
2K Putting the values of C in equation (4)
At x = 0, Pmax K
2K .L
h 2P 2P
ln P x ln 2 K .L
x = L, Pmin 2K h h
§ P · 2P
2k + 2k .L or ln ¨ ¸
© 2K ¹ h
(L x )
h
§ P · 2P
or ln ¨ ¸ (L x )
© 2K ¹ h
2P
(L x )
h
or P 2K . e .... (5)
2h 2k dV x W
For Sticking Region: 2 x 0
dx h
dP 2K
or 0
dx h
x=0 x=L
Elementa
al force, dF = P . B . dx 2 K
or ³ d P h ³ dx
2K ½
or dF = ®2K
K (L x ) ¾ B . dx 2K
¯ h ¿ or P x C ......(6)
L
h
2K ½
F 2 u ³ ®2K L x ) ¾ B . dx
(L x At x xs ; P Ps
0¯ h ¿
2K
Ps xs C
or h
Condition-3: 2K
C Ps . xs
Consid
dering sticking an
nd slidin
ng both model
m off friction or h
(' Temperatu
T re is same throughout body)
2K 2K
P x Ps xs
h h
2K
P Ps ( xs x ) ...............(8)
h
dVx 2Wx
For Slidiing Region: 0
dx h

Example 2: L = 50 mm, h = 10 mm & P 0.08
h § 1 · 10 § 1 ·
xs L ln ¨ ¸ 50 ln ¨ ¸ 64.53 mm absurd value ¬
2P © 2P ¹ 2 u 0.08 © 2 u 0.08 ¹
(' x cannot be –ve) i.e only sliding no sticking occur.
Example 3: L = 50 mm, h = 10 mm & P 0.65
h § 1 · 10 § 1 ·
xs L ln ¨ ¸ 50 ln ¨ ¸ 52.01 mm ¬
2P © 2P ¹ 2 u 0.65 © 2 u 0.65 ¹
Only sticking no sliding
NOTE: If P ! 0.5 then only sticking, In hot forging ( P ) is larger if P ! 0.5 only sticking
condition will occur.
IES – 2005 Conventional

A strip of lead with initial dimensions 24 mm x 24 mm x 150 mm is forged between two flat
dies to a final size of 6 mm x 96 mm x 150 mm. If the coefficient of friction is 0.25,
FTotal FSticking FSliding determine the maximum forging force. The average yield stress of lead in tension is 7
Xs L N/mm2
2 ³P 0
Sticking . B . dx 2 ³P
Xs
Sliding . B dx
d Solution: h = 6 mm, 2L = 96 mm, P 0.25
xs
h § 1 · 6 § 1 ·
2K
L
2P
(L x ) ½ xs L ln ¨ ¸ 48 ln 39.68 mm

2 ³ ®Ps
½
( x s x ) ¾ B . dx 2 ³ ®2K e h
°
¾ B . dx 2P © 2P ¹ 2 u 0.25 ¨© 2 u 0.25 ¸¹
0 ¯ h ¿ xs ¯ °¿ xS L 2P
2K
Ftotal = 2 u ³ ®Ps ½ (L x )
( x s x ) ¾ B. dx 2 u ³ 2 K e h
B . dx
0 ¯ h ¿ xS
To find Ps and x s
V0
At x x s , Shear strresses are same
s for booth sticking
g and slidin
ng Applying Von-Mises theory K 4.04 N / mm2
3
Wx K (if consid
dering stick
king)
K
Wx P Ps dering sliding)
(if consid Ps 16.16 N / mm2
or P
Wx K P Ps 39.68 48 2u0.25
2 u 0.25
39.68 x ½¾ 150 . dx 2 u ³ (2 u 4.04) e
(48 x )
Ps
K
....(9) or F 2u ³
0
®16.16
¯ 6 ¿ 39.68
6
150 . dx
P
510 kN 29.10 kN 539 kN (Von Mises)
At x xs ; P Ps
Vo K 3.5
2P
(L x s ) Applying Tresca’s Theory, K 3.5 N / mm2 ; Ps 14 N / mm2
Ps 2K e h 2 P 0.25
2P 39.68 2u0.25 48
K h
(L xs ) 2 u 3.5 ½ (48 x )
P
2K e F 2u
®14
¯
³ 6
(39.68 x ) ¾ 150 dx 2 ³ (2 u 3.5) e 6
¿
150 dx
or 0 39.68
1 2P
(L xs ) 442 kN 25 kN 467kN (Tresca ' s)
eh
or 2P
§ 1 · 2P Practice Problem-1
ln ¨ ¸ (L x s )
or © 2P ¹ h A strip of metal with initial dimensions 24 mm x 24 mm x 150 mm is forged between two
h § 1 · flat dies to a final size of 6 mm x 96 mm x 150 mm. If the coefficient of friction is 0.05,
. ln ¨ ¸ L xs
2P © 2P ¹
determine the maximum forging force. Take the average yield strength in tension is 7
h § 1 ·
xs L ln ¨ ¸ ....(10) (in any ques
stion first w
we find thiss xs )
2P © 2P ¹ N/mm2
Using this equation
n we can deecide the coondition of friction.
f
Given: 2L = 96 mm; L = 48 mm; h = 6 mm; B = 150 mm; P 0.05
Example 1: L = 50 mm, h = 10 mm & P 0.25
h § 1 ·
h § 1 · 10 § 1 · xs L ln K = 4.04 N/mm2
xs L ln
n¨ ¸ 50 ln
n¨ ¸ 36.13mm 2P ¨© 2P ¸¹
2P © 2P ¹ 2 u 0.25 © 2 u 0.25 ¹
xs 90.155 mm
0 to 36.13 mm stick
king and 36
6.13 mm to 50 mm slid
ding will ta
ake place.
Since xs came negative so there will be no sticking only sliding will take place.

