2019 Metal Cutting Metal Forming Metrology PDF

Page 1
Metal Cutting, Metal Forming & Metrology

Questions & Answers-For 2019 (All Questions are in Sequence)
IES-1992-2018 (27 Yrs.), GATE-1992-2018 (27 Yrs.), GATE (PI)-2000-2018 (19 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-159
Chapter-2: Analysis of Metal Cutting Page-11 Page- 161
Chapter-3: Tool life, Tool Wear, Economics and Machinability Page-23 Page-166
Section‐II: Metrology Questions Answer & Explanations

Chapter-4: Limit, Tolerance & Fits Page-43 Page-172
Chapter-5: Measurement of Lines & Surfaces Page-57 Page-175
Chapter-6: Miscellaneous of Metrology Page-71 Page-176
Section‐III: Metal Forming Questions Answer & Explanations

Chapter-7: Cold Working, Recrystalization and Hot Working Page-76 Page-177
Chapter-8: Rolling Page-81 Page-178
Chapter-9: Forging Page-92 Page-179
Chapter-10: Extrusion & Drawing Page-103 Page-181
Chapter-11: Sheet Metal Operation Page-118 Page-184
Chapter-12: Powder Metallurgy Page-138 Page-186
Section‐IV: Cutting Tool Materials Page‐148 Page-187
For‐2019 (IES, GATE & PSUs)

For-2019(IES, GATE & PSUs) Page 1 of 203 Rev.0

Page 2
Manufacturing Vs Production
Manufacturing Vs Production Machine tool
Machine tool
y Manufacturing is a process of converting raw material in A machine tool is a non portable power operated and
non‐portable
to finished product by using various processes, machines reasonablyy valued device or system
y of device in which
Theory of Metal Cutting and energy, it is a narrow term. energy is expended to produce jobs of desired size,
y Production is a process of converting inputs in to shape and surface finish by removing excess material
outputs it
i is
i a broader
b d term. from the preformed blanks in the form of chips with the
Eg ‘crude
Eg. crude oil production
production’ not ‘crude
crude oil manufacturing,
manufacturing’ h l off cutting
help i tools
l moved
d past the
h work
k surface.
f
By S K Mondal ‘movie
movie production
production’ not ‘movie
movie manufacturing
manufacturing’
y Manufacturing
g and production
p are often used
1 interchangeably. 2 3
IAS 2009 main O th l M hi i
Orthogonal Machining
Whyy even a batteryy operated
p Name four independent variables and three dependent
pencil sharpener
p p cannot be variables in metal cutting. [ 5 marks]
accepted as a machine tool? Independent Variables Dependent Variables
Ans. In spite of having all other major features of •Starting materials •Force or power requirements
machine tools, the sharpener is of low value. (tool/work) •Maximum temperature in b
T l
•Tool geometry cutting
i
•Cutting Velocity •Surface finish
•Lubrication
b
4 • Feed & Depth of cut 5 6
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
D2
1
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
For-2019(IES, GATE & PSUs) 7
Page 2 of 203 8
Rev.0 9
Page 3
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
10 11 12
IES – 2005 IES‐2015 IES – 2002

Statement (I) : The ceramic tools used in machining of
Assertion
A i (A):
(A) Carbide
C bid tips i are generallyll given
i Assertion
A i (A):
(A) Negative
N i rakek is
i usuallyll provided
id d on
material have highly brittle tool tips.
negative rake angle. carbide tipped tools.
Statement (II) : Ceramic tools can be used on hard‐to hard to
Reason (R): Carbide tips are made from very hard machine work material. Reason (R): Carbide tools are weaker in
materials.
materials ( ) Both
(a) B th statement
t t t (I) and
d (II) are individually
i di id ll true
t andd compression.
compression
(a) Both A and R are individually true and R is the statement (II) is the correct explanation of statement (I) (a) Both A and R are individually true and R is the
correct explanation
l off A (b) Both statement (I) and statement(II) are individually correct explanation
l off A
(b) Both
ot A aand d R aaree individually
d v dua y ttrue
ue but R iss not
ot tthee true but statement(II)
( ) is not the correct explanation
p of (b) Both
d v dua y ttrue
ue but R iss not
ot tthee
correct explanation of A statement (I) correct explanation of A
( ) A is
(c) i true
t b t R is
but i false
f l (c) Statement (I) is true but Statement (II) is false ( ) A is
(c) i true
t b t R is
but i false
f l
(d) Statement (I) is false but statement (II) is true
(d) A is false but R is true (d) A is false but R is true
13 14 15
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.
Page 3 of 203 17
Rev.0 18
Page 4
Types of Machining IAS – 1994 IES ‐ 2014

Consider the following characteristics
C id h f ll i h i i Which
Whi h one off theh following
f ll i statements is i correct about
b
g g g
1. The cutting edge is normal to the cutting velocity.y an oblique cutting?
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
Orthogonal Cutting Oblique Cutting
19 20 21
IES ‐ 2012 Chip formation

of a drill
During orthogonal cutting, an increase in cutting speed
D i h l i i i i d
causes
(a) An increase in longitudinal cutting force
(b) An increase in radial cutting force
(c) An increase in tangential cutting force
(d) Cutting forces to remain unaffected
22 23 24
IES‐2006
Which of the following is a single point cutting
tool?
(a) Hacksaw blade
(b) Milling cutter
(c) Grinding wheel
(d) Parting tool

Page 4 of 203 26
Rev.0 27
Page 5
GATE‐2017(PI) A Single Point Turning Tool IES ‐ 2012

Statement
St t t (I):
(I) Negative
N ti rake k angles
l are preferred
f d on rigid
i id set‐
t
Turning, drilling, boring and milling are ups for interrupted cutting and difficult‐to machine
commonly used machining operations.
operations Among materials.
materials
these, the operation(s) performed by a single Statement (II):Negative rake angle directs the chips on to the
machined surface
point cutting tool is (are)
(a) Both Statement (I) and Statement (II) are individually
( ) turning
(a) t i t
true andd Statement
St t t (II) is
i the
th correctt explanation
l ti off
Statement (I)
(b) drilling and milling only (b) Both
B h Statement
S (I) and
d Statement
S (II) are individually
i di id ll
(c) turning and boring only true but Statement (II) is not the correct explanation of
St t
Statement t (I)
(d) boring only (c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement (II) is true
28 29 30
IES‐2003 IES‐2015 GATE(PI)‐1990

The
Th angle l off inclination
i li i off the
h rake
k face
f with
ih
respect to the tool base measured in a plane The purpose of providing side rake angle in the The diameter and rotational speed of a job are 100 mm and
perpendicular to the base and parallel to the width cutting tool is 500 rpm respectively. The high spot (Chatter marks) are
of the tool is called
(a) avoid work from rubbing against tool f
found
d at a spacing off 30 deg
d on the
h job
b surface.
f The
h chatter
h
(a) Back rake angle
(b) Control chip flow
flo frequency is
(b) Side
S d rake
k angle l
(c) S
Side
de cutt
cuttingg edge aangle
ge (c) Strengthen tool edge ((a)) 5 Hz ((b)) 12 Hz ((c)) 100 Hz ((d)) 5500 Hz
(d) End cutting edge angle (d) Break chips
p
31 32 33
IAS – 1996 IAS – 1995 IES 2010

The tool life increases with the
Th l lif i i h h Thrust force will increase with the increase in
Th f ill i i h h i i Consider
C id the
th following
f ll i statements:
t t t
((a)) Increase in side cutting edge angle
g g g ((a)) Side cutting edge angle
g g g In an orthogonal, single
single‐point
point metal cutting,
(b) Decrease in side rake angle (b) Tool nose radius as the side‐cutting edge angle is increased,
( ) Decrease in nose radius
(c) D i di ( ) Rake angle
(c) R k l 1. The tangential force increases.
((d)) Decrease in back rake angle
g ( )
(d) End cutting edge angle.
g g g 2 The longitudinal force drops.
2. drops
33. The radial force increases.
Which of these statements are correct?
(a) 1 and 3 only (b) 1 and 2 only
( ) 2 and
(c) d 3 only
l (d) 1, 2 and
d3
Page 5 of 203 35
Rev.0 36
Page 6
IES‐1995 IES‐2006
The angle between the face and the flank of the Assertion (A): For drilling cast iron, the tool is provided
single point cutting tool is known as with a point angle smaller than that required for a
ductile material.
a) Rake angle
Reason (R): Smaller point angle results in lower rake
b) Clearance angle angle.
c) Lip angle ( ) Both
(a) B th A and d R are individually
i di id ll true
t and
d R is
i the
th
d) Point angle. correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
( ) A is false but R is true
(d)
37 38 39
S
Some Formulae for Drilling
F l f D illi IES‐2002 Nose radius
d
D y It is curvature of the tool tip.
tip
Cone height (h) = Consider the following statements:
2 tan β
The strength of a single point cutting tool depends y It strengthen the tool nose by reducing stress
f
Uncut chip thickness (t ) = sin β upon
2 concentration.
D 1. Rake
R k angle l
Width of cut (b) = 2. Clearance angleg y It increases tool life.
2sin β
3. Lip angle
⎡ ( 2r / D ) tanψ ⎤ y It provide better surface finish.
O th
Orthogonal
l rake l (α ) = tan
k angle t −1 ⎢ ⎥ Which
hi h off these
h statements are correct?
⎣ sin β ⎦ y But too large a nose radius will induce chatter.
(a) 1 aand
d3 ((b)) 2 aand
d3
(c) 1 and 2 (d) 1, 2 and 3 y If nose radius increased cutting force and cutting power
increased.
40 41 42
IES ‐ 2012 IES‐2009 IES‐1995

Tool life increase with increase in
T l lif i i h i i Consider the following statements with respect Consider
C id the
h following
f ll i statements about
b nose radius
di
( )
(a) Cutting speed
g p to the effects of a large g nose radius on the tool:
(b) Nose radius 1. It deteriorates surface finish. 1. It improves tool life
( ) F d
(c) Feed 2. It I increases
i the
h possibility
ibili off chatter.
h 2 It reduces the cutting force
2.
( ) p
(d) Depth of cut 33. It improves
p tool life. 3. It improves the surface finish.
Which of the above statements is/are correct? Select the correct answer using the codes given below:
( ) 2 only
(a) l (b) 3 only
l ( ) 1 and
(a) d2 (b) 2 andd3
(c) 2 aandd3o onlyy (d) 1,, 2 aand
d3 (c) 1 and 3 (d) 1, 2 and 3

Page 6 of 203 44
Rev.0 45
Page 7
IES‐1994 IES‐2009 IES‐1993

Tool geometry of a single point cutting tool is specified by the
following elements: The following tool signature is specified for a In ASA System, if the tool nomenclature is 8‐6‐5‐5‐
1
1. Back rake angle single‐point
g p cutting g tool in American system:
y
10‐15‐2‐mm, then
h the
h side
d rake
k angle
l will
ll be
b
2. Side rake angle 10, 12, 8, 6, 15, 20, 3
3. End d cutting edged angle
l Wh does
What d the
h angle l 12 represent?? ( ) 5°°
(a) (b) 6° ( ) 8°
(c) (d) 10°°
4. Side cutting edge angle ((a)) Side cutting‐edge
g g angle g
5. Side relief angle (b) Side rake angle
6. End relief angle
( ) Back
(c) k rake
k anglel
7. Nose radius
The correct sequence of these tool elements used for (d) Side
de cclearance
ea a ce aangle
ge
correctly specifying the tool geometry is
( ) 1, 2, 3, 6,
(a) 6 5, 4, 7 (b) 1, 2, 6,
6 5, 3, 4, 7
(c) 1, 2, 5, 6, 3, 4, 7 (d) 1, 2, 6, 3, 5, 4, 7 46 47 48
IES‐2018 GATE‐2008
ISRO‐2011 Tool signature is In
I a single
i l point i turningi tool,
l the
h side
id rake
k angle
l
and orthogonal rake angle are equal. Φ is the
A cutting tool having tool signature as 10,
10 9,
9 6,
6 6,
6 8,
8 8,
8 (a) a numerical method of identification of the principal cutting edge angle and its range is
g
2 will have side rake angle tool 0o ≤ φ ≤ 90
. o The chip flows in the orthogonal plane.
plane
(a) 10o (b) 9o (c) 8o (d) 2o (b) the plan of the tool The value of Φ is closest to
( ) the complete specification of the tool
(c) (a) 00 (b) 450
(c) 60 0 (d) 900
(d) associated with the tool manufacturer
49 50 51
GATE‐2001 GATE 2011 GATE‐2018

During orthogonal cutting of mild steel with A single – point cutting tool with 12° rake angle is Following data correspond to an orthogonal
used to machine a steel work – p piece. The depth
p of
a 10
10° rake angle tool,
tool the chip thickness ratio
cut, i.e. uncut thickness is 0.81 mm. The chip Turning of a 100 mm diameter rod on a lathe.
was obtained as 0.4. The shear angle (in thickness under orthogonal machining condition is
degrees) evaluated from this data is 1.8 mm. The shear angle is approximately Rake angle: +15°; Uncut chip thickness 0.5
( ) 6
(a) 6.53 (b)
(b) 20.22
( ) 22°°
(a) mm, nominal chip thickness after the cut 1.25
(c) 22.94 (d) 50.00 ((b)) 26°
(c) 56° mm. The shear angle (in degrees) for this
(d) 76° process is _________(correct
( to two decimal
d l
places).
l )
Page 7 of 203 53
Rev.0 54
Page 8
GATE‐2017 IES‐1994
In
I an orthogonal
h l machining i h a tooll off 90
hi i with The
Th following
f ll i parameters
t determine
d t i the
th IES‐2014 Conventional
IES‐2014 Conventional
orthogonal rake angle, the uncut chip model of continuous chip p formation: A bar of 70 mm diameter is being cut
thickness is 0.2 mm. The chip thickness 1. True feed orthogonally and is reduced to 68 mm by a
fl t t between
fluctuates b t 0.25 mm and d 0.4 mm. cutting tool.
tool In case mean length of the chip is
2. Cutting velocity
The ratio of the maximum shear angle
g to the 68.9 mm, find the cutting ratio. Determine
3 Chip thickness
3. shear
h angle
l also
l if the
h rake
k angle i 10o
l is
minimum shear angle during machining is
___________ 4. Rake angle
4 g of the cutting g tool.
[10 Marks]
The parameters which govern the value of shear
angle
l wouldld include
l d
Hint: length of uncut chip = πD
(a) 1,2
1 2 and 3 (b) 1,31 3 and 4
55
(c) 1,2 and 4 (d) 2,3 and 4 56 57
IAS 2015 Main

IAS‐2015 Main
GATE‐2014 IES ‐ 2004 In an orthogonal cutting operation, the tool has a
rake angle = 10o. The chip thickness before the cut
During
g p
pure orthogonal
g turning
g operation
p of a In a machining
g operation
p chip
p thickness ratio = 0.5
0 5 mm and the cut yields a deformed chip
hollow cylindrical pipe, it is found that the is 0.3 and the rake angle of the tool is 10°. What thickness = 1.125 mm.
thickness of the chip produced is 0.5 mm. The feed is the value of the shear strain? Calculate
given to the zero degree rake angle tool is 0.2 (i) shear
h plane
l angle,
l
(a) 0.31 (b) 0.13
(ii) shear strain for the operation.
operation
mm/rev. The shear strain produced during the (c) 3.00 (d) 3.34
Derive the formulae that are to be used while
operation is ……………….
finding out the shear plane angle and shear
strain.
strain
58 59
[20‐Marks] 60
IES ‐ 2009 GATE (PI)‐1990

IES 2016
IES‐2016
During the formation of chips in machining with a
Minimum shear strain in orthogonal turning A single point cutting tool with 120 rake angle is cutting tool, which one of the following relations
with
ith a cutting
tti tool
t l off zero rake
k angle
l is
i used for orthogonal machining of a ductile h ld good?
holds d
V V V V V V
(a) 0.0
00 (a) = s = c (b) = s = c
material.
i l Th
The shear
h plane
l angle
l f
for the
h cos (φ − α ) cos α sin α sin (φ − α ) cos α cos α
(b) 0.5 theoretically minimum possible shear strain to V V Vs
(c ) = c = (d ) V cos α = Vc sin α = Vs cos (α − φ )
(c) 1.0 cos α sin α sin (φ − α )
occur
(d) 2.0
(a) 51 (b) 45 where V is the cutting speed, Vc is the velocity of the
chip,
hi VsV is
i the
th velocity
l it att which
hi h shearing
h i t k place
takes l
(c) 30 (d) None of these along the shear plane, φ is the shear angle and α is the
rake angle.
Page 8 of 203 62
Rev.0 63
Page 9
GATE 2012
GATE ‐2012 IES‐2004 IES‐2006
Details pertaining to an orthogonal metal cutting process 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
are given below. the relief angle of cutting tool: 1. A large rake angle means lower strength of the
g g g
Chip thickness ratio 0.4 1. This affects the direction of chip flow cutting edge.
Undeformed thickness 0 6 mm
0.6 2 This reduces excessive friction between the tool
2. This reduces excessive friction between the tool 2 Cutting torque decreases with rake angle.
2. Cutting torque decreases with rake angle
Rake angle +10° and work piece Which of the statements given above is/are correct?
Cutting speed 2.5 m/s 3. This affects tool life (a) Only 1 (b) Only 2
Mean thickness of primary shear zone 25 microns 4 This allows better access of coolant to the tool
4. This allows better access of coolant to the tool ( ) Both 1 and 2
(c) B th d (d) Neither 1 nor 2
N ith
The shear strain rate in s–1 during the process is work piece interface
(a) 0.1781×105 (b) 0.7754×105 Which of the statements given above are correct?
h h f h b
1 0104×105
(c) 1.0104×10 4 397×105
(d) 4.397×10 (a) 1 and 2 (b) 2 and 3
64 (c) 2 and 4 (d) 3 and 4 65 66
IES‐2004 IES‐2004, ISRO‐2009 IES‐2008

Match. List I with List II and select the correct answer
M h Li I i h Li II d l h Consider the following statements:
C id h f ll i
The rake angle of a cutting tool is 15°, shear angle 45°
using the codes given below the Lists: In an orthogonal cutting the cutting ratio is found to be
List I List II and
d cutting velocity
l 35 m/min. What
h is the
h velocity
l 0∙75. The cutting speed is 60 m/min and depth of cut 2∙4
A. Plan approach angle 1. Tool face mm. Which of the following are correct?
g
of chip along the tool face?
B. Rake angle 2. Tool flank 1. Chip velocity will be 45 m/min.
C Clearance angle
C. Cl l 3. T l f
Tool face and flank
d fl k (a) 28.5
28 5 m/min (b) 27 3 m/min
27.3 2 Chip velocity will be 80 m/min.
2. Chip velocity will be 80 m/min
D. Wedge angle
g g 4.
4 Cutting edge
g g 3. Chip thickness will be 1∙8 mm.
(c) 25.3
25 3 m/min (d) 23 5 m/min
23.5
5. Tool nose 4. Chip thickness will be 3∙2 mm.
A B C D A B C D Select the correct answer using the code given below:
(a) 1 4 2 5 (b) 4 1 3 2 (a) 1 and 3 (b) 1 and 4
(c) 4 1 2 3 (d) 1 4 3 5 ( ) 2 and 3
(c) d (d) 2 and 4d
67 68 69
IES ‐ 2014 IES‐2001 IES‐2003

In
I an orthogonal
h l turning
i process, the
h chip
hi thickness
hi k = If α is
i theh rake
k angle
l off the
h cutting
i tool,l φ isi the
h An
A orthogonal
h l cutting
i operation
i is
i being
b i
0.32 mm, feed = 0.2 mm/rev. then the cutting ratio will shear angle and V is the cutting velocity, then the carried out under the following conditions:
be velocity of chip sliding along the shear plane is cutting speed = 2 m/s, depth of cut = 0.5 mm,
(a) 2.6
26 given
i b
by chip
hi thickness
thi k = 0.6
6 mm. Then
Th th chip
the hi
(b) 3.2 velocityy is
(c) 1.6 V cos α V sin φ
(a) (b) (a) 2.0 m/s (b) 2.4 m/s
(d) 1.8
18 cos(φ − α ) cos (φ − α )
(c) 1.0 m/s (d) 1.66 m/s
V cos α V sin α
( )
(c) sin(φ − α )
(d) sin(φ − α )

Page 9 of 203 71
Rev.0 72
Page 10
IAS‐2003 IAS‐2002 IAS‐2000

In orthogonal cutting, shear angle is the angle between
( ) Shear plane and the cutting velocity
(a)
(b) Shear plane and the rake plane
Sh l d th k l
(c) Shear plane and the vertical direction
((d)) Shear plane and the direction of elongation of crystals in
p g y
the chip
73 74 75
IAS‐1998 IAS‐1995 GATE – 2009 (PI) Common Data S‐1

The cutting velocity in m/sec, for turning a work piece An
A orthogonal
h l turning
i operation
i is
i carried
i d out at 20
In an orthogonal cutting, the depth of cut is halved and
off diameter
di t 100 mm att the
th spindle
i dl speed
d off 480
8 RPM is
i m/min cutting speed,
speed using a cutting tool of rake angle
the feed rate is double. If the chip thickness ratio is
(a) 1.26
1 26 (b) 2 51
2.51 (c) 48 (d) 151 155o. The chip
p thickness is 0.4
4 mm and the uncut chip
p
unaffected with the changed cutting conditions, the thickness is 0.2 mm.
actual chip thickness will be The shear plane angle (in degrees) is
(a) Doubled (b) halved (a) 26.8 (b) 27.8 (c) 28.8 (d) 29.8
(c) Quadrupled (d) Unchanged

Unchanged.
76 77 78
GATE – 2009 (PI) Common Data S‐2 Mechanism of chip formation in Mechanism of chip formation in

Mechanism of chip formation in
An
A orthogonal
h l turning
i operation
i is
i carried
i d out at 20 ductile material
d l l brittle material
brittle material
m/min cutting speed,
speed using a cutting tool of rake angle
155o. The chip
p thickness is 0.4
4 mm and the uncut chip
p
thickness is 0.2 mm.
The chip velocity (in m/min) is
(a) 8 (b) 10 (c) 12 (d) 14
Fig. Development and propagation of crack
Fi D l t d ti f k
Page 10 of 203 80 causing chip separation. Rev.0 81
Page 11
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 following are correct?
(a) Irregular shaped discontinuous chips Continuous ribbon like chip is formed when turning insufficient cooling help produce
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
82 83 84
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
85 86 87
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 )
(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
Page 11 of 203 89
Rev.0 90
Page 12
ESE ‐2000 (Conventional) Limitations of use of MCD
The following data from the orthogonal cutting test
Special Case‐I
Special Case‐I
1. MCD is valid only for orthogonal cutting.
is available. Rake angle = 100, chip thickness ratio = y If α = 0
0
0.35, uncut chip thickness = 0.51 mm, width of cut = 2. By the ratio F/N, the MCD gives apparent (not actual)
3 mm,
mm yield shear stress of work material = 285
co‐efficient of friction.
N/mm2, mean friction co‐efficient on tool face =
0.65,
6 D
Determinei
((i)) Cutting
g force ((Fc)
(ii) Radial force
(iii) Normal
N l force
f (N) on tooll and
d
((iv)) Shear force ((Fs )).
91 92 93
GATE ‐2010 (PI) Linked S‐1 GATE ‐2010 (PI) Linked S‐2
Special Case‐II
Special Case‐II 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
been observed that the friction force acting at the chip‐ been observed that the friction force acting at the chip‐
y If α = 0 and μ
0 and μ = 1
1
tool interface is 402.5 N and the friction force is also 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
perpendicular
p p to the cuttingg velocityy vector. The feed perpendicular to the cutting velocity vector. The feed
velocity
l it isi negligibly
li ibl small ll with
ith respectt to t the
th cutting
tti
velocity is negligibly small with respect to the cutting velocity. The ratio of friction force to normal force
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
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. /
mm. The cutting velocity is 2 m/s. Assume that the energy gy expended
p during g machining g is
The shear force (in N) acting along the primary shear completely converted to heat. The rate of heat
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
94 95 96
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
Page 12 of 203 98
Rev.0 99
Page 13
GATE 2017 (PI)

GATE‐2017 (PI) Merchant Theory or Analysis
Merchant Theory or Analysis
IES‐2014 Conventional The Merchant circle diagram g showingg various forces Or Theory of Enrst and Merchant
Show schematically the Merchant’s force circle in associated with a cutting process using a wedge ‐ shaped
tool is given in the Figure. Assumption
p
orthogonal cutting. Derive the equations for shear The coefficient of •The work material behaves like an ideal plastics.
and
d frictional
f i i l forces
f i terms off the
in h material
i l friction can be h h l l
•The theory involves minimum energy principle.
estimated from
properties and cutting process parameters.
parameters State the
h ratioi •τs and β are assumed to be constant, independent of φ
are assumed to be constant independent of φ
also the assumptions
p made while arriving
g at the f1 f3 It is based on single shear plane theory.
•It is based on single shear plane theory.
(a) (b)
final equations. f2 f4 • The normal and shear stresses are distributed uniformly
f f on the shear plane
[15‐Marks] (c ) 5 (d ) 6
f6 f5 •The deformation is in two dimensions only.
100 101 102
IAS – 1999
From Merchant Theory or Analysis
From Merchant Theory or Analysis
In an orthogonal cutting process, rake angle of the
π α β y Merchant
M h t theory
th gives
i hi h
higher shear
h plane
l tooll is 20° and
d friction
f angle
l is 25.5°. Using
φ= + − angle means smaller shear plane which means

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

shear angle will be
((a)) 39
39.5°
5 ((b)) 42.25°
4 5
all of which mean easier machining ((c)) 47
47.75°
75 ((d)) 550.5°
5
103 104 105
GATE‐1997 ESE‐2005 Conventional GATE 2008 (PI) Li k d S 1

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

plane angle
g ((in degree)
g ) for minimum cutting
g force
((ii)) Cutting
g and thrust component
p of the force. is
(a) 20.5 (b) 24.5 (c) 28.5 (d) 32.5
Page 13 of 203 107
Rev.0 108
Page 14
GATE 2008 (PI) Li k d S 2

GATE ‐2008 (PI) Linked S‐2 GATE‐2014 GATE‐2014
In an orthogonal cutting experiment,
experiment an HSS tool having Which pair of following statements is correct for Better surface finish is obtained with a large rake
orthogonal cutting using a single‐point cutting angle because
the following
g tool signature
g in the orthogonal
g reference
t l?
tool? (a) the area of shear plane decreases resulting in the
system (ORS) has been used: 0‐10‐7‐7‐10‐75‐1. Given P. Reduction in friction angle
g increases cutting g force decrease in shear force and cuttingg force
width of cut = 3.6 mm; shear strength of workpiece Q. Reduction in friction angle decreases cutting force (b) the tool becomes thinner and the cutting force is
material
i l = 460
6 N/mm
N/ 2; depth
d h off cut = 0.25 mm; R Reduction
R. R d ti in i friction
f i ti anglel increases
i chip
hi thickness
thi k reduced
d d
coefficient of friction at tool
tool‐chip
chip interface = 0.7.
07 g decreases chip
S. Reduction in friction angle p thickness (c) less heat is accumulated in the cuttingg zone
(a) P and R (b) P and S (d) the friction between the chip and the tool is less
Minimum p
power requirement
q ((in kW)) at a cutting
g speed
p
( ) Q and
(c) dR (d) Q and
dS
of 150 m/min is
(a) 3.15 (b) 3.25 (c) 3.35 (d) 3.45 109 110 111
Modified Merchant Theory IES 2010 IES‐2005

The
Th relationship
l ti hi between
b t the
th shear
h angle
l Φ,
Φ
Which one of the following is the correct
τ s = τ so + kσ s g β and cutting
the friction angle g rake angle
g α
expression for the Merchant
Merchant'ss machinability
is given as
⎡ Fn ⎤ constant?
Wh
Where, σs is
i the
th normalstress
l t on shear
h plane
l ⎢σ s = ⎥ (a) 2φ + γ − α
⎣ As ⎦
(b) 2φ − γ + α
and then 2φ + β − α = cot −1 (k )
(c) 2φ − γ − α
((d)) φ + γ − α
(Where φ = shear angle,γ = friction angle
andα = rake angle)
112 113 114
h f d Sh ff
Theory of Lee and Shaffer IFS 2016
IFS‐2016 Other Relations
In a slab milling g operation
p g teeth
with straight
•Based on slip line field theory. cutter, the cutter has 15 teeth with 10o rake angle
•They
h appliedli d the
h theory
h off plasticity
l i i for f an and rotates at 200 rpm.rpm The diameter of the
cutter is 80 mm and table feed is 755 mm/min, the
id l i id l ti body.
ideal-rigid-plastic b d depth of cut is 5 mm, the width of slab is 50 mm y By Stabler
•They also assumed that deformation occured and ultimate shear stress of work material is 420
on a thin
thin-shear
shear zone.
zone N/mm2. Assuming the coefficient of friction
between chip and cutter to be 0.7 and using Lee
And derive and Shaffer relation,
relation plot variation of resultant
π torque and cutter rotation, and estimate average
φ= +α − β power consumption.i
4
Page 14 of 203 116
Rev.0 117
Page 15
The force relations (VIMP) IES‐2003 IES ‐ 2014

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

(a) (b) 969.6 N (c) 620 N
(d) 680 N
( ) 479.4 N
(c) (d) 6 6N
69.6
Fs = Fc cos φ − Ft sin φ
F
and μ = = tan β 118 119 120
N
IES‐2000 IES‐2018
GATE‐2016 While turning a 60 mm diameter bar, it was
In an orthogonal cutting test, the cutting force and
In an orthogonal cutting process the tool used has rake observed that the tangential cutting force was
thrust force were observed to be 1000N and 500 N 3000 N and the feed force was 1200 N. If the tool
angle
g of zero degree.
g The measured cutting
g force and
respectively. If the rake angle of tool is zero, the rake
k anglel is 32°, then
h theh coefficient
ff off friction
f is
thrust force are 500 N and 250 N, respectively. The
coefficient of friction in chip‐tool
chip tool interface will
ill be nearly (may take sin32
sin32° = 0.53, cos32
cos32° = 0.85 and
coefficient of friction between the tool and the chip is tan32° = 0.62)
1 1
(a) 2 ( b) 2 ( c) ( d) 2
________________ (a) 1.37 (b) 1.46 (c) 1.57 (d) 1.68
2
121 122 123
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 anglel andd shear
h f
force, respectively,
ti l are
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 5 5o, 150.21
((a)) 771.565 5 N 435o , 75
((b)) 18.435 751.04
4N
o
(c) 9.218 , 861.64 N o
(d) 23.157 , 686.66 N
For-2019(IES, GATE & PSUs) 124 (c) 1.2 m/s (d) 1.88
Page 15 ofm/s
203 125
Rev.0 126
Page 16
G
GATE – 20 ( ) i k d S2
2011 (PI) Linked S2 IFS 2012
IFS‐2012 GATE‐2006 Common Data Questions(1)
GATE‐2006 Common Data Questions(1)
An orthogonal machining operation is being carried out a o t ogo a ac g ope at o :
In an orthogonal machining operation:
During orthogonal machining of a mild steel specimen
under the following conditions :
with a cutting tool of zero rake angle, the following data Uncut thickness = 0.5 mm
i obtained:
is bt i d depth of cut = 0.1 mm,
Cutting speed = 20 m/min
d Rake angle = 15°
k l
Uncut chipp thickness = 0.25 mm chip thickness = 0.2 mm,
Width of cut = 5 mm
Width of cut 5 mm Chip thickness = 0.7 mm
Chip thickness 0.7 mm
Chip thickness = 0.75 mm width of cut = 5 mm,
Thrust force = 200 N Cutting force = 1200 N
Width off cutt = 2.5 mm rake angle = 10o
Assume Merchant's theory.
Normal force = 95950 N The force components along and normal to the direction
The coefficient of friction at the tool chip interface is
The coefficient of friction at the tool‐chip interface is
of cutting velocity are 500 N and 200 N respectively.
f i l i N d N i l
Thrust force = 475 N (a) 0.23 (b) 0.46
Determine
Th lti t h t
The ultimate shear stress (in N/mm
(i N/ 2) of the work
) f th k ( ) 8
(c) 0.85 (d)
(d) 0.95
(i) The coefficient of friction between the tool and chip.
material is
(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
127 128 129
GATE‐2006
GATE Common Data Questions(2)
2006 Common Data Questions(2)
g g p
In an orthogonal machining operation: GATE‐2006 Common Data Questions(3) GATE‐2018
Uncut thickness = 0.5 mm In an orthogonal machining operation: An
A orthogonal
h l cutting
i operations
i is
i being
b i
C tti
Cutting speed = 20 m/min
d / i Rake angle = 15°
R k l ° Uncut thickness 0 5 mm
Uncut thickness = 0.5 mm carried out in which uncut thickness is 0.010
Cutting speed = 20 m/min Rake angle = 15° mm, cutting speed is 130 m/min, rake angle is
Width of cut = 5 mm
5 Chip thickness = 0.7 mm
p 7
Width of cut = 5 mm Chip thickness = 0.7 mm
15°° and
d width
idth off cutt is
i 6 mm. It is
i observed
b d
Thrust force = 200 N Cutting force = 1200 N
that the chip p thickness is 0.0155 mm,, the
A
Assume Merchant's theory.
M h t' th Thrust force 200 N
Thrust force = 200 N Cutting force 1200 N
Cutting force = 1200 N
cutting force is 60 N and the thrust force is 25
p g gy p
The percentage of total energy dissipated due to Assume Merchant's theory.
N The ratio of friction energy to total energy
N.
friction at the tool‐chip interface is The values of shear angle and shear strain,
respectively are
respectively, are
is______________(correct to two decimal
(a) 30% (b) 42%
places)
(c) 58% (d) 70% (a) 30.3° and 1.98 (b) 30.3° and 4.23
(c) 40.2° and 2.97 (d) 40.2° and 1.65
130 131 132
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 mainly
required by the process.
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.
Page 16 of 203 134
Rev.0 135
Page 17
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 cutting
finish turning tool: turning operation varies between i important
is 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
136 137 138
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
F b= mm The tool has a side cutting edge angle of 60o.
mm.
F
Ft = Fxy = x = y = 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
139 l =πD 140 141
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
Page 17 of 203 143
Rev.0 144
Page 18
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
Ft = x = x = Fx is 0.24
0 24 mm/rev and the depth of cut is 2 mm.mm rotational speed
p = 4
400 rpm,
p , axial feed = 0.4
4 m/min
/
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 90 145 146 147
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
148 149 150
G
GATE‐2003 Common Data Questions(1)
2003 C Q i ( ) GATE‐2003
GATE Common Data Questions(2)
2003 Common Data Questions(2)
A cylinder is turned on a lathe with orthogonal machining GATE‐2008 Common Data Question (1)
A cylinder is turned on a lathe with orthogonal machining principle. Spindle rotates at 200 rpm. The axial feed rate Orthogonal turning is performed on a cylindrical work
principle Spindle rotates at 200 rpm.
principle. rpm The axial feed rate is 0.255 mm p per revolution. Depth
p of cut is 0.4 4 mm. The piece with shear strength of 250 MPa.
MPa The following
is 0.25 mm per revolution. Depth of cut is 0.4 mm. The rake angle is 10°. In the analysis it is found that the shear conditions are used: cutting velocity is 180 m/min. feed
rake angle is 10
10°. In the analysis it is found that the shear angle is 27.75
27.75° is 0.20
0 20 mm/rev.
mm/rev depth of cut is 3 mm.mm chip thickness
angle is 27.75° In the above problem, the coefficient of friction at ratio = 0.5. The orthogonal rake angle is 7o. Apply
The thickness of the produced chip is the chip tool interface obtained using Earnest and
h hi l i f b i d i E d M h ' theory
Merchant's h f analysis.
for l i
Merchant theory is p g ( g )
The shear plane angle (in degree) and the shear
(a) 0 511 mm
(a) 0.511 mm (b) 0 528 mm
(b) 0.528 mm
(a) 0.18 (b) 0.36 force respectively are
(c) 0.818 mm (d) 0.846 mm
(c) 0 71
(c) 0.71 (d) 0 98
(d) 0.98 (a) 52: 320 N (b) 52: 400N
(c) 28: 400N (d) 28:320N

Page 18 of 203 152
Rev.0 153
Page 19
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
154 155 156
GATE‐2013 IES 2016

IES‐2016 Turning
A 125 mm long, 10 mm diameter stainless steel rod is
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
(a ) 2200 mm3 / min (b) 2400 mm3 / min
(c) 2600 mm3 / min (d) 2800 mm3 / min
157 158 159
Power Consumed During Cutting GATE‐2018 (PI) Specific Energy Consumption

During orthogonal machining of a job at a cutting
Power (W ) Fc
speed of 90 m/min with a tool of 10° rake angle, e= =
the cutting force and thrust force are 750 N and
( )
MRR mm / s 1000 fd
3
c 390 N, respectively. Assume a shear angle of 35°.

