2017 Metal Cutting Metal Forming Metrology PDF

Metal
Cutting, Metal Forming & Metrology

Questions & Answers-For 2017 (All Questions are in Sequence)
IES-1992-2016 (25 Yrs.), GATE-1992-2016 (25 Yrs.), GATE (PI)-2000-2016 (17 Yrs.), IAS-1994-
2011 (18 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-2 Page-146
Chapter-2: Analysis of Metal Cutting Page-10 Page- 148
Chapter-3: Tool life, Tool Wear, Economics and Machinability Page-20 Page-153
Section‐II: Metrology Questions Answer & Explanations

Chapter-4: Limit, Tolerance & Fits Page-39 Page-157
Chapter-5: Measurement of Lines & Surfaces Page-52 Page-160
Chapter-6: Miscellaneous of Metrology Page-64 Page-161
Section‐III: Metal Forming Questions Answer & Explanations

Chapter-7: Cold Working, Recrystalization and Hot Working Page-69 Page-161
Chapter-8: Rolling Page-74 Page-162
Chapter-9: Forging Page-84 Page-163
Chapter-10: Extrusion & Drawing Page-94 Page-164
Chapter-11: Sheet Metal Operation Page-107 Page-166
Chapter-12: Powder Metallurgy Page-126 Page-168
Section‐IV: Cutting Tool Materials Page‐136 Page-169
For‐2016 (IES, GATE & PSUs)
For-2017 (IES, GATE & PSUs) Page 1 of 186 Rev.0

Manufacturing
g is a p
process of converting
g raw
Machining
material in to finished product by using various y Machining is an essential process of finishing by
Theory of Metal Cutting processes, machines and energy, it is a narrow term. which jobs are produced to the desired dimensions
and surface finish by gradually removing the
Production is a p
process of converting
g inputs
p in to
excess material
i l from
f the
h preformed
f d blank
bl k in
i the
h
outputs it is a broader term.
form of chips with the help of cutting tools moved
By S K Mondal past tthee work

o susurface.
ace.
y Machining
g is a removal p
process.
1 2 3
Machining aim to Machine tool
Machine tool Whyy even a batteryy operated
p p
pencil
y Fulfill its functional requirements
y A machine
hi tool
t l is
i a non‐portable
t bl power operated
t d
sharpener
p cannot be accepted
p as a
y Improve its performance
and reasonably valued device or system of device
machine tool?
y Prolong its service.
in which energy
gy is expended
p to p
produce jjobs of
y Ans.
Ans In spite of having all other major features of
Drawback in Machining desired size, shape and surface finish by removing
machine tools, the sharpener is of low value.
• Loss of material in the form of chips excess material from the preformed blanks in the
form of chips with the help of cutting tools moved
past the
h work
k surface.
f
4 5 6
Orthogonal Machining
g g
IAS 2009 main Orthogonal Machining
y Name four independent variables and three dependent
variables in metal cutting. [ 5 marks]
Independent Variables Dependent Variables
•Starting materials •Force or power requirements
(tool/work) •Maximum temperature in b
T l
•Tool geometry cutting
i
•Cutting Velocity •Surface finish
•Lubrication
b
• Feed & Depth of cut(IES, GATE & PSUs)
For-2017 7
Page 2 of 186 8
Rev.0 9
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
10 11 12
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
13 14 15
IES – 2005 IES 2015

IES‐2015 IES – 2002
Statement (I) : The ceramic tools used in machining
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
of 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 truet 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
For-2017 (IES, GATE & PSUs) 16

Page 3 of 186 17
Rev.0 18
For IES Only
IES 2011 IES 2007 Conventional
Which one of the following statement is NOT correct
GATE –
GATE – 2008 (PI)
2008 (PI) Cast iron with impurities of carbide requires a
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 particular
ti l rake
k angle
l for
f efficient
ffi i t cutting
tti with
ith single
i l
of a cutting tool? having zero or negative rake angle because it point tools, what is the value of this rake angle, give
reasons for your answer. [ 2 marks]
(a) To guide the chip flow direction (a) results in lower cutting force
Answer: Free carbides in castings reduce their machinability
(b) To reduce the friction between the tool flanks and ((b)) improves
p surface finish
and cause tool chipping or fracture, necessitating tools with
the machined surface
((c)) p
provides adequate
q strength
g to cutting
g tool
hi h toughness.
high t h Z
Zero rake
k tool
t l is
i perfect
f t for
f this
thi purpose.
(c) To add keenness or sharpness to the cutting edges.
(d) results in more accurate dimensions
(d) To provide better thermal efficiency.
19 20 21
IAS – 1994 IES ‐ 2014

IES‐2014 Conventional
IES‐2014 Conventional Consider the following characteristics
C id h f ll i h i i Which
Whi h one off the h following
f ll i statements isi correct
y Differentiate between orthogonal and oblique cutting. g g g
1. The cutting edge is normal to the cutting velocity.y about an oblique cutting?
[4 – marks] 2. The cutting forces occur in two directions only. (a) Direction of chip flow velocity is normal to the
3. The cutting edge is wider than the depth of cut.
Th i d i id h h d h f cutting edge of the tool
pp g g
The characteristics applicable to orthogonal cutting (b) Only two components of cutting forces act on the
would include tooll
( ) 1 and 2
(a) d (b) 1 and 3
d (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) 2 and 3 (d) 1, 2 and 3
(d) Cutting
C tti edged clears
l th width
the idth off the
th workpiece
k i
22 23 24
IES ‐ 2012 IES‐2006 IES ‐ 2012

Statement
St t t (I):
(I) Negative
N ti rake
k angles
l are preferred
f d on
During orthogonal cutting, an increase in cutting
Which of the following is a single point cutting rigid set‐ups for interrupted cutting and difficult‐to
speed
d causes machine
hi materials.
t i l
tool?
Statement (II):Negative rake angle directs the chips
( ) An
(a) A increase
i i longitudinal
in l i di l cutting
i force
f on to the machined surface
(a) Hacksaw blade
( ) Both Statement ((I)) and Statement ((II)) are individuallyy
(a)
(b) An
A increase
i i radial
in di l cutting
tti force
f true and Statement (II) is the correct explanation of
(b) Milling cutter
Statement (I)
(c) An increase in tangential cutting force
(c) Grinding wheel (b) Both Statement (I) and Statement (II) are individually
(d) Cutting forces to remain unaffected true but Statement ((II)) is not the correct explanation p of
(d) Parting tool Statement (I)
((c)) Statement ((I)) is true but Statement ((II)) is false
(d) Statement (I) is false but Statement (II) is true
Page 4 of 186 26
Rev.0 27
IES‐2003 IES‐2015 GATE(PI)‐1990
The angle of inclination of the rake face with
The purpose of providing side rake angle in the The diameter and rotational speed of a job are 100
respectt to
t the
th tool
t l base
b measured
d in
i a plane
l
cutting tool is mm and 500 rpm respectively. The high spot
perpendicular to the base and parallel to the width
(a) avoid work from rubbing against tool (Chatter marks) are found at a spacing of 30 deg on
of the tool is called
(b) Control chip flow
flo the
h job
j b surface.
f Th chatter
The h f
frequency i
is
(a) Back rake angle
(c) Strengthen tool edge ( ) 5 Hz
(a) H (b) 12 Hz
H ( ) 100 Hz
(c) H (d) 500 Hz
H
(b) Side rake angle
(d) Break chips
p
(c) Side cutting edge angle
(d) End cutting edge angle
28 29 30
IAS – 1996 IAS – 1995 IES 2010

The tool life increases with the Thrust force will increase with the increase in Consider
C id the
th following
f ll i statements:
t t t
In an orthogonal, single
single‐point
point metal cutting,
(a) Increase in side cutting edge angle (a) Side cutting edge angle as the side‐cutting edge angle is increased,
(b) Decrease in side rake angle (b) Tool nose radius 1. The tangential force increases.
( ) Decrease in nose radius
(c) ( ) Rake angle
(c) 2 The longitudinal force drops.
2. drops
33. The radial force increases.
(d) Decrease in back rake angle
D i b k k l (d) E d
(d) End cutting edge angle
i d l
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
31 32 33
IES‐1995 IES‐2006 IES‐2002

Assertion (A): For drilling cast iron, the tool is Consider the following statements:
The angle between the face and the flank of the
provided with a p
p point angle
g smaller than that The strength of a single point cutting tool depends
single point cutting tool is known as required for a ductile material. upon
Reason (R): Smaller point angle results in lower 1. Rake
R k angle l
a) Rake angle
rake angle. 2. Clearance angleg
b) Clearance angle (a) Both A and R are individually true and R is the 3. Lip angle
correct explanation
p of A
c) Lip angle 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
d) Point angle
l
(c) A is true but R is false (c) 1 and 2 (d) 1, 2 and 3
Page 5 of 186 35
Rev.0 36
IES ‐ 2012 IES 1995
IES‐1995
IES‐2009
Consider the following statements about nose
Tool life increase with increase in Consider the following statements with respect
to the effects of a large g nose radius on the tool: radius
(a) Cutting speed 1. It deteriorates surface finish.
1. It improves tool life
(b) Nose radius 2. It I increases
i the
h possibility
ibili off chatter.
h
33. It improves
p tool life. 2. It reduces the cutting force
( )
(c) Feed
Which of the above statements is/are correct? 3. It improves the surface finish.
(d) D h f
(d) Depth of cut ( ) 2 only
(a) l (b) 3 only
l
Select the correct answer using the codes given below:
(c) 2 aandd3o onlyy (d) 1,, 2 aand
d3
(a) 1 and 2 (b) 2 and 3
37 38
(c) 1 and 3 (d) 1, 2 and 3 39
IES‐1994 IES 2009

IES‐2009 IES‐1993
Tool geometry of a single point cutting tool is specified by The following tool signature is specified for a single
single‐
the following elements: In ASA System, if the tool nomenclature is 8‐6‐5‐5‐
point cutting tool in American system:
1
1. Back rake angle
10‐15‐2‐mm, then the side rake angle will be
2. Side rake angle 10, 12, 8, 6, 15, 20, 3
3. End d cutting edge
d angle l (a) 5° (b) 6° (c) 8° (d) 10°
What does the angle 12 represent?
4. Side cutting edge angle
5. Side relief angle (a) Side cutting‐edge angle
6. End relief angle
7. Nose radius (b) Side rake angle
The correct sequence of these tool elements used for ( ) Back
(c) B k rake
k angle
l
correctly specifying the tool geometry is
( ) 1,2,3,6,5,4,7
(a) 6 (b) 1,2,6,5,3,4,7
6 (d) Side clearance angle
(c) 1,2,5,6,3,4,7 (d) 1, 2, 6, 3, 5, 4,7 40 41 42
GATE‐2008 GATE‐2001
ISRO‐2011 In a single point turning tool, the side rake angle
During orthogonal cutting of mild steel with
A cutting
tti tool
t l having
h i tool
t l signature
i t as 10, 9, 6,
6 and
d orthogonal
h l rake
k angle
l are equal.
l Φ is the
h
a 10° rake angle tool, the chip thickness ratio
6, 8, 8, 2 will have side rake angle principal cutting edge angle and its range is
was obtained as 0.4. The shear angle (in
(a) 10o (b) 9o (c) 8o (d) 2o 0o ≤ φ ≤ 90o. The chip flows in the orthogonal plane.
plane
degrees) evaluated from this data is
The value of Φ is closest to
((a)) 00 ((b)) 450 (a) 6.53 (b) 20.22
(c) 600 (d) 900 (c) 22.94 (d) 50.00

Page 6 of 186 44
Rev.0 45
GATE 2011 IES‐1994 IES‐2014 Conventional
The
Th following
f ll i parameterst determine
d t i the
th A bar of 70 mm diameter is being cut
A single – point cutting tool with 12° rake angle is
model of continuous chip p formation:
used to machine a steel work – piece. The depth orthogonally
h ll and
d is reduced
d d to 68 mm by
b a
1. True feed
off cut, i.e.
i uncut thickness
hi k i 0.81
is 8 mm. The
Th chip
hi cutting tool.
tool In case mean length of the chip is
2. Cutting velocity
thickness under orthogonal machining 3 Chip thickness
3. 68.9 mm, find the cutting ratio. Determine shear
condition is 1.8 mm. The shear angle

g is 4. Rake angle
4 g of the cutting g tool. angle also if the rake angle is 10o [10 Marks]
approximately The parameters which govern the value of shear

angle
l wouldld include
l d Hint: length of uncut chip = πD
(a) 22° (b) 26° (c) 56° (d) 76°
(a) 1,2
1 2 and 3 (b) 1,31 3 and 4
46
(c) 1,2 and 4 (d) 2,3 and 4 47 48
GATE‐2014 IES ‐ 2004 IES ‐ 2009

During
gppure orthogonal
g turning
g operation
p of In a machining
g operation
p chip
p thickness ratio Minimum shear strain in orthogonal turning
a hollow cylindrical pipe, it is found that the is 0.3 and the rake angle of the tool is 10°. What with a cutting tool of zero rake angle is
thickness of the chip produced is 0.5 mm. The is the value of the shear strain? (a) 0.0 (b) 0.5
feed given to the zero degree rake angle tool is (a) 0.31 (b) 0.13 (c) 1.0 (d) 2.0
0.2 mm/rev. The shear strain produced during (c) 3.00 (d) 3.34
the operation is ……………….
49 50 51
GATE (PI)‐1990
IES 2016
IES‐2016 GATE 2012
GATE ‐2012
During the formation of chips in machining with a Details pertaining to an orthogonal metal cutting
A single point cutting tool with 120 rake angle cutting tool, which one of the following relations process are given below.
is used for orthogonal machining of a ductile h ld good?
holds d Chip thickness ratio 0.4
V V V V V V
(a) = s = c (b) = s = c Undeformed thickness 0 6 mm
0.6
material.
i l The
Th shear
h plane
l angle
l for
f the
h cos (φ − α ) cos α sin α sin (φ − α ) cos α cos α
Rake angle +10°
theoretically minimum possible shear strain V V Vs
(c ) = c = (d ) V cos α = Vc sin α = Vs cos (α − φ ) Cutting speed 2.5 m/s
cos α sin α sin (φ − α )
to occur Mean thickness of primary shear zone 25 microns
(a) 51 (b) 45 where V is the cutting speed, Vc is the velocity of the The shear strain rate in s–1 during the process is
chip,
hi VsV is
i the
th velocity
l it att which
hi h shearing
h i t k place
takes l (a) 0.1781×105 (b) 0.7754×105
(c) 30 (d) None of these along the shear plane, φ is the shear angle and α is the
rake angle. 1 0104×105
(c) 1.0104×10 4 397×105
(d) 4.397×10
Page 7 of 186 53
Rev.0 54
IES‐2004 IES‐2006 IES‐2004
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 Match. List I with List II and select the correct answer
M h Li I i h Li II d l h
the relief angle of cutting tool: 1. A large rake angle means lower strength of the
g g g using the codes given below the Lists:
1. This affects the direction of chip flow cutting edge. List I List II
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 A. Plan approach angle 1. Tool face
and work piece Which of the statements given above is/are correct? B. Rake angle 2. Tool flank
3. This affects tool life C Clearance angle
C. Cl l 3. T l f
Tool face and flank
d fl k
(a) Only 1 (b) Only 2
4 This allows better access of coolant to the tool
4. This allows better access of coolant to the tool D. Wedge angle
g g 4.
4 Cutting edge
g g
( ) Both 1 and 2
(c) B th d (d) Neither 1 nor 2
N ith
work piece interface 5. Tool nose
Which of the statements given above are correct?
h h f h b A B C D A B C D
(a) 1 4 2 5 (b) 4 1 3 2
(a) 1 and 2 (b) 2 and 3
(c) 4 1 2 3 (d) 1 4 3 5
(c) 2 and 4 (d) 3 and 4 55 56 57
IES‐2004, ISRO‐2009 IES‐2008 IES ‐ 2014

Consider the following statements:
C id h f ll i
The rake angle of a cutting tool is 15°, shear angle 45° In an orthogonal turning process, the chip thickness =
In an orthogonal cutting the cutting ratio is found to be
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 0.32 mm, feed
f d = 0.2 mm/rev. then
h the
h cutting ratio will
ll
mm. Which of the following are correct?
g
of chip along the tool face? be
1. Chip velocity will be 45 m/min.
(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 (a) 2.6
26 (b) 3.2
32 (c) 1.6
16 (d) 1.8
18
3. Chip thickness will be 1∙8 mm.
(c) 25.3
25 3 m/min (d) 23 5 m/min
23.5
4. Chip thickness will be 3∙2 mm.
Select the correct answer using the code given below:
(a) 1 and 3 (b) 1 and 4
( ) 2 and 3
(c) d (d) 2 and 4d
58 59 60
IES‐2001 IES‐2003 IAS‐2003

If α is
i theh rake
k angle
l off the
h cutting
i tool,l φ isi the
h An orthogonal cutting operation is being In orthogonal cutting, shear angle is the angle
shear angle and V is the cutting velocity, then the
carried out under the following conditions: between
velocity of chip sliding along the shear plane is
given
i b
by cutting speed = 2 m/s, depth of cut = 0.5 mm, ( ) Shear
(a) Sh plane
l and
d the
h cutting
i velocity
l i
chip thickness = 0.6 mm. Then the chip (b) Shear

Sh plane
l and
d the
th rake
k plane
l
V cos α V sin φ
(a) (b) cos (φ − α )
cos(φ − α ) (c) Shear plane and the vertical direction
velocity is
V cos α V sin α (d) Shear plane and the direction of elongation of
( )
(c) sin(φ − α )
(d) sin(φ − α ) (a) 2.0 m/s (b) 2.4 m/s
crystals
y in the chip
p
(c) 1.0 m/s (d) 1.66 m/s
Page 8 of 186 62
Rev.0 63
IAS‐2002 IAS‐2000 IAS‐1998
The cutting velocity in m/sec, for turning a work
piece off diameter
d 100 mm at the
h spindle
dl speed
d off
480 RPM is
(a) 1.26
1 26 (b) 2 51
2.51 (c) 48 (d) 151
64 65 66
IAS‐1995 GATE – 2009 (PI) Common Data S‐1 GATE – 2009 (PI) Common Data S‐2

In an orthogonal cutting, the depth of cut is halved An
A orthogonal
h l turning
i operation
i is
i carried
i d out at 20 An
A orthogonal
h l turning
i operation
i is
i carried
i d out at 20
and
d the
h feed
f d rate is double.
d bl Iff the
h chip
h thickness
h k m/min cutting speed,
speed using a cutting tool of rake angle m/min cutting speed,
speed using a cutting tool of rake angle
ratio is unaffected with the changed cutting 155o. The chip

p thickness is 0.4
4 mm and the uncut chip
p 155o. The chip
p thickness is 0.4
4 mm and the uncut chip
p
conditions, the actual chip thickness will be thickness is 0.2 mm. thickness is 0.2 mm.
((a)) Doubled ((b)) halved The shear plane angle (in degrees) is The chip velocity (in m/min) is
((c)) Q
Quadrupled
p ((d)) Unchanged.
g (a) 26.8 (b) 27.8 (c) 28.8 (d) 29.8 (a) 8 (b) 10 (c) 12 (d) 14
67 68 69
GATE‐1995 IES 2007 IES‐2015

During machining, excess metal is removed in the form
During machining excess metal is removed in the form
of chip as in the case of turning on a lathe. Which of the Coarse feed , low rake angle, low cutting speed and
Plain milling of mild steel plate produces
g p p following are correct?
Continuous ribbon like chip is formed when turning insufficient cooling help produce
(a) Irregular shaped discontinuous chips
1
1. At a higher cutting speed (a) continuous chips in ductile materials
(b) Regular shaped discontinuous chip 2. At a lower cutting speed
3. A brittle material (b) discontinuous chips in ductile materials
(c) Continuous chips without built up edge 4. A ductile material
4 (c)continuous chips with built
built‐up
up edges in ductile
(d) Joined chips Select the correct answer using the code given below:
(a) 1 and 3 (b) 1 and 4 materials
(c) 2 and 3 (d) 2 and 4 (d) discontinuous chips in brittle materials

Page 9 of 186 71
Rev.0 72
IAS‐1997 GATE‐2002 GATE‐2009
Consider the following machining conditions: BUE will A built‐up‐edge is formed while machining Friction at the tool‐chip interface can be reduced by
f
form in
i
(a) Ductile materials at high speed (a) decreasing the rake angle
(a) Ductile material.
Ductile material (b) High cutting speed
High cutting speed.
(b) Ductile materials at low speed (b) increasing the depth of cut
(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.
( )
(c) Brittle materials at high speed ( ) Decreasing the cutting speed
(c)
(d) B i l
(d) Brittle materials at low speed
i l l d (d) increasing
i i the
h cutting
i speed
d
73 74 75
IES‐1997 Merchant Force Circle Diagram (MCD)
Assertion (A): For high speed turning of cast iron
pistons, carbide tool bits are provided with chip
b k
breakers.
Reason (R): High speed turning may produce long, Analysis of Metal Cutting
ribbon type continuous chips which must be broken
into small lengths which otherwise would be
difficult to handle and may yp
prove hazardous.
(a) Both A and R are individually true and R is the
correct explanation
p of A (β − α )
correct explanation of A
(c) A is true but R is false For orthogonal
(d) A is false but R is true cutting only
B S K M d l
By S K Mondal
76 77 78
ESE ‐2000 (Conventional) GATE ‐2010 (PI) Linked S‐1 GATE ‐2010 (PI) Linked S‐2

In
I orthogonal
h l turning
i off an engineering
i i alloy,
ll it
i has
h In
I orthogonal
th l turning
t i off an engineering
i i alloy,
ll it has
h
The following data from the orthogonal cutting test
been observed that the friction force acting at the chip‐ been observed that the friction force acting at the chip‐
is available. Rake angle = 100, chip thickness ratio = 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
0.35, uncut chip thickness = 0.51 mm, width of cut = tool interface is 402.5 N and the friction force is also
perpendicular
p p to the cuttingg velocityy vector. The feed perpendicular to the cutting velocity vector. The feed
3 mm,
mm yield shear stress of work material = 285 velocity
l it isi negligibly
li ibl small ll with
ith respectt to t the
th cutting
tti
N/mm2, mean friction co‐efficient on tool face = velocity is negligibly small with respect to the cutting velocity. The ratio of friction force to normal force
0.65,
6 D
Determinei velocity The ratio of friction force to normal force
velocity. associated
i t d with
ith the
th chip‐tool
hi t l interface
i t f i 1. The
is Th uncutt
associated with the chip‐tool interface is 1. The uncut chip thickness is 0.2 mm and the chip thickness is 0.4
((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 mm. The
Th cutting
i velocity
l i isi 2 m/s. /
(ii) Radial force mm. The cutting velocity is 2 m/s. Assume that the energy gy expended
p during g machining g is
(iii) Normal
N l force
f (N) on tooll and
d The shear force (in N) acting along the primary shear completely converted to heat. The rate of heat
((iv)) Shear force ((Fs )). plane is generation (in W) at the p
g primaryy shear p plane is
(a) 180.0 (b) 240.0 (c) 360.5 (d) 402.5 (a) 180.5 (b) 200.5 (c) 302.5 (d) 402.5
Page 10 of 186 80
Rev.0 81
GATE 2015
GATE-2015
Linked Answer Questions GATE‐2013 S‐1 Linked Answer Questions GATE‐2013 S‐2
In orthogonal turning of a bar of 100 mm diameter In orthogonal turning of a bar of 100 mm diameter A single point cutting tool with 0° rake angle is
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 used in an orthogonal machining process. At a
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 cutting speed of 180 m/min, the thrust force is 490
the main (tangential)cutting force is perpendicular the main (tangential)cutting force is perpendicular N If the coefficient of friction between
N. bet een the tool
to friction force acting at the chip‐tool interface. to friction force acting at the chip‐tool interface.
and the chip is 0.7, then the power consumption(in
The main (tangential) cutting force is 1500 N. The main (tangential) cutting force is 1500 N.
kW) for the machining
g operation
p is _____
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
(a) zero (b) 3.58 (c) 5 (d) 7.16 (a) 1000 (b) 1500 (c) 20oo (d) 2500
82 83 84
IES‐2014 Conventional IAS – 1999 GATE‐1997

Show schematically the Merchant’s force circle in In an orthogonal cutting process, rake angle of the In a typical metal cutting operation, using a cutting
orthogonal cutting. Derive the equations for shear tooll is 20° and
d friction
f angle
l is 25.5°. Using tool of positive rake angle = 10°, it was observed
and
d frictional
f i i l forces
f i terms off the
in h material
i l Merchant'ss shear angle relationship,
Merchant relationship the value of that the shear angle was 20°. The friction angle is
properties and cutting process parameters.
parameters State shear angle will be
( ) 45°
(a) (b) 30°
also the assumptions
p made while arriving
g at the ((a)) 39
39.5°
5 ((b)) 42.25°
4 5
( ) 60°
(c) 6 ° (d) 40°°
final equations. ((c)) 47
47.75°
75 ((d)) 550.5°
5
[15‐Marks]
85 86 87
ESE‐2005 Conventional GATE 2008 (PI) Li k d S 1

GATE ‐2008 (PI) Linked S‐1 GATE 2008 (PI) Li k d S 2
GATE ‐2008 (PI) Linked S‐2
In an orthogonal cutting experiment,
experiment an HSS tool having In an orthogonal cutting experiment,
experiment an HSS tool having
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 the following
g tool signature
g in the orthogonal
g reference
cut and uncut thickness are 2 mm and 0.2 mm system (ORS) has been used: 0‐10‐7‐7‐10‐75‐1. Given system (ORS) has been used: 0‐10‐7‐7‐10‐75‐1. Given
respectively If the average value of co‐efficient
respectively. co efficient of
width of cut = 3.6 mm; shear strength of workpiece width of cut = 3.6 mm; shear strength of workpiece
friction between the tool and the chip is 0.5 and the
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; material
i l = 460 N/mm2; depth
6 N/ d h off cut = 0.25 mm;
Determine coefficient of friction at tool
tool‐chip
chip interface = 0.7.
07 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 Minimum p
power requirement
q ((in kW)) at a cutting
g speed
p
((ii)) Cutting
g and thrust component
p of the force. is of 150 m/min is
(a) 20.5 (b) 24.5 (c) 28.5 (d) 32.5 (a) 3.15 (b) 3.25 (c) 3.35 (d) 3.45
Page 11 of 186 89
Rev.0 90
GATE‐2014 GATE‐2014 Modified Merchant Theory
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
t l?
tool? τ s = τ so + kσ s
(a) the area of shear plane decreases resulting in the
P. Reduction in friction angle
g increases cutting g force decrease in shear force and cuttingg force ⎡ Fn ⎤
Q. Reduction in friction angle decreases cutting force (b) the tool becomes thinner and the cutting force is
Wh
Where, σs is
i the
th normalstress
l t on shear
h plane
l ⎢σ s = ⎥
⎣ As ⎦
R Reduction
R. R d ti in i friction
f i ti anglel increases
i chip
hi thickness
thi k reduced
d d
g decreases chip
S. Reduction in friction angle p thickness (c) less heat is accumulated in the cuttingg zone
and then 2φ + β − α = cot (k )
−1
(a) P and R (b) P and S (d) the friction between the chip and the tool is less
( ) Q and
(c) dR (d) Q and
dS
91 92 93
IES 2010 IES‐2005 Theory of Lee and Shaffer

The
Th relationship
l ti hi between
b t the
th shear
h angle
l Φ,
Φ
g β and cutting
the friction angle g rake angle
g α
Which one of the following is the correct •They applied the theory of plasticity for an
expression for the Merchant
Merchant'ss machinability
is given as
constant?
ideal-rigid-plastic body.
(a) 2φ + γ − α •They also assumed that deformation occured
(b) 2φ − γ + α on a thin-shear
thi h plane. l
(c) 2φ − γ − α And derive
((d)) φ + γ − α π
(Where φ = shear angle,γ = friction angle φ= +α − β
4
andα = rake angle)
94 95 96
Other Relations The force relations (VIMP) IES‐2003

F = Fc sin α + Ft cos α In orthogonal cutting test, the cutting force = 900 N,
the thrust force = 600 N and chip shear angle is 30o.
y By Stabler N = Fc cos α − Ft sin α Then the chip shear force is
Fn = Fc sin φ + Ft cos φ ( ) 1079.4 N

(a) (b) 969.6 N
( ) 479.4 N
(c) (d) 6 6N
69.6
Fs = Fc cos φ − Ft sin φ
F
and μ = = tan β
Page 12
N of 186
98
Rev.0 99
IES ‐ 2014 IES‐2000
In
I an orthogonal
h l cutting
i operation
i shear
h anglel = 11.31o , GATE‐2016
cutting force = 900 N and thrust force = 810 N. Then the In an orthogonal cutting test, the cutting force and
In an orthogonal cutting process the tool used has rake
shear force will be approximately ( given sin 11.31o = 0.2) thrust force were observed to be 1000N and 500 N
(a) 650 N angle
g of zero degree.
g The measured cutting
g force and
respectively. If the rake angle of tool is zero, the
(b) 720 N thrust force are 500 N and 250 N, respectively. The
(c) 620 N coefficient of friction in chip‐tool
chip tool interface will
ill be
coefficient of friction between the tool and the chip is
(d) 680 N 1 1
(a) 2 ( b) 2 ( c) ( d) 2
________________
2
100 101 102
GATE – 2007 (PI) Common Data‐1
( ) GATE – 2007 (PI) Common Data‐2
( ) G
GATE – 20 ( ) i k d S
2011 (PI) Linked S1
In an orthogonal machining test, test the following In an orthogonal machining test, test the following During orthogonal machining of a mild steel specimen
observations were made observations were made with a cutting tool of zero rake angle, the following data
Cutting force 1200 N Cutting force 1200 N i obtained:
is bt i d
Thrust force 500 N Thrust force 500 N Uncut chip p thickness = 0.25 mm
Tool rake angle zero Tool rake angle zero Chip thickness = 0.75 mm
Cutting speed 1 m/s Cutting speed 1 m/s Width off cutt = 2.5 mm
Depth of cut 0 8 mm
0.8 Depth of cut 0 8 mm
0.8 Normal force = 95 950 N
Chip thickness 1.5 mm Chip thickness 1.5 mm Thrust force = 475 N
Friction angle during machining will be Chip speed along the tool rake face will be Th shear
The h angle
l andd shear
h f
force, respectively,
ti l are
((a)) 771.565o
5 5 , 150.21
5 N ((b)) 18.435o
435 , 75
751.04
4N
22 6o (b) 32.8
(a) 22.6 32 8o (c) 57.1
57 1o 67 4o
(d) 67.4 (a) 0.83
0 83 m/s (b) 0.53
0 53 m/s
103 (c) 1.2 m/s (d) 1.88 m/s 104
(c) 9.218o, 861.64 N (d) 23.157o , 686.66 N 105
G
GATE – 20 ( ) i k d S2
2011 (PI) Linked S2 IFS 2012
IFS‐2012
An orthogonal machining operation is being carried out GATE‐2006 Common Data Questions(1)
During orthogonal machining of a mild steel specimen
under the following conditions : In an orthogonal machining operation:
with a cutting tool of zero rake angle, the following data
i obtained:
is bt i d depth of cut = 0.1 mm, Uncut thickness 0 5 mm
Uncut thickness = 0.5 mm
Uncut chipp thickness = 0.25 mm chip thickness = 0.2 mm, Cutting speed = 20 m/min Rake angle = 15°
Chip thickness = 0.75 mm width of cut = 5 mm, Width of cut = 5 mm Chip thickness = 0.7 mm
Width off cutt = 2.5 mm rake angle = 10o Thrust force 200 N
Thrust force = 200 N Cutting force 1200 N
Cutting force = 1200 N
Normal force = 95950 N The force components along and normal to the direction Assume Merchant's theory.
of cutting velocity are 500 N and 200 N respectively.
f i l i N d N i l
Thrust force = 475 N The coefficient of friction at the tool‐chip interface is
Determine
Th lti t h t
The ultimate shear stress (in N/mm
(i N/ 2) of the work
) f th k (a) 0 23
(a) 0.23 (b) 0 46
(b) 0.46
(i) The coefficient of friction between the tool and chip.
material is (c) 0.85 (d) 0.95
(ii) Ultimate shear stress of the workpiece material [10]
(ii) Ultimate shear stress of the workpiece material. [10]
(a) 235 (b) 139 (c) 564 (d) 380
Page 13 of 186 107
Rev.0 108
GATE‐2006 Common Data Questions(2) GATE‐2006 Common Data Questions(3) T i O ti
Turning Operation
In an orthogonal machining operation: In an orthogonal machining operation:
Uncut thickness 0 5 mm
Uncut thickness = 0.5 mm Uncut thickness 0 5 mm
Uncut thickness = 0.5 mm
Cutting speed = 20 m/min Rake angle = 15° Cutting speed = 20 m/min Rake angle = 15°
Width of cut = 5 mm Chip thickness = 0.7 mm Width of cut = 5 mm Chip thickness = 0.7 mm
Thrust force 200 N
Cutting force = 1200 N Thrust force 200 N
Cutting force = 1200 N
Assume Merchant's theory. Assume Merchant's theory.
The percentage of total energy dissipated due to The values of shear angle and shear strain,
friction at the tool chip interface is
friction at the tool‐chip interface is respectively are
respectively, are
(a) 30% (b) 42% (a) 30.3° and 1.98 (b) 30.3° and 4.23
(c) 58% (d) 70% (c) 40.2° and 2.97 (d) 40.2° and 1.65
109 110 111
y Fc or Fz or tangential component or primary cutting

force acting in the direction of the cutting velocity, IES‐1995 IES‐2001
largest
l force
f andd accounts forf 99%% off the
h power
The primary tool force used in calculating the total Power consumption in metal cutting is
required by the process.
mainly due to
y Fx or axial component or feed force acting in the power consumption in machining is the
direction of the tool feed.
feed This force is about 50% of ((a)) Tangential
g component
p of the force
Fc, but accounts for only a small percentage of the (a) Radial force (b) Tangential force
(b) Longitudinal component of the force
power required
i d because
b f d rates
feed t are usually
ll smallll (c) Axial force (d) Frictional force. (c) Normal component of the force
compared to cutting speeds.
y Fy or radial force or thrust force in turning acting (d) Friction
F i ti att the
th metal‐tool
t l t l interface
i t f
perpendicular to the machined surface. This force is
about 50% of Fx i.e. 25% of Fc and contributes very
little to power requirements because velocity in the
radial direction is negligible. 112 113 114
IES‐1997 IES‐1999 IFS‐2015

Consider the following forces acting on a The radial force in single‐point tool during Q. Why the knowledge of the thrust force in
finish turning tool: turning operation varies between cutting
tti isi important
i t t?
1. Feed force ((a)) 0.2 to 0.4
4 times the main cutting
g force Answer: A knowledge of the thrust force in cutting is
2. Thrust force (b) 0.4 to 0.6 times the main cutting force important because the tool holder, the work‐holding
3. Cutting force. (c) 0.6 to 0.8 times the main cutting force devices, and the machine tool must be sufficiently stiff
Th correctt sequence off the
The th decreasing
d i order
d off (d) 0.5 to
t 0.66 times
ti th main
the i cutting
tti force
f to support that force with nominal deflection.
the magnitudes
g of these forces is
(a) 1, 2, 3 (b) 2, 3, 1
(c) 3, 1, 2 (d) 3, 2, 1
Page 14 of 186 116
Rev.0 117
f d f d h
Determination of Un‐deformed chip GATE‐2014
Conversion Formula
Conversion Formula thickness in Turning: (VIMP)
thickness in Turning: (VIMP)
A straight turning operation is carried out using a
We have to convert turning (3D) to Orthogonal For single point cutting tool
Cutting (2D) single point cutting tool on an AISI 1020 steel rod.
t = f sin λ
Fc = Fz The feed is 0.2 mm/rev and the depth of cut is 0.5
d
Fy b= mm The tool has a side cutting edge angle of 60o.
mm.
Ft = Fxy =
Fx
= = Fx2 + Fy2 Where sin λ The uncut chip thickness (in mm) is ……….
sin λ cos λ t =Uncut chip thickness
f = feed
λ = 90 – Cs = approach angle
Cs = side cutting edge angle
side cutting edge angle
118 l =πD 119 120
ESE‐2003‐ Conventional GATE – 1995 ‐Conventional IAS‐2003 Main Examination

During turning a carbon steel rod of 160 mm diameter by 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 During turning process with 7 ‐ ‐ 6 – 6 – 8 – 30 – 1
400 rpm,
p , feed
eed o
of 0.3
0.32 mm/rev
/ ev aandd 4.0 mm dept
depth o
of cut, tthe
e 315 rpm, 2.5 mm depth of cut and feed of 0.16 (mm) ASA tool the undeformed chip thickness of
following observation were made. mm/rev by a tool of geometry 00, 100, 80, 90,150, 750, 2.0 mm and width of cut of 2.5 mm were used. The
Tangential component of the cutting force, Pz = 1200 N 0(mm) the following observations were made.
0(mm), made side rake angle of the tool was a chosen that the
Axial component of the cutting force, Px = 800 N machining operation could be approximated to be
Tangential component of the cutting force = 500 N
Chi thickness
Chip thi k t) α 2 = 0.8
( ft cut),
(after 0 8 mm
mm. orthogonal
h l cutting.
i Th tangential
The i l cutting
i force
f and
d
Axial component of the cutting force = 200 N
For the above machining condition determine the values of thrust force were 1177 N and 560 N respectively.
(i) Friction force, F and normal force, N acting at the chip tool Chip thickness = 0.48
0 48 mm Calculate: [30 marks]
interface. Draw schematically the Merchant’s circle diagram (i) The side rake angle
(ii) Yield shears strength of the work material under this for the cutting force in the present case.
machining condition. (ii) Co‐efficient of friction at the rake face
(iii) Cutting power consumption in kW. (iii) The dynamic shear strength of the work material
121 122 123
GATE 2015
GATE-2015
Orthogonal Turning (λ = 90o) GATE‐2007
Fc = Fz In orthogonal turning of a low carbon steel bar
of diameter 150 5 mm with uncoated carbide
An
A orthogonal
h l turning
i operation
i isi carried
i d out under
d
the following conditions: rake angle = 55°, spindle
tool, the cutting velocity is 90 m/min. The feed
F F rotational speed
p = 4
400 rpm,
p , axial feed = 0.4
4 m/min
/
Ft = x = x = Fx is 0.24
0 24 mm/rev and the depth of cut is 2 mm.mm
sin λ sin90
The chip thickness obtained is 0.48 mm. If the and radial depth of cut = 5 mm. The chip thickness, tc
orthogonal rake angle is zero and the principal
t = f sin λ = f sin90 = f cutting edge angle is 90°, the shear angle is is found to be 3 mm . The shear angle (in degrees) in
d
degree i
is this turning process is _____
(a) 20.56
.5 ((b)) 26.56
.5
d d
b= = =d (c) 30.56 (d) 36.56
i λ sin90
sin i 90
Page 15 of 186 125
Rev.0 126
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
GATE‐2007
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 In orthogonal turning of low carbon steel pipe with
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 principal cutting edge angle of 90°, the main cutting
The values of shear angle and shear strain is angle (in degree) is force is 1000 N and the feed force is 800 N. The shear
a) 28°20´ and 2.19 angle is 25°

2 ° and orthogonal rake angle is zero.
ero
b) ° ´ and
b)22°20´ d 3.53 Employing Merchant
Merchant’ss theory, the ratio of friction
c) 24
24°20´
20 and 4.19
4 19 force to normal force acting
g on the cutting
g tool is
d)37°20´
37 and 55.19
9 ((a)) 1.56
5 ((b)) 1.255 ((c)) 0.80 ((d)) 0.64
4
127 128 129
GATE‐2003 Common Data Questions(1) GATE‐2003 Common Data Questions(2) GATE‐2008 Common Data Question (1)

A cylinder is turned on a lathe with orthogonal A cylinder is turned on a lathe with orthogonal Orthogonal turning is performed on a cylindrical work
machining principle.
principle Spindle rotates at 200 rpm.
rpm The machining principle.
principle Spindle rotates at 200 rpm.
rpm The piece with shear strength of 250 MPa.
MPa The following
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 conditions are used: cutting velocity is 180 m/min. feed
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 is 0.20
0 20 mm/rev.
mm/rev depth of cut is 3 mm.mm chip thickness
that the shear angle is 27.75° that the shear angle is 27.75° ratio = 0.5. The orthogonal rake angle is 7o. Apply
The thickness of the produced chip is In the above problem, the coefficient of friction at M h ' theory
Merchant's h f analysis.
for l i
(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 p g ( g )
The shear plane angle (in degree) and the shear
(c) 0.818 mm (d) 0.846 mm Merchant theory is force respectively are
(a) 0 18
(a) 0.18 (b) 0 36
(b) 0.36 (a) 52: 320 N (b) 52: 400N
(c) 0.71 (d) 0.98 (c) 28: 400N (d) 28:320N
130 131 132
GATE‐2008 Common Data Question (2) Metal Removal Rate (MRR) IES ‐ 2004

Orthogonal turning is performed on a cylindrical work A medium
di carbon
b steell workpiece
k i is
i turned
d on a
piece with shear strength of 250 MPa.MPa The following lathe at 50 m/min. cutting speed 0.8 mm/rev feed
M l
Metal removal rate (MRR) = A
l (MRR) Ac.V
V = b t V = fdV
b V fdV and 1.5 mm depth of cut. What is the rate of metal
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 removal?
ratio = 0.5. The orthogonal rake angle is 7o. Apply Where (a) 1000 mm3/min
M h ' theory
Merchant's h f analysis.
for l i (b) 60,000 mm3/min
/
Ac = cross‐section area of uncut chip (mm2)
g , p y,
The cutting and Thrust forces, respectively, are 0,000 mm3//min
(c) 20,000
(a) 568N; 387N (b) 565N; 381N
V = cutting speed = π DN , mm / min (d) Can not be calculated with the given data
( )
(c) 440N; 342N
N N (d)
(d) 480N; 356N
N N

Page 16 of 186 134
Rev.0 135
GATE‐2013 IES 2016
IES‐2016
A 125 mm long, 10 mm diameter stainless steel rod is
Power Consumed During Cutting
A steell bar
b 200 mm in
i diameter
di is
i turned d at a feed
f d off
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.
rotational speed of the workpiece is 160 rpm. The The spindle rotates at 360 rpm. With the tool traversing
material removal rate in mm3/s is
at an axial speed of 175 mm/min, the metal removal rate
(a) 160 (b) 167.6 (c) 1600 (d) 1675.5
is nearly.
nearly
3 3
c
(a) 2200 mm / min (b) 2400 mm / min
(c) 2600 mm3 / min (d) 2800 mm3 / min
Where
Fc = cutting force (in N)
πDN
V tti
V = cutting speed = , m/s
d
60
/
136 137 138
Specific Energy Consumption GATE(PI)‐1991 GATE‐2007

Amount of energy consumption per unit volume of In orthogonal turning of medium carbon steel. The
Power (W ) Fc specific machining energy is 2.0 J/mm3. The cutting
e= = metal removal is maximum in
( )
velocity, feed and depth of cut are 120 m/min, 0.2
MRR mm / s 1000 fd
3
mm/rev and 2 mm respectively.
respectively The main cutting
(a) Turning (b) Milling
force in N is
(c) Reaming (d) Grinding (a) 40 (b) 80
(c) 400 (d) 800
Sometimes it is also known as specific power

consumption.
consumption
139 140 141
GATE‐2016 (PI) GATE‐2013 (PI) Common Data Question Example

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 When the rake angle is zero during orthogonal cutting,
show that
straight turned with cutting velocity, feed and depth of facing operation is undertaken at a constant cutting
speed
p of 990 m/min
/ in a CNC lathe. The main τs
=
(1 − μ r ) r
cut of 120 m/min, 0.25 mm/rev and 4 mm, respectively. (tangential) cutting force is 200 N. pc 1+ r2
The specific cutting energy
energ of the work
ork material is 1 103
1×10 Neglecting the contribution of the feed force Wh τs is
Where i the
h shear
h strengrhh off the
h material
i l
towards cutting power, the specific cutting energy pc = specific
p ppower of cutting
g
J/m3. Neglect the contribution of feed force towards
in J/mm3 is
cutting
gppower. The main or tangential
g cutting
g force (in r = chip thickness ratio
(a) 0.2 (b) 2 (c) 200 (d) 2000
μ = coefficient of friction in tool chip interface
N) is ________.

Page 17 of 186 143
Rev.0 144
GATE‐2014 Friction in Metal Cutting
l
Specific Cutting Pressure
Specific Cutting Pressure The
Th main i cutting
i force
f acting
i on a tooll during
d i the
h
The cutting force, Fc, divided by the cross section turning (orthogonal cutting) operation of a metal is
area of the undeformed chip gives the nominal 400 N. The turning was performed using 2 mm
cutting stress or the specific cutting pressure,
pressure pc depth
p of cut and 0.1 mm/rev/ feed rate. The specific
p
cutting pressure is
Fc Fc (a) 1000
pc = = (b) 2000
bt fd
(c) 3000
(d) 4000
145 146 147
GATE 1992 GATE‐1993 IES‐2000

The effect of rake angle on the mean friction angle in The effect of rake angle on the mean friction angle in Assertion (A): In metal cutting, the normal
machining can be explained by machining can be explained by laws of sliding friction are not applicable.
applicable
(A) sliding (Coulomb) model of friction (a) Sliding (coulomb) model of friction
Reason ((R): ) Very y highg temperature
p is
(B) sticking and then sliding model of friction (b) sticking and then siding model of friction produced at the tool‐chip interface.
((C)) sticking
g friction (c) Sticking friction
(D) Sliding and then sticking model of friction ( ) Both
d d ll true andd R is
(d) sliding and then sticking model of friction
the correct explanation of A
(b) Both A and R are individually true but R is
not the correct explanation of A
148 149
(d) A is false but R is true 150
H Di ib i i M l C i
Heat Distribution in Metal Cutting
IES‐2004 IES‐2002
Assertion
A i (A):
(A) The
Th ratioi off uncut chip
hi thickness
hi k to
actual chip thickness is always less than one and is
In a machining process, the percentage of
termed d as cutting ratio in orthogonal
h l cutting heat carried away by the chips is typically
Reason ((R): ) The frictional force is veryy high
g due to the ((a)) 55% ((b)) 25%
5
occurrence of sticking friction rather than sliding
friction
(c) 50% (d) 75%
(a) Both A and R are individually true and R is the correct
explanation of A
correct explanation
l i off A
Page 18 of 186 152
Rev.0 153
For IES Only
IES‐1998 IAS – 2003 Mean Temperature in Turning

As the cutting speed increases
A h i d i
In metal cutting operation, the approximate
ratio of heat distributed among chip,
chip tool ((a)) More heat is transmitted to the work piece and less
p Mean temperature ∞ V a f b
heat is transmitted to the tool
and work, in that order is
(b) More heat is carried away by the chip and less heat is
(a) 80: 10: 10 (b) 33: 33: 33 transmitted to the tool
Tool Material a b
( ) 20: 60: 10 (d) 10: 10: 80
(c) (c) More heat is transmitted to both the chip and the
HSS 0.5 0.375
too
tool
Carbide 0.2 0.125
(d) More heat is transmitted to both the work piece and
th t l
the tool
154 155 156
Determination of cutting heat & temperature

E
Experimentally
i t ll
HEAT
IAS – 2003
y Calorimetric method
The
Th heat
h generatedd in
i metall cutting
i can Dynamometer
conveniently be determined by
TEMPERATURE y Dynamometers are used for measuring Cutting forces.
forces
(a) Installing thermocouple on the job
y Decolourising
g agent
g y For Orthogonal Cutting use 2D dynamometer
(b) Installing thermocouple on the tool
y Tool‐work thermocouple
(c) Calorimetric set‐up y For Oblique
q Cutting
g use 33D dynamometer
y
y Moving thermocouple technique
M i h l h i
(d) Using radiation pyrometer
y Embedded thermocouple technique
p q
y Using compound tool
y Indirectly from Hardness and structural transformation
di l f d d l f i
y Photo‐cell technique
q
y Infra ray detection method 157 158 159
IES 2011 IES‐1993 IES‐1996

The instrument or device used to measure the cutting A 'Dynamometer' is a device used for the Which of the following forces are measured directly by
forces in machining is :
g strain gauges or force dynamometers during metal
measurement of cutting ?
(a) Tachometer
((a)) Chip
p thickness ratio 1. Force exerted byy the tool on the chip p acting
g normallyy to
(b) Comparator
(b) C the tool face.
( ) y
(c) Dynamometer
(b) Forces during metal cutting 2. Horizontal cutting g force exerted byy the tool on the work
(d) Lactometer (c) Wear of the cutting tool piece.
3. Frictional resistance of the tool against the chip flow
(d) Deflection
D fl ti off the
th cutting
tti tool
t l acting along the tool face.
4 Vertical force which helps in holding the tool in
4.
position.
(a) 1 and 3 (b) 2 and 4
(c) 1 and 4 (d) 2 and 3
Page 19 of 186 161
Rev.0 162
Types of Dynamometers Strain Gauge Dynamometers IES‐1998
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
The gauge factor of a resistive pick‐up of
Or resistance, R, of the strain gauges which are firmly
pasted on the surface of the tool‐holding beam as cutting force dynamometer is defined as the
piezoelectric type ratio of
ΔR
ΔR
= Gε (a) Applied strain to the resistance of the wire
R
St i gauge type
Strain t d
dynamometerst are inexpensive
i i but
b t less
l where, G = gauge factor (around 2.0 for conductive (b) The
h proportionall change
h in resistance to the
h
accurate and consistent, whereas, the piezoelectric type gauges) applied strain
are highly accurate, reliable and consistent but very
The change in resistance of the gauges connected in a (c) The resistance to the applied strain
expensive
p for high
g material cost and stringent g
Wh t t
Wheatstone b id produces
bridge d voltage
lt output
t t ΔV,
ΔV through
th h
construction. (d) Change in resistance to the applied strain
a strain measuring bridge (SMB)
163 164 165
IAS‐2001
Assertion
A ti (A):
(A) Piezoelectric
Pi l t i transducers
t d and
d preferred
f d For PSU & IES
For PSU & IES
over strain gauge transducers in the dynamometers for
measurement of three‐dimensional
three dimensional cutting forces.
forces In strain gauge dynamometers the use of how
Reason (R): In electric transducers there is a significant many active gauge makes the dynamometers more
leakage of signal from one axis to the other,
other such cross effective , ,
Tool Wear, Tool Life, Economics &
error is negligible in the case of piezoelectric
transducers.
transducers
(a) Four Machinability
(a) Both A and R are individually true and R is the correct (b) Three
explanation of A (c) Two
(b) Both A and R are individually true but R is not the (d) One
l ti off A
(d) A is false but R is true By S K Mondal
166 167 168
Tool Failure IES 2010 IES – 2007, IES‐2016

Tool failure is two types Flank wear occurs on the Flank wear occurs mainly on which of the
y 1. Slow‐death: The g gradual or pprogressive
g wearingg
away of rake face (crater wear) or flank (flank wear) of ( ) Relief face of the tool
(a) f ll i ?
following?
the cuttingg tool or both. (a) Nose part and top face
y 2. Sudden‐death: Failures leading to premature end (b) Rake
R k face
f
of the tool (b) Cutting edge only
( ) Nose
(c) N off the
th tool
t l
y The sudden‐death type of tool failure is difficult to
predict. Tool failure mechanisms include plastic ((c)) Nose p
part, front relief face, and side relief face of the
(d) Cutting edge
deformation, brittle fracture, fatigue fracture or edge
cutting tool
pp g However it is difficult to p
chipping. predict which of
these processes will dominate and when tool failure (d) Face of the cutting tool at a short distance from
will occur.
the cutting edge
Page 20 of 186 170
Rev.0 171
IES ‐ 2014 Tool Wear
IAS –
IAS – 2009 Main
2009 Main The
Th fatigue
f i failure
f il off a tooll is
i due
d to (a) Flank Wear
y Explain ‘sudden‐death mechanism’ of tool failure.
Explain sudden death mechanism of tool failure. ((a)) abrasive friction,, cutting g fluid and chip
p breakage
g
(b) Variable thermal stresses, chip breakage and variable (b) Crater Wear
[ 4 – marks]
dimensions of cut (c) Chipping off of the cutting edge
(c) Abrasive friction, chip breakage and variable
dimensions of cut
(d) Chip breakage,
breakage variable thermal stresses and cutting
fluid
172 173 174
l
Tool Wear IES – 1994 Flank Wear: (Wear land)
Assertion (A): Tool wear is expressed in terms of
A i (A) T l i d i f
flank wear rather than crater wear.
Reason
y Abrasion
Ab i b hard
by h d particles
i l and
d inclusions
i l i i the
in h work
k
Reason (R): Measurement of flank wear is simple
piece.
and more accurate.
and more accurate
y Shearing off the micro welds between tool and work
material.
material
l f
y Abrasion by fragments of built‐up‐edge ploughing
(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
against
i the
h clearance
l f
face off the
h tool.
l
y At low speed
p flank wear p
predominates.
( ) A is true but R is false
(c) A i t b t R i f l
y If MRR increased flank wear increased.
175 176 177
GATE‐2014 Flank Wear: (Wear land) Flank Wear: (Wear land)

Cutting
C i tooll is
i much h harder
h d than h the
h work‐piece.
k i
Yet the tool wears out during the tool‐work
Effect Stages
interaction, because y Flank
Fl k wear directly
di l affect
ff the
h component dimensions
di i y Flank
Fl k Wear
W occurs in
i three
h stages off varying
i wear rates
produced.
(a) extra hardness is imparted to the work
work‐piece
piece due to
coolant used y Flank wear is usually the most common determinant of
tool life.
life
(b) oxide
d layers
l on the
h work‐piece
k surface
f impart extra
hardness to it
(c) extra hardness is imparted to the work‐piece due to
severe rate of strain
(d) vibration is induced in the machine tool

Page 21 of 186 179
Rev.0 180
Flank Wear: (Wear land) Flank Wear: (Wear land)
Primary wear Tertiary wear
The region
Th i where
h the
h sharp
h cutting
i edge
d i quickly
is i kl The region
Th i where
h wear progresses at a gradually
d ll
broken down and a finite wear land is established. increasing rate.
y In the tertiary region the wear of the cutting tool has
Secondary
y wear become sensitive to increased tool temperature due to
The region where the wear progresses at a uniform rate. high wear land.
y Re‐grinding
R i di i recommended
is d d before
b f they
h enter this
hi
region.
181 182 183
IES – 2004 GATE 2008 (PI)

GATE‐2008 (PI) IFS‐2012
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: Explain the mechanism of flank wear of a cutting
against machining time (T) as given in the following
During g the third stage g of tool‐wear,, rapid
p figure.
figure
deterioration of tool edge takes place because tool.
l Plot
l a flank
fl k wear rate curve and
d indicate
d the
h
1 Flank wear is only marginal
1. region of tool failure.
failure
2. Flank wear is large
[10 Marks]
3. Temperature of the tool increases gradually
4. Temperature
T t off the
th tool
t l increases
i d ti ll
drastically
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
184
(a) 52.00 (b) 51.67 (c) 51.50 (d) 50.00 185 186
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.