L 2P
(L x )
F 4 KB ³ e h dx
0
48 °§ 2u0.05 · °½
®¨ ¸(48 x ) ¾
¯°© 6 ¹ ¿°
4 u 4.04 u 150 ³e
0
dx 177.98 kN
Axi – Symmetrical Forging (Open Die):

Using cylindrical co-ordinate system (r, T, z )
and Using Slab Method of analysis
d1
R
h1
At the start At end of forging

Net resultant force in radially
y outward direction
d is 0.
of forging
dT
( Vr d Vr ) (r dr ) dT . h ( Vr . r dT . h ) 2 Wr . r dT . dr 2 V T dr h . ssin 0
2
Volume before forging = Volume after forging
S 2
d1 u h1 S R 2 h VTdr.h cos dT
4 2
At an angle T, we take an dT element at a radius r we take dr element.
VV dVr
VTdr.h cos dT
2
dT
dr VT dr 2
dT
VT dVT
VT
r VT drh
Vr
T
dT
VTdr.h sin dT 2 VTdr.h sin dT
2 2
For axi-symmetrical forging dV T will be zero. § dT

ncelled ? the
·
¨ coss gets can ey are oppossite ¸
© 2 ¹
For Axi--Symmetr
ry forging
r T
i.e. Vr V T
From aboove equatioon,
dT
( Vr d Vr ) ( r dr ) dT . h ( Vr . r dT . h ) 2 Wr . r dT . dr 2 Vr dr h . 0
2
§ d T dT ·
¨ U sin g : V T Vr ; sin | ¸
© 2 2 ¹
Vr d Vr ) (r dr ) . h ( Vr . rh) 2Wr . r dr Vr . dr
(V d .h 0
or

( Vr . r . h dVr . rh dVr . drh Vr drr . h) Vr . rh
h 2Wr . r drr Vr dr. h 0 2 PR
or C ln V0
d Vr . r h 2Wr . r dr or h
or
d V r 2 Wr 2Pr 2 PR
0 ...(1) uation (4)
From equ ln P ln V0
or d
dr h h h
For ductiile materia
al there are two theoriies of plastiicity P 2P
ln (R r )
1. Tresca’s Theory y: V0 h
or
2P
(R r )
P V0 . e h ………
……….. (5) Pressure distribution
n
or
2P
.R
At r = 0; Pmax V0 e h
At r = R; Pmin V0
Here r = 0 means a point
V1 V3 V0
Vr P V0 ...(2)
or
2. Von Miscs
M Theo
ory:
V1 V2 )2 ( V2 V3 )2 ( V3 V1 )2
(V 2 V20
2 2 2
( Vr Vr ) ( Vr P) ( P Vr ) 2 V20 ding force
For find
or
2 ( Vr P)2 2 V20 Elementaal force (dF
F)
or
V P
r 0V ...(2)
or dr
On differrentiating; r R
d Vr d P
0
dr dr
d Vr dP
...(3)
dr dr Sr dr
dA = 2S
dF = d F P . 2Sr . drr
Condittion 1: 2P
(R r )
Consid
dering sliding
s f
friction all over
r the sur
rface ³dF ³V 0 .eh . 2Sr . dr
R 2P
Wr PP . (R r )
orr F 2SV0 ³ r.e h
dr
d P 2Wr
From (1) and (3); 0 0
dr h ª
R
2P
(R r ) § 2P
(R r ) ·º
dP PP «r . e h eh »
2. 0 orr F 2SV0 « ³ ¨¨1 . d ¸¸ »
dr
or dr h § 2P · § 2P ·
« ¨ ¸ ¨ ¨ ¸ ¸»
dP 2 P P ¬ © h ¹ © © h ¹ ¹¼ 0
R
or dr h ª 2P
(R r )
2P
(R r ) º
r.eh eh
dP 2P orr F 2SV0 « »
or « § 2P · P· »
2
³P ³
h
. dr
« ¨ ¸ §
¨
2
¸ »
«¬ © h ¹ © h ¹ ¼» 0
2P
ln P .r C ...(4) ª 2P
R º
h R 1 eh
At r = R; Vr 0 (becausse on this su
urface therre will be noo force) and
d Vr P V 0 ; P V0 orr F 2S V 0 « 0 »
« § 2P · 2 P
2
2 P
2 »
«¨ § · § · »
¸ ¨ ¸ ¨ ¸
2P . R «¬ © h ¹ © h ¹ © h ¹ ¼»
ln V0 C
or h

2K
C V0 R
IES–2007Conventional or h
2K 2K
From (6) P . r V0 R
A cylinder of height 60 mm and diameter 100 mm is forged at room temperature between h h
two flat dies. Find the die load at the end of compression to a height 30 mm, using slab 2
2K
P V0 . (R r ) ...(7) Pressure Distribution
n linear
method of analysis. The yield strength of the work material is given as 120 N/mm2 and the h
or
coefficient of friction is 0.05. Assume that volume is constant after deformation. There is no
2K
sticking. Also find mean die pressure. [20-Marks] At r = 0; Pmax V0 .R
h
Solution: Given, h1 = 60 mm, d1 = 100 mm, h = 30 mm r = R; Pmin V0
V0 120 N/ mm 2 and P 0.05
S d12
h1 S R2 h
or 4
2
100
u 60 R2 u 30
or 4
or R = 70.7 mm
2P
ª .Rº
R 1 eh
F 2S V 0 « 0 » 2.04 MN
« § 2P · 2 2 »
«¨ § 2P · § 2P · »
¸ ¨ ¸ ¨ ¸
¬« © h ¹ © h ¹ © h ¹ »¼
Total force 2.04 u 106
Mean Die pressure = | 130 MPa
Total Area S u 70.72
For find
ding force:
GATE–2014(PI)
In an open die forging, a circular disc is gradually compressed between two r
flat platens. The exponential decay of normal stress on the flat face of the
disc, from the center of the disc towards its periphery, indicates that R
(a) there is no sticking friction anywhere on the flat face of the disc
(b) sticking friction and sliding friction co-exist on the flat face of the disc 2Srdr
(c) the flat face of the disc is frictionless