The power (in W) expended for shearing along
Where
Fc = cutting force (in N) the
h shear
h plane
l is ______ Sometimes it is also known as specific power
πDN
V tti
V = cutting speed = , m/s
d / consumption.
consumption
60
Page 19 of 203 161
Rev.0 162
Page 20
GATE(PI)‐1991 GATE‐2007 GATE‐2016 (PI)

Amount of energy consumption per unit volume of In orthogonal turning of medium carbon steel. The A cylindrical bar of 100 mm diameter is orthogonally
specific machining energy is 2.0 J/mm3. The cutting
metal removal is maximum in velocity, feed and depth of cut are 120 m/min, 0.2 straight turned with cutting velocity, feed and depth of
mm/rev and 2 mm respectively.
respectively The main cutting cut of 120 m/min, 0.25 mm/rev and 4 mm, respectively.
(a) Turning (b) Milling
force in N is
(c) Reaming (d) Grinding (a) 40 (b) 80 The specific cutting energy
energ of the work 103
ork material is 11×10
(c) 400 (d) 800 J/m3. Neglect the contribution of feed force towards
cutting
gppower. The main or tangential
g cutting
g force (in
N) is ________.
163 164 165
GATE‐2013 (PI) Common Data Question GATE‐2014
A disc
di off 200 mm outer and d 80
8 mm inner
i diameter
di is
i Specific Cutting Pressure
Specific Cutting Pressure The
Th main i cutting
i force
f acting
i on a tooll during
d i the
h
faced of 0.1 mm/rev with a depth of cut of 1 mm. The The cutting force, Fc, divided by the cross section turning (orthogonal cutting) operation of a metal is
facing operation is undertaken at a constant cutting area of the undeformed chip gives the nominal 400 N. The turning was performed using 2 mm
speed
p of 990 m/min
/ in a CNC lathe. The main cutting stress or the specific cutting pressure,
pressure pc depth
p of cut and 0.1 mm/rev/ feed rate. The specific
p
(tangential) cutting force is 200 N. cutting pressure is
Neglecting the contribution of the feed force Fc Fc (a) 1000
towards cutting power, the specific cutting energy
in J/mm3 is
pc = = (b) 2000
(a) 0.2 (b) 2 (c) 200 (d) 2000
bt fd
(c) 3000
(d) 4000
166 167 168
Friction in Metal Cutting
l GATE 1992 GATE‐1993
The effect of rake angle on the mean friction angle in The effect of rake angle on the mean friction angle in
machining can be explained by machining can be explained by
(A) sliding (Coulomb) model of friction (a) Sliding (coulomb) model of friction
(B) sticking and then sliding model of friction (b) sticking and then siding model of friction
((C)) sticking
g friction (c) Sticking friction
(D) Sliding and then sticking model of friction (d) sliding and then sticking model of friction

Page 20 of 203 170
Rev.0 171
Page 21
IES‐2000
Assertion (A): In metal cutting, the normal H Di ib i i M l C i
Heat Distribution in Metal Cutting
IES‐2004
laws of sliding friction are not applicable.
applicable Assertion
A i (A):
(A) The
Th ratio i off uncut chip
hi thickness
hi k to actuall
Reason (R): Very high g temperature is chip thickness is always less than one and is termed as
produced at the tool‐chip interface. cutting ratio in orthogonal
h l cutting
Reason ((R): ) The frictional force is veryy high
g due to the
( ) Both
i di id ll true
t and
d R is
i occurrence of sticking friction rather than sliding
p
the correct explanation of A friction
(b) Both A and R are individually true but R is (a) Both A and R are individually true and R is the correct
not the
h correct explanation
l i off A explanation of A
(c) A is true but R is false correct explanation
l i off A
(d) A is false but R is true (c) A is true but R is false
172 173 174
IES‐2002 IES‐1998 IAS – 2003

As the cutting speed increases
A h i d i
In a machining process, the percentage of In metal cutting operation, the approximate
heat carried away by the chips is typically ratio of heat distributed among chip,
chip tool ((a)) More heat is transmitted to the work piece and less
p
heat is transmitted to the tool
((a)) 55% ((b)) 25%
5 and work, in that order is
(b) More heat is carried away by the chip and less heat is
(c) 50% (d) 75% (a) 80: 10: 10 (b) 33: 33: 33 transmitted to the tool
( ) 20: 60: 10 (d) 10: 10: 80
(c) (c) More heat is transmitted to both the chip and the
too
tool
(d) More heat is transmitted to both the work piece and
th t l
the tool
175 176 177
For IES Only
Determination of cutting heat & temperature
E
Experimentally
i t ll
Mean Temperature in Turning HEAT
IAS – 2003
The
Th heat
h generated d in
i metall cutting
i can conveniently
i l
y Calorimetric method
be determined by
Mean temperature ∞ V f a b
TEMPERATURE
(a) Installing thermocouple on the job
y Decolourising
g agent
g
(b) Installing thermocouple on the tool
y Tool‐work thermocouple
Tool Material a b (c) Calorimetric set‐up
y Moving thermocouple technique
M i h l h i
HSS 0.5 0.375 (d) Using radiation pyrometer
y Embedded thermocouple technique
p q
Carbide 0.2 0.125
y Using compound tool
y Indirectly from Hardness and structural transformation
di l f d d l f i
y Photo‐cell technique
q
y Infra ray detection method
Page 21 of 203 179
Rev.0 180
Page 22
IES 2011 IES‐1993
Dynamometer The instrument or device used to measure the A 'Dynamometer' is a device used for the
y Dynamometers are used for measuring Cutting forces.
forces cutting forces in machining is
measurement of
y For Orthogonal Cutting use 2D dynamometer ((a)) Tachometer
( ) Chip
(a) Chi thickness
thi k ratio
ti
(b) Comparator
y For Oblique
q Cutting
g use 33D dynamometer
y
(b) Forces during metal cutting
(c) Dynamometer
(d) Lactometer
L (c) Wear of the cutting tool
(d) Deflection
e ec o o of thee cu
cutting
g tool
oo
181 182 183
IES‐1996 Types of Dynamometers Strain Gauge Dynamometers

Which of the following forces are measured directly by Strain
S i gauge type The
Th strain,
i ε induced
i d d by b the
h force
f changes
h the
h electrical
l i l
strain gauges or force dynamometers during metal Or resistance, R, of the strain gauges which are firmly
cutting ? pasted on the surface of the tool‐holding beam as
piezoelectric type
1. Force exerted byy the tool on the chip p acting
g normallyy to ΔR
ΔR
the tool face. = Gε
2. Horizontal cutting g force exerted byy the tool on the work R
piece. 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
3. Frictional resistance of the tool against the chip flow accurate and consistent, whereas, the piezoelectric type gauges)
acting along the tool face. are highly accurate, reliable and consistent but very
The change in resistance of the gauges connected in a
4 Vertical force which helps in holding the tool in
4. expensive
p for 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
position. construction.
a strain measuring bridge (SMB)
(a) 1 and 3 (b) 2 and 4
(c) 1 and 4 (d) 2 and 3 184 185 186
IES‐1998 IES‐2018 IAS‐2001

Assertion
A ti (A):
(A) Piezoelectric
Pi l t i transducers
t d and
d preferred
f d
The gauge factor of a resistive pick‐up of For a strain gauge (gauge factor = 2.1 and over strain gauge transducers in the dynamometers for
cutting force dynamometer is defined as the resistance
i = 50 Ω),
Ω) subjected
bj d to a maximum
i measurement of three‐dimensional
three dimensional cutting forces.
forces
ratio of Reason (R): In electric transducers there is a significant
strain of 0.001, the maximum change in leakage of signal from one axis to the other,
other such cross
(a) Applied strain to the resistance of the wire resistance is error is negligible in the case of piezoelectric
transducers.
transducers
(b) The
h proportionall change
h in resistance to the
h (a) 0.084 Ω (b) 0.105 Ω (a) Both A and R are individually true and R is the correct
applied strain explanation of A
(c) 0.135 Ω (d) 0.156 Ω
(c) The resistance to the applied strain (b) Both A and R are individually true but R is not the
correctt explanation
l ti off A
(d) Change in resistance to the applied strain (c) A is true but R is false
Page 22 of 203 188
Rev.0 189
Page 23
Tool Failure
For PSU & IES
For PSU & IES Tool failure is two types
In strain gauge dynamometers the use of how 1 Slow‐death: The gradual or progressive wearing away
1.
of rake face (crater wear) or flank (flank wear) of the
many active gauge makes the dynamometers more , ,
Tool Wear, Tool Life, Economics & cutting tool or both.
both
effective
Machinability 2. Sudden‐death: Failures leading to premature end of
( ) Four
(a) F the tool
h l
(b) Three The sudden‐death type yp of tool failure is difficult to
predict. Tool failure mechanisms include plastic
(c) Two deformation,, brittle fracture,, fatigue
g fracture or edge
g
(d) One chipping. However it is difficult to predict which of these
processes will dominate and when tool failure will occur.
p
By S K Mondal
190 191 192
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
193 194 195
l
Tool Wear IES 2010 IES – 2007, IES‐2016
Flank wear occurs on the Flank wear occurs mainly on which of the following?
( ) Relief face of the tool
(a) (a) Nose part and top face
(b) Rake
R k face
f (b) Cutting edge only
( ) Nose
(c) N off the
th tool
t l ( ) Nose part, front relief face, and side relief face of the
(c)
(d) Cutting edge cutting tool
(d) Face of the cutting tool at a short distance from

the cutting
g edge
g

Page 23 of 203 197
Rev.0 198
Page 24
IES – 1994 Flank Wear: (Wear land) GATE‐2014

Assertion (A): Tool wear is expressed in terms of
A i (A) T l i d i f Cutting
C i tooll is
i much h harder
h d than h the
h work‐piece.
k i
flank wear rather than crater wear.
Reason Yet the tool wears out during the tool‐work
y Abrasion
Ab i b hard
by h d particles
i l and
d inclusions
i l i i the
in h work
k interaction, because
Reason (R): Measurement of flank wear is simple
piece.
and more accurate.
and more accurate (a) extra hardness is imparted to the work
work‐piece
piece due to
y Shearing off the micro welds between tool and work coolant used
material
material.
l f (b) oxide
d layers
l on the
h work‐piece
k surface
f impart extra
y Abrasion by fragments of built‐up‐edge ploughing hardness to it
(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
correct explanation of A (c) extra hardness is imparted to the work‐piece due to
y At low speed
p flank wear p
predominates. severe rate of strain
( ) A is true but R is false
(c) A i t b t R i f l
y If MRR increased flank wear increased. (d) vibration is induced in the machine tool
199 200 201
Flank Wear: (Wear land) Flank Wear: (Wear land)
Effect Stages
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.
y Flank wear is usually the most common determinant of
tool life.
life
202 203 204
Flank Wear: (Wear land) l k ( l d)
Flank Wear: (Wear land) IES – 2004
Consider
C id theh following
f ll i statements:
Primary wear Tertiary wear
During g the third stage g of tool‐wear,, rapid
p
The region
Th i where
h the
h sharp
h cutting
i edge
d is i quickly
i kl broken
b k y The
Th region
i where
h wear progresses at a gradually
d ll
deterioration of tool edge takes place because
down and a finite wear land is established. increasing rate.
1 Flank wear is only marginal
1.
y In the tertiary region the wear of the cutting tool has
Secondary
y wear become sensitive to increased tool temperature due to 2. Flank wear is large
The region where the wear progresses at a uniform rate. high wear land. 3. Temperature of the tool increases gradually
y Re‐grinding
R i di i recommended
is d d before
b f they
h enter this
hi 4. Temperature
T t off the
th tool
t l increases
i d ti ll
drastically
region. Which of the statements g given above are correct?
(a) 1 and 3 (b) 2 and 4
( ) 1 and
(c) d4 (d) 2 and d3
Page 24 of 203 206
Rev.0 207
Page 25
GATE 2008 (PI)

GATE‐2008 (PI) IFS‐2012 Tool life criteria ISO
u g machining,
During ac g, tthee wea a d ((h)) has
wear land as bee
been p otted
plotted
Explain the mechanism of flank wear of a cutting (A certain width of flank wear (VB) is the most common
(A i id h f fl k (VB) i h
against machining time (T) as given in the following
criterion)
figure.
figure tool.
l Plot
l a flank
fl k wear rate curve and
d indicate
d the
h y Uniform wear: 0.3 mm averaged over all past
region of tool failure.
failure y Localized wear: 0.6 mm on any individual past
Localized wear: 0 6 mm on any individual past
[10 Marks]
For a critical wear land of 1.8 mm, the cutting tool life (in
(
minute) is
(a) 52.00 (b) 51.67 (c) 51.50 (d) 50.00 208 209 210
Crater wear Crater wear Contd….. IES – 2002

y More common in ductile materials which produce y Crater depth exhibits linear increase with time. Crater wear on tools always starts at some distance
C l l di
y It increases with MRR.
MRR from the tool tip because at that point
continuous chip.
h (a) Cutting fluid does not penetrate
y Crater
C wear occurs on the
h rake
k face.
f (b) Normal stress on rake face is maximum
(c) Temperature is maximum
y At very high
hi h speed
d crater
t wear predominates
d i t
(d) Tool strength is minimum
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.
211 212 213
IAS – 2007 IES – 2000 IES – 1995

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 Crater wear is predominant in
C i d i i
the tool tip? because ((a)) Carbon steel tools
(a) Tool strength is minimum at that region (a) Cutting fluid cannot penetrate that region (b) Tungsten carbide tools
(b) Cutting fluid cannot penetrate that region (b) Stress on rake face is maximum at that region ( ) High speed steel tools
(c) Hi h d l l
(c) Tool temperature is maximum in that region (c) Tool strength is minimum at that region ((d)) Ceramic tools
(d) Stress on rake face is maximum at that region (d) Tool temperature is maximum at that region

Page 25 of 203 215
Rev.0 216
Page 26
IES 2009 Conventional Wear Mechanism IAS – 2002

Show crater wear and flank wear on a single point Consider
C id the h following
f ll i actions:i
1. Abrasion wear
cutting tool State the factors responsible for wear
cutting tool. State the factors responsible for wear 1. Mechanical abrasion 2. Diffusion
on a turning tool. 3. Plastic deformation 4. Oxidation
2. Adhesion wear
[
[ 2 –marks]
k ] Whi h off the
Which h above
b are the
h causes off tooll wear??
3 Diffusion wear
3. ((a)) 2 and 3 ((b)) 1 and 2
(c) 1, 2 and 4 (d) 1 and 3
4. Chemical or oxidation wear
217 218 219
IES – 1995 IAS – 1999 Why chipping off or fine cracks

Match List I with List II and select the correct
M h Li I i h Li II d l h
answer using the codes given below the lists:
The
Th type off wear that
h occurs due
d to the
h cutting
i
action of the particles in the cutting fluid is
developed at the cutting edge
d l d h d
List I (Wear type) List II (Associated mechanism) referred to as y Tool material is too brittle
A Abrasive wears
A. 1
1. Galvanic action (a) Attritions wear
B. Adhesive wears 2. Ploughing action (b) Diffusion wear y Weak design of tool, such as high positive rake angle
C. Electrolytic wear 3. Molecular transfer (c) Erosive wear
D Diffusion wears
D. Diff i 4. Pl ti d f
Plastic deformation
ti (d) Corrosive wear y As a result of crack that is already in the tool
5. Metallic bond
y Excessive
E i static
i or shock
h k loading
l di off the
h tool.
l
Code: A B C D A B C D
( ) 2
(a) 5 1 3 (b) 5 2 1 3
(c) 2 1 3 4 (d) 5 2 3 4220 221 222
IAS – 2003 Notch Wear IES – 1996

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

Page 26 of 203 224
Rev.0 225
Page 27
List the important properties of cutting tool Why are ceramics normally provided as
materials and explain why each is important.
t i l d l i h hi i t t IES‐2014 Conventional
IES‐2014 Conventional inserts for tools, and not as entire tools?
i f l d i l?
y Hardness at high temperatures ‐ this provides longer y Describe the characteristics of tool materials.
Ceramics are brittle materials and has low toughness
C i b i l i l d h l h
life of the cutting tool and allows higher cutting speeds. [4‐marks] cannot provide the structural strength required for a
y Toughness ‐ to provide the structural strength needed tool.
to resist impacts and cutting forces
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
226 227 228
IES 2015
IES‐2015 Tool Life Criteria IES – 1992
g statements are be correct for
Which of the following
Tool life criteria can be defined as a predetermined Tool life is generally specified by
T l lif i ll ifi d b
temperature rise in metal cutting operation? ((a)) Number of pieces machined
p
numerical value of any type of tool deterioration which
1. It adversely affects the properties of tool material can be measured. (b) Volume of metal removed
( ) Actual cutting time
(c) A l i i
2. It provides better accuracy during machining Some of the ways
((d)) Any of the above
y
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.

229 230 231
IAS – 2012 Main Taylor’s Tool Life Equation Values of Exponent ‘n’

Define “tool life” and list down four methods for Based on Flank Wear n = 0.08 to 0.2 for HSS tool
quantitative measurement off tooll life.
lf Causes
y Sliding of the tool along the machined surface
= 0.1 to 0.15 for Cast Alloys
[M k ]
[Marks ‐12] y Temperature rise = 0.2 to 0.4 for
f carbide
bid tooll
VT n = C [IAS‐1999; IES‐
[IAS 1999; IES
2006]]
Where, V = cutting speed (m/min) = 0.5 to 0.7 for ceramic tool
T Time (min)
T = Time (min)
n = exponent depends on tool material [NTPC‐2003]
C = constant based on tool and work material and cutting
For-2019(IES, GATE & PSUs) 232 condition. Page 27 of 203 233 Reference: Kalpakjian Rev.0 234
Page 28
IES ‐ 2012 IES – 2008 IES – 2006

I T l ’ l lif i VTn
In Taylor’s tool life equation VT = C, the constants n
C h I T l ' l lif i i VTn
In Taylor's tool life equation is VT= constant.
Which
Whi h off the h following
f ll i values
l off index
i d n isi
and C depend upon What is the value of n for ceramic tools? associated with carbide tools when Taylor's tool life
1. Work piece material (a) 0.15 to 0.25 (b) 0.4 to 0.55 equation, V.Tn = constant is applied?
2 Tool material
2. Tool material ( ) 0.6 to 0.75
(c) 6 (d) 0.8 to 0.9
(a) 0∙1 to 0∙15 (b) 0∙2 to 0∙4
3. Coolant (c) 0.45 to 0∙6 (d) 0∙65 to 0∙9
(a) 1, 2, and 3
(b) d l
(b) 1 and 2 only
(c) 2 and 3 only y
(d) 1 and 3 only
235 236 237
IES – 1999 IAS – 1998 IES 2016

IES‐2016
The
Th approximately
i l variation
i i off theh tooll life
lif exponent Match
M t h List
Li t ‐ I (Cutting
(C tti tool
t l material)
t i l) with
ith List
Li t ‐ II In a machining test,
test a cutting speed of 100 m/min
'n' of cemented carbide tools is (Typical value of tool life exponent 'n' in the Taylor's
V Tn = C) and select the correct answer using
equation V.T indicated the tool life as 16 min and a cutting speed
(a) 0.03 to 0.08 (b) 0.08 to 0.20 the codes given below the lists:
of 200 m/min indicated the tool life as 4 min. The
(c) 0.20
0 20 to 0.48
0 48 (d) 0.48
0 48 to 0.70
0 70 List I
List – List II
List –
A. HSS 1. 0.18 values of n and C are
B. Cast alloy 2. 0.12
(a) 0.5 and 200 (b) 0.25 and 200
C. Ceramic 33. 0.255
D. Sintered carbide 4. 0.5 (c) 0.5 and 400 (d) 0.25 and 400
Codes: A B C D A B C D
(a) 1 2 3 4 (b) 2 1 3 4
(c) 2 1 4 3 (d) 1 2 4 3
238 239 240
ISRO‐2011 GATE‐2004, IES‐2000
GATE ‐2009 (PI)
GATE ‐2009 (PI) A 50 mm diameter steel rod was turned at 284 rpm and
In
I a machining
hi i operation,
i doubling
d bli
1
the
h cutting
i
speed reduces the tool life to 8 th of the original
I an orthogonal
In th l machining
hi i operation,
ti th tool
the t l life
lif tool failure occurred in 10 minutes. The speed was value. The exponent n in Taylor's tool life equation
obtained is 10 min at a cutting speed of 100 m/min,
m/min VTn = C,, is
changed
h d to 232 rpm and
d the
h tooll failed
f il d in
i 60
6 minutes.
i
1 1 1 1
while at 75 m/min cutting
g speed,
p the tool life is 330 Assuming straight line relationship between cutting (a) (b) (c ) (d )
8 4 3 2
min. The value of index (n) in the Taylor’s tool life speed
p and tool life,, the value of Taylorian
y Exponent
p is
equation
(a) 0.21 (b) 0.133 (c) 0.11 (d) 0.233
(a) 0.262 (b) 0.323 (c) 0.423 (d) 0.521

Page 28 of 203 242
Rev.0 243
Page 29
IES – 1999, ISRO‐2013 GATE 2016

GATE‐2016 IAS – 1995
In a single point turning operation with cemented carbide
In a single‐point turning operation of steel with a In a single point turning operation with a cemented
tool and steel work piece, it is found that the Taylor’s
cemented
d carbide
b d tool,
l Taylor's
l ' tooll life
l f exponent is carbide
bid and
d steel
t l combination
bi ti h i
having a Taylor
T l
exponent is 0.25. If the cutting speed is reduced by 50% then
0 25 If the cutting speed is halved,
0.25. halved the tool life will exponent of 0.25, if the cutting speed is halved, then
the tool life changes by ______ times.
increase by the tool life will become
(a) Half
((a)) Two times ((b)) Four times
(b) Two times
((c)) Eight
g times ((d)) Sixteen times
(c) Eight times
(d) Sixteen times
244 245 246
GATE-2015 IAS – 2002 GATE‐2018

Under certain cutting conditions, doubling the Using the Taylor equation VTn = c, calculate the Using the Taylor's tool life equation with
cutting speed reduces the tool life to 1/16th of the percentage increase in tooll life
l f when
h the
h cutting exponent n = 0.5, if the cutting speed is
original. Taylor’s tool life index (n) for this tool‐ speed is reduced by 50% (n = 0∙5
0 5 and c = 400)
reduced by 50%, the ratio of new tool life to
workpiece
orkpiece combination will
ill be _______ (a) 300% (b) 400%
original tool life is
(c) 100% (d) 50%
(a) 4 (b) 2 (c) 1 (d) 0.5
247 248 249
IES‐2015 IES‐2013 IAS – 1997

If n = 0.5 and C= 300 for the cutting speed and the A carbide tool(having n = 0.25) with a mild steel In the Taylor's tool life equation, VTn = C, the value
tool life relation, when cutting speed is reduced 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
b 25%
by % , if 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
(d) 100
Page 29 of 203 251
Rev.0 252
Page 30
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%
253 254 255
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
256 257 258
GATE 2017
GATE‐2017 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
Two cutting tools with tool life equations given
cutting test:
below are being compared: components while working at 50 rpm with a tool
Tool 1: VT0.1 = 150 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 2: VT0.3
0 3 = 300
Tool life, min 2.94 3.90 4.77 9.87 28.27 similar batch of 10 tools of the same specification
Where V is cutting speed in m/minute and T is could
ld produce
d 122 components
t while
hil working
ki att 80
8
tool life in minutes. The breakeven cutting speed Determine the constants of the Taylor tool life equation
b
beyond d which
hi h Tool
T l 2 will
ill have
h a higher
hi h tool
t l life
lif is
i VTn = C
C rpm with a feed of 0.25
0 25 mm/rev and 1 mm depth of
____ m/minute. cut. How many
y components
p can be p
produced with
one cutting tool at 60 rpm?

Page 30 of 203 260 (a) 29 (b) 31 (c) 37 (d) 42
Rev.0 261
Page 31
GATE‐2018 GATE‐2017 GATE‐1999

Taylor's
T l ' tooll life
lif equation
i is
i usedd to estimate
i During
D i the h turningi off a 20 mm‐diameter
di steell bar
b What is approximate percentage change is the life, t,
the life of a batch of identical HSS twist drills at a spindle speed of 400 rpm, a tool life of 20
off a tooll with
h zero rake
k angle
l used
d in orthogonal
h l
by drilling through holes at constant feed in minute is obtained.
20 mm thick
thi k mildild steel
t l plates.
l t In I test
t t 1, a drill
d ill cutting when its clearance angle,
angle α,
α is changed from
When the same bar is turned at 200 rpm, the tool
lasted 3300 holes at 150 5 rpm
p while in test 2,, life becomes 60 minute. Assume that Taylor
Taylor’ss tool 10o to 7o?
another drill lasted 200 holes at 300 rpm. The life equation is valid.
((Hint: Flank wear rate is p
proportional
p to cot α))
maximum number of holes that can be made When the bar is turned at 300 rpm, the tool life
by another drill from the above batch at 200 (in minute) is approximately ((a)) 330 % increase ((b)) 330%, decrease
rpm is_________(correct to two decimal
places).
places) (a) 25 (b) 32 (c) 40 (d) 50 (c) 70% increase (d) 70% decrease
262 263 264
Extended or Modified Taylor’s equation IES 2010 ISRO 2012

ISRO‐2012
What is the correct sequence q g
of the following
Tool life is affected mainly with parameters in order of their maximum to minimum
influence on tool life?
( ) Feed
(a)
1. Feed rate
(b) Depth
D h off cut 2. Depth of cut
( ) Coolant
(c) C l t 3. Cutting speed
Select the correct answer using the codes given below
(d) Cutting speed (a) 1, 2, 3 (b) 3, 2, 1 (c) 2, 3, 1 (d) 3, 1, 2
i.e Cutting speed has the greater effect followed by feed
g p g y
and depth of cut respectively.
265 266 267
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 31 of 203 269
Rev.0 270
Page 32
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
271 272 273
GATE‐2017 (PI)
( ) IES 2016 Conventional
In a machining operation with turning tool, the
Write the generalized Taylor's tool life
Tool Life Curve
l f
tool life (T) is related to cutting speed V (m/s),
(m/s)
feed f(mm) and depth of cut d (mm) as equation. Also write the simplified Taylor's
−2.5
2 5 −0.9
0 9 −0.15
0 15 tool life equation.
equation
T = Cv f d During g machining g of low carbon steel with
Where, C is
Wh i a constant.
t t The
Th suggested t d values
l f
for
HSS tool, the following observations have
the cutting gp parameters are: V = 1.55 m/s,, f = 0.255
been made:
mm and d = 3 mm for normal rough turning. If Cutting speed, m/min 40 50
the operation is performed at twice the cutting Tool Life min
Tool Life, min 40 10
speed and the other parameters remain
unchanged, the corresponding percentage change Derive the V‐T relationship.
in tool life is_____________.
is
1. HSS 2. Carbide 3. Ceramic
274 275 276
IES 2010 Conventional IES 2010
IFS 2009
IFS 2009 Draw tool life curves for cast alloy, High speed steel and
D l lif f ll Hi h d l d The above figure shows a typical
ceramic tools. [2 – Marks] relationship between tool life and
With the
th help
h l off Taylor’s
T l ’ tool
t l life
lif equation,
ti cutting speed for different
materials. Match the graphs for
determine the shape of the curve between velocity Ans.
Ans HSS Carbide
HSS, C bid and d Ceramic
C i tooll
of cutting
g and life of the tool. Assume an HSS tool materials and select the correct
answer usingi th code
the d given
i
and steel as work material. below the lists:
C d HSS
Code: SS Carbide
C bid C
Ceramici
[10‐Marks] (a) 1 2 3
(b) 3 2 1
(c) 1 3 2
1. High speed steel 2. cast alloy and 3. ceramic tools. (d) 3 1 2
Page 32 of 203 278
Rev.0 279
Page 33
IAS – 2003 Cutting speed used for different

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
the figure and they follow the tool life equation VTn = C.
Write Taylor
Taylor'ss tool
tool‐life
life equation.
tool materials
Consider the following statements:
d h f ll
1. Value of n for both the tools is same. Draw tool‐life curves for a variety
y of cutting
g HSS (min) 30 m/min < Cast alloyy < Carbide
2. Value of C for both the tools is same. tool materials like ceramic, high speed steel,
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 < Cemented carbide 150 m/min < Cermets
4. Value of C for tool B will be greater than that for the tool A. < Ceramics or sintered oxide (max) 600 m/min
Which of these statements is/are correct?
Whi h f th t t t i / t?
(a) 1 and 3 (b) 1 and 4
(c) 2 only (d) 4 only
280 281 282
For IES Only
Effect of Rake angle on tool life Effect of Clearance angle on tool life
Tool life Tests
Tool life Tests
If clearance angle increased it reduces flank wear but
edge so best compromise is 80 for
weaken the cutting edge, y Conventional test: Using empirical formula
g p
0
HSS and 5 for carbide tool. y Accelerated test: Estimate the tool life quickly
Extrapolating of steady wear rate
E t l ti f t d t
Effect of work piece on tool life High speed test‐will take less time
y With hard micro‐constituents in the matrix gives poor Variable speed test
tool life. Multi pass turning
y With larger grain size tool life is better. Taper turning
283 284
Refer: B.L Juneja+Nitin Seth 285
IES ‐ 2014 Chip Equivalent • The SCEA alters the length of the engaged cutting
In
I accelerated
l d tooll life
lif tests, the
h three
h main
i types off Engaged cutting edge length edge without affecting the area of cut. As a result, the
quick and less costly tool life testing are ChipEquivalent(q) =
Plan area of cut chip equivalent changed. When the SCEA is increased,
(a) Extrapolation on the basis of steady wear;
conventional measurement of flank and crater wear; y It
I is
i used
d for
f controlling
lli the
h tooll temperature. the
h chip
h equivalent
l is increased,
d without
h significantly
f l
comparative performance against tool chipping
(b) Measurement off abrasive
b wear; multi
l –pass turning; changing
h i the
th cutting
tti forces.
f
conventional measurement of diffusion wear
• Increase
I i nose radius
in di also
l increases
i th value
the l off the
th
(c) Extrapolating on the basis of steady wear, multi‐pass
turning; taper turning chip equivalent and improve tool life.
life
(d) comparative performance against tool chipping;
taper turning; measurement of abrasive wear
Page 33 of 203 287
Rev.0 288
Page 34
IES‐1996 E i f t l tti
Economics of metal cutting
Chip
Chi equivalent
i l is
i increased
i d byb
(a) An increases in side‐cutting edge angle of tool
(b) An increase in nose radius and side cutting g
edge angle of tool
( ) Increasing
(c) I i the
th plant
l t area off cutt
(d) Increasing the depth of cut.
cut
289 290 291
l
Formula IES 2009 Conventional
g g
Units:Tc – min (Tool changing time)
Vo To = C
n
Ct – Rs./ servicing or replacement (Tooling
Determine
D i the
h optimumi cutting
i speed
d for
f
operation on a Lathe machine using the following
an
cost)
Optimum tool lifefor minimum cost information:
Cm – Rs/min (Machining cost)
⎛ C ⎞⎛ 1−1 n⎞ Tool change time: 3 min
To = ⎜⎜ Tc + t ⎟⎟⎜ V – m/min (Cutting speed)
⎟ Tool regrinds time: 3 min
⎝ C m ⎠⎝ n ⎠
Machine running cost Rs.0.50 per min
Optimum tool lifefor Maximum Productivity Tooling cost (Ct) = tool regrind cost
Depreciation of tool regrinds Rs.
Rs 5.0
50
+ tool depreciation per service/ replacement
(minimum production time) The constants in the tool life equation are 60 and
Machining cost (Cm) = labour
) labour cost + over head cost per 0.2
⎛ 1− n ⎞ min
To = Tc ⎜ ⎟
⎝ n ⎠
292 293 294
GATE‐2014 ESE‐2001 Conventional
If the Taylor’s tool life exponent n is 0.2, and the In a certain machining operation with a cutting
IAS –
IAS – 2011 Main
2011 Main
Determine the optimum
p speed
p for achievingg
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 maximum production rate in a machining
min) for maximum production rate is ………………. observed When the cutting speed was increased to
observed. p
operation. The data is as follows :
Machining time/job = 6 min.
100 m/min, the tool life decreased to 10 min. T l life
Tool lif = 90 min.
i
Estimate the cutting speed for maximum Taylor's equation constants C = 100, n = 0.5
Job handling time = 4 min./job
productivity if tool change time is 2 minutes.
Tool changing time = 9 min.
min
[10‐Marks]

Page 34 of 203 296
Rev.0 297
Page 35
Example
p Answer Answer(Contd….)
( )
A 600 mm long job of diameter 150 mm is turned with feed Tool change time (Tc ) = 2 min π DL π × 150 × 600
Machining time (Tm ) = = = 5.669min
0.255 mm/rev
/ p of cut 1.55 mm.
and depth Tool grinding cost = 5 x (15 + 50)/60 = Rs.
Rs 5.417/edge
5 417/edge 1000 fV 1000 × 0.25 × 199.5
Data: Labour cost = Rs. 12.00/hr. Initial setuptime for a batch (ti )
Tool will be used 10 times (Because first grinding not Total time (Ttotal ) = Idle time (to ) +
Machine overhead cost = Rs.Rs 40.00/hr.
40 00/hr needed
d d 9 regrinding
i di needed)
d d) Number of parts produced per batch ( p )
Grinding cost = Rs. 15.00/hr. 60 + 5.417 × 9
Tooling cost (Ct ) = = Rs.10.875 / use of tool Machining time (Tm )
+ Machining time (Tm ) + Tool change time (Tc ) ×
G i di machine
Grinding hi overhead
h d = Rs.
R 50/hr.
/h 10 Optimum tool life (To )
Idle time = 5 min Machining cost (Cm ) = Labour cost +Overhead cost per min
5.669
= 5 + 0 + 5.669
5 669 + 2 × = 10.89
10 89min
min
Tool life constants are 0.22 and 475 = (12+40)/60 = Rs. 0.8667/min 51.58
For tool: Initial cost = Rs. 60.00 ⎛ C ⎞⎛1 − n ⎞ ⎛ t ⎞ T
O ti
Optimum life (To ) = ⎜ Tc + t ⎟ ⎜
ttooll lif ⎟ C t off O
Cost ti = Cm ⎜ to + i + Tm ⎟ + (Ct + Tc × Cm ) × m
Operation
Grinding time is 5 min/edge ⎝ C m ⎠⎝ n ⎠ ⎝ p ⎠ To
5 667
5.667
Tool change time 2 min ⎛
= ⎜2 +
10 875 ⎞ ⎛ 1 − 0
10.875 0.22
22 ⎞
= 51.58 min = 0.8667 × ( 5 + 0 + 5.667 ) + (10.875 + 2 × 0.8667 ) ×
9 grinds per tool before salvage. ⎝ 0.8667 ⎟⎠ ⎜⎝ 0.22 ⎟⎠ 51.58
= Rs.10.63 per piece
Fi d minimum
Find i i production
d i cost C 475
Optimum Speed (Vo ) = n = = 199.5m/min
298 To 51.580.22 299 300
GATE‐2016 GATE‐2005 IAS – 2007 Contd…

A diagram
di related
l t d to
t machininghi i economics
i withith
For a certain job, the cost of metal cutting is Rs.
various cost components is given above. Match List I
18C/V and
d the
h cost off tooling
l is Rs. 270C/(TV),
( ) where
h (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
C is a constant,
constant V is cutting speed in m/min and T is th Lists:
the Li t
the tool life in minutes. The Taylor
Taylor’ss tool life List I List II
(Cost Element) (Appropriate Curve)
equation is VT0.25 = 150. The cutting speed (in A Machining cost
A. 1
1. Curve‐l
m/min)) for the minimum total cost is ________ B. Tool cost 2. Curve‐2
C. Tool grinding cost
l d 3. Curve‐3
D. Non‐productive cost
p 4.
4 Curve‐4
4
301 302
5. Curve‐5 303
C d
Contd………. F
From previous
i slide
lid
IES 2011 Minimum Cost Vs Production Rate
The optimum cutting speed is one which should
have:
1. High metal removal rate
2. High
Hi h cutting
i tooll life
lif
33. Balance the metal removal rate and cutting
g
tool life
(a) 1,
1 2 and 3
Code:A B C D A B C D (b) 1 and 2 only
( ) 3
(a) 2 4 5 ((b)) 4 1 3 2 (c) 2 and 3 only
(c) 3 1 4 2 (d) 4 2 3 5 (d) 3 onlyl
Page 35 of 203 305 Vmax.production > Vmax.profit > Vmin. cost
Rev.0 306
Page 36
IES – 1999 IES – 1998 IAS – 2002

Consider
f ll i approaches h normally ll applied
li d The
Th variable
i bl cost and
d production
d i rate off a machining
hi i Optimum
O i cutting
i speed
d for
f minimum
i i cost (Vc min )
for the economic analysis of machining: process against cutting speed are shown in the given and optimum cutting speed for maximum
1. Maximum production rate figure. For efficient machining, the range of best production rate (Vr max ) have which one of the
2 Maximum profit criterion
2. cutting g speed
p would be between following g relationships?
p
3. Minimum cost criterion (a) 1 and 3 (a) Vc min = Vr max (b) Vc min > Vr max
The correct sequence in ascending order of optimum (b) 1 andd5 ( ) Vc min < Vr max
(c) (d) V2c min = Vr max
cutting speed obtained by these approaches is (c) 2 aandd4
(a) 1, 2, 3 (b) 1, 3, 2 (d) 3 and 5
(c) 3, 2, 1 (d) 3, 1, 2
307 308 309
IAS – 1997 IES – 2000 IES – 2004

In
I turning,
i the
h ratioi off the
h optimum
i cutting
i speed
d The
Th magnitude
i d off theh cutting
i speed
d for
f maximum
i Consider
C id the
th following
f ll i statements:
t t t
for minimum cost and optimum cutting speed for profit rate must be 1. As the cutting speed increases, the cost of production
maximum rate of production is always i i i ll reduces,
initially d then
h after
f an optimum
i cutting
i speed
d iti
(a) In between the speeds for minimum cost and increases
(a) Equal to 1 maximum production rate 2. As A the
h cutting
i speed
d increases
i the
h cost off production
d i
(b) In the range of 0.6 to 1 (b) Higher than the speed for maximum production rate also increases and after a critical value it reduces
(c) In the range of 0.1 to 0.6 (c) Below the speed for minimum cost 3. Higher feed rate for the same cutting speed reduces cost
of production
(d) Greater than 1 (d) Equal to the speed for minimum cost
4. Higher feed rate for the same cutting speed increases the
cost of production
Which of the statements given above is/are correct?
((a)) 1 and 3 ((b)) 2 and 3
310 311
(c) 1 and 4 (d) 3 only 312
IES – 2002 IAS – 2007 IES 2010

In
I economics i off machining,
hi i which
hi h one off the
h Assertion
A i (A):
(A) The
Th optimumi cutting
i speed
d for
f theh With increasing
i i cutting
tti velocity,
l it the
th total
t t l time
ti
following costs remains constant? minimum cost of machining may not maximize the for machining g a component
p
(a) Machining cost per piece profit.
(a) Decreases
(b) Tool changing cost per piece Reason (R): The profit also depends on rate of
production. (b) Increases
(c) Tool handling cost per piece
( ) Both
d d ll true and
d R is the
h (c) Remains unaffected
(d) Tool cost per piece
correct explanation of A ((d)) First decreases and then increases
Page 36 of 203 314
Rev.0 315
Page 37 For IES Only
Machinability‐Definition Free Cutting steels
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
being machined’ and more reasonably as ‘ease of also in aluminium,
aluminium copper and their alloys help reduce
machining’. 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
of any
y tool‐work p
pair is to be jjudged
g by:
y reducing friction, cutting forces and temperature, tool
wear and d BUE formation.
f i
y Tool wear or tool life
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
316 y Chip forms. 317 318
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 ease
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
319 320 321
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.
Page 37 of 203 323
Rev.0 324
For IES Only Page 38 For IES Only
IES 2011 Conventionall Role of microstructure on Machinability IES – 1992

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.
325 326 327
For IES Only For IES Only
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
328 329 330
Effects of clearance angle on machinability Effects of Nose Radius on machinability IES – 1992

Proper tool nose radiusing improves machinability to Ease of machining is primarily judged by
some extent through
(a) Life of cutting tool between sharpening
y increase in tool life by increasing mechanical strength
and
d reducing
d i temperature at the h tooll tip
i (b) Rigidity of work ‐piece
y reduction of surface roughness,
g , hmax
( ) Microstructure of tool material
(c)
2
f (d) Shape and dimensions of work
Sh d di i f k
Inadequate clearance angle reduces tool life and surface hmax =
finish by tool – work rubbing, and again too large
clearance reduces the tool strength
g and tool life hence
8R
8R
machinability.
Page 38 of 203 332
Rev.0 333
Page 39
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
(d)
(c) 2 and 3 only (d) 2 only 334 335 336
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
337 338
(c) 1 and 2 (d) 3 and 4 339
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.