Page 22 of 186 188
Rev.0 189
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
190 191 192
IES – 1995 IES 2009 Conventional Wear Mechanism

Crater wear is predominant in
C i d i i Show crater wear and flank wear on a single point 1. Abrasion wear
((a)) Carbon steel tools cutting tool State the factors responsible for wear
cutting tool. State the factors responsible for wear
(b) Tungsten carbide tools on a turning tool.
2. Adhesion wear
( ) High speed steel tools
(c) Hi h d l l [
[ 2 –marks]
k ]
((d)) Ceramic tools 3 Diffusion wear
3.
4. Chemical or oxidation wear
193 194 195
IAS – 2002 IES – 1995 IAS – 1999

Consider
C id the h following
f ll i actions:i Match List I with List II and select the correct
M h Li I i h Li II d l h The
Th type off wear that
h occurs due
d to the
h cutting
i
1. Mechanical abrasion 2. Diffusion answer using the codes given below the lists: action of the particles in the cutting fluid is
3. Plastic deformation 4. Oxidation List I (Wear type) List II (Associated mechanism) referred to as
Whi h off the
Which h above
b are the
h causes off tooll wear?? A Abrasive wears
A. 1
1. Galvanic action (a) Attritions wear
((a)) 2 and 3 ((b)) 1 and 2 B. Adhesive wears 2. Ploughing action (b) Diffusion wear
(c) 1, 2 and 4 (d) 1 and 3 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
5. Metallic bond
Code: A B C D A B C D
( ) 2
(a) 5 1 3 (b) 5 2 1 3
(c) 2 1 3 Page4 23(d) of 186
5 2 3 4 197
Rev.0 198
Why chipping off or fine cracks IAS – 2003 Notch Wear
developed at the cutting edge
d l d h d Consider
C id theh following
f ll i statements: y Notch wear on the trailing edge is to a great extent an
pp g of a cutting
Chipping g tool is due to
oxidation
id ti wear mechanism
h i occurring
i where
h th cutting
the tti
y Tool material is too brittle 1. Tool material being too brittle
edge leaves the machined workpiece material in the feed
2. Hot
H hardness
h d off the
h tooll material.
i l
y Weak design of tool, such as high positive rake angle 33. High g ppositive rake angle
g of the tool. direction.
Which of these statements are correct? y But abrasion and adhesion wear in a combined effect can
y As a result of crack that is already in the tool
( ) 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
y Excessive
E i static
i or shock
h k loading
l di off the
h tool.
l
199 200 201
IES – 1996 List the important properties of cutting tool

Notch wear at the outside edge of the depth of cut is
N h h id d f h d h f i materials and explain why each is important.
t i l d l i h hi i t t IES‐2014 Conventional
due to y Describe the characteristics of tool materials.
y Hardness at high temperatures ‐ this provides longer
(a) Abrasive action of the work hardened chip material [4‐marks]
life of the cutting tool and allows higher cutting speeds.
(b) Oxidation
y Toughness ‐ to provide the structural strength needed
(c) Slip‐stick action of the chip
to resist impacts and cutting forces
(d) Chipping.
y Wear resistance ‐ to prolong usage before replacement
doesn’t chemically react ‐ another wear factor
y Formable/manufacturable ‐ can be manufactured in a
useful geometry
202 203 204
Why are ceramics normally provided as IES 2015

IES‐2015 Tool Life Criteria
g statements are be correct for
Which of the following
inserts for tools, and not as entire tools?
i f l d i l? Tool life criteria can be defined as a predetermined
temperature rise in metal cutting operation?
numerical value of any type of tool deterioration which
Ceramics are brittle materials and has low toughness
C i b i l i l d h l h
1. It adversely affects the properties of tool material can be measured.
cannot provide the structural strength required for a
tool. 2. It provides better accuracy during machining Some of the ways
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.
affects the accuracy of machining y Volume of metal removed.
Volume of metal removed
4. It can distort the accuracyy of machine tool itself.
4 y Number of parts produced.
p p
(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.

Page 24 of 186 206
Rev.0 207
IES – 1992 IAS – 2012 Main Taylor’s Tool Life Equation
Tool life is generally specified by
T l lif i ll ifi d b Define “tool life” and list down four methods for based on Flank Wear
((a)) Number of pieces machined
p Causes
quantitative measurement off tooll life.
lf
(b) Volume of metal removed y Sliding of the tool along the machined surface
( ) Actual cutting time
(c) A l i i [M k ]
[Marks ‐12] y Temperature rise
VT n = C
((d)) Any of the above
y
Where, V = cutting speed (m/min)
T Time (min)
T = Time (min)
n = exponent depends on tool material
C = constant based on tool and work material and cutting
208 209 condition. 210
Values of Exponent ‘n’ IES ‐ 2012 IES – 2008

i VTn = C, the constants n
In Taylor’s tool life equation VT
I T l ’ l lif C h I T l ' l lif i i VTn = constant.
In Taylor's tool life equation is VT
n = 0.08 to 0.2 for HSS tool and C depend upon What is the value of n for ceramic tools?
= 0.1 to 0.15 for Cast Alloys 1. Work piece material (a) 0.15 to 0.25 (b) 0.4 to 0.55
= 0.2 to 0.4 for
f carbide
bid tooll 2 Tool material
2. Tool material ( ) 0.6 to 0.75
(c) 6 (d) 0.8 to 0.9

[IAS‐1999;
[IAS 1999; IES
IES‐2006]
2006] 3. Coolant
(a) 1, 2, and 3
= 0.55 to 0.77 for ceramic tool (b) d l
(b) 1 and 2 only
[NTPC‐2003] (c) 2 and 3 only y
(d) 1 and 3 only
Reference: Kalpakjian 211 212 213
IES – 2006 IES – 1999 IAS – 1998

Which
Whi h off the h following
f ll i values
l off index
i d n is
i 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
associated with carbide tools when Taylor's tool life 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
equation, V.Tn = constant is applied? (a) 0.03 to 0.08 (b) 0.08 to 0.20 the codes given below the lists:
(a) 0∙1 to 0∙15 (b) 0∙2 to 0∙4 (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 –
(c) 0.45 to 0∙6 (d) 0∙65 to 0∙9 A. HSS 1. 0.18
B. Cast alloy 2. 0.12
C. Ceramic 33. 0.255
D. Sintered carbide 4. 0.5
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
Page 25 of 186 215
Rev.0 216
IES 2016
IES‐2016 ISRO‐2011
In a machining test,
test a cutting speed of 100 m/min GATE ‐2009 (PI)
GATE ‐2009 (PI) A 50 mm diameter steel rod was turned at 284 rpm and
indicated the tool life as 16 min and a cutting speed 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
of 200 m/min indicated the tool life as 4 min. The obtained is 10 min at a cutting speed of 100 m/min,
m/min changed
h d to 232 rpm and
d the
h tooll failed
f il d in
i 60
6 minutes.
i
values of n and C are while at 75 m/min cutting
g speed,
p the tool life is 330 Assuming straight line relationship between cutting
(a) 0.5 and 200 (b) 0.25 and 200 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
(c) 0.5 and 400 (d) 0.25 and 400 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
217 218 219
GATE‐2004, IES‐2000 IES – 1999, ISRO‐2013 GATE 2016

GATE‐2016
In a single point turning operation with cemented carbide
In
I a machining
hi i operation,
i doubling
d bli the
h cutting
i In a single‐point turning operation of steel with a
1
speed reduces the tool life to 8 th of the original tool and steel work piece, it is found that the Taylor’s
value. The exponent n in Taylor's tool life equation cemented
d carbide
b d tool,
l Taylor's
l ' tooll life
l f exponent is
exponent is 0.25. If the cutting speed is reduced by 50% then
VTn = C,, is 0 25 If the cutting speed is halved,
0.25. halved the tool life will the tool life changes by ______ times.
1 1 1 1
(a) (b) (c ) (d ) increase by
8 4 3 2
((a)) Two times ((b)) Four times
((c)) Eight
g times ((d)) Sixteen times
220 221 222
GATE-2015
GATE 2015
IAS – 1995 Under certain cutting conditions, doubling the IAS – 2002
In a single point turning operation with a cemented cutting speed reduces the tool life to 1/16th of the Using the Taylor equation VTn = c, calculate the
carbide
bid and
d steel
t l combination
bi ti h i
having a Taylor
T l original. Taylor’s tool life index (n) for this tool‐ percentage increase in tooll life
l f when
h the
h cutting
exponent of 0.25, if the cutting speed is halved, then workpiece combination will be _______ speed is reduced by 50% (n = 0∙5
0 5 and c = 400)
the tool life will become
(a) 300% (b) 400%
(a) Half
(c) 100% (d) 50%
(b) Two times
(c) Eight times
(d) Sixteen times
Page 26 of 186 224
Rev.0 225
IES‐2015 IES‐2013 IAS – 1997
If n = 0.5 and C= 300 for the cutting speed and the tool A carbide tool(having n = 0.25) with a mild steel In the Taylor's tool life equation, VTn = C, the value
life relation, when cutting speed is reduced by 25% , if 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
the
h tooll life
lif is
i increased
i d by
b 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
a) 100% in Taylor’s
y tool life equation
q would be equal
q to: to 45 minutes, then the cutting speed will be
b)95%
)95 (a) 200 ((a)) 9 m/min
/ ((b)) 18 m/min
/
c) 78% (b) 180 ((c)) 336 m/min ((d)) 772 m/min
d)50% (c) 150
226 (d) 100 227 228
IES – 2006 conventional GATE‐2009 Linked Answer Questions (1) GATE‐2009 Linked Answer Questions (2)

An HSS tool is used for turning operation. The tool life is 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:
1 hr.
h when
h turning is carried
d at 30 m/min. The
h tooll life
lf Cutting speed (m/min) Tool life (minutes) Cutting speed (m/min) Tool life (minutes)
will be reduced to 2.0
2 0 min if the cutting speed is 60 81 60 81
doubled. Find the suitable speed in RPM for turning 300 90 36 90 36
The exponent (n) and constant (k) of the Taylor's What is the percentage increase in tool life when
mm diameter so that tool life is 30 min.
tool life equation are the cutting speed is halved?
(a) n = 0.5 and k = 540 (b) n= 1 and k=4860 (a) 50% (b) 200%
(c) n = ‐1 and k = 0.74 (d) n‐0.5 and k=1.15 (c) 300% (d) 400%
229 230 231
IFS 2013
IFS‐2013
In a metal cutting experiment, the tool life was GATE‐2010 GATE‐2013
For tool A, Taylor’s tool life exponent (n) is 0.45 and Two cutting tools are being compared for a
found to vary with the cutting speed in the
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:
following manner :
C i
Cutting speed, V (in m/min)
d V (i / i ) Tool life, T(in min)
T l lif T(i i ) = 60.
60 The cutting speed (in m/min) above which tool Carbide tool: VT 1.6 = 3000
100 120 A will have a higher tool life than tool B is HSS tool: VT 0.6 = 200
130 50 ((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
Derive Taylor's tool life equation for this operation tool life in min. The carbide tool will provide higher
and estimate the tool life at a speed of 2.5 m/s. Also tool life if the cutting speed in m/min exceeds
estimate the cutting speed for a tool life of 80 min. (a) 15.0 (b) 39.4 (c) 49.3 (d) 60.0
Page 27 of 186 233
Rev.0 234
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‐1999
cutting test: What is approximate percentage change is the life, t,
components while working at 50 rpm with a tool
off a tooll with
h zero rake
k angle
l used
d in orthogonal
h l
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
Tool life, min 2.94 3.90 4.77 9.87 28.27 cutting when its clearance angle,
angle α,
α is changed from
similar batch of 10 tools of the same specification
10o to 7o?
could
ld produce
d 122 components
t while
hil working
ki att 80
8
Determine the constants of the Taylor tool life equation
rpm with a feed of 0.25
0 25 mm/rev and 1 mm depth of ((Hint: Flank wear rate is p
proportional
p to cot α))
VTn = C
C
cut. How many
y components
p can be p
produced with ((a)) 330 % increase ((b)) 330%, decrease
one cutting tool at 60 rpm? (c) 70% increase (d) 70% decrease
235 (a) 29 (b) 31 (c) 37 (d) 42 236 237
Extended or Modified Taylor’s equation IES 2010
Tool life is affected mainly with ISRO‐2012
What is the correct sequence of the following
( ) Feed
(a)
parameters in order of their maximum to
(b) Depth
D h off cut minimum influence on tool life?
1. Feed rate
( ) Coolant
(c) C l t
2. Depth of cut
(d) Cutting speed 3 Cutting speed
3.
Select the correct answer using the codes given
below
i.e Cutting speed has the greater effect followed by feed
g p g y (a) 1,
1 2,
2 3 (b) 3,
3 2,
2 1 (c) 2,
2 3,
3 1 (d) 3,
3 1,
1 2
and depth of cut respectively.
238 239 240
IES – 1997 IES – 1994, 2007 IES – 2008

Consider the following elements: For increasing the material removal rate in turning, What are the reasons for reduction of tool life in a
Wh h f d i f l lif i
machining operation?
1. Nose radius 2. Cutting speed without
h any constraints, what
h is the
h right
h sequence 1. Temperature rise of cutting edge
3. Depth of cut 4. Feed to adjust the cutting parameters? 2 Chipping of tool edge due to mechanical impact
2.
3. Gradual wears at tool point
The correct sequence of these elements in DECREASING 1
1. Speed 2
2. Feed 3
3. Depth of cut
4. Increase in feed of cut at constant cutting force
order of their influence on tool life is Select the correct answer using the code given below: S l t th
Select the correct answer using the code given
t i th d i
below:
(a) 2, 4, 3, 1
2 4 3 1 (b) 4 2 3 1
4, 2, 3, 1 (a) 11‐ 22‐ 3 (b) 22‐ 33‐ 1
(a) 1, 2 and 3 (b) 2, 3 and 4
(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 (c) 1, 3 and 4
1 3 and 4 (d) 1, 2 and 4
1 2 and 4
Page 28 of 186 242
Rev.0 243
IAS – 1995 ESE‐1999; IAS ‐2010 Conventional GATE‐2016
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
the tool life. The tool life equation for HSS tool is VT0.14 f 0.7 d0.4
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
= C. The tool life (T) of 30 min is obtained using the
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
following cutting conditions: V = 45 m/min, f = 0.35
mm, d = 2.0 mm. Calculate the effect on tool life if
correct explanation
l off A mm, d = 2.0 mm. If speed (V),
( ) feed(f)
( ) and depth of
(b) Both
d v dua y ttrue
ue but R iss not
ot tthee speed, feed and depth of cut are together increased by
cut (d) are increased individually by 25%,
25% the tool
correct explanation of A 25% and also if they are increased individually by 25%;
( ) A is
(c) i true
t b t R is
but i false
f l life (in min) is
where f = feed, d = depth of cut, v = speed.
(d) A is false but R is true ((a)) 0.155 ((b)) 1.06 ((c)) 22.50
5 ((d)) 330.0
244 245 246
Tool Life Curve
l f IES 2010 Conventional
IFS 2009
IFS 2009 y Draw tool life curves for cast alloy, High speed steel and
D l lif f ll Hi h d l d
ceramic tools. [2 – Marks]
With the
th help
h l off Taylor’s
T l ’ tool
t l life
lif equation,
ti
determine the shape of the curve between velocity Ans.
Ans
of cutting
g and life of the tool. Assume an HSS tool
and steel as work material.
[10‐Marks]
1. HSS 2. Carbide 3. Ceramic 1. High speed steel 2. cast alloy and 3. ceramic tools.

247 248 249
IES 2010 IAS – 2003

The above figure shows a typical The tool life curves for two tools A and B are shown in
Th l lif f l A d B h i IFS‐2015
relationship between tool life and the figure and they follow the tool life equation VTn = C.
Write Taylor
Taylor'ss tool
tool‐life
life equation.
cutting speed for different Consider the following statements:
d h f ll
materials. Match the graphs for 1. Value of n for both the tools is same. Draw tool‐life curves for a variety
y of cutting
g
HSS Carbide
HSS, C bid and d Ceramic
C i tooll
materials and select the correct
2. Value of C for both the tools is same. tool materials like ceramic, high speed steel,
answer usingi th code
the d given
i 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. cast alloy and carbide.
carbide
below the lists: 4. Value of C for tool B will be greater than that for the tool A.
C d HSS
Code: SS Carbide
C bid C
Ceramici Which of these statements is/are correct?
Whi h f th t t t i / t?
(a) 1 2 3 (a) 1 and 3 (b) 1 and 4
(b) 3 2 1 (c) 2 only (d) 4 only
(c) 1 3 2
(d) 3 1 2
Page 29 of 186 251
Rev.0 252
Cutting speed used for different Effect of Rake angle on tool life Effect of Clearance angle on tool life
tool materials If clearance angle increased it reduces flank wear but
edge so best compromise is 80 for
weaken the cutting edge,
HSS (min) 30 m/min < Cast alloyy < Carbide HSS and 50 for carbide tool.
< Cemented carbide 150 m/min < Cermets Effect of work piece on tool life

y With hard micro‐constituents in the matrix gives poor
< Ceramics or sintered oxide (max) 600 m/min tool life.
y With larger grain size tool life is better.
253 254 255
For IES Only
IES ‐ 2014 Chip Equivalent

Tool life Tests
Tool life Tests In
I accelerated
l d tooll life
lif tests, the
h three
h main
i types off Engaged cutting edge length
y Conventional test: Using empirical formula
g p quick and less costly tool life testing are ChipEquivalent(q) =
Plan area of cut
y Accelerated test: Estimate the tool life quickly (a) Extrapolation on the basis of steady wear;
Extrapolating of steady wear rate
E t l ti f t d t conventional measurement of flank and crater wear; y It
I is
i used
d for
f controlling
lli the
h tooll temperature.
High speed test‐will take less time comparative performance against tool chipping
Variable speed test (b) Measurement off abrasive
b wear; multi
l –pass turning;
Multi pass turning conventional measurement of diffusion wear
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
Refer: B.L Juneja+Nitin Seth 256 257 258
• The SCEA alters the length of the engaged cutting IES‐1996 E i f t l tti
Economics of metal cutting
edge without affecting the area of cut. As a result, the Chip
Chi equivalent
i l is
i increased
i d byb
(a) An increases in side‐cutting edge angle of tool
chip equivalent changed. When the SCEA is increased,
(b) An increase in nose radius and side cutting g
the
h 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

Page 30 of 186 260
Rev.0 261
l
Formula
g g
Units:Tc – min (Tool changing time)
Vo To = C
n
Ct – Rs./ servicing or replacement (Tooling
cost)
Optimum tool life for minimum cost Cm – Rs/min (Machining cost)
⎛ C ⎞⎛ 1− n ⎞ V – m/min (Cutting speed)
To = ⎜ Tc + t ⎟ ⎜ ⎟ if Tc , Ct & Cm given
⎝ Cm ⎠ ⎝ n ⎠
C ⎛ 1− n ⎞ Tooling cost (Ct) = tool regrind cost
= t ⎜ ⎟ if Ct & Cm ggiven
Cm ⎝ n ⎠
+ tool depreciation per service/ replacement
Optimum
p tool life for Maximum Productivity
y
Machining cost (Cm) = labour
) labour cost + over head cost per
(minimum production time) min
⎛ 1− n ⎞
To = Tc ⎜ ⎟
262
⎝ n ⎠ 263 264
IES 2009 Conventional GATE‐2014 ESE‐2001 Conventional

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 In a certain machining operation with a cutting
operation on a Lathe machine using the following
information: tooll changing
h time is 1.5 min, then
h the
h tooll life
l f (in
( speed
d off 50 m/min, tooll life
l f off 45 minutes was
Tool change time: 3 min min) for maximum production rate is ………………. observed When the cutting speed was increased to
observed.
Tool regrinds time: 3 min
100 m/min, the tool life decreased to 10 min.
Machine running cost Rs.0.50 per min
Estimate the cutting speed for maximum
Depreciation of tool regrinds Rs.
Rs 5.0
50
The constants in the tool life equation are 60 and productivity if tool change time is 2 minutes.
0.2
265 266 267
Example
p Answer
A 600 mm long job of diameter 150 mm is turned with feed Tool change time (Tc ) = 2 min
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.
Tool grinding cost = 5 x (15 + 50)/60 = Rs.
Rs 5.417/edge
5 417/edge
Tool will be used 10 times (Because first grinding not
Determine the optimum
p speed
p for achievingg Machine overhead cost = Rs.Rs 40.00/hr.
40 00/hr
maximum production rate in a machining needed
d d 9 regrinding
i di needed)
d d)
Grinding cost = Rs. 15.00/hr. 60 + 5.417 × 9
p
operation. The data is as follows : Tooling cost (Ct ) = = Rs.10.875 / use of tool
G i di machine
Grinding hi overhead
h d = Rs.
R 50/hr.
/h 10
Machining time/job = 6 min.
Idle time = 5 min Machining cost (Cm ) = Labour cost +Overhead cost per min
T l life
Tool lif = 90 min.
i Tool life constants are 0.22 and 475 = (12+40)/60 = Rs. 0.8667/min
Taylor's equation constants C = 100, n = 0.5 For tool: Initial cost = Rs. 60.00 ⎛ C ⎞⎛1 − n ⎞
O i
Optimum life (To ) = ⎜ Tc + t ⎟ ⎜
tooll lif ⎟
Job handling time = 4 min./job Grinding time is 5 min/edge ⎝ C m ⎠⎝ n ⎠
Tool changing time = 9 min.
min Tool change time 2 min ⎛ 10 875 ⎞ ⎛ 1 − 0.22
10.875 0 22 ⎞
= ⎜2 + ⎟ ⎜ 0.22 ⎟ = 51.58min
[10‐Marks] 9 grinds per tool before salvage. ⎝ 0.8667 ⎠⎝ ⎠
Fi d minimum
Find i i production
d i cost C 475
Optimum Speed (Vo ) = n = = 199.5m/min
Page 31 of 186 269 To 51.580.22 Rev.0 270
Answer(Contd….)
( )
Machining time (Tm ) =
π DL
=
π × 150 × 600
= 5.669 min GATE‐2016 GATE‐2005
1000 fV 1000 × 0.25 × 199.5
Initial setuptime for a batch (ti ) For a certain job, the cost of metal cutting is Rs.
Total time (Ttotal ) = Idle time (to ) +
Number of parts produced per batch ( p )
18C/V and
d the
h cost off tooling
l is Rs. 270C/(TV),
( ) where
h
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
Optimum tool life (To )
5.669 the tool life in minutes. The Taylor
Taylor’ss tool life
=5 + 0 +5 669 + 2 ×
5.669 = 10
10.89min
89min
51.58
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
⎝ p ⎠ To
5.667
5 667 m/min)) for the minimum total cost is ________
= 0.8667 × ( 5 + 0 + 5.667 ) + (10.875 + 2 × 0.8667 ) ×
51.58
= Rs.10.63 per piece
271 272 273
C d
Contd………. F
From previous
i slide
lid
IAS – 2007 Contd… IES 2011
A diagram
di related
l t d to
t machininghi i economics
i with ith The optimum cutting speed is one which should
various cost components is given above. Match List I have:
(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 1. High metal removal rate
th Lists:
the Li t 2. High
Hi h cutting
i tooll life
lif
List I List II 33. Balance the metal removal rate and cutting
g
(Cost Element) (Appropriate Curve) tool life
A Machining cost
A. 1
1. Curve‐l (a) 1,
1 2 and 3
B. Tool cost 2. Curve‐2 Code:A B C D A B C D (b) 1 and 2 only
C. Tool grinding cost
l d 3. Curve‐3 ( ) 3
(a) 2 4 5 ((b)) 4 1 3 2 (c) 2 and 3 only
D. Non‐productive cost
p 4.
4 Curve‐4
4 (c) 3 1 4 2 (d) 4 2 3 5 (d) 3 onlyl
5. Curve‐5 274 275 276
Minimum Cost Vs Production Rate IES – 1999 IES – 1998

Consider
C id the
h following
f ll i approaches
h normally
ll The
Th variablei bl cost and d production
d i rate off a
applied for the economic analysis of machining: machining process against cutting speed are shown
1. Maximum production rate in the given figure. For efficient machining, the
2 Maximum profit criterion
2. range
g of best cutting
g speed
p would be between
3. Minimum cost criterion (a) 1 and 3
The correct sequence in ascending order of optimum (b) 1 andd5
cutting speed obtained by these approaches is (c) 2 aand
d4
(a) 1, 2, 3 (b) 1, 3, 2 (d) 3 and 5
Vmax.production > Vmax.profit > Vmin. cost (c) 3, 2, 1 (d) 3, 1, 2

Page 32 of 186 278
Rev.0 279
IAS – 2002 IAS – 1997 IES – 2000
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 The
Th magnitude
i d off theh cutting
i speed
d for
f maximum
i
and optimum cutting speed for maximum for minimum cost and optimum cutting speed for profit rate must be
production rate (Vr max ) have which one of the maximum rate of production is always (a) In between the speeds for minimum cost and
following g relationships?
p (a) Equal to 1 maximum production rate
(a) Vc min = Vr max (b) Vc min > Vr max (b) In the range of 0.6 to 1 (b) Higher than the speed for maximum production rate
( ) Vc min < Vr max
(c) (d) V2c min = Vr max (c) In the range of 0.1 to 0.6 (c) Below the speed for minimum cost
(d) Greater than 1 (d) Equal to the speed for minimum cost
280 281 282
IES – 2004 IES – 2002 IAS – 2007

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 Assertion
A i (A):
(A) The
Th optimumi cutting
i speed
d for
f theh
1. As the cutting speed increases, the cost of production following costs remains constant? minimum cost of machining may not maximize the
i i i ll reduces,
initially d then
h after
f an optimum
i cutting
i speed
d iti profit.
increases (a) Machining cost per piece
2. As A the
h cuttingi speedd increases
i the
h cost off production
d i (b) Tool changing cost per piece Reason (R): The profit also depends on rate of
also increases and after a critical value it reduces (c) Tool handling cost per piece production.
3. Higher feed rate for the same cutting speed reduces cost (d) Tool cost per piece ( ) Both
d d ll true and
d R is the
h
of production correct explanation of A
4. Higher feed rate for the same cutting speed increases the (b) Both A and R are individually true but R is not the
cost of production
Which of the statements given above is/are correct?
((a)) 1 and 3 ((b)) 2 and 3 (c) A is true but R is false
(c) 1 and 4 (d) 3 only (d) A is false but R is true
283 284 285
For IES Only
IES 2010 Machinability‐Definition Free Cutting steels

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 y Addition of lead in low carbon re‐sulphurised steels and
time for machining g a component
p being machined’ and more reasonably as ‘ease of also in aluminium,
aluminium copper and their alloys help reduce
machining’.
(a) Decreases their τs. The dispersed lead particles act as discontinuity
Suchh ease off machining
h or machining
h characters
h and solid lubricants and thus improve machinability by
(b) Increases
of any
y tool‐work p
pair is to be jjudged
g by:
y reducing friction, cutting forces and temperature, tool
(c) Remains unaffected wear and d BUE formation.
f i
y Tool wear or tool life
((d)) First decreases and then increases y It contains less than 0.35%
35 lead byy weight
g .
y Magnitude of the cutting forces
y A free cutting steel contains
y Surface finish C
C‐0.07%,
% Si‐0.03%,
Si % Mn‐0.9%,
M % P‐0.04%,
P % S‐0.22%,
S % Pb‐0.15%
Pb %
y Magnitude
g of cuttingg temperature
p
y Chip forms.
Page 33 of 186 287
Rev.0 288
Machinability Index IES ‐ 2012 IAS – 1996
The
Th usuall method h d off defining
d fi i machinability
hi bili off a Assertion (A): The machinability of a material can
A i (A) Th hi bili f i l
Or Machinability Rating material is by an index based on be measured as an absolute quantity.
The machinability index KM is defined by (a) Hardness of work material Reason (R): Machinability index indicates the case
KM = V606 /V60R
6 R (b) Production rate of machined parts with which a material can be machined
Where V60 is the cutting speed for the target material (c) Surface finish of machined surfaces (a) Both A and R are individually true and R is the
that
h ensures tooll life
lif off 60
6 min,
i V60R is
i the
h same for
f the
h correct explanation of A
l f
(d) Tool life
reference material. (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
If KM > 1, the machinability of the target material is correct explanation of A
better that this of the reference material,
material and vice versa ( ) A is true but R is false
(c) A i t b t R i f l
289 290 291
For IES Only For IES Only For IES Only
Machinability of Steel Machinability of Steel contd… Machinability of Steel contd…

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 y Stainless
S i l Steel:
S l Difficult
Diffi l to machine
hi due
d to abrasion.
b i
steel. dispersed fine particle and act as solid lubricants. At y Aluminum and Silicon in steel: Reduce machinability
y
y Resulfurized steel: Sulfur is added to steel only if high speed lead melts and acting as a liquid lubricants. due to aluminum oxide and silicates formation, which
As lead is toxin and p
pollutant,, lead free steel is p
produced are hard and abrasive.
abrasive
th
there i sufficient
is ffi i t manganese in i it.
it Sulfur
S lf f
forms
using Bismuth and Tin. y Carbon and manganese in steel: Reduce
manganese sulfide which exists as an isolated phase
y Rephosphorized steel: Phosphorus strengthens the machinability
h b l due d to more carbide.
bd
and act as internal lubrication and chip breaker.
ferrite, causing increased hardness, result in better chip y Nickel,
c e,C Chromium,
o u , molybdenum,
o ybde u , a and
d va
vanadium
ad u in
y If insufficient manganese is there a low melting iron f
formation and
d surface
f f
finish.
h
sulfide will formed around the austenite grain steel: Reduce machinability due to improved property.
y Calcium
Calcium‐Deoxidized
Deoxidized steel: Oxide flakes of calcium
boundary. Such steel is very weak and brittle. y Effect
Eff t off boron
b i
is negligible.
li ibl O
Oxygen i
improve
silicates are formed. Reduce friction, tool temp, crater machinability. Nitrogen and Hydrogen reduce
y Tellurium and selenium is similar to sulfur.
sulfur wear specially at high speed.
speed machinability.
292 293 294
For IES Only For IES Only
IES 2011 Conventionall Role of microstructure on Machinability IES – 1992

y Discuss the effects of the following elements on the 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
machinability of steels: ((a)) Grain size of the metal is large
g
(i) Aluminium and silicon Therefore, τs can be desirably reduced by (b) Grain size of the metal is small
(ii) Sulphur and Selenium 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
(iii) Lead and Tin y Controlled addition of materials like sulphur
p ((S), lead
), of the tool material
(iv) Carbon and Manganese (Pb), Tellerium etc leading to free cutting of soft ductile (d) None of the above
(v) Molybdenum and Vanadium [5 Marks] metals and alloys.
metals and alloys
y Brittle materials are relatively more machinable.

Page 34 of 186 296
Rev.0 297
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
298 299 300
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)
f2 (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.
301 302 303
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
Page 35 of 186 305
Rev.0 306
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
307 308
(c) 1 and 2 (d) 3 and 4 309
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
l h improves 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.
310 311 312
For IES Only
IES – 1992 IES – 2013 Conventional IES ‐1995

Machining of titanium is difficult due to Why does titanium have poor machinability? Consider the following work materials:
1 Titanium
1. 2
2. Mild steel
(a) High thermal conductivity of titanium
3. Stainless steel 4. Grey cast iron.
(b) Chemical reaction between tool and work The correct sequence of these materials in terms of
increasing order of difficulty in machining is
( ) Low tool‐chip contact area
(c)
(a) 4, 2, 3, 1 (b) 4, 2, 1, 3
(d) None of the above
N f h b (c) 2, 4, 3, 1 (d) 2, 4, 1, 3

Page 36 of 186 314
Rev.0 315
Surface Roughness IES ‐ 2002 IAS ‐ 1996
y Ideal Surface ( Zero nose radius) The
Th value
l off surface
f roughness
h 'h' obtained
b i d during
d i Given
Gi that
h
the turning operating at a feed 'f' with a round nose /
S = feed in mm/rev. and
f tool having radius 'r' is given as
Peak to valley roughness (h) = R = nose radius in mm,
tan SCEA + cot ECEA
the
h maximum i h i h off surface
height f roughness
h Hmax
h f
and (Ra) = = produced by a single‐point turning tool is given by
4 4 ( tan SCEA + cot ECEA ) (a) S2/2R
y Practical Surface ( with nose radius = R)
(b) S2/4R
/ R
f2 f2
h= and Ra = 2
(c) S /4R
8R 18 3R (d) S2/8R
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.
316 317 318
IES ‐ 1999 GATE ‐ 1997 GATE – 2007 (PI)

( )
In turning operation, the feed could be doubled to 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 l off 30o and
Ed angle d
increase the
h metall removall rate. To keep
k the
h same f μ
for a theoretical surface roughness of is 5 m is
h l f h f End Cutting Edge angle of 10o is used for fine
level of surface finish,
finish the nose radius of the tool ( ) 0.268 mm/rev
(a) 68 / turning with a feed of 1 mm/rev.
mm/rev Neglecting nose
should be (b) 0.187 mm/rev
8 / radius of the tool,
tool the maximum (peak to valley)
((a)) Halved ((b)) Kept
p unchanged
g (c) 0.036 mm/rev
0 036 mm/rev height of surface roughness produced will be
((c)) doubled ((d)) Made four times (d) 0.0187 mm/rev
0 0187 mm/rev
(a) 0.16 mm (b) 0.26 mm
319 320 (c) 0.32 mm (d) 0.48 mm 321
GATE ‐ 2005 IES – 1993, ISRO‐2008 IES ‐ 2006

Two
T tools
l P and d Q have
h signatures
i 5°‐5°‐6°‐6°‐8°‐30°‐
° ° 6° 6° 8° ° For achieving a specific surface finish in single point In the selection of optimal cutting conditions, the
0 and 5°‐5°‐7°‐7°‐8°‐15°‐0 (both ASA) respectively.
They are used to turn components under the same 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
machining g conditions. If hp and hQ denote the p peak‐ is which of the following?
to‐valley heights of surfaces produced by the tools P
and Q,
Q the ratio hp/hQ will be (a) Depth of cut (b) Cutting speed (a) The maximum feed
o o o o
tan 8 + cot15 tan15 + cot 8 (c) Feed (d) Tool rake angle (b) The maximum depth of cut
(a) (b)
tan 8o + cot 30o tan 30o + cot 8o (c) The maximum speed
tan15o + cot7o tan7o + cot15o
(c ) (d ) ((d)) The maximum number of p
passes
tan 30o + cot7o tan7o + cot 30o
Page 37 of 186 323
Rev.0 324
GATE‐2014 (PI)
( ) GATE ‐2010 (PI)
GATE ‐2010 (PI) Cutting fluid
Cutting fluid
During turning of a low carbon steel bar with TiN coated y The cutting fluid acts primarily as a coolant and
A spindle
i dl speed d off 300 rpm and d a feed
f d off 0.3 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
mm/revolution are chosen for longitudinal turning the tool‐chip interface and the work‐blank regions.
operation on an engine lathe. In finishing pass, without sacrificing material removal rate.
rate To achieve
y Cast Iron: Machined dry or compressed air, Soluble oil
roughness
g on the work surface can be reduced byy improved surface finish, one should for high speed machining and grinding
(a) reducing the spindle speed (a) decrease nose radius of the cutting tool and increase y Brass: Machined dry or straight mineral oil with or
(b) increasing the
h spindle
dl speedd d h off cut
depth without
ih EPA
EPA.
(c) reducing
educ g tthee feed
eed o
of too
tool (b) Increase nose radius of the cutting tool y Aluminium: Machined dry y or kerosene oil mixed with
(d) increasing the feed of tool mineral oil or soluble oil
(c) Increase feed and decrease nose radius of the cutting
g
y Stainless steel and Heat resistant alloy: High
tool performance soluble oil or neat oil with high
(d) Increase depth of cut and increase feed concentration
i with i h chlorinated
hl i d EP additive.
ddi i
325 326 327
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
328 329 330

Page 38 of 186 Rev.0
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....
y Limits of sizes: There are two extreme permissible
IAS 2014 (Main)
IAS 2014 (Main) y No a ssize:
Nominal e: S
Sizee o
of a pa
partt spec ed in tthee d
specified
It is used for general identification purpose.
aw g.
drawing.
sizes for a dimension of the part. The largest
A
According
di to the
h ISO system, sketch
k h the
h basic
b i size,
i permissible size for a dimension is called upper or high
y Basic size: Size of a part to which all limits of
deviation, and tolerance on a shaft and hole variation ((i.e. tolerances)) are applied.
pp Basic dimension or maximum limit, whereas the smallest size is known
assembly. is theoretical dimension. as lower or minimum limit.
y Tolerance
y Actual size: Actual measured dimension of the part.
The difference between the basic size and the actual ¾The difference between the upper limit and lower
size should not exceed a certain limit, otherwise it will limit.
interfere with the interchangeability of the mating ¾It is the maximum permissible variation in a
parts. dimension.
¾The tolerance may be unilateral or bilateral.
4 5 6
Terminology
e o ogy Contd.... Terminology
Terminology Contd
Contd....
Unilateral Limits occurs when both maximum limit and
minimum limit are either above or below the basic size. For Unilateral Limits,
Limits a case may occur when one of the For PSU
For PSU
limits coincides with the basic size,
e.g. Ø25 +0.18
+0 18 Tolerances are specified
+0.10 e.g. Ø25 +0.20 , Ø25 0 (a) To obtain desired fits
Basic Size = 25.00
25 00 mm 0 ‐0.10
0.10
Upper Limit = 25.18 mm (b) because it is not possible to manufacture a size
Lower Limit = 25.10 mm Bilateral Limits occur when the maximum limit is above exactlyy
Tolerance = 0.08 mm and the minimum limit is below the basic size. (c) to obtain higher accuracy
e g Ø25 -00.10
e.g. 10
(d) to have proper allowances
h ll
-0.20
e.g. Ø25 ±0.04
Basic Size = 25.00 mm Basic Size = 25.00
25 00 mm
Upper Limit = 24.90 mm
Lower Limit = 24.80 mm
Upper Limit = 25.04 mm
Tolerance = 0.10 mm L
Lower Li it = 24.96
Limit 6 mm
For-2017 (IES, GATE & PSUs) 7 Tolerance
Page 39 of 186 = 0.08 mm 8
Rev.0 9
Terminology
Terminology C td
Contd.... Terminology
Terminology C td
Contd....
y Zero line: A straight
g line corresponding
p g to the basic
ISRO‐2010 y Lower deviation: Is the algebraic difference between
size. The deviations are measured from this line.
E
Expressing i as 25.3 ±0.05 mm is
i a dimension
di i the
th case the minimum size and the basic size.
y Deviation: Is the algebraic difference between a size
of y Mean deviation: Is the arithmetical mean of upper
pp
(actual, max. etc.) and the corresponding basic size.
(a) Unilateral tolerance and lower deviations.
y Actual deviation: Is the algebraic difference between
((b)) Bilateral tolerance 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
((c)) Limiting
g dimensions
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.
(d) All of the above the maximum size and the basic size.
size
10 11 12
GATE – 2010, ISRO‐2012 GATE ‐ 1992 GATE ‐ 2004

−0.009 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
A shaft has a dimension,, φ35 mm 100 ± 0.1 mm and 0.1 ± 0.0001 mm respectively.
−0.025
0 025 Which of the following statements is/are true? 25.000
+0.040
25.000
+0.020
The respective values of fundamental deviation and −0.0100 mm mate with holes of size −0.000
tolerance are (a) Tolerance in the dimension is greater in shaft A mm.
( ) − 0.025, ± 0.008
(a) ( ) − 0.025,0.016
(b) (b) The relative error in the dimension is greater in shaft The maximum p possible clearance in the assembly
y
A
(c) − 0.009, ± 0.008 (d) − 0.009,0.016 will be
(c) Tolerance in the dimension is greater in shaft B ( ) 10 microns
(a) i (b) 20 microns
i
(d) The relative error in the dimension is same for shaft (c) 30 microns (d) 60 microns
A and shaft B
d h f
13 14 15
Clearance Fits
IES ‐ 2005 Fit
The
Th tolerance
t l specified
ifi d by
b theth designer
d i for
f the
th
Hole
diameter of a shaft is 20.00 ± 0.025 mm. The shafts Fits: (assembly condition between “Hole” & “Shaft”)
produced
d d by
b three
th diff
different t machines
hi A B and
A, d C Max C
T l
Tolerance zones never meet

have mean diameters of 19∙99 mm, 20∙00 mm and Hole – A feature engulfing a component Min C
20.01 mm respectively,ti l with

ith same standard
t d d Shaft – A feature being engulfed by a Shaft
deviation. What will be the percentage rejection for component
p
th shafts
the h ft produced
d d by
b machines
hi A B and
A, d C?
(a) Same for the machines A, Band C since the standard
deviation is same for the three machines
(b) Least for machine A Max. C = UL of hole - LL of shaft
Min. C = LL of hole - UL of shaft
(c) Least for machine B
(d) Least
L t forf machine
hi C The clearance fits may be slide fit, easy sliding fit, running
Th l fit b lid fit lidi fit i
Page 40 of 186 17 fit, slack running fit and loose running fit.Rev.0 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 Interference Fits

Hole
IES 2015
IES‐2015 Hole Tolerance zones never meet
Consider the following statements but crosses each other
Max C Max I
Tolerance zones always
overlap
In case of assemblyy of mating
gpparts
Shaft Shaft Min I
Max I 1. The difference between hole size and shaft size is called
allowance.
2. In transition fit, small positive or negative clearance
b
between the
h shaft
h f and
d hole
h l member
b isi employable
l bl
Max. C = UL of hole - LL of shaft Max. I = LL of hole - UL of shaft
Max. I = LL of hole - UL of shaft Which of the above statements is/are correct? Min I = UL of hole - LL of shaft
Min.
The transition fits may be tight fit and push fit, wringing ((a)) 1 onlyy ((b)) Both 1 and 2 The interference fits may be shrink fit, heavy drive fit and

The interference fits may be shrink fit heavy drive fit and
fit (Gear, pulley on shaft), press fit. light drive fit.
22 (c) 2 only (d) Neither 1 nor 2 23 24
IES 2011 IES‐2013 GATE ‐ 2005

Interference fit joints are provided for: Which of the following is a joint formed by In order to have interference fit, it is essential that
i t f
interference fit ?
fits? the
h lower
l l
limit off the
h shaft
h f should
h ld be
b
(a) Assembling bush bearing in housing
(a) Joint of cycle axle and its bearing ( ) Greater
(a) G than
h the
h upper limit
li i off the
h hole
h l
(b) Mounting heavy duty gears on shafts
(b) Joint between I.C.
I C Engine piston and cylinder (b) Lesser
L th the
than th upper limit
li it off the
th hole
h l
(c) Mounting pulley on shafts
(c) Joint between a pulley and shaft transmitting power (c) Greater than the lower limit of the hole
(d) Assembly of flywheels on shafts
(d) Joint of lathe spindle and its bearing (d) Lesser than the lower limit of the hole

Page 41 of 186 26
Rev.0 27
IES ‐ 2014
IES
Statement‐I: In interference fit, the outer diameter IES‐2015 GATE 2011
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 +0.015
diameter of the hollow outer cylinder the shaft is greater than the inner diameter of the hole.
St t
Statement‐II:
t II These
Th fit are recommended
fits d d for
f two
t A hole is of dimension φ 9 +0
mm The
mm.
Statement (II) : The amount of clearance obtained from
parts frequently dismantled and assembled. +0.010
the assemblyy of hole and shaft resulting g in interference fit
(a) Both Statement (I) and Statement (II) are is called positive clearance. corresponding shaft is of dimension φ9 +0.001
mm.
individuallyy true and Statement (II) is the correct (a) Both statement (I) and (II) are individually true and The resultingg assemblyy has
explanation of Statement (I)
statement (II) is the correct explanation of statement (I) (a) loose running fit
(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 (b) close
l running
i fit
fi
true but statement(II) is not the correct explanation of (c) transition
a s o fit
statement (I)
()
(c) Statement (I) is true but Statement (II) is false (d) interference fit
(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
IAS 2011 Main

IAS‐2011 Main IES ‐ 2007
GATE ‐2012 Same Q in GATE‐2012 (PI) te e e ce asse
An interference b y, o
assembly, o a d
of nominal a ete 20
diameter 0 mm,,
is of a unilateral holes and a shafts. The manufacturing
In an interchangeable assembly,
assembly shafts of size 25+−0.04
0.01 tolerances for the holes are twice that for the shaft.
shaft
Permitted interference values are 0.03 to 0.09 mm.
mm mate with holes of size 25++0.03
0 03
0.02
mm. D t
Determine
parts.
i th sizes,
the i with
ith limits,
li it for
f the
th two
t mating
ti
[10‐Marks]
The maximum interference (in microns) in the assembly

is
(a) 4
40 ((b)) 330 (c) 20 (d) 10 Hint: Use unilateral hole basis system.
31 32 33
IES ‐ 2006 IES ‐ 2009

ISRO‐2011 Which of the following is an interference fit? Consider
C id the
h following
f ll i joints:
j i
A shaft and hole pair is designated as 50H7d8
A shaft and hole pair is designated as 50H7d8. 1. Railwayy carriageg wheel and axle
(a) Push fit 2. IC engine cylinder and liner
This assembly constitutes
y
(b) Running fit Whi h off the
Which h above
b j i
joints i /
is/are the
h result(s)
l ( ) off
(a) Interference fit interference fit?
( ) Sliding fit
(c) (a) 1 only
(b) Transition fit
(d) Shrink
Sh i k fit
fi (b) 2 only
l
(c) Clearance fit
(c) Neither 1 nor 2
(d) None of the above (d) Both 1 and 2

Page 42 of 186 35
Rev.0 36
IES ‐ 2008 IES 2015
IES‐2015 IES ‐ 2004
Consider
f ll i statements: 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
g
1. The amount of interference needed to create a tight of stress in the shaft due to interference fit is 1. I.C. engine
g cylinder
y and p
piston
joint varies with diameter of the shaft. 2. Ball bearing outer race and housing
2 An interference fit creates no stress state in the
2. a)) onlyy compressive
p radial stress
3. Ball
B ll bearing
b i inner
i race and
d shaft
h f
shaft. b)a tensile radial stress and a compressive tangential stress Which of the above fits are based on the interference
3. The stress state in the hub is similar to a thick‐ c) a tensile tangential stress and a compressive radial stress system?
walled
a ed cy
cylinder
de witht internal
te a p pressure.
essu e. ( ) 1 and
(a) d2
Which of the statements given above are correct? d)a compressive tangential stress and a compressive radial
(b) 2 and 3
( ) 1, 2 and
(a) d3 (b) 1 and d 2 only
l stress (c) 1 and 3
(c) 2 and 3 only (d) 1 and 3 only (d) 1, 2 and
d3
37 38 39
Allowance GATE ‐ 2001

y It is Minimum clearance or maximum interference. It is
IES‐2015 Conventional the intentional difference between the basic Allowance in limits and fits refers to
dimensions of the mating
gpparts. The allowance mayy be
Wh t th diff
What are the different types of fits possible with
t t f fit ibl ith (a) Maximum clearance between shaft and hole
positive or negative.
reference to mechanical systems?
(b) Minimum clearance between shaft and hole
[4 Marks]
( ) Difference between maximum and minimum size of
(c)
hole
(d) Difference between maximum and minimum size of

shaft
40 41 42
GATE ‐ 1998 IES ‐ 2012 IES – 2012 Conventionall

In the specification of dimensions and fits, Clearance in a fit is the difference between Explain the difference between tolerance and
(a) Allowance is equal to bilateral tolerance (a) Maximum hole size and minimum shaft size allowance.
(b) Allowance is equal to unilateral tolerance (b) Minimum hole size and maximum shaft size
( ) Allowance is independent of tolerance

(c) ( ) Maximum hole size and maximum shaft size
(c)
(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
maximum and minimum dimension specified by the
tolerance.