dF P . 2 Sr dr
d
(d) there is only sticking friction on the flat face of the disc
Answer: (a) or F ³ P . 2 Sr dr
d
R
ª 2K
K º
F ³ «¬V 0 . (R r ) » 2S r dr
Condition -2: Considering sticking friction all over the or 0 h ¼
surface
Wr K
From (1) equation (3)
d V r 2 Wr
0
dr h
d P 2K
0
or dr h
2K
or ³dP ³
h
. dr
2K
or P .r C ...(6)
h
At r = R; Vr 0 (because on this surface there will be no force) and Vr P V0 ; P V0
2K
V0 .RC
h

Condition 3: Rs R
h § K ·
ln ¨
When there is sticking and sliding both frictions occur © 2P P V0 ¸¹
or
According to Tresca’s theory
V0 K 1
K or
2 V0 2
g
di n
Sl i Sliding Rs R
h § 1 ·
ln ¨ ¸ ...(10)
2P © 2P ¹
ng
ki
ic Ps According to Von-Miscs Theory
St
Sticking V0 K 1
r = Rs K or
3 V0 3
h § 1 ·
Rs R ln ¨ ¸ ...(11)
2P © 3 P¹
IES–2006–Conventional
A certain disc of lead of radius 150 mm and thickness 50 mm is reduced to a thickness of 25
mm by open die forging. If the co-efficient of friction between the job and die is 0.25,
For sliding region pressure distribution is same as we derived in previous condition same
determine the maximum forging force. The average shear yield stress of lead can be taken
boundary condition same differential equation.
2P
(R r )
as 4 N/mm2 [10 – Marks]
P V0 . e h
Solution: R1 = 150 mm, h1 50 mm, R = ?, h = 25 mm, Ǎ= 0.25
For sticking region: Using equation (6). SR12h1 S R2 h

2K R = 212.1 mm
P .r C
h W y 4 N/ mm2 (Shear yield stress) = K
Boundary condition at r = R; P Ps By Tresca Theory;
2K 25 § 1 ·
or Ps . Rs C Rs 212.1 ln ¨ ¸ = 177.4 mm
h 2 u 0.25 © 2 u 0.25 ¹
2K ª0 mm to 177.4 mm o sticking º
C Ps . Rs
or h «177.4 mm to 212.1mm o sliding »
Putting in equation (6)
¬ ¼
K 4
2K 2K Ps 16 N / mm2
P (r ) Ps Rs P 0.25
h h
2K V0 2K 2u4 8 N / mm2
P Ps . (R s r ) ...(8) °§ 2u0.25 · ½°
h 177.4
§2u4· ½ 212.1
®¨ ¸(212.1 r ) ¾
or °© 25 ¹ ¿°
FTotal Fsticking Fsliding

Ftotal ³ (8) u e ¯
³0 ®¯16 ¨© 25 ¸¹ (177.4 r )¾¿ . 2 Sr dr 177.4 . 2 Sr dr
Rs R 3.93 MN (Tresca’s Theory)

Ftotal ³P
0
sticking 2 Sr dr ³P
Rs
sliding 2 Sr dr Von Miscs Theory;
25 § 1 ·
Rs 212.1 ln ¨ ¸ = 170.25 mm
Rs R 2P
ª 2K º (R r )
2 u 0.25
Ftotal ³ «¬P s (R s r )» 2 Sr dr ³V 0 .e h
. 2 Sr dr © 3 u 0.25 ¹
0
h ¼ Rs
ª0 mm to 170.25 mm o sticking º
To find Ps and Rs «170.25 mm to 212.1mm o sliding »
Wr P Ps K ¬ ¼
K 4
K Ps 16 N / mm2
Ps ......(9) P 0.25
or P
V0 K 3 4 3 N / mm2
At r Rs ; P Ps
2P
(R Rs )
RS
Ps V0 e h
2K ½
R 2P
(R r )
K 2P
(R R s )
Ftotal ³ ®¯P
0
s
h
(R s r ) ¾ 2 Sr dr
¿ RS
³V 0 eh 2 Sr dr
V0 e h
or P 170.25 2u0.25 212.1

2u4 ½ (212.1 r )
§ K · 2P
Ftotal
¯
³
®16
25
(170.25 r ) ¾ 2 Sr dr ³ 4 3. e 25
¿
2 Sr dr
ln ¨ ¸ (R R s ) 0 170.25
© P V0 ¹ h = 3.6 MN (Von Misces)