Page 39 of 203 341
Rev.0 342
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
343 344 345
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 = (c) S2/4R
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.
346 347 348
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

Page 40 of 203 350 (c) 0.32 mm (d) 0.48 mm Rev.0 351
Page 41
GATE‐2018 (PI) GATE ‐ 2005 IES – 1993, ISRO‐2008

A cylindrical
li d i l workpiece
k i is
i turned d at a feed
f d off 0.1 Two
T tools
l P and d Q have
h signatures
i 5°‐5°‐6°‐6°‐8°‐30°‐0
° ° 6° 6° 8° ° For achieving a specific surface finish in single point
mm/rev with a perfectly sharp tool. In ASA 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
system, the side and end cutting edge angles are
machining g conditions. If hp and hQ denote the p peak‐ is
15°° andd 5°,
° respectively,
ti l as shown
h i the
in th figure.
fi to‐valley heights of surfaces produced by the tools P
The p peak‐to‐valleyy roughness
g ((in μ
μm,, upp to one and Q,
Q the ratio hp/hQ will be (a) Depth of cut (b) Cutting speed
decimal place) of the machined surface is ______ o o o o
tan 8 + cot15 tan15 + cot 8 (c) Feed (d) Tool rake angle
(a) (b)
tan 8o + cot 30o tan 30o + cot 8o
tan15o + cot7o tan7o + cot15o
(c ) (d )
352
tan 30o + cot7o tan7o + cot 30o 353 354
IES ‐ 2006 GATE‐2014 (PI)

( ) GATE ‐2010 (PI)
( )
In the selection of optimal cutting conditions, the A spindle
i dl speed d off 300 rpm andd a feed
f d off 0.3 During turning of a low carbon steel bar with TiN coated
mm/revolution are chosen for longitudinal turning carbide insert, one need to improve surface finish
requirement off surface
f f
finish
h would
ld put a limit
l on operation on an engine lathe. In finishing pass,
without sacrificing material removal rate. To achieve
which of the following? roughness
g on the work surface can be reduced by
y
improved surface finish, one should
(a) reducing the spindle speed
(a) The maximum feed (b) increasing the
h spindle
dl speedd (a) decrease nose radius of the cutting tool and increase
(c) reducing
educ g tthee feed
eed o
of too
tool depth of cut
(b) The maximum depth of cut
(d) increasing the feed of tool (b) Increase nose radius of the cutting tool
(c) The maximum speed
(c) Increase feed and decrease nose radius of the cutting
((d)) The maximum number of p
passes tool
355 356 (d) Increase depth of cut and increase feed 357
Cutting fluid
Cutting fluid IAS 2009 Main
IAS ‐2009 Main
GATE‐2017 y The cutting fluid acts primarily as a coolant and
Assume
A that
th t theth surface
f roughness
h profile
fil is
i secondly
dl as a lubricant,
l bi t reducing
d i the th friction
f i ti effects
ff t att y What are extreme pressure lubricants?
What are extreme‐pressure lubricants?
the tool‐chip interface and the work‐blank regions. [ 3 – marks]
g
triangular as shown schematicallyy in the figure.
g If
y Cast Iron: Machined dry or compressed air, Soluble oil Where high
Wh hi h pressures and d rubbing
bbi action
i are
the peak to valley height is 20 μm, the central line encountered, hydrodynamic lubrication cannot be
average surface roughness Ra (in μm) is for high speed machining and grinding maintained;
i i d so Extreme
E P
Pressure (EP) additives
ddi i must be
b
y Brass: Machined dry or straight mineral oil with or added to the lubricant. EP lubrication is provided by a
((a)) 5 ((b)) 6.677 ((c)) 10 ((d)) 20
without
ih EPA
EPA. number
b off chemical
h i l components such h as boron,b
y Aluminium: Machined dry y or kerosene oil mixed with phosphorus, sulfur, chlorine, or combination of these.
mineral oil or soluble oil Th compounds
The d are activated
i d by
b the
h higher
hi h temperature
resulting from extreme pressure. As the temperature
y Stainless steel and Heat resistant alloy: High rises,
i EP molecules
l l b
become reactive
i and d release
l
performance soluble oil or neat oil with high derivatives such as iron chloride or iron sulfide and
concentration
i with i h chlorinated
hl i d EP additive.
ddi i f
forms a solid
lid protective
i coating.
i
Page 41 of 203 359
Rev.0 360
Page 42
IES ‐ 2001 IES ‐ 2012

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
machining ( )
(a) Provide lubrication
(a) Steel (b) Aluminium (b) Cool the tool and work piece
(c) Cast iron (d) Brass ( ) W h
(c) Wash away the chips
h hi
( ) p
(d) Improve surface finish
361 362 363

Page 43
Terminology
Metrology
y The
Th science
i off measurement.
t
y The purpose of this discipline is to establish means

,
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
permissible size for a dimension is called upper or high
According to the ISO system, sketch the basic size, y Basic size: Size of a part to which all limits of
variation ((i.e. tolerances)) are applied.
pp Basic dimension or maximum limit, whereas the smallest size is known
d i ti
deviation, and
d tolerance
t l on a shaft
h ft and
d hole
h l assembly.
bl as lower or minimum limit.
is theoretical dimension.
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-2019(IES, GATE & PSUs) 7 Tolerance
Page 43 of 203 = 0.08 mm 8
Rev.0 9
Page 44
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 44 of 203 17 fit, slack running fit and loose running fit.Rev.0 18
Page 45
Use GATE ‐ 2007 GATE 2015
GATE-2015
y Machine tools spindles
y Pistons of hydraulic machines 0 .0 5 0
A hole is specified as 4 0 mm. The mating
y Piston cylinder in IC engine
0 .0 0 0 +0.040
shaft
h f has
h a clearance
l f with
fit h minimum clearance
l off Holes of diameter 25 mm are assembled
y Inner and outer races of ball, roller and journal bearing +0.020
y Clutch disks
Cl h di k 0 01 mm.
0.01 mm The tolerance on the shaft is 0.04
0 04 mm.
mm The +0.005
interchangeably with the pins of diameter 25 mm.
y Sliding rod maximum clearance in mm between the hole and −0.008
y Crankshaft journals
the shaft is The minimum clearance in the assembly will be
y Bolts
a) 0.048 mm b) 0.015 mm
y Rivets (a) 0.04 (b) 0.05
y Pivots c) 0.005 mm
0 005 mm d) 0.008 mm
0 008 mm
(c) 0.10 (d) 0.11
y Latches
y Fits of parts exposed to corrosive effects 19 20 21
IES‐2015 Transition Fits

A hole and a shaft have a basic size of 25 mm and are to have a IAS 2015 Main
IAS‐2015 Main Hole
clearance fit with a maximum clearance of 0.02 mm and a A 20 mm diameter shaft and bearing g are to be
minimum clearance of 0.01 mm. The hole tolerance is to be 1.5 assembled with a clearance fit. The tolerance and Max C
times the shaft tolerance. The limits of both hole and shaft using Tolerance zones always
hole basis system will be
allowances are as under : overlap
Shaft
a) low limit of hole = 25 mm, high limit of hole = 25.006 mm, Allowance = 0.002 mm Max I
upper limit of shaft = 24.99 mm and low limit of shaft = 24‐

Tolerance on hole = 0.005 mm
986 mm
b) low limit of hole = 25 mm, high limit of hole = 25.026 mm, T l
Tolerance on shaft
h f = 0.003 mm
upper limit of shaft = 24.8 mm and low limit of shaft = 24.76 Find the limits of size for the hole and shaft, if
mm
c) low limit of hole = 24 mm, high limit of hole = 25.006 mm, (i) the hole basis system is used, Max. C = UL of hole - LL of shaft
Max. I = LL of hole - UL of shaft
upper limit of shaft = 25 mm and low limit of shaft = 24.99 mm (ii) the shaft basis system is used.
d) low limit of hole = 25.006 mm, high Ch limit of hole = 25 mm, The transition fits may be tight fit and push fit, wringing
upper limit of shaft = 24.99 mm and low limit of shaft = 25 mm The tolerances are disposed off unilaterally.
unilaterally
fit (Gear, pulley on shaft), press fit.
22
[10 –Marks] 23 24
Interference Fits
IES 2015
IES‐2015 Hole IES 2011
Tolerance zones never meet
Consider the following statements but crosses each other
Max I Interference fit joints are provided for:
In case of assemblyy of mating
gpparts
Shaft Min I (a) Assembling bush bearing in housing
1. The difference between hole size and shaft size is called
allowance. (b) Mounting heavy duty gears on shafts
2. In transition fit, small positive or negative clearance (c) Mounting pulley on shafts
b
between the
h shaft
h f and
d hole
h l member
b isi employable
l bl (d) Assembly of flywheels on shafts
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.
((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
(c) 2 only For-2019(IES,
(d) Neither
GATE1 nor 2
& PSUs) 25 light drive fit. Page 45 of 203 26
Rev.0 27
Page 46
IES ‐ 2014
IES
IES‐2013 GATE ‐ 2005 Statement‐I: In interference fit, the outer diameter
of the inner cylinder will be more than the inner
Which of the following is a joint formed by In order to have interference fit, it is essential that diameter of the hollow outer cylinder
i t f
interference fit ?
fits? the
h lower
l l
limit off the
h shaft
h f should
h ld be
b St t
Statement‐II:
t II These
Th fit are recommended
fits d d for
f two
t
parts frequently dismantled and assembled.
(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 (a) Both Statement (I) and Statement (II) are
individuallyy true and Statement (II) is the correct
(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 explanation of Statement (I)
(c) Joint between a pulley and shaft transmitting power (c) Greater than the lower limit of the hole (b) Both Statement (I) and Statement (II) are
individually true but Statement (II) is not the correct
(d) Joint of lathe spindle and its bearing (d) Lesser than the lower limit of the hole 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
28 29 30
IES‐2017
IES‐2015 Statement (I): In sugarcane crushing rollers, the fit GATE 2011
Statement
S (I) : In
I interference
i f fit,
fi the
h outer diameter
di off between the cast roll and the forged steel shaft is of +0.015
the shaft is greater than the inner diameter of the hole. A hole is of dimension φ 9 +0
mm The
mm.
Statement (II) : The amount of clearance obtained from i t f
interference t
type.
+0.010
the assemblyy of hole and shaft resulting g in interference fit Statement (II): This helps in removing the roll from the
is called positive clearance. corresponding shaft is of dimension φ9 +0.001
mm.
shaft whenever not needed. The resultingg assemblyy has
(a) Both statement (I) and (II) are individually true and
statement (II) is the correct explanation of statement (I) (a) Both statement (I) and (II) are individually true and (a) loose running fit
(b) Both
B th statement
t t t (I) and
d statement(II)
t t t(II) are individually
i di id ll statement (II) is the correct explanation of statement (I)
(b) close
l running
i fit
fi
true but statement(II) is not the correct explanation of (b) Both statement (I) and statement(II) are individually
true but statement(II) is not the correct explanation of (c) transition
a s o fit
statement (I)
()
statement (I) (d) interference fit
(d) Statement (I) is false but statement (II) is true
31 (d) Statement (I) is false but statement (II) is true 32 33
IAS 2011 Main

IAS‐2011 Main GATE‐2018 (PI)
GATE ‐2012 Same Q in GATE‐2012 (PI) An interference assembly,
assembly of nominal diameter 20 mm,mm
In
I a shaft‐hole
h f h l system, the h dimensions
di i with
ih
25+−0.04
is of a unilateral holes and a shafts. The manufacturing
In an interchangeable assembly,
assembly shafts of size tolerances (in mm) are as follows:
0.01 tolerances for the holes are twice that for the shaft.
mm mate with holes of size 25 +0.03

0 03
mm.
Permitted interference values are 0.03 0 03 to 0.09
0 09 mm.
mm Shaft : φ 20+− xx Hole : φ 20−−0.03
y
+0.02 Determine the sizes, with limits, for the two mating
parts. [10‐Marks] where
h b th x and
both d y are positive
iti reall numbers.
b
The maximum interference (in microns) in the assembly Which one of the following g will pprovide an
is
interference fit?
(a) 4
40 ((b)) 330 (c) 20 (d) 10
( ) x = 0.05, y = 0.040 (b) x = 0.04, y = 0.035
(a)
Hint: Use unilateral hole basis system.
(c) x = 0.04,
0 04 y = 0.032
0 032 (d) x = 0.02,
0 02 y = 0.035
0 035
Page 46 of 203 35
Rev.0 36
Page 47
IES ‐ 2007 IES ‐ 2006

ISRO‐2011 Which of the following is an interference fit?
A shaft and hole pair is designated as 50H7d8
A shaft and hole pair is designated as 50H7d8.
(a) Push fit
This assembly constitutes
y
(b) Running fit
(a) Interference fit
( ) Sliding fit
(c)
(b) Transition fit
(d) Shrink
Sh i k fit
fi
(c) Clearance fit
37 38 39
IES ‐ 2009 IES ‐ 2008 IES 2015

IES‐2015
Consider
C id the
h following
f ll i joints:
j i 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
1. Railwayy carriageg wheel and axle g
1. The amount of interference needed to create a tight of stress in the shaft due to interference fit is
2. IC engine cylinder and liner joint varies with diameter of the shaft.
2 An interference fit creates no stress state in the
2. a)) onlyy compressive
p radial stress
Whi h off the
Which h above
b j i
joints i /
is/are the
h result(s)
l ( ) off
interference fit? shaft. b)a tensile radial stress and a compressive tangential stress
(a) 1 only 3. The stress state in the hub is similar to a thick‐ c) a tensile tangential stress and a compressive radial stress
(b) 2 only
l walled
a ed cy
cylinder
de witht internal
te a p pressure.
essu e.
Which of the statements given above are correct? d)a compressive tangential stress and a compressive radial
(c) Neither 1 nor 2
(d) Both 1 and 2 ( ) 1, 2 and
(a) d3 (b) 1 and d 2 only
l stress
(c) 2 and 3 only (d) 1 and 3 only
40 41 42
IES ‐ 2004 Allowance

y It is Minimum clearance or maximum interference. It is
Consider
C id theh following
f ll i fits:
fi IES‐2015 Conventional
IES‐2015 Conventional the intentional difference between the basic
1. I.C. engine
g cylinder
y and p
piston 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
2. Ball bearing outer race and housing positive or negative.
reference to mechanical systems?
3. Ball
B ll bearing
b i inner
i race and
d shaft
h f
Which of the above fits are based on the interference [4 Marks]
system?
( ) 1 and
(a) d2
(b) 2 and 3
(c) 1 and 3
(d) 1, 2 and
d3
Page 47 of 203 44
Rev.0 45
Page 48
GATE ‐ 2001 GATE ‐ 1998 IES ‐ 2012

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

(c) ( ) Allowance is independent of tolerance
(c) ( ) Maximum hole size and maximum shaft size
(c)
hole (d) Allowance
All i equall to the
is h difference
diff b
between (d) Minimum
Mi i h l size
hole i and
d minimum
i i shaft
h f size
i
(d) Difference between maximum and minimum size of maximum and minimum dimension specified by the
shaft tolerance.
46 47 48
Hole Basis System
IES – 2012 Conventional, IAS‐2016 Main ISRO‐2010
Explain the difference between tolerance and Zero Line
+0.02
Dimension of the hole is 50 mm
allowance. −0.00
+0.02
0 02
and shaft is 50 mm.
+0.00
0.00
The minimum clearance is Hole basis system
(a) 0.02 mm (b) 0.00 mm y The hole is kept as a constant member (i.e. when the
lower deviation of the hole is zero))
(c) -0.02
0 02 mm (d) 0.01
0 01 mm
y Different fits are obtained by varying the shaft size then
the limit system is said to be on a hole basis.
basis
49 50 51
Shaft Basis system
y For hole basis system,
y , H stands for dimensions of holes y For shaft basis system,
y , h stands for dimensions of shafts
whose lower deviation is zero. Zero Line whose upper deviation is zero.
y The basic size of the hole is taken as the lower limit of y Basic size of the shaft is taken Upper limit for the shaft (
size of the hole ( Maximum metal condition). Maximum metal condition)
y The higher limit of size of the hole and two limits of size y Lower limit of the shaft and two limits of hole are
for the shaft are then selected to give desired fits. Shaft basis system: selected to give the desired fit.
y When the shaft is kept as a constant member (i.e.
(i e when the
y The actual size of hole is always more than basic size or upper deviation of the shaft is zero) y Actual size of shaft is always less than basic size or equal
equal to basic size
si e but never
ne er less than Basic size.
si e 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.
Page 48 of 203 53
Rev.0 54
For IES Only Page 49
Why Hole Basis Systems are Preferred?
Why Hole Basis Systems are Preferred? IES ‐ 2005
y Holes can be finished by
y tools like reamers,, drills,, ISRO‐2008 Assertion
A i (A):
(A) Hole
H l basis
b i system is i generally ll
broaches, and their sizes are not adjustable. The shaft 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 for getting the required fits.
sizes can be easily obtained by external machining.
deviations and lower deviations respectively are Reason (R): Hole has to be given a larger tolerance
y If shaft basis system is used considerable no of reamers band than the mating shaft.
(a) +ve, ‐ve
ve (b) ‐ve,
ve, +ve
and other precision tools are required for producing ( ) Both
d d ll true andd R is the
h
((c)) Zero,, Zero ((d)) None of the above correct explanation of A
different classes of holes for one class of shaft for
obtaining different fits which increases cost of correct explanation of A
production. (c) A is true but R is false
y It is economical 55 56 57
IFS ‐ 2013 IES ‐ 2005

IAS‐2010 main
IAS‐2010 main Explain, with the help of sketches, the concepts of Which
Whi h one off the h following
f ll i is i not correct in i hole
h l basis
b i
system of fits?
What is the difference between hole basis system 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.
and shaft basis system
y ? Why
y is hole basis system
y specifications Which of the two is preferred and
specifications. (b) The basic size of the hole is taken as the low limit of
the more extensive in use ? size of the hole.
why?
(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.
[8‐Marks] (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
58 59 60
Limits and Fits
y Limits and fits comprises 18 grades of fundamental
µ
µm
Tolerance Zone tolerances for both shaft and hole,, designated g as IT01,,
Tolerance Designation (IS)
IT0 and IT1 to IT16. These are called standard Tolerance on a shaft or a hole can be calculated by using
55 • It is defined graphically tolerances (IS
tolerances. (IS‐919)
919) But ISO 286 specify 20 grades upto table provided.
provided
by the magnitude of the IT18 T = K ×i
Tolerance Zone tolerance and by its y There are 25 (IS 919) and 28 (ISO 286) types of
20 position in relation to the Where, T is the tolerance (in µm)
fundamental deviations.
zero line.
Hole:
l A, A B, C, C CD,
C D, E, EF, F, FG, G G,
G H, J, JS, S K, M, N, P,
Standard Tolerance unit or Fundamental tolerance unit
R, S, T, U, V, X, Y, Z, ZA, ZB, ZC. i = 0.45 3 D + 0.001D in μ m
Basic Size Shaft : a, b, c, cd, d, e, ef, f, fg, g, h, j, js, k, m, n, p, r, s, t,
u, v, x, y, z, za, zb, zc. D = D1D2 (D1 and D2 are the nominal sizes marking
y A unilateral hole basis system is recommended but if the beginning and the end of a range of
necessary a unilateral or bilateral shaft basis system may sizes,, in mm))
K = is a constant [For IT6 to IT16]
also be used.
Page 49 of 203 62
Rev.0
Page 50
Value of the Tolerance Grades of Tolerance
Diameter Steps
Diameter Steps IT01 IT0 IT1 IT2
Above Upto and including 0.3 + 0.008D 0.5 + 0.012D 0.8 + 0.02D ar y It is an indication of the level of accuracy.
(mm)
( ) (mm)
( ) =a r = 101/5
y IT01 to IT4 ‐ For production of gauges, plug gauges,
‐ ‐ 3 IT3
3 IT4 IT5
5 IT6
6
3 ‐ 6 ar2 ar3 ar4 = 7i 10(1.6)(ITn -IT6) measuring instruments
6 ‐
6 10 = 10i
10 ‐ 18 IT7 IT8 IT9 IT10 y IT5 to IT 7 ‐ For fits in precision engineering applications
188 ‐ 30 10(1.6)
( )(ITn -IT6) 10(1.6)
0( 6)(ITn -IT6) 10(1 6)((ITn -IT6))
10(1.6) 10(1 6)(ITn -IT6)
10(1.6) IT6)
30 ‐ 50 = 16i = 25i = 40i = 64i
y IT8 to IT11 – For General Engineering
550 ‐ 80
80 ‐ 120 IT11 IT12 IT13 IT14 y IT12 to IT14 – For Sheet
h metall working
k or press working
k
10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6)
120 ‐ 180
180 ‐ 250 = 100i = 160i = 250i = 400i y IT15
IT to IT16
IT 6 – For
F processes like
lik casting,
i generall cutting
i
250 ‐ 315 IT15 IT16
315 ‐ 400
work
10(1.6)(ITn -IT6) 10(1.6)(ITn -IT6)
400 ‐ 500 64
= 640i = 1000i 65 66
Fundamental Deviation
is chosen to locate the tolerance zone w.r.t. the zero line Shaft Fundamental Deviation
Calculation for Upper and Lower Deviation
a − (265 + 1.3D ) for D ≤ 120 mm
y For Shaft
Holes are designated by capital letter: − 3.5D for D > 120 mm
Letters A to G - oversized holes ei = es – IT
Letters P to ZC - undersized holes b − (140 + 0.85
0 85D ) for D ≤ 160 mm
es = ei + IT −1.8 D for D > 160 mm
y For Hole
F H l c − 52D 0.2 for D ≤ 40 mm
EI = ES – IT
− (95 + 0.8
0 8D ) f D > 40 mm
for
Shafts are designated by small letter: ES = EI + IT
Letters m to zc - oversized shafts d − 16 D 0.44
Letters a to g - undersized shafts
e − 11D 0.41
H is used for holes and h is used for shafts es = upper deviation of shaft
pp
whose fundamental deviation is zero
ei = lower deviation of shaft f − 5.5D 0.41
ES = upper deviation of hole g 2 5D 0.41
− 2.5
67 EI= lower deviation of hole 68 h 0 69
Shaft Fundamental Deviation

j5 to j8 −
k4 to
t k7 + 0.6
0 63 D
m + ( IT 7 − IT 6) y For hole, H stands for a dimension whose lower
n + 5D 0.34
0 34
deviation
d i ti refers
f t the
to th basic
b i size.
i TheTh hole
h l H for
f which
hi h
p + IT 7 + (0 − 5) the lower deviation is zero is called a basic hole.
r Geometric mean of values of
y Similarly, for shafts, h stands for a dimension whose Basic size Hole Tolerance Zone
ei for p and s
upper deviation refers to the basic size. The shaft h for
s IT 8 + 1 to 4 for D ≤ 50 mm Shaft Tolerance Zone
IT 7 + 0.4 D for D > 50 mm
which the upper deviation is zero is called a basic
t IT 7 + 0.63
0 63D
shaft.
u IT 7 + D y A fit is designated by its basic size followed by symbols
v IT 7 + 1.25D representing the limits of each of its two components,
F d
Fundamental Deviation
t l D i ti IT#
x IT 7 + 1.6 D the hole being quoted first.
y IT 7 + 2D
y For example,
example 100 H6/g5 means basic size is 100 mm
z IT 7 + 2.5D
and the tolerance grade for the hole is 6 and for the
za IT 8 + 3.15D
shaft is 5.
5
zb IT 9 + 4 D
For-2019(IES,
zc IT 10 + 5GATE
D & PSUs) 70
Page 50 of 203 71
Rev.0 72
Page 51
GATE 2014
GATE‐2014 IES ‐ 2008 IES‐2006 Conventional
g y 5 g p
For the given assembly: 25 H7/g8, match Group A with
Group B Consider
C id theh following
f ll i statements: Find
Fi d the
h limit
li i sizes,
i tolerances
l and
d allowances
ll for
f a
Group A
p Group B
p A nomenclature φ 550 H8/p8 /p denotes that 100 mm diameter shaft and hole pair designated by
1. Hole diameter is 50 mm. F8h10. Also specify the type of fit that the above pair
P. H I. Shaft Type belongsg to.
2. ItI is
i a shaft
h f base
b system.
Q. IT8 II. Hole Type Given: 100 mm diameter lies in the diameter step
33. 8 indicates fundamental deviation. range of 80‐120
80 120 mm.
mm The fundamental deviation for
R. IT7 III. Hole Tolerance Grade Which of the statements given above is/are incorrect? shaft designation ‘f’ is ‐5.5 D0.41
S
S. g IV Sh ft T l
IV. Shaft Tolerance Grade
G d ( ) 1, 2 and
(a) d3 The values of standard tolerances for grades of IT 8
P Q R S P Q R S (b) 1 and 2 only and IT 10 are 25i and 64i respectively.
(a) I III IV II (b) I IV III II (c) 1 and 3 only Also, indicate the limits and tolerance on a diagram.
( ) 3 only
(d) [ M k ]
[15‐Marks]
(c) II III IV I (d) II IV III I
73 74 75
IES‐2015 Conventional Selected Question IES ‐ 2002

Determine the fundamental deviation and tolerances and the In the tolerance specification 25 D 6, the letter D
A journal of nominal or basic size of 75 mm runs
li it f i f h l d h ft i i th fit
limits of size for hole and shaft pair in the fit: 25 mm H8d9.
H8d represents
The diameter steps are 18 mm and 30 mm. The fundamental
in a bearing with close running fit H8g7. Find the ((a)) Grade of tolerance
deviation for d shaft is given as ‐16D0.44. The tolerance unit is, limits of shaft and bearing also find maximum (b) Upper deviation
i= and minimum clearance? 75 mm lies in the (c) Lower deviation
0 45 3 D + 0
0.45 0.001
001D
The tolerance grade for number 8 quality is 25i and for 9 diameter steps of 50 to 80 mm. Fundamental (d) Type of fit
quality is 40i.
deviation for shaft g is ‐2.5 D0.34
[ M k ]
[10 Marks]
76 77 78
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 μm= 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 For-2019(IES,
limit = 60.000 mm, Upper Limit
GATE & PSUs) = 60.046 mm 79 Page 51 of 203 80
Rev.0 81
Page 52
GATE ‐ 2003 GATE‐2010 (PI) GATE‐2016 (PI)

The dimensional limits on a shaft of 25h7 are A small bore is designated as 25H7. The lower The limits of a shaft designated as 100h5 are 100.000 mm
( ) 25.000, 25.021 mm
(a) (minimum) and upper (maximum) limits of the bore and 100.014 mm. Similarly, the limits of a shaft
(b) 25.000, 24.979 mm 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
(c) 25.000,
25 000 25.007
25 007 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
(d) 25.000, 24.993 mm (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
82 83 84
Recommended Selection of Fits GATE – 1996, IES‐2012 IES ‐ 2000

The fit on a hole‐shaft system is specified as H7‐ Which one of the following tolerances set on inner
s6.The
6 Th type
t off fit is
i di
diameter
t and
d outer
t diameter
di t respectively
ti l off headed
h d d
(a) Clearance fit jig bush for press fit is correct?
(b) Running fit (sliding fit) ((a)) G77 h 6 ((b)) F77 n6
((c)) Push fit ((transition fit)) (c) H 7h 6 (d) F7j6
(d) Force fit (interference fit)
85 86 87
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
Page 52 of 203 89
Rev.0 90
Page 53
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
91 92 i.e. either equally bilateral or equally unilateral. 93
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 L 4 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
94 95 96
GATE – 2007 (PI)
( ) GATE‐2013 GATE ‐ 2017
A cylindrical
li d i l pin
i off mm diameter
di is
i
Diameter of a hole after plating needs to be controlled Cylindrical pins of 25++0.020
0.010 mm diameter are p
electroplated. Plating
g thickness is mm.
between 30++0.050
0.010 mm. If the plating thickness varies electroplated in a shop. Thickness of the Neglecting the gauge tolerance, the diameter (in mm, up
to 3 decimal points accuracy) of the GO ring gauge to
between 10 - 15 microns, diameter of the hole before plating is 30 ±2.0 micron. Neglecting gage inspect the plated pin is_________
plating
l ti should
h ld be
b tolerances, the size of the GO gage in mm
+0.070 +0.065
(a) 30 +0.030 mm (b) 30 +0.020 mm t iinspectt the
to th plated
l t d components
t iis
+0.080 +0.070
(c) 30 +0.030 mm (d) 30 +0.040 mm (a) 25
25.042
042 (b) 25
25.052
052 (c) 25
25.074
074 (d) 25.084
25 084

Page 53 of 203 98
Rev.0 99
Page 54
GATE ‐ 2000 GATE ‐ 2017 Limit Gauges

Limit Gauges
y Plug gauge: used to check the holes.
holes The GO plug gauge is
A slot
l isi to be
b milled
ill d centrally
ll on a block
bl k with
ih a The
Th standard
d d deviation
d i i off linear
li dimensions
di i P the size of the low limit of the hole while the NOT GO plug
dimension of 40 ± 0.05 mm. A milling cutter of 20 and Q are 3 μm and 4 μm, respectively. When gauge corresponds to the high limit of the hole.
hole
mm width is located with reference to the side of assembled, the standard deviation (in μm ) of the y Snap, Gap or Ring gauge: used for gauging the shaft and
the block within ± 0.02 mm. The maximum offset in
mm between the centre lines of the slot and the
resulting
lti linear
li di
dimension
i (P + Q) is_________
i male
l components. The Th Go G snap gauge is i off a size
i
corresponding to the high (maximum) limit of the shaft,
block is while
hil theh NOT GO gauge corresponds d to theh low
l
(a) ± 0.070 (b) 0.070 (minimum limit).
(c) ± 0.020 (d) 0.045
100 101 Fig. Plug gauge Fig. Ring and snap gauges102
Allocation of manufacturing tolerances
ll i f f i l Example
ISRO‐2008 y Unilateral system: gauge tolerance
t l zone lies
li
Size of the hole to be checked 25 ± 0.02 mm
Plug gauges are used to entirely within the work tolerance zone.
y work tolerance zone becomes smaller by the sum of the
H
Here, Hi
Higher
h lilimit
it off hole
h l = 25.02
25 02 mm
(a) Measure the diameter of the workpieces
gauge tolerance.
tolerance Lower limit of hole = 24.98
24 98 mm
(b) Measure the diameter of the holes in the
workpieces
p Work tolerance = 0.04 mm
(c) Check the diameter of the holes in the ∴ Gauge tolerance = 10% of work tolerance = 0.004 mm
workpieces
+0.004
(d) Check the length of holes in the workpieces ∴ Dimension of 'GO' Plug gauge = 24.98 mm
−0.000
0 000
+0.000
Dimension of 'NOT GO' Plug gauge = 25.02 mm
103 104 −0.004 105
• Taking example of above:
• Bilateral system: in this
∴Wear Allowance = 5% of work tolerance = 0.002 mm
system, the GO and NO GO
y Wear allowance: GO gauges which constantly rub
g g y
gauge tolerance zones are Nominal size of GO plug gauge = 24.98
24 98 + 0.002
0 002 mm
against the surface of the parts in the inspection are
bisected by the high and +0.004
subjected to wear and loose their initial size.
low limits off the work ∴ Dimension
Di i off 'GO' Plug
Pl gauge = 24.982
24 982 mm
tolerance zone. y The size of go plug gauge is reduced while that of go −0.000
snap gauge increases.
i
+0.000
y To increase service life of gauges wear allowance is
g g Dimension of 'NOT GO' Plug
g ggauge
g = 25.02 mm
added to the go gauge in the direction opposite to −0.004
0 004
Taking example as above: wear. Wear allowance is usually taken as 5% of the
+0.002 work tolerance.
∴ Dimension of 'GO' Plug gauge = 24.98 mm
−0.002
0 002 y Wear allowance is applied to a nominal diameter
W ll i li d i l di
+0.00
0.002 before gauge tolerance is applied.
Dimension of 'NOT GO' Plug gauge = 25.02 mm
For-2019(IES, GATE & PSUs) −0.002 106
Page 54 of 203 107
Rev.0
108
Page 55
GATE ‐ 2014 GATE ‐ 2004 GATE 2015

GATE-2015
A GO‐NOGO
GO NOGO plug l gauge isi to beb designed
d i d for
f GO and d NO‐GO
NO GO plug
l gages are to beb designed
d i d for
f a Which one of the following statements is TRUE?
measuring a hole of nominal diameter 25 mm with a 0.05
hole 200.01 mm. g
Gage tolerances can be taken as 10% a) The ‘GO’
GO gage controls the upper limit of a hole
0 01
hole tolerance of ± 0.015 mm. Considering 10% of of the hole tolerance. Following ISO system of gage
work tolerance to be the g gauge
g tolerance and no 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
wear condition, the dimension (in mm) of the GO respectively c) The ‘GO’ gage controls the lower limit of a hole
plug gauge as per the unilateral tolerance system is ( ) 20.010 mm and
(a) d 20.050 mm
+0.003 +0.000 d)The ‘NO GO’ gage controls the upper limit of a hole
(b) 20.014
0.0 4 mm aand
d 20.046
0.046 mm
−0.003 −0.006
(a ) 24.985 (b) 25.015 (c) 20.006 mm and 20.054 mm
+0.03 +0.003 (d) 20.014 mm and d 20.054 mm
−0.03 −0.000
(c) 24
24.985
985 (d ) 24
24.985
985
109 110 111
For IES Only
GATE ‐ 1995 GATE – 2006, VS‐2012 T l ’ Pi i l

Taylor’s Principle
Checking
Ch ki the
h diameter
di off a hole
h l using
i GO‐NO‐GO
GO NO GO A ringi gauge is i used d to measure This principle states that the GO gauge should always be
gauges is an, example of inspection by ((a)) Outside diameter but not roundness
…..(variables/attributes) so designed
d d that
h it will
ll cover the
h maximum metall
(b) Roundness but not outside diameter
The above statement is ( ) Both
(c) B h outside
id diameter
di and
d roundness
d condition (MMC) of as many dimensions as possible in
(a) Variables ((d)) Onlyy external threads the same limit gauges, whereas a NOT GO gauges to
(b) Attributes
cover the minimum metal condition of one dimension
(c) Cant say
(d) Insufficient data only.
112 113 114
Limit Gauges Feeler Gauge
IES 2010 Conventional
IES 2010 Conventional Gauge For Measuring
Discuss a Go gauge.
Discuss a ‘Go’ gauge. Snap Gauge External Dimensions
Plug Gauge
g g Internal Dimensions
Taper Plug Gauge Taper hole
Ring Gauge External Diameter
G G
Gap Gauge G d G
Gaps and Grooves
Radius Gauge Gauging radius
Thread pitch Gauge
p g External Thread

Page 55 of 203 116
Rev.0 117
Page 56
GATE‐2016 Why is a unilateral tolerance
Why is a unilateral tolerance
PSU Match the following: preferred over bilateral tolerance ?
preferred over bilateral tolerance ?
A f l
A feeler gauge is used to check the
i d t h k th P. Feeler gauge
P Feeler gauge II. Radius of an object
Radius of an object y This system is preferred for Interchangeable manufacturing.
manufacturing
Q. Fillet gauge II. Diameter within limits by
(a) Pitch of the screw y It is easy and simple to determine deviations.
deviations
comparison
(b) Surface roughness 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
(c) Thickness of clearance S. Cylindrical plug
S C li d i l l IV I id di
IV. Inside diameter of
t f straight
t i ht
gauge hole limit of the shaft and the lower limit of the hole knowing
(d) Flatness of a surface
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
118
(c) P‐IV, Q‐II, R‐I, S‐III (d) P‐IV, Q‐I, R‐II, S‐III 119 120
Preferred Number
Preferred Number Preferred Number Contd.
Preferred Number ….. C td
y A designed product needs standardization. y These are named as Renard series.
IES 2010(Conv) IAS‐2014 (Main)
IES 2010(Conv) IAS‐2014 (Main) y Motor speed, engine power, machine tool speed and y Many other derived series are formed by multiplying or
Why is a unilateral tolerance preferred over bilateral feed, all follows a definite pattern or series. dividing the basic series by 10, 100 etc.
tolerance ? y This also helps in interchangeability of products. y Typical values of the common ratio for four basic G.P.
y It has been observed that if the sizes are put in the form series
i are given
i b l
below.
of ggeometric p progression,
g
with a definite sequence.
, then wide ranges
g are covered R5 : 11.58
58 :1
:1.0,1.6,
0 1 6 22.5,...
5 ( 10,
5
10 100, 5
1000 )
100 1000,.... 5
y These numbers are called preferred numbers having R10 : 1.26