Page 43 of 186 44
Rev.0 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
ISRO‐2008 Assertion
A i (A):
(A) Hole
H l basisb i system isi generallyll IAS‐2010 main
IAS‐2010 main
preferred to shaft basis system in tolerance design
B i shaft
Basic h ft and
d basic
b i hole
h l are those
th whose
h upper What is the difference between hole basis system and
for getting the required fits.
deviations and lower deviations respectively are Reason (R): Hole has to be given a larger tolerance shaft basis system
y ? Whyy is hole basis system
y the more
band than the mating shaft. extensive in use ?
(a) +ve, ‐ve
ve (b) ‐ve,
ve, +ve
( ) Both
d d ll true and
d R is the
h
((c)) Zero,, Zero ((d)) None of the above correct explanation of A
(b) Both A and R are individually true but R is not the [8‐Marks]
Page 44 of 186 53
Rev.0 54
IFS ‐ 2013 IES ‐ 2005 Tolerance Zone
µ
µm
Explain, with the help of sketches, the concepts of Which
f ll i is i not correct in i hole
h l basis
b i
system of fits?
• It is defined graphically
h l basis
hole b and
d shaft
h f basis
b in terms off assembly
bl fit
f (a) The hole size is kept constant.
55
by the magnitude of the
specifications Which of the two is preferred and
specifications. (b) The basic size of the hole is taken as the low limit of Tolerance Zone tolerance and by its
20 position in relation to the
size of the hole.
why? zero line.
(c) The actual size of a hole that is within the tolerance
[
[8 –Marks]
] limitsts aalways
ays less
ess tthan
a tthee bas
basicc ssize.
e.
Basic Size
(d) The high limit of the size of the hole and the two limits
off size
i off the
th shaft
h ft are selected
l t d tot givei desired
d i d fit.
fit
55 56 57
Limits and Fits

Limits and Fits Diameter Steps
Diameter Steps
y Limits and fits comprises 18 grades of fundamental Tolerance Designation (IS) Above Upto and including
tolerances for both shaft and hole, designated as IT01, Tolerance on a shaft or a hole can be calculated by using (mm)
( ) (mm)
( )
IT0 and IT1 to IT16. These are called standard table provided.
provided ‐ ‐ 3
tolerances. (IS‐919) But ISO 286 specify 20 grades upto 3 ‐ 6
T = K ×i
IT18 6 ‐
6 10
y There are 25 (IS 919) and 28 (ISO 286) types of Where, T is the tolerance (in µm) 10 ‐ 18
fundamental deviations.
deviations Standard Tolerance unit or Fundamental tolerance unit 188 ‐ 30
30 ‐ 50
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 550 ‐ 80
R S,
R, S T,
T U,U V,
V X,
X Y,Y Z,
Z ZA,
ZA ZB,
ZB ZC.ZC 80 ‐ 120
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 120 ‐ 180
u, v, x, y, z, za, zb, zc. the beginning and the end of a range of 180 ‐ 250
y A unilateral hole basis systemy is recommended but if sizes,, in mm)) 250 ‐ 315
necessary a unilateral or bilateral shaft basis system may K = is a constant [For IT6 to IT16] 315 ‐ 400
58 400 ‐ 500 60
also be used
Value of the Tolerance Fundamental Deviation

IT01 IT0 IT1 IT2 is chosen to locate the tolerance zone w.r.t. the zero line
0.3 + 0.008D 0.5 + 0.012D 0.8 + 0.02D ar Grades of Tolerance

=a r = 101/5 Holes are designated by capital letter:
y It is an indication of the level of accuracy.
IT3
3 IT4 IT5
5 IT6
6
Letters A to G - oversized holes
Letters P to ZC - undersized holes
ar2 ar3 ar4 = 7i 10(1.6)(ITn -IT6) y IT01 to IT4 ‐ For production of gauges, plug gauges,
= 10i
measuring
i instruments
i
IT7 IT8 IT9 IT10
10(1.6)
( )(ITn -IT6) 10(1.6)
0( 6)(IT n
-IT6)
10(1 6)((ITn -IT6))
10(1.6) 10(1.6)
10(1 6)(ITn -IT6)
IT6)
y IT5
IT to
t IT 7 ‐ For
F fits
fit in
i precision
i i engineering
i i applications
li ti
= 16i = 25i = 40i = 64i Shafts are designated by small letter:
Letters m to zc - oversized shafts
IT11 IT12 IT13 IT14 y IT8 to IT11 – For General Engineering Letters a to g - undersized shafts
10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6) H is used for holes and h is used for shafts
= 100i = 160i = 250i = 400i
y IT12 to IT14 – For Sheet metal working or press working whose fundamental deviation is zero
IT15 IT16 y IT15 to IT16 – For processes like casting,

casting general cutting
10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6)
= 640i For-2017
= 1000i
(IES, GATE & PSUs) 61
workPage 45 of 186 62
Rev.0 63
Shaft Fundamental Deviation
j5 to j8 −
Shaft Fundamental Deviation k4 to
t k7 + 0.6
0 63 D
Calculation for Upper and Lower Deviation m + ( IT 7 − IT 6)
a − (265 + 1.3D ) for D ≤ 120 mm
y For Shaft n + 5D 0.34
0 34
− 3.5D for D > 120 mm p + IT 7 + (0 − 5)

ei = es – IT
b − (140 + 0.85
0 85D ) for D ≤ 160 mm r Geometric mean of values of
es = ei + IT −1.8 D for D > 160 mm ei for p and s
s IT 8 + 1 to 4 for D ≤ 50 mm
y For Hole
F H l c − 52D 0.2 for D ≤ 40 mm IT 7 + 0.4 D for D > 50 mm
EI = ES – IT t IT 7 + 0.63
0 63D
− (95 + 0.8
0 8D ) f D > 40 mm
for
ES = EI + IT u IT 7 + D
d − 16 D 0.44 v IT 7 + 1.25D
0.41 x IT 7 + 1.6 D
e − 11D
es = upper deviation of shaft
pp y IT 7 + 2D
ei = lower deviation of shaft f − 5.5D 0.41 z IT 7 + 2.5D
za IT 8 + 3.15D
ES = upper deviation of hole g 2 5D 0.41
− 2.5
zb IT 9 + 4 D
EI= lower deviation of hole 64 h 0 65
zc IT 10 + 5D 66
y For hole, H stands for a dimension whose lower

GATE 2014
GATE‐2014 IES ‐ 2008
g y 5 g p
For the given assembly: 25 H7/g8, match Group A with
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 Group B Consider
C id theh following
f ll i statements:
the lower deviation is zero is called a basic hole. Group A
p Group B
p A nomenclature φ 550 H8/p8 /p denotes that
y Similarly, for shafts, h stands for a dimension whose
upper deviation refers to the basic size. The shaft h for 1. Hole diameter is 50 mm.
P. H I. Shaft Type
which the upper deviation is zero is called a basic 2. ItI is
i a shaft
h f base
b system.
shaft. Q. IT8 II. Hole Type
33. 8 indicates fundamental deviation.
y A fit is designated by its basic size followed by symbols R. IT7 III. Hole Tolerance Grade Which of the statements given above is/are incorrect?
representing the limits of each of its two components, S
S. g IV Sh ft T l
IV. Shaft Tolerance Grade
G d
the hole being quoted first. ( ) 1, 2 and
(a) d3
y For example,
example 100 H6/g5 means basic size is 100 mm P Q R S P Q R S (b) 1 and 2 only
and the tolerance grade for the hole is 6 and for the (a) I III IV II (b) I IV III II (c) 1 and 3 only
shaft is 5.
5 ( ) 3 only
(d)
(c) II III IV I (d) II IV III I
67 68 69
IES‐2006 Conventional IES‐2015 Conventional IES ‐ 2002

Find
Fi d the
h limit
li i sizes,
i tolerances
l and
d allowances
ll for
f a Determine the fundamental deviation and tolerances and the In
I the
h tolerance
l specification
ifi i 25 D 6,
6 the
h letter
l D
100 mm diameter shaft and hole pair designated by represents
F8h10. Also specify the type of fit that the above pair 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
(a) Grade of tolerance
belongsg to. The diameter steps are 18 mm and 30 mm. The fundamental (b) Upper deviation
Given: 100 mm diameter lies in the diameter step deviation for d shaft is given as ‐16D0.44. The tolerance unit is, (c) Lower deviation
range of 80‐120
80 120 mm.
mm The fundamental deviation for
shaft designation ‘f’ is ‐5.5 D0.41 i = 0.45 3 D + 0.001D (d) Type of fit
The values of standard tolerances for grades of IT 8 The tolerance grade for number 8 quality is 25i and for 9
and IT 10 are 25i and 64i respectively.
quality is 40i.
Also, indicate the limits and tolerance on a diagram.
[ M k ]
[15‐Marks] [ M k ]
[10 Marks]
Page 46 of 186 71
Rev.0 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
Whi h one off theh following
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)

Page 47 of 186 80
Rev.0 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
IES 2010 Conventional
IES 2010 Conventional IAS‐2010 main
IAS‐2010 main y A design engineer keeps one section of the part blank
What is meant by interchangeable manufacture ? What are the differences between interchangeability
(without tolerance) so that production engineer can
and selective assemblyy ?
d
dump all
ll the
h tolerances
l on that
h section
i which
hi h becomes
b
[4‐Marks]
most inaccurate dimension of the part.
part
y Position of sink can be changing the reference point.

point
y Tolerance for the sink is the cumulative sum of all the

tolerances and only like minded tolerances can be added
85 86 i.e. either equally bilateral or equally unilateral. 87
GATE ‐ 2003 GATE ‐ 1997 GATE 2015

GATE-2015
In the assembly shown below, the part dimensions are:
Three
Th blocks
bl k B1 , B2 andd B3 are
to be inserted in a channel of ±0.01
L 1 = 22.0 mm
width S maintaining a
minimum gap of width T = ±0.005
0 125 mm,
0.125 mm as shown in Figure.
Figure L2 = L3 = 10.0
10 0 mm
For P = 18. 75 ± 0.08;
Q = 25.00 ± 0.12; Assuming normal distribution of part dimensions
Assuming normal distribution of part dimensions,
R = 28.125 ± 0.1 and the dimension L4 in mm,
S = 72.35 + X, (where all a) 2.00±0.008 b) 2.00±0.012
dimensions are in mm), the
±0 016
±0.016
tolerance
l X is c) 2.00
) d) 2.00±0.020
d) ±0 020
((a) + 0.38
) 3 ((b) ‐
) 0.38
3 ((c) + 0.05
) 5 ((d) ‐0.05
) 5

Page 48 of 186 89
Rev.0 90
GATE 2007(PI)
GATE ‐2007(PI) GATE – 2007 (PI)
( ) GATE‐2013
The geometric tolerance that does NOT need a datum
for its specification is Diameter of a hole after plating needs to be controlled Cylindrical pins of 25++0.020
0.010 mm diameter are
between 30++0.050
0.010 mm. If the plating thickness varies electroplated in a shop. Thickness of the
((a)) Concentricityy ((b)) Runout
between 10 - 15 microns, diameter of the hole before plating is 30 ±2.0 micron. Neglecting gage
((c)) Perpendicularity
p y ((d)) Flatness
plating
l i should
h ld be
b tolerances, the size of the GO gage in mm
(a) 30++0.070
0.030 mm (b) 30++0.020
0.065
mm tto iinspectt the
th plated
l t d components
t iis
+0.080 +0.070
(c) 30 +0.030 mm (d) 30 +0.040 mm (a) 2525.042
042 (b) 25.052
25 052 (c) 25
25.074
074 (d) 25.084
25 084
91 92 93
GATE ‐ 2000 Limit Gauges

Limit Gauges
A slot
l isi to be
b milled
ill d centrally
ll on a block
bl k with
ih a 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
dimension of 40 ± 0.05 mm. A milling cutter of 20 Plug gauges are used to
gauge corresponds to the high limit of the hole.
hole
mm width is located with reference to the side of
y Snap, Gap or Ring gauge: used for gauging the shaft and (a) Measure the diameter of the workpieces
the block within ± 0.02 mm. The maximum offset in
male
l components. The Th Go G snap gauge is i off a size
i (b) Measure the diameter of the holes in the
mm between the centre lines of the slot and the corresponding to the high (maximum) limit of the shaft,
block is workpieces
p
while
hil theh NOT GO gauge corresponds d to theh low
l
(a) ± 0.070 (b) 0.070 (minimum limit). (c) Check the diameter of the holes in the
workpieces
(c) ± 0.020 (d) 0.045
(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
Page 49 of 186 −0.004 98
Rev.0−0.002
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
A ringi gauge is i used d to measure This principle states that the GO gauge should always be
((a)) Outside diameter but not roundness Discuss a Go gauge.
Discuss a ‘Go’ gauge.
so designed
d d that
h it will
ll cover the
h maximum metall
(b) Roundness but not outside diameter
( ) Both
(c) B h outside
id diameter
di and
d roundness
d condition (MMC) of as many dimensions as possible in
((d)) Onlyy external threads the same limit gauges, whereas a NOT GO gauges to
cover the minimum metal condition of one dimension
only.

Page 50 of 186 107
Rev.0 108
Limit Gauges Feeler Gauge
Gauge For Measuring PSU
Snap Gauge External Dimensions A f l
A feeler gauge is used to check the
i d t h k th
Plug Gauge
g g Internal Dimensions
(a) Pitch of the screw
Taper Plug Gauge Taper hole
(b) Surface roughness
Ring Gauge External Diameter
G G
Gap Gauge G d G
Gaps and Grooves (c) Thickness of clearance
Radius Gauge Gauging radius (d) Flatness of a surface

Thread pitch Gauge
p g External Thread
109 110 111
GATE‐2016 Why is a unilateral tolerance
Why is a unilateral tolerance
Match the following: preferred over bilateral tolerance ?
preferred over bilateral tolerance ? IES 2010(Conv) IAS‐2014 (Main)
IES 2010(Conv) IAS‐2014 (Main)
P. Feeler gauge
P Feeler gauge II. Radius of an object
Radius of an object y This system is preferred for Interchangeable manufacturing.
manufacturing Why is a unilateral tolerance preferred over bilateral
tolerance ?
Q. Fillet gauge II. Diameter within limits by
y It is easy and simple to determine deviations.
deviations
comparison
R. Snap gauge III. Clearance or gap between y It helps
p standardize the GO g
gauge
g end
components
y Helpful for operator because he has to machine the upper
S. Cylindrical plug
S C li d i l l IV I id di
IV. Inside diameter of
t f straight
t i ht
gauge hole limit of the shaft and the lower limit of the hole knowing
fully well that still some margin is left for machining before
(a) P‐III, Q‐I, R‐II, S‐IV (b) P‐III, Q‐II, R‐I, S‐IV
the part is rejected.
rejected
(c) P‐IV, Q‐II, R‐I, S‐III (d) P‐IV, Q‐I, R‐II, S‐III 112 113 114
Preferred Number
Preferred Number Preferred Number Contd.
Preferred Number ….. C td
y A designed product needs standardization. y These are named as Renard series.
y Motor speed, engine power, machine tool speed and y Many other derived series are formed by multiplying or
IES‐2013 conventional
IES‐2013 conventional
feed, all follows a definite pattern or series. dividing the basic series by 10, 100 etc. W it the
Write th amountt off allowance
ll and
d tolerance
t l
y This also helps in interchangeability of products. y Typical values of the common ratio for four basic G.P.
series
i are given
i b l
below. that is permitted by the following classes of fit
y It has been observed that if the sizes are put in the form
of g
geometric pprogression,
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,.... as p
per ANSI class 4 : Snug
g fit and class 7
:1 0 1 25 1 6 ( 10, 1000 )
10 10 10
:Medium force fit. Also mention applications.
y These numbers are called preferred numbers having R10 : 1.26
1 26 :1.0,1.25,1.6,... 10 100,
100 1000,....
common ratios as,
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
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
formed; these are R5 , R10 , R20 and R40

Page 51 of 186 116
Rev.0 117
Snug fit
e ca Sta da d ssoc at o o e a ce Syste
American Standard Association Tolerance System 1/3
1. Heavy force shrunk fit Tolerance = 0.0004D and Deviation = 0
2. M di f
Medium force fit
fi Medium force fit :
3. Tight fit 1/3 1/3
Tolerance = 0.0006D
0 0006D De iation = 0.0005
and Deviation 0 0005D − 0
0.0006
0006 D
4. Wringing fit Measurement of Lines & Surfaces
5
5. Snug fit y Snug fit is applicable where no shake is permissible
S fi i li bl h h k i i ibl
6. Medium fit y Medium force fit is applicable for shrink fit on cast iron
7. Free fit
8. Loose fit
118 119 By S K Mondal 120
Accuracy & Precision

Accuracy & Precision Repeatability
y Accuracy ‐ The ability of a measurement to match the actual y It is the ability of a measuring system to reproduce
(true) value of the quantity being measured. The expected output readings when the same input is applied to it
ability for a system to discriminate between two settings.settings consecutively,
i l under
d theh same conditions,
di i and
d in
i the h
Smaller the bias more accurate the data.
same direction.
y P i i
Precision ‐ The
Th precision
i i off an instrument
i i di
indicates i
its
ability to reproduce a certain reading with a given accuracy
y Imperfections in mechanical systems can mean that
‘OR’ it
i is
i the
h degree
d off agreement between
b repeated d results.
l during a Mechanical cycle,
cycle a process does not stop at the
same location, or move through the same spot each
y Precision data have small dispersion
p ( spread
p or scatter ) but
may be far from the true value. ti
time. Th variation
The i ti range is
i referred
f d to
t as repeatability.
t bilit
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
and precise. 121 122 123
Reliability of measurement
Reliability of measurement Calibration y Drift: It is a slow change of a metrological characteristics of a
y It is a quantitative characteristic which implies
y It
I is
i the
h setting
i or correcting
i off a measuring
i device
d i measuring instruments
confidence in the measured results depending on
whether or not the frequency
q y distribution usually by adjusting it to match or conform to a y Resolution: It is the smallest change of the measured
characteristics of their deviations from the true values dependably known value or act of checking. quantity
tit which
hi h changes
h th indication
the i di ti off a measuring
i
of the corresponding
p g q
quantities are known. It is the instruments
y Calibration determines the performance characteristics
probability that the results will be predicted. 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
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 It is very widely used in industries. y Rule of 10 or Ten‐to one rule: That the discrimination
y A calibration certificate is issued and,
and mostly,
mostly a sticker is (resolutions) of the measuring instrument should divide the
Which of these targets represents A change in one variable, such as wind,
accurate shooting? Precise alters the results as shown. Dose this provided for the instrument. tolerance of the characteristic to be measured into ten parts.
shooting?
h ti ? Reliable
R li bl shooting?
h ti ? show
h which
hi h shooting
h ti was the
th mostt In other words,
words the gauge or measuring instrument should be
reliable? 10 times as accurate as the characteristic to be measured. 126
Page 52 of 186 125
Rev.0
Errors Linear measurements Vernier Caliper
y A vernier scale is an auxiliary scale that slides along the main
y Systematic
S i errors or fixed
fi d errors (Bias):
(Bi ) Due
D to faulty
f l 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
or improperly calibrated instruments.
instruments These may be
y Rules (Scale) the vernier scale is equal in length to a different number
reduced or eliminated byy correct choice of instruments. y Vernier (usually one less) of main
main‐scale
scale divisions.
divisions
y Micrometer (Most widely used, Working Standard) nV = (n −1)S
Eg.
g calibration errors, Errors of technique
q etc.
where
h n = number
b off divisions
d on the
h vernier scale
l
y Height gauge
y Random errors: Random errors are due to non‐specific V = The length
g of one division on the vernier scale
y Bore
B gauge
cause like natural disturbances that may occur during 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
the experiment. These cannot be eliminated. y Slip gauges or gauge blocks (Most accurate, End directly by use of a vernier scale.
Eg. Errors stemming from environmental variations, Due
E E i f i l i i D Standard) y Least count = S − V = 1 S
n
to Insufficient sensitivity of measuring system 127 128 129
ISRO‐2010
The
Th vernier
i reading
di should
h ld not be
b taken
k at its
i face
f ISRO‐2008
value before an actual check has been taken for Th least
The l t countt off a metric
t i vernier
i caliper
li
(a) Zero error having 25 divisions on vernier scale, matching
(b) Its calibration with 24

4 divisions of main scale ((1 main scale
divisions = 0.5 mm) is
((c)) Flatness of measuring
g jjaws
(a) 0.005 mm (b) 0.01 mm
((d)) Temperature
p equalization
q
(c) 0.02 mm (d) 0.005mm
Vernier Caliper
130 131 132
M t i Mi t
Metric Micrometer
y A micrometer allows a measurement of the size of a ISRO‐2009, 2011
ISRO‐2009 2011
body. It is one of the most accurate mechanical devices I a simple
In i l micrometer
i t with
ith screw pitch
it h 0.5
in common use. mm and divisions on thimble 50, the reading
y It consists a main scale and a thimble corresponding
p g to 5 divisions on barrel and 12
Method of Measurement divisions on thimble is
Step‐I: Find the whole number of mm in the barrel (a) 2.620 mm (b) 2.512 mm
Step‐I: Find the reading of barrel and multiply by 0.01 Micrometer (c) 2.120 mm (d) 5.012 mm
Step‐III: Add the value in Step‐I and Step‐II

Page 53 of 186 134
Rev.0 135
y Bore Gauge: used for measuring bores of different y Dial indicator: Converts a linear
g g from small‐to‐large
sizes ranging g sizes. displacement into a radial pp cat o s o d a d cato c ude:
Applications of dial indicator include:
y Provided with various extension arms that can be movement to measure over a y centering workpices to machine tool spindles
added for different sizes.
sizes small
ll range off movement for
f theh
plunger. y offsetting lathe tail stocks
y The typical least count that can be
y aligning a vice on a milling machine
obtained with suitable gearing
dial indicators is 0.01 mm to 0.001 y checking dimensions
mm.
mm
y It is possible to use the dial
indicator as a comparator by
mounting g it on a stand at anyy
136
suitable height. Principle of a dial indicator
137 138
GATE – 2008 S‐1 GATE – 2008 contd… from S‐2

d f GATE – 2014(PI) S‐1
( )
A displacement
di l sensor (a
( dial
di l indicator)
i di ) measures the
h If Rp= RQ>0, >0 which one of the The
Th alignment
li test
following would be consistent with the
lateral displacement of a mandrel mounted on the taper observation? “Spindle square with
hole inside a drill spindle. The mandrel axis is an (A) The drill spindle rotational axis is base plate” is applied
extension of the drill spindle
p taper
p hole axis and the coincident with the drill spindle
p taper
p to the radial drilling g
protruding portion of the mandrel surface is perfectly hole axis machine. A dial
(B) The drill spindle rotational axis
cylindrical Measurements are taken with the sensor
cylindrical. i
intersects the
h drill
d ill spindle
i dl taper hole
h l indicator is fixed to
placed at two positions P and Q as shown in the figure. axis at point P the cylindrical spindle
Th readings
The di are recorded
d d as Rx = maximum
i d fl ti
deflection (C) The
Th drill
d ill spindle
i dl rotational
t ti l axis
i is
i and
d the
th spindle
i dl is i
minus minimum deflection, corresponding to sensor parallel to the drill spindle taper hole rotated to make the
axis
position at X, over one rotation. 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
139 140 141
GATE – 2014(PI) S‐2
( ) Slip Gauges or Gauge blocks y Come in sets with different number of pieces in a given
This
Thi test inspects
i whether
h h the h 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
((a)) spindle
p vertical feed axis is p perpendicular
p to the base 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
plate y Not to be used for regular and continuous shown in.
(b) axis of symmetry of the cylindrical spindle is measurement
measurement. y To
T build
b ild any given
i di
dimension,
i it is
i necessary to
t
perpendicular to the base plate y Rectangular blocks with thickness representing the identifyy a set of blocks,, which are to be p
put together.
g
(c) axis of symmetry, the rotational axis and the vertical dimension of the block. The cross‐section of the block y Number of blocks used should always be the smallest.
feed
eed aaxiss o
of tthee sp
spindle
d e aaree aall co
coincident
c de t iss usua
usuallyy 332 mm x 9 mm..
y Generally
G ll the
h top and
d bottom
b Sli Gauges
Slip G i the
in h pile
il
(d) spindle rotational axis is perpendicular to the base y Are hardened and finished to size. The measuring
are 2 mm wear g gauges.
g This is so that theyy will be the
plate
l t surfaces
f off the
th gauge blocks
bl k are finished
fi i h d to
t a very high
hi h
degree of finish, flatness and accuracy. only ones that will wear down, and it is much cheaper
to replace
l two gauges than
h a whole
h l set.
Page 54 of 186 143
Rev.0 144
To make up a Slip Gauge pile to 41.125 mm To make up a Slip Gauge pile to 41.125 mm
41.125
y A Slip
Sli Gauge
G pile
il is
i sett up with
ith the
th use off simple
i l -4.000
______
maths. 37.125
-1.005
1 00
_______
y Decide what height
g y you want to set up,
p in this 36.120
-1.020
1 020
_______
case 41.125mm. 35.100
-1.100
1 100
y Take away the thickness of the two wear gauges, _______
34.000
-4.000
4 000
and then use the gauges in the set to remove _______
30.000
each place of decimal in turn,
turn starting with the -30.000
30 000
_______
0.000
lowest.
145 146 147
A M t i li t (88 Pi )
A Metric slip gauge set (88 Pieces)
ISRO‐2010
Slip gauges size or Increment, mm
Increment mm Number of
A master gauge is ISRO‐2008
range, mm Pieces
1.005 ‐ 1 (a) A new gauge St d d to
Standards t be
b used
d for
f reference
f purposes in
i
1.001 to 1.009 0.001 9 (b) An international
te at o a reference
e e e ce sta
standard
da d laboratories and workshops are termed as
1.010 to 1.490 0.010 49 (c) A standard gauge for checking accuracy of
0 500 to 9.500
0.500 to 9 500 0 500
0.500 19 (a) Primary standards
gauges used on shop floors
10 to 100 10.000 10
(d) A gauge used by experienced technicians ((b)) Secondaryy standards
((c)) Tertiaryy standards
(d) Working standards

148 149 150
Comparators GATE – 2007 (PI)

( )
y Comparator is another form of linear measuring
Which one of the following instruments is a
method, which is quick and more convenient for
checking
h ki largel number
b off identical
id ti l dimensions.
di i comparator
t ?
y Duringg the measurement, a comparator
p is able to g
give
(a) Tool Maker
Maker’ss Microscope
the deviation of the dimension from the set dimension.
y Cannot measure absolute dimension but can only (b) GO/NO GO gauge
compare two dimensions.
(c) Optical Interferometer
y Highly reliable.
y To magnify the deviation, a number of principles are (d) Dial Gauge
used such as mechanical, optical, pneumatic and
electrical.
electrical
Page 55 of 186
Fig. Principle of a comparator 152
Rev.0 153
Mechanical Comparators
Mechanical Comparators Sigma Mechanical Comparator
y The Mikrokator principle
greatly magnifies any The Sigma Mechanical Comparator uses a partially
d i ti
deviation i size
in i so that
th t wrapped
d band
b d wrapped
d about
b a driving
d d
drum to turn a
even small deviations
produce
d l
large d fl
deflections off pointer needle.
needle The assembly provides a frictionless
the p
pointer over the scale. movement with a resistant pressure provided by the
springs.
Sigma Mechanical Comparator
154 155 156
Optical Comparators
Mechanical Comparators
Mechanical Comparators y These
Th devices
d i use a plunger
l to rotate a mirror.
i A light
li h
y The Eden‐Rolt Reed system
y uses a beam is reflected off that mirror, and simply by the y In this system, Mechanical amplification
virtue of distance, the small rotation of the mirror can y = 20 /1 ,
pointer attached to the end of two
be converted to a significant
g translation with little
y And, Optical amplification
A d O i l lifi i
reeds. One reed is pushed by a friction.
y 50 /1 x 2
plunger, while the other is fixed. As y It is multiplied by 2, because if mirror
one reed
d moves relative
l ti tot the
th other,
th y is tilted by an angle δθ, then image
is tilted by an angle δθ then image
y will be tilted by 2 x δθ. Thus overall
the pointer that they are commonly
y magnification of this system
attached to will deflect. y = 2 x (20/1) ( 50/1 =2000 units)
2 x (20/1) ( 50/1 2000 units)
157 158 159
Pneumatic Comparators Pneumatic Comparators
y Flow type:
IFS‐2015
Define a comparator.
comparator
y The float height is essentially proportional to the air
that
h escapes from
f the
h gauge head
h d Write at least six desirable features it should possess.
possess
Also name four types

yp of comparators.
p
y Master
M t gauges are used
d to
t find
fi d calibration
lib ti points
i t on
[ 8 Marks]
the scales
y The input pressure is regulated to allow

magnification adjustment

Page 56 of 186 161
Rev.0 162
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
A Bevel Protractor
163 164 165
Sine Bar
Sine Bar
y When a reference for a non‐square angle is required, a sine bar
can be used.
ISRO‐2011
y Basically a sine bar is a bar of known length.
length When gauge blocks A sine
i bar
b is
i specified
ifi d by
b
are placed under one end, the sine bar will tilt to a specific
(a) Its total length
angle.
y Knowing the height differential of the two rollers in alignment (b) The size of the rollers
with the workpiece ,the angle can be calculated using the sine
(c) The centre distance between the two rollers
formula.
y A sine bar is specified by the distance between the centre of the (d) The distance between rollers and upper surface
two rollers, i.e. 100 mm, 200 mm, & 300 mm. the various part of
sine bar are hardened before grinding & lapping. H
s in θ =
166
L 167 168
( )
GATE ‐2012 (PI) Dis‐advantages Thread Measurements
y 1. Sine bars cannot be used for conveniently for y Threads are normally specified by the major diameter.
Th d ll ifi d b h j di
A sine bar has a length of 250 mm. Each roller has y Though there are a large variety of threads used in
g g y
measuring angles h 60o because
l more than b off slip
l gauge engineering, the most common thread encountered is
a diameter of 20 mm. During taper angle
adjustment problems.
problems the metric V thread shown in Fig.
the metric V‐thread shown in Fig
measurement of a component, the height from the
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
sometimes introduce considerable errors.
Th calculated
The l l t d taper
t angle
l (in
(i degrees)
d ) is
i
( ) 21.1
(a) (b) 22.8
8 ( ) 23.6
(c) 6 (d) 68.9
68

Page 57 of 186 170
Rev.0 171
y The parameters that are normally measured are: Three-Wire Method The Three-Wire Method of Measuring Threads
y Major diameter
y Three wires of equal diameter placed in thread, two
y Micrometer
y Pitch diameter on one side and one on other side
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
D p = pitch diameter or Effective diameter
y Optical projector
172 173 p = pitch of thread , and α = thread angle 174
y Pitch
Pit h Diameter
Di t or Eff
Effective
ti Di
Dia.
y Distance W over the outer edge Two-Wire Method Dp = T + P
⎛ α⎞ p α =T +
p ⎛α ⎞ ⎛ α ⎞
cot ⎜ ⎟ − d ⎜ cosec − 1⎟
W = D p + d ⎜1 + cosec ⎟ − cot y Two wires of equal diameter placed in thread, two on 2 ⎝2⎠ ⎝ 2 ⎠
⎝ 2⎠ 2 2
one side and one on other side T = Dimensions under the wire = D + ( Dm − Ds )
For ISO metric thread,, α = 60 and D p = D − 0.6496 p
D=D Diameter
i t off master
t or standard
t d d cylinder
li d
W = D + 3d − 1.5156 p Dm = Micrometer reading over standard cylinder with two wire
y Best wire size D s = Micrometer reading over the plug screw gauge with the wire
P = Pitch value
p α
d= sec
2 2 y Best wire size
For ISO metric thread, α = 60 p α
d= sec
d = 0.5774 p 2 2
175 176 177
GATE‐2013
GATE –
GATE – 2011 (PI)
2011 (PI) A metric thread of pitch 2 mm and thread angle 60
GATE –
GATE – 2011 (PI)
2011 (PI)
The best wire size (in mm) for measuring To measure the effective diameter of an external
inspected
d for
f its pitch
h diameter
d using 3‐wire metric thread (included angle is 60o) of 3.5 mm
effective diameter of a metric thread
(included angle is 60o) of 20 mm diameter and method The diameter of the best size wire in mm is
method. pitch,, a cylindrical
p y standard of 330.55 mm diameter
2.5 mm pitch using two wire method is and two wires of 2 mm diameter each are used.
(a) 0.866 (b) 1.000 (c) 1.154 (d) 2.000 The micrometer readings over the standard and
(a) 1.443 over the wires are 16.532 mm and 15.398 mm,
(b) 0.723
0 723 respectively. The effective diameter (in mm) of the
(c) 2.886 thread is
(a) 33.366
33 366 (b) 30.397
30 397
(d) 2.086
(c) 29.366 (d) 26.397

Page 58 of 186 179
Rev.0 180
Surfaces y Surface geometry can be quantified a few different
y Roughness
g g
height: is the p
parameter with which
ways.
ways
y No surface is perfectly smooth, but the better the generally the surface finish is indicated. It is specified
either as arithmetic average value or the root mean
surface
f quality,
l the
h longer
l a product
d generally
ll lasts,
l
square value.
and the better is performs.
performs 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
y Surface texture can be difficult to analyse
valleys, which constitutes the predominant pattern of
q
quantitatively.
y y Real surfaces are rarely so flat, or smooth, but most
Real surfaces are rarely so flat or smooth but most the roughness.
g
commonly a combination of the two. y Roughness width cut‐off: is the maximum width of
y Two surfaces may
y be entirelyy different, yyet still p
provide
the surface that is included in the calculation of the
the same CLA (Ra) value. roughness height.
181 182 183
Lay
y Waviness: refers to those surface irregularities that have Diagram Symbol Description
a greater spacing than that of roughness width.
width Parallel lay: Lay parallel to
y Determined by the height of the waviness and its the Surface. Surface is
width. produced
d d b
by shaping,
h i
y The greater the width,
width the smoother is the surface and planning etc.
thus is more desirable. Perpendicular lay: Lay
y Lay
L di
direction:
i i the
is h direction
di i off the
h predominant
d i perpendicular to the
surface pattern produced on the workpiece by the tool Surface. Surface is produced
marks. b shaping
by h i and d planning
l i
y Flaw: are surface irregularities that are present which are Crossed lay: Lay angular in
y y g
random and therefore will not be considered. both directions.
Surface is produced by
184 185
knurling, honing. 186
Lay Contd..
Diagram Symbol Description IES‐2012 Representation of Surface Roughness
Multidirectional lay: Lay In
I connection i with
i h surface
f texture define
d fi
multidirectional. Surface is ((a)) waviness
produced
d d by b grinding,
i di
(b) flaws, and
lapping, super finishing.
( ) lay.
(c) l
Circular lay:
Approximately circular List three defects found on surfaces.
relative to the center. [2 marks]
S f
Surface i produced
is d d by b
facing.
Radial lay: Approximately
radial relative to the center
of the nominal surface. 187
For-2017 (IES, GATE & PSUs) Page 59 of 186 188
Rev.0 189
Roughness Roughness Grade Roughness Symbol
Ra (μm) Number
50 N12 ‐ IES ‐ 1992 y Waviness height ‐ the distance from a peak to a valley
25
2 N11 Which
Whi h grade
d symbol
b l represents surface
f rough
h off
∇ y Waviness width ‐ the distance between peaks or
12.5 N10 broaching? valleys
y
6.3 N9 (a) N12 (b) N8 y Roughness width cutoff ‐ a value greater than the
32
3.2 N8 ∇∇ (c) N4 (d) N1 maximum roughness width that is the largest
1.6 N7 separation of surface irregularities included in the
0.8 N6 measurements. Typical
T i l values
l are (0.003”,
( ” 0.010”,”
∇∇∇ 0.030”, 0.100”, 0.300”)
04
0.4 N5
y Lay ‐ the direction the roughness pattern should
0.2 N4
follow
0.1 N3
y Stylus travel is perpendicular to the lay specified.
0 05
0.05 N2 ∇∇∇∇
0.025 N1 190 191 192
IFS‐2011 Evaluation of Surface Roughness Determination of Mean Line

What is meant by interchangeable manufacture? 1. Centre line average (CLA) or arithmetic mean y M‐System: After plotting the characteristic of any
surface a horizontal line is drawn by joining two points.
points
Laser light has unique advantages for inspection. deviation denoted as Ra. This line is shifts up and down in such a way that 50%
What are they ? Define the terms 'roughness area is above the line and 50% area is below the line
2. Root mean square value (Rg) : rms value
h i ht' 'waviness
height', ' i width'
idth' and
d 'lay'
'l ' in
i connection
ti 3. Maximum peak to valley roughness (hmax)
with surface irregularities.
irregularities
4. The average of the five highest peak and five deepst
[10 marks]
[10‐marks] valleys
ll i the
in th sample.
l
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
The surface roughness parameter Ra (in μm) is _______

Page 60 of 186 197
Rev.0 198
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 ISRO‐2010

Surface roughness on a drawing is represented by
IAS –
IAS – 2013 Main
2013 Main
F a machined
For hi d surface,
f show
h macro‐ and
d micro‐
i
(a) Triangles
irregularities What are their causes?
irregularities.
(b) Circles
What are the various measures of surface finish?
(c) Squares
Explain any three of them.
(d) Rectangles

Page 61 of 186 206
Rev.0 207
Methods of measuring Surface Roughness
h d f i S f h Observation Methods Stylus Equipment
There are a number of useful techniques for measuring y uses a stylus
l that
h tracks
k small
ll changes
h in
i surface
f
y Human perception is highly relative.
surface roughness: height, and a skid that follows large changes in surface
y To give the human tester a reference for what they are height.
y Observation and touch ‐ the human finger
g is veryy y The relative motion between the skid and the stylus is
touching,
hi commercial
i l sets off standards
d d are available.
il bl
perceptive to surface roughness 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
y stylus based equipment ‐ very common unit.
identical processes.
processes
y Interferometry ‐ uses light wave interference patterns
y One method of note is the finger nail assessment of
(discussed later)
roughness and touch method.
208 209 210
Profilometer
y Measuring instrument used to measure a surface's
profile, in order to quantify its roughness.
y Vertical resolution is usually in the nanometre level,

though
h h lateral
l l resolution
l is usually
ll poorer.
211 212 213
Contact profilometers Non‐contact Profilometers Advantages of optical Profilometers

y A diamond stylus is moved vertically in contact with a
A di d l i d i ll i i h y Because the non‐contact profilometer does not touch
sample and then moved laterally across the sample for y An optical profilometer is a non‐contact method for
a specified distance and specified contact force. the
h surface
f the
h scan speeds
d are dictated
d d by
b the
h light
l h
providing much of the same information as a stylus
y A profilometer can measure small surface variations in reflected from the surface and the speed of the
vertical stylus displacement as a function of position. based profilometer.
acquisition electronics.
y The radius of diamond stylus ranges from 20
h d fd d l f y There are many different techniques which are
nanometres to 25 μm. y Optical
p profilometers do not touch the surface and
p
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
(triangulation sensor),
sensor) confocal microscopy and digital
careless operators.
holography.
g p y

Page 62 of 186 215
Rev.0 216
Optical Flats
y Optical‐grade
O ti l d clear
l fused
f d quartz
t or glass
l structures
t t
lapped and polished to be extremely flat on one or
b th sides.
both id
y Used with a monochromatic light to determine the
flatness of other optical surfaces by interference.
y When a flat surface of another optic p is p placed on the
optical flat, interference fringes are seen due to
te e e ce in tthee ttinyy gap bet
interference between
ee tthee ttwoo su
surfaces.
aces.
y The spacing between the fringes is smaller where the
gap is changing more rapidly,
rapidly indicating a departure
from flatness in one of the two surfaces, in a similar
way to the contour lines on a map.
map
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
IES – 2012 Conventionall Optical flat as a comparator

Optical flat as a comparator
IAS – 2012 Main
Explain how flatness of a surface is measured with an optical Write in short about optical flat. Two fringe patterns
flat. are supplied for two completely different surfaces using
[
[12 marks]
k ] optical
ti l flat,
fl t name the
th types
t off surfaces,
f and
d draw
d if
required
Fig. Fringe patterns for two completely different types
of surfaces.
Page 63 of 186 224
Rev.0 225
GATE ‐ 2003 GATE – 2011 (PI)
nλ l
Δh = Two
T slip
li gauges off 10 mm width
id h measuringi 1.000 mm
and 1.002 mm are kept side by side in contact with each
Observation of a slip gauge on a flatness
interferometer produced fringe counts numbering
2 other lengthwise. An optical flat is kept resting on the 10 and 14 for two readings. The second reading is
Wh l = separation of edges
Where slip
pggauges
g as shown in the figure.
g Monochromatic light
g set up by 180o. Assume that
taken by rotating the set‐up
of wavelength 0.0058928 mm is used in the inspection. both faces of the slip gauge are flat and the
n = number of fringes / cm
The total number of straight fringes that can be observed wavelength
l h off the
h radiation
di i i 0.5086
is 86 µm. The
Th
Δh = The difference of height between gauges on both slip gauges is parallelism error (in µm) between the two faces of
λ = wevlength of monochomatic light
(a) 2 (b) 6 the slip gauge is
(c) 8 (d) 13 (a) 0.2543
0 2543 (b) 1.172
1 172
(c) 0.5086 (d) 0.1272
226 227 228
Talysurf Cli t
Clinometer
y It
I is
i based
b d upon measuring
i the
h generated
d noise
i due
d to y An
A optical
i l device
d i for
f measuring
i elevation
l i angles
l above
b
dry friction of a metallic blade which travels over the horizontal.
surface under consideration. y Compass clinometers are fundamentally just magnetic
y If the frictional force is made small enough to excite compasses held with their plane vertical so that a
the blade, and not the entire system, then the noise Miscellaneous of Metrology plummet or its equivalent can point to the elevation of
will
ill be proportional to surface roughness,
roughness and the sight line.
line
independent of the measured specimen size and y The clinometer can read easily and accurately angles of
material.
l elevation that would be very difficult to measure in any
y The specimen surface roughness was measured by a other simple and inexpensive way.
widely used commercial instrument (Talysurf 10), and y A fairly common use of a clinometer is to measure the
the prototype transducer.
transducer h i ht off trees.
height t
229 By S K Mondal 230 231
Clinometer A t lli t
Autocollimator y Visual autocollimators are used for lining up laser rod
y An opt ca instrument
optical st u e t for
o non‐contact
o co tact measurement
easu e e t o
of
ends
d andd checking
h ki the
th face
f parallelism
ll li off optical
ti l
small angles or small angular tilts of a reflecting surface.
windows and wedges.
y Used
U d to t align
li components t and d measure deflections
d fl ti i
in
optical or mechanical systems. y Electronic and digital autocollimators are used as
y An autocollimator works by projecting an image onto a angle
l measurementt standards,
t d d for f monitoring
it i angular l
target mirror, and measuring the deflection of the movement over long periods of time and for checking
returned image against a scale, either visually or by angular position repeatability in mechanical systems.
means of an electronic detector.
detector y Servo
S autocollimators
t lli t are specialized
i li d compactt forms
f
y A visual autocollimator can measure angles as small as of electronic autocollimators that are used in high
0.5 arcsecond, while an electronic autocollimator can be speed servo feedback loops for stable platform
up
p to 100 times more accurate. applications.
pp

Page 64 of 186 233
Rev.0 234
Autocollimator GATE ‐ 1998
Auto
A collimator
lli is
i used
d to check
h k GATE –
GATE – 2009 (PI)
2009 (PI)
((a)) Roughness
g
A autocollimator
An t lli t is i used
d to
t
(b) Flatness
( ) Angle
(c) A l (a) measure small angular displacements on flat
((d)) Automobile balance. surface
((b)) compare
p known and unknown dimensions
((c)) measure the flatness error
(d) measure roundness error between centers

235 236 237
Optical Square
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
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.
measured using y One mirror(horizon glass) is half silvered and other(index
glass) is wholly silvered.
(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)) Auto collimator incident ray and the last reflected ray is 90o
((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) Tool maker’s microscope y Used to set out right angles at a given point on a line in the
fi ld
field.
238 y Two mirrors may be replaced by two prisms. 239 An Optical Square 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
Page 65 of 186 242
Rev.0 243
IES ‐ 1998 GATE‐2014 McLeod gauge
Match List‐I
List I with List‐II
List II and select the correct answer using the
codes given below the lists: y Used
d to measure vacuum by
b application
l off the
h
Which one of the following instruments is widely
List‐I List‐II principle of Boyle's law.
(Measuring Device) (Parameter Measured)
used to check and calibrate geometric features of
y Works on the principle, "Compression of known
A. Diffraction grating 1. Small angular deviations on long machine tools during their assembly?
flat surfaces volume of low p pressure ggas to higher
g pressure and
p
B. Optical flat 2. On‐line measurement of moving (a) Ultrasonic probe measuring resulting volume & pressure, one can
p
parts calculate initial p
pressure usingg Boyle's
y Law equation."
q
C. Auto collimators 3. Measurement of gear pitch (b) Coordinate Measuring Machine (CMM) y Pressure of gases containing vapours cannot normally
D. Laser scan micrometer4. Surface texture using interferometer
measured with a McLeod gauge, gauge for the reason that
5. Measurement off very smallll ( ) Laser interferometer
(c) f
displacements compression will cause condensation .
Code: A B C D A B C D (d) Vernier calipers y A pressure from
f 0.01 micron
i t 50 mm Hg
to H can beb
(a) 5 4 2 1 (b) 3 5 1 2
((c)) 3 5 4 1 ((d)) 5 4 1 2
measured. Generally McLeod gauge is used for
calibration
lib ti purpose.
244 245 246
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
247 248 angular displacement. 249
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.
Page 66 of 186 251
Rev.0 252
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
253 254 255
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
g is critical
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
256 257 258
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)
Page 67 of 186 260
Rev.0 261
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
262 263
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 subjected
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
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.

Page 69 of 186 8
Rev.0 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
ld k
Cold Working Advantages of Cold Working
d f ld k
1. Better accuracy, closer tolerances 1.
Disadvantages of Cold Working
d f ld k
Equipment of higher forces and power required
y Working below recrystalization temp. 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
2. Better surface finish
dirt
3. Strain hardening increases strength and hardness
3. Ductility and strain hardening limit the amount of forming
4. Grain flow during deformation can cause desirable that can be done
directional properties in product 4. In some operations, metal must be annealed to allow
5 No heating of work required (less total energy)
5. further deformation
55. Some metals are simply not ductile enough to be cold
py g
worked.
Page 70 of 186 17
Rev.0 18
Advantages of Hot Working
Hot Working
1. The porosity of the metal is largely eliminated.
2 The grain structure of the metal is refined.
2. refined
3. The impurities like slag are squeezed into fibers and
di ib d throughout
distributed h h the
h metal.l
y Working above recrystalization temp
Working above recrystalization temp. 4. The mechanical p
4 properties
p such as toughness,
g ,
percentage elongation, percentage reduction in area, and
resistance to shock and vibration are improved due to
the refinement of grains.
19 20 21
Micro‐Structural Changes in a Hot
Mi St t l Ch i H t IES 2016
IES‐2016
Dis‐advantages of Hot Working Statement (I) : Pursuant to p
plastic deformation of
1. It requires expensive tools. Working Process (Rolling)
Working Process (Rolling) metals, the mechanical properties of the metals get
2 It produces poor surface finish,
2. finish due to the rapid changed.
oxidation and scale formation on the metal surface. Statement (II) : Mechanical properties of metals
3. Due
D to the
h poor surface
f fi i h close
finish, l tolerance
l d
depend d on grain
i size
i also
l which
hi h gets
t changed
h d by
b
cannot be maintained. 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
22 23 24
Annealing
g
•Annealing relieves the stresses from cold working – three W F i
Warm Forming Isothermal Forming
h l
y Deformation produced at temperatures intermediate to
stages: recovery,
recovery recrystallization and grain growth.
growth hot and cold forming is known as warm forming. y During hot forming, cooler surfaces surround a hotter
•During recovery, physical properties of the cold‐worked
material
i l are restored
d without
ih any observable
b bl change
h i
in y Compared to cold forming,
forming it reduces loads,
loads increase interior and the variations in strength can result in non‐
interior, non
microstructure. material ductility. uniform deformation and cracking of the surface.
y Compared to hot forming, it produce less scaling and
y For temp.‐sensitive materials deformation is performed
decarburization, better dimensional precision and
smoother surfaces. under isothermal conditions.
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
out at a temperature range between 550–950°C. It is temperature,
p , sacrificing
g die life for p
product q
quality.
y
useful for forging of details with intricate shapes, with
desirable grain flow, good surface finish and tighter y Close tolerances, low residual stresses and uniform metal
dimensional tolerances. flow.
Page 71 of 186 26
Rev.0 27
IES 2011 GATE‐2003 GATE‐2002, ISRO‐2012
Assertion (A): Lead, Zinc and Tin are always hot 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
worked. ((a)) At its recrystallisation
y temperature
p ((a)) At recrystallisation
y temperature
p
Reason (R) : If they are worked in cold state (b) Above its recrystallisation temperature (b) Between 100°C to 150°C
they cannot retain their mechanical properties.
properties ( ) Below
(c) B l itsi recrystallisation
lli i temperature ( ) Below
(c) B l recrystallisation
lli i temperature
(a) Both A and R are individually true and R is the ((d)) At two thirds of the melting g temperature
p of the ((d)) Above recrystallisation
y temperature
p
correct explanation of A metal
(b) Both A and R are individually true but R is NOT
( ) A is true but
(c) b R is false
f l
28 29 30
ISRO 2010
ISRO‐2010 IES – 2006 IES – 2004
Materials
M t i l after
ft cold
ld working
ki are subjected
bj t d to
t Which one of the following is the process to refine Consider
C id theh following
f ll i statements:
p
In comparison to hot working,
g, in cold working,
g,
follo ing process to relieve
following relie e stresses the
h grains off metall after
f it has
h been
b d
distorted
d by
b
1. Higher forces are required
( ) Hot
(a) H working
ki hammering or cold working? 2. NoN heating
h i is i required
i d
( ) Annealing
(a) g ((b)) Softening
g 33. Less ductilityy is required
q
(b) Tempering (c) Re‐crystallizing (d) Normalizing 4. Better surface finish is obtained
(c) Normalizing Which
h h off the
h statements given above
b are correct?
(a) 1, 2 and 3 (b) 1, 2 and 4
(d) Annealing (c) 1 and 3 (d) 2, 3 and 4
31 32 33
IES – 2009 IES – 2008 IES – 2008

Consider
C id theh following
f ll i characteristics:
h i i Consider
f ll i statements: Cold
C ld forging
f i results
l ini improved
i d quality
li dued to
1. Porosityy in the metal is largely
g y eliminated. 1. Metal forming g decreases harmful effects of which of the following?
2. Strength is decreased. impurities and improves mechanical strength. 1. Better mechanical properties of the process.
3. Close
Cl tolerances
l cannot be
b maintained.
i i d 2 Metal working process is a plastic deformation
2. 2 Unbroken grain flow.
2. flow
Which of the above characteristics of hot working
g is/are
/ process. 3. Smoother finishes.
correct? 3. Very intricate shapes can be produced by forging 4. High pressure.
( ) 1 only
(a) l (b) 3 only
l 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:
(c) 2 and 3 (d) 1 and 3 Which of the statements given above are correct? (a) 1, 2 and 3 (b) 1, 2 and 4
( ) 1, 2 and
(a) d3 (b) 1 and d 2 only
l (c) 2, 3 and 4 (d) 1, 3 and 4
(c) 2 and 3 only (d) 1 and 3 only

Page 72 of 186 35
Rev.0 36
IES – 2004 IES – 2003 IES – 2000
Assertion
A i (A):
(A) Cold
C ld workingki off metals
l resultsl in i 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
increase of strength and hardness p in the metal
1. Stresses are set up working intermediate annealing is not required.
Reason (R): Cold working reduces the total number 2. Grain structure gets distorted Reason (R): Cold working is performed below the
of dislocations per unit volume of the material 3. Strength
S h and
d hardness
h d off the
h metall are decreased
d d recrystallisation temperature of the work material.
material
(a) Both A and R are individually true and R is the 4. Surface finish is reduced
4 (a) Both A and R are individually true and R is the
correct explanation
l off A correct explanation
l off A
(b) Both
d v dua y ttrue
ue but R iss not
ot tthee (b) Both
d v dua y ttrue
ue but R iss not
ot tthee
correct explanation of A ( ) 1and
(a) d2 (b) 1, 2 and d3 correct explanation of A
( ) A is
(c) i true
t b t R is
but i false
f l (c) 3 and 4 (d) 1 and 4 ( ) A is
(c) i true
t b t R is
but i false
f l
37 38 39
IES – 1997 IES – 1996

ISRO‐2009 In metals subjected to cold working, strain
I l bj d ld ki i Consider the following statements:
C id h f ll i
In the metal forming process, the stresses hardening effect is due to y
When a metal or alloy is cold worked
encountered are (a) Slip mechanism 1. It is worked below room temperature.
( ) Greater
(a) G than
h yield
i ld strength
h but
b l
less than
h (b) Twining mechanism 2. It is worked below recrystallisation
I i k d b l lli i temperature.
ultimate strength (c) Dislocation mechanism 33. Its hardness and strength increase.
g
(b) Less than yield strength of the material (d) Fracture mechanism 4. Its hardness increases but strength does not
(c) Greater than the ultimate strength of the increase.
material Of these correct statements are
(d) Less than the elastic limit (a) 1 and 4 (b) 1 and 3
( ) 2 and 3
(c) d (d) 2 and 4
d
40 41 42
IES – 2006 IES – 1992 IAS – 1996

Assertion
A i (A):
(A) InI case off hot
h workingki off metals,
l the h 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
temperature at which the process is finally stopped ((a)) Grain ggrowth,, recrystallisation,
y , stress relief ((a)) 44000C to 6000C
should
h ld not be b above
b the
h recrystallisation
ll temperature.
(b) Stress relief, grain growth, recrystallisation (b) 7000C to 9000C
Reason ((R): ) If the p process is stopped
pp above the
recrystallisation temperature, grain growth will take ( ) Stress
(c) S relief,
li f recrystallisation,
lli i grain
i growth h ( ) 10000C to 12000C
(c)
place again
p g and spoil
p the attained structure. ((d)) Grain g
growth,, stress relief,, recrystallisation
y 3 0Cto 1500
((d)) 1300 5 0C
explanation of A
correct explanation
l i off A
Page 73 of 186 44
Rev.0 45
IAS – 2004 IAS‐2002 IES‐2008
Assertion (A): Hot working does not produce strain
A i (A) H ki d d i 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?
hardening. working.
Reason (R): Hot working is done above the re‐ Reason (R): In hot working physical properties are Malleability is the property by which a metal or
crystallization temperature.
crystallization temperature generally improved.
improved alloy
ll can be
b plastically
l i ll deformed
d f d by
b applying
l i
(a) Both A and R are individually true and R is the (a) Both A and R are individually true and R is the
l f correct explanation
l off A ( ) Tensile
(a) T il stress
t (b) B di stress
Bending t
ot a d R a e d v dua y t ue but R s ot tthe
e (b) Both
d v dua y ttrue
ue but R iss not
ot tthee (c) Shear stress (d) Compressive stress
correct explanation of A correct explanation of A
(c) A i t b t R i f l ( ) A is
(c) i true
t b t R is
but i false
f l
46 47 48
Rolling GATE‐2013
y Definition: The process of plastically deforming metal In a rolling process, the state of stress of the
b passing it between
by b rolls.
ll materiall undergoing
d d f
deformation is
g
Rolling y Most
M widely
id l used,
y Friction
F i ti b t
d high
between
hi h production
d i and
th rolls
the ll and
d the
d close
l
th metal
tolerance.
l
t l surface
f
( ) pure compression
(a)
(b) pure shear

h
i
produces high compressive stress.

stress (c) compression and shear
y Hot
Hot‐working
working (unless mentioned cold rolling.) (d) tension and shear
y Metal will undergo
g bi‐axial compression.
p
By S K Mondal
49 50 51
Hot Rolling
y Done above the recrystallization temp.
y Results fine grained structure.
y Surface
S f quality
lit and
d final
fi l dimensions
di i are less
l accurate.
t
y Breakdown of ingots into blooms and billets is done by
hot‐rolling.
g This is followed byy further hot‐rolling
g into
plate, sheet, rod, bar, pipe, rail.
y Hot rolling is terminated when the temp. falls to about
(50 to 100°C) above the recrystallization temp.
Page 74 of 186 53
Rev.0 54
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 surface
2 Surface finish is not good
2. fi i h and
finish d increased
i d mechanical
h i l strength
h with
i h close
l
3. Heavy reduction in areas can be obtained
product dimensions.
dimensions
Which of these characteristics are associated with hot
rolling? y Performed on four
four‐high
high or cluster
cluster‐type
type rolling mills.
mills
(a) 1 and 2 (b) 1 and 3 ((Due to high
g force and p
power))
Hot rolling is an effective way to reduce grain size in (c) 2 and 3 (d) 1, 2 and 3
metals for improved
p strength
g and ductility.
y
55 56 57
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.
58 59 60
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

Page 75 of 186 62
Rev.0 63
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
64 65 66
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
67 68 69
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.

Page 76 of 186 71
Rev.0 72
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)
(d) None of the above
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
73 74 75
IES – 2013 Conventional Manufacture of gears by rolling

Write two advantages of thread rolling and explain y The straight and helical teeth of disc or rod type external
with figure two‐die cylindrical machine.
hf d l d l h steell gears off small
ll to medium
d d
diameter and
d module
d l are
[ M k ]
[ 5 Marks] 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
76 finished by machining. 77 Fig. Gear rolling between three gear roll tools 78
Roll piercing
ll 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.