Practice Problem -1 d1 150 mm; h1 100 mm; h 50 mm; P 0.2;
A strip of metal with initial dimensions 24 mm x 24 mm x 150 mm is forged between two flat dies to a ' Volume before forging = Volume after forging
final size of 6 mm x 96 mm x 150 mm. If the coefficient of friction is 0.05, determine the maximum
forging force. Take the average yield strength in tension is 7 N/mm2 S S
d12 h1 S R 2 h or u 1502 u100 S R 2 u 50 R 106.66 mm
4 4
Answer:
h 50
True strain H ln ln 0.693
Given: 2L = 96 mm; L = 48 mm; h = 6 mm; B = 150 mm; P 0.05
h1 100
Flow stress V o V f 1030H 0.17
1030 u 0.6930.17 967.74 MPa
h § 1 ·
xs L ln K = 4.04 N/mm2 By Tresca Theory;
2P ¨© 2P ¸¹
50 § 1 ·
xs 90.155 mm Rs 106.66 ln ¨ ¸ =-7.87mm
2 u 0.2 © 2 u 0.2 ¹
Since xs came negative so there will be no sticking only sliding will take place. VonMiscsTheory;
L 2P
(L x )
F 4 KB ³ e h dx
0 Practice Problem -4
48 °§ 2u0.05 ·
®¨
°½
¸ (48 x ) ¾
A circular disc of 200 mm in diameter and 70 mm in height is forged to 40 mm in height.
¯°© 6 ¹ ¿°
4 u 4.04 u 150 ³e dx 177.98 kN Coefficient of friction is 0.05. The flow curve equation of the material is given by
0
Vf 200(0.01 H )0.41 MPa . Determine maximum forging load, mean die pressure and maximum
Practice Problem -2 pressure.
A circular disc of 200 mm in diameter and 100 mm in height is compressed between two flat dies to a
height of 50 mm. Coefficient of friction is 0.1 and average yield strength in compression is 230 MPa. Answer:
Determine the maximum die pressure.
d1 200 mm; h1 70 mm; h 40 mm; P 0.05; V f 200(0.01 H )0.41
Answer: ' Volume before forging = Volume after forging
d1 200 mm; h1 100 mm; h 50 mm; P 0.1; V Y 230 MPa V O S S
' Volume before forging = Volume after forging d12 h1 S R 2 h or u 2002 u 70 S R 2 u 40 R 132.28 mm
4 4
S S h 40
d 2 h S R 2 h or u 2002 u100 S R 2 u 50 R 141.421 mm True strain H ln ln 0.5596
4 1 1 4 h1 70
According to Von-Mises Vf 200(0.01 H )0.41
h § 1 · 50 § 1 · Vf 200(0.01 0.5596)0.41 158.78 V o
Rs R ln 141.21 ln 297.1 mm
2 P ¨© 3P ¸¹ 2 u 0.1 ¨© 3 u 0.1 ¸¹ NowuseTresca’stheory
According to Tresca
VonͲMisesTheory
h § 1 · 50 § 1 ·
Rs R
ln 141.21 ln 261.1 mm
2P ¨© 2P ¸¹ 2 u 0.1 ¨© 3 u 0.1 ¸¹ Practice Problem -5 {GATE-2010 (PI)}
During open die forging process using two flat and parallel dies,
' Rs came out to be negative so only sliding friction takes place.
a solid circular steel disc of initial radius (R IN ) 200 mm and initial
The formula for pressure we get after the slab method of analysis of forging;
2P height (H IN ) 50 mm attains a height (H FN ) of 30 mm and radius of R FN .
Rr
P V oe h Along the die-disc interfaces.
at r 0; P Pmax R
§ IN ·
2u0.1
(141.21) i. the coefficient of friction (P ) is: P = 0.35 ¨ 1 e RFN ¸
Pmax 230 u e 50 404.94 MPa ¨ ¸
© ¹
ii. in the region R ss d r d RFN ,sliding friction prevails, and
Practice Problem -3 2P
A cylindrical specimen 150 mm in diameter and 100 mm in height is upsetted by open RFN r
die forging to a height of 50 mm. Coefficient of friction is 0.2 and flow curve equation is p 3Ke H FN and W P p,
V f 1030H 0.17 MPa . Calculate the maximum forging force. where p and W are the normal and shear stresses, respectively;
K is the shear yield strength of steel and r is the radial distance
Answer: of any point

iii.In the region 0 d r d R SS ,sticking condition prevails
The value of R SS (in mm), where sticking condition changes to sliding
friction, is
(a) 241.76 (b) 254.55 (c) 265.45 (d) 278.20
Answer:
S RIN2 H IN 2
S RFN H FN
2 2
or 200 u 50 RFN u 30 RFN 258.2 mm
200
§ ·
and P 0.35 ¨1 e 258.2 ¸ 0.51
© ¹
Now at Rss
Shear stress in sticking K = shear stress in sliding P Pss
2P
RFN Rss
or K = P 3Ke H FN
§ 1 · 2P
or ln ¨ ¸ RFN Rss
© 3P ¹ H FN
H § 1 ·
or FN ln ¨ ¸ RFN Rss
2 P © 3P ¹
H § 1 · 30 § 1 ·
or Rss RFN FN ln ¨ ¸ 258.2 ln 254.55 mm
2P © 3P ¹ 2 u 0.51 ¨© 3 u 0.51 ¸¹
IFS-2012
Discuss Tresca and Von Mises yield criterion for metal forming operations. Also derive tensile and
shear yield stress relationships for their approaches. Which of this criterion is more realistic? Why?
[10 Marks]
Answer: Refer forging analysis