1 26 :1 0 1 25 1 6 ( 10
:1.0,1.25,1.6,... 10
10, 100 10
1000,....)
100, 1000 10
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 12 :1 0 1 12 1 4 ( 10
:1.0,1.12,1.4,... 20
10, 100,20
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
121
formed; these are R5 , R10 , R20 and R40 122 123
Snug fit
IES‐2013 conventional
IES‐2013 conventional e ca Sta da d ssoc at o o e a ce Syste
American Standard Association Tolerance System
Tolerance = 0.0004D
1/3
and Deviation = 0
1. Heavy force shrunk fit
W it the
Write th amountt off allowance
ll and
d tolerance
t l 2. M di f
Medium force fit
fi Medium force fit :
that is permitted by the following classes of fit 3. Tight fit 1/3 1/3
Tolerance = 0.0006D
0 0006D and Deviation = 0.0005
0 0005D − 0.0006
0 0006 D
4. Wringing fit
as p
per ANSI class 4 : Snug
g fit and class 7 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
:Medium force fit. Also mention applications. 6. Medium fit y Medium force fit is applicable for shrink fit on cast iron
7. Free fit
8. Loose fit

Page 56 of 203 125
Rev.0 126
Page 57
Accuracy & Precision

Accuracy & Precision
y Accuracy ‐ The ability of a measurement to match the actual
(true) value of the quantity being measured. The expected
ability for a system to discriminate between two settings.settings
Smaller the bias more accurate the data.
y P i i
Precision ‐ The
Th precision
i i off an instrument
i i di
indicates i
its
Measurement of Lines & Surfaces ability to reproduce a certain reading with a given accuracy
‘OR’ it
i is
i the
h degree
d off agreement between
b repeated d results.
l
y Precision data have small dispersion
p ( spread
p or scatter ) but
may be far from the true value.
y A measurement can be accurate but not precise,
precise precise but
not accurate, neither, or both.
y A measurementt system
t i called
is ll d valid
lid if it is
i both
b th accurate t
By S K Mondal 127 and precise. 128 129
GATE‐2017 (PI) Repeatability Reliability of measurement

Reliability of measurement
y It is a quantitative characteristic which implies
Accuracy
A off a measuringi instrument
i is
i y It is the ability of a measuring system to reproduce confidence in the measured results depending on
output readings when the same input is applied to it whether or not the frequency
q y distribution
expressed as
consecutively,
i l under
d theh same conditions,
di i and
d in
i the h characteristics of their deviations from the true values
(a) true value – measured value same direction. of the corresponding
p g q
quantities are known. It is the
(b) measured value ‐ true value y Imperfections in mechanical systems can mean that probability that the results will be predicted.
t
true value-measured
l d value
l during a Mechanical cycle,
cycle a process does not stop at the
(c) 1- same location, or move through the same spot each
true value
ti
time. Th variation
The i ti range is
i referred
f d to
t as repeatability.
t bilit
true value-measured value
(d)1+
true value Which of these targets represents A change in one variable, such as wind,
accurate shooting? Precise alters the results as shown. Dose this
shooting?
h ti ? Reliable
R li bl shooting?
h ti ? show
h which
hi h shooting
h ti was the
th mostt
reliable?
130 131 132
Calibration y Drift: It is a slow change of a metrological characteristics of a Errors

y It
I is
i the
h setting
i or correcting
i off a measuring
i device
d i measuring instruments y Systematic
S i errors or fixed
fi d errors (Bias):
(Bi ) Due
D to faulty
f l
usually by adjusting it to match or conform to a y Resolution: It is the smallest change of the measured
quantity
tit which
hi h changes
h th indication
the i di ti off a measuring
i or improperly calibrated instruments.
instruments These may be
dependably known value or act of checking.
instruments
y Calibration determines the performance characteristics reduced or eliminated byy correct choice of instruments.
y Sensitivity: The smallest change in the value of the
of an instrument, system or reference material. It is
measured variable to which the instrument respond is Eg.
g calibration errors, Errors of technique
q etc.
usuall achieved
usually achie ed by
b means of a direct comparison against sensitivity. It denotes the maximum changes in an input
measurement standards or certified reference materials. signal
g that will not initiate a response
p on the output.
p y Random errors: Random errors are due to non‐specific
y It is very widely used in industries. y Rule of 10 or Ten‐to one rule: That the discrimination cause like natural disturbances that may occur during
y A calibration certificate is issued and,
and mostly,
mostly a sticker is (resolutions) of the measuring instrument should divide the
provided for the instrument. tolerance of the characteristic to be measured into ten parts. the experiment. These cannot be eliminated.
In other words,
words the gauge or measuring instrument should be Eg. Errors stemming from environmental variations, Due
E E i f i l i i D
10 times as accurate as the characteristic to be measured. 134
Page 57 of 203 Rev.0
to Insufficient sensitivity of measuring system 135
Page 58
Linear measurements Vernier Caliper

y A vernier scale is an auxiliary scale that slides along the main
Some
S off the
h instruments
i used
d for
f the
h linear
li scale.
measurements are: y The vernier scale is that a certain number n of divisions on
y Rules (Scale) the vernier scale is equal in length to a different number
y Vernier (usually one less) of main
main‐scale
scale divisions.
divisions
y Micrometer (Most widely used, Working Standard) nV = (n −1)S
where
h n = number
b off divisions
d on the
h vernier scale
l
y Height gauge
V = The length
g of one division on the vernier scale
y Bore
B gauge
and S = Length of the smallest main‐scale division
y Dial indicator
y Least count is applied to the smallest value that can be read
y Slip gauges or gauge blocks (Most accurate, End directly by use of a vernier scale.
Standard) y Least count = S − V = 1 S
n Vernier Caliper
136 137 138
ISRO‐2010 M t i Mi t
Metric Micrometer
The
Th vernier
i reading
di should
h ld not be
b taken
k at its
i face
f ISRO‐2008 y A micrometer allows a measurement of the size of a
value before an actual check has been taken for Th least

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

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

((c)) Flatness of measuring
g jjaws
(a) 0.005 mm (b) 0.01 mm Step‐I: Find the whole number of mm in the barrel
((d)) Temperature
p equalization
q
(c) 0.02 mm (d) 0.005mm Step‐I: Find the reading of barrel and multiply by 0.01
139 140
Step‐III: Add the value in Step‐I and Step‐II 141
y Bore Gauge: used for measuring bores of different

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

Micrometer (c) 2.120 mm (d) 5.012 mm

Page 58 of 203 143
Rev.0 144
Page 59
y Dial indicator: Converts a linear GATE – 2008 S‐1

displacement into a radial pp cat o s o d a d cato c ude:
Applications of dial indicator include:
A displacement
di l sensor (a
( dial
di l indicator)
i di ) measures the
h
movement to measure over a y centering workpices to machine tool spindles lateral displacement of a mandrel mounted on the taper
small
ll range off movement for
f theh hole inside a drill spindle. The mandrel axis is an
plunger. y offsetting lathe tail stocks extension of the drill spindle
p taper
p hole axis and the
y The typical least count that can be protruding portion of the mandrel surface is perfectly
y aligning a vice on a milling machine
obtained with suitable gearing cylindrical Measurements are taken with the sensor
cylindrical.
dial indicators is 0.01 mm to 0.001 y checking dimensions placed at two positions P and Q as shown in the figure.
mm.
mm Th readings
The di are recorded
d d as Rx = maximum
i d fl ti
deflection
y It is possible to use the dial minus minimum deflection, corresponding to sensor
indicator as a comparator by position at X, over one rotation.
mounting g it on a stand at anyy
suitable height. Principle of a dial indicator
145 146 147
GATE – 2008 contd… from S‐2
d f GATE – 2014(PI) S‐1
( ) GATE – 2014(PI) S‐2
( )
If Rp= RQ>0, >0 which one of the The
Th alignment
li test This
Thi test inspects
i whether
h h the h
following would be consistent with the
observation? “Spindle square with ((a)) spindle
p vertical feed axis is p perpendicular
p to the base
(A) The drill spindle rotational axis is base plate” is applied plate
coincident with the drill spindle
p taper
p to the radial drilling g
hole axis (b) axis of symmetry of the cylindrical spindle is
machine. A dial perpendicular to the base plate
(B) The drill spindle rotational axis
i
intersects the
h drill
d ill spindle
i dl taper hole
h l indicator is fixed to
the cylindrical spindle (c) axis of symmetry, the rotational axis and the vertical
axis at point P
and
d the
th spindle
i dl is i feed
eed aaxiss o
of tthee sp
spindle
d e aaree aall co
coincident
c de t
(C) The
Th drill
d ill spindle
i dl rotational
t ti l axis
i is
i
parallel to the drill spindle taper hole rotated to make the (d) spindle rotational axis is perpendicular to the base
axis plate
l t
indicator
d touch h the
h
(D) The drill spindle rotational axis
intersects the drill spindle taper hole base p
plate at different
axis at point Q points
148 149 150
Slip Gauges or Gauge blocks y Come in sets with different number of pieces in a given To make up a Slip Gauge pile to 41.125 mm
y These
Th are small
ll blocks
bl k off alloy
ll steel.
l sett to
t suit
it the
th requirements
i t off measurements.
t y A Slip
Sli Gauge
G pile
il is
i sett up with
ith the
th use off simple
i l
y Used in the manufacturing
g shops
p as length
g standards. y A typical
yp set consisting
g of 88 p
pieces for metric units is maths.
y Not to be used for regular and continuous shown in.
y Decide what height
g y you want to set up,
p in this
measurement.
measurement y To
T build
b ild any giveni di
dimension,
i it is
i necessary to t
y Rectangular blocks with thickness representing the identifyy a set of blocks,, which are to be pput together.
g case 41.125mm.
dimension of the block. The cross‐section of the block y Number of blocks used should always be the smallest. y Take away the thickness of the two wear gauges,
iss usua
usuallyy 332 mm x 9 mm..
y Generally
G ll the
h top and d bottom
b Sli Gauges
Slip G i the
in h pile
il and then use the gauges in the set to remove
y Are hardened and finished to size. The measuring
are 2 mm wear g gauges.
g This is so that theyy will be the
surfaces
f off the
th gauge blocks
bl k are finished
fi i h d to
t a very high
hi h each place of decimal in turn,
turn starting with the
degree of finish, flatness and accuracy. only ones that will wear down, and it is much cheaper
lowest.
to replace
l two gauges than
h a whole
h l set.
Page 59 of 203 152
Rev.0 153
Page 60
To make up a Slip Gauge pile to 41.125 mm A M t i li t (88 Pi )

A Metric slip gauge set (88 Pieces)
41.125
-4.000 Slip gauges size or Increment, mm
Increment mm Number of
______
37.125 range, mm Pieces
-1.005
1 00
_______ 1.005 ‐ 1
36.120 1.001 to 1.009 0.001 9
-1.020
1 020
_______ 1.010 to 1.490 0.010 49
35.100
-1.100
1 100 0 500 to 9.500
0.500 to 9 500 0 500
0.500 19
_______
34.000 10 to 100 10.000 10
-4.000
4 000
_______
30.000
-30.000
30 000
_______
0.000
154 155 156
ISRO‐2010 Comparators
A master gauge is ISRO‐2008 y Comparator is another form of linear measuring
method, which is quick and more convenient for
(a) A new gauge St d d to
Standards t be
b used
d for
f reference
f purposes in
i checking
h ki largel number
b off identical
id ti l dimensions.
di i
(b) An international
te at o a reference
e e e ce sta
standard
da d laboratories and workshops are termed as y Duringg the measurement, a comparator
p is able to g
give
the deviation of the dimension from the set dimension.
(c) A standard gauge for checking accuracy of (a) Primary standards y Cannot measure absolute dimension but can only
gauges used on shop floors
compare two dimensions.
(d) A gauge used by experienced technicians ((b)) Secondaryy standards
y Highly reliable.
((c)) Tertiaryy standards y To magnify the deviation, a number of principles are
used such as mechanical, optical, pneumatic and
(d) Working standards
electrical.
electrical
157 158 159
GATE – 2007 (PI)
( ) Mechanical Comparators
Mechanical Comparators
y The Mikrokator principle
Which one of the following instruments is a
greatly magnifies any
comparator
t ? d i ti
deviation i size
in i so that
th t
even small deviations
(a) Tool Maker
Maker’ss Microscope produce
d l
large d fl
deflections off
the p
pointer over the scale.
(b) GO/NO GO gauge
(c) Optical Interferometer
(d) Dial Gauge
For-2019(IES, GATE & PSUs)

Fig. Principle of a comparator 160
Page 60 of 203 161
Rev.0 162
Page 61
Sigma Mechanical Comparator
The Sigma Mechanical Comparator uses a partially
y The Eden‐Rolt Reed system
y uses a
wrapped
d band
b d wrapped
d about
b a driving
d d
drum to turn a
pointer attached to the end of two
pointer needle.
needle The assembly provides a frictionless
reeds. One reed is pushed by a
movement with a resistant pressure provided by the
plunger, while the other is fixed. As
springs.
one reed
d moves relative
l ti tot the
th other,
th
the pointer that they are commonly
attached to will deflect.
Sigma Mechanical Comparator
163 164 165
Optical Comparators Pneumatic Comparators
y These
Th devices
d i use a plunger
l to rotate a mirror.
i A light
li h In this system,
system Mechanical amplification = 20 /1 , And,
And
y Flow type:
beam is reflected off that mirror, and simply by the p
Optical amplification
p 550 /1 x 2
virtue of distance, the small rotation of the mirror can y The float height is essentially proportional to the air
be converted to a significant
g translation with little
that
h escapes from
f the
h gauge head
h d
friction. It is multiplied by 2, because if mirror is tilted by an angle
y Master
M t gauges are used
d to
t find
fi d calibration
lib ti points
i t on
δθ, then image will be tilted by 2 x δθ. Thus overall
magnification
ifi i off this
hi system the scales
= 2 x (20/1) ( 50/1 =2000

2000 units) y The input pressure is regulated to allow
magnification adjustment
166 167 168
Pneumatic Comparators Angular Measurement
IFS‐2015 This involves the measurement of angles of tapers and
Define a comparator.
comparator similar
l surfaces.
f The
h most common angular
l measuring
Write at least six desirable features it should possess.
possess tools are:
Also name four types
yp of comparators.
p y Bevel protractor
[ 8 Marks]
y Sine bar

Page 61 of 203 170
Rev.0 171
Page 62
Bevel Protractor Sine Bar

Sine Bar
y When a reference for a non‐square angle is required, a sine bar
y Is part of the machinist's combination square. can be used.
y Basically a sine bar is a bar of known length.
length When gauge blocks
y The flat base of the protractor helps in setting it firmly
are placed under one end, the sine bar will tilt to a specific
on the
h workpiece
k i and
d then
h byb rotating
i the
h rule,
l iti is
i angle.
possible to measure the angle.
angle It will typically have a y Knowing the height differential of the two rollers in alignment
discrimination of one degree.

g with the workpiece ,the angle can be calculated using the sine
formula.
y A sine bar is specified by the distance between the centre of the
two rollers, i.e. 100 mm, 200 mm, & 300 mm. the various part of
A Bevel Protractor sine bar are hardened before grinding & lapping.
172 173 174
ISRO‐2011 ( )
GATE ‐2012 (PI)
A sine bar has a length of 250 mm. Each roller has
A sine
i bar
b is
i specified
ifi d by
b
a diameter of 20 mm. During taper angle
(a) Its total length
measurement of a component, the height from the
(b) The size of the rollers surface
f plate
l to the
h centre off a roller
ll isi 100 mm.
(c) The centre distance between the two rollers Th calculated
The l l t d taper
t angle
l (in
(i degrees)
d ) is
i
(d) The distance between rollers and upper surface ( ) 21.1
(a) (b) 22.8
8 ( ) 23.6
(c) 6 (d) 68.9
68
H
s in θ =
L 175 176 177
GATE‐2018 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
The height (in mm) for a 125 mm sine bar to
y Though there are a large variety of threads used in
g g y
measure a taper of 27o32' on a flat work piece measuring angles h 60o because
l more than b off slip
l gauge engineering, the most common thread encountered is
adjustment problems.
problems the metric V thread shown in Fig.
the metric V‐thread shown in Fig
is___________(correct to three decimal
y 2.
2 Misalignment of workpiece with sine bar may
places).
sometimes introduce considerable errors.

Page 62 of 203 179
Rev.0 180
Page 63
y The parameters that are normally measured are: Three-Wire Method

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
y Optical projector
181 182 183
The Three-Wire Method of Measuring Threads y Distance W over the outer edge Two-Wire Method
⎛ α⎞ p α
W = D p + d ⎜1 + cosec ⎟ − cot y Two wires of equal diameter placed in thread, two on
⎝ 2⎠ 2 2
one side and one on other side
For ISO metric thread,, α = 60 and D p = D − 0.6496 p
W = D + 3d − 1.5156 p
y Best wire size
p α
d= sec
2 2
For ISO metric thread, α = 60
D p = pitch diameter or Effective diameter
d = 0.5774 p
p = pitch of thread , and α = thread angle 184 185 186
y Pitch
Pit h Diameter
Di t or Eff
Effective
ti Di
Dia. GATE‐2013
Dp = T + P
p ⎛α ⎞ ⎛ α ⎞
GATE –
GATE – 2011 (PI)
2011 (PI) A metric thread of pitch 2 mm and thread
=T + cot ⎜ ⎟ − d ⎜ cosec − 1⎟
2 ⎝2⎠ ⎝ 2 ⎠ The best wire size (in mm) for measuring
T = Dimensions under the wire = D + ( Dm − Ds ) effective diameter of a metric thread angle 60 inspected for its pitch diameter
D=D
Diameter
i t off master
t or standard
t d d cylinder
li d (included angle is 60o) of 20 mm diameter and
2.5 mm pitch using two wire method is using 3‐wire method. The diameter of the
Dm = Micrometer reading over standard cylinder with two wire
D s = Micrometer reading over the plug screw gauge with the wire (a) 1.443 best size wire in mm is
P = Pitch value (b) 0.723
0 723
(a) 0.866 (b) 1.000 (c) 1.154 (d) 2.000
y Best wire size (c) 2.886
p α (d) 2.086
d= sec
2 2
Page 63 of 203 188
Rev.0 189
Page 64
IES‐2017 (Pre)
( )
A metric thread of pitch 2 mm and thread
GATE –
GATE – 2011 (PI)
2011 (PI)
To measure the effective diameter of an external
angle 60o is inspected for its pitch diameter metric thread (included angle is 60o) of 3.5 mm
pitch,, a cylindrical
p y standard of 330.55 mm diameter
using the 3‐wire method. The indicated and two wires of 2 mm diameter each are used.
The micrometer readings over the standard and
Measurement of Surfaces
fS f
diameter of the wire will be nearly over the wires are 16.532 mm and 15.398 mm,
respectively. The effective diameter (in mm) of the
(a) 0.85 mm (b) 1.05 mm thread is
(a) 33.366
33 366 (b) 30.397
30 397
(c) 1.15 mm (d) 2.05 mm (c) 29.366 (d) 26.397
190 191 192
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.
193 194 195
y Waviness: refers to those surface irregularities that have

a greater spacing than that of roughness width.
width
y Determined by the height of the waviness and its
width.
y The greater the width,
width the smoother is the surface and
thus is more desirable.
y Lay
L di
direction:
i i the
is h direction
di i off the
h predominant
d i
surface pattern produced on the workpiece by the tool
marks.
y Flaw: are surface irregularities that are present which are
random and therefore will not be considered.

Page 64 of 203 197
Rev.0 198
Page 65
Lay Lay Contd..
Diagram Symbol Description Diagram Symbol Description IES‐2012
Parallel lay: Lay parallel to Multidirectional lay: Lay
In connection with surface texture define
the Surface. Surface is multidirectional. Surface is
produced
d d b
by shaping,
h i produced
d d by b grinding,
i di ( ) waviness
(a)
planning etc. lapping, super finishing.
(b) flaws,
fl and
d
Perpendicular lay: Lay Circular lay:
perpendicular to the Approximately circular (c) lay.
lay
Surface. Surface is produced relative to the center.
S f
Surface i produced
is d d by b List three defects found on surfaces.
b shaping
by h i and d planning
l i
Crossed lay: Lay angular in
y y g facing. [
[2 marks]
]
both directions. Radial lay: Approximately
Surface is produced by radial relative to the center
knurling, honing. 199
of the nominal surface. 200 201
INDICATION OF SURFACE TEXTURE

Representation of Surface Roughness
y
The basic symbol g of
consists of two legs
unequal length inclined at approximately
60’ to the line representing the considered
surface
The symbol must be represented by thin line
If the removal of material by machining is

required, a bar is added to the basic symbol,
If the removal of material is not permitted,

a circle is added to the basic symbol
symbol.
When special surface characteristics have to

be indicated, a line is added to the longer arm of
any of the above symbols,
202 203 Basic symbol : only be used alone when its meaning is explained by a note 204
Roughness Roughness Grade Roughness Symbol

Ra (μm) Number Surface Roughness expected from manufacturing processes
GATE‐2017 (PI) 50 N12 ‐
A machined
hi d surface
f with
ith standard
t d d symbols
b l 25
2 N11
∇
indicatingg the surface texture is shown in the 12.5 N10
Figure. (All dimensions in the Figure are in 6.3 N9
micrometer).
micrometer) 32
3.2 N8 ∇∇
The waviness height g ((in micrometer)) of the 1.6 N7
surface is 0.8 N6
04
0.4 N5 ∇∇∇
( )1
(a) (b) 50
0.2 N4
(c) 60 (d) 120
0.1 N3
0 05
0.05 N2 ∇∇∇∇
For-2019(IES, GATE & PSUs) 205 0.025 N1 of 203
Page 65 206
Rev.0 207
Page 66
Surface Roughness expected from manufacturing processes
IES ‐ 1992
IES‐2016 conventional
IES‐2016 conventional Which
Whi h grade
d symbol
b l represents surface
f rough
h off
broaching?
Sh
Show i a figure
in fi l
location
ti off the
th surface
f (a) N12 (b) N8
texture details when used with (c) N4 (d) N1
machining symbols.
[4 Marks]
208 209 210
Geometric Tolerance symbol
y
y Waviness height ‐ the distance from a peak to a valley IFS‐2011
y Waviness width ‐ the distance between peaks or What is meant by interchangeable manufacture?
valleys
y
y Roughness width cutoff ‐ a value greater than the Laser light has unique advantages for inspection.
maximum roughness width that is the largest What are they ? Define the terms 'roughness
separation of surface irregularities included in the
measurements. Typical
T i l values
l are (0.003”,
( ” 0.010”,” h i ht' 'waviness
height', ' i width'
idth' and
d 'lay'
'l ' in
i connection
ti
0.030”, 0.100”, 0.300”) with surface irregularities.
irregularities
y Lay ‐ the direction the roughness pattern should
follow [10 marks]
[10‐marks]
y Stylus travel is perpendicular to the lay specified.
211 212 213
GATE‐2018 (PI)
Match the geometric tolerances with their correct
M h h i l i h h i GATE 2007(PI)
GATE ‐2007(PI) Evaluation of Surface Roughness
symbols:
The geometric tolerance that does NOT need a datum
P. Flatness 1. 1. Centre line average (CLA) or arithmetic mean
for its specification is
deviation denoted as Ra.
Q. Perpendicularity 2. ((a)) Concentricityy ((b)) Runout
2. Root mean square value (Rg) : rms value
((c)) Perpendicularity
p y ((d)) Flatness
R Concentricity
R. Concentricity 3
3.
3. Maximum peak to valley roughness (hmax)
S. Roundness (Circularity) 4. 4. The average of the five highest peak and five deepst
valleys
ll i the
in th sample.
l
(a) P – 1, Q –
Q 33, R – 44, S – 2 (b) P – 33, Q –
Q 1, R – 4
4, S – 2
5 The average or leveling depth of the profile.
5. profile
(c) P – 3, Q – 1, R – 2, S – 4 (ds) P – 3, Q – 2, R – 1, S –2144
For-2019(IES, GATE & PSUs) Page 66 of 203 215
Rev.0 216
Page 67
Determination of Mean Line Determination of Mean Line Arithmetical Average:

y Measured
M d for
f a specified
ifi d area and
d the
h figures
fi are added
dd d
y M‐System: After plotting the characteristic of any y E‐System: (Envelop System) A sphere of 25 mm
surface a horizontal line is drawn by joining two points.
points diameter is rolled over the surface and the locus of its together and the total is then divided by the number of
This line is shifts up and down in such a way that 50% centre is being traced out called envelope. This envelope measurements taken to obtain the mean or
area is above the line and 50% area is below the line 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
217 218 219
GATE 2016 (PI)

GATE‐2016 (PI)
The roughness profile of a surface is depicted below. y The other parameter that is used sometimes is the root
mean square value of the deviation in place of the ISRO‐2011
arithmetic average , This in expression form is
g p
CLA value and RMS values are used for measurement
1
RRMS =
N
∑y 2
i
of
(a) Metal hardness
(b) Sharpness of tool edge
(c) Surface dimensions
(d) Surface roughness
The surface roughness parameter Ra (in μm) is _______ 220 Fig. Surface roughness parameters 221 222
IES ‐ 2006 IES ‐ 2007 IES ‐ 2008

The M and E‐system in metrology are related to What is the dominant direction of the tool marks or What term is used to designate the direction of the
measurement of:
f scratches
h in a surface
f texture having
h a directional
d l predominant
d surface
f pattern produced
d d b
by
( ) Screw
(a) S threads
h d (b) Fl
Flatness quality called?
quality, machining operation?
( ) Angularity
(c) A l it (d) S f
Surface fi i h
finish (a) Primary texture (b) Secondary texture (a) Roughness (b) Lay
(c) Lay (d) Flaw (c) Waviness (d) Cut off

Page 67 of 203 224
Rev.0 225
Page 68
IES 2010 IES ‐ 2008 ISRO‐2010

Match List I with List II and select the correct answer
using the code given below the lists: Surface roughness on a drawing is represented by
List I List II
(a) Triangles
(Symbols for direction of lay) (Surface texture)
(b) Circles
(c) Squares
(d) Rectangles
A B C D A B C D
(a) 4 2 1 3 (b) 3 2 1 4
(c) 4 1 2 3 (d) 3 1 2 4226 227 228
Methods of measuring Surface Roughness
h d f i S f h Observation Methods
IAS –
IAS – 2013 Main
2013 Main There are a number of useful techniques for measuring
y Human perception is highly relative.
F a machined
For hi d surface,
f show
h macro‐ and
d micro‐
i surface roughness:
y To give the human tester a reference for what they are
irregularities What are their causes?
irregularities. y Observation and touch ‐ the human finger
g is veryy
touching,
hi commercial
i l sets off standards
d d are available.
il bl
What are the various measures of surface finish? perceptive to surface roughness
y Comparison
C i should
h ld b
be made
d against
i t matched
t h d
Explain any three of them. y stylus based equipment ‐ very common
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.
229 230 231
Stylus Equipment
y Uses a stylus that tracks small changes in surface
h i ht and
height, d a skid
kid that
th t follows
f ll l
large changes
h i surface
in f
height.
y The relative motion between the skid and the stylus
y is
measured with a magnetic circuit and induction coils.
y One example of this is the Brown & Sharpe Surfcom
unit.

Page 68 of 203 233
Rev.0 234
Page 69
Profilometer Contact profilometers Non‐contact Profilometers

y A diamond stylus is moved vertically in contact with a
y Measuring instrument used to measure a surface's y An optical profilometer is a non‐contact method for
sample
l and
d then
th moved
d laterally
l t ll across the
th sample
l for
f
profile, in order to quantify its roughness. providing much of the same information as a stylus
a specified distance and specified contact force.
y Vertical resolution is usually in the nanometre level, based profilometer.
yAp
profilometer can measure small surface variations in
though
h h lateral
l l resolution
l is usually
ll poorer. y There are many different techniques which are
vertical stylus displacement as a function of position.
currently
tl being
b i employed,
l d such
h as laser
l ti
triangulation
l ti
y The radius of diamond stylus ranges from 20
(triangulation sensor),
sensor) confocal microscopy and digital
nanometres to 25 μm.
holography.
g p y
235 236 237
Advantages of optical Profilometers Optical Flats
y Optical‐grade
O ti l d clear
l fused
f d quartz
t or glass
l structures
t t
y Because the non‐contact profilometer does not touch
lapped and polished to be extremely flat on one or
the
h surface
f the
h scan speeds
d are dictated
d d by
b the
h light
l h b th sides.
both id
y Used with a monochromatic light to determine the
reflected from the surface and the speed of the flatness of other optical surfaces by interference.
acquisition electronics. y When a flat surface of another optic p is p placed on the
optical flat, interference fringes are seen due to
y Optical
p profilometers do not touch the surface and
p te e e ce in tthee ttinyy gap bet
interference between
ee tthee ttwoo su
surfaces.
aces.
therefore cannot be damaged by surface wear or y The spacing between the fringes is smaller where the
gap is changing more rapidly,
rapidly indicating a departure
careless operators. from flatness in one of the two surfaces, in a similar
way to the contour lines on a map.
map
238 239 240
GATE‐2018 (PI)
Which one of the following instruments makes
use of the principle of interference of light?
(a) Optical flat
(b) Auto‐collimator
(c) Optical projector
(d) Coordinate measuring machine
g
Page 69 of 203 242
Rev.0 243
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 th order is =
p of interference fringe
2 spacing of 1 mm is 450 nm,nm the wavelength of light
244 (in nm) to get a fringe spacing of 1.5 mm is _______
245 246
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
247
of surfaces. 248 249
GATE ‐ 2003
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
2 other lengthwise. An optical flat is kept resting on the
Wh l = separation of edges
Where slip
pggauges
g as shown in the figure.
g Monochromatic light
g
of wavelength 0.0058928 mm is used in the inspection.
n = number of fringes / cm
The total number of straight fringes that can be observed
Δh = The difference of height between gauges on both slip gauges is
λ = wevlength of monochomatic light
(a) 2 (b) 6
(c) 8 (d) 13

Page 70 of 203 251
Rev.0 252
Page 71
Parallelism Error
Parallelism Error
y In case of large‐length
g g slip
p g g
gauges, the p
parallelism of GATE – 2011 (PI)
surfaces can also be measured by placing the gauge on a Observation of a slip gauge on a flatness
NPL Flatness rotary table in a specific position and reading number 1 interferometer produced fringe counts numbering
Interferometer can be taken. 10 and 14 for two readings. The second reading is
set up by 180o. Assume that
taken by rotating the set‐up
y The
Th number b off fringes
fi obtained
bt i d is
i the
th result
lt off the
th angle
l
that the gauge surface makes with the optical flat. (n1) both faces of the slip gauge are flat and the
y Then the table is turned through 180o and reading wavelength
l h off the
h radiation
di i i 0.5086
is 86 µm. The
Th
number 2 can be taken. (n2) parallelism error (in µm) between the two faces of
the slip gauge is
y The change in distance between the gauge and optical
fl = λ/2
flat λ/ (a) 0.2543
0 2543 (b) 1.172
1 172
Parallelism Error =
( n2 − n1 ) × λ (c) 0.5086 (d) 0.1272
4
253 254 255
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
256 By S K Mondal 257 258
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 71 of 203 260
Rev.0 261
Page 72
Autocollimator GATE ‐ 1998

Auto collimator is used to check
GATE –
GATE – 2009 (PI)
2009 (PI)
( ) Roughness
(a) A autocollimator
An t lli t is i used
d to
t
(b) Flatness
Fl t (a) measure small angular displacements on flat
(c) Angle surface
(d) Automobile balance. ((b)) compare

p known and unknown dimensions
((c)) measure the flatness error
(d) measure roundness error between centers

262 263 264
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.
265 y Two mirrors may be replaced by two prisms. 266 An Optical Square 267
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 72 of 203 269
Rev.0 270
Page 73
IES ‐ 1998 Laser interferometer

Laser interferometer
Match List‐I
List I with List‐II
List II and select the correct answer using the y Laser interferometers represent the ultimate feedback
codes given below the lists: device for high‐precision motion control application.
List‐I List‐II
(Measuring Device) (Parameter Measured) y The
h combination
b off high
h h resolution
l and
d outstanding
d
A. Diffraction grating 1. Small angular deviations on long accuracyy has made it the ideal transducer for wafer
flat surfaces
B. Optical flat 2. On‐line measurement of moving steppers, flat panel inspection, and high‐accuracy laser
p
parts micromachining.
C. Auto collimators 3. Measurement of gear pitch
D. Laser scan micrometer4. Surface texture using interferometer y A laser interferometer system employs a highly stabilized
5. Measurement off very smallll li ht source and
light d precision
i i optics
ti to
t accurately
t l measure
displacements
distances.
Code: A B C D A B C D
(a) 5 4 2 1 (b) 3 5 1 2 y An additional advantage is that interferometers measure
((c)) 3 5 4 1 ((d)) 5 4 1 2 distances directly at the workpiece.
271 272 273
GATE‐2014 Ultrasonic Probe

Ultrasonic Probe Ultrasonic Probe
Ultrasonic Probe
y Ultrasonic sensors are used in many
y fields. y Low accuracy,
y, low reliabilityy due to reflection of a
Which one of the following instruments is widely y Key features of ultrasound transducers change depending on transmitted signals.
used to check and calibrate geometric features of the propagation medium (solid,
(solid liquid,
liquid or air).
air) y Limited range
machine tools during their assembly? y Most important application is distance measurement. y In the short fixed distance and controlled atmosphere
y Common applications associated with distance measurement (
(temperature and
d humidity)
h idi ) excellent
ll performance
f can be
b
(a) Ultrasonic probe achieved.
are
(b) Coordinate Measuring Machine (CMM) ¾ Presence detection y Depending upon application different types of transdures are
¾ Identification of objects used. Most commonlyy used 4 40 KHz ceramic based
( ) Laser interferometer
(c) f transducers.
¾ The measurement of the shape and orientation of workpiece.
(d) Vernier calipers ¾ Collision
C lli i avoidance
id
¾ Room surveillance
¾ Liquid level and flow measurement
274 275 276
McLeod gauge Planimeter
y Used
d to measure vacuum by
b application
l off the
h y A device used for measuring the area of any plane
principle of Boyle's law. surface by tracing the boundary of the area.
y g y
y Works on the principle, "Compression of known
volume of low p pressure ggas to higher
g pressure and
p
measuring resulting volume & pressure, one can
calculate initial p
pressure usingg Boyle's
y Law equation."
q
y Pressure of gases containing vapours cannot normally
measured with a McLeod gauge, gauge for the reason that
compression will cause condensation .
y A pressure from
f 0.01 micron
i t 50 mm Hg
to H can beb
measured. Generally McLeod gauge is used for
calibration
lib ti purpose.
Page 73 of 203 278
Rev.0 279
Page 74
LVDT LVDT GATE ‐ 1992

y Acronym for Linear Variable Differential Transformer, Match
M t h the
th instruments
i t t with
ith the
th physical
h i l quantities
titi they
th
measure:
a common type yp of electromechanical transducer that
I
Instrument M
Measurement
can convert the rectilinear motion of an object to
(A) Pilot‐tube (1) R.P.M. of a shaft
which it is coupled mechanically into a corresponding
(B) McLeod Gauge (2) Displacement
electrical signal.
((C)) Planimeter (3) Flow velocityy
y LVDT linear
li position
i i sensors are readily
dil available
il bl that
h (D) LVDT (4) Vacuum
can measure movements as small as a few millionths of
(5) Surface finish
an inch up to several inches, but are also capable of
(6) Area
measuring
easu g pos positions
o s up to
o ±20 inches
c es ((±0.5
.5 m).
).
C d A
Codes:A B C D A B C D
y A rotary variable differential transformer (RVDT) (a) 4 1 2 3 (b) 3 4 6 2
i a type
is t off electrical
l t i l transformer
t f used d for
f measuring i (c) 4 2 1 3 (d) 3 1 2 4
angular displacement. 280 281 282
Tool Maker’s Microscope GATE ‐ 2004

An essential part of engineering inspection, Match
M h the h following
f ll i
measurement and calibration in metrology gy labs. Feature to be inspected Instrument
Hence is used to the following: P Pitch and Angle errors of screw thread 1. Auto Collimator
y Examination of form tools, tools plate and template Q Flatness error of a surface plate 2.
2 Optical Interferometer
gauges, punches and dies, annular grooved and R Alignment error of a machine slide way 3. Dividing Head
threaded
h d d hobs
h b etc. andd Dial
Di l Gauge
G
y Measurement of g glass ggraticules and other surface S Profile of a cam 4. Spirit
p Level
marked parts. 5. Sine bar
y Elements
El t off external
t l thread
th d forms
f off screw plug
l 6 Tool maker
6. maker'ss Microscope
gauges, taps, worms and similar components. (a) P‐6 Q‐2 R‐4 S‐6 (b) P‐5 Q‐2 R‐1 S‐6
y Shallow bores and recesses. (c) P‐6 Q‐4 R‐1 S‐3 (d) P‐1 Q‐4 R‐4 S‐2
283 284 285
Telescopic Gauges
Telescopic Gauges GATE ‐ 1995 C di t M i M hi
Coordinate Measuring Machine
y Used to measure
easu e a bo e s ssize,
bore's e, by ttransferring
a se g tthee (CMM)
List
Li I List
Li II
internal dimension to a remote measuring tool.
(
(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 They
Th are a direct
di t equivalent
i l t off inside
i id callipers
lli and
d
require the operator to develop the correct feel to (A) Talysurf 1. T‐slots dimensional structures mainly used for quality control
obtain repeatable results. (B) Telescopic
Tl i gauge 2. Fl
Flatness applications
applications.
((C)) Transfer callipers
p 33. Internal diameter y The highly sensitive machine measures parts down to
the fraction of an inch.
(D) Autocollimator 4. Roughness
y Specifically, a CMM contains many highly sensitive air
Codes:A
d B C D A B C D
bearings on which the measuring arm floats.
(a) 4 1 2 3 (b) 4 3 1 2
(c) 4 2 1 3 (d) 3 1 2 4

Page 74 of 203 287
Rev.0 288
Page 75
GATE ‐ 2010
g ,
Advantages,
A taper hole
h l is
i inspected
i d using
i a CMM,
CMM with i h a probe
b
y can automate inspection process
of 2 mm diameter. At a height, Z = 10 mm from the
y less prone to careless errors
l l bottom, 5 points are touched and a diameter of
y allows direct feedback into computer system
p y circle ((not compensated
p for p
probe size)) is obtained
Disadvantages, as 20 mm. Similarly, a 40 mm diameter is obtained
y Costly
C l at a height Z = 40 mm.
mm the smaller diameter (in mm)
of hole at Z = 0 is
y fixturing
g is critical
( ) 13.334
(a)
y requires a very good tolerance model
(b) 15.334
(c) 15.442
( ) 15.542
(d)
289 290 291
GATE 2008 (PI)

GATE ‐2008 (PI) GATE 2014
GATE ‐2014
The diameter of a recessed ring was measured by using two GATE‐2016
An experimental setup is planned to determine the taper of For the situation shown in the figure below the
spherical
h i l balls
b ll off diameter
di d2 = 60
6 mm andd d1 = 40 mm as
workpiece as shown in the figure. If the two precision rollers expression for H in terms of r, R and D is
shown in the figure.
have radii 8 mm and 5 mm and the total thickness of slip
The distance
gauges inserted between the rollers is 15.54 mm, the taper H2 = 35.55
angle θ is H2 H1 (a) H = D + r2 + R2
mm and d1 Diameter
(a) 6 degree H1 = 20.55 C
(b) H = (R + r) + (D + r)
(b) 10 degree mm. Th
The
diameter (D, H (c) H = (R + r) + D2 − R2
(c) 11 degree i mm)) off the
in th A B
R (d) H = (R + r) + 2D(R + r) − D2
(d) 12 degree ring gauge is
………….
Recessed Ring
D
292 293 294
d2 Diameter
GATE‐2018 (PI)
In
I a V‐thread,
V h d a wire i isi fitted
fi d such
h that
h it i makes
k
contact with the flank of the thread on the pitch
line as shown in the figure. If the pitch p of the
th d is
thread i 3 mm and d the
th included
i l d d anglel is
i 60°,
6 ° the
th
diameter ((in mm,, up
p to one decimal p
place)) of the
wire is ______

Page 75 of 203 296
Rev.0
Page 76
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 Strain Hardening GATE‐1995

y In
I sheet
h metall working
ki operations,
i the
h cross‐section
i off
workpiece does not change—the material is only y When metal is formed in cold state, there is no A test specimen is stressed slightly beyond the yield
subjected to shape changes. recrystalization of grains and thus recovery from grain point and then unloaded. Its yield strength
y The
Th ratio
i cross‐section
i area/volume
/ l i very high.
is hi h distortion or fragmentation does not take place. (a) Decreases
y Sheet metalworking operations are performed on thin y As grain deformation
d f proceeds,
d greater resistance to this
h
(less than 5 mm) sheets, strips or coils of metal by means (b) Increases
off a set off tools
l called
ll d punch
h and
d die
di on machine
hi toolsl action results in increased hardness and strength i.e.
ie
(c) Remains same
called stamping presses. strain hardening.
(d) Become equal to UTS
y They are always performed as cold working operations.