Page 77 of 186 80
Rev.0 81
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 82 83 84
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
85 86 one value of the roll force). 87
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

Page 78 of 186 89
Rev.0 90
Defects in Rolling
Defects What is Cause
Surface Scale, rust, Inclusions and GATE –
GATE – 2009 (PI)
2009 (PI) IES‐2003
Defects scratches,, impurities
p in the
A i t
Anisotropy i rolled
in ll d components
t is
i caused
d by
b A
Assertion
ti (A):
(A) While
Whil rolling
lli metal
t l sheet
h t in
i rolling
lli
pits, cracks materials
(a) changes in dimensions mill the edges are sometimes not straight and flat
mill,
Wavy edges Strip is Due to roll
thinner along g bendingg edges
g (b) scale formation but are wavy.
y
its edges than elongates more
at its centre.
centre and buckle.
buckle (c) closure of defects Reason (R) : Non uniform mechanical properties
of the flat material rolled out result in waviness of
Alligatoring Edge breaks Non uniform
Non‐uniform (d) grain orientation
deformation the edges.
91 92 93
Geometry of Rolling Process Draft
y Total
T l reduction
d i or “draft”
“d f ” taken
k ini rolling.
lli
Δh=h0 - hf =2(R- Rcos α) =D(1- cos α)

Formula in Rolling y Usually,
y, the reduction in blooming
g mills is about 100
mm and in slabbing mills, about 50 to 60 mm.
94 95 96
IAS‐2012 Main GATE‐2007 GATE – 2012 Same Q in GATE – 2012 (PI)

What is the significance of (1) angle of nip, and (2) The thickness of a metallic sheet is reduced from an
In a single pass rolling process using 410 mm
angle
l off bite
b during
d rolling
ll operation? How are they
h initiall value
l off 16 mm to a final
f l value
l off 10 mm in diameter steel rollers, a strip of width 140 mm and
related to roll friction? one single pass rolling with a pair of cylindrical thickness
h k 8 mm undergoes
d 10%
% reduction
d off
[10 marks] rollers each of diameter of 400 mm. The bite angle thickness The angle of bite in radians is
thickness.
in degree will be ((a)) 0.006 ((b)) 0.031
3
(a) 5.936 (b) 7.936 (c) 0.062 (d) 0.600
(c) 8.936 (d) 9.936

Page 79 of 186 98
Rev.0 99
Roll strip contact length
Roll strip contact length
GATE‐1998 GATE‐2004
A strip with a cross‐section 150 mm x 4.5 mm is y Roll strip contact length
R ll i l h In a rolling process, sheet of 25 mm thickness is
b
being rolled
ll d with
h 20%
% reduction
d off area using 450 L = R α rolled
ll d to 20 mm thickness.
h k Roll
ll is off diameter
d 600
mm diameter rolls.
rolls The angle subtended by the mm and it rotates at 100 rpm.
rpm The roll strip contact
[ α must be in radian]
deformation zone at the roll centre is (in radian) length will be
((a)) 0.01 ((b)) 0.02 ((a)) 5 mm ((b)) 39 mm
((c)) 0.033 ((d)) 0.06 ((c)) 778 mm ((d)) 120 mm
100 101 102
For Unaided entry Maximum Draft Possible GATE 2011

The maximum possible draft in cold rolling of
μ ≥ tan α ( Δh )max =μ R 2
sheet increases with the
(a) increase in coefficient of friction
(b) decrease
d in coefficient
ff off friction
f
( ) decrease
(c) d i roll
in ll radius
di
(d) increase
i i roll
in ll velocity
l it
103 104 105
GATE 2016
GATE-2016 GATE 2015
GATE-2015
GATE 2014
In a rolling process,
process the maximum possible draft,draft
A 300 mm thick slab is being cold rolled using In a rolling operation using rolls of diameter
defined as the difference between the initial and
th final
the fi l thickness
thi k off the
th metal t l sheet,
h t mainly
i l 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
depends on which pair of the following parameters?
friction is 0 08,
0.08, the maximum possible reduced to less than 20 mm in one pass, the
P: Strain
Q: Strength of the work material reduction (in mm) is ____________ coefficient of friction between the roll and the
R: Roll diameter plate is _______
S: Roll velocity
T: Coefficient of friction between roll and work
(a) Q, S (b) R, T
(c) S, T (d) P, R
Page 80 of 186 107
Rev.0 108
GATE 2015
GATE-2015 IES – 1999 Minimum Possible Thickness (h f min )
In
I a slab
l b rolling
lli operation
i , the
h maximum
i Assertion
A i (A):
(A) InI a two high
hi h rolling
lli mill
ill there
h is
i a
ho − h f min = μ 2 R
limit to the possible reduction in thickness in one
thickness reduction(∆h)max is given by ∆hmax = µ
µ²R
R,
pass.
where R is the radius of the roll and µ is the co‐ Reason (R): The reduction possible in the second
efficient of friction between the roll and the sheet. pass is less than that in the first pass.
( ) Both
h
If µ = 0.1, the maximum angle subtended by the correct explanation of A
deformation zone at the centre of the roll (bite (b) Both A and R are individually true but R is not the
angle
l in degrees)
d ) is _____ correct explanation of A
109 110 111
GATE‐2006 Number of pass needed G
GATE – 20 ( )
2011 (PI)
A 4 mm thick sheet is rolled with 300 mm diameter The
Th thickness
hi k off a plate
l is
i reduced
d d from
f 30 mm to 10
rolls
ll to reduce
d thickness
h k without
h any change
h in its
Δhrequired mm by successive cold rolling passes using identical
n=
width The friction coefficient at the work‐roll
width. work roll q rolls of diameter 600 mm. Assume that there is no
Δhmax
interface is 0.1. The minimum possible thickness of change in width. If the coefficient of friction
the sheet that can be produced in a single pass is between the rolls and the work piece is 0.1, the
minimum number of passes required is
(a) 1.0 mm (b) 1.5 mm
(c) 2.5 mm (d) 3.7 mm (a) 3 (b) 4 (c) 6 (d) 7
112 113 114
Neutral Point and Neutral Plane
The point
Th i where
h roll
ll velocity
l i equals
l
IES – 2001 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
A strip is to be rolled from a thickness of 30 mm to
rolled to 40 mm thickness in 4 passes with equal R roll radius
R = roll radius
15 mm using a two‐high
h h mill
ll having
h rolls
ll off reduction in each pass, by using rolls of 800 mm ho = back height
diameter 300 mm.
mm The coefficient of friction for diameter. Assuming g the pplane‐strain deformation,,
hf =output or final
fi l
what is the minimum coefficient of friction
thickness
unaided bite should nearly be required for unaided rolling to be possible?
α = angle of bite
((a)) 0.35
35 ((b)) 0.55 (a) 0.111 (b) 0.158 (c) 0.223 (d) 0.316
N N neutral point or no
N‐N = neutral point or no‐
slip point
((c)) 0.255 ((d)) 0.077 Vr − Vo
Backward slip = × 100% To the left of the Neutral Point:
Vr
Velocity of the strip < Velocity of the roll
V f − Vr
Forward slip = ×100% To the right of the Neutral Point:
Page 81 of 186 116 Vr Rev.0
Velocity of the strip > Velocity of the roll
117
IES 2014
IES ‐
In the process of metal rolling operation, along the arc GATE ‐2008(PI)
GATE‐1990 (PI)
GATE‐1990 (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
neutral point, because
Whil rolling
While lli a strip
t i the
th peripheral
i h l velocity
l it off (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 roll is ….A…..than
A than the entry velocity of the and on the other side,, the work material is in compression
p
rotating at 100 rpm.
rpm The velocity of the strip in
(b) On one side of this point, the work material has velocity
strip
p and is ……B …..the exit velocity
y of the greater than that of the roll and on the other side,
side it has (m/s) at the neutral point is
strip. velocity lesser than that of the roll
((a)) 1.57
57 ((b)) 33.14
4 ((c)) 47
47.10 ((d)) 94
94.20
( ) On
(c) O one side id off this
thi point,
i t the
th work k material
t i l has
h rough h
(a) less than/greater less surface finish and on the other side, the work material has
very fine
fi finish
fi i h
(b) Greater than/less than
(d) At this ppoint there is no increase in material width, but
on either side of neutral point, the material width increases
118 119 120
IES – 2002 Selected Questions C ti it E

Continuity Equation
ti
y Generally rolling increases the
In rolling a strip between two rolls, the position of The effect of friction on the rolling mill is work width from an initial value
of bo to a final one of bf and this
the
h neutrall point in the
h arc off contact does
d not (a) always bad since it retards exit of reduced metal is called spreading.
depend on (b) always good since it drags metal into the gap between y The
Th inlet
i l and
d outlet
l volume
l
rates of material flow must be
(a) Amount of reduction (b) Diameter of the rolls th rolls
the ll the
h same, thath is,
i
(c) Coefficient of friction (d) Material of the rolls (c) advantageous before the neutral point hobovo = hf bfvf
(d) disadvantageous after the neutral point where vo and vf are the entering
g
and exiting velocities of the
work.
121 122 123
GATE‐2014 Elongation Factor or Elongation Co‐efficient GATE‐1992(PI)

A mild steel plate has to be rolled in one pass such L A If the elongation factor during rolling of an
that the final plate thickness is 2/3rd of the initial E= 1 = o for single pass ingot is 1.22. The minimum number of passes
Lo A1
thickness,
hi k with
i h the
h entrance speed
d off 10 m/min
/ i needed
d d to produce
d a section
i 250 mm x 250 mm
Ln Ao
and roll diameter of 500 mm.
mm If the plate widens
En = = f n − pass
for from an ingot of 750 mm x 750 mm are
byy 2% during
g rolling,
g, the exit velocityy ((in m/min)
/ ) Lo An (a) 8 (b) 9
is …………… (c) 10 (d) 12

Page 82 of 186 125
Rev.0 126
Force, Torque and Power Projected length ( L p ) = R sin α = RΔh , mm
Projected
j Area ( Ap ) = Lp × b , mm 2 GATE‐2016 (PI)
g Force ( F ) = σ o × L p × b , N
RollSeparating
p In a single‐pass rolling operation, a 200 mm wide
metallic strip is rolled from a thickness 10 mm to a
[σ o in N / mm 2 i.e. MPa ]
thickness 6 mm. The roll radius is 100 mm and it rotates
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
= 0.45 Lp for cold rolling roll radius and,
and initial and final thickness of the strip.
strip If
a the average
g flow stress in p
plane strain of the strip
p
Will b
be T
Torque ll (T ) = F ×
per roller , Nm
N
discussed 1000 material in the roll gap is 500 MPa, the roll separating
in class 127 Total power for two roller ( P ) = 2T ω , inW 128

force (in kN) is _______. 129
GATE‐2008 IES – 2000, GATE‐2010(PI) IAS – 2007

In a single pass rolling operation, a 20 mm thick In the rolling process, roll separating force can be Consider
C id theh following
f ll i statements:
g can be reduced byy
Roll forces in rolling
plate
l with
h plate
l width
d h off 100 mm, is reduced
d d to 18 d
decreased
d by
b
1. Reducing friction
mm The roller radius is 250 mm and rotational
mm. ( ) 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
speed is 10 rpm. The average flow stress for the plate area.
(b) Increasing
I i the
th roll
ll diameter
di t
3. Taking smaller reductions per pass to reduce the
material is 300 MPa. The power required for the
(c) Providing back‐up
back up rolls contact area.
area
rolling operation in kW is closest to Which of the statements given above are correct?
(d) Increasing the friction between the rolls and the
(a) 15.2 (b) 18.2 (a) 1 and 2 only (b) 2 and 3 only
metal (c) 1 and 3 only (d) 1, 1 2 and 3
(c) 30.4 (d) 45.6 130 131 132
Assumptions in Rolling IES – 2001 IAS – 1998

1. Rolls
R ll are straight,
i h rigid
i id cylinders.
li d 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)
( )
2. Strip
p is wide compared
p with its thickness,, so that no cold rolling? and select the correct answer using the codes given
widening of strip occurs (plane strain conditions). 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
3 The arc of contact is circular with a radius greater than
3.
the radius of the roll.
the radius of the roll. A. M.S. angles and channels 1. Welding
3 Coefficient of friction is constant over the arc of
3.
4. The material is rigid perfectly plastic (constant yield contact and acts in one direction throughout the arc of B. Carburetors 2. Forging
st e gt ).
strength). contact.
contact C Roof trusses
C. 3
3. Casting
5. The co‐efficient of friction is constant over the tool‐ Select the correct answer using the codes given below: D. Gear wheels 4. Rolling
workk interface.
i t f 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 (c) 1 2 4 3(d) 4 3 1 2135
Page 83 of 186 134
Rev.0
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
136 137 138
IES‐2013
Statement (I): The dies used in the forging process are Open and Closed die forging
d l dd f Advantages of Forging
d f
made in pair.
pair y Depending
D di upon complexity
l i off the
h part forging
f i is
i y Discrete
Di shape
h off product
d can be
b produced.
d d
Statement (II): The material is pressed between two carried out as open die forging and closed die forging.
surfaces and the compression force applied, gives it a y Mechanical properties and reliability of the materials
shape.
p y In open die forging, the metal is compressed by repeated increases due to improve in crystal structure.
blows by
bl b a mechanical
h i l h
hammer and
d shape
h i
is
(a) Both Statement (I) and Statement (II) are individually y In forging favorable grain orientation of metal is
manipulated manually.
true and Statement (II) is the correct explanation of obtained that strengthen the component but forging
Statement (I) y In closed die forging, the desired configuration is distorts the previously created uni‐directional fibre.
(b) Both Statement (I) and Statement (II) are individually obtained
b i d byb squeezing i the
h workpiece
k i b
between two
y Forging reduces the grain size of the metal, which
true but Statement ((II)) is not the correct explanation
p of shaped and closed dies.
increases strength and toughness.
toughness
Statement (I)
(c) Statement (I) is true but Statement (II) is false y Fatigue and creep strength increases.
(d) Statement (I) is false but Statement (II) is true 139 140 141
Disadvantages of Forging
d f IES – 1996 IES‐2013
y Costly
C l Which one of the following is an advantage of In the forging process:
I h f i
y Poor dimensional accuracy and surface finish.
finish forging? 1. The metal structure is refined
Th t l t t i fi d
y Forging operations are limited to simple shapes and has 2 Original unidirectional fibers are distorted.
2. Original unidirectional fibers are distorted
( ) Good
(a) G d surface
f fi i h
finish
limitations for parts having undercuts, re‐entrant
surfaces etc
surfaces, (b) Low
L tooling
t li costt 3 Poor reliability as flaws are always there due to intense
3. Poor reliability, as flaws are always there due to intense
(c) Close tolerance working

g
(d) Improved physical property.

property 4
4. Part are shaped by plastic deformation of material
p yp
(a) 1, 2 and 3 (b) 1, 3 and 4

Page 84 of 186 143 (c) 1, 2 and 4 (d) 2, 3 and 4
Rev.0 144
IES 2005
IES – IES ‐ 2012 IES 2016
IES‐2016
Consider the following statements: Statement (I): It is difficult to maintain close Consider the following g statements about forging
g g:
tolerance in normal forging operation. 1. Forgings have high strength and ductility.
1. Forging reduces the grain size of the metal, which Statement (II): Forging is workable for simple 2. Forgings
F i offer
ff greatt resistance
i t t impact
to i t and
d
results in a decrease in strength
g and toughness.
g shapes and has limitation for parts having fatigue loads.
undercuts.
undercuts
3. Forging assures uniformity in density as well as
2. Forged components can be provided with thin (a) Both Statement (I) and Statement (II) are
dimensions of the forged parts.
i di id ll true and
individually d Statement
S (II) is
i theh correct
sections, without reducing the strength. explanation of Statement (I) Which of the above statements are correct?
(b) Both Statement (I) and Statement (II) are (a) 1 and 2 only (b) 1 and 3 only
Which of the statements given above is/are correct?
individuallyy true but Statement ((II)) is not the correct (c) 2 and 3 only (d) 1,
1 2 and 3
(a) Only 1 (b) Only 2 explanation of Statement (I)
(c) Both 1 and 2 (d) Neither 1 nor 2 (d) Statement (I) is false but Statement (II) is true 146
145 147
ISRO‐2013 Forgeability
bl IES ‐ 2012
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 Which
f ll i statements is i correct for
f
stress in the metal? capability to undergo deformation by forging without forging?
cracking. (a) Forgeability is property of forging tool, by which
(a) Hot rolling
y Metal
M l which
hi h can be
b formed
f d easily
il without
ih cracking,
ki with
ih forging can be done easily.
easily
(b) Forging (b) Forgeability decreases with temperature upto lower
low force has good forgeability.
(c) Swaging criticall temperature.
y Upsetting test and Hot‐twist test are used to determine
(c) Ce
Certain
ta mechanical
ec a ca p properties
ope t es o
of tthee material
ate a aaree
( ) Turning
(d) f
forgeability.
bili
influenced by forging.
y Forgeability increases with temperature.
temperature (d) Pure
P metals
t l have
h good d malleability,
ll bilit therefore,
th f poor
forging properties.
148 149 150
Draft
f IES – 2006 Flash
l h
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 The
Th excess metall added
dd d to the
h stockk to ensure complete
l
forging. or draft angles on vertical surfaces. filling of the die cavity in the finishing impression is
Reason (R): It facilitates complete filling of die called Flash.
y Adequate draft should be provided‐at least 3o for
aluminum
l i d 5 to 7o for
and f steel.
l cavity and favourable grain flow.flow
y Internal surfaces require more draft than external correct explanation
l off A
surfaces. During cooling, forging tends to shrink towards
(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
to be separated, whereas the internal surfaces tend to
cling to the die more strongly. ( ) A is
(c) i true
t b t R is
but i false
f l

Page 85 of 186 152
Rev.0 153
IES‐2016
Flash
l h Contd… IES ‐ 2014 Statement (I) : In drop forging, the excess metal
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 added to the stock for complete filling of the die
finishing impression and also helps to restrict the the forging is cavity is called flash.
outward flow of metal, thus helping in filling of thin ribs (a) Gutter space, which fills up hot gases Statement (II) : Flash acts as a cushion against
and bosses in the upper
pp die. impact
p blows attributable to the finishing g
(b) Flash,
Flash the width of it is an indicator of the pressure
impression.
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
Statement (II) is the correct explanation of Statement (I).
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
Statement ((II)) is not the correct explanation
)
154 155 156
IAS – 2002 Gutter Gutter Contd….

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 y Without a gutter, a flash may become excessively thick,
forging: die for additional space so that any excess metal can flow
1. Flash is excess material added to stock which flows and help in the complete closing of the die. This is called not allowing
ll the
h dies
d to close
l completely.
l l
around parting line.
around parting line g
gutter.
y Gutter
G d h and
depth d width
id h should
h ld be
b sufficient
ffi i to
2. Flash helps in filling of thin ribs and bosses in upper
die. accommodate the extra,
extra material.
material
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?
( ) 1, 2 and 3
(a) d (b) 1 and 2d
(c) 1 and 3 (d) 2 and 3
157 158 159
IES – 1993, GATE‐1994(PI) IES – 1997

Which one of the following manufacturing
Assertion
A ti (A):
(A) In
I drop
d forging
f i besides
b id theth provision
i i GATE‐1989(PI)
for flash, provision is also to be made in the forging
processes requires the
h provision off ‘gutters’?
‘ ’ di for
die f additional
dditi l space called
ll d gutter.
tt At th l t h
At the last hammer stroke the excess material from
t k th t i l f
Reason (R): The gutter helps to restrict the outward the finishing cavity of a forging die is pushed
( ) Closed
(a) Cl d die
di forging
f i flow of metal thereby helping to fill thin ribs and
bases in the upper die. into……………..
(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)
Page 86 of 186 161
Rev.0 162
IES‐2015 Sequential steps involved in closed die forging
Which of the following statements apply to provision
Fullering or
swaging
Reducing cross section and making it longer. Example
l
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.
forged? Bending Required for those parts which have a bent
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
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.
163
Trimming or cut off Removal of flash present around forging 164 165
IES – 1998 IES – 2001 IES – 2003

Which one of the following processes is most In the forging operation, fullering is done to A forging method for reducing the diameter of a bar
commonly
l used
d for
f the
h forging
f off bolt
b l heads
h d off (a) Draw out the material and
d in the
h process making
k it longer
l is termed
d as
hexagonal shape? (b) Bend the material ( ) Fullering
(a) F ll i (b) P
Punching
hi
(a) Closed die drop forging ( ) Upset the material
(c) ( ) Upsetting
(c) U tti (d) E t di
Extruding
(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
166 167 168
IES 2011 IES – 2005 IES – 2002

Which of the following processes belong to forging The process of removing the burrs or flash from a Consider
f ll i steps involved
i l d in
i hammer
h
operation
p ? forging a connecting rod from bar stock:
f
forged
d component in drop
d f
forging is called:
ll d 1. Blocking 2. Trimming
1. Fullering
2. Swaging
S i ( ) Swaging
(a) S i (b) P f
Perforating
i 3 Finishing 4.
3. 4 Fullering 5 Edging
5.
33. Welding g Which of the following is the correct sequence of
( ) Trimming
(c) Ti i (d) F ttli
Fettling operations?
(a) 1 and 2 only
(b) 2 and d 3 only
l (a) 1,
1 4,
4 3,
3 2 and 5
(c) 1 aand
d3o onlyy (b) 4, 5, 1, 3 and 2
(b) 1, 2 and 3 only (c) 5, 4, 3, 2 and 1
(d) 5,
5 1,
1 4,
4 2 and 3
Page 87 of 186 170
Rev.0 171
IES – 2003 IAS – 2001 IES‐2012 Conventionall
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) In
I forging
f i define
d fi the
h terms
and select the correct answer using the codes given below
rod from the bar stock: the Lists: ((i)) Edging
g g
1. Blocking 2. Trimming List I List II
(ii) Fullering
A. Flattening 1. Thickness is reduced continuously at
3 Finishing 4.
3. 4 Edging diff
different sections
i along
l l
length
h and d (iii) Flash
Fl h
Select the correct sequence of these operations using the B. Drawing 2. Metal is displaced away from centre,
reducing thickness in middle and
codes given below: increasing length
Codes: C. Fullering g 33. Rod is p
pulled through
g a die
D. Wire drawing 4. Pressure a workpiece between two flat
(a) 1‐2‐3‐4 (b) 2‐3‐4‐1 dies
(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
( ) 3
(c) 1 2 4 ( )
(d) 4 2 1 3
172 173 174
IAS – 2003 Drop Forging

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
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
List‐I List‐II
(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.
175 176 177
Click to see file Page 4 – 5 ‐6
Press Forging
g g
IES – 1994, ISRO‐2010 IAS – 2000 y Metal is squeezed gradually by a hydraulic or mechanical
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 press and component is produced in a single closing of
die, hence the dimensional accuracy is much better than
((a)) The work ppiece at high
g velocityy ((a)) Small components
p
d
drop f i
forging.
(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.

Page 88 of 186 179
Rev.0 180
Advantages of Press Forging over Drop Forging
IES 2011
IES 2011
Consider the following statements :
y Press forging is faster than drop forging 1. Any metal will require some time to undergo IFS‐2011
complete
p plastic deformation p
p particularly
y if
What advantages does press forging have over drop
y Alignment of the two die halves can be more easily deforming metal has to fill cavities and corners of
small radii. forging
g g ? Whyy are p
pure metals more easilyy cold worked
maintained
i i d than
h with
i h hammering.
h i
2. For larger work piece of metals that can retain than alloys ?
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
use forge press rather than forge hammer. [5‐marks]
forging.
forging
(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
181 182 183
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.
184 185 186
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
Page 89 of 186 188
Rev.0 189
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 4190 (c) 2 1 4 3 (d) 4 1 2 3 191 rocket component. 192
IES‐2013
Statement (I): In high velocity forming process, high
gy can be transferred to metal with relativelyy small
energy
weight.
IFS‐2011 IAS‐2011 Main
IAS‐2011 Main
Statement (II): The kinetic energy is the function of Write four advantages of high velocity forming process.
C
Compare S ith forging,
Smith f i d
drop f i
forging, press
mass and velocity. [2‐marks]
forging and upset forging.
forging Mention three points
(a) Both Statement (I) and Statement (II) are individually
true and Statement ((II)) is the correct explanation
p of for each.
Statement (I)
[10 – Marks]
(b) Both
B th Statement
St t t (I) and
d Statement
St t t (II) are individually
i di id ll
true but Statement (II) is not the correct explanation of
Statement (I)
()
(d) Statement (I) is false but Statement (II) is true 193 194 195
For IES Only
Flashless forging Lubrication for Forging

b f
y The work material is completely surrounded by the die IES – 2008
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 Lubricants influence: friction, wear, deforming forces
y Most important requirement in flashless forging is that from steel rods. The operations involved are:
1. Ground and
d flow
fl off materiall in die‐cavities,
d non‐sticking,
k
the work volume must equal the space in the die cavity to
a very close tolerance.
tolerance 2 Hot forged on hammers
2. thermal barrier.
barrier
3. Heat treated
y For hot forging: graphite,
graphite MoS2 and sometimes molten
4. Polished
g
glass.
Wh t is
What i the
th correctt sequence off the th above
b
operations from start? y For cold forging:
g g mineral oil and soaps.
p
(a) 3‐2‐4‐1 (b) 3‐2‐1‐4
y In hot forging, the lubricant is applied to the dies, but in
(c) 2‐3‐1‐4 (d) 2‐3‐4‐1
cold forging, it is applied to the workpiece.
Page 90 of 186 197
Rev.0 198
Forging Defects
f Forging Defects
f Contd…. Forging Defects
f Contd….
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 y Forging Laps: These are folds of metal squeezed
improper cleaning of the stock.
completely
l l filled,
f ll d due
d to improper y Die Shift: Due to Misalignment of the two die halves or together
h during
d f
forging. They
h have
h irregular
l contours
design of die making the two halves of the forging to be of improper and occur at right angles to the direction of metal flow.
flow
shape.
y Cold Shut or fold: A small crack at y Flakes:
l k Internall ruptures caused d by
b the
h improper y Hot tears and thermal cracking: These are surface
the corners and at right
g angles
g to cooling. cracks occurring
g due to non‐uniform cooling
g from the
y Improper Grain Flow: This is caused by the improper
the forged surface. Cause: improper forging stage or during heat treatment.
design of the die,
die which makes the flow of metal not
design of the die flowing the final intended directions.
199 200 201
IAS – 1998 IES 2011

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 GATE ‐2008 (PI)
GATE ‐2008 (PI)
of metal in the component called 'Lap' occurs because of inclusions in the blank material Match the following
because Reason (R) : Bonding between the inclusions Group ‐1 Group‐2
(a) The corner radius provided is too large and the p parent material is through
g p physical
y P . Wrinkling
P 11. Upsetting
Upsetting
and chemical bonding.
(b) The corner radius provided is too small Q. Centre burst 2. Deep drawing
(c) Draft is not provided correct explanation of A R. Barrelling 3. Extrusion
(d) The shrinkage allowance is inadequate (b) Both A and R are individually true but R is NOT S C ld h t
S. Cold shut 4. Closed die forging
Cl d di f i
( ) A is true but
(c) b R is false
f l (a) P – 2, Q – 3, R – 4, S‐1 (b) P – 3, Q – 4, R – 1, S‐2
((d)) A is false but R is true (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
202 203 204
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
IES ‐
IES ‐ 2007 two flat dies:
S
Sometimes
ti th parting
the ti plane
l b t
between t
two f i
forging 1 Lubricated specimens show more surface movement
1.
than un‐lubricated ones.
dies is not a horizontal plane,
plane give the main reason
2. Lubricated
b d specimens show
h l
less surface
f movement
for this design
g aspect,
p whyy is p
parting
g p
plane than un‐lubricated ones.
provided, in closed die forging? 3. Lubricated specimens show more barrelling than un‐
lubricated ones.
ones
[ 2 marks] 4. Lubricated specimens shows less barrelling than un‐
lubricated ones.
Inhomogeneous deformation with barreling of the workpiece (a) 1 and 3 (b) 1 and 4 (c) 2 and 3 (d) 2 and 4207
Page 91 of 186 206
Rev.0
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. 208 209 210
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⎞ ⎛A ⎞ ⎛ do ⎞
(a) Both Statement (I) and Statement (II) are individually
True strain (ε T ) = ln(1
( + ε ) = ln ⎜ ⎟ = ln ⎜ o ⎟ = 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)
211 212 213
GATE‐2014 GATE‐1992, ISRO‐2012, VS‐2013 GATE‐2016

The relationship between true strain (εT ) and The true strain for a low carbon steel bar which is Engineering strain of a mild steel sample is
engineering strain (ε
( E ) in a uniaxiall tension test is doubled in length by forging is
recorded as 0.100%. The true strain is
(a) 0.307
( ) E = ln(1 + ε
(a) ε l ( T ) (b) E = ln(1 ‐
(b) ε l ( εT ) (b) 0.5 (a) 0.010 %
( ) εT = ln(1 + ε
(c) l ( E ) (d) T = ln(1 ‐
(d) ε l ( εE ) (c) 0.693
0 693 (b) 0.055 %
(d) 1.0
( ) 0.099 %
(c)
(d) 0.101 %

Page 92 of 186 215
Rev.0 216
Strain Hardening & Flow Stress
y In the plastic region,
region the material behaviour is expressed
GATE‐2007 GATE‐2016 by the flow curve:
In
I open‐diedi forging,
f i a disc
di off diameter
di 200 mm andd The value of true strain produced in compressing a
σ = Kε n
Where K is strength coefficient and n is strain‐hardening
height 60 mm is compressed without any barreling
cylinder
l d to half
h lf its originall length
l h is (or work‐hardening)
work hardening) exponent and at UTS,
UTS ε = n
effect. The final diameter of the disc is 400 mm. The
true strain is
( ) 0.69
(a) 6 (b) ‐0.69
6
(a) 1.986 (b) 1.686
( ) 1.386
(c) (d) 0.602 ( ) 0.5
(c) (d) ‐0.5
217 218 219
Average Flow Stress St i
Strain rate effects
t ff t GATE‐2006
y Strain rate effect (hot Working) The ultimate tensile strength of a material is 400
y Average (mean) flow stress is not on the basis of
instantaneous flow stress,
stress but on an average value over 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
the stress – strain curve from the beginning of strain to 1 dh v Platen Velocity then the true stress‐true strain relation (stress in
the final (maximum) value that occurs during ε = = =
deformation. h dt h Instantaneous height MPa) in the plastic deformation range is:
K ε nf (a) σ = 540 ε0.30 (b) σ = 775 ε0.30

0 30
g flow stress (σ o ) =
Average (c) σ = 540 ε 0.35 (d) σ = 775 ε 0.35
1+ n
Here εf is the maximum strain value during deformation.
220 221 222
GATE 2015
GATE-2015
GATE‐2012 Same Q GATE ‐2012 (PI) GATE‐2016 (PI)
The strain hardening exponent n of stainless A solid cylinder of diameter 100 mm and height 50 mm Two solid cylinders of equal diameter have different
steall SS 304 with
h distinct
d yield
ld and
d UTS values
l is forged between two frictionless flat dies to a height of
f db f l fl d h h f heights. They are compressed plastically by a pair of rigid
undergoing plastic deformation is 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) n<0 (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
b)n=0 interface friction is negligible.
negligible The ratio of the final
c) 0<n<1 diameter of the shorter cylinder
y to that of the longer
g
d)n=1 cylinder is __________.

Page 93 of 186 224
Rev.0 225
GATE‐2015 Assumption IES ‐ 2012

The
Th flow
fl stress (in
(i MPa)
MP ) off a material
i l is
i given
i by
b y Forging force is maximum at the end of the forging.
forging Assumptions
A i adopted
d d in
i the
h analysis
l i off open die
di forging
f i
y Coefficient of friction is constant between workpiece and are
σ = 500ε 0.1
01
dies (platens). 1. Forging force attains maximum value at the middle of
Where ε is true strain.
strain The Young
Young’ss modulus of y Thickness
Thi k off the
h workpiece
k i i small
is ll compared
d with
i h other
h the operation.
operation
elasticity of the material is 200 GPa. A block of 2. Coefficient of friction is constant between work piece
thickness 100 mm made of this material is dimensions,, and the variation of stress field along
g yy‐
and d die
d
compressed to 95 mm thickness and then the load direction is negligible.
i removed.
is d The
Th final
fi l dimension
di i off the
th block
bl k (in
(i
2.. St
Stress
ess in tthee ve
vertical
t ca ((Y‐direction)
d ect o ) iss zero.
e o.
y Length is much more than width, problem is plain strain
mm) is _________ (a) 1 and 2 (b) 1 and 3
type.
type ( ) 2 and
(c) d3 (d) 1, 2 and
d3
y The entire workpiece
p is in the p
plastic state during
g the
226
process. 227 228
Extrusion & Drawing Extrusion
y The extrusion process is like squeezing toothpaste out of
y Metal is compressed and forced to flow through a
a tube.
suitably
bl shaped
h d die
d to form
f a product
d with
h reduced
d d but
b
constant cross section.
section
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.
By S K Mondal
229 230 231
y Steels, stainless steels, and nickel‐based alloys are IES – 2007 Extrusion Ratio
Which
Whi h one off the th following
f ll i is
i theth correctt
difficult to extrude. (high yield strengths, welding with y Ratio of the cross‐sectional area of the billet to the cross‐
statement?
wall). Use phosphate‐based and molten glass (a) Extrusion is used for the manufacture of seamless sectionall area off the
h product.
d
tubes.
lubricants . y about
b 40: 1 for
f hot
h extrusion
i off steell
(b) Extrusion is used for reducing the diameter of round
bars and tubes byy rotating g dies which open
p and close
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
For-2017 (IES, GATE & PSUs) 232 finished part. Page 94 of 186 233
Rev.0 234
DRDO‐2008 Advantages of Extrusion
d f IES ‐ 2012
If the extrusion ratio is 20, the percentage reduction y Any cross‐sectional shape can be extruded from the Extrusion process can effectively reduce the cost of
in the
h cross‐sectionall area off the
h billet
b ll after
f the
h nonferrous
f metals.
t l product
d through
h h
extrusion will be y Many shapes (than rolling) ( ) Material
(a) M i l saving
i
(a) 98% (b) 95% (c) 20% (d) 5% y No
oddraft
at
(b) process time
ti saving
i
y Huge reduction in cross section.
(c) Saving in tooling cost
y Conversion from one product to another requires only a
(d) saving in administrative cost
single die change
y Good dimensional precision.

235 236 237
IES – 2009 Limitation of Extrusion

f Application
l
Which
Whi h one off the
h following
f ll i statements is i correct?? y Cross section must be uniform for the entire length of y Working of poorly plastic and non ferrous metals and
((a)) In extrusion p
process,, thicker walls can be obtained
by increasing the forming pressure the
h product.
d alloys.
ll
(b) Extrusion is an ideal process for obtaining rods from y Manufacture
M f off sections
i and
d pipes
i off complex
l
metal having poor density
configuration.
configuration
(c) As compared to roll forming, extruding speed is high
(d) Impact extrusion is quite similar to Hooker
Hooker'ss process y Medium and small batch production.
production
including the flow of metal being in the same direction
y Manufacture of parts of high dimensional accuracy.
238 239 240
IES – 1994 GATE‐1994

E t i
Extrusion
Metal extrusion process is generally used for The process of hot extrusion is used to produce
producing
d (a) Curtain rods made of aluminium
Hot Cold
( ) Uniform
(a) U if solid
lid sections
i (b) Steel pipes/or domestic water supply
(b) Uniform
U if h ll sections
hollow ti ( ) Stainless steel tubes used in furniture
(c)
Direct Indirect Forward Backward
(c) Uniform solid and hollow sections (d) Large
L shape
h pipes
i used
d in
i city
i water mains
i
(d) Varying solid and hollow sections.
sections Cold Impact
Hydrostatic Extrusion Extrusion
Forging

Page 95 of 186 242
Rev.0 243
IES – 1999 IAS – 2012 main Hot Extrusion Process
Which one of the following is the correct Classify the process of extrusion with the help of y The temperature range for hot extrusion of aluminum is
temperature range for
f hot
h extrusion off aluminium?
l sketches.
k h 430‐480°C
( ) 300‐340°C
(a) °C (b) 350‐400°C
°C y Used
U d to produce
d curtain
i rods
d made
d off aluminum.
l i
( ) 430‐480°C
(c) 8 °C (d) 550‐650°C
6 °C y Design
D i off die
di is
i a problem.
bl
y Either direct or indirect method used.

used
244 245 246
IES – 2009 Direct Extrusion IES – 1993

y A solid
lid ram drives
di the
h entire
i billet
bill to and
d through
h h a Assertion
A i (A):
(A) Direct
Di extrusion
i requiresi larger
l force
f
What is the major problem in hot extrusion?
stationary die and must provide additional power to than indirect extrusion.
(a) Design of punch (b) Design of die overcome the
h frictional
f l resistance between
b the
h surface
f off the
h
Reason (R): In indirect extrusion of cold steel, zinc
moving billet and the confining chamber.
phosphate coating is used. used
(c) Wear and tear of die (d) Wear of punch
correct explanation
l off A
(b) Both
d v dua y ttrue
ue but R iss not
ot tthee
( ) A is
(c) i true
t b t R is
but i false
f l
247 248 249
IES – 2000 Indirect Extrusion

d Indirect Extrusion
d Contd…
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
y Required force is lower (25 to 30% less)
In forward extrusion process confined billet.
1. The ram and the extruded product travel in the same y Since no relative motion, friction between the billet and y Low process waste.
direction. the chamber is eliminated.
2. The ram and the extruded product travel in the opposite
direction.
3. The speed of travel of the extruded product is same as that
of the ram.
4. The speed of travel of the extruded product is greater than
that of the ram.
Which of these Statements are correct?
(a) 1 and 3 (b) 2 and 3
(c) 1 and 4 (d) 2 and 4
Page 96 of 186 251
Rev.0 252
IES ‐ 2012 IES – 2007 IAS – 2004
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 Assertion
A i (A):
(A) Indirect
I di extrusion
i operation
i can be
b
extrusion process? in case of direct extrusion than indirect one. performed either by moving ram or by moving the
1. Billet remains stationary Reason (R): In case of direct extrusion, the direction of container.
the force applied
pp on the p plunger
g and the direction of Reason (R): Advantage in indirect extrusion is less
2 There is no friction force between billet and container
2.
the movement of the extruded metal are the same. quantity of scrap compared to direct extrusion.
walls.
3. The force required on the punch is more in ( ) Both
h
explanation of A
comparison
co pa so to d direct
ect eextrusion.
t us o . correct explanation of A
(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 (b) Both A and R are individually true but R is not the
( ) 1, 2, 3 and
(a) d4 (b) 1, 2 and
d 3 only
l correct explanation of A
(c) 1, 2 and 4 only (d) 2, 3 and 4 only ((d)) A is false but R is true (c) A is true but R is false
253 254 255
IES‐2016
Statement (I): Employing the extrusion process is Cold Extrusion
ld Backward cold extrusion
k d ld
not economicall in case off large
l billets.
b ll y Used with low‐strength metals such as lead, tin, zinc, y The metal is extruded through the gap between the
Statement (II): A significant part of the press
and
d aluminum
l to produce
d collapsible
ll bl tubes
b f
for punch
h and
d die
d opposite to the
h punch
h movement.
capacity is lost overcoming frictional resistance
between workpiece and cylinder wall during the toothpaste medications,
toothpaste, medications and other creams; small "cans"
cans y For
F softer
f materials
i l such
h as aluminium
l i i and
d its
i alloys.
ll
extrusion process.
for shielding electronic components and larger cans for y Used
U d for
f making
ki collapsible
ll ibl tubes,
t b cans for
f liquids
li id and
d
Statement ((II)) is the correct explanation
) food and beverages. similar articles.
articles
(b) Both Statement (I) and Statement (II) are individually true but y Now‐a‐days also been used for forming mild steel parts.
St t
Statementt (II) is
i nott the
th correctt explanation
l ti off Statement
St t t (I).
(I)
256 257 258
Impact Extrusion IES – 2008, GATE‐1989(PI) IES – 2003

Which one of the following methods is used for the The
Th extrusioni process (s)( ) usedd for
f the
h production
d i off
toothpaste tube is/are
manufacture
f off collapsible
ll bl tooth‐paste
h tubes?
b 1. Tube extrusion
( ) Impact
(a) I extrusion
i (b) Di
Direct extrusion
i 2 Forward extrusion
2.
3. Impact extrusion
( ) Deep
(c) D d
drawing
i (d) Pi i
Piercing
C d
Codes:
(a) 1 onlyy (b) 1 and 2
(c) 2 and 3 (d) 3 only
y The extruded parts are stripped by the use of a stripper
plate, because they (IES,
For-2017 tend to stick&to
GATE the punch.
PSUs) 259
Page 97 of 186 260
Rev.0 261
IES ‐ 2014 IAS‐2010 Main Hooker Method
k h d
A toothpaste tube can be produced by How are metal tooth‐paste tubes made
(a) Solid forward extrusion commercially ? Draw the tools configuration with
(b) Solid backward extrusion the help of a neat sketch.
( ) Hollow backward extrusion

(c) [
[30‐Marks]
k ]
(d) Hollow
H ll forward
f d extrusion
i
262 263 264
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.
265 and the die. 266 267
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.
Page 98 of 186 269
Rev.0 270
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
271 272
(c) 2 and 3 (d) 2 and 4 273
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
274 275 276
IES ‐ 2014
IES 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
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.
Page 99 of 186 278
Rev.0 279
GATE‐2014
With respect to metal working,
working match Group A with Group B
JWM 2010 IAS – 2012 main Group A Group B
Assertion (A): Extrusion speed depends on work P: Defect in extrusion I: alligatoring
Enumerate the conditions under which central burst
material.
Q: Defect in rolling II: scab
Reason (R): High extrusion speed causes cracks in may occur. Where does a 'pipe' occur ?
h d ' '
R: Product of skew III: fish tail
the material. rolling
lli
(a) Both A and R are individually true and R is the S: Product of rolling IV: seamless tube
l ti off A through cluster mill
(b) Both A and R are individuallyy true but R is not the V: thin sheet with tight tolerance
correct explanation of A VI: semi‐finished balls of ball bearing
P Q R S P Q R S
(d) A is false but R is true (a) II III VI V (b) III I VI V
280 281
(c) III I IV VI (d) I II V VI
282
Wire Drawing Wire Drawing Contd…. Wire Drawing Contd….

y A cold working process to obtain wires from rods of y Wire getting continuously wound on the reel.
b
bigger d
diameters through
h h a die.
d y For
F fine
fi wire,
i theth material
t i l may be
b passed
d through
th h a number
b
of dies,, receiving
g successive reductions in diameter,, before
y Same
S process as bar
b drawing
d i except that
h iti involves
i l
being coiled and known as Tandem Drawing.
smaller‐diameter material.
material
y The wire is subjected to tension only. But when it is in
y At the start of wire drawing, the end of the rod or wire to
be drawn is pointed to make for an easier entrance of contact with
i h dies
di then
h a combination
bi i off tensile,
il compressive
i
wire into the die. This pointing is done by means of and shear stresses will be there in that p
portion only.
y
rotary swaging or by simple hammering.
y Wire drawing is always a cold‐working process, need
sufficient ductility, may be annealed before drawing.
283 284 285
IES – 2007 IES – 2009 IES – 2005

Which metal forming process is used for 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 /
involved in the wire‐drawing operation?
manufacture
f off long
l steell wire? wire drawing
d process? (a) Tensile only
( ) Deep
(a) D d
drawing
i (b) F i
Forging ( ) Compressive
(a) C i (b) T il
Tensile (b) Compressive only
(c) A combination of tensile and compressive stresses
( ) Drawing
(c) D i (d) E t i
Extrusion ( ) Shear
(c) Sh (d) H d t ti stress
Hydrostatic t
(d) A combination of tensile, compressive and shear
stresses

Page 100 of 186 287
Rev.0 288
IES‐2016
Statement (I) : In wire‐drawing, the end of the stock Cleaning and Lubrication in wire Drawing
GATE‐1987 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
wire into the die. y Lubrication boxes precede the individual dies to help reduce
F i d
For wire drawing operation, the work material
i ti th k t i l Statement (II) : The pointing of the wire is done friction drag and prevent wear of the dies.
should essentially be exclusivelyy by
y rotaryy swaging
g g and not by y simple
p
hammering. y Sulling: The wire is coated with a thin coat of ferrous
(a) Ductile (b) Tough (a) Both Statement (I) and Statement (II) are individually true and hydroxide which when combined with lime acts as filler for
Statement (II) is the correct explanation of Statement (I). the lubricant.
((c) Hard
) ((d) Malleable
)
(b) Both Statement (I) and Statement (II) are individually true but y Phosphating: A thin film of Mn, Fe or Zn phosphate is
( ) p ()
Statement (II) is not the correct explanation of Statement (I). applied on the wire.
wire
y Electrolytic
y coating:
g For veryy thin wires,, electrolytic
y coating
g
289 290
of copper is used to reduce friction. 291
IES 2010 IES – 2000 IAS – 1995

Assertion (A): Pickling and washing of rolled rods 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
is carried out before wire drawing. suitable for drawing mild steel wires? preparing the billets for extrusion process:
Reason (R): They lubricate the surface to reduce (a) Sodium stearate (b) Water 1. Alkaline cleaning
friction while drawing g wires. (c) Lime‐water
Lime water (d) Kerosene 2 Phosphate coating
2.
(a) Both A and R are individually true and R is the 3. Pickling
l ti off A
4. Lubricating with reactive soap.
(b) Both A and R are individuallyy true but R is NOT the
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
292 293 294
IES ‐ 2014
IES
IES – 1996 Statement‐I: In drawing process, cross‐section of
In wire drawing process, the bright shining surface
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
on the
h wire is obtained
b d iff one I this
In thi process, many wires
i ( much
(as h as severall
are polygonal in cross‐section rather than round
( ) does
(a) d not use a lubricant
l bi thousand) are drawn simultaneously as a bundle.
bundle (a) Both Statement (I) and Statement (II) are
To p
prevent sticking,
g the wires are separated
p from individually true and Statement (II) is the correct
(b) uses solid
lid powdery
d l bi
lubricant.
t explanation
l i off Statement
S (I)
each other by a suitable material. The cross‐ ((b)) Both Statement ((I)) and Statement ((II)) are
(c) uses thick paste lubricant
section of the wires is somewhat polygonal. individually true but Statement (II) is not the correct
(d) uses thin film lubricant explanation of Statement (I)
Page 101 of 186 296
Rev.0 297
Wire Drawing Die Rod and Tube Drawing
d d b
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
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
y Die materials: tool steels or tungsten carbides or i t
internall mandrel
d l is
i called
ll d tube
t b sinking.
i ki
polycrystalline diamond (for fine wire) 298 299 300
Rod and Tube Drawing
d d b Contd…
IES‐1993; GATE‐1994(PI), 2014(PI)
IES 1993; GATE 1994(PI) 2014(PI) IAS‐2006
A moving mandrel is used in Which one of the following processes necessarily
(a) Wire drawing (b) Tube drawing requires

q mandrel of requisite
q diameter to form the
((c)) Metal Cutting

g ((d)) Forging
g g internal hole?
Tube Sinking Fixed Plug Drawing
(a) Hydrostatic Extrusion
(b) Tube drawing
(c) Swaging
(d) Wire
Wi Drawing
D i
Floating plug Drawing Moving Mandrel 301 302 303
Swaging or kneading
k d Swaging or kneading
k d Contd… IES‐2015
y The hammering of a rod or tube to reduce its diameter Rotary swaging is a process for shaping
where
h the
h die
d itself
lf acts as the
h hammer.
h a) Round bars and tubes
y Repeated
R d blows
bl are delivered
d li d from
f various
i angles,
l b)Billets
b)Bill
causing the metal to flow inward and assume the shape c) Dies
of the die. d)Rectangular
) g blocks
y It is cold working.
g The term swaging
g g is also applied
pp to
processes where material is forced into a confining die to
reduce its diameter.
Page 102 of 186 305
Rev.0 306
IES – 1993 IES – 2000 IES – 1999
Tandem
T d drawing
d i off wires
i andd tubes
b is i necessary 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
because (Manufacturing processes) and select the correct answer using the codes given below the Lists:
answer using i the
th codesd given
i b l
below th Lists:
the Li t List‐I List‐II
(a) It is not possible to reduce at one stage
List I List II A. Drawing g 1. Soapp solution
(b) Annealing is needed between stages
A. Base with stand 1. Stamping and B. Rolling 2. Camber
(c) Accuracy in dimensions is not possible otherwise p
pressingg C Wire drawing
C. dra ing 3
3. Pilots
(d) Surface finish improves after every drawing stage B. Blade 2. Wire drawing D. Sheet metal operations using 4. Crater
C Armature
C. A t coil
il wire
i 3. T i
Turning progressive dies 5. Ironing
D. Armature shaft 4. Casting Code:A B C D A B C D
Codes:A B C D A B C D (a) 2 5 1 4 (b) 4 1 5 3
(a) 4 3 2 1 (b) 2 1 4 3 ( ) 5
(c) 2 3 4 (d) 5 2 1 3
307 (c) 2 3 4 1 (d) 4 1 2 3308 309
IES – 1996 IES – 1994 IES – 1993, ISRO‐2010

Match List I with List II and select the correct answer 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
List I (Metal/forming process) List II (Associated force) using the codes given below the Lists: answer using the codes given below the lists:
A. Wire drawing 1. Shear force List I (Metal farming process) List II (A similar process) List I (Mechanical property) List II (Related to)
A.
A Blanking 1
1. Wire drawing A. Malleabilityy 1. Wire drawing g
B Extrusion
B. E t i 2. T il force
Tensile f
B. Coining 2. Piercing B. Hardness 2. Impact loads
g
C. Blanking 3. Compressive
p force
C Resilience
C. 3
3. Cold rolling
D. Bending 4. Spring back force C. Extrusion 3. Embossing
D. Isotropy 4. Indentation
C d A B
Codes:A C D A B C D D
D. Cup drawing 4
4. Rolling
5. Direction
(a) 4 2 1 3 (b) 2 1 3 4 5. Bending
Codes:A B C D A B C D
(c) 2 3 1 4 (d) 4 3 2 1 Codes:A B C D A B C D (a) 4 2 1 3 (b) 3 4 2 5
(a) 2 3 4 1 (b) 2 3 1 4 ( ) 5
(c) 4 2 3 (d) 3 2 1 5
310 (c) 3 2 1 5 (d) 2 3 1 5 311 312
GATE 2015
GATE-2015
IES – 2002 IAS – 2001 Match the followingg pproducts with p
preferred
Match
M h List
Li I with
i h List
Li II and
d select
l the
h correct Match
M h List Li I (Products)
(P d ) with i h List
Li II (Suitable
(S i bl manufacturing processes:
answer: processes) and select the correct answer using the
codes given below the Lists: Product Process
List I (Parts) List II (Manufacturing processes)
A. Seamless tubes
A 1 Roll forming
1. List I List II P Rails 1 Blow molding
B. Accurate and smooth tubes 2. Shot peening A. Connecting rods 1. Welding Q Engine Crankshaft 2 Extrusion
C. Surfaces having higher 3. Forging B. Pressure vessels 2. Extrusion R Al i i
Aluminium Ch
Channels
l 3 F i
Forging
hardness and fatigue strength4.
strength4 Cold forming C Machine tool beds
C. 3
3. Forging S PET water bottles 4 Rolling
g
Codes: A B C A B C D. Collapsible tubes 4. Casting
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
(a) 1 4 2 (b) 2 3 1 Codes:A B C D A B C D
(c) 1 3 2 (d) 2 4 1 (a) 3 1 4 2 (b) 4 1 3 2
c ) P -2 ,Q -4 ,R -3 ,S -1 d ) P -3 ,Q -4 ,R -2 ,S -1
For-2017 (IES, GATE & PSUs) 313 (c) 3 2 4 Page1 103(d)of 1864 2 3 1 314 Rev.0 315
IAS – 2002 IES 2011
IES 2011
Assertion
A ti (A):
(A) InI wire‐drawing
i d i process, the
th rod d the code given below the lists :
g
Match List –I with List –II and select the correct answer using
Seamless tube Manufacturing
Seamless tube Manufacturing
cross‐section is reduced gradually by drawing it
severall times
ti i successively
in i l reduced
d d diameter
di t dies.
di List I
List –I List II
List –II 1 Rolling
1. Rolling
Reason (R): Since each drawing reduces ductility of A Connecting rods
A. Connecting rods 1 Welding
1. Welding 2 Extrusion
the wire, so after final drawing the wire is
normalized. B. Pressure vessels 2. Extrusion 3
3. Tube Drawing
g
correct
co ect eexplanation
p a at o o
of A C. Machine tool beds 3. Forming 4. Spinning
(b) Both A and R are individually true but R is not the D. Collapsible tubes 4. Casting
correct explanation of A Codes
(c) A is true but R is false A B C D A B C D
(a) 2 1 4 3 (b) 3 1 4 2
(d)
316 (c) 2 4 1 3 (d) 3 4 1 2317 318
IAS 1994
GATE‐1991(PI) Which of the following methods can be used for IES‐2012 Conventional
manufacturing 2 meter long seamless metallic
S
Seamless
l l
long steel
t l tubes
t b are manufactured
f t d by b rolling,
lli How are the seamless tubes produced ?
tubes?
b
drawing and 1. Drawing g 2. Extrusion
3. Rolling 4. Spinning
Select
l the
h correct answer using the
h codes
d given below
b l
Codes:
(a) 1 and 3 (b) 2 and 3
( ) 1, 3 and 4
(c) ( ) 2, 3 and 4
(d)
319 320 321
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 × × K × ln ⎜ o
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
Page 104 of 186 323
Rev.0 324
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 wire‐drawing operation, the maximum A wire
i off 0.1 mm diameter
di is
i drawn
d from
f a rod
d off 15
mm diameter. Dies giving reductions of 20%, 40%
interface
f f
friction and
d no redundant
d d work,
k the
h reduction
d per pass for
f perfectly
f l plastic
l materiall in and 80% are available. For minimum error in the
theoretically maximum possible reduction in the ideal condition is final size,, the number of stages g and reduction at
each stage respectively would be
wire drawing operation is (a) 68 % (b) 63 % (a) 3 stages and 80% reduction for all three stages
((a)) 0.36
3 ((b)) 0.633 (c) 58 % (d) 50% (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)
Page 105 of 186 332
Rev.0 333
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
IES – 2011 Conventional G
GATE – 20 ( ) C S
2011 (PI) Common Data‐S1 G
GATE – 20 ( ) C S2
2011 (PI) Common Data‐S2
In a multi pass drawing operation,
multi‐pass operation a round bar of 10 mm In a multi pass drawing operation,
multi‐pass operation a round bar of 10 mm
A 12.5 mm diameter
d rod
d is to be
b reduced
d d to 10 mm
diameter by drawing in a single pass at a speed of 100 diameter and 100 mm length is reduced in cross‐section diameter and 100 mm length is reduced in cross‐section
m/min. Assuming a semi die angle of 5o and coefficient b drawing
by d i it successively
i l through
th h a series
i off seven dies
di b drawing
by d i it successively
i l through
th h a series
i off seven dies
di
of friction between the die and steel rod as 0.15, of decreasing exit diameter. During each of these of decreasing exit diameter. During each of these
calculate: d
drawing operations, the
h reduction
d in cross‐sectionall area d
drawing operations, the
h reduction
d in cross‐sectionall area
((i)) The p
power required
q in drawing
g is 35
35%. The yyield strength
g of the material is 200 MPa. 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. Ignore strain hardening.
(iii) If the rod is subjected to a back pressure of 50 The total true strain applied and the final length (in Neglecting friction and redundant work the force (in
Neglecting friction and redundant work, the force (in
N/mm2 , what would be the draw stress and maximum mm), respectively, are kN) required for drawing the bar through the first die, is
possible
ibl reduction
d ti ? (a) 2.45 and 8 17 (b) 2.45 and 345 (a) 15.71 (b) 10.21
Take stress of the work material as 400 N/mm2 . (c) 3.02 and 2043 (d) 3.02 and 3330 (c) 6.77 (d) 4.39
[15 Marks]
337 338 339
GATE – 2014 IAS – 1997 IES – 2012

A metal rod of initial length is subjected to a Extrusion
E i force
f DOES NOT depend
d d upon the
h Write
W i theh process variables
i bl in
i wire
i drawing.
d i
((a)) Extrusion ratio Ans.
d
drawing process. The
h length
l h off the
h rod
d at any
(b) Type of extrusion process 1. Reduction in cross sectional area
expression L(t) = Lo(1 + t2)
instant is given by the expression, ( ) Material
(c) M i l off the
h die
di 2. Die
Di anglel
where t is the time in minutes. The true strain rate ((d)) Workingg temperature
p 33. Friction
at the end of one minute is ………..

