METAL CUTTING

a) Differentiate between orthogonal and oblique cutting. Draw merchant's

force circle diagram for orthogonal cutting process. Give two examples of
oblique cutting.
b) Draw a neat sketch of a single point cutting tool indicating its complete
geometry on it.
c) Explain with neat sketch the importance and functions of different tool
angles associated with the geometry of a single point cutting tool.
d) Draw neat sketch of single point cutting tool with label of six major
angles and other terminology of it. Discuss essential characteristic and
function of cutting fluids.
e) Draw neat sketch of chip formation in metal cutting and derive following
relation for the shear angle (Ø), Where r = chip thickness ratio, α = tool rake
angle.
f) Explain types of chips that occur in metal cutting. Why a built up edge on a
tool is undesirable.
g) What are chip breakers? Explain them briefly. If they are not used what
adverse effects chip can produce on the work, tool and surroundings?
h) How cutting tools are are classified? Name few tools of each type. What do
you mean by chip with built up edge? What factors are responsible for this
type of chip formation?
i) Describe each type of chip with the help of suitable sketch.
j) Draw a merchant circle diagram and derive expressions to show relationship
among the different forces acting on the cutting tool and different parameter
involved in metal cutting.
k) Draw Merchant‟s force diagram. Derive the equations for frictional force,
normal reaction, shear force and normal force.
l) Draw a Merchant„s Circle Diagram and derive expressions to show
relationships amongst the different forces acting on the cutting tool and
different parameter involved in metal cutting.
m) What is tool life? State factors influencing on it in detail.
n) Enumerate the factors affecting tool life. Briefly explain the effect of each
factor.
o) Derive the Taylor‟s equation for tool life.
p) What are crater wear and flank wear? Explain.
q) Define tool life? What are Crater wear and flank wear. What are the factors
responsible for them?
r) In Orthogonal turning of a 50 mm diameter Mild steel bar on a lathe the
following data were obtained. Rack angle = 15 degree ,, cutting
speed=100m/min, Feed = 0.2 mm / rev., Cutting force = 180 Kg, Feed
Force=60 Kg, Calculate the shear plane angle, Coefficient of friction ,
Cutting power, the chip flow velocity and shear force, if the chip thickness =
0.3 mm
s) The following observations were made during orthogonal turning of a
mild steel tubing of 60 mm diameter on a lathe. (1) Cutting speed
…….………24 m/min (2) Tool rake angle ……….......32º (3) Feed rate
…………………..0.12 mm/rev (4) Tangential cutting force……3000 (5)
Feed force…………………..1200N (6) Length of continuous chip in one
revolution…96 mm Determine:
t) Co-efficient of friction
u) Shear plane angle
v) Velocity of chip tool face
w) Chip thickness
x) The following relates to orthogonal turning o f a mild steel rod of 50 mm
diameter. Feed 0.8 mm; chip thickness 1.2 mm; work rotational speed 70
rpm. Calculate chip thickness ratio (r), chip reduction ratio (K) and total
length of chip removed per minute.
y) In orthogonal cutting, if the feed is 1.25 mm/rev and chip thickness after
cutting is 2mm, determine the following. 1. Chip thickness ratio
2. Shear angle The tool bit has a rake angle of 10º. If shear strength = 600
N/mm2 Width of cut = 10 mm Cutting speed = 30 m/min Co-efficient of
friction = 0.9 Determine, a. Shear force b. Friction angle c. Cutting force
d. Horse power at the cutting tool

z) The following equation for tool life has been obtained for H. S. S. tool. VT
0.13 0.6 0.3
f d = C. A 60 minute tool life was obtained while cutting at V = 40
m/min, f = 0.25 mm/rev and d= 2 mm. Calculate the effect on tool life if
speed, feed and depth of cut are together increased by 25% and also if they
are increased individually by 25%. Also give your comments.
 Thermal Aspects in Machining
a) Name several techniques for determining tool chip contact
temperature. Describe the Tool/work thermocouple method of measuring
temperatures
b) What are the methods by which cutting fluids are applied in a machining
operation? Explain EP method.