Page 76 of 203 8
Rev.0 9
Page 77
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 2018
IES‐2018 IES 2016
IES‐2016 Grain growth
h
y
Recrystallization p
temperature is one at which The recrystallization behaviour of a particular metal
y Grain growth follows complete crystallization if the materials
(a) crystals first start forming from molten metal alloy is specified in terms of recrystallization
left at elevated temperatures.
p
when
h cooled l d temperature, which is typically 1/3rd of the absolute
y Grain growth does not need to be preceded by recovery and
(b) new spherical crystals first begin to form melting temperature of a metal or an alloy and depends recrystallization; it may occur in all polycrystalline materials.
ll ll l ll l
from the old deformed ones when that strained on several factors including
g the amount of y In contrary to recovery and recrystallization, driving force
metal is heated 1. cold working and purity of the metal and alloy for this process is reduction in grain boundary energy.
(c) the allotropic form changes 2. hot working and purity of the metal and alloy y In practical applications, grain growth is not desirable.
((d)) crystals
y grow bigger
g gg in size Which of the above is/are correct? y Incorporation of impurity atoms and insoluble second phase
(a) 1 only (b) 2 only particles are effective in retarding grain growth.
(c) Both 1 and 2 (d) Neither 1 nor 2 y Grain growth is very strongly dependent on temperature.
13 14 15
Malleability
ll b l
y Malleability is the property of a material whereby it can
y Working below recrystalization temp.
b shaped
be h d when
h cold
ld by
b hammering
h or rolling.
ll
y A malleable
ll bl material
i l is
i capable
bl off undergoing
deformation without fracture.
fracture
d i plastic
l i
g
Cold Working
y A malleable material should be plastic but it is not
essential to be so strong.
g
y Lead, soft steel, wrought iron, copper and aluminium are

some materials in order of diminishing malleability.
Page 77 of 203 17
Rev.0 18
Page 78
Advantages of Cold Working
d f ld k Disadvantages of Cold Working
d f ld k
1. Better accuracy, closer tolerances 1. Equipment of higher forces and power required
2. Better surface finish 2. Surfaces of starting work piece must be free of scale and

S f f t ti k i t b f f l d
dirt
3. 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
19
worked. 20 21
Advantages of Hot Working
1. The porosity of the metal is largely eliminated.
y Working above recrystalization temp.
2. The grain structure of the metal is refined.
3
3. The impurities like slag are squeezed into fibers and
distributed throughout
g the metal.
4. The mechanical properties such as toughness,
percentage elongation, percentage reduction in area, and
H t W ki g
Hot Working resistance to shock and vibration
the refinement of grains.
g
ibration are improved
impro ed due to
22 23 24
Micro Structural Changes in a Hot

Micro‐Structural Changes in a Hot 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
changed.
2. It produces poor surface finish, due to the rapid
Statement (II) : Mechanical properties of metals
oxidation and scale formation on the metal surface.
surface d
depend d on grain
i size
i also
l which
hi h gets
t changed
h d by
b
33. Due to the p
poor surface finish, close tolerance plastic deformation.
cannot be maintained. (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
Page 78 of 203 26
Rev.0 27
Page 79
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
28
dimensional tolerances. 29
flow.
30
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 they (b) Above its recrystallisation temperature (b) Between 100°C to 150°C
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 the
( ) A is true but
(c) b R is false
f l
31 32 33
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:
the grains of metal after it has been distorted by p
In comparison to hot working,
g, in cold working,
g,
follo ing process to relieve
following relie e stresses
hammering or cold working? 1. Higher forces are required
( ) Hot
(a) H working
ki 2. NoN heating
h i is i required
i d
(a) Annealing (b) Softening
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

Page 79 of 203 35
Rev.0 36
Page 80
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
37 38 39
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
40 41 42
ISRO‐2009 IES – 1997 IES – 1996

In
I the
h metall forming
f i process, the
h stresses encountered
d In metals subjected to cold working, strain
I l bj d ld ki i Consider the following statements:
C id h f ll i
are hardening effect is due to y
When a metal or alloy is cold worked
(a) Slip mechanism 1. It is worked below room temperature.
(a) Greater than yield strength but less than ultimate
(b) Twining mechanism 2. It is worked below recrystallisation
I i k d b l lli i temperature.
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
( ) Greater
(c) G than
h the
h ultimate
li strength
h off the
h material
i l increase.
(d) Less than the elastic limit Of these correct statements are
(a) 1 and 4 (b) 1 and 3
( ) 2 and 3
(c) d (d) 2 and 4
d
Page 80 of 203 44
Rev.0 45
Page 81
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
(a) Both A and R are individually true and R is the correct
explanation of A
correct explanation
l i off A
46 47 48
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
(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 (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
49 50 51
Rolling
GATE‐2017 y Definition: The process of plastically deforming
It is desired to make a product having T‐shaped metal by passing it between rolls.
cross‐section
cross section from a rectangular aluminium
block. Which one of the following processes is y Most widely used, high production and close
expected
product?
d to provide
d the
h highest
h h strength
h off the
h g
Rolling tolerance.
(a) Welding (b) Casting y Friction between the rolls and the metal surface
(c) Metal forming (d) Machining produces high compressive stress.
y Hot‐working (unless mentioned cold rolling.)

By S K Mondal
Page 81 of 203 53 y Metal will undergo bi‐axial compression.
Rev.0 54
Page 82
GATE‐2013
In a rolling process, the state of stress of the
material undergoing deformation is
(a) pure compression
(b) pure shear
(c) compression and shear
(d) tension and shear

55 56 57
Hot Rolling
y Done above the recrystallization temp. Ch
Change in grains structure in Hot‐rolling
i i t t i H t lli IAS – 2001
y Results fine grained structure. Consider
C id the
h following
f ll i characteristics
h i i off rolling
lli
process:
y Surface quality and final dimensions are less accurate. 1. Shows work hardening effect
2 Surface finish is not good
2.
y Breakdown of ingots into blooms and billets is done by
3. Heavy reduction in areas can be obtained
h
hot‐rolling.
ll This
h is followed
f ll d by
b further
f h hot‐rolling
h ll into Which of these characteristics are associated with hot
plate sheet,
plate, sheet rod,
rod bar,
bar pipe,
pipe rail.
rail rolling?
(a) 1 and 2 (b) 1 and 3
y Hot rolling is terminated when the temp.
temp falls to Hot rolling is an effective way to reduce grain size in (c) 2 and 3 (d) 1, 2 and 3
about (50 to 100
100°C)
C) above the recrystallization temp.
temp metals for improved
p strength
g and ductility.
y
58 59 60
Cold Rolling
y Done below the recrystallization temp..
ISRO‐2006
Whi h off
Which th following
the f ll i processes would
ld
y Products are sheet, strip, foil etc. with good
produce strongest components?
surface finish and increased mechanical strength
(a) Hot rolling
with close product dimensions.
((b)) Extrusion
y Performed on four‐high or cluster‐type rolling ((c)) Cold rolling
g
mills. (Due to high force and power) (d) Forging

Page 82 of 203 62
Rev.0 63
Page 83
Ring Rolling
y Ring rolls are used for tube rolling, ring rolling.
ISRO‐2009
Ring rolling is used
y As the rolls squeeze and rotate, the wall thickness is
(a) To decrease the thickness and increase
reduced
d d and
d the
h diameter
di off the
h ring
i increases.
i diameter
y Shaped
Sh d rolls
ll can be
b used
d to
t produce
d a wide
id variety
i t off (b) To
T increase
i th thickness
the thi k off a ring
i
cross‐section
cross section profiles.
profiles (c) For producing a seamless tube
y Ring rolls are made of spheroidized graphite bainitic and (d) For producing large cylinder
pearlitic matrix or alloy cast steel base.
64 65 66
Sheet rolling Roll Forming Roll Bending

y In sheet rolling we are only attempting to reduce the
y A continuous form of three‐point bending is roll
cross section thickness
h k off a material.
l
bending, where plates, sheets, and rolled shapes can
be bent to a desired curvature on forming rolls.
y Upper roll being adjustable to control the degree of

curvature.
t
67 68 69
IES – 2006 Shape rolling

Which one of the following is a continuous bending
process in which
h h opposing rolls
ll are used
d to produce
d
long sections of formed shapes from coil or strip
stock?
((a)) Stretch forming

g ((b)) Roll forming
g
((c)) Roll bending

g ((d)) Spinning
p g

Page 83 of 203 71
Rev.0 72
Page 84
Pack rolling Thread rolling Thread rolling contd….

y Pack rolling involves hot rolling multiple sheets of y Used to produce threads in substantial quantities. y Major diameter is always greater than the diameter of the
materiall at once, such
h as aluminium
l f l
foil. y This is a cold‐forming process in which the threads are bl k
blank.
y Improved
I d productivity
d i i 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
y Aluminum sheets (aluminum foil) that cause the metal to flow radially into the desired diameter of the thread.
thread
y Matte, satin side – foil‐to‐foil contact
shape.
p y Restricted to ductile materials.
materials
y Shiny,
h b h side
bright d – foil‐to‐roll
f l ll contact due
d to high
h h contact
stresses with polished rolls y No metal is removed, g
greater strength,
g smoother, harder,
y A thin surface oxide film prevents their welding and more wear‐resistant surface than cut threads.
73 74 75
IES – 1992, GATE‐1992(PI)
Thread rolling is restricted to
(a) Ferrous materials
(b) Ductile materials
( ) Hard materials
(c)
N f h b
76 77 78
IES – 1993, GATE‐1989(PI) IES – 2013 Conventional Manufacture of gears by rolling

The blank diameter used in thread rolling will be Write two advantages of thread rolling and explain y The straight and helical teeth of disc or rod type external
(a) Equal to minor diameter of the thread 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
(b) Equal to pitch diameter of the thread [ M k ]

[ 5 Marks] generated by cold rolling.
rolling
y High accuracy and surface integrity.

integrity
( ) A little large than the minor diameter of the thread
(c)
y Employed for high productivity and high quality.
quality (costly
(d) A little
li l larger
l than
h the
h pitch
i h diameter
di off the
h thread
h d
machine))
y Larger size gears are formed by hot rolling and then

finished by machining.
Page 84 of 203 80
Rev.0 81
Page 85
Roll piercing
Roll piercing
Fig. Gear rolling between three gear roll tools 82 83 84
y It is a variation of rolling called roll piercing.

IAS – 2007
y The billet or round stock is rolled between two rolls,, 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
both of them rotating in the same direction with their the code given below the Lists:
axes at an angle of 4.5 to 6.5 degree. List I List II
y These rolls have a central cylindrical portion with the (Type of Rolling Mill) (Characteristic)
sides tapering slightly.
slightly There are two small side rolls,
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
which help in guiding the metal. B. Three high mills 2. By small working roll, power
y Because of the angle at which the roll meets the metal, for rolling is reduced
it gets in addition to a rotary motion, an additional C. Four high mills 3. Rolls of equal size are
rotated only in one direction
axial advance, which brings the metal into the rolls.
D. Cluster mills 4. Diameter of working roll is
y This cross‐rolling
g action makes the metal friable at the very small
centre which is then easily pierced and given a Code:A B C D A B C D
cylindrical shape by the central
central‐piercing
piercing mandrel. (a) 3 4 2 1 (b) 2 1 3 4
85 86
(c) 2 4 3 1 (d) 3 1 2 4 87
IAS – 2003 IAS – 2000 Planetary mill

y Consist of a pair of heavy backing rolls surrounded by a large
In one setting of rolls in a 3‐high rolling mill, one Rolling very thin strips of mild steel requires number of planetary rolls.
y Each planetary roll gives an almost constant reduction to the
gets (a) Large diameter rolls slab as it sweeps out a circular path between the backing rolls
and the slab.
( ) One
(a) O reduction
d i in i thickness
hi k (b) Small diameter rolls y As each pair of planetary rolls ceases to have contact with the
work piece, another pair of rolls makes contact and repeat
(b) Two
T reductions
d ti i thickness
in thi k ( ) High speed rolling
(c) that
h reduction.
d i
y The overall reduction is the summation of a series of small
(c) Three reductions in thickness (d) Rolling without a lubricant
R lli i h l b i reductions
d ti b each
by h pair
i off rolls.
ll Therefore,
Th f th planetary
the l t millill
can reduce a slab directly to strip in one pass through the
(d) Two or three reductions in thickness depending mill.
mill
y The operation requires feed rolls to introduce the slab into
upon
p the setting
g the mill, and a pair of planishing rolls on the exit to improve
the surface finish.
Page 85 of 203 89
Rev.0 90
Page 86
Camber IES – 1993

In order to get uniform thickness of the plate by
rolling
ll process, one provides
d
( ) Camber
(a) C b on the
h rolls
ll
(b) Offset
Off t on the
th rolls
ll
(c) Hardening of the rolls
(d) Antifriction bearings
y Camber can be used to correct the roll deflection (at only

91 one value of the roll force). 92 93
Defects in Rolling
Lubrication for Rolling IAS – 2004 Defects What is Cause
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 Surface Scale, rust, Inclusions and
increases forces and power consumption. Defects scratches,, impurities
p in the
y Hot rolling of non‐ferrous metals a wide variety of Reason (R): To prevent damage to the surface of the pits, cracks materials
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
Wavy edges Strip is Due to roll
(a) Both A and R are individually true and R is the thinner along g bendingg edges
g
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 its edges than elongates more
viscosity lubricants,
lubricants such as mineral oils,
oils emulsions,
emulsions (b) Both
d v dua y ttrue
ue but R iss not
ot tthee at its centre.
centre and buckle.
buckle
paraffin and fattyy acids.
p Alligatoring Edge breaks Non uniform
Non‐uniform
( ) A is
(c) i true
t b t R is
but i false
f l
deformation
94 95 96
Defects in Rolling
Anisotropy Example
Material develops anisotropy during cold rolling of sheet
•Material develops anisotropy during cold rolling of sheet GATE –
GATE – 2009 (PI)
2009 (PI) A rectangular block 100 mm x 20 mm x 2 mm
metal
Three principal true strain A i t
Anisotropy i rolled
in ll d components
t is
i caused
d by
b
is elongated to 130 mm. If the anisotropy
⎛L ⎞ (a) changes in dimensions
Inlengthdirection, ε l = ln ⎜ f ⎟
⎝ Lo ⎠
(b) scale formation ratio = 2,, find true strain in all directions.
⎛W ⎞
Inwidthdirection, ε w = ln ⎜ f ⎟
⎝ Wo ⎠ (c) closure of defects
⎛t ⎞
Inthethicknessdirection, ε t = ln ⎜ f ⎟
⎝ to ⎠
(d) grain orientation
For isotropicmaterials,ε w = ε t but in a cold rolled sheet ε w ≠ ε t
εw
Anisotropyratio ( r ) =
εt
Page 86 of 203 98
Rev.0 99
Page 87
Geometry of Rolling Process
IES‐2003
A
Assertion
ti (A) While
(A): Whil rolling
lli metal
t l sheet
h t in
i rolling
lli
mill the edges are sometimes not straight and flat
mill,
but are wavy.
y Formula in Rolling
Reason (R) : Non uniform mechanical properties
of the flat material rolled out result in waviness of
the edges.
100 101 102
Draft IAS‐2012 Main GATE‐2007

y Total
T l reduction
d i or “draft”
“d f ” taken
k ini rolling.
lli The thickness of a metallic sheet is reduced from an
What is the significance
g of (1) angle
g of nip,
p and (2)
Δh=h0 - hf =2(R- Rcos α) =D(1- cos α) angle of bite during rolling operation? How are they
initiall value
l off 16 mm to a final
f l value
l off 10 mm in
one single pass rolling with a pair of cylindrical
related to roll friction?
y Usually,
y, the reduction in blooming
g mills is about 100 rollers each of diameter of 400 mm. The bite angle
mm and in slabbing mills, about 50 to 60 mm. [10 marks]
in degree will be
(a) 5.936 (b) 7.936
(c) 8.936 (d) 9.936
103 104 105
GATE – 2012 Same Q in GATE – 2012 (PI) GATE 2017 (PI)

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

Page 87 of 203 107
Rev.0 108
Page 88
Roll strip contact length

Roll strip contact length
GATE‐2018 (PI) GATE‐2004
y Roll strip contact length
R ll i l h In a rolling process, sheet of 25 mm thickness is
A 10 mm thick plate is rolled to 7 mm thickness
L = R α rolled
ll d to 20 mm thickness.
h k Roll
ll is off diameter
d 600
in a rolling mill using 1000 mm diameter rigid
mm and it rotates at 100 rpm.
rpm The roll strip contact
rolls. The neutral point is located at an angle of [ α must be in radian]
length will be
0.3 times the bite angle from the exit. The
((a)) 5 mm ((b)) 39 mm
thickness (in mm, up to two decimal places) of
((c)) 778 mm ((d)) 120 mm
the
h plate
l at the
h neutrall point is ______
109 110 111
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
112 113 114
GATE 2016
GATE-2016
GATE 2014 GATE 2018
In a rolling process,
process the maximum possible draft,draft The maximum possible draft in rolling,
rolling A 300 mm thick slab is being cold rolled using
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 which is the difference between initial and roll
ll off 600
6 mm diameter.
di t If the
th coefficient
ffi i t off
depends on which pair of the following parameters? final thicknesses of the sheet metal,
friction is 0 08,
0.08, the maximum possible
P: Strain depends on
Q: Strength of the work material reduction (in mm) is ____________
(a) rolling force
R: Roll diameter
S: Roll velocity (b) roll
ll radius
di
T: Coefficient of friction between roll and work (c) roll width
(a) Q, S (b) R, T
(d) yield shear stress of the material
(c) S, T (d) P, R
Page 88 of 203 116
Rev.0 117
Page 89
GATE 2015
GATE-2015 GATE 2015
GATE-2015 IES – 1999
In a rolling operation using rolls of diameter 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
limit to the possible reduction in thickness in one
500 mm , if a 25 mm thick
thi k plate
l t cannott be
b thickness reduction(∆h)max is given by ∆hmax = µ
µ²R
R,
pass.
reduced to less than 20 mm in one pass, the 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.
coefficient of friction between the roll and the
( ) Both
h
plate is _______ 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
118 119 120
Minimum Possible Thickness (h f min ) GATE‐2006 Number of pass needed

A 4 mm thick sheet is rolled with 300 mm diameter
ho − h f min = μ 2 R rolls
ll to reduce
d thickness
h k without
h any change
h in its
width The friction coefficient at the work‐roll
width. work roll
n=
Δhrequired
q
interface is 0.1. The minimum possible thickness of
the sheet that can be produced in a single pass is
Δhmax
(a) 1.0 mm (b) 1.5 mm
(c) 2.5 mm (d) 3.7 mm
121 122 123
G
GATE – 20 ( )
2011 (PI) IES – 2001 GATE‐2014(PI)
The
Th thickness
hi k off a plate
l is
i reduced
d d from
f 30 mm to 10 A strip is to be rolled from a thickness of 30 mm to A 80 mm thick steel plate with 400 mm width is
mm by successive cold rolling passes using identical 15 mm using a two‐high
h h mill
ll having
h rolls
ll off rolled
ll d to
t 40 mm thickness
thi k i 4 passes with
in ith equall
rolls of diameter 600 mm. Assume that there is no diameter 300 mm.
mm The coefficient of friction for reduction in each pass, by using rolls of 800 mm
change in width. If the coefficient of friction unaided bite should nearly be diameter. Assuming the plane‐strain deformation,
between the rolls and the work piece is 0.1, the what is the minimum coefficient of friction
((a)) 0.35
35 ((b)) 0.55
minimum number of passes required is required for unaided rolling to be possible?
((c)) 0.255 ((d)) 0.077
( ) 0.111
(a) (b) 0.158
8 ( ) 0.223
(c) (d) 0.316
6
(a) 3 (b) 4 (c) 6 (d) 7

Page 89 of 203 125
Rev.0 126
Page 90
Neutral Point and Neutral Plane
The point
Th i where
h roll
ll velocity
l i equals
l IES 2014
IES ‐
work velocity is known as the no‐slip V0 = input velocity In the process of metal rolling operation, along the arc
point
i t or the
th neutral
t l point.
i t Vf = final or output velocity 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
R roll radius
R = roll radius 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
ho = back height
the roll is ….A…..than
A than the entry velocity of the and on the other side,, the work material is in compression
p
hf =output or final
fi l
thickness (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
α = angle of bite velocity lesser than that of the roll
strip.
N N neutral point or no
N‐N = neutral point or no‐ ( ) On
(c) O one side id off this
thi point,
i t the
th work k material
t i l has
h rough h
slip point (a) less than/greater less
Vr − Vo surface finish and on the other side, the work material has
Backward slip = × 100% To the left of the Neutral Point: very fine
fi finish
fi i h
Vr (b) Greater than/less than
V f − Vr
Velocity of the strip < Velocity of the roll (d) At this ppoint there is no increase in material width, but
Forward slip = × 100% To the right of the Neutral Point: on either side of neutral point, the material width increases
Vr Velocity of the strip > Velocity of the roll
127 128 129
GATE ‐2008(PI) IES – 2002 Selected Questions

In a rolling process, thickness of a strip is reduced In rolling a strip between two rolls, the position of The effect of friction on the rolling mill is
f
from 4 mm to 3 mm using 300 mm diameter
d rolls
ll the
h neutrall point in the
h arc off contact does
d not (a) always bad since it retards exit of reduced metal
rotating at 100 rpm.
rpm The velocity of the strip in depend on (b) always good since it drags metal into the gap between
(m/s) at the neutral point is (a) Amount of reduction (b) Diameter of the rolls th rolls
the ll
((a)) 1.57
57 ((b)) 33.14
4 ((c)) 47
47.10 ((d)) 94
94.20 (c) Coefficient of friction (d) Material of the rolls (c) advantageous before the neutral point
(d) disadvantageous after the neutral point
130 131 132
C ti it E
Continuity Equation
ti GATE‐2014 Elongation Factor or Elongation Co‐efficient
y Generally rolling increases the
work width from an initial value A mild steel plate has to be rolled in one pass such L1 Ao
of bo to a final one of bf and this
that the final plate thickness is 2/3rd of the initial E= = for single pass
is called spreading. Lo A1
y The
Th inlet
i l and
d outlet
l volume
l thickness,
hi k with
i h the
h entrance speed
d off 10 m/min
/ i
rates of material flow must be Ln Ao
the
h same, thath is,
i and roll diameter of 500 mm.
mm If the plate widens
En = = f n − pass
for
hobovo = hf bfvf byy 2% during
g rolling,
g, the exit velocityy ((in m/min)
/ ) Lo An
where vo and vf are the entering
g is ……………
and exiting velocities of the
work.

Page 90 of 203 134
Rev.0 135
Projected length ( Lp ) = R sin α = RΔh , mm
Page 91
Force, Torque and Power
GATE‐1992(PI) Projected
j Area ( Ap ) = L p × b , mm 2
If the elongation factor during rolling of an ingot is
g Force ( F ) = σ o × L p × b , N
RollSeparating
p
1.22. The minimum number of passes needed to
produce
d a section
i 250 mm x 250 mm from
f an ingot
i
[σ o in N / mm 2 i.e. MPa ]
of 750 mm x 750 mm are e gt ( a in mm ) = 0.5L p for
Arm length o hot
ot rolling
o g
(a) 8 (b) 9 = 0.45 L p for cold rolling
a
ll (T ) = F ×
(c) 10 (d) 12
Will b
be T
Torque per roller , Nm
N
discussed 1000
136 in class137 Total power for two roller ( P ) = 2T ω , inW 138
GATE‐2016 (PI) GATE‐2008 GATE‐2017

In a single pass rolling operation, a 20 mm thick A strip
i off 120 mm width
id h andd 8 mm thickness
hi k is
i
In a single‐pass rolling operation, a 200 mm wide
plate
l t with
ith plate
l t width
idth off 100 mm, is
i reduced
d d to
t 18
8 rolled between two 300 mm ‐ diameter rolls to get
metallic strip is rolled from a thickness 10 mm to a a strip of 120 mm width and 7.2 mm thickness.
mm. The roller radius is 250 mm and rotational
thickness 6 mm. The roll radius is 100 mm and it rotates Th speed
The d off the
th strip
t i att the
th exit
it is
i 30 m/min.
/ i
speed is 10 rpm. The average flow stress for the plate There is no front or back tension. Assuming g
at 200 rpm.
rpm The roll‐strip
roll strip contact length is a function of
material is 300 MPa. The power required for the uniform roll pressure of 200 MPa in the roll bite
roll radius and,
and initial and final thickness of the strip.
strip If and 100% mechanical efficiency,
efficiency the minimum
rolling operation in kW is closest to
the average
g flow stress in p
plane strain of the strip
p total power (in kW) required to drive the two
( ) 15.2
(a) (b) 18.2
8 rolls is___________
material in the roll gap is 500 MPa, the roll separating
(c) 30.4
30 4 (d) 45 6
45.6
force (in kN) is _______. 139 140 141
IAS ‐2017 Main

IAS ‐2017 Main
An annealed copper
pp p plate of 3300 mm width and 20
IES – 2000, GATE‐2010(PI) IAS – 2007
In the rolling process, roll separating force can be Consider
C id theh following
f ll i statements:
mm thickness is rolled to 16 mm thickness in one g can be reduced byy
Roll forces in rolling
pass. Considering radius of the roller as 400 mm, d
decreased
d by
b
1. Reducing friction
rotational speed of 80 rpm and average
a erage flow
flo stress ( ) 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
during rolling as 400 MPa, calculate the true strain area.
(b) Increasing
I i the
th roll
ll diameter
di t
and rolling force (kN). 3. Taking smaller reductions per pass to reduce the
(c) Providing back‐up
back up rolls contact area.
area
[10 Marks] Which of the statements given above are correct?
(d) Increasing the friction between the rolls and the
metal (c) 1 and 3 only (d) 1, 1 2 and 3
Page 91 of 203 143
Rev.0 144
Page 92
Assumptions in Rolling IES – 2001 IAS ‐2012 Main

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
2. Strip
p is wide compared
p with its thickness,, so that no cold rolling?
What is friction hill ?
What is "friction hill" ?
widening of strip occurs (plane strain conditions). 1. The material is plastic.
2. The arc of contact is circular with a radius g greater than
3 The arc of contact is circular with a radius greater than
3.
the radius of the roll.
the radius of the roll.
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
st e gt ).
strength). contact.
contact
5. The co‐efficient of friction is constant over the tool‐ Select the correct answer using the codes given below:
workk interface.
i t f Codes:
d
((a)) 1 and 2 ((b)) 1 and 3
145
(c) 2 and 3 (d) 1, 2 and 3 146 147
For IES Only
IAS – 1998
What is ragging?
What is ragging? IFS –
IFS – 2010
2010 Match
M h ListLi ‐ I (products)
( d ) with
i h List
Li ‐ II (processes)
( )
and select the correct answer using the codes given
y Ragging is the process of making certain Calculate the neutral plane to roll 250 mm wide
below the lists:
fine grooves on the surface of the roll to annealed copper
pp strip
p from 2.55 mm to 2.0 mm List – I List ‐II
II
increase the
h friction.
f
thickness with 350 mm diameter steel rolls. Take µ A. M.S. angles and channels 1. Welding
y In case of primary reduction rolling mills
= 0.05 and σ’o =180 MPa. B. Carburetors 2. Forging
such as blooming or rough rolling mills for
C Roof trusses
C. 3
3. Casting
structural elements the rolls may ragged. [10‐marks]
D. Gear wheels 4. Rolling
Codes: A B C D A B C D
(a) 1 2 3 4(b) 4 3 2 1
148 149 (c) 1 2 4 3(d) 4 3 1 2150
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
Page 92 of 203 152
Rev.0 153
Page 93
IES‐2013
IES‐2016 Statement (I): The dies used in the forging process are Open and Closed die forging
d l dd f
made in pair.
pair y Depending
D di upon complexity
l i off the
h part forging
f i is
i
Illustrate the difference between 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
(i) open die forging and shape.
p y In open die forging, the metal is compressed by repeated
bl
blows b a mechanical
by h i l h
hammer and
d shape
h i
is
(ii) closed die forging with appropriate manipulated manually.
true and Statement (II) is the correct explanation of
sketches Statement (I) y In closed die forging, the desired configuration is
(b) Both Statement (I) and Statement (II) are individually obtained
b i d byb squeezing i the
h workpiece
k i b
between two
[4
[4 Marks]
] true but Statement ((II)) is not the correct explanation
p of shaped and closed dies.
Statement (I)
154
(d) Statement (I) is false but Statement (II) is true 155 156
Advantages of Forging
d f Disadvantages of Forging
d f IES – 1996
y Discrete
Di shape
h off product
d can be
b produced.
d d y Costly
C l Which one of the following is an advantage of
y Mechanical properties and reliability of the materials y Poor dimensional accuracy and surface finish.
finish forging?
increases due to improve in crystal structure.
y Forging operations are limited to simple shapes and has
( ) Good
(a) G d surface
f fi i h
finish
y In forging favorable grain orientation of metal is limitations for parts having undercuts, re‐entrant
obtained that strengthen the component but forging surfaces etc
surfaces, (b) Low
L tooling
t li costt
distorts the previously created uni‐directional fibre.
(c) Close tolerance
y Forging reduces the grain size of the metal, which
increases strength and toughness.
toughness (d) Improved physical property.
property
y Fatigue and creep strength increases.
157 158 159
IES‐2013 IES 2005

IES – IES ‐ 2012
Consider the following statements: Statement (I): It is difficult to maintain close
In the forging process:
I h f i
tolerance in normal forging operation.
1. The metal structure is refined
Th t l t t i fi d 1. Forging reduces the grain size of the metal, which Statement (II): Forging is workable for simple
results in a decrease in strength
g and toughness.
g shapes and has limitation for parts having
2 Original unidirectional fibers are distorted.
2. Original unidirectional fibers are distorted undercuts.
undercuts
2. Forged components can be provided with thin (a) Both Statement (I) and Statement (II) are
3 Poor reliability as flaws are always there due to intense
3. Poor reliability, as flaws are always there due to intense i di id ll true and
individually d Statement
S (II) is
i theh correct
sections, without reducing the strength. explanation of Statement (I)
working
g
Which of the statements given above is/are correct? (b) Both Statement (I) and Statement (II) are
4
4. Part are shaped by plastic deformation of material
p yp individuallyy true but Statement ((II)) is not the correct
(a) Only 1 (b) Only 2 explanation of Statement (I)
(a) 1, 2 and 3 (b) 1, 3 and 4 (c) Statement (I) is true but Statement (II) is false
(c) Both 1 and 2 (d) Neither 1 nor 2 (d) Statement (I) is false but Statement (II) is true 162
(c) 1, 2 and 4 (d) 2, 3 and 4
Page 93 of 203 161
Rev.0
Page 94
IES 2016
IES‐2016 ISRO‐2013 Forgeability
bl
Consider the following g statements about forging
g g:
Which of the following processes induce more stress y The
Th forgeability
f bili off a metall can be
b defined
d fi d as its
i
1. Forgings have high strength and ductility.
capability to undergo deformation by forging without
2. Forgings
F i offer
ff greatt resistance
i t t impact
to i t and
d in the metal?
cracking.
fatigue loads.
(a) Hot rolling y Metal
M l which
hi h can be
b formed
f d easily
il without
ih cracking,
ki with
ih
3. Forging assures uniformity in density as well as
dimensions of the forged parts. ((b)) Forging
g g low force has good forgeability.
Which of the above statements are correct? (c) Swaging y Upsetting test and Hot‐twist test are used to determine
(a) 1 and 2 only (b) 1 and 3 only f
forgeability.
bili
(d) Turning
(c) 2 and 3 only (d) 1,
1 2 and 3 y Forgeability increases with temperature.
temperature
163 164 165
IES ‐ 2012 Draft

f IES – 2006
Which
f ll i statements is i correct for
f y The
Th draft
d f provided
id d on the
h sides
id for
f withdrawal
i hd l off the
h Assertion
A i (A):
(A) Forging
F i dies
di are provided id d with
i h taper
forging? forging. or draft angles on vertical surfaces.
(a) Forgeability is property of forging tool, by which y Adequate draft should be provided‐at least 3o for Reason (R): It facilitates complete filling of die
forging can be done easily.
easily aluminum
l i d 5 to 7o for
and f steel.
l cavity and favourable grain flow.flow
(b) Forgeability decreases with temperature upto lower (a) Both A and R are individually true and R is the
criticall temperature. y Internal surfaces require more draft than external correct explanation
l off A
surfaces. During cooling, forging tends to shrink towards
(c) Ce
Certain
ta mechanical
ec a ca p properties
ope t es o
of tthee material
ate a aaree (b) Both
d v dua y ttrue
ue but R iss not
ot tthee
i centre and
its d as a result,
l the
h externall surfaces
f are likely
lik l
influenced by forging. correct explanation of A
to be separated, whereas the internal surfaces tend to
(d) Pure
P metals
t l have
h good d malleability,
ll bilit therefore,
th f poor cling to the die more strongly. ( ) A is
(c) i true
t b t R is
but i false
f l
forging properties. (d) A is false but R is true
166 167 168
Flash
l h Flash
l h Contd… IES ‐ 2014
The
Th excess metall added
dd d to the
h stockk to ensure complete
l y A flash
fl h acts as a cushion
hi for
f impact
i blows
bl from
f the
h In
I hot
h die di forging,
f i thin
hi layer
l off material
i l all
ll around
d
filling of the die cavity in the finishing impression is finishing impression and also helps to restrict the the forging is
called Flash. outward flow of metal, thus helping in filling of thin ribs (a) Gutter space, which fills up hot gases
and bosses in the upper
pp die. (b) Flash,
Flash the width of it is an indicator of the pressure
y The amount of flash depends on the forging size and developed in the cavity
may vary from 10 to 50 per cent. (c) Coining, which indicates the quality of the forging
y The
Th forging
f i l d can be
load b decreased
d d by
b increasing
i i the
h (d) Cavity,
Cavity which is filled with hot impurities in the
flash thickness. material

Page 94 of 203 170
Rev.0 171
Page 95
IES‐2016
Statement (I) : In drop forging, the excess metal IAS – 2002 Gutter
added to the stock for complete filling of the die Consider the following statements related to
C id h f ll i l d y In
I addition
ddi i to the
h flash,
fl h provision
i i should
h ld be
b made
d in
i the
h
cavity is called flash. forging: die for additional space so that any excess metal can flow
Statement (II) : Flash acts as a cushion against 1. Flash is excess material added to stock which flows and help in the complete closing of the die. This is called
impact
p blows attributable to the finishing g around parting line.
around parting line g
gutter.
impression.
2. Flash helps in filling of thin ribs and bosses in upper
(a) Both Statement (I) and Statement (II) are individually true and die.
Statement (II) is the correct explanation of Statement (I).
3. Amount of flash depends upon forging force.
ou t o as depe ds upo o g g o ce.
Which of the above statements are correct?
Statement ((II)) is not the correct explanation
)
( ) 1, 2 and 3
(a) d (b) 1 and 2d
(c) 1 and 3 (d) 2 and 3
172 173 174
Gutter Contd…. IES – 1993, GATE‐1994(PI) IES – 1997