Page 106 of 186 341
Rev.0 342
The Degree of Drawing or Reduction factor IAS – 2006
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
= Outgoing diameter, then what is the degree of
drawing equal to?
D=
Ao − Af
=
Do2 − D 2f
2 (a)
Di − Do
(b)
Do − Di
(c )
Di2 − Do2
(d )
Di2 − Do2 Sheet Metal Operation
Ao D o Di Do Di2 Di2
⎛A ⎞ ⎛ 1 ⎞
ThereforeTrue strain ( ε ) = ln ⎜ o ⎟⎟ = ln ⎜ ⎟
⎜A ⎝ 1− D ⎠
⎝ f ⎠
By S K Mondal
y
343 344 345
Piercing (Punching) and Blanking
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
y Most commonly used – low carbon steel sheet (cost,
strength, formability) 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 y Both done on some form of mechanical press.
346 347 348
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. Punching Blanking
y Note: In pu
punching
c g cclearance
ea a ce iss p
provided
ov ded o
on Die
e
In Blanking clearance is provided on punch
Page 107 of 186 350
Rev.0 351
Clearance
Clearance Contd
Contd….
Example
l
y The clearance is determined with g
following
Clearance in %
Clearance in % Determine
D i the
h die
di and
d punch
h sizes
i for
f blanking
bl ki a
equation circular disc of 20‐mm diameter from a sheet whose
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
thickness is 1.5 mm.
C = 0.075
0 075 x thickness of the sheet
Shear strength of sheet material = 294 MPa
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 Also determine the die and punch sizes for punching a
circular hole of 20‐mm diameter from a sheet whose
y Total clearance between punch and die size will be thi k
thickness i 1.5 mm.
is
twice these ‘C’ i.e. 2C
352 353 354
GATE‐2003 Punching Force and Blanking Force
h d l k Capacity of Press for Punching and Blanking
Fm ax = Ltτ
A metal disc of 20 mm diameter is to be punched
f
from a sheet
h off 2 mm thickness.
die clearance is 3%.
h k The
h punch
h and
d the
h
3% The required punch diameter is
Press capacity will be = Fmax ×C
(a) 19.88
19 88 mm (b) 19 94 mm
19.94
The punching force for holes which are smaller than the stock [Where C is a constant and equal to 1.1 to 1.75 depending
(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 upon the profile]
th fil ]
π dtσ
Fmax =
3
d
355 t 356 357
Example
l GATE 2014
GATE‐2014 IAS‐2011 Main
Estimate the blanking force to cut a blank 25 mm wide A rectangular
l hole
h l off size
i 100 mm × 50 mm is
i to be
b For
F punching
hi a 10 mm circular
i l hole,
h l and
d cutting
i a
and
d 30 mm long
l f
from a 1.5 mm thick
h k metall strip, iff the
h made on a 5 mm thick sheet of steel having rectangular blank of 50 x 200 mm from a sheet of 1 mm
ultimate tensile strength
g and shear strength
g of 5500 thickness ((mild steel,, shear stress = 240
4 N/mm
/ 2),
ultimate shear strength of the material is 450 N/mm2.
Also determine the work done if the percentage MPa and 300 MPa, respectively. The hole is made by Calculate, in each case :
penetration is 25 percent of material thickness. punching process. Neglecting the effect of (i) Size of punch
clearance, the punching force (in kN) is (ii) Size of die
(a) 300 (b) 450 (c) 600 (d) 750 (iii) Force required. [10‐Marks]

Page 108 of 186 359
Rev.0 360
GATE‐2016 (PI) Minimum Diameter of Piercing
f IES – 1999
The ratio of press force required to punch a square hole A hole is to be punched in a 15 mm thick plate
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 h
having ultimate
l shear
h h off 3N‐mm‐2. Iff the
strength h
τs πd.t
Piercing pressure, = Strength of punch, σc × d 2
4
needed to punch a square hole of 60 mm side in a 2 mm allowable crushing stress in the punch is 6 N mm‐22,
N‐mm
thick aluminium sheet is__________________ the diameter of the smallest hole which can be
punched is equal to
(a) 15 mm (b) 30 mm
(c) 60 mm (d) 120 mm
361 362 363
IES ‐ 2014 ISRO‐2008, 2011 IES‐2013

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 A hole of diameter d is to be punched in a plate of
sheet metal of thickness t and ultimate shear
strength 400 MPa, using punching force of 44 kN. stress is 4 times the
h maximum shearing
h stress off the
h thi k
thickness t For
t. F the
th plate
l t material,
t i l the
th maximum
i
The maximum value of t is plate the biggest hole that can be punched in the
plate, crushing stress is 4 times the maximum allowable
(a) 0.5 mm
plate would be of diameter equal to shearing
g stress. For p
punching
g the biggest
gg hole, the
(b) 10 mm
1
(c) 1 mm (a) × Thickness of plate ratio of diameter of hole to plate thickness should
4
(d) 2 mm 1 be equal to:
(b) × Thickness of plate 1
1
2 (a) (b) 2
4
(c) Plate thickness
(c) 1 (d) 2
364 (d) 2 × Plate thickness 365 366
Energy and Power for Punching and Blanking Shear on Punch
h h
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)
Where p is percentage penetration required for rupture the

h die
d or punch.
h
E×N
Ideal power in press ( P inW ) = y It distribute the cutting action over a period of time.
60
[Where N = actual number of stroke per minute]
Actual Energy ( E in J ) = Fmax × ( p × t ) × C y Shear only reduces the maximum force to be applied but
Where C is a constant and equal to 1.1 to 1.75 depending upon the profile total work done remains same.
E×N
A
Actual
l power in W)=
i press ( P iinW
60 ×η
WhereE is actual energy and η is efficiency of the press

Page 109 of 186 368
Rev.0 369
Force required with shear on Punch
Force required with shear on Punch Example
l
Example
Fmax × ptt [for
[f circular
i l hole
h l and
d other
h searing
i A washer
h with
i h a 12.7 mm internal
i l hole
h l and d an outside
id
F= y A hole, 100 mm diameter, is to be punched in steel plate diameter of 25.4 mm is to be made from 1.5 mm thick
S + pt operations]
strip. The
h ultimate
l shearing
h strengthh off the
h materiall off
5.6 mm thick. The ultimate shear stress is 550 N/mm2 . the washer is 280 N/mm2.
Fmax × pt With normal clearance on the tools, cutting is complete (a) Find the total cutting force if both punches act at
F= the same time and no shear is applied
pp to either p
punch
S [For Shear cutting, or if force Vs at 40 per cent penetration
i off the
h punch.
h Give
Gi suitable
i bl or the die.
displacement curve trapezoidal mentioned shear angle for the punch to bring the work within the (b) What will be the cutting force if the punches are
in the question.] staggered, so that only one punch acts at a time.
capacity
capac ty o
of a 30
30T p
press.
ess.
Wh
Where p = penetration
i off punch h as a fraction
f i ( ) Taking
(c) T ki 6 % penetration
60% i andd shear
h on punchh off 1
S = shear on the punch or die, mm mm, what will be the cutting force if both punches act
together.
h
370 371 372
GATE‐2010 Statement Linked 1 GATE‐2010 Statement Linked 2 Fine Blanking

l k
Statement
S for
f Linked
Li k d Answer
A Questions:
Q i Statement for Linked Answer Questions: Fine
Fi Blanking
Bl ki ‐ dies
di are designed
d i d that
h have
h small
ll
In a shear cutting operation, a sheet of 5 mm thickness In a shear cutting operation, a sheet of 5mm thickness clearances and pressure pads that hold the material
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. while it is sheared. The final result is blanks that have
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 extremelyy close tolerances.
The ultimate shear strength of the sheet is 100 MPa and penetration to thickness ratio is 0.2. Neglect friction.
penetration to thickness ratio is 0.2. Neglect
p g friction. 400
400
S
S
Assuming force vs displacement curve to be rectangular, A shear of 20 mm (S = 20 mm) is now provided on the
the work done ((in J) is blade. Assuming g force vs displacement curve to be
trapezoidal,
d l the
h maximum force
f ( kN)
(in k ) exerted
d is
(a) 100 (b) 200 (c) 250 (d) 300 373 (a) 5 (b) 10 (c) 20 (d) 40 374 375
y Slitting ‐ moving rollers trace out complex paths during y Trimming ‐ Cutting unwanted excess material from the
cutting (like a can opener). periphery of a previously formed component.
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
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

Page 110 of 186 377
Rev.0 378
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

Page 111 of 186 386
Rev.0 387
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

Page 112 of 186 395
Rev.0 396
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

Page 113 of 186 404
Rev.0 405
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
Page 114 of 186 413
Rev.0 414
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

Page 115 of 186 422
Rev.0 423
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 y Drawing Force

A shell of 100 mm diameter and 100 mm height with
ISRO‐2011 ⎡D ⎤
The initial blank diameter required to form P = π dtσ ⎢ − C ⎥
the
h corner radius
d off 0.4 mm is to be
b produced
d d by
b
a cylindrical cup of outside diameter 'd‘ and
⎣d ⎦
y Blank Holding Force
cup drawing.
drawing The required blank diameter is totall height
h h 'h' having
h a corner radius
d ' ' is
'r' Blank holding force required depends on the
(a) 118 mm (b) 161 mm obtained using the formula wrinkling
i kli t d
tendency off the
th cup. The
Th maximum
i
(c) 224 mm (d) 312 mm (a ) Do = d 2 + 4dh − 0.5r limit is g
generallyy to be one‐third of the drawing
g
(b) Do = d + 2h + 2r force.
y Draw
D Cl
Clearance
(c) Do = d 2 + 2h 2 + 2r
Punch diameter = Die opening diameter – 2.5 25t
For-2017 (IES, GATE & PSUs) 430 (d ) Do = d 2 +Page − 0.5
4dh116 ofr186 431
Rev.0 432
IAS – 2013 Main IFS‐2013
A cup, of 50 mm diameter and 100 mm height, is to be A symmetrical cup of circular cross section with
d
drawn f
from l
low carbon
b steell sheet.
h Neglecting
l the
h d
diameter 40 mm and
d height
h h 60 mm with
h a corner
influence of thickness and corner radii: radius of 2 mm is to be obtained in C20 steel of 0.6
06
(i) Calculate the blank diameter mm thickness. Calculate the blank size for the
(ii) Decide whether it can be drawn in a single draw,

draw if drawn cup. Will it be possible to draw the cup in
maximum reduction p
permitted is 4
40%. single step?
[10 marks] [10 Marks]
433 434 435
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 Stresses on Deep Drawing
Stresses on Deep Drawing
termed deep
p drawing.
g drawn by y In flange of blank:
(a) Shallow drawing Bi‐axial tension and
y Easy with ductile materials.
(b) Single action deep drawing compression
y Due to the radial flow of material, the side walls increase in (c) Double action deep drawing
thickness as the height is increased. (d) Triple action deep drawing y In wall of the cup:
simple uni‐axial
uni axial
y A cylindrical vessel with flat bottom can be deep drawn by
tension
double action deep drawing.
drawing
y Deep drawing ‐ is a combination of drawing and stretching.

436 437 438
Deep Drawability
bl Limiting Drawing Ratio (LDR) IES – 1997
y The ratio of the maximum blank diameter to the y The average reduction in deep drawing A cup of 10 cm height and 5 cm diameter is to be
d
d
diameter off the
h cup drawn
d . i.e. D/d.
d = 0.5
05 made
d from
f a sheet
h metall off 2 mm thickness.
h k The
h
D
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 ⎞ number of deductions necessary will be
Reduction = ⎜ 1 − ⎟ × 100% = 50%
⎝ D ⎠
punch will pierce a hole in the blank instead of drawing.
drawing Th b rule:
Thumb l (a) One
First draw:Reduction = 50 %
y This ratio depends upon material,
material amount of friction (b) Two
Second draw:Reduction = 30 %
present, etc.
p Third draw:Reduction = 25 % (c) Three
y Limiting drawing ratio (LDR) is 1.6 to 2.3 Fourth draw:Reduction = 16 %
((d)) Four
Fifth draw:Reduction = 13 %
Page 117 of 186 440
Rev.0 441
For IES Only
IES – 1998 Die Design

Assertion
A i (A):
(A) The
Th first
fi draw
d in
i deep
d drawing
d i operationi IFS ‐
IFS ‐ 2009 y Progressive dies
can have up to 60% reduction, the second draw up to
40%% reduction
d and,
d theh third
h d draw
d off about
b 30%
% only.
l y What
Wh t is
i deep
d d
drawing
i process for
f sheet
h t metal
t l
y Compound dies
Reason ((R): ) Due to strain hardening, g, the subsequent
q forming? Explain the function of a blank holder.
holder
draws in a deep drawing operation have reduced
p
percentages.
g g ratio and how is the drawing
What is drawing g ratio y Combination dies
(a) Both A and R are individually true and R is the correct increased ?
explanation of A
(b) Both A and R are individually true but R is not the [10 – marks]
correct explanation
l i off A
442 443 444
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
IAS‐1996 IFS‐2013 Lubrication

b
Compound die performs y Differentiate among the simple, compound and y In drawing operation, proper lubrication is essential for
(a) Two or more operations at one station in one stroke progressive dies.
d
1. To improve die life.
(b) Two or more operations at different stations in one [ 6 Marks]
[ 6 – M k ]
2. To reduce drawing forces.
stroke
t k
3. To reduce temperature.
(c) high frequency sound wave
4. To improve surface finish.
(d) High frequency eddy current

Page 118 of 186 449
Rev.0 450
IAS – 2007 Defects in Drawing ‐
f wrinkle
kl Defects in Drawing ‐
f Fracture
In
I drawing
d i operation,
i proper lubrication
l b i i is
i 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
essential for which of the following reasons? develop on the flange, which may also extend to the wall may cause a thinning of the walls and a fracture at the
1. To improve die life of the cup. flange, bottom, and the corners (if any).
2 To reduce drawing forces
2.
3. To reduce temperature
4. To improve surface finish
S l t the
i the
th code
d given
i b l
below:
(a) 1 and 2 onlyy (b) 1, 3 and 4 onlyy
(c) 3 and 4 only (d) 1, 2, 3 and 4
451 Flange Wrinkle Wall Wrinkle 452 453
Defects in Drawing ‐earing
f IES‐1999 Defects in Drawing –
f miss strike
k
y While
Whil drawing
d i a rolled
ll d stock,
k ears or lobes
l b tend
d to occur y Due
D to the
h misplacement
i l off the
h stock,
k unsymmetrical
i l
because of the anisotropy induced by the rolling flanges may result. This defect is known as miss strike.
operation. E i in a drawn cup can be due non‐uniform
Earing i d b d if
1. Speed of the press
p p
2. Clearance between tools
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
Defects in Drawing –
f Orange peel l St t h t i (lik L d Lines)
Stretcher strains (like Luders Li )
y A surface
f roughening
h i (defect)
(d f ) encountered
d in
i forming
f i y Caused
C d by
b plastic
l ti deformation
d f ti due
d to
t inhomogeneous
i h Surface scratches
Surface scratches
products from metal stock that has a coarse grain size. yielding. y Die or punch not having a smooth surface, insufficient
y It is due to uneven flow or to the appearance of the lubrication
overly large grains usually the result of annealing at too y These lines can criss‐cross the surface of the workpiece
p and
high a temperature. may be visibly objectionable.
y Low carbon steel and aluminium shows more stretcher

strains.

Page 119 of 186 458
Rev.0 459
GATE‐2008 IAS – 1997 GATE‐1999
In
I the
h deep
d drawing
d i off cups, blanks
bl k show
h a tendency
d to Which
f ll i factor
f promotes the
h Identify
Id if the
h stress ‐ state ini the
h FLANCE portion i off a
wrinkle up around the periphery (flange). tendency for wrinking in the process of drawing? PARTIALLYDRAWN CYLINDRICAL CUP when deep ‐
The most likely cause and remedy of the phenomenon are, (a) Increase in the ratio of thickness to blank diameter drawing without a blank holder
respectively,
p y, of work material (a) Tensile in all three directions
(A) Buckling due to circumferential compression; Increase (b) Decrease in the ratio thickness to blank diameter of (b) No stress in the flange at all, because there is no
blank holder pressure
workk materiall bl k h ld
blank‐holder
(B) High blank holder pressure and high friction; Reduce
bl k holder
blank h ld pressure and d apply
l lubricant
l bi t
(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
(d) Use of solid lubricants the one other direction
(C) High temperature causing increase in circumferential
length: Apply coolant to blank (d) Compressive
C i in i two
t di ti
directions and
d tensile
t il ini the
th
((D)) Buckling g due to circumferential compression;
p ; decrease third direction
blank holder pressure
460 461 462
GATE‐2006 IES – 1999 IAS – 1994

Match
M h the h items
i in
i columns
l I and
d II.
II Consider
C id the
h following
f ll i statements: Earring
E i in
i a Consider
f ll i factors
f
Column I Column II drawn cup can be due to non‐uniform 1. Clearance between the p punch and the die is too
P. Wrinkling 1. Yield point elongation 1. Speed of the press small.
Q Orange peel
Q. 2
2. Anisotropy 2 Clearance between tools
2. 2 The finish at the corners of the punch is poor.
2. poor
R. Stretcher strains 3. Large grain size 3. Material properties 3. The finish at the corners of the die is poor.
S. Earing 4. Insufficient blank holding 4. Blank holding 4. The punch and die alignment is not proper.
force
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
5. Fine grain size
(a) 1, 2 and 3 (b) 2, 3 and 4 the axis noticed on the outside of a drawn cylindrical cup
6
6. Excessive blank holding force wouldld include.
l d
(a) P – 6, Q – 3, R – 1, S – 2 (b) P – 4, Q – 5, R – 6, S – 1
(c) 1, 3 and 4 (d) 1, 2 and 4
(a) 2, 3 and 4 (b) 1 and 2
(c) P – 2, Q – 5, R – 3, S – 4 (d) P – 4, Q – 3, R – 1, S – 2
463 464 (c) 2 and 4 (d) 1, 3 and 4 465
Spinning 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.

Page 120 of 186 467
Rev.0 468
GATE‐1992
The thickness of the blank needed to produce, by
power spinning a missile cone of thickness 1.5 mm
l f h k
tc = tb sinα and half cone angle 30°, is
and half cone angle 30 is
(a) 3.0 mm
3 0 mm (b) 2 5 mm
2.5 mm
(c) 2.0 mm
2 0 mm (d) 1 5 mm
1.5 mm
469 470 471
For IES Only
IES – 1994
The mode of deformation of the metal during
IFS‐2011
Compare metal spinning with press work.
spinning is
[2‐marks]
( ) Bending
(a) B di
g gy g( )
High Energy Rate Forming(HERF)
(b) Stretching
St t hi
(c) Rolling and stretching
(d) Bending and stretching.

stretching
472 473 474
Underwater
HERF explosions. U d
Underwater Explosions
E l i
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
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.
Page 121 of 186 476
Rev.0 477
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.
478 479 480
Electromagnetic or Magnetic Pulse Forming 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 y The
Th process is
i very rapid
id and
d is
i used
d primarily
i il to expand
d
an induced current always opposes the electromagnetic or contract tubing, or to permanently assemble
field of the inducing current. component parts.
y This process is most effective for relatively thin materials
y A large capacitor bank is discharged, producing a current (0.25 to 1.25 mm thick).
surge through
h h a coiled
l d conductor.
d y The workpiece must be electrically conductive but need
not be magnetic.
magnetic
y If the coil has been placed within a conductive cylinder, y Short life of the coil is the major problem.
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
a die or mating workpiece. 481 482 483
IES 2016
Petro ‐ Forging or Petro ‐ Forge Forming Consider the following in case of high energy forming
p
processes:
y In
I this
hi process, the
h stored
d chemical
h i l energy off a hydrocarbon,
h d b
like petrol or diesel is utilized to move the dies at very high 1. The evacuation between die and blank in explosive
velocity.
l The
h principlel off working
k off a Petro‐forge
f h
hammer is forming forming is done by a vacuum pump.
pump
just similar to I.C. engine. 2. The pressure waves produced in water in explosive
y It is a piston‐cylinder arrangement and a piston drives a ram fforming deform
d f the
h blank
bl k to the
h die
d shape.
h
(piston rod)) and a die.
(p 33. The electrohydraulic
y formingg makes use of discharge g of
y After air‐fuel mixture is ignited in the combustion chamber large amount of electrical energy used in a capacitor bank.
pressure increases by 5 to 7 times which breaks the seal and 4
4. In Petroforge,
Petroforge the piston is moved by combustion of fuel
the high pressure gases act on the top face of the piston. moving at the rate of 150 – 200 m/s.
y The
Th piston,
i ram and d die
di are accelerated
l d at a very rapid
id rate Whi h off the
Which th above
b are correct?
t?
and strike upto 250 m/s. (a) 1, 2, 3 and 4 (b) 1, 2 and 3 only
(c) 3 and 4 only (d) 1, 2 and 4 only
Page 122 of 186 485
Rev.0 486
IES 2011 JWM 2010 IES 2010
Assertion (A) : In magnetic pulse‐forming
pulse forming method,
method Assertion (A) : In the high energy rate forming
High energy rate forming process used for magnetic field produced by eddy currents is used to method, the explosive forming has proved to be an
forming components from thin metal sheets or create force
f b
between coil
il and
d workpiece.
k i excellent
ll method
h d off utilizing
ili i energy at high
hi h rate and d
Reason ((R)) : It is necessary y for the workpiece
p utilizes both the high explosives and low explosives.
d f
deform thin
hi tubes
b is:
i Reason (R): The gas pressure and rate of detonation
material to have magnetic properties.
can be controlled for both types yp of explosives.
p
( ) 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
correct explanation of A (a) Both A and R are individually true and R is the correct
(b) Magnetic pulse forming explanation of A
(b) Both A and R are individually true but R is NOT the
correct explanation of A (b) Both A and R are individually true but R is NOT the
(c) Explosive forming
(d) electro
electro‐hydraulic
hydraulic forming (c) A is true but R is false
487 488
(d) A is false but R is true 489
IES – 2007 IES – 2009 IES – 2005

Which one of the following metal forming Which one of the following is a high energy rate Magnetic forming is an example of:
processes is not a high
h h energy rate forming
f process? forming process? (a) Cold forming (b) Hot forming
( ) Electro‐mechanical
(a) El h i l forming
f i ( ) Roll
(a) R ll forming
f i (c) High energy rate forming (d) Roll forming
(b) Roll‐forming
R ll f i (b) Electro‐hydraulic
El t h d li forming
f i
(c) Explosive forming (c) Rotary forging
(d) Electro‐hydraulic
Electro hydraulic forming (d) Forward extrusion
490 491 492
Stretch Forming
h Stretch Forming
h Contd......
IES‐2013 Conventional y Produce
P d large
l sheet
h t metal
t l parts
t in
i low
l or limited
li it d
y Popular in the aircraft industry and is frequently used to
quantities.
y Name at least four methods by which high energy y A sheet of metal is gripped by two or more sets of jaws f
form aluminum
l and
d stainless
l steell
release rates are obtained. that stretch it and wrap it around a single form block.
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
y Why might less springback be observed in HERF? 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
[5 marks]
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
For-2017 (IES, GATE & PSUs) 493 plastic. Page 123 of 186 494
Rev.0 495
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
496 497 498
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.
499 500 501
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.

Page 124 of 186 503
Rev.0 504
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
505 506 507
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
508 509 510
For IES Only
Spanking
k
y During bending, the area of the sheet under the punch
h a tendency
has d to flow
fl and
d form
f a bulge
b l on the
h outer
surface.
surface
y The lower die should be provided with mating surfaces,

surfaces
so that when the p
punch and die are completely
p y closed on
the blank, any bulging developed earlier will be
completely presses or “spanked” out.

Page 125 of 186 512
Rev.0 513
GATE‐2007 GATE ‐2012 Same Q in GATE‐2012 (PI) GATE‐2004
Match
M t h the
th correctt combination
bi ti for
f following
f ll i metal
t l Match the following metal forming processes with their Match
M h the h following
f ll i
working processes. associated stresses in the workpiece.
p Product Process
Processes Associated state of stress
Metal forming process Type of stress P. Moulded luggage 1. Injection moulding
P. Blankingg 1. Tension
1. Coining P. Tensile Q Packaging
Q. P k i containers i f liquid
for li id 2. H rolling
Hot lli
Q. Stretch Forming 2. Compression
R Coining
R. 3
3. Shear 2 Wire Drawing
2. Wire Drawing Q Shear
Q. Shear R. Longg structural shapes
p 33. Impact
p extrusion
S. Deep Drawing 4. Tension and Compression 3. Blanking R. Tensile and S. Collapsible tubes 4. Transfer moulding
5. Tension and Shear compressivei 5. Blow
l moulding
ld
Codes:P Q R S P Q R S 4
4. Deep Drawing
p g S. Compressive
p 6. Coining
(a) 2 1 3 4 (b) 3 4 1 5 (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
( ) 5
(c) 4 3 1 (d) 3 1 2 4 ( ) 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)
514 515 516
IAS – 1999 IAS – 1997 IES 2010

Match
M t h List
Li t I (Process)
(P ) with
ith List
Li t II (Production
(P d ti off parts)
t ) 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
and select the correct answer using the codes given (Associated feature) and select the correct answer
below the lists: 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‐I List‐II
A Rolling
A. R lli 1. Di
Discrete parts List‐ll
List List‐ II
List 1. Ratio
R ti off yield
i ld stress
t t ultimate
to lti t stress.
t
B. Forging 2. Rod and Wire A. Blanking 1. Shear angle 2.Rate of increase of yyield stress relative to
C. Extrusion 3. Wide variety of shapes with thin B. Flow forming 2. Coiled stock progressive amounts of cold work.
walls C Roll forming
C. 3
3. Mandrel
D. Drawing 4. Flat plates and sheets 3. Rate
R off workk hardening.
h d i
D. Embossing 4. Closed matching dies
5
5. Solid and hollow parts Which of the above statements is/are correct?
Codes:A B C D A B C D Codes:A B C D A B C D
(a) 1 and 2 only (b) 2 and 3 only
(a) 2 5 3 4 (b) 1 2 5 4 (a) 1 3 4 2 (b) 3 1 4 2
(c) 1 only (d) 1, 2 and 3
(c) 4 1 3 2 (d) 4 1 5 2517 (c) 1 3 2 4 (d) 3 1 2 4518 519
Manufacturing of Powder
Atomization using a gas stream
Powder Metallurgy
Powder Metallurgy
Molten metal is
y Powder metallurgy is the name given to the f
forcedd through
th h a
small orifice and
Powder Metallurgy process byy which fine p
p
blended, pressed
powdered materials are
into a desired shape
is disintegrated by
a jet of
compressed air, air
(compacted), and then heated (sintered) in a inert gas or water
jet It is used for
jet,.
controlled
ll d atmosphere
h to bond
b d the
h contacting
low melting point
surfaces of the particles and establish the desired materials brass,
materials, brass
bronze, Zn, Tn,
p p
properties. Al, Pb etc.
By S K Mondal
Page 126 of 186 521
Rev.0 522
IES‐2016
IAS – 2003 IAS – 2007 Statement (I) : Metal powders can be produced by
Assertion
A i (A):
(A) Atomization
A i i method
h d for
f production
d i off Assertion
A ti (A):
(A) Mechanical
M h i l disintegration
di i t ti off a atomization process.
process
metal powders consists of mechanical disintegration of molten metal stream into fine particles by means of Statement (II) : In case of metals with low melting
molten
l stream into fine
f particles.
l 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
Reason ((R): ) Atomization method is an excellent means Reason (R): In atomization process inert‐gas or the shapep of the p particles remains regular
g in
of making powders from high temperature metals. water cannot be used as a substitute for compressed atomization.
(a) Both A and R are individually true and R is the correct air.
explanation of A (a) Both A and R are individually true and R is the
Statement (II) is the correct explanation of Statement (I).
(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
correct
co ect eexplanation
p a at o oof A
correct explanation of A (b) Both A and R are individually true but R is not the
correct explanation of A Statement ((II)) is not the correct explanation
)
(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
(d) (d) Statement (I) is false but Statement (II) is true
523 524 525
IES – 1999 Reduction
Assertion
A i (A):
(A) In
I atomization
i i process off manufacture
f off GATE ‐2011 (PI)
GATE ‐2011 (PI)
metal powder, the molten metal is forced through a y Metal oxides are turned to pure metal powder when
smallll orifice
f andd broken
b k up by b a stream off compressedd Whi h off
Which th
the f ll i
following powder
d production
d ti
air. exposed to below melting point gases results in a
methods produces spongy and porous particles?
Reason (R): The metallic powder obtained by product of cake of sponge metal.
atomization p process is q
quite resistant to oxidation. (a) Atomization
y The
h irregular
i l sponge‐like
lik particles
i l are soft,
f readily
dil
explanation of A compressible and give compacts of good pre‐sinter
compressible, ((b)) Reduction of metal oxides
(b) Both A and R are individually true but R is not the (“green”)
g strength
g ((c)) Electrolytic
y deposition
p
correct explanation
l i off A
(c) A is true but R is false y Used for iron, Cu, tungsten, molybdenum, Ni and (d) Pulverization
(d) A is false but R is true Cobalt.
526 527 528
Only for IES
Manufacturing of Powder Manufacturing of Powder
Manufacturing of Powder IES‐2013 Conventionall
Comminution
C i i
Grinding
g Explain the terms comminution and reduction used in
y Granular
G l material,
t i l which
hi h may be
b coarsely
l atomized
t i d
powder metallurgy.
This metallic powder is nothing but the unburnt tiny p
powder,, is fed in a stream of ggas under p
pressure through
g
chips formed during the process of grinding. a venturi and is cooled and thereby embrittled by the [ 2 marks]
adiabatic
di b i expansion i off the
h gas before
b f i i i
impinging on a
g on which the g
target granules shatters
y Process is used for production of very fine powders such
as are required for injection moulding . Brittle materials
such as inter
inter‐metallic
metallic compounds,
compounds ferro
ferro‐alloys
alloys ‐ ferro
ferro‐
For-2017 (IES, GATE & PSUs) 529 chromium, ferro‐silicon
Pageare
127produces
of 186 530
Rev.0 531
Electrolytic Deposition
IES ‐ 2012 Manufacturing of Powder
In
I electrolysis
l l i Granulations ‐ as metals are cooled they are stirred rapidly
y Used for iron, copper, silver
((a)) For making g copper
pp p powder,, copper
pp p plate is made Machining ‐ coarse powders such as magnesium
y Process is similar to electroplating.
electroplating
cathode in electrolyte tank
y For making copper powder, copper plates are placed as Milling
g ‐ crushers and rollers to break down metals. Used for
(b) For making aluminum powder,
powder aluminum plate is
anode in the tank of electrolyte, whereas the aluminium made anode brittle materials.
plates
l t are placed
l d in i the
th electrolyte
l t l t to t actt as cathode.
th d (c) High amperage produces powdery deposit of cathode Shooting ‐ drops of molten metal are dropped in water, used
When DC current is p passed, the copper
pp ggets deposited
p metal
eta oon aanode
ode for low melting point materials.
materials
on cathode. The cathode plated are taken out and (d) Atomization process is more suitable for low melting Condensation – Metals are boiled to produce metal vapours
powder
d is
i scrappedd off.
ff The
Th powderd isi washed,
h d dried
d i d and d point
i t metals
t l
and then condensed to obtain metal powders. Used for Zn,
pulverized to the desired g
p grain size.
Mg Cd.
Mg, Cd
y The cost of manufacturing is high. 532 533 534
GATE‐2014 (PI) IAS – 2000 IES 2010

Which
f ll i methods
h d is
i NOT used
d Consider
C id theh following
f ll i processes: Metallic
M t lli powders d can be
b produced
d d by
b
for producing metal powders? 1. Mechanical pulverization
p (a) Atomization
(a) Atomization 2. Atomization (b) Pulverization
(b) Compaction 3. Chemical
Ch i l reduction
d i
(c) Electro‐deposition process
(c) Machining and grinding 4. Sintering
4 g
(d) Electrolysis (d) All off the
h above
b
Which of these processes are used for powder
preparation
ti in
i powder
d metallurgy?
t ll ?
(a) 2, 3 and 4 (b) 1, 2 and 3
(c) 1, 3 and 4 (d) 1, 2 and 4
535 536 537
Conventional Questions
Characteristics
Ch i i off metall powder: d y Discuss
Di the
h terms fineness
fi and d particle
i l size
i
y Fineness: refers to p particle size of p powder,, can be distribution in powder metallurgy. [IES‐2010, 2 Marks]
determined either by pouring the powder through a sieve or Ans.
by microscopic testing.
testing A standard sieves with mesh size Fineness: Is the diameter of spherical shaped particle and
varies between (100) and (325) are used to determine mean diameter of non‐spherical shaped particle.
particle
ti l size
i andd particle
ti l size
i distribution
di t ib ti off powder
d ini a
Particle size distribution: Geometric standard deviation
certain range. ((a measure for the bredth or width of a distribution),), is the
y Particle size distribution: refers to amount of each particle ratio of particle size diameters taken at 84.1 and 50% of the
size in the powder and have a great effect in determining cumulative undersized weight plot, respectively and mean
flowability, apparent density and final porosity of product. mass diameter define the particle size distribution.

Page 128 of 186 539
Rev.0 540
IES – 1999 Blending
l d
The
Th correct sequence off the h given
i processes in
i y Blending
Bl di or mixing
i i operations
ti can be
b done
d either
ith dry
d or wet.
t
manufacturing by powder metallurgy is y Lubricants such as graphite or stearic acid improve the flow
(a) Blending, compacting, sintering and sizing
characteristics and compressibility at the expense of reduced
(b) Blending,
Blending compacting,
compacting sizing and sintering
strength.
(c) Compacting, sizing, blending and sintering
y Binders produce the reverse effect of lubricants.
(d) Compacting, blending, sizing and sintering
Thermoplastics or a water
water‐soluble
soluble methylcellulose binder is
used.
y Most lubricants or binders are not wanted in the final
product and are removed ( volatilized or burned off)
541 542 543
IES‐2013 Conventionall Compacting C ti
Compacting
Why lubricants are used to mix the metal powders? y Powder is pressed into a “green compact”
[ 2 marks] y 40 to 1650 MPa pressure (Depends on materials,
product complexity)
y Still very porous, ~70% density
y May be done cold or warm (higher density)
544 545 546
Sintering GATE‐2016 (PI)
In powder metallurgy, sintering of the component
GATE ‐2010 (PI)
GATE ‐2010 (PI)
y Controlled atmosphere: no oxygen
(a) increases density and reduces ductility I powder
In d metallurgy,
t ll sintering
i t i off a componentt
y Heat to 0.75*T melt
(b) increases porosity and reduces density
y Particles bind together, diffusion, recrystalization
P ti l bi d t th diff i t li ti (a) Improves strength and reduces hardness
(c) increases density and reduces porosity
and grain growth takes place.
g g p
(d) increases porosity and reduces brittleness
(d) increases porosity and reduces brittleness. (b) Reduces brittleness and improves strength
y Part shrinks in size
(c) Improves hardness and reduces toughness
y Density increases, up to 95%
y Strength increases, Brittleness reduces, Porosity
St th i B ittl d P it (d) Reduces porosity and increases brittleness
decreases. Toughness increases.
g

Page 129 of 186 548
Rev.0 549
IES – 2002 Cold Isostatic
ld Pressing (CIP)
( )
The
Th rate off production
d i off a powder
d metallurgy
ll part IES –
IES – 2007 Conventional
2007 Conventional y The powder is contained in a flexible mould made of
depends on
y Metal powders are compacted by many methods,
methods rubber
bb or some other
h elastomer
l materiall
(a) Flow rate of powder
but sintering
g is required
q to achieve which
(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 property? What is hot iso‐static pressing?
high‐pressure water or oil.
oil (same pressure in all
(d) Compressibility of powder [ 2 Marks]
directions))
y No lubricant is needed
y High and uniform density can be achieved
550 551 552
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
553
of the materials is a prime consideration 554 555
For IES Only
IAS – 1997 S
Spray Deposition
D iti
Assertion
A ti (A):
(A) Close
Cl dimensional
di i l tolerances
t l are IES –
2011 Conventional y Spray
S deposition
d iti isi a shape‐generation
h ti process.
NOT possible with isostatic pressing of metal
powder
d in i powder
d metallurgy
t ll t h i
technique. y What is isostatic
Wh t i i t ti pressing of metal powders ?
i f t l d ? y Basic components of a spray deposition process
Reason (R): In the process of isostatic pressing, the (a) Atomiser
pressure is equal in all directions which permits y What are its advantage ?
(b) Spray chamber with inert atmosphere
uniform density of the metal powder.
[ 2 Marks] (c) Mould for producing preforms.
preforms
correct
co ect eexplanation
p a at o oof A y After the metal is atomised,, it is deposited
p into a cooler
(b) Both A and R are individually true but R is not the preformed mould.
(c) A is true but R is false y Achieve density above 99%, fine grain structure,
(d) mechanical
h i l properties
ti same as wrought
ht product
d t
Page 130 of 186 557
Rev.0 558
Metal Injection Moulding

Metal Injection Moulding R ll C
Roll Compaction
ti
y Fine metal powders are blended with an organic binder such y Powders are compacted by passing between two rolls
as a polymer or a wax‐based binder. rotating in opposite direction.
y The powder‐polymer mixture is then injected into split dies, y The powders are put in a container and are forced by a
preheated to remove the binder and, finally, sintered. ram between two rotating rolls,
rolls and is compacted into a
y Volumetric shrinkage during sintering is very high. continuous strip at speeds of up to 0.5 m/s.
y Complex shapes that are impossible with conventional y Sheet metal for electrical and electronic components and
compaction.
ti for coins can be made by this process.
process
y Good dimensional accuracy. y The rolling

g p
processes can be carried out at room or at
elevated temperature.
y High production rate.
y Good mechanical properties. 559 560 561
l
Explosive Compaction ISRO 2013
ISRO ‐2013
Liquid Phase Sintering
y High Energy Rate Forming (HERF) or Explosive Forming y During sintering a liquid phase, from the lower MP Following is a process used to form powder metal to
of the metal powders at rather higher velocities 3500 m/s component,
p , mayy exist
than
h thath off the
h usuall speedd off compaction
i during
d i the h shape
h
y Alloying may take place at the particle‐particle interface
ordinary die compacting.
y Molten
M l component may surround d the
h particle
i l that
h hash ( ) Sintering
(a) Si i
y Higher green densities not melted
(b) Explosive
E l i Compacting
C ti
y Higher sintered strength y High compact density can be quickly attained
y Important variables: (c) Isostatic Molding
y More uniform density distribution
y Nature of alloy, molten component/particle wetting,
(d) All of these
capillary action of the liquid
562 563 564
Features of PM products
f d Production of magnets
d f Advantages
d
y For
F high
hi h tolerance
l parts, a sintering
i i part is
i put back
b k into
i 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
a die and repressed. In general this makes the part more y Al‐Ni‐Fe is used for permanent magnets
p g y Highly complex shapes made quickly
g y p p q y
accurate with a better surface finish. y Sintering is done in a wire coil to align the magnetic y Can produce porous parts and hard to manufacture
y A part has many voids that can be impregnated.
impregnated One poles of the material materials (e g cemented oxides)
materials (e.g. cemented oxides)
method is to use an oil bath. Another method uses y H2 is used to rapidly cool the part (to maintain magnetic y Pores in the metal can be filled with other
vacuum
acuum first,
first then impregnation.
impregnation alignment) materials/metals
y A part surface can be infiltrated with a low melting point
y Total shrinkage is approximately 3‐7% (for accurate parts y Surfaces can have high wear resistance
metal to increase density, strength, hardness, ductility an extra sintering step may be added before magnetic y Porosity can be controlled
and impact resistance. alignment)
li t) y Low waste
y Plating, heat treating and machining operations can also
y The sintering temperature is 600°C in H
g p
b used.
be d 2 y Automation is easy
Page 131 of 186 566
Rev.0 567
Advantages
d Contd…. IES – 2007
y Physical properties can be controlled
GATE –
GATE – 2009 (PI)
2009 (PI) What
Wh are the h advantages
d off powder
d metallurgy?
ll ?
1. Extreme p purityy p
product
y Variation from part to part is low Whi h off the
Which th following
f ll i process is
i used
d to
t
2. Low labour cost
y Hard to machine metals can be used easily
H d t hi t l b d il manufacture products with controlled porosity?
3. Low
L equipmenti cost.
y No molten metals (a) Casting Select the correct answer using g the code g
given below
(a) 1, 2 and 3 (b) 1 and 2 only
y No need for many/any finishing operations ((b)) welding
g
( ) 2 and
(c) d 3 only
l (d) 1 and d 3 only
l
y Permits high volume production of complex shapes
g p p p ((c)) formation
y Allows non‐traditional alloy combinations (d) Powder metallurgy
y Good control of final density 568 569 570
Disadvantages
d IES ‐ 2012 IES – 2006
y Metal powders deteriorate quickly when stored
M l d d i i kl h d 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
improperly have as good physical properties as parts casted. powder metallurgy?
y Fixed and setup costs are high Statement (II): Particle shape in powder metallurgy 1. High tooling and equipment costs.
influences the flow characteristic of the powder.
y Part size is limited by the press, and compression of the
Part size is limited by the press and compression of the 2 Wastage of material.
2. material
(a) Both Statement (I) and Statement (II) are
powder used. individuallyy true and Statement ((II)) is the correct 3. It cannot be automated.
y Sharp corners and varying thickness can be hard to explanation of Statement (I) 4. Expensive metallic powders.
p oduce
produce (b) Both Statement (I) and Statement (II) are S l t the
i the
th codes
d given
i b l
below:
y Non‐moldable features are impossible to produce. individually true but Statement (II) is not the correct
explanation of Statement (I) (a) Onlyy 1 and 2 (b) Onlyy 3 and 4
(c) Statement (I) is true but Statement (II) is false (c) Only 1 and 4 (d) Only 1, 2 and 4
( ) Statement (I)
(d) ( ) is false but Statement (II)
( ) is true
571 572 573
IES – 2004 A li ti
Applications
Consider
C id theh following
f ll i factors:
f y Oil impregnated bearings made from either iron or
Oil‐impregnated IES‐2015 Conventional
copper alloys for home appliance and automotive
1. Size and shapep that can be p
produced economicallyy Classify the products that are commonly produced by
applications
li ti
2. Porosity of the parts produced
y P/M filters can be made with p pores of almost anyy size. p
powder metallurgy. Give examples of each.
gy p
3. Available
A il bl press capacity
i
y Pressure or flow regulators.
4. High
4 g densityy [10 Marks]
y Small
S ll gears, cams etc.t
Which of the above are limitations of powder
y Products where the combined p properties
p of two or more
metallurgy?
t ll ?
metals (or both metals and nonmetals) are desired.
(a) 1, 3 and 4 (b) 2 and 3
y Cemented carbides are produced by the cold‐
Cemented carbides are produced by the cold
(c) 1, 2 and 3 (d) 1 and 2 compaction of tungsten carbide powder in a binder, such
as cobalt ( 5 to 12%), followed by liquid‐phase sintering.
b lt ( t %) f ll d b li id h i t i
Page 132 of 186 575
Rev.0 576
IES 2010 IAS – 1998 IES – 2009
Consider
C id theth following
f ll i parts: t Throwaway
Th tungsten carbide
bid tip
i tools
l are Which of the following cutting tool bits are made by
1. Grinding wheel manufactured by
(a) Forging (b) Brazing powder
d metallurgy
ll process?
2. Brake lining
(c) Powder metallurgy (d) Extrusion ( ) Carbon
(a) C b steell tooll bits
bi (b) S lli tooll bits
Stellite bi
3. Self‐lubricating bearings
Whi h off these
Which h parts are made d by
b powder
d ( ) Ceramic
(c) C i tool
t l bits
bit (d) HSS tool
t l bits
bit
metallurgy gy technique?
q
(a) 1, 2 and 3 (b) 2 only
(c) 2 and 3 only (d) 1 and 2 only
577 578 579
IAS – 2003 IES – 1997

GATE –
GATE – 2011 (PI)
2011 (PI) Which
f ll i are produced
d d by
b powder
d Which
f ll i components can be b
The binding material used in cemented carbide metallurgy process? manufactured by powder metallurgy methods?
cutting tools is 1. Cemented carbide dies 1. Carbide tool tips 2. Bearings
( ) graphite
(a) hi 2 Porous bearings
2. 3 Filters
3. 4
4. Brake linings
((b)) tungsten
g 3. Small magnets Select the correct answer using the codes given below:
(c) nickel 4. Parts with intricate shapes (a) 1, 3 and 4 (b) 2 and 3
(d) cobalt
b l S l t the
i the
th codes
d given
i b l
below: ( ) 1, 2 and
(c) d 4 (d) 1, 2, 3 and d4
Codes:
(a) 1, 2 and 3 (b) 1, 2 and 4
( ) 2, 3 and
(c) d 4 (d) 1, 3 and d4
580 581 582
IES‐2015
IES – 2001 Consider the following statements regarding powder Pre ‐ Sintering
metallurgy :
Carbide‐tipped
C bid i d cutting
i toolsl are manufactured
f d by
b y If a part made by PM needs some machining, it will be
1. Refractory materials made of tungsten can be
powder‐ metal technology process and have a
manufactured easily.
easily rather
h very difficult
d ff l iff the
h materiall is very hard
h d and
d
composition of
2. In metal powder, control of grain size results in
(a) Zirconium
Zirconium‐Tungsten
Tungsten (35% ‐65%)
65%) relatively
l i l much h uniform
if structure strong These machining operations are made easier by
strong.
(b) Tungsten carbide‐Cobalt (90% ‐ 10%) 3. The powder heated in die or mould at high temperature the pre
pre‐sintering
sintering operation which is done before
(c) Aluminium oxide‐ Silica (70% ‐ 30%) is then pressed and compacted to get desired shape and
strength.
g sintering operation.
(d) Nickel‐Chromium‐ Tungsten (30% ‐ 15% ‐ 55%)
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
For-2017 (IES, GATE & PSUs) 583 (c) 2, 3 and 4 only (d) 1, 2, 3
Page 133 of 186and 4 584
Rev.0 585
IAS – 2003 Repressing Infiltration
fl
In
I parts produced
d d by
b powder d metallurgy
ll process, y Repressing is performed to increase the density and y Component is dipped into a low melting‐temperature
pre‐sintering is done to
(a) Increase the toughness of the component improve the
h mechanical
h l properties. alloy
ll liquid
l d
(b) Increase the density of the component y Further
F h improvement
i i achieved
is hi d byb re‐sintering.
i i y The
Th liquid
li id would
ld flow
fl i
into the
h voids
id simply
i l byb capillary
ill
(c) Facilitate bonding of non‐metallic particles
action thereby decreasing the porosity and improving
action,
(d) Facilitate machining of the part
the strength
g of the component.
p
y The p
process is used q
quite extensivelyy with ferrous p
parts
using copper as an infiltrate but to avoid erosion, an alloy
586 587
of copper containing iron and manganese is often used.
588
Impregnation Oil‐impregnated Porous Bronze Bearings
GATE 2011
y Impregnation
I i isi similar
i il to infiltration
i fil i
The operation in which oil is permeated into the
y PM component
p is kept
p in an oil bath. The oil p
penetrates
into the voids by capillary forces and remains there. pores of a powder metallurgy product is known
y The oil is used for lubrication of the component when as
necessary. During the actual service conditions, the oil is
released
l d slowly
l l to provide
d the
h necessary lubrication.
l b ( ) mixing
(a) i i
y The e co
components
po e ts ca
can abso
absorbb bet
between
ee 12%% aand
d 30% o
oil by (b) sintering
volume.
y It is
i being
b i used
d on P/M self‐lubricating
lf l b i ti b
bearing
i (c) impregnation
components since the late 1920's.
(d) Infiltration
589 590 591
IAS – 1996 IES – 1998 IES ‐ 2014

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
Th process off impregnation
i i in
i powder d metallurgy
ll
in powder metallurgy to promote self‐lubricating improve the bearing property of a bush is called technique is best described by which of the following?
properties in sintered parts? (a) infiltration (b) impregnation (a) After sintering operation of powder metallurgy, rapid
(a) Infiltration (b) Impregnation (c) plating (d) heat treatment cooling is performed to avoid thermal stresses.stresses
(c) Plating (d) Graphitization (b) Low melting point metal is filled in the pores of a
sintered
d powder
d metallurgy
ll product
d
(c) Liquid
qu d ooil o
or g
grease
ease iss filled
ed in tthee po
pores
es o
of a ssintered
te ed
powder metallurgy product
(d) During
D i sintering
i t i operation
ti off powderd metallurgy,
t ll
rapid heating is performed to avoid sudden produce of
high internal pressure due to volatilization of lubricant
Page 134 of 186 593
Rev.0 594
IAS – 2007 IAS – 2004 IES – 2001
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 Match
M h List‐I
Li I (Components)
(C ) with
ih List‐II
Li II
production of porous bearings: process of powder metallurgy: (Manufacturing Processes) and select the correct
1. Sintering 1. Powder conditioning answer using the codes given below the lists:
2 Mixing
2. 2 Sintering
2. List I List II
3. Repressing 3. Production of metallic powder A. Car body (metal) 1. Machining
4. Impregnation 4. Pressing or compacting into the desired shape B. Clutch lining 2. Casting
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 C Gears
C. 3
3. Sheet metal pressing
g is the correct sequence
Which one of the following q of the performed and select the correct answer using the codes D. Engine block 4. Powder metallurgy
above steps? given below:
b l Codes:A B C D A B C D
(a) 11‐2‐3‐4
234 (b) 33‐1‐4‐2
142 (a) 3 4 2 1 (b) 4 3 1 2
595 (c) 2‐4‐1‐3 (d) 4‐3‐2‐1 596 (c) 4 3 2 1 (d) 3 4 1 2597
GATE 2008 (PI)

GATE ‐2008 (PI) Conventional Questions Conventional Questions
Matc t e o ow g
Match the following
y Explain why metal powders are blended. Describe Enumerate
E the
h steps involved
i l d in
i “powder
“ d metallurgy”
ll ”
Group – 1 Group ‐2 process. Discuss these steps. Name the materials used
P. Mulling 1. Powder metallurgy what
h happens
h d
during sintering. [IES‐2010,
[ 2 Marks]
k ] in “powder metallurgy”. What are the limitations of
Q Impregnation
Q. Impregnation 2 Injection moulding
2. Injection powder metallurgy?
p gy [[IES‐2005,
5, 10 Marks]]
R. Flash trimming 3. Processing of FRP composites
S. Curing 4. Sand casting
(a) P – 4, Q – 3, R – 2, S – 1 (b) P – 2, Q – 4, R – 3, S ‐ 1

(c) P – 2, Q – 1, R – 4, S – 3 (d) P – 4, Q – 1, R – 2, S ‐ 3
598 599 600
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

Page 135 of 186 Rev.0
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 y With time the effectiveness and efficiency of HSS

Assertion
A i (A):
(A) Cutting
C i tools
l made
d off high
hi h carbon
b (tools) and their application range were gradually
(t l ) d th i li ti d ll
y These steels are used for cutting metals at a much
steel have shorter tool life. enhanced by improving its properties and surface
higher cutting speed than ordinary carbon tool steels.
steels condition through ‐
diti th h
Reason(R): During machining, the tip of the cutting y The high speed steels have the valuable property of y Refinement of microstructure
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 Addition of large amount of cobalt and Vanadium to
y Most of the high
g speed
p steels contain tungsten
g as the increase hot hardness and wear resistance
( ) Both
h chief alloying element, but other elements like cobalt, respectively
correct explanation of A chromium vanadium,
chromium, vanadium etc.
etc may be present in some y Manufacture by powder metallurgical process
(b) Both A and R are individually true but R is not the proportion. y Surface coating with heat and wear resistive
correct explanation of A materials like TiC
t i l lik TiC , TiN
TiN , etc by Chemical Vapour
t b Ch i l V
(c) A is true but R is false Deposition (CVD) or Physical Vapour Deposition
(d) A is false but R is true (PVD)
Page 136 of 186 Contd…
8
Rev.0 9
IES‐2013 IAS‐1997 18‐4‐1 High speed steel
Vanadium in high speed steels: Which of the following processes can be used for y This steel contains 18 per cent tungsten, 4 per cent
production thin, hard, heat resistant coating at TiN, chromium and 1 per cent vanadium.
vanadium
( ) Has a tendency to promote decarburization
(a) on HSS?
y p
1. Physical vapour deposition.
p y It is considered to be one of the best of all purpose tool
(b) Form
F very hard
h d carbides
bid and
d thereby
h b increases
i the
h 2. Sintering under reducing atmosphere. steels.
l
wear resistance of the tool 3 Chemical vapour deposition with post treatment
3. y It is widely
y used for drills,, lathe,, p
planer and shaper
p
4. Plasma spraying. tools, milling cutters, reamers, broaches, threading
(c) Helps in achieving high hot hardness S l t th
t i th d i b l dies punches,
dies, punches etc.
etc
Codes:
(d) Has a tendency to promote retention of Austenite
(a) 1 and 3 (b) 2 and 3
((c)) 2 and 4
4 ((d)) 1 and 44
10 11 12
IES‐2003 IES 2007 IES‐1993

The correct sequence of elements of 18‐4‐1 HSS Cutting tool material 18‐4‐1 HSS has which one of The blade of a power saw is made of
tool is the following compositions? (a) Boron steel
(a) W, Cr, V (a) 18% W, 4% Cr, 1% V (b) 18% Cr, 4% W, 1% V (b) High speed steel
(b) Mo, Cr, V (c) 18% W, 4% Ni, 1% V (d) 18% Cr, 4% Ni, 1% V (c) Stainless steel
(c) Cr, Ni, C
Cr Ni C (d) Malleable cast iron
(d) Cu, Zn, Sn
13 14 15
Molybdenum high speed steel Super high speed steel IES‐1995

y This steel contains 6 per cent tungsten, 6 per cent y This steel is also called cobalt high speed steel The compositions of some of the alloy steels are as
molybdenum, 4 per cent chromium and 2 per cent
molybdenum because cobalt is added from 2 to 15 per cent,
cent in order under:
vanadium. to increase the cutting efficiency especially at high 1. 18 W 4 Cr 1 V
y It
I has
h excellent
ll toughness
h andd cutting
i ability.
bili temperatures.
temperatures 2 12 Mo 1 W 4 Cr 1 V
2.
y The molybdenum
y high
g speed
p steels are better and y This steel contains 20 per cent tungsten, 4 per cent 3. 6 Mo 6 W 4 Cr 1 V
cheaper than other types of steels. chromium, 2 per cent vanadium and 12 per cent cobalt. 4. 18 W 8 Cr 1 V
y It is particularly used for drilling and tapping The compositions of commonly used high speed steels
operations. would include
(a) 1 and 2 (b) 2 and 3
(c) 1 and 4 (d) 1 and 3

Page 137 of 186 17
Rev.0 18
IES‐2000 IES‐1992 IAS‐2001
Percentage of various alloying elements present The main alloying elements in high speed Steel in Assertion (A): For high‐speed turning of magnesium
alloys, the coolant or cutting fluid preferred is water‐
in different steel materials are given below: order of increasing proportion are miscible mineral fatty oil.
i ibl i l f il
1. 18% W; 4% Cr; 1% V; 5% Co; 0.7% C (a) Vanadium, chromium, tungsten Reason (R): As a rule, water‐based oils are recommended
2. 8% Mo; 4% Cr; 2% V; 6% W; 0.7% C (b) Tungsten, titanium, vanadium f hi h
for high‐speed operations in which high temperatures are
d ti i hi h hi h t t
generated due to high frictional heat. Water being a good
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 coolant the heat dissipation is efficient
coolant, the heat dissipation is efficient.
4. 18% Cr; 8% Ni; 0.15% C (d) Tungsten, chromium, titanium (a) Both A and R are individually true and R is the correct
explanation of A
Which of these relate to that of high speed steel? (b) Both A and R are individually true but R is not the correct
(a) 1 and 3 (b) 1 and 2 e p a at o o
explanation of A
(c) 2 and 3 (d) 2 and 4
19 20 21
IAS 1994 Cast cobalt alloys/Stellite
Assertion (A): The characteristic feature of High IAS –
IAS – 2013 Main
2013 Main y Cast cobalt alloys are cobalt‐rich, chromium‐tungsten‐ carbon
speed Steel is its red hardness. cast alloys
y having g p properties
p and applications
pp in the
Compare HSS and ceramic tools with regard to their intermediate range between high‐speed steel and cemented
Reason (R): Chromium and cobalt in High Speed
promote martensite formation when the tool is cold
p application in high speed machining.
pp g p g carbides.
worked. y Although comparable in room‐temperature hardness to high‐
speed steel tools, cast cobalt alloy tools retain their hardness to
((a)) Both A and R are individually true and R is the correct
y a much higher temperature.
temperature Consequently,
Consequently they can be used at
explanation of A higher cutting speeds (25% higher) than HSS tools.
(b) Both A and R are individually true but R is not the y Cutting speed of up to 80‐100
80 100 fpm can be used on mild steels.
steels
correct explanation of A y Cast cobalt alloys are hard as cast and cannot be softened or
(c) A is true but R is false heat treated.
treated
(d) A is false but R is true y Cast cobalt alloys contain a primary phase of Co‐rich solid
solution strengthened by Cr and W and dispersion hardened by
complex hard, refractory carbides of W and Cr.
22 23 Contd…
24
y Other elements added include V, B, Ni, and Ta.