Stress Equilibrium of an Element in Rolling
ANALYSIS
Y OF ROLLING Which
Whi h off the
th following
f ll i
IES – 2001
assumptions
ti are correctt for
f
Assumptions in Rolling cold rolling?
1. Rolls are straight, rigid cylinders. 1. The material is plastic.
2 Strip is wide compared with its thickness,
2. thickness so that no 2. The arc of contact is circular with a radius g greater than
widening of strip occurs (plane strain conditions). the radius of the roll.
3. The
Th arc off contact is
i circular
i l withi h a radius
di greater than
h 3 Coefficient of friction is constant over the arc of
3.
contact and acts in one direction throughout the arc of
the radius of the roll.
contact.
contact
4. The material is rigid perfectly plastic (constant yield Select the correct answer using the codes given below: Considering the thickness of the element perpendicular to the
strength).
strength) plane of paper to be unity,
unity We get equilibrium equation in xx‐
Codes:
d
5. The co‐efficient of friction is constant over the tool‐ direction as, - σ x h + (σ x +dσ x ) (h + dh) - 2pR dθ sin θ
((a)) 1 and 2 ((b)) 1 and 3
workk interface.
f
(c) 2 and 3 (d) 1, 2 and 3 + 2 τ x R dθ cos θ = 0
For sliding friction, τ x = μp Simplifying and neglecting Due to cold rolling, σ 0' increases as h decreases, 2Rθdθ 2Rθdθ 2θdθ ⎛h⎞
secondd order
d terms,
t i θ ≅ θ and
sin d cos θ = 11, we gett
I= ∫h f + Rθ
2
= ∫ h
= ∫h/R = ln ⎜ ⎟
⎝R⎠
thus σ 0' h nearly a constant and itsderivative zero.
d (σ x h ) hf
Now h / R = + θ2
dθ
= 2 pR (θ ∓ μ ) d
dθ
( p / σ 0' )
2R
R
2 = (θ ∓ μ ) or
d ⎛h⎞
= 2θ
θ\
p −σ x = σ 0 = σ 0' p /σ0 '
h dθ ⎜⎝ R ⎟⎠
3
h = h f + 2 R (1 − cos θ ) ≈ h f + Rθ 2 2Rμ
R
d
⎡ h ( p − σ 0' ) ⎤ = 2 pR (θ ∓ μ )
II = ∫h + Rθ2
dθ
dθ ⎣ ⎦ d ( p / σ 0' )
f
2R
= (θ ∓ μ ) dθ = ∫h
2μ
d ⎡ ' ⎛ p ⎞⎤
⎢σ 0 h ⎜ ' − 1 ⎟ ⎥ = 2 pR (θ ∓ μ )
( p /σ )'
0
h f + Rθ 2 f / R + θ2
dθ
dθ ⎣ ⎝σ0 ⎠⎦ Integrating both side R ⎛ R ⎞

= 2μ .tan −1 ⎜ .θ ⎟
hf ⎜ h ⎟
d ⎛ p ⎞ ⎛ p ⎞ d 2 Rθ dθ 2 Rμ ⎝ ⎠
σ 0' h ⎜ ' ⎟ + ⎜ ' − 1⎟
dθ ⎝ σ 0 ⎠ ⎝ σ 0
(σ 0' h ) = 2 pR (θ ∓ μ ) ln ( p / σ 0' ) = ∫ ∓ ∫h dθ = I ∓ II ( say )
f
⎠ dθ h f + Rθ 2 f + Rθ
2
⎛h⎞ R ⎛ R ⎞ ⎛h ⎞
∴ ( )
ln p / σ '0 = ln ⎜ ⎟ ∓ 2μ
⎝R⎠ hf
.tan −1 ⎜⎜ .θ ⎟ + ln C
⎟ y zone,, p = C.σ '0 ⎜ o ⎟ e− μHo
In the entry hn μ H −H h
. e ( 0 n ) = n . eμ Hn
⎝ hf ⎠ ⎝R⎠ h0 hf
⎛h⎞ R μHo ho
∴ p = C σ '0 ⎜ ⎟ e∓ μH
and C = = e ( 0 n)
μ H − 2H
⎝R⎠ .e or
ho hf
R ⎛ R ⎞
where H = 2 .tan −1 ⎜⎜ .θ ⎟ h 1⎡ 1 ⎛ h0 ⎞ ⎤
⎟ . e ( 0 )
μ H −H
hf ⎝ hf ⎠ p = σ '0 or Hn = ⎢H0 − ln ⎜ ⎟ ⎥
h0 2 ⎣⎢ μ ⎝ h f ⎠ ⎦⎥
Now at entry ,θ = α
Hence H = H0 with θ replaced by ∝ in above equation I th
In the exit
it zone R ⎛ R ⎞
From H = 2 .tan −1
⎜⎜ .θ ⎟
At exit θ = 0 ⎛ h ⎞ hf ⎟
p = σ '0 ⎜ ⎟ .eμH ⎝ hf ⎠
Therefor p = σ '0
⎝ hf ⎠ hf ⎛ h f Hn ⎞
∴ θn = .tan ⎜ . ⎟⎟
At the neutral po int above equations R ⎜
⎝ R 2 ⎠
will give same results and h n = h f + 2R (1 − cos θn )
If back tension σ b is there at Entry,
Entry
h
IAS ‐2012 Main
p = ( σ ′o − σ b ) . e ( 0 )
μ H −H
IFS –
IFS – 2010
2010
h0
Calculate the neutral plane to roll 250 mm wide What is friction hill ?
What is "friction hill" ?
If front tension σ f is there at Exit,
annealed copper
pp strip
p from 2.55 mm to 2.0 mm
h
p = ( σ ′o − σ f ) . eμ H thickness with 350 mm diameter steel rolls. Take µ
hf
= 0.05 and σ’o =180 MPa.
[10‐marks]
or σ x 2rdr + dσ x r 2 + 2rτ x dx + Px 2rdx tan α = 0 dσ x 2σ o 2 μ (σ o − σ x )