Assertion
A ti (A):
(A) In
I drop
d forging
f i besides
b id theth provision
i i
y Without a gutter, a flash may become excessively thick, Which one of the following manufacturing processes
for flash, provision is also to be made in the forging
not allowing
ll the
h dies
d to close
l completely.
l l requires the
h provision off ‘gutters’?
‘ ’ di for
die f additional
dditi l space called
ll d gutter.
tt
Reason (R): The gutter helps to restrict the outward
y Gutter
G d h and
depth d width
id h should
h ld be
b sufficient
ffi i to ( ) Closed
(a) Cl d die
di forging
f i flow of metal thereby helping to fill thin ribs and
bases in the upper die.
accommodate the extra,
extra material.
material (b) Centrifugal
C t if l casting
ti
(c) Investment casting correct
co ect eexplanation
p a at o o of A
(d) Impact extrusion correct explanation of A
(d)
175 176 177
Sequential steps involved in closed die forging
IES‐2015 Fullering or Reducing cross section and making it longer.
Which of the following statements apply to provision swaging
GATE‐1989(PI) of flash gutter and flash land around the parts to be
Edging or rolling Preform shape. Gathers the material as required
Preform shape Gathers the material as required
in the final forging.
At the
th last
l t hammer
h stroke
t k the
th excess material
t i l forged? B di
Bending R
Required for those parts which have a bent
i d f th t hi h h b t
shape
from the finishing cavity of a forging die is 1. Small cavities are provided which are directly outside
Drawing or
k f ll b / f l d is reduced
Like fullering but c/s of only one end d d
the die impression. cogging
pushed into……………..
p 2 The volume of flash land and flash gutter should be
2. Flattening Flatten the stock so that it fits properly into the
about 20%‐25% of the volume of forging. finishing impression.
3. Gutter
G tt is i provided
id d to
t ensure completel t closing
l i off the
th Blocking Semi‐finishing impression, Imparts to the
die. forging it’s general but not exact or final shape.
g g g p
Finishing Final impression, Flash land and Gutter
((c)) 1,, 2 and 3 ((d)) 2 and 3 onlyy provided to the die.
to the die
Trimming or cut Removal of flash present around forging
Page 95 of 203 179
Rev.0 180
ff
Page 96
Example
l IES – 1998 IES – 2001
Which one of the following processes is most In the forging operation, fullering is done to
commonly
l used
d for
f the
h forging
f off bolt
b l heads
h d off (a) Draw out the material
hexagonal shape? (b) Bend the material
(a) Closed die drop forging ( ) Upset the material
(c)
(b) Open die upset forging (d) Extruding the material
E di h i l
(c) Close die press forging
((d)) Open
p die p
progressive
g forging
g g
181 182 183
IES – 2003 IES 2011 IES – 2005

A forging method for reducing the diameter of a bar Which of the following processes belong to forging The process of removing the burrs or flash from a
operation
p ?
and
d in the
h process making
k it longer
l is termed
d as f
forged
d component in drop
d f
forging is called:
ll d
1. Fullering
( ) Fullering
(a) F ll i (b) P
Punching
hi 2. Swaging
S i ( ) Swaging
(a) S i (b) P f
Perforating
i
33. Welding g
( ) Upsetting
(c) U tti (d) E t di
Extruding ( ) Trimming
(c) Ti i (d) F ttli
Fettling
(a) 1 and 2 only
(b) 2 and d 3 only
l
(c) 1 aand
d3o onlyy
(b) 1, 2 and 3 only
184 185 186
IAS – 2001
Matchh List I (Forging
( operations)) with
h List II
IES – 2002 IES – 2003 (Descriptions) and select the correct answer using
Consider
f ll i steps involved
i l d in
i hammer
h Consider
C id theh following
f ll i steps in i forging
f i a connecting i the codes given below the Lists:
forging a connecting rod from bar stock: rod from the bar stock: List I List II
1. Blocking 2. Trimming 1. Blocking 2. Trimming A. Flattening 1.Thickness is reduced continuously at
3 Finishing 4.
3. 4 Fullering 5 Edging
5. 3 Finishing 4.
3. 4 Edging different sections along length
B. Drawing 2.Metal is displaced away from centre,
Which of the following is the correct sequence of Select the correct sequence of these operations using the reducing thickness in middle and
operations? codes given below: increasing length
(a) 1,
1 4,
4 3,
3 2 and 5 Codes: C
C. Fullering 3 Rod is pulled through a die
3.
(b) 4, 5, 1, 3 and 2 (a) 1‐2‐3‐4 (b) 2‐3‐4‐1 D. Wire drawing 4. Pressure a workpiece between two flat
Codes:A B C dies
di D A B C D
(c) 5, 4, 3, 2 and 1 (c) 3‐4‐1‐2 (d) 4‐1‐3‐2
(a) 3 2 1 4 (b) 4 1 2 3
(d) 5,
5 1,
1 4,
4 2 and 3
(c) 3 1 2 4 (d) 4 2 1 3
Page 96 of 203 188
Rev.0 189
Page 97
IES‐2012 Conventionall IAS – 2003 Drop Forging

In
I forging
f i define
d fi the
h terms Match
M h List Li I (Forging
(F i Operation)
O i ) withi h List
Li II (View
(Vi off the h
y The drop forging die consists of two halves. The lower
Forging Operation) and select the correct answer using the
((i)) Edging
g g codes
d given
i b l
below th lists:
the li t h lf off the
half h die
d is fixed
f d to the
h anvill off the
h machine,
h while
hl
(ii) Fullering List‐I List‐II
and d (iii) Flash
Fl h (Forging Operation) (View of the Forging Operation) the upper half is fixed to the ram.
ram The heated stock is
g g
(A) Edging 1
1. kept in the lower die while the ram delivers four to five
2.
(B) Fullering
(C) Drawing
blows on the metal, in quick succession so that the metal
3. 4.
(D) Swaging spreads and completely fills the die cavity. When the two
C d A B
Codes:A C D A B C D
die halves close, the complete cavity is formed.
(a) 4 3 2 1 (b) 2 1 4 3
(c) 4 1 2 3 (d) 2 3 4 1 y Drop forging is used to produce small components.
190 191 192
Click to see file Page 4 – 5 ‐6
IES – 1994, ISRO‐2010 IAS – 2000

InI drop
d forging,
f i forging
f i isi done
d by
b dropping
d i Drop
D forging
f i isi used
d to produce
d
((a)) The work ppiece at high
g velocityy ((a)) Small components
p
(b) The hammer at high velocity. (b) Large components
( ) The
(c) Th die
di with
i h hammer
h at high
hi h velocity
l i ( ) Identical
(c) Id i l Components
C i large
in l numbers
b
((d)) a weight
g on hammer to p produce the requisite
q ((d)) Medium‐size components
p
impact.
193 194 195
Press Forging
g g IES 2011
IES 2011
y Metal is squeezed gradually by a hydraulic or mechanical Advantages of Press Forging over Drop Forging Consider the following statements :
press and component is produced in a single closing of 1. Any metal will require some time to undergo
y Press forging is faster than drop forging
die, hence the dimensional accuracy is much better than complete
p plastic deformation p
p particularly
y if
d
drop f i
forging. y Alignment of the two die halves can be more easily deforming metal has to fill cavities and corners of
small radii.
maintained
i i d than
h with
i h hammering.
h i
2. For larger work piece of metals that can retain
y Structural
St t l quality
lit off the
th product
d t is
i superior
i tot drop
d toughness
h at forging
f i temperature it i is
i preferable
f bl to
forging.
forging use forge press rather than forge hammer.
(a) 1 and 2 are correct and 2 is the reason for 1
y With ejectors in the top and bottom dies, it is possible to (b) 1 and 2 are correct and 1 is the reason for 2
handle reduced die drafts. (c) 1 and 2 are correct but unrelated
(d) 1 only correct
Page 97 of 203 197
Rev.0 198
Page 98
Machine Forging
h Upset Forging
IFS‐2011 y Unlike the drop or press forging where the material is y Increasing the diameter of a material by compressing its
What advantages does press forging have over drop d
drawn out, in machine
h f
forging, the
h materiall is only
l upset l
length.
h
forging
g g ? Whyy are p
pure metals more easilyy cold worked 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
than alloys ?
cavities.
cavities
[5‐marks]
199 200 201
Roll Forging
ll Roll Forging
ll Contd….
Skew Rolling
y When the rolls are in the open position, the heated stock y A rapid
id process. y Skew rolling produces
metal ball
is advanced
d d up to a stop. As the
h rolls
ll rotate, they
h grip and
d
y Round stock is fed
roll down the stock.
stock The stock is transferred to a second
continuously to two
set of grooves. The rolls turn again and so on until the p y
specially designed
g
opposing rolls.
piece is finished.
y Metal is forged by each
of the grooves in the rolls
and emerges from the
end as a metal ball.
ball
202 203 204
IES – 2008
IES
Smith Forging
h IES – 2005 Match List‐I with List‐II and select the correct answer using
Match the code given below the lists:
y Blacksmith
Bl k i h uses this
hi forging
f i method
h d M t h List
Li t I (Type
(T off Forging)
F i ) withith List
Li t II (Operation)
(O ti )
and select the correct answer using the code given List‐I (Forging Technique) List‐II (Process)
y Quality of the product depends on the skill of the below the Lists: A Smith Forging
A. Smith Forging 11. Material is only upset to get the
operator. List I List II desired shape
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
y Not used in industry. pressure is applied on the heated end
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
pushed D. Machine Forging 4. Done in closed impression dies by
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
(a) 4 1 2 3 (b) 3 2 1 4 (a) 2 3 4 1 (b) 4 3 2 1
(c) 4 2 1 3 (d) 3 1 2 4206 (c) 2 1 4 3 (d) 4 1 2 3207
Page 98 of 203 Rev.0
IES‐2013
Hi h V l it F i (HVF)
High Velocity Forming (HVF) Statement (I): In high velocity forming process, high
y The
ep ocess de
process o s metals
deforms eta s by us g ve
using veryy high
provided on the movements of rams and dies.
g ve oc t es,
velocities, gy can be transferred to metal with relativelyy small
energy
weight.
IFS‐2011
Statement (II): The kinetic energy is the function of Write four advantages of high velocity forming process.
y As K.E ∞ V2, high energy is delivered to the metal with [2‐marks]
mass and velocity.
relativelyy small weights
g ((ram and die).
)
y Cost and size of machine low. true and Statement ((II)) is the correct explanation
p of
y Ram strokes short (due to high acceleration) Statement (I)
(b) Both
B th Statement
St t t (I) and
d Statement
St t t (II) are individually
i di id ll
y Productivity high, overall production cost low true but Statement (II) is not the correct explanation of
y Used for Alloy steel, titanium, Al, Mg, to fabricate one Statement (I)
()
piece complex components of smaller size like valve, (c) Statement (I) is true but Statement (II) is false
rocket component. 208 (d) Statement (I) is false but Statement (II) is true 209 210
For IES Only
Flashless forging
y The work material is completely surrounded by the die IES – 2008
IAS‐2011 Main
IAS‐2011 Main cavity during compression and no flash is formed. The
Th balls
b ll off the
h ball
b ll bearings
b i are manufactured
f d
y Most important requirement in flashless forging is that from steel rods. The operations involved are:
C
Compare S ith forging,
Smith f i d
drop f i
forging, press
the work volume must equal the space in the die cavity to 1. Ground
forging and upset forging.
forging Mention three points a very close tolerance.
tolerance 2 Hot forged on hammers
2.
for each. 3. Heat treated
4. Polished
[10 – Marks]
Wh t is
What i the
th correctt sequence off the th above
b
operations from start?
(a) 3‐2‐4‐1 (b) 3‐2‐1‐4
(c) 2‐3‐1‐4 (d) 2‐3‐4‐1
211 212 213
Lubrication for Forging
b f Forging Defects
f Forging Defects
f Contd….
y Lubricants influence: friction, wear, deforming forces y Unfilled Sections: Die cavity is not y Scale
S l Pits:
Pi Irregular
I l depressions
d i on the
h surface
f due
d to
improper cleaning of the stock.
and
d flow
fl off materiall in die‐cavities,
d non‐sticking,
k completely
l l filled,
f ll d due
d to improper y Die Shift: Due to Misalignment of the two die halves or
thermal barrier.
barrier design of die making the two halves of the forging to be of improper
shape.
y For hot forging: graphite,
graphite MoS2 and sometimes molten y Cold Shut or fold: A small crack at y Flakes:
l k Internall ruptures caused d by
b the
h improper
g
glass. the corners and at right
g angles
g to cooling.
y Improper Grain Flow: This is caused by the improper
y For cold forging:
g g mineral oil and soaps.
p the forged surface. Cause: improper
design of the die,
die which makes the flow of metal not
y In hot forging, the lubricant is applied to the dies, but in
design of the die flowing the final intended directions.
cold forging, it is applied to the workpiece.

Page 99 of 203 215
Rev.0 216
Page 100
Forging Defects
f Contd…. IAS – 1998 IES 2011
y Forging Laps: These are folds of metal squeezed The
Th forging
f i defect
d f due
d to hindrance
hi d to smooth
h flow
fl Assertion (A) ( ) : Hot tears occur during
d forging
f
of metal in the component called 'Lap' occurs because of inclusions in the blank material
together
h during
d f
forging. They
h have
h irregular
l contours because Reason (R) : Bonding between the inclusions
and occur at right angles to the direction of metal flow.
flow (a) The corner radius provided is too large and the p parent material is through
g p physical
y
and chemical bonding.
(b) The corner radius provided is too small
y Hot tears and thermal cracking: These are surface (a) Both A and R are individually true and R is the
(c) Draft is not provided correct explanation of A
cracks occurring
g due to non‐uniform cooling
g from the (d) The shrinkage allowance is inadequate (b) Both A and R are individually true but R is NOT
forging stage or during heat treatment. the correct explanation of A
( ) A is true but
(c) b R is false
f l
((d)) A is false but R is true
217 218 219
B lli
Barrelling
GATE ‐2008 (PI)
GATE ‐2008 (PI) IES ‐
IES ‐ 2007
Match the following
S
Sometimes
ti th parting
the ti plane
l b t
between t
two f i
forging
Group ‐1 Group‐2
P Wrinkling
P . 1 Upsetting
1. Upsetting dies is not a horizontal plane,
plane give the main reason
Q. Centre burst 2. Deep drawing for this design
g aspect,
p whyy is p
parting
g p
plane
R. Barrelling 3. Extrusion provided, in closed die forging?
S C ld h t
S. Cold shut 4. Closed die forging
Cl d di f i
[ 2 marks]
(a) P – 2, Q – 3, R – 4, S‐1 (b) P – 3, Q – 4, R – 1, S‐2
(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
Inhomogeneous deformation with barreling of the workpiece
220 221 222
IES‐2013
Consider
C id the
h following
f ll i statements pertaining i i to the
open‐die forging of a cylindrical specimen between
h Die Materials Should have
l h ld h GATE ‐2010 (PI)
two flat dies: 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,
1 Lubricated specimens show more surface movement
1. elevated temperatures
p
should
h ld necessarily
l have
h
than un‐lubricated ones. y Adequate fatigue resistance
2. Lubricated
b d specimens show
h l
less surface
f movement ( ) high
(a) hi h strength
h and
d high
hi h copper content
y Sufficient hardenability
than un‐lubricated ones.
y Low thermal conductivity (b) high
hi h hardness
h d and
d low
l hardenability
h d bilit
3. Lubricated specimens show more barrelling than un‐
lubricated ones.
ones y Amenability to weld repair
A bili ld i (c) high toughness and low thermal conductivity
4. Lubricated specimens shows less barrelling than un‐
lubricated ones. y Good machinability (d) high hardness and high thermal conductivity
Which of these statements are correct? Material: Cr‐Mo‐V‐alloyed tool steel and Cr‐Ni‐Mo‐
y
(a) 1 and 3 (b) 1 and 4 (c) 2 and 3 (d) 2 and 4223 alloyed tool steel.
For-2019(IES, GATE & PSUs) Page 100 of 203 224
Rev.0 225
IES 2013
IES‐2013
Statement (I): In power forging energy is provided by
compressed d air
i or oil
il pressure or gravity.
it
Statement ((II):) The capacity
p y of the hammer is g given byy
the total weight, which the falling pans weigh.
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)
226 227 228
True Stress & True Strain GATE‐2014 GATE‐1992, ISRO‐2012, VS‐2013

True stress (σ T ) = σ (1 + ε ) The relationship between true strain (εT ) and
The true strain for a low carbon steel bar
⎛ L⎞ engineering strain (ε
( E ) in a uniaxiall tension test is
⎛A ⎞ ⎛d ⎞
True strain (ε T ) = ln(1
( + ε ) = ln ⎜ ⎟ = ln ⎜ o ⎟ = 2 ln ⎜ o ⎟ which is doubled in length by forging is
⎝ Lo ⎠ ⎝ A⎠ ⎝d ⎠ ( ) E = ln(1 + ε
(a) ε l ( T ) (b) E = ln(1 ‐
(b) ε l ( εT )
((a)) 0.307
3 7
( ) εT = ln(1 + ε
(c) l ( E ) (d) T = ln(1 ‐
(d) ε l ( εE )
(b) 0.5
(c) 0.693
0 693
(d) 1.0
10
229 230 231
GATE‐2016 GATE‐2007
In open‐die forging, a disc of diameter 200
GATE‐2017 (PI)
GATE‐2017 (PI)
Engineering strain of a mild steel sample is
mm and height 60 mm is compressed A steell wire
i off 2 mm diameter
di i to be
is b drawn
d
recorded as 0.100%. The true strain is
without any barreling effect. The final f
from a wire
i off 5 mm diameter.
di t TheTh value
l off
(a) 0.010 %
diameter of the disc is 400 mm. The true true strain developed
de eloped is _____________(up
(up
(b) 0.055 %
strain is to three decimal places).
places)
((c)) 0.099
99 %
(a) 1.986 (b) 1.686
(d) 0.
0.101
0 %
(c) 1.386 (d) 0.602
Page 101 of 203 233
Rev.0 234
Page 102
GATE‐2016 GATE 2017

GATE‐2017
GATE‐2018
A rod of length 20 mm is stretched to make a rod
The value of true strain produced in A bar is compressed to half of its original
of length 40 mm. Subsequently, it is compressed
compressing a cylinder to half its original length. The magnitude of true strain
to make a rod of final length 10 mm. Consider the
length is produced in the deformed bar
longitudinal
g tensile strain as p
positive and
(a) 0.69 (b) ‐0.69 is__________(correct to two decimal places).
compressive
p strain as negative.
g The total true
(c) 0.5 (d) ‐0.5 longitudinal
g strain in the rod is
((a)) ‐0.55 ((b)) ‐0.69

9 ((c)) ‐0.75
75 ((d)) ‐1.0
235 236 237
Strain Hardening & Flow Stress
y In the plastic region,
region the material behaviour is expressed GATE 2018
GATE‐2018
by the flow curve: Average Flow Stress
σ = Kε n
Where K is strength coefficient and n is strain‐hardening
The true stress (in MPa) versus true strain
y Average (mean) flow stress is not on the basis of
(or work‐hardening)
work hardening) exponent and at UTS,
UTS ε = n relationship for a metal is given by, σ = 1020 x instantaneous flow stress,
stress but on an average value over
the stress – strain curve from the beginning of strain to
ε0.4. The cross
cross‐sectional
sectional area at the start of a the final (maximum) value that occurs during
test ((when the stress and strain values are deformation.
K ε nf
equal
q to zero)) is 100 mm2. The cross‐sectional g flow stress (σ o ) =
Average
area at the time of necking
g (in mm2)
1+ n
Here εf is the maximum strain value during deformation.
is_______(correct to two decimal places).
238 239 240
St i
Strain rate effects
t ff t GATE 2015
GATE-2015
GATE‐2006
y Strain rate effect (hot Working) The ultimate tensile strength of a material is 400
The strain hardening exponent n of stainless
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 steell SS 304 with
h distinct
d yield
ld and
d UTS values
l
then the true stress‐true strain relation (stress in
undergoing plastic deformation is
MPa) in the plastic deformation range is:
(a) σ = 540 ε0.30 (b) σ = 775 ε0.30
0 30 a) n<0
(c) σ = 540 ε0.35 (d) σ = 775 ε0.35 b)n=0
c) 0<n<1
d)n=1

Page 102 of 203 242
Rev.0 243
Page 103
GATE‐2012 Same Q GATE ‐2012 (PI) GATE‐2016 (PI)
GATE‐2017 A solid cylinder of diameter 100 mm and height 50 mm Two solid cylinders of equal diameter have different
The Poisson
Poisson’ss ratio for a perfectly is forged between two frictionless flat dies to a height of
f db f l fl d h h f
incompressible linear elastic material is heights. They are compressed plastically by a pair of rigid
25 mm The percentage change in diameter is
25 mm. The percentage change in diameter is dies to create the same percentage reduction in their
(a) 1 (b) 0.5
( )0
(c) (d) Infinite
I fi it (a) 0 (b) 2 07
(b) 2.07 (c) 20 7
(c) 20.7 (d) 41 4
(d) 41.4 respecti e heights.
respective heights Consider that the die‐workpiece
die orkpiece
interface friction is negligible.
negligible The ratio of the final
diameter of the shorter cylinder
y to that of the longer
g
cylinder is __________.
244 245 246
GATE‐2018
GATE‐2015 The true stress (σ),
Th ( ) true strain
i (ɛ)
( ) diagram
di off a strain
i GATE 2000 (PI)
GATE‐2000 (PI)
hardening material is shown in figure.
The
Th flow
fl stress (in
(i MPa)
MP ) off a material
i l is
i given
i by
b A cylindrical billet of 100 mm diameter is forged from 50
First, there is loading up to point A, i.e. up to stress
of 500 MPa and strain of 0.5.
0 5 then from point A,A mm height to 40 mm at 1000
1000°C.
C. The material has
σ = 500ε 0.1
01
there is unloading up to constant flow stress of 80 MPa. Find the work of
Where ε is true strain.
strain The Young
Young’ss modulus of point
i t B,
B i.e.
i to t stress
t off
elasticity of the material is 200 GPa. A block of 100 MPa, Given that the deformation. If a 10 KN drop hammer is used to
thickness 100 mm made of this material is Young's modulus E =
compressed to 95 mm thickness and then the load complete the reduction in one blow. What will be the
200 GPa,, the natural
i removed.
is d The
Th final
fi l dimension
di i off the
th block
bl k (in
(i height of fall?
strain at point B (εB)
mm) is _________
________(correct
(correct to two
decimal places).
247 248 249
Assumption IES ‐ 2012 Extrusion & Drawing

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
dies (platens). 1. Forging force attains maximum value at the middle 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
dimensions,, and the variation of stress field along
g yy‐ 2. Coefficient of friction is constant between work piece
and d die
d
direction is negligible.
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
(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
By S K Mondal
process.
Page 103 of 203 251
Rev.0 252
Page 104
Extrusion y Steels, stainless steels, and nickel‐based alloys are

y The extrusion process is like squeezing toothpaste out of
y Metal is compressed and forced to flow through a difficult to extrude. (high yield strengths, welding with
a tube.
suitably
bl shaped
h d die
d to form
f a product
d with
h reduced
d d but
b wall). Use phosphate‐based and molten glass
constant cross section.
section lubricants .
y Metal will undergo tri‐axial compression.
compression
y Hot extrusion is commonly employed.

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

metals are commonly extruded.
253 254 255
IES – 2007 Extrusion Ratio DRDO‐2008

Which
Whi h one off the th following
f ll i is
i theth correctt
y Ratio of the cross‐sectional area of the billet to the cross‐ If the extrusion ratio is 20, the percentage reduction
statement?
(a) Extrusion is used for the manufacture of seamless sectionall area off the
h product.
d in the
h cross‐sectionall area off the
h billet
b ll after
f the
h
tubes.
y about
b 40: 1 for
f hot
h extrusion
i off steell extrusion will be
(b) Extrusion is used for reducing the diameter of round
bars and tubes byy rotating g dies which open
p and close (a) 98% (b) 95% (c) 20% (d) 5%
y 400: 1 for
f aluminium
l i i
rapidly on the work?
(c) Extrusion is used to improve fatigue resistance of the
metal by setting up compressive stresses on its surface
(d) Extrusion
E t i comprises
i pressing
i th metal
the t l inside
i id a
chamber to force it out by high pressure through an
orifice
ifi which
hi h is
i shaped
h d to
t provide
id the
th desired
d i d from
f off the
th
finished part. 256 257 258
Advantages of Extrusion
d f IES ‐ 2012 IES – 2009
y Any cross‐sectional shape can be extruded from the Extrusion
E i process can effectively
ff i l reduce
d the
h cost off Which
Whi h one off the
h following
f ll i statements is i correct??
product through ((a)) In extrusion p
process,, thicker walls can be obtained
nonferrous
f metals.
t l
(a) Material saving by increasing the forming pressure
y Many shapes (than rolling) (b) process time saving (b) Extrusion is an ideal process for obtaining rods from
y No
oddraft
at (c) Saving in tooling cost metal having poor density
(d) saving in administrative cost (c) As compared to roll forming, extruding speed is high
y Huge reduction in cross section.
(d) Impact extrusion is quite similar to Hooker
Hooker'ss process
y Conversion from one product to another requires only a including the flow of metal being in the same direction
single die change
y Good dimensional precision.

Page 104 of 203 260
Rev.0 261
Page 105
Limitation of Extrusion
f Application
l IES – 1994
y Cross section must be uniform for the entire length of y Working of poorly plastic and non ferrous metals and Metal
M l extrusion i process isi generally
ll used
d for
f
producing
the
h product.
d alloys.
ll (a) Uniform solid sections
y Manufacture
M f off sections
i and
d pipes
i off complex
l (b) Uniform hollow sections
(c) Uniform solid and hollow sections
configuration.
configuration
(d) Varying solid and hollow sections.
y Medium and small batch production.
production
y Manufacture of parts of high dimensional accuracy.
262 263 264
GATE‐1994 IES – 1999

The
Th process off hot
h extrusioni is i usedd to produce
d E t i
Extrusion Which
f ll i is
i theh correct
((a)) Curtain rods made of aluminium temperature range for hot extrusion of aluminium?
(b) Steel pipes/or domestic water supply (a) 300‐340°C (b) 350‐400°C
Hot Cold
( ) Stainless
(c) S i l steell tubes
b used d in
i furniture
f i (c) 430‐480°C
430 480°C (d) 550‐650°C
550 650°C
((d)) Large
g shape
p ppipes
p used in cityy water mains
Direct Indirect Forward Backward
Cold Impact
Hydrostatic Extrusion Extrusion
Forging
265 266 267
IAS – 2012 main Hot Extrusion Process IES – 2009

Classify the process of extrusion with the help of y The temperature range for hot extrusion of aluminum is What
Wh is i the
h major
j problem
bl in
i hot
h extrusion?
i ?
((a)) Design
g of p
punch ((b)) Design
g of die
sketches.
k h 430‐480°C
(c) Wear and tear of die (d) Wear of punch
y Used
U d to produce
d curtain
i rods
d made
d off aluminum.
l i
y Design
D i off die
di is
i a problem.
bl
y Either direct or indirect method used.

used

Page 105 of 203 269
Rev.0 270
Page 106
Direct Extrusion IES – 1993 IES – 2000

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 Consider
C id theth following
f ll i statements:
t t t
stationary die and must provide additional power to than indirect extrusion. In forward extrusion process
overcome the
h frictional
f l resistance between
b the
h surface
f off the
h 1. The ram and the extruded product travel in the same
Reason (R): In indirect extrusion of cold steel, zinc
moving billet and the confining chamber. direction.
phosphate coating is used. used
2. The ram and the extruded product travel in the opposite
(a) Both A and R are individually true and R is the direction.
correct explanation
l off A 3. The speed of travel of the extruded product is same as that
(b) Both
d v dua y ttrue
ue but R iss not
ot tthee of the ram.
correct explanation of A 4. The speed of travel of the extruded product is greater than
that of the ram.
( ) A is
(c) i true
t b t R is
but i false
f l
Which of these Statements are correct?
(d) A is false but R is true (a) 1 and 3 (b) 2 and 3
271 272
(c) 1 and 4 (d) 2 and 4 273
Indirect Extrusion
d Indirect Extrusion
d Contd… IES ‐ 2012
y A hollow
h ll ram drives
di the
th die
di back
b k through
th h a stationary,
t ti Which
f ll i are correct for
f an indirect
i di hot
h
y Required force is lower (25 to 30% less)
confined billet. extrusion process?
y Since no relative motion, friction between the billet and y Low process waste. 1. Billet remains stationary
the chamber is eliminated.
2 There is no friction force between billet and container
2.
walls.
3. The force required on the punch is more in
comparison
co pa so to d direct
ect eextrusion.
t us o .
4. Extrusion parts have to be provided a support.
( ) 1, 2, 3 and
(a) d4 (b) 1, 2 and
d 3 only
l
(c) 1, 2 and 4 only (d) 2, 3 and 4 only
274 275 276
IES‐2016
IES – 2007 IAS – 2004 Statement (I): Employing the extrusion process is not
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 economical in case of large billets.
billets
in case of direct extrusion than indirect one. performed either by moving ram or by moving the Statement (II): A significant part of the press capacity is lost
Reason (R): In case of direct extrusion, the direction of container. overcoming
i f i i
frictional
l resistance
i b
between workpiece
k i and
d
the force applied
pp on the p plunger
g and the direction of cylinder wall during the extrusion process.
Reason (R): Advantage in indirect extrusion is less
the movement of the extruded metal are the same. (a) Both Statement (I) and Statement (II) are individually true and
quantity of scrap compared to direct extrusion.
(a) Both A and R are individually true and R is the correct Statement ((II)) is the correct explanation
)
( ) Both
h
explanation of A (b) Both Statement (I) and Statement (II) are individually true but
(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 St t
Statementt (II) is
i nott the
th correctt explanation
l ti off Statement
St t t (I).
(I)
correct explanation of A (b) Both A and R are individually true but R is not the
(c) A is true but R is false (d) Statement (I) is false but Statement (II) is true
((d)) A is false but R is true (c) A is true but R is false
Page 106 of 203 278
Rev.0 279
Page 107
Cold Extrusion
ld Backward cold extrusion
k d ld Impact Extrusion
y Used with low‐strength metals such as lead, tin, zinc, y The metal is extruded through the gap between the
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.
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
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
food and beverages. similar articles.
articles
y Now‐a‐days also been used for forming mild steel parts.
y The extruded parts are stripped by the use of a stripper

280 281 plate, because they tend to stick to the punch. 282
IES – 2008, GATE‐1989(PI) IES – 2003 IES ‐ 2014

Which one of the following methods is used for the The
Th extrusioni process (s)( ) usedd for
f the
h production
d i off A toothpaste
h tube
b can be
b produced
d d by
b
toothpaste tube is/are ((a)) Solid forward extrusion
manufacture
f off collapsible
ll bl tooth‐paste
h tubes?
b 1. Tube extrusion (b) Solid backward extrusion
( ) Impact
(a) I extrusion
i (b) Di
Direct extrusion
i 2 Forward extrusion
2. ( ) Hollow
(c) H ll backward
b k d extrusion
i
3. Impact extrusion ((d)) Hollow forward extrusion
( ) Deep
(c) D d
drawing
i (d) Pi i
Piercing
Select the correct answer using the codes given below:
C d
Codes:
(a) 1 onlyy (b) 1 and 2
(c) 2 and 3 (d) 3 only
283 284 285
IAS‐2010 Main Hooker Method
k h d Hooker Method
k h d
y The
Th ram/punch
/ h has
h a shoulder
h ld and d acts
t as a mandrel.
d l
How are metal tooth‐paste tubes made 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
commercially ? Draw the tools configuration with the punch
the help of a neat sketch. y when
h the
h punch h starts downward
d d movement. Pressure
P i
is
exerted by the shoulder of the punch, the metal being forced
[
[30‐Marks]
k ] t flow
to fl th
through h the
th restricted
t i t d annular
l space between
b t th
the
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
y If the tube sticks to the punch on its upward stroke, a
stripper willll strip it from
f the
h punch.h
y Small copper tubes and cartridge cases are extruded by this
method.
Page 107 of 203 287
Rev.0 288
Page 108
Hydrostatic Extrusion
d Hydrostatic Extrusion
d Contd…. Hydrostatic Extrusion
d Contd….
y Another type of cold extrusion process. y Temperature

T is
i limited
li i d since
i the
h fluid
fl id acts as a heat
h sink
i k
and the common fluids (light hydrocarbons and oils)
y High‐pressure fluid applies the force to the workpiece burn or decomposes at moderately low temperatures.
through
h h a die.
di y The metal deformation is performed in a high high‐
compression environment. Crack formation is
y It i forward
is f d extrusion,
t i b t the
but th fluid
fl id pressure suppressed leading to a phenomenon known
suppressed, kno n as
pressure‐induced ductility.
surrounding the billet prevents upsetting.
upsetting
y Relatively brittle materials like cast iron, stainless steel,
y Billet
Billet‐chamber
chamber friction is eliminated, and the molybdenum, tungsten and various inter inter‐metallic
metallic
compounds can be plastically deformed without
pressurized fluid acts as a lubricant between the billet
fracture and materials with limited ductility become
fracture,
and the die. 289 290 highly plastic. 291
IAS – 2000 IES – 2006

Application Assertion
A i (A):
(A) Brittle
B i l materials i l such h as grey cast What
Wh does
d hydrostatic
h d i pressure in
i extrusion
i process
iron cannot be extruded by hydrostatic extrusion. improve?
y Extrusion of nuclear reactor fuel rod
E t i f l t f l d
Reason(R): In hydrostatic extrusion, billet is (a) Ductility (b) Compressive strength
y Cladding of metals uniformly compressed from all sides by the liquid. liquid (c) Brittleness (d) Tensile strength
y Making wires for less ductile materials 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
292 293 294
IES – 2001 Lubrication for Extrusion

b f
GATE‐1990(PI) Which
Whi h off the th following
f ll i statements
t t t are the
th salient
li t y For
F hot
h extrusion
i glass
l is
i an excellent
ll lubricant
l bi with
ih
features of hydrostatic extrusion? steels, stainless steels and high temperature metals and
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 alloys.
2. It is suitable for high‐strength super‐alloys.
(a) Impact extrusion y For cold extrusion,
extrusion lubrication is critical,
critical especially with
3.The billet is inserted into the extrusion chamber and pressure
is applied by a ram to extrude the billet through the die.
steels, because of the possibility of sticking (seizure)
(b) Closed cavity extrusion bet een the workpiece
between orkpiece and the tooling if the lubrication
4. The billet is inserted into the extrusion chamber where it is
surrounded byy a suitable liquid.q The billet is extruded breaks down. Most effective lubricant is a phosphate
(c) Hydrostatic extrusion
through the die by applying pressure to the liquid. conversion coating on the h workpiece.
k
(d) Backward extrusion Select the correct answer using g the codes g
given below:
Codes:
(a) 1 and 3 (b) 1 and 4
(c) 2 and 3 (d) 2 and 4
Page 108 of 203 296
Rev.0 297
Page 109 For IES Only For IES Only
IES ‐ 2014
IES
IES 2009 Conventional Statement‐I: For high extrusion pressure, the initial
Explain the processes of extrusion given below.
Process variables in Extrusion
Process variables in Extrusion temperature of billet should be high. high
1. Experimental
p studies of flow
Statement‐II: As the speed of hot extrusion is
Indicate one typical product made through each of these i
increased,
d it may lead l d to t melting
lti off alloy
ll
2. Temperature and Metallurgy: Variations in temperature
constituents
during extrusion seem to influence flow behaviour in
processes: number of ways. As indicated, flow patterns may be (a) Both Statement (I) and Statement (II) are
changed
g considerablyy byy rendering g the temperature
p individuallyy true and Statement (II) is the correct
(i) Direct
Di t Extrusion
E t i explanation of Statement (I)
distribution in the container. It is known that the extrusion
pressure mayy be lowered if either the temperature
p p of the (b) Both Statement (I) and Statement (II) are
(ii) Indirect Extrusion
billet or the velocity of the stem is increased, and that there individually true but Statement (II) is not the correct
are certain limitations, because the material starts melting g explanation of Statement (I)
(iii) Hydrostatic Extrusion
or cracking if it is leaves the die with too high temperature.
(iv) Impact Extrusion (d) Statement
St t t (I) is
i false
f l but
b t Statement
St t t (II) is
i true
t
298 299 300
For IES Only
Extrusion Defects
Extrusion Defects IES 2016
IES‐2016
y Surface crack due to high
g temperature,
p g speed,
high p GATE‐2018 (PI) Surface cracking occurring at low temperature in
high friction etc. Which one of the following defects is NOT hydrostatic extrusion is know as
y Bamboo defects at low temperature due to sticking of
metals in die land. associated with the casting process? (a) Fluid Defect (b) Bamboo Defect
y Pipe defects or tail pipe or fishtailing, during
(a) Hot tear (c) Fishtailing (d) Arrowhead Fracture
extrusion surface oxides and impurities p are driven
towards the centre of the billet, like funnel called pipe.
(b) Porosity
y Centre Burst or Chevron defect are attributed to a
state of hydrostatic tensile stress at the centreline in the (c) Blister
d f
deformation
i zone in
i the
h die.
di Tendency
T d i
increases with
ih
increasing die angle and amount of impurities. Tendency (d) Central burst
decrease with increasing extrusion ratio and friction.
301 302 303
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
(c) III I IV VI (d) I II V VI
Page 109 of 203 305
Rev.0 306
Page 110
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.
307 308 309
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
310 311 312
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
of copper is used to reduce friction.
Page 110 of 203 314
Rev.0 315
Page 111
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
316 317 318
IES ‐ 2014
IES
IES – 1996 Statement‐I: In drawing process, cross‐section of
In
I wire
i drawing
d i process, the
h bright
b i h shining
hi i surface
f Bundle Drawing
Bundle Drawing round d wire
i is
i reduced
d d by
b pulling
lli it through
th h a die
di
on the wire is obtained if one Statement‐II: Bundle drawing g p
produces wires that
In this process,
process many wires (as much as several
(a) does not use a lubricant are polygonal in cross‐section rather than round
thousand)) are drawn simultaneouslyy as a bundle. To (a) Both Statement (I) and Statement (II) are
(b) uses solid powdery lubricant.
lubricant
(c) uses thick paste lubricant prevent sticking, the wires are separated from each individually true and Statement (II) is the correct
explanation
l i off Statement
S (I)
(d) uses thin film lubricant other by a suitable material. The cross‐section of the
((b)) Both Statement ((I)) and Statement ((II)) are
wires is somewhat
h polygonal.
l l individually true but Statement (II) is not the correct
explanation of Statement (I)
319 320 321
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 diamondGATE
For-2019(IES, (for fine wire)
& PSUs) 322
Page 111 of 203 323
Rev.0 324
Page 112
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 325 326 327
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. 328 329 330
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
(c) 2 3 4 1 (d) 4 1 2 3332
Page 112 of 203 Rev.0 333
Page 113
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 11. 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
334 (c) 3 2 1 5 (d) 2 3 1 5335 336
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
337 (c) 3 2 4 1 (d) 4 2 3 1 338 339
IAS – 2002 IES 2011