IES 2011
y Tools of cast cobalt alloys are generally cast to shape and
finished to size by grinding. Stellite is a non‐ferrous cast alloy composed of: IAS –
IAS – 2013 Main
2013 Main
y They are available only in simple shapes,
shapes such as single‐
single (a) Cobalt,
Cobalt chromium and tungsten What are the desirable properties while selecting a tool
point tools and saw blades, because of limitations in the (b) Tungsten, vanadium and chromium
casting process and expense involved in the final shaping material for metal‐cutting applications?
g pp
(grinding). The high cost of fabrication is due primarily to (c) Molybdenum, tungsten and chromium
the high hardness of the material in the asas‐cast
cast condition. (d)Tungsten molybdenum,
(d)Tungsten, molybdenum chromium and vanadium
y Materials machinable with this tool material include plain‐
carbon steels, alloy steels, nonferrous alloys, and cast iron.
y Cast cobalt alloys are currently being phased out for
cutting‐tool
cutting tool applications because of increasing costs, costs
shortages of strategic raw materials (Co, W, and Cr), and
the development of other, superior tool materials at lower
cost.
Page 138 of 186 26
Rev.0 27
Cemented Carbide y Cemented carbide tool materials based on TiC have
been developed,
b d l d primarily
i il f
for auto
t i d t
industry y Speeds
S d up to 300 fpm
f are common on mild
ild steels
l
y Carbides, which are nonferrous alloys, are also called,
sintered ((or cemented)) carbides because theyy are
applications using predominantly Ni and Mo as a y Hot hardness p
properties
p are veryy g
good
manufactured by powder metallurgy techniques. bi d
binder. Th
These are used d for
f hi h
higher‐speedd (>
( 1000
ft/min) finish machining of steels and some malleable y Coolants and lubricants can be used to increase tool
y Most carbide tools in use today are either straight life but are not required.
life, required
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 Special alloys are needed to cut steel
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
Contd…
28 Contd…
29 Contd…
30
IES‐1995 IAS – 1994

Assertion
A i (A):
(A) Cemented
C d carbide
bid tooll tips
i are
The straight grades of cemented carbide cutting
produced by powder metallurgy.
tool materials contain
Reason (R): Carbides cannot be melted and cast.
(a) Tungsten carbide only
(b) Tungsten carbide and titanium carbide
(c) Tungsten carbide and cobalt
(d) Tungsten carbide and cobalt carbide correct
co ect eexplanation
p a at o oof A
(d) A is false
f l but
b R is true
31 32 33
The standards developed by ISO for grouping of carbide tools Table below shows detail grouping of cemented carbide tools
K01 Hard grey C.l., chilled casting, Turning, precision turning and boring, milling,
pp g g
and their application ranges are given in Table below. ISO Material
M t i l Process
P Al.
Al alloys with high silicon scraping
Application K10 Grey C.l. hardness > 220 HB. Turning, milling, boring, reaming, broaching,
ISO Code Colour Code Application group
Malleable C.l., Al. alloys scraping
containing Si
P01 Steel, Steel castings Precision and finish machining, high speed K20 Grey C.l. hardness up to 220 Turning, milling, broaching, requiring high
P For machining long chip forming HB toughness
P10 Steel Steel castings
Steel, Turning, threading,
Turning threading and milling high speed
speed, K30 Soft grey C.l.
C l Low tensile Turning reaming under favourable conditions
Turning,
common materials like plain carbon small chips strength steel
and low alloy steels P20 Steel, steel castings, Turning, milling, medium speed with small chip K40 Soft non-ferrous metals Turning milling etc.
M10 Steel steel castings
Steel, castings, Turning, milling,
Turning milling medium cutting speed and medium
malleable cast iron section
M For machining long or short chip manganese steel, grey C.l. chip section
M20 Steel casting, austentic steel, Turning, milling, medium cutting speed and medium
formingg ferrous materials like P30 Steel, steel castings, Turning, milling, medium speed with small chip
manganese steelsteel, chip section
malleable
ll bl cast iiron section
i
Stainless steel spherodized C.l., Malleable
P40 Steel and steel casting Turning, planning, low cutting speed, large chip C.l.
K For machining short chipping,
chipping with
ith sand
d iinclusions
l i section
ti M30 Steel austenitic steel,
Steel, steel Turning milling,
Turning, milling planning,
planning medium cutting speed,
speed
spherodized C.l. heat medium or large chip section
ferrous and nonferrous material P50 Steel and steel castings Operations requiring high toughness turning, resisting alloys
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 M40 Free cutting steel
steel, low tensile Turning profile turning
Turning, turning, specially in automatic
Brass etc. strength strength steel, brass and light
alloy
machines.

Page 139 of 186 35
Rev.0 36
IES‐1999 Ceramics
Match List‐I (ISO classification of carbide tools) with List‐ y Ceramics are essentially alumina ( Al2O3 ) based high
II (Applications) and select the correct answer using the
pp g refractory materials introduced specifically for high
codes given below the Lists: speed machining of difficult to machine materials and
List‐I List‐II cast iron.
iron
A. P‐10 1. Non‐ferrous, roughing cut
y These can withstand very high temperatures, are
B. P‐505 2. Non‐ferrous, finishing cut
, g
chemically more stable,
stable and have higher wear
C. K‐10 3. Ferrous material, roughing cut
resistance than the other cutting tool materials.
D.. K‐50
5 4. Ferrous material, finishing cut
e ous a e a , s g cu
y In
I view
i off their
h i ability
bili to withstand
ih d high
hi h temperatures,
Code: A B C D A B C D
they can be used for machining at very high speeds of
(a) 4 3 1 2 (b) 3 4 2 1
the
h order
d off 10 m/s.
/
(c) 4 3 2 1 (d) 3 4 1 2
y They can be operated at from two to three times the
y p
cutting speeds of tungsten carbide.
37 Contd…
38 Comparison of important properties of ceramic and tungsten carbide tools 39
y Through last few years remarkable improvements in y Introducing nitride ceramic (Si3N4) with proper sintering
y Itt iss poss b e to get mirror
possible o finish
s oon cast iron
o us g
using technique – this material is very tough but prone to built‐up‐
built up
ceramic turning. strength and toughness and hence overall performance
edge formation in machining steels
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 y Developing SIALON – deriving beneficial effects of Al2O3
means which include; and Si3N4
strength, poor thermal characteristics, and the
y Sinterability,
Sinterability microstructure
microstructure, strength and y Addi
Adding carbide
bid like
lik TiC (5
( ~ 15%)
%) in
i Al2O3
Al O powder d – to t
tendency to chipping.
toughness of Al2O3 ceramics were improved to impart toughness and thermal conductivity
y They are not suitable for intermittent cutting or for low
some extent byb adding
ddi TiO2
TiO and d MgO,
M O y Reinforcing
f oxide
d or nitride
d ceramics by
b SiC whiskers,
h k which
h h
cutting speeds. enhanced strength, toughness and life of the tool and thus
y Transformation toughening
g g byy addingg appropriate
pp p
y Very
V hi h hot
high h t hardness
h d properties
ti productivity
d i i spectacularly.
l l
amount of partially or fully stabilised zirconia in
y Often used as inserts in special
p holders. y Toughening Al2O3 ceramic by adding suitable metal like
Al2O3 powder,
powder
silver which also impart thermal conductivity and self
y Isostatic and hot isostatic pressing (HIP) – these are lubricating property; this novel and inexpensive tool is still
very effective
ff i but b expensivei route. i experimental
in i l stage.
Contd…
40 Contd…
41 Contd…
42
IES 2016
IES‐2016
y Cutting
g fluid, if applied
pp g with
should in flooding Statement (I): Ceramics withstand very high High Performance ceramics (HPC)
copious quantity of fluid, to thoroughly wet the entire temperatures that range from 1000°C to 1600°C.
machining zone, since ceramics have very poor Statement ((II):
) Silicon carbide is an exceptionp from
thermal shock resistance. Else, it can be machined among ceramics that cam withstand high
with no coolant.
coolant p
temperatures.
y Ceramic tools are used for machining work pieces,
(a) Both Statement (I) and Statement (II) are
individually true and Statement (II) is the correct
which have high hardness, such as hard castings, case explanation of Statement (I).
hardened and hardened steel.
(b) Both Statement (I) and Statement (II) are Silicon Nitride
Sili Nit id Alumina toughned
Al i t h d byb
y Typical products can be machined are brake discs, individually true but Statement (II) is not the correct (i) Plain (i) Zirconia
brake drums,
drums cylinder liners and flywheels.
flywheels explanation
l ti off Statement
St t t (I).
(I)
(ii) SIALON (ii) SiC whiskers
(iii) Whisker toughened (iii) Metal (Silver etc)
Page 140 of 186 44
Rev.0 45
IES‐2013 IES 2010 IAS‐1996
Sialon ceramic is used as: Constituents
C tit t off ceramics i are oxides
id off Match List I with List II and select the correct answer
different materials, which are using the codes given below the lists:
( )
(a) Cutting tool material List I (Cutting tools)
( l ) List II (Major constituent)
( )
(a) Cold mixed to make ceramic pallets A. Stellite l. Tungsten
(b) C
(b) Creep resistant
i (b) Ground, sintered and palleted to make ready B. H.S.S. 2. Cobalt
ceramics C. Ceramic 3. Alumina
( ) F
(c) Furnace linens
li D. DCON 4. Columbium
(c) Ground, washed with acid, heated and cooled 55. Titanium
(d) High strength Codes: A B C D A B C D
(d) Ground, sintered, palleted and after calcining
((a)) 5 1 33 4 ((b)) 2 1 4 3
cooled
l d in
i oxygen (c) 2 1 3 4 (d) 2 5 3 4
46 47 48
IES‐1997 IES‐1996 IES 2007

Assertion (A): Ceramic tools are used only for light, A machinist desires to turn a round steel stock of Which one of the following is not a ceramic?
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 ( ) Alumina
(a) Al i
Reason (R): Ceramics have a high wear resistance and material has tensile strength of 75 kg/mm2. The
high temperature resistance. ((b)) Porcelain
d
depth of cut chosen is 3 mm at a feed rate of 0.3
h f h i f d f
mm/rev. Which one of the following tool (c) Whisker
materials will be suitable for machining the (d) Pyrosil
P il
correct explanation of A component under the specified cutting
p p g
(c) A is true but R is false conditions?
A i f l b R i (a) Sintered carbides (b) Ceramic
(c) HSS (d) Diamond
49 50 51
IAS‐2000 IAS‐2003 Coated Carbide Tools

Consider the following cutting tool materials used for At room temperature, which one of the following y Coated tools are becoming the norm in the metalworking
g p
metal‐cutting operation at is the correct sequence of increasing hardness of industry because coating , can consistently improve,
improve tool
high speed: the tool materials? life 200 or 300% or more.
1
1. Tungsten carbide y In
I cutting
tti tools,
t l material
t i l requirements
i t att the
th surface
f off the
th
(a) Cast alloy‐HSS‐Ceramic‐Carbide
2. Cemented titanium carbide tool need to be abrasion resistant, hard, and chemically
3. High‐speed steel
Hi h d l (b) HH
HH‐Cast alloy‐Ceramic‐Carbide
Cast alloy Ceramic Carbide i
inert to prevent the
h tooll and d the
h work k material
i l from
f
4. Ceramic (c) HSS‐Cast alloy‐Carbide‐Ceramic interacting chemically with each other during cutting.
The correct sequence in increasing order of the range of (d) Cast alloy‐HSS‐Carbide‐Ceramic y A thin, chemically stable, hard refractory coating of TiC,
cutting speeds for optimum use of these materials is TiN,, or Al2O3 accomplishes
p this objective.
j
(a) 3,1,4,2 (b) 1,3,2,4 y The bulk of the tool is a tough, shock‐resistant carbide that
(c) 3,1,2,4 (d) 1,3,4,2 can withstand high
high‐temperature
temperature plastic deformation and
resist breakage.
Page 141 of 186 53
Rev.0 Contd…
54
y The coatings
g must be fine g
grained, & free of binders y The most successful combinations are
and porosity. TiN/TiC/TiCN/TiN and TiN/TiC/ Al2O3 .
y Naturally,
Naturally the coatings must be metallurgically bonded y Chemical
h l vapour deposition
d (
(CVD)
) is the
h technique
h
to the substrate. used to coat carbides.
y Interface coatings are graded to match the properties
of the coating
g and the substrate.
y The coatings must be thick enough to prolong tool life
but thin enough to prevent brittleness.
brittleness
y Coatings should have a low coefficient of friction so
that the chips do not adhere to the rake face.
y Multiple coatings are used,
used with each layer imparting
its own characteristic to the tool. Contd…
55 Contd…
56 57
IAS‐1999 TiN‐Coated High‐Speed Steel y Physical

y p
vapour p
deposition (PVD) has p
proved to be the
The coating materials for coated carbide tools, y Coated high‐speed steel (HSS) does not routinely best process for coating HSS, primarily because it is a
includes provide as dramatic improvements in cutting speeds as relatively low temperature process that does not
do coated carbides, with increases of 10 to 20% being exceed the tempering point of HSS.
(a) TiC, TiN and NaCN (b) TiC and TiN
typical.
i l y Therefore,
Th f no subsequent
b t heat
h t treatment
t t t off the
th
(c) TiN and NaCN (d) TiC and NaCN
y In addition to hobs,, ggear‐shaper
p cutters,, and drills,, cutting tool is required.
HSS tooling coated by TiN now includes reamers, taps, y The advantage of TiN‐coated HSS tooling is reduced
chasers spade
chasers, spade‐drill
drill blades,
blades broaches,
broaches bandsaw and tool wear.
circular saw blades, insert tooling, form tools, end y Less tool wear results in less stock removal during tool
mills and an assortment of other milling cutters.
mills, cutters regrinding,
i di thus
h allowing
ll i i di id l tools
individual l to be b
reground more times.
58 Contd…
59 60
C t
Cermets IES 2010 IES‐2000
y These sintered hard inserts are made by combining ‘cer’
cer from
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 Cermets are
likee Ni,, Ni‐Co,
Co, Fee etc. sustain high temperature is ( ) Metals for high temperature use with ceramic like
(a) M l f hi h i h i lik
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 properties
(b) Ceramics with metallic strength and luster
y Wt% of binder metal varies from 10 to 20%. (b) Composite of lead and steel
y Cutting edge sharpness is retained unlike in coated carbide (c) Coated tool materials
inserts (c) Cermet (d) Metal‐ceramic composites
y Can machine steels at higher cutting velocity than that used for (d) Alloy of steel, zinc and tungsten
tungsten carbide, even coated carbides in case of light cuts.
y Modern cermets with rounded cutting edges are suitable for
finishing and semi‐finishing of steels at higher speeds, stainless
steels but are not suitable for jerky interrupted machining and
machiningFor-2017
of aluminium (IES,
andGATE & materials.
similar PSUs) 61
Page 142 of 186 62
Rev.0 63
IES – 2003 Di d
Diamonds
The
Th correct sequence off cutting i tools
l ini theh
y Diamond is the hardest of all the cutting
y Diamond has the following properties:
g tool materials.
GATE –
GATE – 2009 (PI)
2009 (PI)
ascending order of their wear resistance is y extreme hardness,
hardness Di
Diamond
d cutting
tti t l are nott recommended
tools d d for
f
(a) HSS‐Cast non‐ferrous alloy (Stellite)‐Carbide‐ y low thermal expansion,
Nitride y high
hi h heat
h conductivity,
d i i and d machining of ferrous metals due to
(b) Cast non‐ferrous alloy (Stellite)‐HSS‐Carbide‐ y a very low co‐efficient of friction.
(a) high tool hardness
Nitride
d y This is used when good surface finish and dimensional accuracy
(c) HSS‐Cast
SS Cast non‐ferrous
o e ous aalloy oy (Ste
(Stellite)‐Nitride‐
te) t de are desired. ((b)) high
g thermal conductivityy of work material
Carbide y The work‐materials on which diamonds are successfully employed
are the non‐ferrous one, such as copper,
pp brass, zinc, aluminium ((c)) p
poor tool toughness
g
(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 (d) chemical affinity of tool material with iron
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 IES‐1995
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. Assertion (A): Non‐ferrous materials are best
improved, as is control over part size, finish, and
p p machined with diamond tools.
y Due
D to their
h i brittle
b i l nature, the h diamond
di d toolsl have
h poor
surface integrity. Reason (R): Diamond tools are suitable for high speed
resistance to shock and so, should be loaded lightly.
y Positive rake tooling is recommended for the vast machining.
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) Both A and R are individually true and R is the
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. (b) Both A and R are individually true but R is not the
use of more positive rake angles may eliminate it.
p g y correct explanation of A
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) A is true but R is false
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) A is false but R is true
A i f l b R i
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
Contd…
67 68 69
IES‐2001 IES – 1999 IES‐1992

Assertion (A): Diamond tools can be used at high
C id h f ll i
Which of the following given the correct order of
p
speeds. p g y,
For precision machining of non‐ferrous alloys, diamond increasing hot hardness of cutting tool material?
Reason (R): Diamond tools have very low coefficient is preferred because it has
of friction. (a) Diamond, Carbide, HSS
1 Low coefficient of thermal expansion
1.
(a) Both A and R are individually true and R is the (b) Carbide, Diamond, HSS
correct explanation of A 2. High wear resistance
(c) HSS, carbide, Diamond
HSS carbide Diamond
(b) Both A and R are individually true but R is not the 3. High compression strength
(d) HSS, Diamond, Carbide
correct explanation of A 4. Low fracture toughness
L f t t h
(c) A is true but R is false Which of these statements are correct?
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
Page 143 of 186 71
Rev.0 72
IAS – 1999 Cubic boron nitride/Borazon y The operative speed range for cBN when machining
Assertion (A): During cutting, the diamond tool is
A i (A) D i i h di d l i grey castt iron
i is
i 300 ~400 m/min
/ i
y Next to diamond, cubic boron nitride is the hardest
kept flooded with coolant. y Speed
p ranges
g for other materials are as follows:
material presently available.
available
Reason (R): The oxidation of diamond starts at y Hard cast iron (> 400 BHN) : 80 – 300 m/min
y It is made by bonding a 0.5 – 1 mm layer of
about 4500C y Superalloys
S ll ( 35 RC) : 80
(> 8 – 140 m/min
/ i
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 y Hardened steels ((> 45 RC) : 100 – 3
300 m/min
l f pressure. y It is best to use cBN tools with a honed or chamfered
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 edge preparation,
preparation especially for interrupted cuts.
cuts Like
correct explanation of A toughness at elevated machining speeds. ceramics, cBN tools are also available only in the form
(c) A i t b t R i f l y It shows excellent performance in grinding any off indexable
i d bl inserts.
i
(d) A is false but R is true material of high
g hardness and strength.
g y The only y limitation of it is its high
g cost.
73 Contd…
74 Contd…
75
IES‐1994 IES‐2002
y CBN is less reactive with such materials as hardened Consider the following tool materials: Which one of the following is the hardest cutting
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 tool material next only to diamond?
based superalloys. 33. Ceramic 4.
4 Borazon. (a) Cemented carbides
y CBN can be used efficiently and economically to (b) Ceramics
Correct sequence of these tool materials in increasing
machine these difficult‐to‐machine materials at higher
g order of their ability to retain their hot hardness is (c) Silicon
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 (d) Cubic boron nitride
accuracy, finish, and surface integrity. (c) 2, 1, 3, 4 (d) 2, 1, 4, 3
76 77 78
IES‐1996 IES‐1994 IAS‐1998

Cubic boron nitride Cubic boron nitride is used Which of the following tool materials have cobalt
( ) 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 as a constituent element?
that of diamond. ((b)) For making optical quality glass.
g p q yg 1. Cemented carbide 2. CBN
(b) Has a hardness which is slightly more than that of (c) For heat treatment 3. Stellite 4. UCON
HSS (d) For none of the above.
F f h b Select the correct answer using the codes given below:
(c) Is used for making cylinder blocks of aircraft Codes:
engines
i (a) 1 and 2 (b) 1 and 3
((d)) Is used for making optical glasses.
g p g (c) 1 and 4 (d) 2 and 3

Page 144 of 186 80
Rev.0 81
C it
Coronite IES‐1993 IES‐2003
y Coronite is made basically by combining HSS for strength and
toughness and tungsten carbides for heat and wear resistance. Match List I with List IT and select the correct answer using the Which one of the following is not a synthetic
codes given below the lists:
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 abrasive material?
y Unlike a solid carbide, the coronite based tool is made of three characteristic constituent)
A. High speed steel 1. Carbon (a) Silicon Carbide (b) Aluminium Oxide
layers;
y the central HSS or spring steel core
B. Stellite 2. Molybdenum (c) Titanium Nitride (d) Cubic Boron Nitride
C. Diamond 3. Nitride
y a layer of coronite of thickness around 15% of the tool D. Coated carbide tool 4. Columbium
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) 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
coating of TiN or TiCN outperformed HSS tools in respect of
cuttingg forces, tool life and surface finish.
82 83 84
IES‐2000 IES‐1999 IAS‐2001

Consider the following tool materials: Match List‐I with List‐II and select the correct answer Match. List I (Cutting tool materials) with List II
using the codes given below the Lists: (Manufacturing methods) and select the correct answer
1. HSS 2. C
Cemented carbide
d bid List I List II using the codes given below the Lists:
i th d i b l th Li t
(Materials) (Applications) List I List II
33. Ceramics 4.
4 Diamond
A Tungsten carbide
A. bid 1. Ab i h l
Abrasive wheels A HSS
A. 1
1. Casting
The correct sequence of these materials in decreasing B. Silicon nitride 2. Heating elements B. Stellite 2. Forging
order of their cutting speed is C Aluminium
C. Al i i oxide
id 3. Pi f
Pipes for conveying
i C Cemented carbide
C. 3
3. Rolling
liquid metals D. UCON 4. Extrusion
(a) 4, 3, 1, 2 (b) 4, 3, 2, 1
D Silicon carbide
D. 4
4. Drawing dies 5
5. Powder metallurgy
(c) 3, 4, 2, 1 (d) 3, 4, 1, 2 Code: A B C D A B C D Codes:A B C D A B C D
(a) 3 4 1 2 (b) 4 3 2 1 (a) 3 1 5 2 (b) 2 5 4 3
(c) 3 4 2 1 (d) 4 3 1 2 (c) 3 5 4 2 (d) 2 1 5 3
85 86 87
Attrition wear IES‐1996 IES‐2005

y The strong bonding between the chip and tool material at The limit to the maximum hardness of a work Consider the following statements: An increase in
high temperature is conducive for adhesive wear. material which can be machined with HSS tools the cobalt content in the straight carbide grades
g g
y The adhesive wear in the rough region is called attrition of carbide tools
wear . even at low speeds is set by which one of the
following tool failure mechanisms? 1 Increases the hardness.
1. Increases the hardness
y In the rough region, some parts of the worn surface are still
covered by molten chip and the irregular attrition wear (a) Attrition 2. Decreases the hardness.
occurs in this region . 3. Increases the transverse rupture strength
I h h
y The irregular attrition wear is due to the intermittent (b) Abrasion
adhesion during interrupted cutting which makes a 4. Lowers the transverse rupture strength.
4 p g
(c) Diffusion
periodic attachment and detachment of the work material Which of the statements given above are correct?
on the tool surface. (d) Plastic deformation under compression.
(a) 1 and 3 (b) 2 and 4
y Therefore, when the seizure between workpiece to tool is
broken, the small fragments of tool material are plucked (c) 1 and 4 (d) 2 and 3
andd brought
b h away byb the
h chip.
h
Page 145 of 186 89
Rev.0 90
IES-2003 Page No.5 Slide No.28 Ans. (b)

Ch-1 Basics of Metal Cutting: Answers with Explanations
GATE(PI)-1990 Page No.5 Slide No.30 Ans. (c)
IES-2013 Page No.3 SlideNo.11 Ans.(c) No of chattering per cycle 360/30 = 12
No of cycle per second = 500 /60
S DN S u 30 u1000 Therefore chattering frequency is 12 x 500/60 = 100 Hz
Speed V m / min m / min 94.2 m / min IAS-1996 Page No.5 Slide No.31 Ans. (a)
1000 1000
IES-2001 Page No.3 Slide No.12 Ans. (c) For cutting brass recommended rake angle is -5 to +5 IAS-1995 Page No.5 Slide No.32 Ans. (a) Fy Ft cos O Ft sin CS
degree.
IES-2010 Page No.5 Slide No.33 Ans. (c) Fy n Ft cos O Ft sin CS n (radial force)
IES-1995 Page No.3 Slide No.13 Ans. (a) It is true form-cutting procedure, no rake should be
Fx p Ft sin O Ft cos CS n (axial force)and SCEA has no influence on cutting force i.e. tangential force. But
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 this question is not for Orthogonal Cutting it should be turning.
of this method is that the absence of side and back rake results in poor cutting (except on cast iron or
IES-1995 Page No.5 Slide No.34 Ans. (c)
brass). The surface finish on steel usually will be poor.
IES-2006 Page No.5 Slide No.35 Ans.(c) Smaller point angle results in higher rake angle.
GATE-1995;2008 Page No.3 Slide No.14 Ans. (a) Increasing rake angle reduces the cutting force
on the tool and thus power consumption is reduced. IES-2002 Page No.5 Slide No.36 Ans. (d)Strength of a single point cutting tool depends on lip
angle but lip angle also depends on rake and clearance angle.
IES-1993 Page No.3 Slide No.15 Ans. (d) Negative rake angle increases the cutting force i.e.
Cutting force IES-2012 Page No.6 Slide No.37 Ans. (b)
specific pressure. Specific pressure =
feed×depth of cut IES-2009 Page No.6 Slide No.38 Ans. (c)Large nose radius improves tool life. A sharp point on the
IES-2005 Page No.3 Slide No.16 Ans.(b) Carbide tips are generally given negative rake angle it end of a tool is highly stressed, short lived and leaves a groove in the path of cut. There is an
is very hard and very brittle material. Negative rake is used as carbides are brittle not due to hardness. improvement in surface finish and permissible cutting speed as nose radius is increases from zero value.
Hardness and brittleness is different property But too large a nose radius will induce chatter.
IES-2015 Page No. 3 Slide No.17 Ans.(b) IES-1995 Page No.6 Slide No.39 Ans. (c) It will increase tool cutting force.
IES-2002 Page No.3 Slide No.18 Ans.(c) Carbide tools are stronger in compression. IES-1994 Page No.6 Slide No.40 Ans. (b)

IES-2011 Page No.4 Slide No.19 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. IES-1993 Page No.6 Slide No.42 Ans. (b)The second item is the side rake angle. Thus 6° is
the side rake angle.
GATE-2008(PI) Page No.4 Slide No.20 Ans. (c) Brittle workpiece materials are hard and needs ISRO-2011 Page No. 6 Slide No.43 Ans. (b)
stronger tool. Tools having zero or negative rake angle provides adequate strength to cutting tool due to
large lip angle. GATE-2008 Page No. 6 Slide No.44 Ans.(d) We may use principal cutting edge angle or approach
angle = 90 - CS . When, principal cutting edge angle =90;then D S D. Don’t confuse with side cutting
IAS-1994 Page No.4 Slide No.23 Ans. (d)
edge angle. Side cutting edge angle is not principal cutting edge angle.
IES-2014 Page No.4 Slide No.24 Ans. (c) GATE-2001Page No.6 Slide No.45 Ans.(c)
IES-2012 Page No.4 Slide No.25 Ans.(d) When cutting velocity is increased, it will lead to r cos D 0.4 cos10
I tan 1
tan 1
22.944
increase in power and temperature, and cutting force will be slightly reduce so we take as cutting forces will not 1 r sin D 1 0.4sin10
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. t 0.81
GATE-2011Page No. 7 Slide No.46 Ans. (b) r 0.45
Therefore the force will remain unaffected. But in actual practice it will reduce due to high tc 1.8
temperature. As velocity increases power consumption will increase and temperature will increase.
IES-2006 Page No.4 Slide No.26 Ans. (d) All other tools are multi-point. r cos D 0.45cos12o
I tan 1 tan 1 25.90o
1 r sin D 1 0.45sin12o
IES-2012 Page No.4 Slide No.27 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 IES-1994 Page No.7 Slide No.47 Ans. (b) Shear angle does not depends on velocity.
from the machined surface, Whereas negative back rake angle directs the chip on to the machined surface.
VC V
sin I sin 90 D I
lc 68.9 r cos D
IES-2014 Conventional Page No. 7 Slide No. 48 Ans. 18.3o r and tan I 35 u sin 45
l S u 69 1 r sin D VC 28.577m / min
sin 90 15 45
GATE-2014 Page No.7 Slide No.49 Ans. 2.8 to 3.0
t f sin O 0.2 u sin 90o

r (for turning) = 0.4 IES-2008 Page No.8 Slide No.59 Ans. (b)
tc tc 0.5
r cos D r cos 0 Cutting ratio means chip thickness ratio, r 0.75; V 60 m / min
I tan 1 tan 1 tan 1 r tan 1 0.4
1 r sin D 1 r sin 0
t 2.4
I 21.80o r tC 3.2 mm
tC 0.75
Shear strain(H )= cot I tan I D cot 21.80o tan(21.80 0)o 2.9
VC sinI
r 0.75
V sin(90 D I )
IES-2004 Page No.7 Slide No.50 Ans.(d)
VC 0.75 u 60 45 m / min
r cos D 0.3cos10
r = 0.3, D 10 ? I tan 1 tan 1 17.31o
1 r sin D 1 0.3sin10 IES-2014 Page No.8 Slide No.60 Ans. (c)f = f sinǌ = 0.2 sin 90 = 0.2 mm ; tc= 0.32 mm;
o cutting ratio = chip thickness ratio = t / tc = 0.2/0.32 = 0.625 But examiner has given reciprocal value = 1.6
shear strain (H ) = cot I tan I D cot17.31o tan 17.31 10 3.34
Without using calculator we can’t solve this question. IES-2001 Page No.8 Slide No.61 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
IES-2009 Page No. 7 Slide No.51 Ans. (d)as rake angle is zero. shear strain (H ) = cot I tan I face is chip velocity (Vc ).
GATE-1990(PI)Page No.7 Slide No.52 Ans. (a) IES-2003 Page No.8 Slide No.62 Ans. (d)
V t 0.5
H cot I tan I 12 t 0.5 mm , tc 0.6 mm, C r
V tc 0.6
dH 2 u 0.5
cos ec 2I sec2 I 12 0 gives I 51o or VC 1.66 m / s
dI 0.6
IAS-2003 Page No.8 Slide No.63 Ans. (a)
V Vs Vc
IES-2016 Page No. 7 Slide No.53 Ans.(a) IAS-2002 Page No.9 Slide No.64 Ans. (a)
cos I D cos D sin I
GATE-2012 Page No. 7 Slide No.54 Ans. (c) IAS-2000 Page No.9 Slide No.65 Ans. (d)
IAS-1998Page No.9 Slide No.66 Ans. (b)
r 0.4; D 10
S DN S u100 u 480
r cos D 0.4 cos10 V m/s m / s 2.51 m / s
I tan 1 tan 1 22.94 1000 u 60 1000 u 60
1 r sin D 1 0.4sin10
from the velocity triangle; IAS-1995 Page No.9 Slide No.67 Ans. (b) It is orthogonal cutting means depth of cut equal to
uncut chip thickness. As depth of cut halved, uncut chip thickness is also halved and hence chip thickness will
V VS
be halved.
sin 90 I D sin 90 D
2.5 VS GATE-2009 (PI -common data S-1) Page No.9 Slide No.68 Ans.(c)
sin 90 22.94 10 sin 90 10 t 0.2 mm; tc 0.4 mm; D 15q
t r cos D 0.5cos15q
VS 2.526m / s ?r 0.5; I tan 1 tan 1 29.02q
tc 1 r sin D 1 0.5sin15q
VS 2.526 m / s
Shear strain rate(H < ) 1.0104 u 105 / s Nearest option is c
tS 25 u106 m
IES-2004 Page No.8 Slide No.55 Ans. (b) actually 2, 3 and 4 are correct. But best choice is (b) GATE-2009 (PI- common data S-2) Page No.9 Slide No.69 Ans. (b)
V
V 20 m / min; C r 0.5 orVC 10 m / min
IES-2006 Page No.8 Slide No.56 Ans. (c)Cutting torque decreases with increase in rake angle. V
IES-2004 Page No.8 Slide No.57 Ans. (c) GATE-1995 Page No.9 Slide No.70 Ans. (b)It is multi-point cutter and mild steel is ductile material.
Ductile material with multipoint cutter will produce regular shaped discontinuous chip.
IES-2004,ISRO-2009 Page No.8 Slide No.58 Ans. (a)

IES
S-2007Page No.9 Slide No.71
N Anss. (b) ' Friction force is perpendicular to the
IES
S-2015 Pag
ge No.9 Slide No.72
N Anss. (c)
cutting velocity vector that means D = 0q
F
S-1997Page No.10
IAS Slide No.73
N Anss. (a) F 402.5 N ; and P 1( given) ? N 402.5 N
N
GAT TE-2002 Pa age No.10 Slide No.74 4 Ans. (b b)Low cuttin
ng speed m
means long chip
c tool con
ntact
t 0.2
t 0.2 mm; tc 0.4mm, r 0.5
timee. And long contact
c timee will sufficient to form bond
b betwee
en chip and tool. tc 0.4
r cos D r cos 0
GAT TE-2009 Pa age No.10 Slide No.75
N Anss. (d)Low cu utting speed d means long ontact time. And
g chip tool co tan I r 0.5.......('D = 0q)
1 r sin D 1 r sin 0
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
or I tan r tan 0.5 26.565q
1 1
rela
ative motion between chiip and tool. It will increease co-efficient of frictioon.
tan E P 1; E 45q
IESS-1997Page No.10 Slide No.76
N Anss. (d)Cast iron mea
ans brittle material and will form
disccontinuous chip. So chip breaker is not
n needed. From merchant circle:
F R sin E or R 402.5 N 569.22 N
Ch
h-2: An
nalysis of Mettal Cuttting: Answer
A rs with
h Expla
anation
ns sin 45q
In FS and FC triangle:
ESEE-2000(co onvention nal) Pagge No.10 Slide No
o.79 Fs =Rcos E D I 569.22 u cos 45 0 26.565 N 180.0 N
Ans. GATE-2010 (PI) linked S-2 Page No.10 Slide No.81 Ans.
D 10q, r 0.335, t 0.51 mm
m , b=3mm
m, V 2m ;
s
W y 285 N / mm
m , P 0.655
2
From the velocity triangle , applying sine rule;
r cos D 0.35 u cos10
tan I 0.3669 V VS
1 r sinn D 1 0.35sin10
sin ^90 I D ` sin 90 D
I tan 1 0.36669 20.152q
bt 3 mm u 0.51 mm 2 VS
FS W y m2
285 N / mm sin 90 26.565 sin 90
sin I sin 20.1152q
12265.7 N VS 2.2361 m
s
P tan E , ? E tan 1 P tan 1 0.65 33.023q ? Heat generation at the primary shear zone
Froom Merchannt Circle: will be because of shear velocity and shear force
? Fs R cos I E D Heat =FS u VS 180.0 N u 2.2361 m / s 402.5W
FS GATE-2013 linked queS-1 Page No.11 Slide No.82 Ans. (a)
R 1735.6N
cos I E D From Merchant Circle if cutting force ( FC ) is perpendicular to the friction force ( F ) then the rake
(i) Cutting
C force (Fc ): Fc R cos E D 1597.3 N angle will be zero
GATE-2013 linked queS-2 Page No.11 Slide No.83 Ans. (b)
(ii) Radial forcee (Fy ) =0 [Thhis force is present
p in turning
t but it is orthogonnal cutting] From merchant circle;
(iii)) Normal forrce on tool (N): N c E
R cos 1455.2 N 'D = 0, then F, N, FC , Ft will form a rectangle.
(iv))Shear forcee (Fs ):1265.77 N Fc N 1500 N
Notte : Shear foorce on tool face
f is fricttion force ( F ) R sin E 945.86 N Ft F
GA
ATE-2010 (PI) linke ed S-1 Pa age No.10 Slide No.80 Ans. GATE-2015 Page No.11 Slide No.84 Ans. 2.1
IAS-1999 Page No.11 Slide No.86 Ans. (b)
D E
I =45q +
2 2
q
20 25.5q
I 45q 42.25q
2 2
GATE-1997 Page No.11 Slide No.87 Ans. (c)

Ussing Merchaant Analysiss: D Ep
Using Merchant Analysis, I n 45q
D E 2 2
I = 45 + q
As shear angle increases cutting force will decrease and length of shear plane decreased results chip
2 2
thickness decrease.
10 q
Eq
20q 45q E 60q GATE-2014 Page No.12 Slide No.92 Ans. (a)
2 2
ESE
E-2005(coonvention nal) Page No..11 Slide No.88 Ans. D Ep
Using Merchant Analysis, I n 45q
P 0.55; ? E tan 1 P tan 1 0.5 26.565q 2 2
As shear angle increases area of the shear plane decreased, it results cutting force hence improve
using Merchant
M Annalysis: surface finish. Here option (b) is also correct but best one is option (a).
D E IES-2010 Page No.12 Slide No.94 Ans. (b) Merchant Analysis
I = 45q +
2 2 IES-2005 Page No.12 Slide No.95 Ans. (a)
266.565q IES-2003 Page No.12 Slide No.99 Ans.(c)
or I 4 q 5q
45 36..717q
2 Fs Fc cos I Ft sin I 900cos 30 600sin 30 479.4 N
bt 2 mm u 0.22 mm IES-2014 Page No.13 Slide No.100 Ans. (b)
FS W y m2
400 N / mm 2677.61N
sin I sin 36.7717q Fs Fc cos M Ft sin M 900 cos11.31q 810sin11.31q 723 N
Froom merchant circle: But we have to calculate without using calculator
Fs R cos I E -D sin11.31q = 0.2 given ? cos 11.31q 1 sin 2 11.31q 1 0.22 0.98
or 267.61
2 N R cos(36.717q 26.5655q 10q ) 900 cos11.31q 810sin11.31q 900 u 0.98 810 u 0.2 720 N
or R 447.6 N IES-2000 Page No.13 Slide No.101 Ans. (a)
andd Fc R cos E -D F Fc sin D Ft cos D
FC 447.6 cos(26.565q 10
1 q) 429.002 N N Fc cos D Ft sin D
Ft 447.6sin(226.565q 10
0q ) 127.611N 'D 0;
. so F= Ft 500 N
N Fc 1000 N
GA
ATE-2008 (PI) Link
ked S-1 Page No..11 Slide No.89 Ans. ((d)
Forr minimum cutting
c forcee we have too use mercha
ant Theory F 500 1
P
D 10q , P 0.7 tan E or E tan 1 P 34.99q N 1000 2
Using Merchant
M A
Analysis GATE-2007 (PI) Linked S-1 Page No.13 Slide No.103 Ans. (a)
FC 1200 N ; Ft 500 N ; D 0q
D E
I 45q Using the relations:
2 2
10 34.99q
q F FC sin D Ft cos D 1200sin 0 500 cos 0 500 N
I 45q 32.5q
2 2 N FC cos D Ft sin D 1200 cos 0 500sin 0 1200 N
GA
ATE-2008 (PI) Linkked S-2 Page No..11 Slide No.90 Ans. ((b) F 500
b 3.6 mm P tan E
N 1200
Calculaating shear force
f Fs : 500
? E tan 1 22.6q
bt 3.6 mm u 0.25
0 mm 1200
Fs Wy u 4660 N / mm 2 7
770.52 N
sin I sin 322.5q GATE-2007 (PI) Linked S-2 Page No.13 Slide No.104 Ans. (b)
Using Merchant
M Circle:
C Orthogonal machining, t = depth of cut = 0.8 mm,
In trianngle formed by Fs , Fn annd R; t c =1.5 mm, V =1m/s
Fs c I E D
R cos t 0.8 Vc Vc
r
tc 1.5 V 1
or 770.52 N R N u cos(32.5 34.99 10 ) R 1433.7 N
q q q
Vc 0.53 m / s
In trianngle formed by Ft , Fc annd R;
GATE-2011 (PI) linked S-1 Page No.13 Slide No.105 Ans. (b)
Fc =Rcoos E D 1433.7 u coos(34.99q 10
1 q ) 1299..5 N
1500
=FC <V
Power= 12999.5 N u m / s 32448.8W | 3.2
25 KW
60
GA
ATE-2014 Pag
ge No.12 Slide No.91 Ans. (d)

t 0.25 mm; tc 0.75 mm; D 0q; b 2.5 mm; N 950 N ; Ft 475 N D 15; t 0.5mm; tc 0.7mm; Fc 1200 N ; Ft 200 N
t 0.25 t 0.5
r 0.33333 r 0.7142
tc 0.75 tc 0.7
r cos D r cos 0 r cos D 0.7142 cos15q
tan I r 0.33333 I tan 1 tan 1 40.24q
1 r sin D 1 r sin 0 1 r sin D 1 0.7142sin15q
I 18.435q F Fc sin D Ft cos D 1200sin15q 200 cos15q 503.77 N
To calculate shear force; N Fc cos D Ft sin D 1200 cos15q 200sin15q 1107.3 N
as D = 0, N = Fc 950 N F 503.77
?P 0.455 | 0.46
Fs Fc cos I Ft sin I 950 cos18.435q 475sin18.435q 751.04 N N 1107.3
GATE-2011 (PI) linked S-2 Page No.13 Slide No.106 Ans. (d) Alternatively
bt Using Merchant Theory:
We know, FS W y ;
sin I D E
I 45q

2.5 mm u 0.25 mm 2 2
751.04 N W y N / mm 2
sin18.435q 15q
E 45q 40.24q 24.5q
W y 379.90 N 2
mm 2
P tan E tan 24.5q 0.456 | 0.46
IFS-2012 Page No.13 Slide No.107 Ans.
d t 0.1 mm, tc 0.2mm, b 5 mm, Fc 500 N , Ft 200 N , D 10q GATE-2006 common data Q-2 Page No.14 Slide No.109 Ans.(a)
V 20m / min; Fc 1200 N ; Ft 200 N ( given)
To calculate co-efficient of friction:
Vc t Vc 0.5
Using relations: r or
V tc 20 m / min 0.7
F Fc sin D Ft cos D 500sin10q 200 cos10q 283.79 N
orVC 14.286 m / min
N Fc cos D Ft sin D 500 cos10q 200sin10q 457.67 N
20
F 283.79 Total power Fc u V 1200 N um / s 400W
P 0.62 60
N 457.67 14.286
To calculate shear strength; Frictional power=F u VC 503.77 N u m / s 119.95W
60
t 0.1 mm Percentage of total energy dissipated as frictional power is
r= 0.5
tc 0.2 mm F u VC 119.95
u 100% u 100% 29.988% | 30%
r cos D 0.5cos10 Fc u V 400
I tan 1 tan 1 28.334q
1 r sin D 1 0.5sin10 GATE-2006 common data Q-3 Page No.14 Slide No.110 Ans. (d)
Using relation; H cot I tan(I D ) cot 40.24q tan(40.24q 15q ) 1.653
Fs Fc cos I Ft sin I 500 cos 28.334q 200sin 28.334q 345.18 N IES-1995 Page No.14 Slide No.113 Ans. (b) Tangential force accounts for 99% of
the power consumption.
§ bt ·
Shear force(FS ) shear strength(W y ) u shear area ¨ ¸ IES-2001 Page No.14 Slide No.114 Ans. (a)
© sin I ¹ IES-1997 Page No.14 Slide No.115 Ans. (c)
bt 5 u 0.1 IES-1999 Page No.14 Slide No.116 Ans. (a)
Fs W y 345.18 W y u
sin I sin 28.334q GATE-2014 Page No.15 Slide No.120 Ans.0.08to0.12
W y 327.65 N / mm 2 t f sin O
GATE-2006 common data Q-1 Page No.13 Slide No.108 Ans. (b) O 90q CS 90q 60q 30q
t 0.2sin 30q 0.1 mm
ESE-2003(conventional) Page No.15 Slide No.121 Ans.

D 0;f 0.2mm / rev, d 4mm, tc 0.8mm, dia ( D ) 160mm, speed 400rpm Givven :
' it is a turning operation, Db 7; CS 300;? O 90q 30q 60q
Fc 1200 N t 2mm; b 2..5mm; Fc 1
1177 N ; Ft 560 N
Fx 800 Usiing relationss:
Ft 828.22 N
sin O sin 75q tan D tan D s sin O taan D b cos O
(i) Using the force relations t D
or tan tan D s sin 60q tan 7q cos 60q...........(i )
F=FC sin D Ft cos D 1200sin 0 828.22 cos 0 828.22 N tan D b tann D cos O sin O tan i
N Fc cos D Ft sin D 1200 cos 0 828.22sin 0 1200 N or ttan 7q tan D cos 60q sin 60q tan 0q
(ii ) ' it is a turning operation, or D 13.79q
t f sin O 0.32sin 75q 0.3091 mm Froom (i ) D s 12q
1
d 4 Usiing force relaations
b 4.1411 mm,
sin O sin 75q F = FC sin D Ft cos D
t 0.3091 mm
Now , r 0.38638 1177 sin13.79 560 cos13.79 8224.44 N
tc 0.8 mm
N FC cos D Ft sin D 1177
1 cos13.79 560sinn13.79 10009.6 N
r cos D r cos 0
I tan 1 tan 1 tan 1 r tan 1 0.38638 21.13q F 824.444
1 r sin D 1 r sin 0 P 0.816 E tann 1 P tan 1 0.816 39..214q
N 1009..6
Fs Fc cos I Ft sin I 1200 cos 21.13 828.22sin 21.13 820.76 N
Usiing Merchannt Theory
bt
Fs Wy u D E 3.79q 39.2214q
13
sin I I = 45q+ 45q 32.288q
2 2 2 2
Fs 820.76
or W y 230.93 N / mm 2 Usiing force rellation:
bt 4.1411u 0.3091
sin I sin 21.13 Fs Fc cos I Ft sin I 1177
1 cos 32..288q 560 sin 32.288q 695.87 N
S DN S u 0.160 u 400 Fs 6695.87
(iii ) V 3.351 m / s Sheear strength (W y ) 74.34 N / mm 2
60 60 bt 2 u 2.55
sinn I sin 32.288
Power consumption(P)=Fc u V 1200 u 3.351W 4.021kW GA
ATE-2007 Pagge No.15 Slide No.125 5 An
ns. (b)
GATE-1995(conventional) Page No.15 Slide No.122 Ans. O 90q ; D 0q
0
Given : D =10 t f sin O 0.15455mm
t f sinn O f sin 90
9 q 0.24 mm
m
0 t
O 75 r 0.32197 tc 0.448 mm
tc
r cosD t 0.24 mm
tc 0.48 mm tanI = 0.33586 r 0.5
1 r sinD tc 0.48 mm
f = 0.16 mm/rev or I =18.5650 r cos D r cos 0
Fc 500N I tan 1 tan 1 tann 1 r tan 1 0.5 26.566q
1 r sin D 1 r sin 0
Fx 200
Ft 207N
sin O sin75 GA
ATE-2015 Pag
ge No.15 Slide No.126
6 An
ns. 18.88
F = Fc sin D Ft cos D 500 sin10 207 cos10 290.68 N GA
ATE-2015 Pag
7 An
ns. (a)
N Fc cos D Ft sin D 500 cos10 207sin10 456.56N GA
ATE-2016 Pag
8 Anss.(b)
F 290.68
P 0.63667
N 456.56
1
E tan P 32.484 o
Fn Fc sin I Ft cos I 500 sin18.565 207 cos18.565 355.42N
Fs Fc cos I Ft sin I 500 cos18.565 207 sin18.565 408.08 N
IAS-2003(main exam) Page No.15 Slide No.123 Ans.