ANALYSIS OF WIRE DRAWING + + cotα = 0
Dividing by r 2 dr and taking dx/dr = cotα we get dr r r
Let μ cotα = B
dσ x 2 2τ
+ (σ x + Px ) + x cotα = 0 dσ x 2
dr r r = ⎡⎣ Bσ x − (1 + B ) σ o ⎤⎦
i l component off Px ≅ Px due
Vertical d to small ll half
h lf die
di dr r
dσ x 2
angles and that of τ x can be neglected
neglected. or = dr
The equilibrium equation in x-direction will be ⎡⎣ Bσ x − (1 + B ) σ o ⎤⎦ r
Thefore two principal stresses are σ x and − Px
Thefore,
⎛ dx ⎞ Integrating both side
(σ x + dσ x ) π ( r + dr )
2
− σ xπ r 2 + τ x cos α ⎜ 2π r ⎟ Both Tresca's and Von-Mises criteria will g
give
⎝ cos α ⎠ 1
σ x + Px = σ o ln ⎡⎣ Bσ x − (1 + B ) σ o ⎤⎦ × = 2 ln ( rC )
⎛ dx ⎞ B
+ Px sin α ⎜ 2π r =0
⎝ cos α ⎟⎠ and τ x = μ Px = μ (σ o − σ x ) {Cis integration cont.}
or Bσ x − (1 + B ) σ o = ( rC )
2B
IFS 2013
IFS‐2013 ANALYSIS OF EXTRUSION
B.C s at r = ro ,σ x = σ b An a u u rod,
aluminium od, 6.
6.255 mm d a ete , iss d
diameter, aw into
drawn to For a round bar both wire drawingg and extrusion will ggive
1 a wire 5.60 mm diameter. Neglecting friction same equation except B.Cs
⎡ Bσ b − (1 + B ) σ o ⎤⎦ 2 B between the rod and the dies, dies determine the
∴C = ⎣ drawing stress and the reduction in area when the ∴ Bσ x − (1 + B ) σ o = ( rC )
2B
ro yield
i ld stress
t f
for aluminium
l i i i 35 N/mm
is N/ 2. Also
Al
B.C s at r = rf , σ x = 0 (at exit stress is zero)
σ o (1 + B ) ⎡ ⎤ ⎛ r ⎞2 B
2B calculate the tangential stress at the exit. [8‐Marks]
⎛r⎞
or σ x = ⎢1 − ⎜ ⎟ ⎥ + ⎜ ⎟ .σ b 1
Hint: Drawing Stress ⎡ − (1 + B ) σ o ⎦⎤
⎣⎢ ⎝ o ⎠ ⎦⎥ ⎝ o ⎠
2B
∴C = ⎣
B r r
P ⎛A ⎞ ⎛r ⎞
σd = = σ o ln ⎜ o ⎟⎟ = 2 × σ o × ln ⎜⎜ o ⎟⎟ rf
σ o (1 + B ) ⎡ ⎛ rf ⎞ ⎤ ⎛ rf ⎞
2B 2B
Af ⎜A
⎝ f ⎠ ⎝ rf ⎠
∴ Drawing stress (σ d ) = ⎢1 − ⎜ ⎟ ⎥ + ⎜ ⎟ .σ b
σ o (1 + B ) ⎡ ⎤
2B
For Tangential Stress i.e. Shear Stress ⎛ ⎞
B ⎢⎣ ⎝ ro ⎠ ⎥⎦ ⎝ ro ⎠ τ x = μ Px = μ (σ o − σ x ) or σ x = ⎢1 − ⎜ r ⎟⎟ ⎥
B ⎢ ⎝⎜ rf ⎠ ⎥
at Exit τ = μ P = μ (σ o − σ d ) = 0 ⎣ ⎦
at r = ro
If effect of container friction is considered
σ o (1 + B ) ⎡ ⎤
2B
⎛r ⎞
σ xo = ⎢1 − ⎜ o ⎟⎟ ⎥ p f = ram pressure required by container friction
B ⎢ ⎜r ⎥
⎣ ⎝ f ⎠ ⎦ τ i = uniform interface shear stress between
2
Ao ⎛ ro ⎞ billet and container wall
Extrusion ratio,, R = = ⎜ ⎟ for round bar
Af ⎜⎝ rf ⎟⎠ 2τ i L
p f .π r0 2 = 2π r0τ i L or p f =
ro
⎛h ⎞
=⎜ o ∴ Total Extrusion Pressure(Pt ) = σ xo + p f
⎟⎟
for flat stock
⎜h
⎝ f ⎠
and Extrusion Load = pt .π r0 2
σ o (1 + B )
σ xo = ⎡⎣1 − R 2 B ⎤⎦
B

d) Transform Theory
e) Numerical Methods
GATE -2018: Mechanical f)

g)
h)
Calculus, Gradient, Multiple Integrals
Complex Variables
Matrix Algebra
i) Fourier Series
j) Partial Derivatives
Following Topics are very important for GATE Examination 2. Production
a) Theory of metal cutting, forces, tool life
b) Rolling calculations
c) Wire drawing and Extrusion Calculations
d) Sheet metal operations, clearance, force, power, shear calculations
Grade-A Subjects ǥǥǥǥǤmore than 10 revisions are required
e) Lathe, drilling, milling, shaping cutting time calculations, all numericals
x Mathematics (2010 By IIT Guwahati-12%) f) Grinding and finishing
x Production (2010 By IIT Guwahati-13%) g) ECM MRR, feed calculations, EDM theory, comparison of all NTMM
x TOM (2010 By IIT Guwahati-12%) h) NC/CNC Machine, BLU calculations, upto M & G code
i) Limit, tolerance, fit
x Industrial Engineering (2010 By IIT Guwahati-11%)
j) Jig & Fixture, 3-2-1 principle
x Fluid Mechanics & Machines (2010 By IIT Guwahati-10%)
k) Welding: V-I Characteristics calculations, Resistance welding calculations, Special welding
x SOM (2010 By IIT Guwahati-6%) theory
x Thermodynamics (2010 By IIT Guwahati-5%) l) Casting: allowances, Riser Design, Sprue Design, Pouring time calculations, Special
Castings, Casting Defects.
Grade-B Subjects ǥǥǥǥǤͻare required
3. TOM
x Design (2010 By IIT Guwahati-6%)
x Heat Transfer (2010 By IIT Guwahati-2%) a) Mechanism (VIMP)
b) Linear Vibration Analysis of Mechanical Systems (VIMP)
x Power plant (2010 By IIT Guwahati-4%)
c) Gear train (VIMP)
Grade-C Subjects ǥǥǥǥǤ5 revisions are required d) Flywheel (Coefficient of Fluctuation of speed, Coefficient of Fluctuation of energy), mass
calculation,
x RAC (2010 By IIT Guwahati-2%) e) Critical Speed of Shafts
x Engineering Mechanics (2010 By IIT Guwahati-1%) f) Gyroscope
Grade-D Subjects ǥǥǥǥǤͷ2 revisions are sufficient 4. Industrial Engineering