IES 2011
g
Match List –I with List –II and select the correct answer using GATE‐2018
Assertion
A ti (A):
(A) InI wire‐drawing
i d i process, the
th rod d the code given below the lists : Match the following products with the suitable
M h h f ll i d i h h i bl
cross‐section is reduced gradually by drawing it manufacturing process
severall times
ti i successively
in i l reduced
d d diameter
di t dies.
di List I
List –I List II
List –II
Product Manufacturing Process
Reason (R): Since each drawing reduces ductility of A Connecting rods
A. Connecting rods 1 Welding
1. Welding
the wire, so after final drawing the wire is P Toothpaste tube 1 Centrifugal casting
normalized. B. Pressure vessels 2. Extrusion Q Metallic pipes 2 Blow moulding
correct
co ect eexplanation
p a at o o
of A C. Machine tool beds 3. Forming R Plastic bottles 3 Rolling
(b) Both A and R are individually true but R is not the D. Collapsible tubes 4. Casting S Threaded bolts 4 Impact extrusion
correct explanation of A Codes
(c) A is true but R is false A B C D A B C D (a) P‐4, Q‐3, R‐1, S‐2 (b) P‐2, Q‐1, R‐3, S‐4
(a) 2 1 4 3 (b) 3 1 4 2 ( ) P Q R S
(c) P‐4, Q‐1, R‐2, S‐3 (d) P Q R S
(d) P‐1, Q‐3, R‐4, S‐2
(d)
(c) 2 4 1 3 (d) 3 4 1 2341
Page 113 of 203 Rev.0 342
Page 114
IAS 1994
Seamless tube Manufacturing
Seamless tube Manufacturing GATE‐1991(PI) Which of the following methods can be used for
manufacturing 2 meter long seamless metallic
1 Rolling
1. Rolling S
Seamless
l l
long steel
t l tubes
t b are manufactured
f t d by b rolling,
lli tubes?
b
2 Extrusion drawing and 1. Drawing g 2. Extrusion
3. Rolling 4. Spinning
3
3. Tube Drawing
g
Select
l the
h correct answer using the
h codes
d given below
b l
4. Spinning Codes:
(a) 1 and 3 (b) 2 and 3
( ) 1, 3 and 4
(c) ( ) 2, 3 and 4
(d)
343 344 345
Extrusion Load Extrusion Stress
IES‐2012 Conventional 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
How are the seamless tubes produced ? friction) “work – formula” friction) “work – formula”
⎛A ⎞ πd2 ⎛d ⎞ π d o2 P ⎛A ⎞ ⎛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 )
⎜A 4 4 ⎜A
⎝ f ⎠ ⎝ df ⎠ A0 ⎝ f ⎠ ⎝ df ⎠
y For real conditions y For real conditions
⎛A ⎞ πd 2 ⎛d ⎞ P ⎛A ⎞ ⎛d ⎞
P = KAo ln ⎜ o ⎟⎟ = 2 × × K × ln ⎜ o
o
⎟⎟ σE = = K ln ⎜ o ⎟⎟ = 2 × K × ln ⎜⎜ o ⎟⎟
⎜ 4 ⎜ ⎜
⎝ Af ⎠ ⎝ df ⎠ A0 ⎝ Af ⎠ ⎝ df ⎠
K = extrusion
t i constant.
t t K = extrusion
t i constant.
t t
346 347 348
Force required in Wire or Tube drawing GATE‐2003 GATE – 2009 (PI)

y Approximate method (Uniform deformation,
deformation no
friction) “work – formula” A brass billet is to be extruded from its initial Using direct extrusion process, a round billet of 100
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
⎛A ⎞ π d 2f ⎛d ⎞
P = Af σ o ln ⎜ o ⎟⎟ = 2 × × σ o × ln ⎜ o ⎟⎟ The working temperature of 700°C
700 C and the Considering an ideal deformation process (no
⎜A 4 ⎜d
⎝ f ⎠ ⎝ f ⎠ extrusion constant is 250 MPa. The force required friction and no redundant work), extrusion ratio 4,
Drawing Stress
for extrusion is and average flow stress of material 300 MPa, the
P ⎛A ⎞ ⎛d ⎞
σd = = σ o ln ⎜ o ⎟⎟ = 2 × σ o × ln ⎜⎜ o ⎟⎟ (a) 5.44 MN (b) 2.72 MN pressure (in MPa) on the ram will be
Af ⎜A
⎝ f ⎠ ⎝ df ⎠ (c) 1.36 MN (d) 0.36 MN (a) 416 (b) 624 (c) 700 (d) 832

Page 114 of 203 350
Rev.0 351
Page 115
GATE‐2006 GATE 2008 (PI) Linked S 1

GATE ‐2008 (PI) Linked S‐1 GATE 2008 (PI) Linked S 2
GATE ‐2008 (PI) Linked S‐2
A 10 mm diameter annealed steel wire is drawn A 10 mm diameter annealed steel wire is drawn
In a wire drawing operation, diameter of a steel 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
is reduced
d d from
f 10 mm to 8 mm. The
h mean flow
fl
diameter by 20%. The yield stress of the material is diameter by 20%. The yield stress of the material is
stress of the material is 400 MPa.
MPa The ideal force
800 MPa. 800 MPa.
required for drawing (ignoring friction and
Neglecting friction and strain hardening, the stress The power required for the drawing process (in kW)
redundant work) is
required for drawing (in MPa) is is
(a) 4.48 kN (b) 8.97 kN
(a) 178.5 (b) 357.0 (c) 1287.5 (d) 2575.0 (a) 8.97 (b) 14.0 (c) 17.95 (d) 28.0
(c) 20.11 kN (d) 31.41 kN
352 353 354
IES‐2014 Conventional GATE‐2001, GATE ‐2007 (PI) GATE‐2018

(i) What kind of products are manufactured by wire For rigid perfectly‐plastic work material, negligible The maximum reduction in cross‐sectional
drawing process? interface
f f
friction and
d no redundant
d d work,
k the
h area per pass (R) of a cold wire drawing
(ii) How
H much
h force
f will
ill approximately
i l be
b required
i d theoretically maximum possible reduction in the
process is R = 1 – e‐(n+1) where n represents the
to draw a wire from 1.5
1 5 mm diameter steel wire to 1.0
10 wire drawing operation is
strain hardening co‐efficient. For the case of
mm diameter wire if the average
g yyield strength
g of ((a)) 0.36
3 ((b)) 0.633
a perfectly plastic material, R is
the work material is 300 MPa? ((c)) 1.00 ((d)) 2.72
7
[10 Marks]
(a) 0.865 (b) 0.826 (c) 0.777 (d) 0.632
355 356 357
IES ‐ 2014 GATE 2015

GATE-2015
GATE‐1996
In
I wire‐drawing
i d i operation,
i the
h maximum
i A wire
i off 0.1 mm diameter
di is
i drawn
d from
f a rod
d off 15 In a two stage wire drawing operation , the
reduction per pass for perfectly plastic material in mm diameter. Dies giving reductions of 20%, 40%
ideal condition is and 80% are available. For minimum error in the f ti
fractional
l reduction
d ti ( ti off change
(ratio h i cross –
in
(a) 68 % (b) 63 % final size,, the number of stages g and reduction at sectional area to initial cross
cross‐sectional
sectional area) in the
(c) 58 % (d) 50% each stage respectively would be
first stage
g is 0.4.
4 The fractional reduction in the
(a) 3 stages and 80% reduction for all three stages
(b) 4 stages and 80% reduction for first three stages second stage is 0.3. The overall fractional
followed by a finishing stage of 20% reduction reduction is _____
(c) 5 stages and reduction of 80%,
80% 80%.40%,
80% 40% 40%,
40% 20%
(a) 0.24 (b) 0.58 (c) 0.60 (d) 1.0
in a sequence
( ) none of the above
(d)
Page 115 of 203 359
Rev.0 360
Page 116
Wire Drawing
Wire Drawing
GATE‐2018 (PI) Maximum Reduction per pass
σ o (1 + B ) ⎡ ⎛r ⎞ ⎤ ⎛r ⎞
2B 2B
In a two‐pass wire drawing process, there is a 40% σd = ⎢1 − ⎜ f ⎟ ⎥ + ⎜ f ⎟ .σ b With back stress, σ b
B ⎢⎣ ⎝ ro ⎠ ⎥⎦ ⎝ ro ⎠
reduction in wire cross‐sectional area in 1st pass σ o (1 + B ) ⎡ ⎛r ⎞ ⎤ ⎛r
2B
⎞
2B
σo = ⎢1 − ⎜ f min ⎟ ⎥ + ⎜ f min ⎟ .σ b
and further 30% reduction in 2nd pass. The overall B ⎢⎣ ⎝ ro ⎠ ⎥⎦ ⎝ ro ⎠
reduction (in percentage) is ______
stress σ b
Without back stress,
σ o (1 + B ) ⎡ ⎞ ⎤
2B
⎛r
σo = ⎢1 − ⎜ f min ⎟ ⎥
f
B ⎢⎣ ⎝ ro ⎠ ⎥⎦
361 362 363
IFS 2016
IFS‐2016
IES – 2011 Conventional GATE‐2018
A 12.5 mm diameter
d rod
d is to be
b reduced
d d to 10 mm A steell wire
i isi drawn
d from
f an initial
i i i l diameter
di (di) off 10 A round rod of annealed brass 70‐30 is being
diameter by drawing in a single pass at a speed of 100 mm to a final diameter (df ) of 7.5 mm. The half cone drawn from a diameter of 6 mm to 3 mm at a
m/min. Assuming a semi die angle of 5o and coefficient angle (α) of the die is 5° and the coefficient of friction (μ)
of friction between the die and steel rod as 0.15, between the die and the wire is 0.1. The average g of the speed
p of 0.6 m/s. Assume that the frictional and
calculate: initial and final yield stress [(σy)avg] is 350 MPa. The
((i)) The p
power required
q in drawing
g redundant work together constitutes 35% of the
equation for drawing stress σf (in MPa) is given as:
(ii) Maximum possible reduction in diameter of the rod 2 μ cot α
1 ⎫⎡ ⎛ df ⎞ ⎤ ideal work of deformation.
⎧
(iii) If the rod is subjected to a back pressure of 50 σ f = (σ y )avg ⎨1 + ⎬ ⎢1 − ⎜ ⎟ ⎥
N/mm2 , what would be the draw stress and maximum
possible
ibl reduction
d ti ?
⎩ μ cot α ⎭ ⎢⎣ ⎝ di ⎠ ⎥⎦ Calculate (i) power required in this operation and
Take stress of the work material as 400 N/mm2 . The drawing stress (in MPa) required to carry out this (ii) die pressure at the exit of the die. [10‐Marks]
[15 Marks] operation is________ (correct
( to two decimal places).
)
364 365
Hint: K =895 MPa and n = 0.49 366
G
GATE – 20 ( ) C S
2011 (PI) Common Data‐S1 G
GATE – 20 ( ) C S2
2011 (PI) Common Data‐S2 GATE – 2014
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
diameter and 100 mm length is reduced in cross‐section diameter and 100 mm length is reduced in cross‐section A metal rod of initial length is subjected to a
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 d
drawing process. The
h length
l h off the
h rod
d at any
of decreasing exit diameter. During each of these of decreasing exit diameter. During each of these
d
drawing operations, the
h reduction
d in cross‐sectionall area d
drawing operations, the
h reduction
d in cross‐sectionall area expression L(t) = Lo(1 + t2)
instant is given by the expression,
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. where t is the time in minutes. The true strain rate
Ignore strain hardening. Ignore strain hardening.
at the end of one minute is ………..
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
mm), respectively, are kN) required for drawing the bar through the first die, is
(a) 2.45 and 8 17 (b) 2.45 and 345 (a) 15.71 (b) 10.21
(c) 3.02 and 2043 (d) 3.02 and 3330 (c) 6.77 (d) 4.39
Page 116 of 203 368
Rev.0 369
Page 117
IAS – 1997 IES – 2012 The Degree of Drawing or Reduction factor

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 in Cross Sectional area
in Cross Sectional area
((a)) Extrusion ratio Ans.
(b) Type of extrusion process 1. Reduction in cross sectional area
( ) Material
(c) M i l off the
h die
di 2. Die
Di anglel Ao − Af Do2 − D 2f
D= =
((d)) Workingg temperature
p 33. Friction Ao Do2
⎛A ⎞ ⎛ 1 ⎞
ThereforeTrue strain ( ε ) = ln ⎜ o ⎟⎟ = ln ⎜ ⎟
⎜A ⎝ 1− D ⎠
⎝ f ⎠
370 371 372
IAS – 2006
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?
Di − Do Do − Di Di2 − Do2 Di2 − Do2
(a) (b) (c ) (d )
Di Do Di2 Di2
373 374 375

Page 117 of 203 377
Rev.0 378
Page 118
Piercing (Punching) and Blanking
( h ) d l k
Sheet Metal
y Product has light weight and versatile shape as y Piercing and blanking are shearing operations.
compared to forging/casting
y In blanking, the piece being punched out becomes
Sheet Metal Operation y Most commonly used
strength, formability)
– low carbon steel sheet (cost,
the
h workpiece
k i and
d any major
j burrs
b or undesirable
d i bl
y Aluminium and titanium for aircraft and aerospace features should be left on the remaining strip.
strip
y Sheet metal has become a significant material for,
y In piercing (Punching),
(Punching) the punch
punch‐out
out is the scrap
‐ automotive bodies and frames,
‐ office furniture and the remaining
g strip
p is the workpiece.
p
frames for home appliances
By S K Mondal
y ‐ y Both done on some form of mechanical press.
379 380 381
Piercing (Punching) and Blanking
GATE‐2018
The
Th percentage scrap in
i a sheet
h metall
blanking operation of a continuous strip of
sheet metal as shown in the
fi
figure_________(correct
( t t
to t
two d i l
decimal
p
places)
)
382 383 384
Clearance (VIMP)
Clearance (VIMP) Clearance
Clearance Contd
Contd….
y Die opening must be larger than punch and known as
y The clearance is determined with g
following
clearance.
‘clearance’
y Punching equation
C = 0.0032t τ
Punch = size of hole
Die = punch size +2 clearance
y Remember: In punching punch is correct size.
y Where τ is the shear strength of the material in
y Blanking
N/mm2(MPa)
Die = size
Di i off product
d
Punch = Die size ‐2 clearance y Total clearance between punch and die size will be
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 twice these ‘C’ i.e. 2C
In Blanking clearance is provided on punch
Page 118 of 203 386
Rev.0 387
Page 119
Example
l GATE‐2003
Clearance in %
Clearance in % Determine
D i the
h die
di andd punchh sizes
i for
f blanking
bl ki a circular
i l
A metal disc of 20 mm diameter is to be punched
disc of 20‐mm diameter from a sheet whose thickness is 1.5
y If the
th allowance
ll f the
for th material
t i l is
i a = 0.075 given
i th
then mm. f
from a sheet
h off 2 mm thickness.
h k The
h punch
h and
d the
h
C = 0.075
0 075 x thickness of the sheet die clearance is 3%.
3% The required punch diameter is
Shear strength of sheet material = 294 MPa
y If clearance is 1% given then (a) 19.88
19 88 mm (b) 19 94 mm
19.94
Also determine the die and punch sizes for punching a
C = 0.01
0 01 x thickness of the sheet (c) 20.06
20 06 mm (d) 20 12 mm
20.12
circular hole of 20‐mm diameter from a sheet whose
thickness is 1.5 mm.
388 389 390
Punching Force and Blanking Force
h d l k Capacity of Press for Punching and Blanking Example
l
Fm ax = Ltτ
Estimate the blanking force to cut a blank 25 mm wide
Press capacity will be = Fmax ×C and

d 30 mm long
l f
from a 1.5 mm thick
h k metall strip, iff the
ultimate shear strength of the material is 450 N/mm2.
h
Also determine the work done if the percentage

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 penetration is 25 percent of material thickness.
thi k
thickness may be estimated as follows:
b ti t d f ll upon the profile]
th fil ]
π dtσ
Fmax =
3
d
t 391 392 393
GATE‐2016 (PI)
GATE‐2014 IAS‐2011 Main
IAS‐2011 Main The ratio of press force required to punch a square hole
A rectangular hole of size 100 mm × 50 mm is to be For punching a 10 mm circular hole, and cutting a off 30 mm side
id in
i a 1 mm thick
thi k aluminium
l i i sheet
h t to
t that
th t
made on a 5 mm thick sheet of steel having rectangular blank of 50 x 200 mm from a sheet of 1
ultimate tensile strength and shear strength of 500 mm thickness (mild steel,
steel shear stress = 240 needed to punch a square hole of 60 mm side in a 2 mm
MPa and 300 MPa, respectively. The hole is made N/mm2), Calculate, in each case : thick aluminium sheet is__________________
b punching
by hi process. Neglecting
N l i the
h effect
ff off (i) Size of punch
clearance, the punching force (in kN) is (ii) Size of die
(a) 300 (b) 450 (iii) Force required. [10‐Marks]
(c) 600 (d) 750

Page 119 of 203 395
Rev.0 396
Page 120
Minimum Diameter of Piercing
f IES – 1999 IES ‐ 2014
A hole is to be punched in a 15 mm thick plate A hole
h l off diameter
di 35 mm is
i to be
b punched
h d in
i a
sheet metal of thickness t and ultimate shear
π h
having ultimate
l shear
h h off 3N‐mm‐2. Iff the
strength h strength 400 MPa, using punching force of 44 kN.
τs πd.t
Piercing pressure, = Strength of punch, σc × d 2
4 The maximum value of t is
allowable crushing stress in the punch is 6 N mm‐22,
N‐mm
(a) 0.5 mm
the diameter of the smallest hole which can be
(b) 10 mm
punched is equal to (c) 1 mm
(a) 15 mm (b) 30 mm (d) 2 mm
(c) 60 mm (d) 120 mm
397 398 399
ISRO‐2008, 2011 IES‐2013 Energy and Power for Punching and Blanking

A hole of diameter d is to be punched in a plate of Id l Energy
Ideal E i J) = maximum
(E in i force
f h travell = Fmax × ( p × t )
x punch
With a punch for which the maximum crushing
(Unit:Fmax in kN and t in mm othrwise use Fmax in N and t in m)
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
Where p is percentage penetration required for rupture
plate the biggest hole that can be punched in the
plate, crushing stress is 4 times the maximum allowable E×N
Ideal power in press ( P inW ) =
60
plate would be of diameter equal to shearing
g stress. For p
punching
g the biggest
gg hole, the
[Where N = actual number of stroke per minute]
1 Actual Energy ( E in J ) = Fmax × ( p × t ) × C
(a) × Thickness of plate ratio of diameter of hole to plate thickness should
4 Where C is a constant and equal to 1.1 to 1.75 depending upon the profile
1 be equal to:
(b) × Thickness of plate 1 E×N
1 A
Actual i W)=
l power iin press ( P inW
2 (a) (b) 2 60 ×η
4
(c) Plate thickness WhereE is actual energy and η is efficiency of the press
(c) 1 (d) 2
(d) 2 × Plate thickness 400 401 402
Shear on Punch
h h Force required with shear on Punch
Force required with shear on Punch
Fmax × ptt [for
[f circular
i l hole
h l and
d other
h searing
i
y To reduce shearing force, shear is ground on the face of F=
the
h die
d or punch.
h S + pt operations]
y It distribute the cutting action over a period of time. Fmax × pt

F=
y Shear only reduces the maximum force to be applied but S [For Shear cutting, or if force Vs
displacement curve trapezoidal mentioned
total work done remains same. in the question.]
Wh
Where p = penetration
i off punch h as a fraction
f i
S = shear on the punch or die, mm

Page 120 of 203 404
Rev.0 405
Page 121
Example Example
l GATE‐2010 Statement Linked 1
A washer
h with
i h a 12.7 mm internal
i l hole
h l and d an outside
id Statement
S for
f Linked
Li k d Answer
A Questions:
Q i
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 In a shear cutting operation, a sheet of 5 mm thickness
strip. The
h ultimate
l shearing
h strengthh off the
h materiall off is cut along a length of 200 mm. The cutting blade is 400
5.6 mm thick. The ultimate shear stress is 550 N/mm2 . the washer is 280 N/mm2. mm long g and zero‐shear ((S = 0)) is p
provided on the edge.
g
With normal clearance on the tools, cutting is complete (a) Find the total cutting force if both punches act at The ultimate shear strength of the sheet is 100 MPa and
the same time and no shear is applied
pp to either p
punch penetration to thickness ratio is 0.2. Neglect
p g friction.
at 40 per cent penetration
i off the
h punch.
h Give
Gi suitable
i bl or the die.
400
shear angle for the punch to bring the work within the (b) What will be the cutting force if the punches are
staggered, so that only one punch acts at a time. S
capacity
capac ty o
of a 30
30T p
press.
ess.
( ) Taking
(c) T ki 6 % penetration
60% i andd shear
h on punchh off 1 Assuming force vs displacement curve to be rectangular,
mm, what will be the cutting force if both punches act the work done ((in J) is
together.
h
406 407
(a) 100 (b) 200 (c) 250 (d) 300 408
GATE‐2010 Statement Linked 2 Fine Blanking
l k y Slitting ‐ moving rollers trace out complex paths during
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 5mm thickness is cut
clearances and pressure pads that hold the material cutting (like a can opener).
along a length of 200 mm. The cutting blade is 400 mm long
and zero‐shear (S = 0) is provided on the edge. The ultimate while it is sheared. The final result is blanks that have y Perforating: Multiple holes which are very small and
shear strength of the sheet is 100 MPa and penetration to extremelyy close tolerances.
thickness ratio is 0.2.
0 2 Neglect friction.
friction
400 close together are cut in flat work material.
y Notching: Metal pieces are cut from the edge of a sheet,
S strip
t i or blank.
bl k
A shear of 20 mm (S = 20 mm) is now provided on the blade.
Assuming force vs displacement curve to be trapezoidal, the
maximum force (in kN) exerted is
( ) 5
(a) ( )
(b) 10 ( )
(c) 20 ( )
(d) 40
409 410 411
y Trimming ‐ Cutting unwanted excess material from the y Lancing – A hole is partially cut and then one side is bent
periphery of a previously formed component. down to form a sort of tab or louver. No metal removal, no
y Shaving
h ‐ Accurate dimensions
d off the
h part are obtained
b d by
b scrap.
removing a thin strip of metal along the edges.

edges
y Squeezing ‐ Metal is caused to flow to all portions of a die

cavity under the action of compressive forces.

Page 121 of 203 413
Rev.0 414
Page 122
Dinking
k Elastic recovery or spring back
l b k
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 y Total deformation = elastic deformation + plastic
rubber, fiber, or cloth.
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 d f
deformation.
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 y At the
th end
d off a metal
t l working
ki operation,
ti when
h th
the
allows a simple
p die to cut complex
p slots. pressure is released,
released there is an elastic recovery and the
total deformation will g
get reduced a little. This
phenomenon is called as "spring back".
415 416 417
Elastic recovery or spring back
l b k Contd.. IAS – 2003 ISR0– 2013
y More important in cold working. The
Th 'spring
' i back'
b k' effect
ff in
i press working
ki is i Spring back in metal forming depends on
((a)) Elastic recoveryy of the sheet metal after removal of
the load (a) Modulus of Elasticity
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 (b) Load Applied
strength, greater spring back. (c) Release of stored energy in the sheet metal
(d) Partial recovery of the sheet metal (c) Strain Rate
(d) None
N off these
h
y To compensate this, the cold deformation be carried
beyond the desired limit by an amount equal to the
spring back.
418 419 420
Punch and Die material Punching Press
h Bolster plate
l l
y Commonly used – tool steel
y For high production ‐ carbides

Page 122 of 203 422
Rev.0 423
Page 123
Bolster plate
l l Contd.... Punch plate
h l Stripper
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.
424 425 426
Stripper Contd.... Knockout
k Pitman
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. y It is a connecting rod which is used to transmit motion
operated by the press ram, for freeing a work piece from
Ps = KLt a die. f
from the
h main drive
d shaft
h f to the
h press slide.
ld
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
427 428 429
Dowel pin
l GATE 2011 GATE‐2016
The shear strength of a sheet metal is 300 MPa. The In a sheet metal of 2 mm thickness a hole of 10 mm
blanking g force required
q to p
produce a blank of 100
mm diameter from a 1.5 mm thick sheet is close to diameter needs to be punched. The yield strength in
(a) 45 kN tension of the sheet material is 100 MPa and its ultimate
(b) 70 kN shear strength is 80 MPa. The force required to punch
(c) 141 kN the hole (in kN) is _______
(d) 3500 kN

Page 123 of 203 431
Rev.0 432
Page 124
GATE‐2013 (PI)
( ) ISRO‐2009
GATE –
GATE – 2009 (PI)
2009 (PI) Circular blanks of 10 mm diameter are punched The force required to punch a 25 mm hole in a
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
mild steel plate 10 mm thick, when ultimate shear
of an aluminum alloy of thickness 3.2
3 2 mm.
mm The shear strength of aluminium is 80 MPa. The
minimum punching force required in kN is stress of the plate is 500 N/mm2 will be nearly
material shear strength
g to fracture is 150
5 MPa. The
blanking force (in kN) is (a) 2.57 (a) 78 kN (b) 393 kN (c) 98 kN (d) 158 kN
(a) 291 (b) 301 (c) 311 (d) 321 (b) 3.29
(c) 5.03
(d) 6.33
433 434 435
The force requirement in a blanking operation of 10 mm diameter
di holes
h l are to be
b punched
h d in
i a steell GATE ‐
GATE ‐ 2012
sheet of 3 mm thickness. Shear strength of the Calculate the p punch size in mm,, for a circular
l
low carbon
b steel
t l sheet
h t is
i 5.0 kN.
kN The
Th thickness
thi k off material is 400 N / mm2 and penetration is 40%. blanking operation for which details are given
the sheet is ‘t’
t and diameter of the blanked part is Shear pprovided on the ppunch is 2 mm. The blanking
g below.
force during the operation will be Size of the blank 25 mm
‘d’. For the same work material, if the diameter of
(a) 22.6
22 6 kN (b) 37.7
3 kN Thi k
Thickness off the
th sheet
h t 2 mm
the blanked part is increased to 1.5 d and thickness
(c) 61.6 kN (d) 94.3 kN Radial clearance between punch and die 0.06 mm
is reduced to 0.4 t, the new blanking force in kN is Die allowance 0.05 mm
( ) 3.0
(a) (b) 4.5 (a) 24.83
24 83 (b) 24.89
24 89
(c) 25.01 (d) 25.17
(c) 5.0
50 (d) 80
8.0
436 437 438
GATE‐2008(PI) In
I a blanking
bl ki operation,
i the
h clearance
l is
i provided
id d The
Th cutting i force
f in
i punching
hi and
d blanking
bl ki
on operations mainly depends on
A blank of 50 mm diameter is to be sheared from a
(a) The die (a) The modulus of elasticity of metal
sheet of 2.5 mm thickness. The required radial
(b) Both the die and the punch equally (b) The shear strength of metal
clearance between the die and the punch is 6% of
(c) The punch (c) The bulk modulus of metal
sheet thickness. The punch and die diameters (in mm) (d) Brittle the punch nor the die (d) The yield strength of metal
for this blanking operation,
operation respectively,
respectively are
(a) 50.00 and 50.30 (b) 50.00 and 50.15
(c) 49.70 and 50.00 (d) 49.85 and 50.00

Page 124 of 203 440
Rev.0 441
Page 125
GATE‐1996 IES – 1994 IES – 2002

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 Consider
C id the
h following
f ll i statements related
l d to
carbon steel sheet 1.0 mm thick. The diameter of punches and dies so that piercing and blanking:
the punch should be (a) Press load is reduced 1. Shear on the punch reduces the maximum cutting
(a) 49.925
49 925 mm (b) 50.00
50 00 mm (b) Good cut edge is obtained.
obtained force
(c) 50.075 mm (d) none of the above (c) Warping of sheet is minimized 2. Shear increases the capacity of the press needed
(d) Cut blanks are straight. 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
442 443 (c) 2 and 3 (d) 3 and 4 444
IAS – 1995 IES – 2006 IES – 2004

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 Which
Whi h one off theh following
f ll i statements is i correct??
((a)) 550% on ppunch and 550% on die employed? If the size of a flywheel
y in a ppunching
g machine is
(b) On die (a) Lathe (b) Electric motor increased
( ) On
(c) O punch h (c) Punching machine (d) Gearbox (a) Then the fluctuation of speed and fluctuation of
((d)) On die or p
punch depending
p g upon
p designer’s
g choice energy will both decrease
(b) Then the fluctuation of speed will decrease and the
fluctuation
uctuat o oof eenergy
e gy will increase
c ease
(c) Then the fluctuation of speed will increase and the
fl t ti off energy will
fluctuation ill decrease
d
(d) Then the fluctuation of speed p and fluctuation of
energy both will increase
445 446 447
IES – 1997 IAS – 2000 GATE – 2007 (PI)

( )
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 Circular
Ci l blanks
bl k off 35 mm diameter
di t are punched
h d
single shear equal to thickness will 10 mm thick sheet on a simple die. If 6% clearance is from a steel sheet of 2 mm thickness. If the
(a) Reduce the punch load to half the value recommended, then the nominal diameters of die clearance per side between the punch and die is
(b) Increase the punch load by half the value and p
punch are respectively
p y to be kept as 40 microns,
microns the sizes of punch and
(c) Maintain the same punch load (a) 30.6 mm and 29.4 mm die should respectively be
(b) 30.6 mm andd 30 mm
(d) Reduce the punch load to quarter load (a) 35+0.00 and 35+0.040 (b) 35‐0.040 and 35‐0.080
(c) 30 mm aand
d 29.4
9.4 mm
(d) 30 mm and 28.8 mm (c) 35‐0.080 and 35+0.00 (d) 35+0.040 and 35‐0.080

Page 125 of 203 449
Rev.0 450
Page 126
IAS – 1994 IAS – 2002 IAS – 2007

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 For
F punchinghi operation
i the
h clearance
l is
i provided
id d
maximum punch load used in 2 x 105 N. The plate press work in shearing, the following rule is helpful: on which one of the following?
thickness is 4 mm and percentage penetration is 25. (a) Punch size controls hole size die size controls blank (a) The punch
The work done duringg this shearing
g operation
p is size (b) The die
(a) 200J (b) 400J (b) Punch size controls both hole size and blank size (c) 50% on the punch and 50% on the die
( ) 600 J
(c) (d) 800 J (c) Die size controls both hole size and blank size (d) 1/3rd on the punch and 2/3rd on the die
(d) Die size controls hole size,
size punch size controls blank
size
451 452 453
IAS – 1995 IES – 2002, GATE(PI)‐2003 IAS – 2003

Assertion
A i (A):
(A) A flywheel
fl h l isi attached
h d to a punching
hi Match List I (Press‐part)
(Press part) with List II (Function) and select the
Which one is not a method of reducing cutting correct answer using the codes given below the lists:
press so as to reduce its speed fluctuations. List‐I List‐II
forces to prevent the overloading of press?
Reason(R): The flywheel stores energy when its (Press‐part) (Function)
speed
p increase. ((a)) Providing
g shear on die (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
(a) Both A and R are individually true and R is the (b) Providing shear on punch distance
correct explanation
e planation of A (C) Stopper 3
3. Ejection of the work‐piece
work piece from die cavity
(c) Increasing die clearance (D) Knockout 4. Holding the small punch in the proper
correct explanation of A position
(d) Stepping punches Codes: A B C D A B C D
(c) A is true but R is false (a) 4 3 2 1 (b) 2 1 4 3
(c) 4 1 2 3 (d) 2 3 4 1
454 455 456
IES – 2000 IES – 1999

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
mechanical press is clearance must be given to the die.
(a) Top dead centre Reason (R): The blank should be of required
(b) 20 degrees below top dead centre dimensions.
dimensions
(c) 20 degrees before bottom dead centre (a) Both A and R are individually true and R is the
(d) Bottom dead centre 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 Drawing

Page 126 of 203 458
Rev.0 459
Page 127
Drawing Drawing
y Drawing is a plastic deformation process in which a flat y Hot drawing is used for thick‐walled parts of simple
sheet
h or plate
l is formed
f d into a three‐dimensional
h d l part geometries, thinning
h takes
k place.
l
with a depth more than several times the thickness of y Cold
C ld drawing
d i uses relatively
l i l thin
hi metal,
l changes
h the
h
the metal. thickness very little or not at all,
all and produces parts in a
y As a p
punch descends into a mating
g die,, the metal wide varietyy of shapes.
p
assumes the desired configuration.
460 461 462
Blank Size
Blank Size IES – 1994 GATE‐2003
D = d + 4dh 2 When d > 20r For obtaining a cup of diameter 25 mm and height 15 A shell of 100 mm diameter and 100 mm height with
mm by
b drawing,
d the
h size off the
h round
d blank
bl k should
h ld the
h corner radius
d off 0.4 mm is to be
b produced
d d by
b
D = d 2 + 4dh − 0.5r when15r ≤ d ≤ 20r
be approximately cup drawing.
drawing The required blank diameter is
( d − 2r ) + 4d ( h − r ) + 2π r ( d − 0.7 r )
2
D= when d < 10r
(a) 42 mm (b) 44 mm (a) 118 mm (b) 161 mm
(c) 46 mm (d) 48 mm (c) 224 mm (d) 312 mm
463 464 465
y Drawing Force
GATE‐2017 ISRO‐2011 ⎡D ⎤
The
Th initial
i i i l blank
bl k diameter
di required
i d to form
f a
F = π dt σ ⎢ − C ⎥
A 10 mm deep cylindrical cup with diameter of 15 ⎣d ⎦
cylindrical cup of outside diameter 'd‘
d and total
mm is drawn from a circular blank. Neglecting height 'h' having a corner radius 'r' is obtained F = Drawing Force ,N
using
i the
th formula
f l t = Original BlankThickness ,mm
the variation in the sheet thickness, the diameter
(a ) Do = d 2 + 4dh − 0.5
0 5r σ = TensileStrength , MPa
(up to 2 decimal points accuracy) of the blank is
(b) Do = d + 2h + 2r
______ mm. d = PunchDiameter
P hD , mm
(c) Do = d 2 + 2h 2 + 2r
D = Starting
St ti Blank
Bl k Diameter
Di t , mm
(d ) Do = d 2 + 4dh − 0.5r C = 0.7
0 7acorrection
ti factortoaccount
f t t t for
f friction
f i ti
Page 127 of 203 467
Rev.0 468
Page 128
Example y Blank Holding Force

Blank
Bl k holding
h ldi force
f required
i d depends
d d on theh
y A cup of 50 mm diameter and 20 mm height is to be
wrinklingg tendencyy of the cup.p The maximum
produced by drawing from a 1.5 mm thick sheet metal. limit is generally to be one‐third of the drawing
force.
What is the maximum drawing force ? If ultimate tensile
strength of metal is 650 MPa. y Draw Clearance

Punch diameter = Die opening diameter – 2.5 t
469 470 471
IAS – 2013 Main IFS‐2013 Deep drawing

d
y Drawing when cup height is more than half the diameter is
A cup, of 50 mm diameter and 100 mm height, is to be A symmetrical cup of circular cross section with
termed deep
p drawing.
g
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
y Easy with ductile materials.
influence of thickness and corner radii: radius of 2 mm is to be obtained in C20 steel of 0.6
06
y Due to the radial flow of material, the side walls increase in
(i) Calculate the blank diameter mm thickness. Calculate the blank size for the
thickness as the height is increased.
(ii) Decide whether it can be drawn in a single draw,
draw if drawn cup. Will it be possible to draw the cup in
y A cylindrical vessel with flat bottom can be deep drawn by
maximum reduction p
permitted is 4
40%. single step?
double action deep drawing.
drawing
[10 marks] [10 Marks]
y Deep drawing ‐ is a combination of drawing and stretching.
472 473 474
IES – 2008 Deep Drawability

bl
A cylindrical vessel with flat bottom can be deep
Stresses on Deep Drawing
Stresses on Deep Drawing y The ratio of the maximum blank diameter to the
d
drawn b
by y In flange of blank:
d
diameter off the
h cup drawn
d . i.e. D/d.
d
Bi‐axial tension and
(a) Shallow drawing compression y There
Th i a limiting
is li i i drawing
d i ratio
i (LDR),
(LDR) after
f which
hi h the
h
(b) Single action deep drawing punch will pierce a hole in the blank instead of drawing.
drawing
y In wall of the cup:
((c)) Double action deep
p drawing
g simple uni‐axial
uni axial y This ratio depends upon material,
material amount of friction
(d) Triple action deep drawing tension
present, etc.
p
y Limiting drawing ratio (LDR) is 1.6 to 2.3

Page 128 of 203 476
Rev.0 477
Page 129
Limiting Drawing Ratio (LDR) IES – 1997 IES – 1998

y The average reduction in deep drawing Assertion
A i (A):
(A) The
Th first
fi draw
d in
i deep
d drawing
d i operationi
A cup of 10 cm height and 5 cm diameter is to be
d can have up to 60% reduction, the second draw up to
= 0.5
05 made
d from
f a sheet
h metall off 2 mm thickness.
h k The
h 40%% reduction
d and,
d theh third
h d draw
d off about
b 30%
% only.
l
D
⎛ d ⎞ Reason ((R): ) Due to strain hardening, g, the subsequent
q
Reduction = ⎜ 1 − ⎟ × 100% = 50% number of deductions necessary will be
draws in a deep drawing operation have reduced
⎝ D⎠
(a) One p
percentages.
g
Th b rule:
Thumb l
First draw:Reduction = 50 %
(b) Two explanation of A
Second draw:Reduction = 30 %
Third draw:Reduction = 25 % (c) Three correct explanation
l i off A
Fourth draw:Reduction = 16 %
((d)) Four (c) A is true but R is false
Fifth draw:Reduction = 13 %
478 479 480
For IES Only
Die Design
IFS ‐
IFS ‐ 2009 IFS‐2016 y Progressive dies
Wh t is
What i deep
d d
drawing
i process for
f sheet
h t metal
t l E i
Estimate the
h limiting
li i i d
drawing
i ratio
i (LDR)
y Compound dies
forming? Explain the function of a blank holder.
holder th t you would
that ld expectt from
f a sheet
h t metal
t l
g ratio and how is the drawing
What is drawing g ratio y Combination dies
when
hen stretched by
b 23% in length,
length decreases
increased ?
thickness by 10%.
10%
[10 – marks]
[8 M k ]
[8‐Marks]
481 482 483
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
Back Back
Page 129 of 203 485
Rev.0 486
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
487 488 489
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
490 Flange Wrinkle Wall Wrinkle 491 492
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

Page 130 of 203 494
Rev.0 495
Page 131
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.
496 497 498
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
499 500 501
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
(c) 2 and 4 (d) 1, 3 and 4
Page 131 of 203 503
Rev.0 504
Page 132
Spinning Spinning Spinning

y Spinning is a cold‐forming operation in which a rotating 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).
d k off sheet
disk h metall is shaped
h d over a male
l form,
f or 2. A blank or tube is held to the face of the mandrel.
mandrel.
mandrel 3 A roller is pushed against the material near the
3.
center of rotation, and slowly moved outwards, pushing
y Localized pressure is applied through a simple round‐ the
h blank
bl k against the h mandrel.
d l
ended wooden or metal tool or small roller,, which 4. Thee pa
partt co
conforms
o s to tthee sshape
ape oof tthee mandrel
a d e ((with
t
some springback).
traverses the entire surface of the part
5. The
Th process is i stopped,
t d and d the
th partt is i removed d andd
trimmed.
505 506 507
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
508 509 510
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

Page 132 of 203 512
Rev.0 513
For IES Only Page 133 For IES Only For IES Only
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.
514 515 516
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.
517 518 519
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
For-2019(IES,
a die or mating GATE & PSUs)
workpiece. 520
Page 133 of 203 521
Rev.0 522
Page 134
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
523 524 525
IES 2011 JWM 2010 IES 2010

Assertion (A) : In magnetic pulse‐forming
pulse forming method,
method Assertion (A) : In the high energy rate forming method,
method
High energy rate forming process used for magnetic field produced by eddy currents is used to the explosive forming has proved to be an excellent
forming components from thin metal sheets or create force
f b
between coil
il and
d workpiece.
k i method
h d off utilizing
ili i energy at high
hi h rate andd utilizes
ili
Reason ((R)) : It is necessary y for the workpiece
p 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
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
526 527
(d) A is false but R is true 528
IES – 2007 IES – 2009 IES – 2005

Which one of the following metal forming processes Which one of the following is a high energy rate Magnetic forming is an example of:
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

Page 134 of 203 530
Rev.0 531
Page 135
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
532 plastic. 533 534
Stretch Forming
h Contd...... Stretch Forming
h Contd...... GATE‐2000
A 1.5 mm thick sheet is subject to unequal biaxial
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) 6 (d) 289
8
535 536 537
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.