For an Orthogonal Turning (Orthogonal Cutting)
This question is somehow confusing,datagiven GATE-2008(common data)S-2 Page No.16 Slide No.133 Ans. (b)
Using Merchant Theory:
for orthogonal turning but written orthogonal cutting
7 E 7q E
Principal cutting edge angle O 90o I 45q
28q 45q 41q
2 2 2 2
o
t f sin O or t 0.4 sin 90 0.4 mm Using Merchant Circle:
tc 0.8 mm Fs R cos I E D
t 0.4 320 R cos(28q 41q 7q) R 681.62 N
r 0.5
tc 0.8 Fc R u cos E D 681.62 cos(41 7) 565.09 N
r cos D 0.5 cos 22
Now,tan I or I 29.7o Ft R u sin E D 681.62sin(41 7) 381.16 N
1 r sin D 1 0.5sin 22
GATE-2007 Page No.16 Slide No.129 Ans.(c) IES-2004 Page No.16 Slide No.135 Ans.(b)
MRR Vfd
O 90q ;D 0q ; I 25q ; Fc 1000 N
Fx 800
50 u 10 u 0.8 u 1.5mm
3 3
/ min
We know; Ft 800 N 60000mm / min 3
sin O sin 90q
Using relations: GATE-2013 Page No.17 Slide No.136 Ans.(d)
S DN S u 200 u160
F Fc sin D Ft cos D 1000sin 0 800 cos 0 800 N MRR fd u
fdV mm / s 0.25mm u 4 mm u mm / s 1675.5mm3 / s
60 60
N Fc cos D Ft sin D 1000 cos 0 800sin 0 1000 N IES-2016 Page No.17 Slide No.137 Ans.(c)
F 800 MRR Cross Section u AxialVelocity
P 0.8
N 1000 S
GATE-2003(common data)S-1 Page No.16 Slide No.130 Ans. (a) 4
D 1
2

D22 u F
f 0.25 mm / rev, d 0.4 mm, D 10q, I 27.75q S
t f sin O 0.25sin 90q 0.25 mm 4

102 92 u 175 mm3 / min 2611.45 mm3 / min
r cos D r cos10q Or MRR fdV fd S DN S dDaverage fN S dDaverage F
tan I
1 r sin D 1 r sin10q
S u 0.5 u 9.5 u 175 mm3 / min 1611.45 mm3 / min
r cos10q
tan 27.75q GATE(PI)-1991 Page No.17 Slide No.140 Ans. (d)
1 r sin10q
GATE-2007 Page No.17 Slide No.141 Ans. (d)
t 0.25
r 0.4888 The energy consumption per unit volume of material removal, commonly known as specific energy.
tc tc Power (W ) Fc
tc 0.51138 mm e
MRR mm3 / s 1000 fd
GATE-2003(common data)S-2Page No.16 Slide No.131 Ans. (d)
using Merchant Analysis; Fc
or 2.0 Fc 800 N
1000 u 0.2 u 2
D E
I =45q+ GATE-2016(PI) Page No.17 Slide No.142 Ans.0.001 N
2 2
GATE-2013(PI) common data question Page No.17 Slide No.143 Ans. (b)
10q E
27.75q 45q E 44.5q FC 200
2 2 Specific cutting energy J / mm3 2 J / mm3
1000 fd 1000 u 0.1u1
P tan E tan 44.5q 0.9826
GATE-2014 Page No.18 Slide No.146 Ans. (b)
GATE-2008(common data)S-1 Page No.16 Slide No.132 Ans. (d)
FC FC 400
W y 250 MPa;V 180 m / min; Specific pressure 2000 N / mm 2
bt fd 2 u 0.1
f 0.20 mm / rev; d 3 mm; r 0.5; D 7q GATE-1992 Page No.18 Slide No.148 Ans. (b)
r cos D 0.5cos 7q GATE-1993 Page No.18 Slide No.149 Ans. (b)
I tan 1 tan 1 27.85q | 28q
1 r sin D 1 0.5sin 7q IES-2000 Page No.18 Slide No.150 Ans. (a)
We know; IES-2004 Page No.18 Slide No.151 Ans. (b)
d b sin O º IES-2002 Page No.18 Slide No.153 Ans. (d)
.........(O 90); d b&t f chip : work piece : tool = 80 : 10 : 10
t f sin O »¼ IES-1998 Page No.19 Slide No.154 Ans. (a)
bt 0.20 u 3 IAS-2003 Page No.19 Slide No.155 Ans. (b)
Fs Wy 250 u 321.09 N | 320 N
sin I sin 27.85q IAS-2003 Page No.19 Slide No.158 Ans. (c)

IES-2011 Page No.19 Slide No.160 Ans. (c) Using Taylor's Tool Life Equation VT n C
IES-1993 Page No.19 Slide No.161 Ans. (b) V1T1n V2T2 n
IES- 1996 Page No.19 Slide No.162 Ans. (b)
or 100 u 10n 75 u 30n
'R
IES- 1998 Page No.20 Slide No.165 Ans. (b) GH or n 0.2616 can be solved using solve function on calculator
R
IAS- 2001 Page No.20 Slide No.166 Ans. (c) ISRO-2011 Page No.26 Slide No.219 Ans.(c)
FOR PSU & IES Page No.20 Slide No.167 Ans. (a) For higher sensitivity, two D 50mm;
gauges are used for tensile strain, while two others are for compressive strain, total of which adds up to four
S D u 284
gauges. All the four gauges in each bridge are active gauges, and the bridge fully compensates for temperature N1 284rpm; T1 10 min;V1 m / min
changes. For 3-D lathe dynamometer total 12 strain gauge is needed, 4 for main cutting force, 4 for Radial force 1000
and 4 for feed force. S D u 232
N 2 232rpm; T2 60 min;V2 m / min
1000
Using Taylor's Tool Life Equation,VT n C
ChǦ3ToolLife:AnswerswithExplanation V1T1n V2T2 n
S D u 284 S D u 232
IES-2010 Page No.20 Slide No.170 Ans.(a) or u10n u 60n or n 0.1128
1000 1000
IES-2007 Page No.20 Slide No.171 Ans.(c) In the question straight line relation is mentioned which is wrong.
IES-2014 Page No.21 Slide No.173 Ans. (b) Think only the parameters which can produce cyclic GATE-2004, IES-2000 Page No.26 Slide No.220 Ans.(c)
stress on tool material.
IES-1994 Page No.21 Slide No.176 Ans.(b) Flank wear directly affect the component dimensions.
GATE-2014 Page No.21 Slide No.178 Ans.(c) Strain hardening don’t confuse with oxide layers because
Using Taylor's Tool Life Equation, VT n C
if workpiece is clean then also tool will wear. V1T1n V2T2 n
IES-2004 Page No.22 Slide No.184 Ans.(b) n
GATE-2008(PI) Page No.22 Slide No.165 Ans.(b) §T · 1
or V u T n 2V u ¨ ¸ or 8n 2 or n
Solving using straight line equation: ©8¹ 3
y2 y1
y y1 < x x1
x2 x1 IES-1999, ISRO-2013 Page No.26 Slide No.221 Ans.(d)
2 0.8
1.8 0.8
60 10
x 10 Using Taylor's Tool Life Equation, VT n C
x 51.666 V1T1n V2T2 n
IES-2002 Page No.23 Slide No.190 Ans.(c)For crater wear temperature is main culprit and tool § V1 · 0.25
defuse into the chip material & tool temperature is maximum at some distance from the tool tip that so or V1T10.25 ¨ 2 ¸ T2
why crater wear start at some distance from tip. © ¹
IAS-2007 Page No.23 Slide No.191 Ans.(c) § 1 ·
¨ ¸
IES-2000 Page No.23 Slide No.192 Ans.(d) or T2 2© 0.25 ¹ T1 16T1
IES-1995 Page No.23 Slide No.193 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 IAS-1995 Page No.26 Slide No.223 Ans.(d)
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. Using Taylor's Tool Life Equation, VT n C
IAS-2002 Page No.23 Slide No.196 Ans.(c)
IES-1995 Page No.23 Slide No.197 Ans.(a) V1
V1T1n V2T2 n or n 0.25;V2
IAS-1999 Page No.23 Slide No.198 Ans.(c)Chemical reaction between abrasive and workpiece 2
material at elevated temperature and in the presence of grinding fluid. V1
IAS-2003 Page No.24 Slide No.200 Ans.(b) or V1 u T10.25 u T 0.25 or T2 16T1
IES-1996 Page No.24 Slide No.202 Ans.(b) 2 2
IES-1992 Page No.25 Slide No.208 Ans.(d) GATE-2015 Page No.26 Slide No.224 Ans.0.25
IES-2012 Page No.25 Slide No.212 Ans.(a)
IES-2008 Page No.25 Slide No.213 Ans. (c) IAS-2002 Page No.26 Slide No.225 Ans.(a)
In Taylor’s tool life equation is
n = 0.08 – 0.20 o for H.S.S. Using Taylor's Tool Life Equation, VT n C
n = 0.20 – 0.60 o for Carbides. V1 º
ª
n = 0.60 – 0.80 o for Ceramics. V1T1n V2T2 n «Where, n 0.5;V2
IES-2006 Page No.25 Slide No.214 Ans.(b) ¬ 2 »¼
IES-1999 Page No.25 Slide No.215 Ans.(c) § V1 · 0.5
IAS-1998 Page No.25 Slide No.216 Ans.(d) or V1T10.5 ¨ 2 ¸ T2
IES-2016 Page No.26 Slide No.217 Ans.(c) © ¹
GATE-2009(PI) Page No.26 Slide No.218 Ans.(a)

or T2 20.5 T1 4T1 GATE-2009 Linked Q-2 Page No.27 Slide No.231 Ans.(c)
T2 T1 4T1 T1 V1 60
%change u100% u 100% 300% Now, according to the given question V = 30m / min;
T1 T1 2 2
1/n
§C·
T1 ¨V ¸
IES-2015 Page No.27 Slide No.226 Ans.(c) © 1¹
1/ n
IES-2013 Page No.27 Slide No.227 Ans.(b) § C·
T2 ¨V ¸
© 2¹
Using Taylor's Tool Life Equation, VT n C 1/ n
T2 T1 § V1 · 1/0.5
n 0.25;V 60m / min; T 1 hr 21min 81min
T1 ¨V ¸ 1 2 1 300%
60 u 810.25 C 180 © 2¹
IAS-1997 Page No.27 Slide No.228 Ans.(c) Using Taylor's Tool Life Equation:
Using Taylor's Tool Life Equation, VT n C V1T1n V2T2 n
V1T1n V2T2 n or 100 u120n 130 u 50n
n 0.5; V1 18 m / min; T1 180 min; T2 45 min;V2 ? or n 0.2997 | 0.3
Putting in equation: NowC 100 u1200.3 420.49
or 18 u1800.5 V2 u 450.5 Tool life when cutting speed is 2.5 m/s = 2.5 u 60 m/min
or V2 36m / min 2.5 u 60 T 0.3 420.49
IES-2006 (conventional) Page No.27 Slide No.229 Ans. or T 31.06 min
Given:V1=30m/min;T1=1hr=60min,V2=2V1,T2=2min,T3=30min,
Velocity when tool life is 80 min
Taylortoollifeequationgives
VTn C
V u 800.3 420.49
or V1 T1n V2 T2n or V 112.94 m / min
n GATE-2010 Page No.27 Slide No.233 Ans.(a)
§ T1 · § V2 ·
or ¨ ¸ ¨ ¸ for Carbide o n1 1.6, K1 90
© T2 ¹ © V1 ¹ for HSS o n2 0.6, K 2 60
taking log on both side we get
Using Taylor's Tool Life Equation:VT n =C
§T · §V ·
n ln ¨ 1 ¸ ln ¨ 2 ¸ let cutting speed is x m/min
© T2 ¹ © V1 ¹ 1
0.45
§ V2 · § 2V1 · § 90 ·
ln ¨ ¸ ln ¨ ¸ x×TA 0.45 =90 TA = ¨ ¸
or n = © V1 ¹ © V1 ¹ 0.204
© x ¹
§T · § 60 · 1
In ¨ 1 ¸ ln ¨ ¸ § 60 · 0.30
© T2 ¹ © 2 ¹ and x×TB0.3 = 60 TB = ¨ ¸
Now for = T3 30 min, V3 ?
© x ¹
Here V1 T1n V3 T3n
for TA >TB
1 1
n
V1 T1n §T · § 60 ·
0.204
§ 90 · 0.45 § 60 · 0.30
or V3 V1 x ¨ 1 ¸ 30 u ¨ ¸ 34.55 m/min ¨ x ¸ !¨ ¸
T3n © T3 ¹ © 30 ¹ © ¹ © x ¹
V3 = ǑdN Solve for x using calculator, x = 26.7 m/min
V3 34.55 GATE-2013 Page No.27 Slide No.234 Ans.(b)
or N = = =36.66 rpm
Ǒd Ǒ×0.3 for A o n1 0.45, K1 3000
GATE-2009 Linked Q-1 Page No.27 Slide No.230 Ans.(a)
for B o n2 0.3, K 2 200
VTn C V1 T1n V2 T2n
Using Taylor's Tool Life Equation:VT n =C
60 u 81n 90 u 36n
n let cutting speed is x m/min
§ 81 · 90
or ¨ ¸ 1.5 1
© 36 ¹ 60 § 3000 · 1.6
x×Tc1.6 =3000 Tc = ¨ ¸
In1.5 © x ¹
n= n = 0.5
§ 81 · 1
In ¨ ¸ 0.6
36
© ¹ § 200 ·
and x×TH 0.6 = 200 TH = ¨ ¸
C =60 u 810.5 90 u 360.5 540 K © x ¹

for Tc >TH Using Taylor's Tool Life Equation:VT n C V1T1n V2T2 n
1 1 n n
§ 3000 · 1.6
§ 200 · 0.60 § L · § L ·
¨ x ¸ !¨ x ¸ or S D u 50 u ¨ 50 u ¸ S D u 80 u ¨ 12.2 u 0.25 u 80 ¸
© ¹ © ¹ © 0.25 u 50 ¹ © ¹
Solve for x using calculator, x = 39.389 m/min or n 0.2499 | 0.25
EXAMPLE Page No.28 Slide No. 235 Ans. For 3rd case : N 60rpm, f 0.25mm / rev
This can be solved using regression analysis:
L
Using Taylor's Tool Life Equation:VT n C Let t3 be the time to produce 1 component in 3rd case,t 3 min
fN
taking log on both sides: log V n log T log C
L
or log V log C n log T Tool life(T3 ) ( x )components u t2 xu min
f u 60
On comparing with straight line equation,in Casio Calculator:
now, V1T10.25 V3T30.25
y A Bx 0.25 0.25
§ L · § L ·
y log V ; x log T ; A log C ; B n or S D u 50 u ¨ 50 u S D u 60 u ¨ x u
© 0.25 u 50 ¸¹ © 0.25 u 60 ¸¹
T V X=logT Y=logV
0.25
2.94 49.74 X1= log2.94 Y1= log49.47 § x ·
3.90 49.23 X2= log3.90 Y2= log49.23 or 50 60 u ¨ ¸
4.77 48.67 X3= log4.77 Y3= log48.67 © 60 ¹
9.87 45.76 X4= log9.87 Y4= log45.76 or x 28.926 | 29components
28.27 42.58 X5= log28.27 Y5= log42.58 GATE-1999 Page No.28 Slide No.237 Ans.(b)
Now on calculator, ' flank wear v cot D
Press mode – 2 times-then press ‘2’ (Reg-2)
Then select the type – (lin-1) ? tool life v tan D
Then start entering the values as below; tan D 2 tan D1 tan 7 tan10
x1 ,y1 i.e. log2.94, log49.47 then press DT(M+) it will display n =1 then press AC % change in life u 100% u 100% 30%
x2 ,y2 i.e. log3.90, log49.23 then press DT(M+) it will display n =2 then press AC
tan D1 tan10
x3 ,y3 i.e. log4.77, log48.67 then press DT(M+) it will display n =3 then press AC ? % change in life = 30% decrease
x4 ,y4 i.e. log9.87, log45.76 then press DT(M+) it will display n =4 then press AC IES-2010 Page No.28 Slide No.239 Ans.(d)
x5 ,y5 i.e. log28.27, log42.58 then press DT(M+) it will display n =5 then press AC ISRO-2012 Page No.28 Slide No.240 Ans.(d)
After entering all values then press shift then S-VAR(on number 2),then press the right arrow 2 times IES-1997 Page No.28 Slide No.241 Ans.(a)
then A (1) press 1 then = it will give A = 1.732 IES-1994,2007 Page No.28 Slide No.242 Ans.(c)
Again press the right arrow 2 times then B(2) press 2 and = it will give B = -0.07 We know that cutting speed has the greatest effect on tool life followed by feed and depth of cut
From y A Bx; A log C C 10 A 54 respectively. For maximizing tool life we will adjust 3- 2- 1 respectively.
B n 0.07 n 0.07 IES-2008 Page No.28 Slide No.243 Ans.(a) If we increase feed rate it must increase cutting force and
temperature. Therefore statement ‘4’ is wrong.
? equation becomes:VT n C VT 0.07 54 IAS-1995 Page No.29 Slide No.244 Ans. (a) It is comparing, if we increase speed it will increase maximum
GATE-2003 Page No.28 Slide No.236 Ans.(a) temperature and depth of cut increase temperature least. That so why tool life affected mostly by velocity
10 cutting tools produce 500 components and least by depth of cut.
Therefore, 1 cutting tool will produce 50 components ESE-1991, IAS-2010(conventional) Page No.29 Slide No.245 Ans.
we know : V S DNm / min given;VT 0.3 f 0.6 d 0.3 C
For the 1st case: V 40m / min; T 60 min; f 0.25mm / rev; d 2mm
N 50rpm, f 0.25mm / rev Putting in equation : 40 u 600.3 u 0.250.6 u 20.3 C C 36.49
st
L When speed, feed & depth of cut are together increased by 25%; tool life will be
Let t1 be the time to produce 1 component in 1 case,t1 min Now when V, f and d are increased by 25%
fN
L New V,f and d are:V 40 0.25 u 40 50 m / min
Tool life(T1 ) 50components u t1 50 u min
f u 50 f 0.25 0.25 u 0.25 0.3125mm / rev
10 cutting tools produce 122 components d 2 0.25 u 2 2.5mm
Therefore, 1 cutting tool will produce 12.2 components
For the 2 nd
case: putting in given equation:VT 0.13 f 0.6 d 0.3 36.49
N 80rpm, f 0.25mm / rev 50 u T 0.13 u 0.31250.6 u 2.50.3 34.99
L T 2.29 min
Let t2 be the time to produce 1 component in 2 nd case,t 2 min When only speed is increased by 25%, rest parameters remain same; then
fN
L
Tool life(T2 ) 12.2components u t2 12.2 u min
f u 80

Now when V is increased by 25% Tc 1.5 min; n 0.2
New V,f and d are:V 40 0.25 u 40 50m / min, f 0.25mm / rev, d 2mm Using optimum tool life equation for maximum productivity:
putting in given equation: VT 0.13 f 0.6 d 0.3 34.99 § 1 n · § 1 0.2 ·
To Tc ¨ ¸ or To 1.5 ¨ ¸ 6 min
or 50 u T 0.13 u 0.250.6 u 20.3 34.99 © n ¹ © 0.2 ¹
or T 10.779 min ESE-2001(conventional) Page No.31 Slide No.267
When only feed is increased by 25% , rest parameters remain same; then tool life V1 50m / min; T1 45 min;V2 100m / min; T2 10 min; Tc 2 min
Now when f is increased by 25% Using Taylor's Tool Life Equation:VT n C V1T1n V2T2 n
New V,f and d are:V 40m / min, f 0.25 0.25 u 0.25 0.3125mm / rev, d 2mm 50 u 45n 100 u10n or n 0.46, C 50 u 450.46 288
putting in given equation:VT 0.13 f 0.6 d 0.3 36.49 Using equation of optimum tool life:
or 40 u T 0.13 u 0.31250.6 u 20.3 36.49 § 1 n · § 1 0.46 ·
To Tc ¨ ¸ 2 ¨ 0.46 ¸ 2.34
or T 21.41min © n ¹ © ¹
When only depth of cut is increased by 25%, rest parameters remain same; then Again Using Taylor's Tool Life Equation:VoTon C
Now when d is increased by 25%
Vo u 2.340.46 288 orVo 195m / min
New V,f and d are:V 40m / min, f 0.25mm / rev, d 2 0.25 u 2 2.5mm
IAS-2011(main) Page No.31 Slide No.268 Ans.
putting in given equation:VT 0.13 f 0.6 d 0.3 36.49 Tc 9 min; n 0.5; C 100
or 40 u T 0.13 u 0.250.6 u 2.50.3 36.49 Using optimum tool life equation for max productivity:
or T 35.844 min § 1 n · § 1 0.5 ·
GATE-2016 Page No.29 Slide No.246 Ans. (b) To Tc ¨ ¸ or To 9 ¨ ¸ 9 min
© n ¹ © 0.5 ¹
45 u 300.14 u 0.350.7 u 20.4 C 45.84
Using Taylor's Tool Life Equation:VoTon C , Vo u 90.5 100 orVo 33.33 m / min
V1 45 u 1.25 56.25 m / min
T1 ? GATE-2016 Page No.32 Slide No.272 Ans.57.91m/min
TotalCost Ct MetalCutting Cost Cm Tooling Cost Ct
f1 0.35 u 1.25 0.4375 mm
1
18C 270C ª § 150 · 0.25
§ 150 ·
4 º
d1 2.0 u 1.25 2.5 mm Ct « Now T »
V VT ¨ V ¸ ¨ V ¸
45.84 «¬ © ¹ © ¹ »¼
T10.14 1.007538
56.25 u 0.43750.7 u 2.50.4 18C 270C
Ct 4
T1 1.055 | 1.06 V § 150 ·
V¨ ¸
IES-2010 Page No.29 Slide No.250 Ans.(a) © V ¹
IAS-2003 Page No.29 Slide No.251 Ans.(a) dCt 18C 270C u 3V 2
IES-2014 Page No.30 Slide No.257 Ans. 2 4
0 orV 57.91 m / min
IES-1996 Page No.30 Slide No.260 Ans.(b)
dV V 150
IES-2009(conventional) Page No.31 Slide No.265 Ans. GATE-2005 Page No.32 Slide No.273 Ans.(a)
Tc 3min, Tool regrind time(Tr ) 3min, Cm Rs.0.50 / min IAS-2007 Page No.32 Slide No.274-275 Ans.(b)
Depriciation cost Rs.5.0, n 0.2; C 60 IES-1999 Page No.32 Slide No.278 Ans.(c)
Using the equation for optimum tool life for minimum cost IES-1998 Page No.32 Slide No.279 Ans.(c)
IAS-2002 Page No.33 Slide No.280 Ans.(c)
§ Ct · § 1 n · The minimum cost criterion will give a lower cutting speed i.e. lower prodeuction rate, while the
To ¨ Tc C ¸ ¨ n ¸ maximum production rate criteria will result higher cutting speed i.e. higher cost per piece as it reduces
© m ¹© ¹
tool life.
Ct Cm u Tr Depriciation cost IAS-1997 Page No.33 Slide No.281 Ans.(b) it is less than one but very close to each other so 0.1 is not
Ct Rs.0.50 / minu 3min Rs.5.0 Rs.6.5 / regrind possible.
Putting in equation: IES-2004 Page No.33 Slide No.283 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
§ 6.5 · § 1 0.2 ·
To ¨ 3 0.50 ¸ ¨ 0.2 ¸ 64 min feed.
© ¹© ¹ IES-2002 Page No.33 Slide No.284 Ans.(c)
Using Taylor's Tool Life Equation:VoTon C IAS-2007 Page No.33 Slide No.285 Ans.(a)At optimum cutting speed for the minimum cost of
machining gives low production rate.
0.2
Vo 64 60 orVo 26.11 m / min IES-2010 Page No.33 Slide No.286 Ans.(d) After some time cutting speed will be so that tool
changing time will be significant.
GATE-2014 Page No.31 Slide No.266 Ans. 5.9 to 6.1min
IAS-1996 Page No.34 Slide No.291 Ans.(d) Machinability is a comparative measure not absolute.
IES-2011(conventional) Page No.34 Slide No.295 Ans.
Effect of elements on machinability of steels:

S.NO ELEMENTS Cause MACHINABILITY f 1mm / rev; SCEA 30q; ECEA 10q
1. Aluminium& silicon Hard oxide former Decrease
f 1
2. Sulphur& selenium Internal lubrication, chip Increases Using formula: h 0.16mm
breaker tan SCEA cot ECEA tan 30 cot10
3. Lead & Tin Internal Lubrication, chip Increases GATE-2005 Page No.37 Slide No.322 Ans. (b)
breaker f
Using formula:h
4. Carbon Carbide former Decreases tan SCEA cot ECEA
5. Molybedenum, vanadium Strong carbide former Decreases f f
IES-1992 Page No.34 Slide No.297 Ans.(a) large grain means soft workpiece material. hP and hQ
tan 30 cot 8 tan15 cot 8
IAS-2000 Page No.35 Slide No.299 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.
? P
h tan15 cot 8
IES-1992 Page No.35 Slide No.303 Ans.(a) hQ tan 30 cot 8
IES-2007,2009 Page No.35 Slide No.304 Ans.(a)Machinability: Machinability can be tentatively defined as
‘ability of being machined’ and more reasonably as ‘ease of machining’. IES-1993, ISRO-2008 Page No.37 Slide No.323 Ans. (c) Surface roughness is directly dependent on
Such ease of machining or machining characters of any tool-work pair is to be judged by: square of feed. Slow cutting results in formation of built-up edge, but after certain speed the finish
• Magnitude of the cutting forces remains same. Rake angle has noticeable effect at slow speeds, but its effect is small at speeds, used for
• Tool wear or tool life finish machining. So f has maximum effect.
• Surface finish IES-2006 Page No.37 Slide No.324 Ans. (a) refer previous question
• Magnitude of cutting temperature GATE-2014(PI) Page No.38 Slide No.325 Ans.
• Chip forms GATE-2010(PI) Page No.38 Slide No.326 Ans. (b)
ISRO-2007 Page No.35 Slide No.305 Ans.(a)But All of the above are machinability criteria. We have to For increasing surface finish means reduce roughness we have to increase nose radius and reduce feed.
select best option that so why chosen (a) Here MRR remains same therefore feed remains same only nose radius can be changed.
IES-2003 Page No.35 Slide No.306 Ans.(c)Free-machining steels are basically carbon steels that IES-2001 Page No.38 Slide No.329 Ans. (c)
have been modified by an alloy addition to enhance machinability. Sulfur, lead, bismuth, selenium, IES-2012 Page No.38 Slide No.330 Ans. (b)
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 Ch-4: Limit, Tolerance & Fit: Answers with Explanations
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 For PSU PageNo.39 Slide No.9 Ans.(b)
cutting geometry. ISRO-2010 Page No.40 Slide No. 10 Ans.(b)
IES-2009 Page No.36 Slide No.307 Ans.(a) Sulphur, Lead and Phosphorous are added to steel which GATE-2010, ISRO-2012 Page No.40 Slide No.13 Ans.(d)
when added to Manganese forms Manganese sulphide etc. which has low shear strength. upper limit = 35-0.009 = 34.991mm
IES-1998 Page No.36 Slide No.308 Ans.(c) It is CNC machine, dimensional accuracy and surface lower limit = 35-0.025 = 34.975 mm
finish are prime factor.
IES-1996 Page No.36 Slide No.309 Ans.(d) smaller shear angle means higher force. Fundamental Deviation = basic size-nearer limit = 35-34.991= 0.009 mm
IES-1996 Page No.36 Slide No.310 Ans.(b) Tolerance = upper limit-lower limit = 34.991 - 34.975 = 0.016 mm
IES-1995 Page No.36 Slide No.311 Ans.(c)
GATE-1992 Page No.40 Slide No.14 Ans.(a)
IES-1992 Page No.36 Slide No.313 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 Tolerance of shaft A=100.1-99.9=0.2
chemically with titanium. Tolerance of shaft B=0.1001-0.0999=0.0002
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 So, tolerance of shaft A > tolerance of shaft B
high shearing angle is formed. This causes a thin chip to contact a relatively small area on the cutting Never confused with relative errors because we even don’t know the actual dimensions of all product. we
tool face and results in high loads per unit area. These high forces, coupled with the friction developed by can’t calculate error.
the chip as it passes over the cutting area, result in a great increase in heat on a very localized portion of GATE-2004 Page No.40 Slide No.15 Ans.(c)
the cutting tool. All this heat (which the titanium is slow to conduct away), and pressure, means that tool Maximum clearance = Higher limit of hole – lower limit of shaft
life can be short, especially as titanium has a tendency to gall and weld to the tool surface. = 25.020-24.990 = 0.03 mm = 30 microns
IES-1995 Page No.36 Slide No.315 Ans. (a) Titanium high cost and need 10 times much energy than IES-2005 Page No.40 Slide No.16 Ans.(c)
steel to produce. Light weight, strong, corrosion resistant, properties between steel and aluminium. Since basic size is 20 mm so, minimum rejection will be of the batch having mean diameter 20 mm. Due
IES-2002 Page No.37 Slide No.317 Ans. (b) to natural variations dimensions of the component will increase and decrease same from basic size.
IAS-1996 Page No.37 Slide No.318 Ans. (d) GATE-2007 Page No.41 Slide No.19 Ans.(c)
IES-1999 Page No.37 Slide No.319 Ans. (d)
f2
we know : hc
8R
f2 f12 f2 4f
When f1 2 f , and hc remains the same; or R1 4R
8R 8 R1 8R 8 R1
GATE-1997 Page No.37 Slide No.320 Ans. (a)
h 5P m 5 u106 m; R 1.8mm 1.8 u103 m
f2 f2
we know : h or 5 u106 or f 2.68 u 104 m / rev 0.268mm / rev
8R 8 u1.8 u 103
GATE-2007(PI) Page No.37 Slide No.321 Ans.(a)

max clearance = upper limit of hole - lower limit of shaft = 40.50-39.95 = 0.1 mm Using unilateral hole base system;
GATE-2015 Page No.41 Slide No.20 Ans.(b)This being an clearance fit , so minimum clearance will Min clearance = 0.03mm; Max clearance = 0.09 mm; Basic size = 20 mm
be
Min C= LL of hole –UL of Shaft Refering the figure:2 x 0.03 x 0.09 or x 0.02 mm
Min C = 25.020-25.005 mm = 0.015 mm ? size of hole: lower limit = 20 mm
upper limit =20+2x 20+2 u 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
ISRO-2011 Page No.42 Slide No.34 Ans.(c)
IES-2015 Page No.41 Slide No.21 Ans.(a) An interference fit creates stress state in the shaft therefore “2” is wrong.
IES-2015 Page No.41 Slide No.23 Ans.(c)Allowance is the minimum clearance between shaft and hole. IES-2015 Page No.43 Slide No.38 Ans. (d)
It is thick cylinder under external pressure.
GATE-2005 Page No.41 Slide No.27 Ans.(a) Distribution of radial and circumferential stresses within the
cylinder wall when only external pressure acts

GATE-2001 Page No.43 Slide No.42 Ans.(b)
GATE-1998 Page No.43 Slide No.43 Ans.(c)
IES-2014 Page No.42 Slide No.28 Ans. (c) ISRO-2010 Page No.44 Slide No.46 Ans.(c)
IES-2015 Page No.42 Slide No.29 Ans. (c) It is transition fit, Using formula of minimum clearance
Min clearance = upper limit of shaft - lower limit of hole = -0.02 mm
GATE-2011 Page No.42 Slide No.30 Ans.(c)
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.
ISRO-2008 Page No.44 Slide No.52 Ans.(c)

GATE-2014 Page No.46 Slide No.68 Ans.(d)
GATE -2012 Same Q in GATE-2012 (PI) Page No.42 Slide No.31 Ans.(c) IES-2008 Page No.46 Slide No.69 Ans.(a) All statements are wrong. 50 mm is not hole diameter it
Maximum Interference = Maximum size of shaft – Minimum size of hole is basic size. And examiner ask INCORRECT not correct options. Therefore all options are incorrect.
= (25 + 0.04) – (25 + 0.02) mm = 20 μm IES-2006(conventional) Page No.46 Slide No.70 Ans.
IAS-2011(main) Page No.42 Slide No.32 Ans. Basicsize =100 mm; D D1 u D2
80 u120 97.97mm
Fundamental deviation of shaft
= 5.5 D 0.41 36 P m
? Fundamental deviation of hole 36 P m
1
i 0.45D 0.001D 2.1711P m
3
IT 8 25i 25 u 2.17 P m 54 P m
IT 10 64i 64 u 2.17 P m 139 P m
Allowance = min clearance = 36 μm

IES
S-2015(conv
ventional) Page No.46
N Slid
de No.71 Ans ' diametric steps are not given we take given dia as the basic diameter only.
i 0.45 3 D 0.001D 1.34P m 1.34 u103 mm
For IT 7 16i 16 u 1.34 u 103 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.47 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
Geomettric mean diameter(D) = 18 u 30 23.238mm
Standarrd tolerancee unit (i) = 0..45 u 3 D 0..001 u D 1.3074 P m
10 u1.6ITn IT6
Use formula
nce of hole = 25i = 33Pm 0.033mm
Toleran m
GATE-2010(PI) Page No.47 Slide No.78 Ans.(b)Allareshaftbasissystem.
nce of shaft = 40i = 52Pm 0.052mm
Toleran m GATE-1996,IES-2012 Page No.47 Slide No.80 Ans.(d)
0.4
44 Remember
Fundam
mental devia
ation of shafft d = -16D 64 Pm 0.064mm
m
Fundammental devia ation of holee H = zero H7 with p6, s6: Interference fit
H7 with k6, n6: Transition fit
LL of hoole = BS =25
5mm All other fits are clearance fit.
UL of hole
h = BS + Tolerance
T = 25.033mm IES-2000 Page No.47 Slide No.81 Ans.(b)
UL of sh
haft = BS +F 064mm = 24.936mm
FD = 25- 0.0 ISRO-2008 Page No.48 Slide No.84 Ans.(a)
LL of sh
haft = UL - tolerance
t = 24.936-0.052
2 2 = 24.884 mm
m GATE-2003 Page No.48 Slide No. 88 Ans.(b)
P 35+0.08mm
IES
S-2002 Page No.46 6 Slide No.72
N Anss.(c)
GATTE-2009 Page No.47 7 Slide No.73
N Anss.(a) Q 12.00+0.02mm
60 mm diameter liees in the dia
ameter step of
o 50-80mm m. Therefore R 13.00.04
0.02 13.01 r 0.03
Geomettric mean diameter,D Dmin ×Dmax 50 u 80 63.246 mm
m Now all have same bilateral tolerance, so
mental tolerance unit i
Fundam (0.45D1/3 +0.001D)
+ Ǎm
m P QWR
1
1/3 Considering dimension
[0
0.45(63.246) 0.001(63 859 Ǎm = 0.00
3.246)] 1.8 0186 mm
35 12 W 13.01
Foor IT8 25i 25 u 0.001
186 0.0464
46 mm
0.41 0.41 w 9.99mm
Fundam
mental devia haft, 5.5D
ation for 'f'sh D 5.5[663.246] 0.030115mm
Tolerance are probabilities and not the absolute value on any part, at
GAT
TE-2008(PII) Pag ge No.47 Slide No.74 4 Ans.(c))Without callculating wee can choose option (c) ass
fundamental deviattion is zero therefore
t LL m
L = Basic size = 25.000 mm least one section must be there that treated as sink, and tolerance of
But proper calculattion is sink will be cumulative sum of all tolerances.
D D1 u D2 1 u 30
18 23.23 mm ? Tolerance 0.08 0.02 0.03 0.13
1
GATE-1997 Page No.48 Slide No. 89 Ans.(d)
i 0.455 D 0.001D 1.3076P m 1.30776 u103 mm
3 S P Q R T or T S P Q R or Tmin Smin Pmax Qmax Rmax
For IT 8 25i 0.0 0326mm GATE-2015 Page No.48 Slide No. 90 Ans.(d)
upper limit of holee = basic sizze + tolerancce = 25+0.0
0326=25.032mm LL of L4 = LL of L1 –UL of L2 –UL of L3
' hole base system
m so, lower limit = basiic size=25m
mm = 21.99-10.005-10.005=1.98mm
GAT
TE-2000 Page No.47 7 Slide No.75
N Anss.(d) UL of L4 = UL of L1 –LL of L2 –LL of L3
Hole: Loower limit = Basic size = 25 mm = 22.01-9.995-9.995=2.02mm
Higher limit = loweer limit + tolerance = 25 + 0.033 = 25.033 mm GATE-2007(PI) Page No.49 Slide No.91 Ans.(d)
Shaft: Higher
H limit = basic sizee – fundamenntal deviatioon = 25 – 0.0
04 = 24.96 m mm GATE-2007(PI) Page No.49 Slide No.92 Ans.(d)
Lower liimit = Higheer limit – tolerance = 24
4.96 – 0.033 = 24.927 mm m Before plating the hole size will be bigger ,
Therefore Maximum m clearance = Higher limit
l of hole – lower limiit of shaft Maximum limit will correspond to min thickness;so,
= 25.0333 – 24.927 = 0.106 mm = 106 micron ns
GAT
N Anss.(b) min thickness 2 u 10 u 103 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 u 15 u 103 mm 0.03mm
Min limit = min size of hole + max thickness = 30.010+0.03=30.04 mm

GATE-2013 Page No.49 Slide No.93 Ans. (d) GATE-2012(PI) Page No.57 Slide No.169 Ans.(a)
Upper limit of pin = 25.020 mm
Lower limit of pin = 25.010 mm
Max thickness of plating =2 u 0.032=0.064 mm
Min thickness of plating =2 u 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 L 250 mm; H r 100 mm ;( Diameter d 20 mm or r 10 mm) or H 90 mm
GATE-2000 Page No.49 Slide No.94 Ans.(a) It is a case of tolerance sink. Final product will be
§H· § 90 ·
tolerance sink because due to the errors in the block and due to the errors in the cutter locations both T sin 1 ¨ ¸ sin 1 ¨ ¸ 21.1o
errors will affect. ©L¹ © 250 ¹
ISRO-2008 Page No.49 Slide No.96 Ans.(c) GATE-2011(PI) Page No.58 Slide No.178 Ans.(a)
GATE-2014 Page No.50 Slide No.102 Ans.(d) p D 2.5 § 60 ·
Lower limit of hole = 25-0.015=24.958 mm Best Wire Size : d sec sec ¨ ¸ 1.443 mm
2 2 2 © 2 ¹
lower limit of GO-Guage = 24.985 mm GATE-2013 Page No.58 Slide No.179 Ans.(none) refer formula
Work tolerance = 10% of guage tolerance = 10% of (2 u 0.015) = 0.003mm
GATE-2011(PI) Page No.58 Slide No.180 Ans.(c)
Upper limit of GO- Guage = 24.9850+0.003 mm Difference between the readings of micrometers= 16.532-15.398=1.134mm
GATE-2004 Page No.50 Slide No.103 Ans. (None) Diameter of cylindrical standard = 30.5mm
Higher limit of hole = 20.05 mm ?Effective diameter= 30.5-1.134=29.366mm
Lower limit of hole = 20.01 mm IES-2012 Page No.59 Slide No.188 Ans. Refer slides for theory
Work tolerance = 20.05 – 20.01 = 0.04 mm IES-1992 Page No.60 Slide No.191 Ans.(b)
Gauge tolerance = 10% of work tolerance = 0.004 mm IFS-2011 Page No.60 Slide No.193 Ans. Refer slides for theory
0.004 GATE-2016(PI) Page No.60 Slide No.198 Ans. Ans. 2 Ǎm (Range 2.0 to 2.0)
Therefore, Dimension of ‘GO’ gauge 20.01 mm ISRO-2011 Page No.61 Slide No.200 Ans.(d)
0
0.004 IES-2007 Page No.61 Slide No.202 Ans.(c)Lay direction: is the direction of the predominant surface
Dimension of ‘NOT GO’ gauge 20.05 mm pattern produced on the workpiece by the tool marks.
0
IES-2008 Page No.61 Slide No.203 Ans.(b)Lay – directional of predominant surface texture produced
GATE-2015 Page No.50 Slide No.104 Ans.(b, c and d are correct.) by machining operation is called Lay.
GATE-1995 Page No.50 Slide No.105 Ans.(b) IES-2010 Page No.61 Slide No.204 Ans.(b)
GATE – 2006, VS-2012 Page No.50 Slide No.106 Ans.(c) IES-2008 Page No.61 Slide No.205 Ans.(c)
PSU Page No.51 Slide No.111 Ans.(c)
Ch-5 Measurement of Lines & Surface: Answers with Explanations

ISRO-2010 Page No.53 Slide No.131 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.53 Slide No.132 Ans.(c) Least count = 0.5/25 = 0.02 mm
ISRO-2009, 2011 Page No.53 Slide No.135 Ans.(a)
Pitch
Total dimension= pitch u No.of div + u reading
No.of div in thimble
0.5x5 + (0.5/50) x 12 = 2.62 mm
GATE-2008 Page No.54 Slide No.139,140 Ans.(c) If there is axial intersection Rp must not ISRO-2010 Page No.61 Slide No.206 Ans.(a)
equal to RQ IAS-2013(main) Page No.61 Slide No.207 Ans. Refer sildes for theory
IAS-2012(main) Page No.63 SlideNo.223 Ans. Refer sildes for theory
GATE-2014(PI) Page No.54 Slide No.141,142 Ans. (d) GATE-2003 Page No.64 Slide No.227 Ans.(a)
nOl
ISRO-2010 Page No.55 Slide No.149 Ans.(c) A measuring device of a standard size that is used 'h
2
to calibrate other measuring instruments.
n u 0.0058928 u 101 cm u 101 cm
ISRO-2008 Page No.55 Slide No.150 Ans.(d) Primary standards are used for calibration only. (1.002 1.000) u101 cm
In workshop it has no use. 2
GATE-2007(PI) Page No.55 Slide No.153 Ans.(d) During the measurement, a comparator is able to n 0.678 / cm
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)
So for both fringes=2 u n 1.357 | 2 fringes
ISRO-2011 Page No.57 Slide No.168 Ans.(c) A sine bar is specified by the distance between the centre
of the two rollers

GATE-2016 Page No.68 Slide No.263 Ans. (d)
Ch-6 Miscellaneous of Metrology: Answers with Explanations
GATE-1998 Page No.65 Slide No.236 Ans. (c) Autocollimator isan optical instrument for non-contact
measurement of small angles or small angular tilts of a reflecting surface AB ( R r )2 ( D R r )2
GATE-2009(PI) Page No.65 Slide No.237 Ans. (a)
GATE-2014 Page No.65 Slide No. 238 Ans. (b) Autocollimator is also measure flatness.
( R r D R r )( R r D R r )
ISRO-2010 Page No.65 Slide No. 241 Ans. (b) In optical square two mirrors are placed at an angle of 2 D( R r ) D 2
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. H R AB r
IES-1998 Page No.66 Slide No.244 Ans. (d)
GATE-2014 Page No.66 Slide No. 245 Ans. (c) Laser interferometer is widely used to check and R r 2 D( R r ) D 2
calibrate geometric features of machine tools during their assembly
GATE-1992 Page No.66 Slide No. 251 Ans. (b)
10
tan T
30
T 18.434
Also,
x Ch-7 Metal Forming: Answers with Explanations
tan T GATE-1995 Page No. 69 Slide No.9 Ans. (b)If the specimen is stressed slightly beyond the yield point
10
and unloaded then the phenomena of strain hardening takes place as a result of which strength
x increases.
tan18.434
10 IES-2013 Page No.70 Slide No. 10 Ans. (b)
x 3.334 IES-2016 Page No.70 Slide No. 13 Ans. (a)
IES-2016 Page No.71 Slide No. 24 Ans. (a)
? diameter at z 0 is (20 2 x) Mechanical properties of the material is depends on grain size.
? diameter (20 2 u 3.334) 13.336 Due to plastic deformation grain gets elongated.
GATE-2008(PI) Page No.67 Slide No. 261 Ans. (d) IES-2011 Page No.72 Slide No. 28 Ans. (b) If cold worked it will improve mechanical properties.
GATE-2003 Page No.72 Slide No. 29 Ans. (c) If working below Rx temp then it is cold-working process
GATE-2002, ISRO-2012 Page No. 72 Slide No. 30 Ans. (d)
T C2 A 3
ISRO-2010 Page No. 72 Slide No. 31 Ans. (d) Annealing is used to induce ductility,
tan
2 5 15.54 8 28.54 soften material, relieve internal stresses, refine the structure by making it homogeneous, and
T improve cold working properties.Normalization is an annealing process in which a metal is cooled in
6.006 air after heating.
2
IES-2006 Page No.72 Slide No.32 Ans. (c) When a metal is heated & deformed under mechanical
T 12.001 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.
GATE-2014 Page No.68 Slide No. 262 IES-2004 Page No. 72 Slide No. 33 Ans. (b) For cold working metal should have high ductility.
IES-2009 Page No. 72 Slide No.34 Ans. (d) Strength increases due to grain refinement.
BC = (H2 + d2/2) – ( H1 + d1/2) = 35.55 + 60/2 -20.55 IES-2008 Page No. 72 Slide No. 35 Ans. (b)
– 40/2 = 25 mm IES-2008 Page No. 72 Slide No. 36 Ans. (a)
Advantages of Cold Forming vs. Hot Working:
AC = 60/2 + 40/2 = 50 mm • Better accuracy, closer tolerances
• Better surface finish
• Strain hardening increases strength and hardness
AB 50 2
252 43.30 mm
• Grain flow during deformation can cause desirable directional properties in product
D = 60/2 + 43.30 + 40/2 = 93.30 mm • 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. 73 Slide No. 37 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. 73 Slide No. 38 Ans. (a)

IES-2000 Page No. 73 Slide No. 39 Ans. (d) Annealing required. IES-2003 Page No.79 Slide No.93 Ans. (c) Wavy edges due to roller deflection.
ISRO-2009 Page No. 73 Slide No. 40 Ans. (a) GATE -2007 Page No.79 Slide No.98 Ans.(d)
IES-1997 Page No. 73 Slide No. 41 Ans. (c)
x Phenomenon where ductile metals become stronger and harder when they are deformed plastically is
ho 16 mm ; h f 10 mm ;D 400 mm;R=200 mm?'h 6 mm;
called strain hardening or work hardening. 'h D(1 cos D )
x During plastic deformation, dislocation density increases. And thus their interaction with each other
resulting in increase in yield stress. 6 400(1 cos D ) D 9.936q
IES-1996 Page No. 73 Slide No. 42 Ans. (c)Cold working increases the strength and hardness of the GATE – 2012 Same Q in GATE – 2012 (PI) Page No.79 Slide No.99 Ans.(c)
material due to strain hardening. Strength, fatigue, and wear properties are improved through strain ho 8 mm ; h f 8 x 1 – 0.1 7.2 mm; D 410 mm;
hardening.
IES-2006 Page No. 73 Slide No. 43 Ans. (d) Should be above the recrystallisation temperature. 'h 10% of 8 mm 0.8 mm ª¬ alternative : ho h f 8 7.2 0.8 mm º¼
IES-1992 Page No. 73 Slide No. 44 Ans. (c)
• Annealing relieves the stresses from cold working – three stages: recovery, recrystallization and grain We know that, 'h D(1 cos D ) or 0.8 410 (1 cos D )
growth. S
• During recovery, physical properties of the cold-worked material are restored without any observable or D 3.58o 3.58 u rad 0.062 rad
change in microstructure.
180
GATE -1998 Page No.80 Slide No.100 Ans.(d) For strip rolling sheet rolling width remains same.
• Grain growth follows complete crystallization if the material is left at elevated temperatures.
Initial thickness (h1) = 4.5 mm.
• Grain growth does not need to be preceded by recovery and recrystallization; it may occur in all
As width constant therefore 20% reduction in area means 20% reduction in thickness also.
polycrystalline materials.
Final thickness (h2 = 0.8 x 4.5 = 3.6 mm
IAS-1996 Page No. 73 Slide No. 45 Ans. (c) For Mild Steel, recrystallisation temp is of the order of 10000C
IAS-2004 Page No. 74 Slide No. 46 Ans. (a) 'h D 1 cos T or 4.5 3.6 450 1 cos T or T 3.62q 0.063 radian
IAS-2002 Page No. 74 Slide No. 47 Ans. (b) Ulta hai. Assertion reason me hona chahiye. GATE -2004 Page No.80 Slide No.102 Ans.(b)
IES-2008 Page No. 74 Slide No. 48 Ans. (d)Malleability- It is a special case of ductility which permits Roll strip contact length, L = R ǂ
materials to be rolled or hammered into thin sheets. A malleable material should be plastic but it is not 'h D(1 cos D ) or 25 20 600 1 cos D or D 7.402q 0.129 rad
essential to be so strong. Lead, soft steel, wrought iron, copper and aluminium are some materials in
order of diminishing malleability. Therefore L RD 300 x 0.129 38.76 mm | 39 mm
GATE -2011 Page No.80 Slide No.105 Ans.(a) Maximum possible draft. 'hmax P2R
Ch-8 Rolling: Answers with Explanations GATE -2014 Page No.80 Slide No.106 Ans.(b) Maximum possible draft. 'hmax P2R
GATE -2013 Page No.74 Slide No.51 Ans.(c)Bi axial compression and frictional force between roller
and workpiece produces shear stress GATE -2016 Page No.80 Slide No.107 Ans. 1.92
IAS-2001 Page No.75 Slide No.56 Ans.(c)Rolling means hot working it will not show work R 300 mm, and 'hmax P 2 R 0.082 u 300 1.92 mm
hardening GATE -2015 Page No.80 Slide No.108 Ans.0.1414
ISRO-2006 Page No.75 Slide No.59 Ans.(c) You may confused with Forging but forging is hot GATE -2015 Page No.81 Slide No.109 Ans. 5.71
working, but Cold rolling (cold working) is mentioned therefore answer will be (c). In cold working IES-1999 Page No.81 Slide No.110 Ans.(b) Actually metal will get hardened in every pass due to
product will be stronger. If we compare cold forging and cold rolling then cold forging produce stronger strain hardening. Therefore in actual practice the reduction in second pass is less than in the first pass.
components. GATE-2006 Page No.81 Slide No.112 Ans.(c)
ISRO-2009 Page No.75 Slide No.62 Ans.(a)
IES-2006 Page No.76 Slide No.67 Ans.(c) A continuous form of three-point bending is roll bending, 'h max ho h f ,min P 2 R 0.12 u 150 mm 1.5 mm
where plates, sheets, and rolled shapes can be bent to a desired curvature on forming rolls. or 4 h f ,min 1.5 or h f ,min 2.5 mm
IES – 1992, GATE-1992(PI) Page No.77 Slide No.74 Ans.(b)Since brittle materials cannot handle
GATE – 2011 (PI) Page No.81 Slide No.114 Ans.(d)
plastic deformation. 2
IES – 1993, GATE-1989(PI) Page No.77 Slide No.75 Ans.(d) 'h max P 2 R 0.1 u 300 mm 3 mm
• 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
Therefore we cannot reduce more than 3 mm in a single pass but we have
the metal to flow radially into the desired shape. Because no metal is removed in the form of chips, less to reduce total, 30 mm -10 mm = 20 mm
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
20
? Number of pass needed = |7
obtained. 3
• One obvious characteristic of a rolled thread is that its major diameter always is greater than the IES-2001 Page No.81 Slide No.115 Ans.(a)
diameter of the blank. When an accurate class of fit is desired, the diameter of the blank is made about R 150 mm; ho 30 mm; h f 15 mm
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. 'h 1 15 1
IES-2013(conventional) Page No.77 Slide No.76 Ans. Refer slides 'h P 2 R or P | | 0.3something
R 10 3.something
150
IAS-2007 Page No.78 Slide No.82 Ans.(d)
IAS -2003 Page No.78 Slide No.83 Ans.(b) In IESobjective exam calculators are not allowed, we have to use above apporx.calculation
IAS-2000 Page No.78 Slide No.84 Ans.(b)Rolling with smaller diagram rolls requires lower force. GATE-2014(PI) Page No.81 Slide No.116 Ans.(b) same as above
IES-1993 Page No.78 Slide No.88 Ans.(a)In order to get uniform thickness of the plate by rolling GATE-1990(PI) Page No.82 Slide No.118 Ans.(b)
process, one provides camber on the rolls to take care of unavoidable tool bending. Cylindrical rollers IES-2014 Page No.82 Slide No.119 Ans. (b)
would result in production of plate with convex surface. Because of the limitations in the equipment and GATE-2008(PI) Page No.82 Slide No.120 Ans.(a)
workability of the metal, rolling is accomplished progressively in many steps. Plate, sheet and strip are The velocity at neutral point is equal to the velocity of roller, as there is no slip occur
rolled between rolls having a smooth, cylindrical, slightly cambered (convex) or concave working surface.
IAS-2004 Page No.78 Slide No.90 Ans.(c) Rolling means hot rolling where no lubricant is used. S DN S u 0.300m u 100rpm
V= 1.57 m / s
GATE -2009(PI) Page No.79 Slide No.92 Ans.(d) Due to directional granule deformation. 60 60