Non-Conventional machining
(a) Define Non-conventional machining? Why do we need these processes?
Give classification of the Non-conventional processes?
(b) Define Non-conventional machining? Why do we need these processes?
Give classification of the Non-conventional processes?
(c) Describe principle of Electrical Discharge Machining (EDM) with figureand
state its advantages, limitation and application.
(d) Write important functions of dielectric fluid and electrolyte. Also write
various types of commonly used dielectric fluid and electrolyte.
(e) Explain with suitable diagram working of electro discharge machine. State its
advantage, disadvantage and application.
(f) Explain with the principle of EDM. State characteristics of dielectric fluid.
(g) Explain basic principle of EDM process. Also discuss the characteristics of
various materials that are used for EDM tool.
(h) Explain basic principle of EDM process. Also discuss the characteristics of
various materials that are used for EDM tool.
(i) Describe Ultrasonic Machining (USM) process with neat sketch. Discusshow
the following factors effects the material removal rate of USM.
(i) Grain Size (iv) Feed force (ii) Frequency (v) Hardness ratio
(iii) Amplitude (vi) Abrasive concentration
(j) Explain principle of Ultrasonic machining with the help of neat diagram.
State its advantages and application.
(k) Explain with neat sketch working principle, advantages and limitations of
USM.
(l) How are unconventional machining methods classified? Compare LBM
and EBM process with different factors which consider for classification
of unconventional machining.
(m) Explain Laser beam machining process in detail.
(n) What is LASER? Explain LBM.
(o) Write short note on any two i) LBM ii) USM iii) ECM
(p) Write the difference between AJM and 'AWJM processes from the view
point of working principle, application & limitations.
(q) Explain Abrasive Jet machining with schematic diagram stating its
advantages and limitation.
(r) What do you mean by MMR in unconventional machining? How this
MMR is affected by various parameters in abrasive jet machining?
(s) What do you mean by MMR in unconventional machining? How this MMR
is affected by various parameters in abrasive jet machining?
(t) Describe water jet machining process with the help of neat sketch. State its
advantages and application.
(u) With neat sketch, explain the process of Electro –chemical grinding. State its
limitation.
 Jig and Fixture
a) Differentiate between Jigs and Fixture. Enlist different types of clamping
devices. Explain any two with neat sketches.
b) Differentiate between a jig and a fixture. Explain one clamping device.
c) Distinguish between jig and fixture. State advantages of jigs and fixtures.
d) Distinguish between a Jig and Fixture. Sketch different drill bushes useful
in drill jigs.
e) List the various types of locating devices used for both Jigs and Fixture
and Explain any three of them with neat sketch.
f) Explain “Principle of location” in detail.
g) Draw and discuss following clamping devices
(i) Hinged Clamp (ii) Quick Action Nut (iii) Hydraulic Clamp
h) Describe with neat sketch any three types of clamping device with their
features and application.
i) Enlist types of Jig. Explain construction and working of template jig.
j) Enlist types of Fixtures. Explain any two with sketch.
k) Explain the degree of freedom of a workpiece located in a space with a
neat sketch. Analyze the Location of a Cylinder on a Vee Block.
 Presses
a) Draw neat schematic diagram of a sectioned view of a blanking die and
punch assembly and label on it. Explain the function of (i) Die Block (ii)
Punch (iii) Knock out.
b) Differentiate Between (i) Capstan and Turret lathes (ii) Piercing and
Blanking operation
c) Describe the methods of punch support.
d) Draw neat sketch showing various components of a press working set up and
explain importance of each in short.
e) Discuss the various types of pilots used in progressive die.
f) How the Presses are classified? Sketch and describe any one of it.
g) Make a neat sketch of a die- set and describe its various details and
accessories
h) How the Presses are classified? Sketch and describe any one of it.
i) Write short note on material utilization factor for a sheet metal on a press
tool using press tool die. (ii) Coated cutting punch increase the life of punch.
Discuss.
j) Explain with neat sketches , How does the provision of shear angle affect the
work done in shearing of sheet metal in press work? What is the effect of
angles on product quality?
k) Write in detail the methods of reducing the cutting forces in press
working.
l) What are common ejecting mechanisms used in power presses? Describe.
m) Describe the common bending operations performed on presses.
n) Sketch and design a progressive die to make a steel washer 30 mm outside
diameter with 15 mm hole. From 1.6 mm thick steel sheet. The ultimate
shear strength of the material is 320 N/mm2. Calculate,
a. Maximum punch force necessary to blank and punch the washer if
both punches operate at the same time.
b. Punch and die size for piercing and blanking operation
 Gear and Thread Manufacturing
a) Discuss following thread manufacturing methods with neat sketch (i)
Chasing (ii) Rolling (iii) Tapping
b) What are the different types of thread manufacturing processes? Explain
with neat sketch
c) List the various types thread manufacturing methods. And explain thread
grinding.
d) Enlist different types of gears and draw gear tooth terminology.
With appropriate example discuss plain indexing and compound indexing
methods of manufacturing a gear on milling machine.
e) Explain with the help of sketch, principle, types, and applications of gear
hobbing.
f) Classify the generating process for gear cutting ? Explain “Gear Hobbing” in
detail.
g) Write short note on Gear finishing process.