a) EOQ Models (VIMP)
x IC Engine (2010 By IIT Guwahati-1%)
b) PERT & CPM (VIMP)
x Engineering Materials (2010 By IIT Guwahati-1%)
c) Queuing Model (VIMP)
d) Forecasting (VIMP)
e) LPP
Detailed Topics f) Work Study & Work Measurement (standard time calculations, theriblings symbol)
g) Break even Analysis
h) The Scheduling 3UREOHPDQG-RKQVRQ·V5XOH
1. Mathematics i) Assembly line balancing
a) Probability and Statistics
b) Eigen Values and Eigen Vectors
c) Differential Equations
By: S K Mondal (GATE 99.96 Percentile) E-Mail: swapan_mondal_01@yahoo.co.in Page 1 By: S K Mondal (GATE 99.96 Percentile) E-Mail: swapan_mondal_01@yahoo.co.in Page 2

5. Fluid Mechanics & Fluid Machines 10. Power plant
a) Properties of fluid a) Steam Cycle (VIMP)
b) Pressure measurement, manometers b) Gas Cycle
c) Fluid kinematics (VIMP) c) Compressor
d) %HUQRXOOL·V(TXDWLRQ ( Fluid Dynamics)
e) Venturimeter
f) Flow ( Laminar and Turbulent) 11. RAC
g) Boundary Layer, Thermal Boundary Layer
a) Heat engine, heat pump, refrigerator (VIMP)
h) Compressible Flow
b) Psychrometry (VIMP)
i) Hydraulic Turbine
c) Vapour Compression Systems
j) Centrifugal Pump
6. SOM 12. Engineering Mechanics

a) Equilibrium
a) Principal Stress and Principal Strain, Mohr Circle(VIMP)
b) Truss
b) Stress and Strain (VIMP)
c) Friction
c) Bending Moment and Shear Force Diagram (VIMP)
d) Deflection of Beam
13. IC Engine
e) Torsion
f) Theories of Column (Euler method, end conditions) a) Gas Power Cycles (All) (VIMP)
g) 6WUDLQ(QHUJ\0HWKRG&DVWLJOLDQR·VWKHRU\ b) IC Engine Performances
h) Theories of failure c) Octane number, cetane number
i) Thin cylinder
j) Riveted and Welded Joint
14. Engineering materials
k) Spring a) Crystal structure & crystal defects
b) Iron-carbon Equilibrium diagram, TTT diagram,
7. Thermodynamics c) Heat treatment
a) Basic Concepts
b) Application of First law
c) Entropy, Availability
d) Pure Substance (VIMP)
e) Gases and Gas mixture
8. Design
a) Fluctuating Load Consideration for Design
b) Rolling Contact Bearings, Load-life Relationship
c) Sliding contact bearing, Modes of Lubrication, Sommerfeld Number
d) Clutch , Brake
9. Heat Transfer
a) Conduction
b) Critical Thickness of Insulation
c) Unsteady Conduction (Lumped Parameter Analysis)
d) Radiation (The Stefan-Boltzmann Law, Shape Factor Algebra, Heat Exchange between Non-
black Bodies)
e) Heat Exchangers (LMTD, NTU)

