DEPARTMENT OF MECHANICAL ENGINEERING

ANSWER KEY –IAT-I

Subject Name: Manufacturing Technology Year/Sem: II/III
Subject Code: 17MECC04

PART-A
Answer all the Questions (7x2 = 14 Marks)

1.What is the effect of back rake angle?

Rake Angle
Clearance angle
Nose angle
Cutting edge angle
2. Classify the different types of chip breaker.
Step Type
Groove type
Clam Type
3. What are the forces acting on a cutting tool?
frictional force
normal force
resultant force
4. Define tool life.
Tool life depends as the time elapsed between two consecutive tool resharpening.
During this period the tool serves effectively and efficiently.
5.What is an Apron?
Apron is and integral part of several gears, levers and clutches which are mounted with
saddle for moving the carriage along with lead screw while thread cutting
6.Give the classification of lathes.
Sped Lathe
Engine Lathe
Bench Lathe
Tool room Lathe
7.What is thread cutting ?
The process of following the same path of the tool when travels in the previous cut is
called as thread cutting
 PART-B
8.a.Illustrate the nomenclature of a single point cutting point tool with sketch in detail
Single-point cutting tool,
As distinguished from other cutting tools such as a The cutting edge is ground to suit
a particular machining operation and may be re sharpened or reshaped as needed. The
ground
tool bit is held rigidly by a tool holder while it is cutting.
Back Rake is to help control the direction of the chip, which naturally curves into the
work
due to the difference in length from the outer and inner parts of the cut. It also helps
counteract the pressure against the tool from the work by pulling the tool into the work.
Side Rake along with back rake controls the chip flow and partly counteracts the
resistance
of the work to the movement of the cutter and can be optimized to suit the particular
material
being cut. Brass for example requires a back and side rake of 0 degrees while aluminum
uses
a back rake of 35 degrees and a side rake of 15 degrees. Nose Radius makes the finish of
the
cut smoother as it can overlap the previous cut and eliminate the peaks and valleys that a
pointed tool produces. Having a radius also strengthens the tip, a sharp point being quite
fragile

All the other angles are for clearance in order that no part
of the tool besides the actual
cutting edge can touch the work. The front clearance angle
is usually 8 degrees while the side
clearance angle is 10-15 degrees and partly depends on the
rate of feed expected.
Minimum angles which do the job required are advisable
because the tool gets weaker as the
edge gets keener due to the lessening support behind the
edge and the reduced ability to
absorb heat generated by cutting.
The Rake angles on the top of the tool need not be precise
in order to cut but to cut
efficiently there will be an optimum angle for back and side rake.
8.b.Illustrate orthogonal cutting and oblique cutting with neat diagrams in detail

Orthogonal metal cutting Oblique metal cutting

Depending on whether the stress and deformation in cutting occur in a plane

(twodimensional
case) or in the space (three-dimensional case), we consider two principle types
of cutting:
Orthogonal cutting the cutting edge is straight and is set in a position that is
perpendicular to
the direction of primary motion. This allows us to deal with stresses and strains that act
in a
plane.
Oblique cutting the cutting edge is set at an angle.
According to the number of active cutting edges engaged in cutting, we distinguish
again two
types of cutting:
Single-point cutting the cutting tool has only one major cutting edge
Examples: turning, shaping, boring
Multipoint cutting the cutting tool has more than one major cutting edge
Examples: drilling, milling, broaching, reaming. Abrasive machining is by definition a
process of multipoint cutting.

9.a.Draw the special attachments of lathe and explain any three in detail
Lathe machines are used for machining cylindrical work. Attachments are used to
enhance the capability of the machine. This improve efficiency in production, and widen
the scope that can be carried out with this machine.
These attachments are widely used:
(a) Taper turning attachment
(b) Ball turning attachment
(c) Thread Chasing Dial
(d) Carriage Stop
(e) Eccentric turning attachment
(f) Grinding attachment
(A) TAPER TURNING ATTACHMENT
The function of a taper attachment is to guide the tool in a direct path set at an angle to
the axis of rotation of the workpiece. A taper turning attachment consists of a bracket or
frame that is attached to the end of the lathe bed, supporting a guide bar pivoted at the
centre. The bar with graduations in degrees can be swiveled on either side of the zero
graduation. It can be set at the desired angle to axis of the lathe.
The benefits of using a taper turning attachment are (i) It leaves the alignment of dead
and live centres untouched. So, both straight and taper turning may be performed on the
in one setting without downtime. (ii) Once the taper is set, any length of a piece of work
could be turned within limits. (iii) Several work pieces could be turned. (iv) Internal
tapers can be turned effortlessly.
Chucks:
Some work pieces, because of their size and shape, cannot be held and machined
between lathe centers. Lather chucks are used extensively for holding work for
machining operations. The most commonly used lathe chucks are the three jaw
universal, four jaw independent, and the collects chuck.
Three-jaw universal chuck:
Three-jaw universal chuck is used to hold round and hexagonal work. It grasps the work
quickly and within a few hundredths of a millimeters or thousandths of an inch of
accuracy, because the three jaws move simultaneously when adjusted by the chuck
wrench. This simultaneous motion is cause by a scroll plate into which all here jaws fit.
Three jaws chucks are made in various sizes from 1/8-16 inch in diameter. They are
usually provided with two sets of jaws, one for outside chucking and the other for inside
chucking.