IES-2002 Page No.82 Slide No.121 Ans.(d) IES-2006 Page No.85 Slide No. 152 Ans.(c) The draft provided on the sides for withdrawal of the forging.
Selected Questions Page No.82 Slide No.122 Ans.(c & d) IES-2014 Page No.86 Slide No.155 Ans. (b)
GATE-2014 Page No.82 Slide No.124 Ans.14.6 to 14.8 m/min IES-2016 Page No.86 Slide No.156 Ans. (a)
The inlet and outlet volume rates of material flow must be the same, that is, IAS-2002 Page No.86 Slide No. 157 Ans.(b)Amount of flash depends on the forging size not on forging force.
IES – 1993, GATE-1994(PI) Page No.86 Slide No.160 Ans.(a)Closed die forging requires the provision of
h o bo vo h f b f v f gutters to provide space for excess material and ensure complete closure of die and defect free forged
2 part.
hf h ; b 1.02bo ; vo 10m / min IES-1997 Page No.86 Slide No.161 Ans.(c) The provision of gutters to provide space for excess material and
3 o f
ensure complete closure of die and defect free forged part.
2 GATE-1989(PI) Page No.86 Slide No. 162 Ans. Gutter
h o bo u10 h u1.02bo v f v f 14.706 m / min
3 o IES-2015 Page No.87 Slide No. 163 Ans.(c)
GATE-1992(PI) Page No.82 Slide No.126 Ans.(d) IES-1998 Page No.87 Slide No. 166 Ans.(c)
A IES-2001 Page No.87 Slide No. 167 Ans.(a)
Elongation factor = E = o 1.22...........( given) IES-2003 Page No.87 Slide No. 168 Ans.(a)
A1
IES-2011 Page No.87 Slide No. 169 Ans.(a)
Ao 750 u 750 IES-2005 Page No.87 Slide No. 170 Ans.(c)
En or 1.22n or 11.04
An 250 u 250 IES-2002 Page No.87 Slide No. 171 Ans.(b)
GATE-2016(PI) Page No.83 Slide No.129 Ans. 2000 (Range 1990 to 2010) IES-2003 Page No.88 Slide No. 172 Ans.(d)
IAS-2001 Page No.88 Slide No. 173 Ans.(b)
F V o L p b V o u R'h u b IES-2012 Conventional Page No.88 Slide No. 174 Ans. refer theory slides
IAS-2003 Page No.88 Slide No. 175 Ans.(a) The term swaging is also applied to processes where
500 u 100 u 4 u 200 N 2000 KN material is forced into a confining die to reduce its diameter.
GATE-2008 Page No.83 Slide No.130 Ans.(a) IES – 1994, ISRO-2010 Page No.88 Slide No. 178 Ans.(c)The drop forging die consists of two halves.
'h 20mm 18 mm 2mm 0.002m 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
R 250 mm 0.250m 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
Pr ojected Length (L p ) R'h 0.250 u 0.002 0.02236m
formed.
Arm length (a) O R'h 0.5 0.250 u 0.002 0.01118m IAS-2000 Page No.88 Slide No. 179 Ans.(a) Due to low toughness.
IES-2011 Page No.89 Slide No. 182 Ans.(b)
Force(F) Pr essure u Pr ojected area V o u (L p u b) 300 u 10 u 0.02236 u 0.1
6
670.8 kN
IFS-2011 Page No.89 Slide No. 183 Ans. Refer slides
Torque(T) Fua [Force F on both roller] IES-2005 Page No.90 Slide No. 190 Ans.(c)
670.8 u 10 u 0.01118
3
7.5kNm
IES-2013 Page No.90 Slide No. 293 Ans.(a) As K.E V2, high energy is delivered to the metal with
2S N 2S u 10 relatively small weights (ram and die).
Total Power for both roller (P) 2 u T u Z 2u Tu
60
2 u 7.5 u 103 u 60

15.7 KW
IES – 2000, GATE-2010(PI) Page No.83 Slide No.131 Ans.(a)The roll-separating force which separates Advantages of High Velocity Forming:
the two rolls apart can be obtained by multiplying the average roll pressure with the total contact area. 1. K.E V2, high energy is delivered to the metal with relatively small weights (ram and die).
The average roll pressure can be decreased by reducing the maximum pressure, which is a function of 2. Cost and size of machine low.
the contact length. Smaller contact lengths means lesser friction forces acting. Thus, by reducing the 3. Productivity high, overall production cost low
contact length, it is possible to decrease the roll-separating force. This in turn, can be achieved by 4. A shapes having straight or tapered reduced sections may be forged with the aid of rolls.
reducing the roll diameter, since; smaller rolls would have less contact length than larger rolls for the 5. Ram strokes short (due to high acceleration)
same reduction. IAS-2011(main) Page No.90 Slide No.195 Ans.
IAS-2007 Page No.83 Slide No.132 Ans.(c)Use small dia rolls to reduce Roll force. Smith Forging
IES-2001 Page No.83 Slide No.134 Ans.(a)Coefficient of friction is constant over the arc of contact x Blacksmith uses this forging method
and But does not acts in one direction throughout the arc of contact. x Quality of the product depends on the skill of the operator.
IAS-1998 Page No.83 Slide No.135 Ans.(d) x Not used in industry.
Upset Forging
x Upset forging involves increasing the diameter of a material by compressing its length.
Ch-9 Forging: Answers with Explanations x Parts can be upset forged both hot and cold on special high-speed machines where the workpiece
is rapidly moved from station to station.
x Upset forging generally employs split dies that contain multiple positions or cavities.
IES-1996 Page No.84 Slide No. 143 Ans.(d)
Drop Forging
IES-2013 Page No.84 Slide No. 144 Ans.(c) Forging components poses high reliability i.e. point3. is
y The drop forging die consists of two halves. The lower half of the die is fixed to the anvil of the
wrong, means (a), (b) and (d) wrong.
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
IES-2012 Page No.85 Slide No. 146 Ans.(b) If undercut is present it is not moldable means can’t be
and completely fills the die cavity. When the two die halves close, the complete cavity is formed.
withdrawn from die.
y Drop forging is used to produce small components.
Press Forging
• Forging means hot working it will increases strength and ductility both.
y Metal is squeezed gradually by a hydraulic or mechanical press and component is produced in a
• Hot working reduced or eliminates porosity of the metal and increase resistance to shock and vibrating.
single closing of die, hence the dimensional accuracy is much better than drop forging.
• Forging pressure is not uniform so it can’t guarantee uniformly and forging has poor dimensional accuracy and
y Similar to drop forging, press forging is also done in closed impression dies with the exception
surface finish.
that the force is a continuous squeezing type applied by the hydraulic presses.
ISRO-2013 Page No.85 Slide No. 148 Ans.(b)
y Most commonly used for the forging of bolt heads of hexagonal shape is close die press forging.
IES-2012 Page No.85 Slide No. 150 Ans.(c)

IES-2008 Page No.90 Slide No. 197 Ans.(None) Correct sequence is 2 – 1 – 3 - 4
IAS-1998 Page No.91 Slide No. 202 Ans.(b)
IES-2011 Page No.91 Slide No. 203 Ans.(c) Bonding between the inclusions and the parent material is
throughphysicalbondingnochemicalbondingpossible.
GATE-2008(PI) Page No.91 Slide No. 204 Ans.(c)
IES-2007 Page No.91 Slide No.205 Ans.
The mating surfaces of the two halves of the die define a parting line around the edges of the forging as
they come together. It can be located such that the line will surround the largest projected area of the
piece. The angle of the surface at the parting line from the primary parting plane should not exceed 75o,
in general, much shallower angles are preferred. Select the parting line so that no undercut are in either
die impression at the time of ejection of workpiece.
GATE-2010(PI) Page No.92 Slide No. 209 Ans.(c)Low thermal conductivity because low heat loss GAT
TE-2015 Page No.933 Slide No.
N 223 Anss.(c)
from workpiece. GAT
TE-2012 Sa
ame Q GATE -2012 (PII) Pag
ge No.93 Slide No. 224
2 Ans.(d))
IES-2013 Page No.92 Slide No. 212 Ans.(b) Volumee of materiaal will remainn same due to
t incompressibility
GATE-2014 Page No.92 Slide No. 214 Ans.(c)
S d12 S d 22
elongation u h1 u h2
Engineering strain or Conventional Strain(H E ) 4 4
original length
elongation h1 50
True Strain(H T ) d2 d1 100 u 1411.42 mm
instantaneous length h2 25
If suppose x is the length; dx is the elongation which is infinitely small d 2 d1
Percenttage change in diameterr u 100% 41..42%
L dx L d1
HT ³ ln GAT
TE-2016 Page No.93 3 Slide No.N 225 Anss. 1.0 (Rangee 1.0 to 1.0)
Lo x Lo
GAT
N Anss. 95.19 mm
m
L Lo 'L 'L 1000
as 1 1 H E True strain = ln 0.5129
Lo Lo Lo 5
95
0.1
1
HT ln 1 H E V 500 0 u (0.5129) 371.51
Upto elastic limits using Hookee's Law
' volume change will not be there so,Ao Lo AL
V ul 371.51 u 106 u 100
L Ao S / 4 d o 2 E= 09
or 200 u 10
'l 'l
Lo A S / 4 d 2 'l 0.1 18575mm (coonsidering thhis for elasttic recovery)
L Ao do This is elastic compponent and after
a releasee of the comp pressive load this
ln ln 2 ln amountt of recoveryy takes placee.
Lo A d
This wiill be added to 95mm. Therefore,
T fin
nal dimensioon = 95.185775mm
GATE-1992, ISRO-2012, VS-2013 Page No.92 Slide No. 215 Ans.(c)
IES
S-2012 Pagee No.94 Slid de No.228 Ans.(c)Forg ging force atttains maxim
mum value a
at the end off the operatiion.
§ L· § 2L ·
HT ln ¨ ¸ ln ¨ 0 ¸ ln 2 0.693
© Lo ¹ © Lo ¹ Ch
h-10 Ex
xtrusio
on and Drawing: Answers with E
Explanations
s
GATE-2016 Page No.92 Slide No. 216 Ans.(c)
IESS-2007 Page No.9 94 Slide No. N 233 Anss. (d)
§ 0.100 · The equipment consists of a cylinder orr container into
i which thhe heated metal
m billet iss loaded.
HT ln(1 H ) ln ¨1 u 100% 0.09995
© 100 ¸¹ On one
o end of th he containerr, the die pla
ate with the necessary opening
o is fix
xed. From th he other endd, a plunger or
GATE-2007 Page No.93 Slide No. 217 Ans.(c) ram
m compressess the metal billet
b againsst the contaiiner walls an
nd the die pllate, thus forcing it to fllow through the
L
L¬ A ¬ D ¬ 200 ¬ die opening, annd acquiringg the shape ofo the openinng. The extru uded metal is then carried by the metal-handli
m ing
dx
True strain T
¨ ln ln o 2ln o 2ln 1.386 systtem as it com
mes out of thhe die.
Lo
x L ®
o A ® D ® 400 ® DRD DO-2008 Page No.95 5 Slide No. N 235 Anss.(b)
negative¬sign indicates compressive strain. IESS-2012 Page No.9 95 Slide No. N 237 Anss.(c)
GATE-2016 Page No.93 Slide No. 216 Ans.(b) Advvantages: 1. Material sa aving 2. Proocess time saving 3. Sav ving in toolin ng cost
All are correct but only a die
d change ca an change thhe product therefore
t (c) is most apppropriate.
§L· §L /2· IESS-2009 Page No.9 95 Slide No. N 238 Anss.(c)
HT ln ¨ ¸ ln ¨ o ¸ ln 2 0.69
IESS-1994 Page No.9 95 Slide No. N 241 Anss.(c)Metal extrusion proocess is geneerally used for f producing
© Lo ¹ © Lo ¹
consstant solid and
a hollow seections overr any length..
GATE-2006 Page No.93 Slide No. 222 Ans.(b)
GAT TE-1994 Page No.9 95 Slide No. N 242 Anss. (a)
IESS-1999 Page No.9 96 Slide No. N 244 Anss.(c)
IASS-2012(main n) Pag ge No.96 Slide No. 245 2 Ans. Reefer slides
IESS-2009 Page No.9 96 Slide No. N 247 Anss. (b)
IESS-1993 Page e No.96 Slid de No. 249 Ans.
A (b) Both A and R are true butt R is not corrrect explan nation of A.
Zincc phosphate coating is used
u to preveent metal contact.In dire ect extrusion n, friction wwith the cham mber opposees
forw
ward motion of the billett. For indirecct extrusion
n, there is noo friction, sin
nce there is n no relative motion.
m
IESS-2000 Page No.9 96 Slide No.250
N Anss.(c)As diammeter decrea ases thereforre for same mass
m flow ra
ate

the speed of travel of the extruded product must be greater than that of the ram. GATE-1991(PI) Page No.104 Slide No. 319 Ans. Extrusion
IES-2012 Page No.97 Slide No. 253 Ans.(c) The force required on the punch is less in comparison to IAS-1994 Page No.104 Slide No.320 Ans. (b) Extrusion and skew rolling produce seamless metallic
direct extrusion. tubes.
IES-2007 Page No.97 Slide No. 254 Ans. (b)In direct extrusion, friction with the chamber opposes IES-2012(conventional) Page No. 104 Slide No. 321 Ans. Refer slide
forward motion of the billet. GATE-2003 Page No.105 Slide No. 325 Ans. (b)
IAS-2004 Page No.97 Slide No. 255 Ans. (d) Only ram movement is there. Extrusion constant k = 250MPa
IES-2016 Page No.97 Slide No. 256 Ans. (a) In the direct extrusion a significant amount of energy is
used to overcome frictional resistance between workpiece and cylinder wall. S do 2 Sdf 2
IES – 2008, GATE-1989(PI) Page No.97 Slide No.260 Ans. (a) Impact Extrusion is used for Initial area A o and Final area A f
4 4
manufacture of collapsible toothpaste tubes
IES-2003 Page No.97 Slide No. 261 Ans. (d) Force required for extrusion:
IES-2014 Page No.98 Slide No.262 Ans. (c) §A · S § S / 4 u 0.12 ·
IAS-2010(main) Page No. 98 Slide No. 263 Ans. Refer slides P kA0 ln ¨ o ¸¸ 250 u u 0.12 ln ¨ 2 ¸
2.72219 MN
IAS-2000 Page No.98 Slide No. 270 Ans. (d)Hydrostatic extrusion suppresses crack formation by Ä 4 © S / 4 u 0.05 ¹
© f ¹
pressure induced ductility. Relative brittle materials can be plastically deformed without fracture. And materials
GATE-2009(PI) Page No.105 Slide No.326 Ans. (a)
with limited ductility become highly plastic.
IES-2006 Page No.99 Slide No.271 Ans. (a) It is pressure induced ductility. §A ·
Pressure (V ) V o ln ¨ o ¸¸ V o ln r 300 ln 4 416 MPa
GATE-1990(PI) Page No.99 Slide No. 272 Ans.(c) Ä
IES-2001 Page No.99 Slide No.273 Ans. (d) © f ¹
IES-2009(conventional) Page No. 99 Slide No. 275 Ans. GATE-2006 Page No.105 Slide No. 327 Ans. (b)
For sketches refer slides. Given : Do 10mm; Df 8mm;V 0 400 MPa; Ignore friction and redundant work means
(i)Direct Extrusion-curtain rods §r · S u 82
§5·
(ii) Indirect Extrusion- 2V 0 A f ln ¨ o ¸
Ideal Force 2 u 400 u ln ¨ ¸ 8.97 kN
(iii) Hydrostatic Extrusion-Cladding of metals, Extrusion of nuclear fuel reactor fuel rod © rf ¹ 4©4¹
(iv) Impact Extrusion-Collapsible tubes for toothpastes, creams etc. GATE -2008 (PI) Linked S-1 Page No. 105 Slide No.328 Ans. (b)
IES-2014 Page No.99 Slide No.277 Ans. (d) For high extrusion pressure, the initial temperature of do 10 mm, d f (1 0.2) u d o (1 0.2) u 10 8 mm
billet should be low.
IES-2016 Page No.99 Slide No.279 Ans. (b) Bamboo defects at low temperature due to sticking of metals in §A · §d · § 10 ·
Stress V d V o ln ¨ o ¸¸ 2 u V o u ln ¨ o ¸¸ 2 u 800 u ln ¨ ¸ 357 MPa
die land. Ä ¨d ©8¹
JWM-2010 Page No.100 Slide No. 280 Ans. (a) © f ¹ © f ¹
IAS-2012(main) Page No.100 Slide No.281 Ans. Refer slide GATE -2008 (PI) Linked S-2 Page No.105 Slide No. 329 Ans. (a)
GATE-2014 Page No.100 Slide No. 282 Ans. (b) Power Drawing force u Velocity
IES-2007 Page No.100 Slide No. 286 Ans.(c)
IES-2009 Page No.100 Slide No. 287 Ans. (b)The wire is subjected to tension only. But when it is in
Stress V d u area Af uVelocity
contact with dies then a combination of tensile, compressive and shear stresses will be there in that portion only. S u 82
IES-2005 Page No.100 Slide No. 288 Ans. (a) 357 u u 0.5W 8.97 KW
GATE-1987 Page No.101 Slide No. 289 Ans. (a) 4
IES-2016 Page No.101 Slide No. 290 Ans.(c) IES-2014 Conv. Page No.105 Slide No.330 Ans. 190 N
IES-2010 Page No.101 Slide No. 292 Ans.(c) GATE-2001, GATE -2007 (PI) Page No.105 Slide No. 331 Ans. (b)
Cleaning is done to remove scale and rust by acid pickling. §A ·
Lubrication boxes precede the individual dies to help reduce friction drag and prevent wear of the dies. V d V o ln ¨ o ¸ For Maximum reduction,V d V o
© Af ¹
It is done by sulling, phosphating, electroplating.
IES-2000 Page No.101 Slide No.293 Ans.(c) § Ao · Ao A Af § 1·
V o V o ln ¨ ¸ or e 2.71828 ? o u 100 ¨1 ¸ u 100 63%
IAS-1995 Page No.101 Slide No. 294 Ans. (d)The correct sequence for preparing a billet for extrusion © Af ¹ Af Ao © e¹
process is pickling, alkaline cleaning, phosphate coating, and lubricating with reactive soap. IES-2014 Page No.105 Slide No.332 Ans. (b)
IES-1996 Page No.101 Slide No. 295 Ans. (d) GATE-1996 Page No.105 Slide No. 333 Ans. (b)
IES-2014 Page No. 101 Slide No.297 Ans. (b)
IES-1993; GATE-1994(PI), 2014(PI) Page No. 102 Slide No. 302 Ans. (b)
Case(a ) : 3 stage reduction final dia =15 u 1 0.8 u 1 0.8 u 1 0.8 0.12 mm ? error 0.02mm
IAS-2006 Page No.102 Slide No. 303 Ans. (b) (b) 4 stage reduction final dia =15 u 1 0.8 u 1 0.8 u 1 0.8 u 1 0.2 0.096mm ? error 0.004mm
IES-2015 Page No.102 Slide No. 306 Ans. (a)
IES-1993 Page No.103 Slide No. 307 Ans. (a) Tandem drawing of wires and tubes is necessary because (c) 5 stage reduction final dia
it is not possible to reduce at one stage.
=15 u 1 0.8 u 1 0.8 u 1 0.4 u 1 0.4 u 1 0.2 0.1728mm? error 0.0728mm
IES-2000 Page No.103 Slide No. 308 Ans. (d)
IES-1999 Page No.103 Slide No. 309 Ans. (d) GATE-2015 Page No.106 Slide No. 334 Ans. (b)
IES-1996 Page No.103 Slide No. 310 Ans.(c) IES-2011(conventional) Page No. 106 Slide No.337 Ans.
IES-1994 Page No.103 Slide No. 311 Ans. (d) do 12.5mm; d f 10mm;V 100m / min; D 5q; P 0.15; V o 400MPa
IES-1993, ISRO-2010, Page No. 103 Slide No. 312 Ans. (b)since malleability is related to cold rolling,
hardness to indentation, resilience to impact loads, and isotropy to direction.
B P cot D 0.15cot 5 1.7145
IES-2002 Page No.103 Slide No. 313 Ans. (a) 2B
V o 1 B ª §r · º
IAS-2001 Page No.103 Slide No. 314 Ans. (a) Vd «1 ¨ f ¸ »
GATE-2015 Page No.103 Slide No. 315 Ans. (b) B «¬ © ro ¹ »¼
IAS-2002 Page No.104 Slide No. 316 Ans. (b)
IES-2011 Page No.104 Slide No. 317 Ans. (b)

2u1.7145 GATE-2014 Page No.106 Slide No. 340 Ans. = 0.9 to 1.1
400(1 1.7145) ª § 5 · º
Vd «1 ¨ » 338.653MPa t
1.7145 6.25 ¸¹ True strain at any instant t H T
dL dL 2tdt
ln ª¬1 t 2 º¼
¬« © ¼» ³ L ³ L 1 t ³ 1 t
2
0
2
0
S
Force P 338.653 u 102 N
4 as, L
L0 1 t 2 ,? dL L0 2tdt
100 S dHT 2t 2 u1
Power P u V 338.653 u 102 u m/s 44.329 kW HT 1.0
4 60
Maximum possible reduction;V o V d
dt 1 t 2
1 12
IAS-1997 Page No.106 Slide No. 340 Ans.(c)
2B 2u1.7145
V o 1 B ª§r · º 400(1 1.7145) ª § rf min · º IES-2012 Page No.106 Slide No. 341 Ans. Refer slides
Vo «1 ¨ f min ¸ » or 400 «1 ¨ ¸ » or rf min 4.67mm IAS-2006 Page No.107 Slide No. 344 Ans. (c)
B r
«¬ © o ¹ »¼ 1.7145 «¬ © o ¹r »¼
d o d f min ro rf min Ch-11 Sheet Metal Operation: Answers with Explanations
Max possible reduction in dia = u100% u100% 25.3%
do ro Example Page No.108 Slide No. 354 Ans.
If the rod is subjected to a back pressure of 50 N/mm2 The clearance to be provided is given by, C = 0.0032 u t u ¥W
2B 2B Shear strength of annealed C20 steel = 294 MPa
V o 1 B ª §r · º §r ·
Vd «1 ¨ f ¸ » ¨ f ¸ .V b Hence, C = 0.0032 u1.5 u 294 = 0.0823 mm
B «¬ © ro ¹ »¼ © ro ¹ Since it is a blanking operation,
Die size = blank size = 20 mm
2u1.7145
2u1.7145
400(1 1.7145) ª § 5 · º § 5 · Punch size = blank size – 2 C = 20 – 2 u 0.0823 = 19.83 mm
Vd «1 ¨ ¸ »¨ ¸ u 50 361.26MPa Now when it is punching operation,
1.7145 «¬ © 6.25 ¹ »¼ © 6.25 ¹ Punch size= size of hole = 20 mm
For maximum possible reduction;V o Vd Die size = Punch size +2 C = 20 +2 u 0.0823 = 20.1646 mm
GATE-2003 Page No.108 Slide No.355 Ans.(a)
2B 2B
V o 1 B ª §r · º §r · It is blanking operation
Vo «1 ¨ f min ¸ » ¨ f min ¸ .V b Therefore Diameter of die = metal disc diameter = 20 mm
B r
«¬ © o ¹ »¼ © o ¹ r 3% clearance (c) = 0.06 mm on both side of the die (of sheet thickness)
2u1.7145
Therefore Diameter of punch = 20 – 2c = 20 – 2 x 0.06 = 19.88 mm
2u1.7145
400(1 1.7145) ª § rf min · º § rf min · Example Page No.108 Slide No. 358 Ans.
400 «1 ¨ ¸ »¨ ¸ u 50 rf min 4.78 mm
1.7145 6.25 ¹ 6.25 ¹
¬« © ¼» ©
d o d f min
Max possible % reduction in diameter = u 100% 23.5%
do
Ao Af min
Max possible % reduction in area = u 100% 41.5%
Ao
GATE – 2011 (PI) Common Data-S1 Page No. 106 Slide No. 338 Ans.(c)
S d o2 S u102
Initial area A o mm 78.54 mm 2
2
4 4
After first pass area A1 1 0.35 Ao 1 0.35 u 78.54 mm2 51 mm 2
2
After second pass area A 2 1 0.35 Ao and then ........
7 7
After 7 pass area A 7 1 0.35 Ao 1 0.35 u 78.54 mm 2
th
3.85 mm 2 GATE-2014 Page No.108 Slide No. 359 Ans.(b)
§ L· §A · § 78.54 · Punching Force(F) LtW
True strain ln ¨ ¸ ln ¨ o ¸ ln ¨ ¸ 3.02 F 2(a b)tW 2(100 50) u 5 u 300 450 kN
© Lo ¹ © A¹ © 3.85 ¹
IAS-2011(main) Page No.108 Slide No. 360 Ans.
and Ao Lo A7 L7 or 78.54 u100 3.85 u L7 L7 2040 mm For punching operation 10 mm circular hole
d 10 mm; t 1 mm;W 240 MPa
GATE – 2011 (PI) Common Data-S-2 Page No. 106 Slide No. 339 Ans. (d) (i) Punch size size of hole 10 mm
§A · §A · § 78.54 · ii Die size Punch size 2 C 10 2(0.0032t W )=10 2(0.0032 u1u 240)= 10.09914 mm
P V o Af ln ¨ o ¸¸ V o A1 ln ¨ o ¸ 200 u 51u ln ¨ ¸N 4.40 KN
¨ Af A
© 1¹ © 51 ¹ (iii) Punching Force(F) LtW S dtW S u10 u 1u 240 N 7.54 KN
© ¹

For blanking 50×200 mm rectangular blank IAS-2003 Page No.111 Slide No. 384 Ans.(a)
ISRO-2013 Page No.111 Slide No. 385 Ans.(a) Higher the modulus of elasticity higher will be the spring
(i) Punch size size -2C back.
Length will be = 200-2C =200 - 2(0.0032 u1u 240) =199.90 mm GATE-2011 Page No.112 Slide No. 396 Ans.(c)
Blanking Force(F) LtW S dtW S u100 u1.5 u 300 141.371kN
Width will be = 50 -2C =50 - 2(0.0032 u1u 240) = 49.90 mm GATE-2016 Page No.113 Slide No. 397 Ans. 5.026 KN
ii Die size correct size F S dtW S u 10 u 2 u 80 5026 N 5.026 KN
GATE-2009(PI) Page No.113 Slide No.398 Ans.(b)
Length will be = 200 mm
Blanking Force(F) LtW S dtW S u 200 u 3.2 u150 301.592kN
Width will be = 50 mm GATE-2013(PI) Page No.113 Slide No. 399 Ans.(c)
(iii ) F 2(a b)tW 2(200 50) u 1u 240 120 kN Blanking Force(F) LtW S dtW S u10 u 2 u 80 5.026kN
ISRO-2009 Page No.113 Slide No. 400 Ans.(b)
GATE-2016(PI) Page No.109 Slide No. 361 Ans.0.25(Range0.24to0.26) Blanking Force(F) LtW S dtW S u 25 u10 u 500 392.69kN
f 3 GATE-2007 Page No.113 Slide No. 401 Ans.(a)
IES-1999 Page No.109 Slide No.363 Ans.(b) min dia =4t s 4 u 20 u 30 mm Blanking Force(F) LtW S dtW
fc 6
IES-2014 Page No.109 Slide No.364 Ans. (c) F1 5 S dtW and F2 S u1.5d u 0.4t uW
Sd2 4tW 4tW F1 S dtW 5 1
ISRO-2008, 2011 Page No.109 Slide No. 365 Ans.(c) S dtW d V c u or d t t or or F2 3
4 Vc 4W F2 S u1.5d u 0.4t uW F2 1.5 u 0.4
IES-2013 Page No.109 Slide No. 366 Ans.(c)same as previous question GATE-2004 Page No.113 Slide No.402 Ans.(a)
EXAMPLE Page No.110 Slide No. 371 Ans. The blanking force (Fmax ) =S dtW S u10 u 3 u 400 37.7 kN
Maximum force without shear = 550 x 100 x Ǒ x 5.6 N = 968 kN
Capacity of press, F = 30 T = 30 x 9.81 KN = 294 KN Fmax u pt 37.7 u 0.40 u 3
F 22.6 kN
Fmax u pt 968 u 0.4 u 5.6 S 2
F or 294 or s 5.13mm GATE_2012 Page No.113 Slide No. 403 Ans.(a)
s pt s 0.4 u 5.6 Punch size without allowance = Die size – 2 x radial clearance = 25 – 2 x 0.06 = 24.88 mm
Angle of shear, tanǉ = 5.13/100 or ǉ = 2.9o We need another gap (die allowance ) i.e. final punch size will be = 24.88 – 0.05 = 24.83 mm
GATE-2008(PI) Page No.113 Slide No. 404 Ans.(c)
EXAMPLE Page No.110 Slide No. 372 Ans. C = 6% of t = 0.06×2.5 mm = 0.15 mm
d1 25.4 mm; d 2 12.7 mm; t 1.5 mm;W 280 N / mm 2
Punch size = die size - 2C = 50 - 2×0.15mm = 49.70 mm
Total cutting force when both punches act at the same time and no shear is
Die size = 50.00 mm
applied to either the die or punch; GATE-2002 Page No.113 Slide No.405 Ans.(c)
F S d1tW S d 2tW S u 25.4 u 1.5 u 280 S u 12.7 u 1.5 u 280 50.27 KN GATE-2001 Page No.114 Slide No. 406 Ans.(b)
GATE-1996 Page No.114 Slide No. 407 Ans.(d) Clearance only on punch for Blanking operation. Due to
The cutting force if the punches are staggered, so that only one punch acts at a time: insufficient data we cant calculate.
Fmax S d outsidetW S u 25.4 u 1.5 u 280 33.515 kN IES-1994 Page No.114 Slide No. 408 Ans.(a)
Taking 60% penetration and shear on punch of 1 mm, IAS-1995 Page No.114 Slide No. 410 Ans.(c)
The cutting force if both punches act together; IES-2006 Page No.114 Slide No. 411 Ans.(c)
F
S d1tW S d 2tW u pt S 25.4 u1.5 u 280 S u12.7 u1.5 u 280 u 0.6 u1.5 23.81KN IES-1997 Page No.114 Slide No. 413 Ans.(a)
S pt 1 0.6 u 1.5 IAS-2000 Page No.114 Slide No. 414 Ans.(d)
GATE-2010 Statement Linked 1 Page No.110 Slide No. 373 Ans.(a) It is blanking operation so clearance must be provided on punch.
p Therefore, Die size = blank size = 30 mm
t 5 mm; L 200 mm;W 100 MPa; 0.2 Punch size = blank size – 2C = 30 -2 x 0.06 x t = 30 – 2 x 0.06 x 10 = 28.8 mm
t GATE-2007(PI) Page No.115 Slide No. 415 Ans.(c)
Fmax LtW 200 u 5 u 100 100 kN C 40 microns 0.040 mm; 2C 0.08 mm
Work Done Fmax u ( pt ) 100 u (0.2 u 5) 100 J It is blanking operation : Punch size 35 0.080 mm and Die size 35 mm
IAS-1994 Page No.115 Slide No. 416 Ans.(a)
Work done = Fmax u pt 200 kN u 0.25 u 4 200 J [2 u 105 N 200kN ]
GATE-2010 Statement Linked 2 Page No.110 Slide No. 374 Ans.(b) IAS-2002 Page No.115 Slide No. 417 Ans.(a) In punching usable part is sheet so punch size is
For 400mm length shear is 20mm; therefore for Correct and clearance on die. In blanking usable part is punched out circular part so die size is correct
200mm length it becomes10mm. Only 200 mm length and clearance on punch
is effective. IAS-2007 Page No.115 Slide No. 418 Ans.(b)In punching useable part is punched sheet so size of hole
Fmax ( pt ) must be accurate i.e. size of punch must be accurate. Clearance have be given on Die only.
F
S IAS-1995 Page No.115 Slide No. 419 Ans.(a)Both A and R are true and R is the correct explanation of A
100 IES-2002, GATE(PI)-2003 Page No.115 Slide No. 420 Ans.(c)
F 10kN IAS-2003 Page No.115 Slide No. 421 Ans.(c)
10

IES-2000 Page No.115 Slide No. 422 Ans.(b) tc 1.5mm; D 30q now tc tb sin D ; or 1.5 tb sin 30 tb 3 mm
IES-1999 Page No.115 Slide No. 423 Ans.(d) In blanking operation clearance is always given on the
punch . Die size is always the exact dimension IES-1994 Page No.121 Slide No. 472 Ans.(d)Mode of deformation of metal during spinning is bending
IES-1994 Page No.116 Slide No. 429 Ans.(c) and stretching.
IFS-2011 Page No.121 Slide No. 473 Ans. Refer slides
d 25mm; h 15mm;We know D d 2 4dh 252 4 u 25 u15 46 mm IES-2016 Page No.122 Slide No. 486 Ans.(a)
GATE-2003 Page No.116 Slide No. 430 Ans.(c) IES-2011 Page No.123 Slide No. 487 Ans.(b)
d 100 Option (b) Magnetic pulse forming and (d) Eletro-hydraulic formingboth are High Energy Rate
Here 250 For d t 20r ;D d 2 4dh 1002 4 u 100 u 100 224 mm Forming (HERF). But Question is "usedfor forming components form thin metal sheets or deform
r 0.4
thin tubes"it is done by Magnetic pulse forming only.
ISRO-2011 Page No.116 Slide No. 431 Ans.(a) JWM-2010 Page No.123 Slide No. 488 Ans.(c)
IAS-2013(mains) Page No.117 Slide No. 434 Ans. IES-2010 Page No.123 Slide No. 489 Ans.(c)
d 50 mm; h 100 mm; BlankDia D d 2 4dh 502 4 u 50 u 100 150 mm IES-2007 Page No.123 Slide No. 490 Ans.(b)
High-Energy-Rate-Forming is metal forming through the application of large amount of energy in a very sort
d d time interval.
Reduction 1 ; 1st Reduction; 0.4 1 d 90 mm
D 150 High energy-release rate can be obtained by five distinct methods:
So, it can't be draw in a single draw. (i) Underwater explosions.
IFS-2013 Page No.117 Slide No. 435 Ans. (ii) Underwater spark discharge (electro-hydraulic).
(iii)Pneumatic-mechanical means.
d 40 mm; h 60 mm; r 2 mm
(iv)Internal combustion of gaseous mixtures.
D d 2 4dh 402 4 u 40 u 60 105.83mm (v) Electro-magnetic (the use of rapidly formed magnetic fields)
First draw 50% reduction, d1 0.5D=52.415mm IES-2005 Page No.123 Slide No. 492 Ans.(c)
Second draw 30% reduction, d 2 0.6d1 31.44mm (possible) IES-2013(conventional) Page No.123 Slide No. 493 Ans. Refer slides for theory
GATE-2000 Page No.124 Slide No. 498 Ans.(b)
It is not possible to draw the cup in single step.we have to use double step. li1 li 2
IES-2008 Page No.117 Slide No. 437 Ans.(c) A cylindrical vessel with flat bottom can be deep drawn For bi-axial strectching of sheets: H1 ln and H 2 ln
lo1 lo 2
by double action deep drawing
IES-1997 Page No.117 Slide No. 441 Ans.(c) initial thickness (t )
Final thickness =
2
D = d 4dh = 15 cm eH1 u eH 2
First draw 50% reduction, d1 = 7.5 cm 1.5
t 1.5mm; H1 0.05; H 2 0.09 ?Final thickness 1.304 mm
Second draw 30% reduction, d2 = 5.25 cm e0.05 u e0.09
Third draw 25% reduction, d3 = 3.94 cm possible IES-1998 Page No.125 Slide No. 508 Ans.(a)
IES-1998 Page No.118 Slide No. 442 Ans.(d) GATE-2005 Page No.125 Slide No. 510 Ans.(c)
d § d· D 1 radian; R 100mm; k 0.5; t 2mm
0.5; Reduction ¨1 ¸ u 100% 50%
D © D¹ Lb D (R kt) 1(100 0.5 u 2) 101 mm
Thumb rule: GATE-2007 Page No.126 Slide No. 514 Ans.(d)
GATE -2012 Same Q in GATE-2012 (PI) Page No.126 Slide No.515 Ans.(a)
First draw:Reduction 50 % GATE-2004 Page No.126 Slide No. 516 Ans.(b)
Second draw:Reduction 30 % IAS-1999 Page No.126 Slide No. 517 Ans.(d)
IAS-1997 Page No.126 Slide No. 518 Ans.(c)
Third draw:Reduction 25% IES-2010 Page No.126 Slide No. 519 Ans.(d)
Fourth draw:Reduction 16 %
Ch-12 Powder Metallurgy: Answers with Explanations
Fifth draw:Reduction 13%
IAS-2003 Page No.127 Slide No.523 Ans. (c)It is for low melting point temperature metals.
IFS-2009 Page No.118 Slide No. 443 Ans.. Refer slides for theory IAS-2007 Page No.127 Slide No.524 Ans. (c)In atomization process inert gas or water may be used as
IAS-1996 Page No.118 Slide No.448 Ans. (a) a substitute for compressed air.
IFS-2013 Page No.118 Slide No. 449 Ans..Refer slides for theory IES-2016 Page No.127 Slide No.525 Ans. (c)
IAS-2007 Page No.119 Slide No. 451 Ans.(d) In drawing operation, proper lubrication is essential for • Molten metal is forced through a small orifice and is disintegrated by a jet of compressed air, inert gas or
1. To improve die life. water jet.
2. To reduce drawing forces. • In atomization, the particles shape is determined largely by the rate of solidification and varies from
3. To reduce temperature. spherical, if a low-heat-capacity gas is employed, to highly irregular if water is used. By varying the
4. To improve surface finish. design and configurations of the jets pressure and volume of the atomizing fluid, thickness of the stream
IES-1999 Page No.119 Slide No. 455 Ans. (b) of metal, etc, it is possible to control the particle size distribution over a wild range.
GATE-2008 Page No.120 Slide No. 460 Ans.(a)An insufficient blank holder pressure causes wrinkles to IES-1999 Page No.127 Slide No.526 Ans. (c)An oxide film is formed in the case of air atomization and
develop on the flange, which may also extend to the wall of the cup. that film can be avoided by using an inert gas.
IAS-1997 Page No.120 Slide No. 461 Ans.(c) GATE-2011(PI) Page No.127 Slide No.528 Ans. (b)In reduction Metal oxides are turned to pure
GATE-1999 Page No.120 Slide No. 462 Ans.(b)It is without a blank holder, so no stress. metal powder when exposed to below melting point gases results in a product of cake of sponge metal.
GATE-2006 Page No.120 Slide No. 463 Ans.(d) IES-2013(conventional) Page No.127 Slide No.531 Ans. Refer slide
IES-1999 Page No.120 Slide No. 464 Ans.(b) IES-2012 Page No.128 Slide No.533 Ans. (b)
IAS-1994 Page No.120 Slide No. 465 Ans.(d) GATE -2014 (PI) Page No.128 Slide No.535 Ans. (b) Compaction is used for making product.
GATE-1992 Page No.121 Slide No. 471 Ans.(a) IAS-2000 Page No.128 Slide No.536 Ans. (b)Sintering used for making bond

IES-2010 Page No.128 Slide No.537 Ans. (d) IES-1999 Page No.140 Slide No.37 Ans.(c)
IES-1999 Page No.129 Slide No.541 Ans. (a) IES-2016 Page No.140 Slide No.44 Ans. (b)
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. Creamics tool is sued upto 1300°C SiC can with stand upto 2700°C that so why we
GATE-2016(PI) Page No.129 Slide No.548 Ans. (c) can use it for furnace part also. But statement-I and statement-II has no relation.
GATE-2010(PI) Page No.129 Slide No.549 Ans. (b)Due to formation of bonding brittleness reduces. IES-2013 Page No.141 Slide No.46 Ans.(a)
IES-2002 Page No.130 Slide No.550 Ans. (c) IES-2010 Page No.141 Slide No.47 Ans.(b)Constituents of ceramics are oxides of different materials,
IES-2007(conventional) Page No.130 Slide No.551 Ans. Refer slide which areGround, sintered and palleted to make ready ceramics
IAS-1997 Page No.130 Slide No.556 Ans. (d)A is false. Closed dimensional tolerances are possible IES-1996 Page No.141 Slide No.48 Ans.(c)
with iso-static pressing of metal power in powder metallurgy technique. IES-1997 Page No.141 Slide No.49 Ans.(b)Ceramic tools are used only for light, smooth and
IES-2011(conventional) Page No.130 Slide No.557 Ans. Refer Slide continuous cuts at high speeds.This is because of low strength of ceramics
ISRO-2013 Page No.131 Slide No.564 Ans. (b& c) Best choice will be ( c) IES-1996 Page No.141 Slide No.50 Ans.(b)
GATE-2009(PI) Page No.132 Slide No.569 Ans. (d) S D(mm) N S u100 u1000
IES-2007 Page No.132 Slide No.570 Ans. (b)Disadvantage of PM is relatively high die cost. V m / min 314.15m / min
1000 1000
IES-2012 Page No.132 Slide No.572 Ans. (b) Cutting speed in this case is 314 m / min, at which ceramic is suited.
IES-2006 Page No.132 Slide No.573 Ans. (c)No wastage of material.It may be automated though it is IES-2007 Page No.141 Slide No.51 Ans.(d)
difficult for automation. this is not true IAS-2000 Page No.141 Slide No.52 Ans.(c)
IES-2004 Page No.132 Slide No.574 Ans. (a) H.S.S < Cast alloy < Carbide < Cemented carbide < Cermets < ceramics
IES-2015(conventional) Page No.132 Slide No. 576 Ans. Refer slides IAS-2003 Page No.141 Slide No.53 Ans.(c)
IES-2010 Page No.133 Slide No.577 Ans. (c) IAS-1999 Page No.142 Slide No.58 Ans.(b)
IAS-1998 Page No.133 Slide No.578 Ans. (c) IES-2010 Page No.142 Slide No.62 Ans.(c)
IES-2009 Page No.133 Slide No.579 Ans. (c) IES-2000 Page No.142 Slide No.63 Ans.(d)CermetsareMetal-ceramic composites
GATE-2011(PI) Page No133 Slide No.580 Ans. (d) IES-2003 Page No.143 Slide No.64 Ans.(a)
IAS-2003 Page No.133 Slide No.581 Ans. (a) GATE-2009(PI) Page No.143 Slide No.66 Ans.(d)On ferrous materials, diamonds are not suitable
IES-1997 Page No.133 Slide No.582 Ans. (d) because of the diffusion of carbon atoms from diamond to the work-piece material.
IES-2001 Page No.133 Slide No.583 Ans. (b) IES-1995 Page No.143 Slide No.69 Ans.(b)Nonferrous materials are best to work with diamond
IES-2015 Page No.133 Slide No. 584 Ans. (b) because ferrous materials have affinity towards diamond and diffusion of carbon atoms takes place.
IAS-2003 Page No.134 Slide No.586 Ans. (d) IES-2001 Page No.143 Slide No.70 Ans.(b)
GATE-2011 Page No.134 Slide No.591 Ans. (c) IES-1999 Page No.143 Slide No.71 Ans.(a)
IAS-1996 Page No.134 Slide No.592 Ans. (b) IES-1992 Page No.143 Slide No.72 Ans.(c)
IES-1998 Page No.134 Slide No.593 Ans. (b) IAS-1999 Page No.144 Slide No.73 Ans.(a)“Oxidation of diamond starts at about 450oC and
IES-2014 Page No.134 Slide No.594 Ans. (c) thereafter it can even crack. For this reason the diamond tool is kept flooded by the coolant during cutting, and
IAS-2007 Page No.135 Slide No.595 Ans. (b) light feeds are used.” - Book B L Juneja and Nitin seth page 88
IAS-2004 Page No.135 Slide No.596 Ans. (b) IES-1994 Page No.144 Slide No.77 Ans.(a)
IES-2001 Page No.135 Slide No.597 Ans. (d) IES-2002 Page No.144 Slide No.78 Ans.(d)
GATE-2008(PI) Page No.135 Slide No.598 Ans. (d) IES-1996 Page No.144 Slide No.79 Ans.(a)Hardness of CBN is comparable to diamond
Conventional Question,IES-2010 Page No.135 Slide No.599 Ans. Refer slide IES-1994 Page No.144 Slide No.80 Ans.(d)None of the uses is true for CBN.
Conventional Question,IES-2005 Page No.135 Slide No.600 Ans. Refer slide IAS-1998 Page No.144 Slide No.81 Ans.(b)
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.
Ch-xx Tool Materials: Answers with Explanations The major constituent of diamond is carbon. Thus C matches with 1.
Coated carbide tools are treated by nitriding. Thus D matches with 3
IAS-1997 Page No.136 Slide No.7 Ans.(a)Carbon steel tools have Limited tool life. Maximum IES-2003 Page No.145 Slide No.84 Ans.(b)This is one of the natural abrasives found, and is also
cutting speeds about 8 m/min. dry and used upto 250oC called corundum and emery. However, the natural abrasives generally have impurities and, as a result, their
IES-2013 Page No.137 Slide No.10 Ans.(b) Addition of large amount of cobalt and Vanadium to performance is inconsistent. Hence the abrasive used in grinding wheels is generally manufactured from the
increase hot hardness and wear resistance respectively aluminium ore, bauxite, Silicon carbide (SiC) Silicon carbide is made from silica sand and coke with small
IAS-1997 Page No.137 Slide No.11 Ans.(a)Coating if TiC and TiN on HSS is done by by Chemical amounts of common salt.
Vapour Deposition (CVD) or Physical Vapour Deposition (PVD) IES-2000 Page No.145 Slide No.85 Ans.(b)Cutting speed of diamond is very high but small feed rate
IES-2003 Page No.137 Slide No.13 Ans.(a)18-4-1 High speed steel- contains 18 per cent tungsten, 4 with low depth of cut. Degarmo and Kalpakjian both book written this.
per cent chromium and 1 per cent vanadium IES-1999 Page No.145 Slide No.86 Ans.(d)WC is used for drawing dies, silicone nitride for pipes to
IES-2007 Page No.137 Slide No.14 Ans.(a) carry liquid metal, Al2O3 for abrasive wheels, and silicon carbide for heating elements.
IES-1993 Page No.137 Slide No.15 Ans.(b)The blade of a power saw is made of high speed steel. IAS-2001 Page No.145 Slide No.87 Ans.(d)
IES-1995 Page No.137 Slide No.18 Ans.(d) IES-1996 Page No.145 Slide No.89 Ans.(a)
x 18-4-1 High speed steel- contains 18 per cent tungsten, 4 per cent chromium and 1 per cent vanadium IES-2005 Page No.145 Slide No.90 Ans.(d)
x Molybdenum high speed steel contains 6 per cent tungsten, 6 per cent molybdenum, 4 per cent
chromium and 2 per cent vanadium.
IAS-2001 Page No.138 Slide No.21 Ans.(a)
IAS-1994 Page No.138 Slide No.22 Ans.(b)

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.

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 ⎠ ⎥
For-2017 (IES, GATE & PSUs) at Exit τ = μ P = μ (σ o − σPage
d ) = 0 182 of 186 ⎣ ⎦ Rev.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 -2017: 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 (2009 By IIT Roorkee-15%) f) Grinding and finishing
x Production (2009 By IIT Roorkee-16%) g) ECM MRR, feed calculations, EDM theory, comparison of all NTMM
x TOM (2009 By IIT Roorkee-10%) h) NC/CNC Machine, BLU calculations, upto M & G code
i) Limit, tolerance, fit
x Industrial Engineering (2009 By IIT Roorkee-12%)
j) Jig & Fixture, 3-2-1 principle
x Fluid Mechanics & Machines (2009 By IIT Roorkee-8%)
k) Welding: V-I Characteristics calculations, Resistance welding calculations, Special welding
x SOM (2009 By IIT Roorkee-6%) theory
x Heat Transfer (2009 By IIT Roorkee-9%) l) Casting: allowances, Riser Design, Sprue Design, Pouring time calculations, Special
Castings, Casting Defects.
Grade-B Subjects ǥǥǥǥǤͻare required
3. TOM
x Thermodynamics (2009 By IIT Roorkee-5%)
x Design (2009 By IIT Roorkee-6%) a) Mechanism (VIMP)
b) Linear Vibration Analysis of Mechanical Systems (VIMP)
Grade-C Subjects ǥǥǥǥǤ5 revisions are required c) Gear train (VIMP)
d) Flywheel (Coefficient of Fluctuation of speed, Coefficient of Fluctuation of energy), mass
x RAC (2009 By IIT Roorkee-2%) calculation,
x Power plant (2009 By IIT Roorkee-4%) e) Critical Speed of Shafts
x Engineering Mechanics (2009 By IIT Roorkee-3%) f) Gyroscope
Grade-D Subjects ǥǥǥǥǤͷ2 revisions are sufficient 4. Industrial Engineering

a) EOQ Models (VIMP)
x IC Engine (2009 By IIT Roorkee-2%)
b) PERT & CPM (VIMP)
x Engineering Materials (2009 By IIT Roorkee-2%)
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. RAC
a) Properties of fluid a) Heat engine, heat pump, refrigerator (VIMP)
b) Pressure measurement, manometers b) Psychrometry (VIMP)
c) Fluid kinematics (VIMP) c) Vapour Compression Systems
d) %HUQRXOOL·V(TXDWLRQ ( Fluid Dynamics)
e) Venturimeter 11. Power plant
f) Flow ( Laminar and Turbulent) a) Steam Cycle (VIMP)
g) Boundary Layer, Thermal Boundary Layer b) Gas Cycle
h) Compressible Flow c) Compressor
i) Hydraulic Turbine
j) Centrifugal Pump 12. Engineering Mechanics
a) Equilibrium
6. SOM
b) Truss
a) Principal Stress and Principal Strain, Mohr Circle(VIMP) c) Friction
b) Stress and Strain (VIMP)
c) Bending Moment and Shear Force Diagram (VIMP) 13. IC Engine
d) Deflection of Beam
a) Gas Power Cycles (All) (VIMP)
e) Torsion
b) IC Engine Performances
f) Theories of Column (Euler method, end conditions)
c) Octane number, cetane number
g) 6WUDLQ(QHUJ\0HWKRG&DVWLJOLDQR·VWKHRU\
h) Theories of failure 14. Engineering materials
i) Thin cylinder
a) Crystal structure & crystal defects
j) Riveted and Welded Joint
b) Iron-carbon Equilibrium diagram, TTT diagram,
k) Spring
c) Heat treatment
7. 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)
8. Thermodynamics
a) Basic Concepts
b) Application of First law
c) Entropy, Availability
d) Pure Substance (VIMP)
e) Gases and Gas mixture
9. 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

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

Section‐II: Metrology Questions Answer & Explanations

Section‐III: Metal Forming Questions Answer & Explanations

Section‐IV: Cutting Tool Materials Page‐136 Page-169

For-2017 (IES, GATE & PSUs) Page 1 of 186 Rev.0

By S K Mondal past tthee work

IES‐1995 GATE‐1995; 2008 IES‐1993

IES – 2005 IES 2015

For-2017 (IES, GATE & PSUs) 16

IAS – 1994 IES ‐ 2014

IES ‐ 2012 IES‐2006 IES ‐ 2012

IAS – 1996 IAS – 1995 IES 2010

IES‐1995 IES‐2006 IES‐2002

IES‐1994 IES 2009

((a)) 00 ((b)) 450 (a) 6.53 (b) 20.22

(c) 600 (d) 900 (c) 22.94 (d) 50.00

For-2017 (IES, GATE & PSUs) 43

condition is 1.8 mm. The shear angle

approximately The parameters which govern the value of shear

GATE‐2014 IES ‐ 2004 IES ‐ 2009

IES‐2004, ISRO‐2009 IES‐2008 IES ‐ 2014

IES‐2001 IES‐2003 IAS‐2003

chip thickness = 0.6 mm. Then the chip (b) Shear

IAS‐1995 GATE – 2009 (PI) Common Data S‐1 GATE – 2009 (PI) Common Data S‐2

ratio is unaffected with the changed cutting 155o. The chip

GATE‐1995 IES 2007 IES‐2015

For-2017 (IES, GATE & PSUs) 70

ESE ‐2000 (Conventional) GATE ‐2010 (PI) Linked S‐1 GATE ‐2010 (PI) Linked S‐2

IES‐2014 Conventional IAS – 1999 GATE‐1997

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

(i) shear angle and Shear p

IES 2010 IES‐2005 Theory of Lee and Shaffer

Other Relations The force relations (VIMP) IES‐2003

Fn = Fc sin φ + Ft cos φ ( ) 1079.4 N

100 101 102

y Fc or Fz or tangential component or primary cutting

IES‐1997 IES‐1999 IFS‐2015

ESE‐2003‐ Conventional GATE – 1995 ‐Conventional IAS‐2003 Main Examination

a) 28°20´ and 2.19 angle is 25°

GATE‐2003 Common Data Questions(1) GATE‐2003 Common Data Questions(2) GATE‐2008 Common Data Question (1)

GATE‐2008 Common Data Question (2) Metal Removal Rate (MRR) IES ‐ 2004

For-2017 (IES, GATE & PSUs) 133

Specific Energy Consumption GATE(PI)‐1991 GATE‐2007

Sometimes it is also known as specific power

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

For-2017 (IES, GATE & PSUs) 142

GATE 1992 GATE‐1993 IES‐2000

IES‐1998 IAS – 2003 Mean Temperature in Turning

154 155 156

Determination of cutting heat & temperature

IES 2011 IES‐1993 IES‐1996

163 164 165

Tool Failure IES 2010 IES – 2007, IES‐2016

172 173 174

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

For-2017 (IES, GATE & PSUs) 178

181 182 183

IES – 2004 GATE 2008 (PI)

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

y For crater wear temperature is main culprit and tool

For-2017 (IES, GATE & PSUs) 187

190 191 192