x TOM (Class note + Question set GATE,IES,IAS)
General Guidelines x Industrial Engineering (Class note + Question set GATE,IES,IAS)
x Please follow the step by step procedure given below for preparing GATE where only x Engineering Mechanics ( Book: D P Sharma or Bansal or Khurmi)
objective type questions are asked. x Thermodynamics {Class note + P K Nag Unsolved all (My solutions available)}
x I found that in all competitive examinations similar type of questions are asked. They are x Fluid Mechanics & Machines (Class note + Only 20 Years GATE Questions)
similar but not the same. The questions are not repeated but the theory (Funda) which is x Heat Transfer (Class note + Only 20 Years GATE Questions)
QHHGHGWRVROYHWKHTXHVWLRQUHPDLQVVDPH6R\RXGRQ·WQHHGWRUHPHPEHUWKHTuestions and x Design (Class note + Only 20 Years GATE Questions)
answers but you must remember the funda behind it. x RAC (Class note + Only 20 Years GATE Questions)
x *$7( SDSHUV DUH VHW E\ 3URIHVVRUV RI ,,7V DQG WKH\ FKHFN VWXGHQW·V IXQGDPHQWDOV RI WKH x Power plant (Class note + Only 20 Years GATE Questions)
VXEMHFW6RZHPXVWEHSUHSDUHGZLWKIXQGDPHQWDOV7KDW·VZK\IXQGDLVUHSHDWHG x IC Engine (Class note + Only 20 Years GATE Questions)
x You know that in the engineering books are not made for objective type questions. The x Engineering Materials (Class note + Only 20 Years GATE Questions)
theory involves rigorous derivations, enormous calculations etc and our University
examinations are also conventional type.
x We have to prepare for Objective Questions.
For self preparing students
x Meticulously read book only of the topics mentioned in topic list.
For regular eye on your progress x Practice all solved examples from the books of respective subject as listed below of ONLY the
x Paste the topic list in front of study table, tick mark the topics completed by you (class note + topics mentioned in the topic list
all questions from question set) on daily basis. x It is recommended to solve my question set on your own and cross check with my explanations.
x One tick when topic is completed once, then second tick after the second revision, and so on. x Mathematics (Grewal or Dash + My Question set)
x Topic list should contain as many tick marks as many times revision for a particular topic is x Manufacturing Science { Book P.C Sharma (Vol 1& 2) + My Question set GATE,IES,IAS }
completed. x SOM (Book Sadhu Singh or B.C Punmia or only My Book + My Question set GATE,IES,IAS)
x Once one subject gets completed it has to be revised frequently (once in a month or so), so x TOM ( Book Ghosh Mallick + My Question set GATE,IES,IAS)
that formulae can be remembered on the long run. x Industrial Engineering (Ravi Shankar or Kanti Swarup or my book + My Question set
GATE,IES,IAS)
x Engineering Mechanics ( Book: D P Sharma or Bansal )
ǯ who are attending coaching x Thermodynamics {Book Rajput + P K Nag Unsolved all (My solutions available)}
x Fluid Mechanics & Machines (Book Bansal or Rajput or my book + Only 20 Years GATE
x Attend all classes.
Questions, My set)
x Meticulously read class notes
x Heat Transfer (Book Rajput or Domkundwar + Only 20 Years GATE Questions, My set)
x From the question set solve all previous year asked questions which are given in topic wise
x Design (Book Bhandari or Khurmi + Only 20 Years GATE Questions, My set)
sequence.
x RAC (Book Rajput or CP Arora+ Only 20 Years GATE Questions, My set)
x It is recommended to solve my question set on your own and then cross check with my
x Power plant (Book PK Nag + Only 20 Years GATE Questions, My set)
explanations.
x IC Engine (Book V Ganeshan + Only 20 Years GATE Questions, My set)
x Mathematics (Class note + My Question set)
x Engineering Materials (NPTEL IISc material from net + Only 20 Years GATE Questions, My
x Manufacturing Science (Class note + My Question set GATE,IES,IAS)
set)
x SOM (Class note + My Question set GATE,IES,IAS)

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Metal Cutting, Metal Forming & Metrology

Questions & Answers-For 2018 (All Questions are in Sequence)

Section-II: Metrology Questions Answer & Explanations

Section-III: Metal Forming Questions Answer & Explanations

Section-IV: Cutting Tool Materials Page-133 Page-195

For-2018 (IES, GATE & PSUs)

IES‐1995 GATE‐1995; 2008 IES‐1993

IES 2011 IAS – 1994

IES ‐ 2014 IES ‐ 2012 IES‐2006

IES‐2015 GATE(PI)‐1990 IAS – 1996

(d) Break chips

IAS – 1995 IES 2010 IES‐1995

IES‐2009 IES‐1995 IES‐1994

IAS 2015 Main

IES‐2004 IES‐2004, ISRO‐2009 IES‐2008

IAS‐2003 IAS‐2002 IAS‐2000

IAS‐1998 IAS‐1995 GATE – 2009 (PI) Common Data S‐1

(a) 26.8 (b) 27.8 (c) 28.8 (d) 29.8

IES‐2015 IAS‐1997 GATE‐2002

GATE ‐2010 (PI) Linked S‐2 Linked Answer Questions GATE‐2013 S‐1 Linked Answer Questions GATE‐2013 S‐2

φ= + − angle means smaller shear plane which means

4 2 2 y Result: lower cutting forces, power, temperature,

GATE‐1997 ESE‐2005 Conventional GATE 2008 (PI) Li k d S 1

(i) shear angle and Shear p

GATE 2008 (PI) Li k d S 2

The force relations (VIMP) IES‐2003 IES ‐ 2014

Fn = Fc sin φ + Ft cos φ ( ) 1079.4 N

IES‐1995 IES‐2001 IES‐1997

For-2018 (IES,GATE & PSUs)

IAS‐2003 Main Examination Orthogonal Turning (λ = 90o) GATE‐2007

GATE‐2008 Common Data Question (1) GATE‐2008 Common Data Question (2) Metal Removal Rate (MRR)

IES ‐ 2004 GATE‐2013 IES 2016

133 134 135

GATE‐2007 GATE‐2016 (PI) GATE‐2013 (PI) Common Data Question

139 140 141

145 146 147

IES‐2002 IES‐1998 IAS – 2003

151 152 153

157 158 159

IES‐1996 Types of Dynamometers Strain Gauge Dynamometers

IES 2010 IES – 2007, IES‐2016 IES ‐ 2014

(d) Face of the cutting tool at a short distance from

Flank Wear: (Wear land) GATE‐2014 Flank Wear: (Wear land)

175 176 177

178 179 180

Tool life criteria ISO Crater wear Crater wear Contd…..

y For crater wear temperature is main culprit and tool

184 185 186

IES – 2002 IAS – 2007 IES – 2000

187 188 189

190 191 192

IES – 1995 IAS – 1999 Why chipping off or fine cracks

IAS – 2003 Notch Wear IES – 1996

196 197 198

(c) 3 and 4 only (d) 1, 3 and 4 y Length of work machined.

IES – 1992 Taylor’s Tool Life Equation Values of Exponent ‘n’

IES ‐ 2012 IES – 2008 IES – 2006

205 206 207

211 212 213

IES – 1999, ISRO‐2013 GATE 2016

(c) 100% (d) 50% b)95%

217 218 219

IES‐2013 IAS – 1997 IES – 2006 conventional