Four-jaw independent chuck:

This four- jaw independent chuck has four jaws; each of which can be adjusted
independently by a chance wrench. They are used to held wound, square, hexagonal, and
irregular-shaped workpieces. The jaws can be reversed to hold work by the inside
diameter.
Collect chuck:
The collect chuck is the most accurate chuck and is used for high precision work and
small tools. Spring collects are available to hold round, square, or hexagon shaped
workpieces. A adaptor is filled into the taper of the headstock spindle, and a hollow draw
bar having an internal thread is instead in the opposite end of the headstock spindled. As
the hand wheel and draw bar is revolved, it draws the collet into the tapered adaptor,
causing the collet to tighten on the workpieces.
Magnetic chucks:
A magnetic chucks are used to hold iron or steel parts that are too thin, or that may be
damaged if held in a conventional chuck. These chucks are fitted to an adaptor mounted
on the headstock spindle. Work id held lightly for aligning purposes by turning the
chuck wrench approximately ¼. After the work has been turned
Faceplates:
A faceplates are used to hold work that is too large or of such a shape that it cannot be
held in a chuck or between centers. Faceplates are equipped with several slots to permit
the use of bolts to secure the work, so that the axis of the workpiece may be aligned with
the lathe centers. When work is mounted off – center, a counterbalance should be
fastened to the faceplate to prevent imbalance and the resultant vibrations when the lathe
is in operation.
PART-C
10. a. Enumerate on Merchant Circle Diagram in detail.

There are numerous forces are acting on workpiece during machining.

The forces which are acting on w/p that are given below
1. Friction Force
2. Shear Friction Force
3. Normal Force
4. Shear Normal Force
5. Cutting Force
6. Tangent or Tangential ForceForce
But by Dynamometer we can find Cutting and tangent forces , for get magnitude of
rest forces we need to draw merchant’s circle diagram .
“The relation between various forces have been worked out by Merchant’s circle
diagram
A Merchant circle diagram is a graphical
representation of number of forces acting
on a workpiece during metal cutting
operation.
Image source: Google images.
There are 3 triangle of forces acting during
metal cutting operation. They are:-
1. Triangle of forces for cutting force
(Fc).
2. Triangle of forces for shear force
(Fs).
3. Triangle of forces for frictional force (F).
Assumptions made while drawing a Merchant circle diagram.
1. The shear plane is always acting upwards.
2. The cutting edge is too sharp.
3. Chip width is constant.
4. The Depth of cut is constant.
5. No built-up-edge is formed
Various operations are performed in a lathe machine other than plain turning. These are:-
Facing
Facing is the operation of machining the ends of a piece of
work to produce flat surface square with the axis. The
operation involves feeding the tool perpendicular to the axis of
rotation of the work.

Turning
Turning in a lathe is to remove excess material from the workpiece to produce a cylindrical
surface of required shape and size.
Straight turning
The work is turned straight when it is made to rotate about the lathe axis and the tool is fed
parallel to the lathe axis. The straight turning produces a cylindrical surface by removing
excess metal from the workpieces.

Step turning
Step turning is the process of turning different surfaces
having different diameters. The work is held between centres
and the tool is moved parallel to the axis of the lathe. It is
also called shoulder turning.

Chamfering
Chamfering is the operation of bevelling the
extreme end of the workpiece. The form tool used
for taper turning may be used for this purpose.
Chamfering is an essential operation after thread
cutting so that the nut may pass freely on the
threaded workpiece.

Grooving
Grooving is the process of cutting a narrow goove on the cylindrical surface of the
workpiece. It is often done at
end of a thread or adjacent to a
shoulder to leave a small
margin. The groove may be
square, radial or bevelled in
shape.