Page 135 of 203 539
Rev.0 540
Page 136
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.
541 542 543
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 di
die-opening,
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
544 545 546
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

Page 136 of 203 548
Rev.0 549
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.
550 551 552
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. Deep Drawing
4 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)
553 554 555
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) 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 1For-2019(IES,
3 2 GATE(d)& PSUs)
4 1 5 2556 (c) 1 3 2 Page
4 137(d) 3
of 203 1 2 4557 Rev.0 558
Page 138
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 559 560 561
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.
(a) Both Statement (I) and Statement (II) are individually true and
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
562 563 564
GATE 2017(PI)
GATE‐2017(PI) Manufacturing of Powder
IES – 1999 Reduction
Assertion
A i (A):
(A) In
I atomization
i i process off manufacture
f off In powder
d metallurgy,
ll the
h process 'atomization'
' '
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 compressed d refers
f to a method
h d off
air. exposed to below melting point gases results in a
Reason (R): The metallic powder obtained by (a) Producing powders product of cake of sponge metal.
atomization p process is q
quite resistant to oxidation.
(b) compaction of powders 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) Both A and R are individually true but R is not the (c) sintering of powder compacts
(“green”)
g strength
g
correct explanation
l i off A
(c) A is true but R is false (d) blending of metal powders y Used for iron, Cu, tungsten, molybdenum, Ni and
(d) A is false but R is true Cobalt.
Page 138 of 203 566
Rev.0 567
Page 139 Only for IES
Manufacturing of Powder Manufacturing of Powder
GATE ‐2011 (PI)
GATE ‐2011 (PI) Comminution
C i i
Grinding
g
Whi h off
Which th
the f ll i
following powder
d production
d ti y Granular
G l material,
t i l which
hi h may be
b coarsely
l atomized
t i d
methods produces spongy and porous particles? 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
(a) Atomization
adiabatic
di b i expansion i off the
h gas before
b f i i i
impinging on a
((b)) Reduction of metal oxides g on which the g
target granules shatters
((c)) Electrolytic
y deposition
p y Process is used for production of very fine powders such
as are required for injection moulding . Brittle materials
(d) Pulverization such as inter
inter‐metallic
metallic compounds,
compounds ferro
ferro‐alloys
alloys ‐ ferro
ferro‐
568 569 chromium, ferro‐silicon are produces 570
IES‐2013 Conventionall Electrolytic Deposition
IES ‐ 2012
In
I electrolysis
l l i
Explain the terms comminution and reduction used in y Used for iron, copper, silver
((a)) For making g copper
pp p powder,, copper
pp p plate is made
y Process is similar to electroplating.
electroplating
powder metallurgy. cathode in electrolyte tank
y For making copper powder, copper plates are placed as
(b) For making aluminum powder,
powder aluminum plate is
[ 2 marks] anode in the tank of electrolyte, whereas the aluminium made anode
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
When DC current is p passed, the copper
pp ggets deposited
p metal
eta oon aanode
ode
on cathode. The cathode plated are taken out and (d) Atomization process is more suitable for low melting
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
pulverized to the desired g
p grain size.
571
y The cost of manufacturing is high. 572 573
Manufacturing of Powder GATE‐2014 (PI) IAS – 2000

Granulations ‐ as metals are cooled they are stirred rapidly Which one of the following methods is NOT used Consider
C id theh following
f ll i processes:
Machining ‐ coarse powders such as magnesium 1. Mechanical pulverization
p
f producing
for d i metal
t l powders?
d ?
2. Atomization
Milling
g ‐ crushers and rollers to break down metals. Used for (a) Atomization 3. Chemical
Ch i l reduction
d i
brittle materials.
(b) Compaction 4. Sintering
4 g
Shooting ‐ drops of molten metal are dropped in water, used
Which of these processes are used for powder
for low melting point materials.
materials ((c)) Machining
g and g
grinding
g
preparation
ti in
i powder
d metallurgy?
t ll ?
Condensation – Metals are boiled to produce metal vapours (d) Electrolysis (a) 2, 3 and 4 (b) 1, 2 and 3
and then condensed to obtain metal powders. Used for Zn, (c) 1, 3 and 4 (d) 1, 2 and 4
Mg Cd.
Mg, Cd
Page 139 of 203 575
Rev.0 576
Page 140
IES 2010 GATE‐2018 (PI)
Metallic
ll powders
d can be
b produced
d d by
b Characteristics
Ch i i off metall powder: d
Which one of the following processes is NOT
y Fineness: refers to p particle size of p powder,, can be
( ) Atomization
(a) A i i used for producing powders? determined either by pouring the powder through a sieve or
(b) Pulverization
P l i ti by microscopic testing.
testing A standard sieves with mesh size
(a) Atomization varies between (100) and (325) are used to determine
( ) Electro‐deposition
(c) El t d iti process particle
ti l size
i and d particle
ti l size
i distribution
di t ib ti off powder
d ini a
(b) Ball milling certain range.
(d) All of the above y Particle size distribution: refers to amount of each particle
(c) Sintering size in the powder and have a great effect in determining
flowability, apparent density and final porosity of product.
(d) Electrolysis
y
577 578 579
Conventional Questions IES – 1999

y Discuss
Di the
h terms fineness
fi and d particle
i l size
i The
Th correct sequence off the h given
i processes in
i
distribution in powder metallurgy. [IES‐2010, 2 Marks] manufacturing by powder metallurgy is
Ans. (a) Blending, compacting, sintering and sizing
Fineness: Is the diameter of spherical shaped particle and (b) Blending,
Blending compacting,
compacting sizing and sintering
mean diameter of non‐spherical shaped particle.
(c) Compacting, sizing, blending and sintering
Particle size distribution: Geometric standard deviation (d) Compacting, blending, sizing and sintering
((a measure for the bredth or width of a distribution),), is the
ratio of particle size diameters taken at 84.1 and 50% of the
cumulative undersized weight plot, respectively and mean
mass diameter define the particle size distribution.
580 581 582
Blending
l d IES‐2013 Conventionall
y Blending
Bl di or mixing
i i operations
ti can be
b done
d either
ith dry
d or wet.
t
Why lubricants are used to mix the metal powders?
y Lubricants such as graphite or stearic acid improve the flow
characteristics and compressibility at the expense of reduced [ 2 marks]
strength.
y Binders produce the reverse effect of lubricants.
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)
Page 140 of 203 584
Rev.0 585
Page 141
Compacting C ti
Compacting Sintering
y Powder is pressed into a “green compact” y Controlled atmosphere: no oxygen
y Heat to 0.75*T melt
y 40 to 1650 MPa pressure (Depends on materials,
y Particles bind together, diffusion, recrystalization
P ti l bi d t th diff i t li ti
product complexity)
and grain growth takes place.
g g p
y Still very porous, ~70% density
y Part shrinks in size
y May be done cold or warm (higher density) y Density increases, up to 95%
y Strength increases, Brittleness reduces, Porosity
St th i B ittl d P it
decreases. Toughness increases.
g
586 587 588
GATE‐2016 (PI) IES – 2002

GATE ‐2010 (PI)
GATE ‐2010 (PI) The rate of production of a powder metallurgy part
In powder metallurgy, sintering of the component
I powder
In d metallurgy,
t ll sintering
i t i off a componentt d
depends
d on
(a) increases density and reduces ductility
(a) Improves strength and reduces hardness (a) Flow rate of powder
(b) increases porosity and reduces density
(b) Reduces brittleness and improves strength (b) Green strength of compact
( )
(c) increases density and reduces porosity
d d d
(c) Improves hardness and reduces toughness ((c)) Apparent
pp densityy of compact
p
(d) i
(d) increases porosity and reduces brittleness.
it d d b ittl
(d) Reduces porosity and increases brittleness (d) Compressibility of powder
589 590 591
Cold Isostatic
ld Pressing (CIP)
( )
IES –
IES – 2007 Conventional
2007 Conventional Cold Isostatic Pressingg
y The powder is contained in a flexible mould made of
y Metal powders are compacted by many methods,
methods rubber
bb or some other
h elastomer
l materiall
but sintering
g is required
q to achieve which
y The
Th flexible
fl ibl mould
ld is
i then
h pressurized
i d by
b means off
property? What is hot iso‐static pressing?
high‐pressure water or oil.
oil (same pressure in all
[ 2 Marks]
directions))
y No lubricant is needed
y High and uniform density can be achieved

Page 141 of 203 593
Rev.0 594
Page 142
H t I t ti Pressing (HIP)
Hot Isostatic P i (HIP) IAS – 1997
y Is carried out at high
g temperature
p and p
pressure using
ga
Assertion
A ti (A):
(A) Close
Cl dimensional
di i l tolerances
t l are
gas such as argon. NOT possible with isostatic pressing of metal
powder
d in i powder
d metallurgy
t ll t h i
technique.
y The flexible mould is made of sheet metal. (Due to high
Reason (R): In the process of isostatic pressing, the
temperature) pressure is equal in all directions which permits
uniform density of the metal powder.
y Compaction
C i and
d sintering
i i are completed
l d (a) Both A and R are individually true and R is the
simultaneously.
simultaneously correct
co ect eexplanation
p a at o oof A
yU
Used in the p
production of billets of super‐alloys,
p y , high‐
g correct explanation of A
speed steels, titanium, ceramics, etc, where the integrity (c) A is true but R is false
of the materials is a prime consideration ( ) A is false but R is true
(d)
595 596 597
S
Spray Deposition
D iti Metal Injection Moulding
Metal Injection Moulding
IES –
2011 Conventional y Spray
S deposition
d iti isi a shape‐generation
h ti process. y Fine metal powders are blended with an organic binder such
as a polymer or a wax‐based binder.
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
y The powder‐polymer mixture is then injected into split dies,
(a) Atomiser preheated to remove the binder and, finally, sintered.
y What are its advantage ?
(b) Spray chamber with inert atmosphere
y Volumetric shrinkage during sintering is very high.
[ 2 Marks] (c) Mould for producing preforms.
preforms
y Complex shapes that are impossible with conventional
y After the metal is atomised,, it is deposited
p into a cooler
compaction.
ti
preformed mould.
y Good dimensional accuracy.
y Achieve density above 99%, fine grain structure,
y High production rate.
mechanical
h i l properties
ti same as wrought
ht product
d t
598 599 y Good mechanical properties. 600
R ll C
Roll Compaction
ti l
Explosive Compaction
y Powders are compacted by passing between two rolls y High Energy Rate Forming (HERF) or Explosive Forming
rotating in opposite direction. of the metal powders at rather higher velocities 3500 m/s
y The powders are put in a container and are forced by a than
h thath off the
h usuall speedd off compaction
i during
d i the h
ram between two rotating rolls,
rolls and is compacted into a ordinary die compacting.
continuous strip at speeds of up to 0.5 m/s. y Higher green densities
y Sheet metal for electrical and electronic components and y Higher sintered strength
for coins can be made by this process.
process
y More uniform density distribution
y The rolling
g p
processes can be carried out at room or at
elevated temperature.

Page 142 of 203 602
Rev.0 603
ISRO 2013
ISRO ‐2013 Features of PM products
f d
Liquid Phase Sintering
y During sintering a liquid phase, from the lower MP Following is a process used to form powder metal to y For
F high
hi h tolerance
l parts, a sintering
i i part is
i put back
b k into
i
component,
p , mayy exist a die and repressed. In general this makes the part more
shape
h accurate with a better surface finish.
y Alloying may take place at the particle‐particle interface
y Molten
M l component may surround d the
h particle
i l that
h hash ( ) Sintering
(a) Si i y A part has many voids that can be impregnated.
impregnated One
not melted method is to use an oil bath. Another method uses
(b) Explosive
E l i Compacting
C ti vacuum
acuum first,
first then impregnation.
impregnation
y High compact density can be quickly attained
y A part surface can be infiltrated with a low melting point
y Important variables: (c) Isostatic Molding
metal to increase density, strength, hardness, ductility
y Nature of alloy, molten component/particle wetting, and impact resistance.
(d) All of these
capillary action of the liquid
y Plating, heat treating and machining operations can also
b used.
be d
604 605 606
Production of magnets
d f Advantages
d Advantages
d Contd….
y 50:50 Fe‐Al alloys is used for magnetic parts
F Al ll i d f i y Good tolerances and surface finish
G d l d f fi i h y Physical properties can be controlled
y Al‐Ni‐Fe is used for permanent magnets
p g y Highly complex shapes made quickly
g y p p q y
y Variation from part to part is low
y Sintering is done in a wire coil to align the magnetic y Can produce porous parts and hard to manufacture
poles of the material materials (e.g. cemented oxides)
materials (e g cemented oxides) y Hard to machine metals can be used easily
H d t hi t l b d il
y H2 is used to rapidly cool the part (to maintain magnetic y Pores in the metal can be filled with other
y No molten metals
alignment) materials/metals
y Total shrinkage is approximately 3‐7% (for accurate parts y Surfaces can have high wear resistance y No need for many/any finishing operations
an extra sintering step may be added before magnetic y Porosity can be controlled y Permits high volume production of complex shapes
g p p p
alignment)
li t) y Low waste
y The sintering temperature is 600°C in H
g p y Allows non‐traditional alloy combinations
2 y Automation is easy
607 608 y Good control of final density 609
IES – 2007 Disadvantages

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

Page 143 of 203 611
Rev.0 612
Page 144
IES ‐ 2012 IES – 2006 IES – 2004

Statement
St t t (I):
(I) Parts
P t made d by
b powder
d metallurgy
t ll do
d nott Which
f ll i are the
h limitations
li i i off Consider
C id theh following
f ll i factors:
f
have as good physical properties as parts casted. powder metallurgy? 1. Size and shapep that can be p
produced economicallyy
Statement (II): Particle shape in powder metallurgy 1. High tooling and equipment costs.
influences the flow characteristic of the powder. 2. Porosity of the parts produced
2 Wastage of material.
2. material 3. Available
A il bl press capacity
i
(a) Both Statement (I) and Statement (II) are
individuallyy true and Statement ((II)) is the correct 3. It cannot be automated. 4. High
4 g densityy
explanation of Statement (I) 4. Expensive metallic powders. Which of the above are limitations of powder
(b) Both Statement (I) and Statement (II) are S l t the
i the
th codes
d given
i b l
below: metallurgy?
t ll ?
individually true but Statement (II) is not the correct
explanation of Statement (I) (a) Onlyy 1 and 2 (b) Onlyy 3 and 4 (a) 1, 3 and 4 (b) 2 and 3
(c) Statement (I) is true but Statement (II) is false (c) Only 1 and 4 (d) Only 1, 2 and 4 (c) 1, 2 and 3 (d) 1 and 2
( ) Statement (I)
(d) ( ) is false but Statement (II)
( ) is true
613 614 615
A li ti
Applications IES 2010
y Oil impregnated bearings made from either iron or
Oil‐impregnated IES‐2015 Conventional
IES‐2015 Conventional Consider
C id theth following
f ll i parts: t
copper alloys for home appliance and automotive
applications
li ti Classify the products that are commonly produced by 1. Grinding wheel
y P/M filters can be made with p pores of almost anyy size. p
powder metallurgy. Give examples of each.
gy p 2. Brake lining
y Pressure or flow regulators. 3. Self‐lubricating bearings
[10 Marks]
y Small
S ll gears, cams etc.t Whi h off these
Which h parts are made d by
b powder
d
y Products where the combined p properties
p of two or more metallurgy gy technique?
q
metals (or both metals and nonmetals) are desired.
(a) 1, 2 and 3 (b) 2 only
y Cemented carbides are produced by the cold‐
Cemented carbides are produced by the cold
compaction of tungsten carbide powder in a binder, such (c) 2 and 3 only (d) 1 and 2 only
as cobalt ( 5 to 12%), followed by liquid‐phase sintering.
b lt ( t %) f ll d b li id h i t i
616 617 618
IAS – 1998 IES – 2009

Throwaway
Th tungsten carbide
bid tip
i tools
l are Which of the following cutting tool bits are made by
GATE –
GATE – 2011 (PI)
2011 (PI)
manufactured by The binding material used in cemented carbide
(a) Forging (b) Brazing powder
d metallurgy
ll process?
cutting tools is
(c) Powder metallurgy (d) Extrusion ( ) Carbon
(a) C b steell tooll bits
bi (b) S lli tooll bits
Stellite bi ( ) graphite
(a) hi
((b)) tungsten
g
( ) Ceramic
(c) C i tool
t l bits
bit (d) HSS tool
t l bits
bit
(c) nickel
(d) cobalt
b l

Page 144 of 203 620
Rev.0 621
Page 145
IAS – 2003 IES – 1997 IES – 2001

Which
f ll i are produced
d d by
b powder
d Which
f ll i components can be b Carbide‐tipped
C bid i d cutting
i toolsl are manufactured
f d by
b
metallurgy process? manufactured by powder metallurgy methods? powder‐ metal technology process and have a
1. Cemented carbide dies 1. Carbide tool tips 2. Bearings composition of
2 Porous bearings
2. 3 Filters
3. 4
4. Brake linings (a) Zirconium
Zirconium‐Tungsten
Tungsten (35% ‐65%)
65%)
3. Small magnets Select the correct answer using the codes given below: (b) Tungsten carbide‐Cobalt (90% ‐ 10%)
4. Parts with intricate shapes (a) 1, 3 and 4 (b) 2 and 3 (c) Aluminium oxide‐ Silica (70% ‐ 30%)
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 (d) Nickel‐Chromium‐ Tungsten (30% ‐ 15% ‐ 55%)
Codes:
(a) 1, 2 and 3 (b) 1, 2 and 4
( ) 2, 3 and
(c) d 4 (d) 1, 3 and d4
622 623 624
IES‐2015
Consider the following statements regarding powder Pre ‐ Sintering IAS – 2003
metallurgy :
If a part made by PM needs some machining, it will be In
I parts produced
d d by
b powder d metallurgy
ll process,
1. Refractory materials made of tungsten can be
pre‐sintering is done to
manufactured easily.
easily rather
h very difficult
d ff l iff the
h materiall is very hard
h d and
d strong.
2. In metal powder, control of grain size results in (a) Increase the toughness of the component
relatively
l i l much h uniform
if structure These machining operations are made easier by the pre‐
pre (b) Increase the density of the component
3. The powder heated in die or mould at high temperature sintering operation which is done before sintering (c) Facilitate bonding of non‐metallic particles
is then pressed and compacted to get desired shape and (d) Facilitate machining of the part
strength.
g operation.
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
(c) 2, 3 and 4 only (d) 1, 2, 3 and 4 625 626 627
IES‐2016 Conventional Repressing Infiltration

fl
In reference to primary processes of Powder y Repressing is performed to increase the density and y Component is dipped into a low melting‐temperature
Metallurgy, explain the following: improve the

h mechanical
h l properties. alloy
ll liquid
l d
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
(i) Blending
action thereby decreasing the porosity and improving
action,
(ii) Compacting the strength
g of the component.
p
(iii) Pre‐sintering y The p
process is used q
quite extensivelyy with ferrous p
parts
(iv) Sintering
g [4
4 Marks] using copper as an infiltrate but to avoid erosion, an alloy
of copper containing iron and manganese is often used.
Page 145 of 203 629
Rev.0 630
Page 146
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
631 632 633
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
634 635 636
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
(c) 2‐4‐1‐3 (d) 4‐3‐2‐1 (c) 4 3 2 1 (d) 3 4 1 2639
Page 146 of 203 638
Rev.0
Page 147
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 the steps involved in “powder metallurgy”
Group – 1 Group ‐2
what
h happens
h d
during sintering. process. Discuss
Di th
these steps.
t N
Name th materials
the t i l used
d
P. Mulling 1. Powder metallurgy
Q Impregnation
Q. Impregnation 2 Injection moulding
2. Injection in “powder
powder metallurgy
metallurgy”.. What are the limitations of
[IES
[IES‐2010, 2 Marks]
M k ]
R. Flash trimming 3. Processing of FRP composites powder metallurgy? [IES‐2005, 10 Marks]
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
640 641 642
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
643 644

Page 148
Introduction y Cemented carbides,
y Cast carbides,
y Success in metal cutting depends on selection of the
proper cutting tool (material and geometry) for a given y Coated carbides,
work material. y Coated high speed steels,
y A wide range of cutting tool materials is available with y Ceramics,
Cutt g oo ate a s
Cutting Tool Materials a varietyy of p
cost.
properties,
p , p
performance capabilities,
p , and y Cermets,
Cermets
y Whisker reinforced ceramics,
y These include: y Sialons,
y High carbon Steels and low/medium alloy steels,
y Sintered polycrystalline cubic boron nitride (CBN),
Sintered polycrystalline cubic boron nitride (CBN)
y High‐speed steels,
y Sintered polycrystalline diamond, and single‐crystal
y Cast cobalt alloys,
alloys natural diamond.
l di d
By S K Mondal 1 Contd…
2 3
Carbon Steels
Carbon Steels
y Limited tool life. Therefore,, not suited to mass
production.
y Can be formed into complex shapes for small production
runs
y Low cost
y Suited to hand tools, and wood working
y Carbon content about 0.9 to 1.35% with a hardness
ABOUT 62 C Rockwell
y Maximum cutting speeds about 8 m/min. dry and used
upto 250oC
y The hot hardness value is low. This is the major factor in
FIGURE: Improvements in cutting tool materials have reduced
tool life.
life
Fig. Productivity raised by cutting tool materials
machining time. 4 5 6
IAS – 1997 High speed steel

Assertion
A i (A):
(A) Cutting
C i tools
l made
d off high
hi h carbon
b y These steels are used for cutting metals at a much
steel have shorter tool life. higher cutting speed than ordinary carbon tool steels.
steels
Reason(R): During machining, the tip of the cutting y The high speed steels have the valuable property of
tool is heated to 600/700
600/700°C C which cause the tool tip retaining
i i their
h i hardness
h d even when
h heated
h d to red
d heat.
h
to lose its hardness.
y Most of the high
g speed
p steels contain tungsten
g as the
( ) Both
h chief alloying element, but other elements like cobalt,
correct explanation of A chromium vanadium,
chromium, vanadium etc.
etc may be present in some
(b) Both A and R are individually true but R is not the proportion.
Page 148 of 203 8
Rev.0 Contd…
9
Page 149
y With time the effectiveness and efficiency of HSS
IES‐2013 IAS‐1997
(tools) and their application range were gradually
(t l ) d th i li ti d ll Vanadium in high speed steels: Which of the following processes can be used for
enhanced by improving its properties and surface production thin, hard, heat resistant coating at TiN,
condition through ‐
diti th h ( ) Has a tendency to promote decarburization
(a) on HSS?
y Refinement of microstructure y p
1. Physical vapour deposition.
p
y Addition of large amount of cobalt and Vanadium to (b) Form
F very hard
h d carbides
bid and
d thereby
h b increases
i the
h 2. Sintering under reducing atmosphere.
increase hot hardness and wear resistance wear resistance of the tool 3 Chemical vapour deposition with post treatment
3.
respectively 4. Plasma spraying.
y Manufacture by powder metallurgical process (c) Helps in achieving high hot hardness S l t th
Select the correct answer using the codes given below:
t i th d i b l
y Surface coating with heat and wear resistive Codes:
materials like TiC
t i l lik TiC , TiN
TiN , etc by Chemical Vapour
t b Ch i l V (d) Has a tendency to promote retention of Austenite
(a) 1 and 3 (b) 2 and 3
Deposition (CVD) or Physical Vapour Deposition ((c)) 2 and 4
4 ((d)) 1 and 44
(PVD)
10 11 12
18‐4‐1 High speed steel IES‐2003 IES 2007

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

The blade of a power saw is made of y This steel contains 6 per cent tungsten, 6 per cent y This steel is also called cobalt high speed steel
(a) Boron steel molybdenum, 4 per cent chromium and 2 per cent
molybdenum because cobalt is added from 2 to 15 per cent,
cent in order
(b) High speed steel vanadium. to increase the cutting efficiency especially at high
y It
I has
h excellent
ll toughness
h andd cutting
i ability.
bili temperatures.
temperatures
(c) Stainless steel
y The molybdenum
y high
g speed
p steels are better and y This steel contains 20 per cent tungsten, 4 per cent
(d) Malleable cast iron chromium, 2 per cent vanadium and 12 per cent cobalt.
cheaper than other types of steels.
y It is particularly used for drilling and tapping
operations.

Page 149 of 203 17
Rev.0 18
Page 150
IES‐1995 IES‐2000 IES‐1992

The compositions of some of the alloy steels are as Percentage of various alloying elements present The main alloying elements in high speed Steel in
under: in different steel materials are given below: order of increasing proportion are
1. 18 W 4 Cr 1 V 1. 18% W; 4% Cr; 1% V; 5% Co; 0.7% C (a) Vanadium, chromium, tungsten
2 12 Mo 1 W 4 Cr 1 V
2. 2. 8% Mo; 4% Cr; 2% V; 6% W; 0.7% C (b) Tungsten, titanium, vanadium
3. 6 Mo 6 W 4 Cr 1 V
3 27% Cr; 3% Ni; 5% Mo; 0.25% C
3. 27% Cr; 3% Ni; 5% Mo; 0 25% C (c) Chromium, titanium, vanadium
Chromium titanium vanadium
4. 18 W 8 Cr 1 V
4. 18% Cr; 8% Ni; 0.15% C (d) Tungsten, chromium, titanium
The compositions of commonly used high speed steels
would include Which of these relate to that of high speed steel?
(a) 1 and 2 (b) 2 and 3 (a) 1 and 3 (b) 1 and 2
(c) 1 and 4 (d) 1 and 3 (c) 2 and 3 (d) 2 and 4
19 20 21
IAS‐2001 IAS 1994
Assertion (A): For high‐speed turning of magnesium Assertion (A): The characteristic feature of High IAS –
IAS – 2013 Main
2013 Main
alloys, the coolant or cutting fluid preferred is water‐ speed Steel is its red hardness.
miscible mineral fatty oil.
i ibl i l f il Compare HSS and ceramic tools with regard to their
Reason (R): Chromium and cobalt in High Speed
Reason (R): As a rule, water‐based oils are recommended promote martensite formation when the tool is cold
p application in high speed machining.
pp g p g
f hi h
for high‐speed operations in which high temperatures are
d ti i hi h hi h t t worked.
generated due to high frictional heat. Water being a good
coolant the heat dissipation is efficient
coolant, the heat dissipation is efficient. ((a)) Both A and R are individually true and R is the correct
y
(a) Both A and R are individually true and R is the correct explanation of A
explanation of A (b) Both A and R are individually true but R is not the
(b) Both A and R are individually true but R is not the correct correct explanation of A
e p a at o o
explanation of A (c) A is true but R is false
(c) A is true but R is false (d) A is false but R is true
22 23 24
y Other elements added include V, B, Ni, and Ta.

Cast cobalt alloys/Stellite y Tools of cast cobalt alloys
y are g
generallyy cast to shape
p and IES 2011
y Cast cobalt alloys are cobalt‐rich, chromium‐tungsten‐ carbon finished to size by grinding. Stellite is a non‐ferrous cast alloy composed of:
cast alloys
y having g p properties
p and applications
pp in the y Theyy are available onlyy in simple
p shapes,
p such as single‐
g (a) Cobalt,
Cobalt chromium and tungsten
intermediate range between high‐speed steel and cemented point tools and saw blades, because of limitations in the
carbides. casting process and expense involved in the final shaping (b) Tungsten, vanadium and chromium
y Although comparable in room‐temperature hardness to high‐ (grinding) The high cost of fabrication is due primarily to
(grinding).
the high hardness of the material in the as‐cast condition. (c) Molybdenum, tungsten and chromium
speed steel tools, cast cobalt alloy tools retain their hardness to
a much higher temperature.
temperature Consequently,
Consequently they can be used at y Materials machinable with this tool material include plain‐ (d)Tungsten molybdenum,
(d)Tungsten, molybdenum chromium and vanadium
higher cutting speeds (25% higher) than HSS tools. carbon steels, alloy steels, nonferrous alloys, and cast iron.
y Cutting speed of up to 80‐100
80 100 fpm can be used on mild steels.
steels y Cast cobalt alloys are currently being phased out for
y Cast cobalt alloys are hard as cast and cannot be softened or cutting‐tool applications because of increasing costs,
heat treated.
treated
shortages of strategic raw materials (Co, W, and Cr), and
the
h development
d l off other,
h superior tooll materials l at lower
l
y Cast cobalt alloys contain a primary phase of Co‐rich solid cost.
solution strengthened by Cr and W and dispersion hardened by
complex hard, refractory carbides of W and Cr.
For-2019(IES, GATE & PSUs) Contd…
25
Page 150 of 203 26
Rev.0 27
Page 151
Cemented Carbide y Cemented carbide tool materials based on TiC have

IAS –
IAS – 2013 Main
2013 Main y Carbides, which are nonferrous alloys, are also called,
been developed,
b d l d primarily
i il f
for auto
t i d t
industry
sintered ((or cemented)) carbides because theyy are
applications using predominantly Ni and Mo as a
What are the desirable properties while selecting a tool bi d
binder. Th
These are used d for
f hi h
higher‐speedd (>
( 1000
manufactured by powder metallurgy techniques.
material for metal‐cutting applications?
g pp ft/min) finish machining of steels and some malleable
y Most carbide tools in use today are either straight
tungsten carbide (WC) or multicarbides of W‐Ti or W‐
castt irons.
i
Ti‐Ta,, depending
p g on the work material to be machined. y Cemented carbide tools are available in insert form in
y Cobalt is the binder. many different shapes; squares, triangles, diamonds,
y These tool materials are much harder,
harder are chemically more and rounds.
stable, have better hot hardness, high stiffness, and lower y Compressive strength is high compared to tensile
friction, and operate at higher cutting speeds than do HSS. strength, therefore the bits are often brazed to steel
y They are more brittle and more expensive and use strategic shanks, or used as inserts in holders.
metals (W,
(W Ta,
Ta Co) more extensively.
extensively y These inserts may often have negative rake angles.
angles
28 Contd…
29 Contd…
30
IES‐1995
y Speeds
S d up to 300 fpm
f are common on mild
ild steels
l
The straight grades of cemented carbide cutting
y Hot hardness p
properties
p are veryy g
good tool materials contain
y Coolants and lubricants can be used to increase tool (a) Tungsten carbide only
life, but are not required.
life required
(b) Tungsten carbide and titanium carbide
y Special alloys are needed to cut steel
(c) Tungsten carbide and cobalt
(d) Tungsten carbide and cobalt carbide
Contd…
31 32 33
IAS – 1994 The standards developed by ISO for grouping of carbide tools Table below shows detail grouping of cemented carbide tools

pp g g
and their application ranges are given in Table below.
Assertion
A i (A):
(A) Cemented
C d carbide
bid tooll tips
i are ISO Material
M t i l Process
P
Application
produced by powder metallurgy. ISO Code Colour Code Application group
Reason (R): Carbides cannot be melted and cast. P01 Steel, Steel castings Precision and finish machining, high speed
P For machining long chip forming
(a) Both A and R are individually true and R is the common materials like plain carbon
P10 Steel Steel castings
Steel, Turning, threading,
Turning threading and milling high speed
speed,
small chips
correct explanation of A and low alloy steels P20 Steel, steel castings, Turning, milling, medium speed with small chip
malleable cast iron section
(b) Both A and R are individually true but R is not the M For machining long or short chip
correct
co ect eexplanation
p a at o oof A formingg ferrous materials like P30 Steel, steel castings, Turning, milling, medium speed with small chip
malleable
ll bl cast iiron section
i
Stainless steel
(c) A is true but R is false P40 Steel and steel casting Turning, planning, low cutting speed, large chip
K For machining short chipping,
chipping with
ith sand
d iinclusions
l i section
ti
(d) A is false
f l but
b R is true
ferrous and nonferrous material P50 Steel and steel castings Operations requiring high toughness turning,
and non – metals like Cast Iron,
Iron off medium
di or llow ttensile
il planning,
l i shaping
h i att llow cutting
tti speeds
d
Brass etc. strength
Page 151 of 203 35
Rev.0 36
Page 152
IES 2018
IES‐2018
K01 Hard grey C.l., chilled casting, Turning, precision turning and boring, milling, IES‐1999 Consider the following statements:
Al.
Al alloys with high silicon scraping 1 HSS tools wear very rapidly,
1. rapidly whereas in cemented
K10 Grey C.l. hardness > 220 HB. Turning, milling, boring, reaming, broaching, Match List‐I (ISO classification of carbide tools) with List‐ carbide tools, even though hardness is retained, crater
Malleable C.l., Al. alloys scraping
containing Si
II (Applications) and select the correct answer using the
pp g wear can occur due to solid
solid‐state
state diffusion.
K20 Grey C.l. hardness up to 220 Turning, milling, broaching, requiring high codes given below the Lists: 2. Cutting tools made of Super‐HSS also known as cobalt‐
HB toughness
List‐I List‐II based HSS,, are made byy adding g 2% to 15%
5 of cobalt which
K30 Soft grey C.l.
C l Low tensile Turning reaming under favourable conditions
Turning,
strength steel A. P‐10 1. Non‐ferrous, roughing cut increases the cutting efficiency at heavier cuts by
K40 Soft non-ferrous metals Turning milling etc.
B. P‐505 2. Non‐ferrous, finishing cut
, g increasing the hot hardness and wear resistance.
M10 Steel steel castings
Steel, castings, Turning, milling,
Turning milling medium cutting speed and medium
manganese steel, grey C.l. chip section C. K‐10 3. Ferrous material, roughing cut 3. Tooll failure
f l d to excessive stress can be
due b minimized d by
b
M20 Steel casting, austentic steel, Turning, milling, medium cutting speed and medium providing small or negative rake angles on brittle tool
manganese steelsteel, chip section D.. K‐50
5 4. Ferrous material, finishing cut
e ous a e a , s g cu materials protecting tool tip by providing large side‐
materials, side
spherodized C.l., Malleable
C.l.
Code: A B C D A B C D cutting edge angles, and honing a narrow chamfer along
M30 Steel austenitic steel,
Steel, steel Turning milling,
Turning, milling planning,
planning medium cutting speed,
speed (a) 4 3 1 2 (b) 3 4 2 1 the cutting g edge.
g
spherodized C.l. heat
resisting alloys
medium or large chip section
(c) 4 3 2 1 (d) 3 4 1 2 Which of the above statements are correct?
M40 Free cutting steel
steel, low tensile Turning profile turning
Turning, turning, specially in automatic (a) 1 and 2 only (b) 1 and 3 only
strength steel, brass and light machines.
alloy
(c) 2 and 3 only (d) 1, 2 and 3
37 38 39
Ceramics y Itt iss poss b e to get mirror

possible o finish
s oon cast iron
o us g
using
y Ceramics are essentially alumina ( Al2O3 ) based high ceramic turning.
refractory materials introduced specifically for high y The
Th main
i problems
bl off ceramic
i tools
t l are their
th i low
l
speed machining of difficult to machine materials and
strength, poor thermal characteristics, and the
cast iron.
iron
tendency to chipping.
y These can withstand very high temperatures, are
chemically more stable,
stable and have higher wear y They are not suitable for intermittent cutting or for low
resistance than the other cutting tool materials. cutting speeds.
y In
I view
i off their
h i ability
bili to withstand
ih d high
hi h temperatures, y Very
V hi h hot
high h t hardness
h d properties
ti
they can be used for machining at very high speeds of y Often used as inserts in special
p holders.
the
h order
d off 10 m/s.
/
y They can be operated at from two to three times the
y p
cutting speeds of tungsten carbide.
Contd…
40 Comparison of important properties of ceramic and tungsten carbide tools 41 Contd…
42
y Through last few years remarkable improvements in y Introducing nitride ceramic (Si3N4) with proper sintering
technique – this material is very tough but prone to built‐up‐
built up
y Cutting
g fluid, if applied
pp g with
should in flooding
strength and toughness and hence overall performance copious quantity of fluid, to thoroughly wet the entire
edge formation in machining steels
of ceramic tools could have been p possible byy several machining zone, since ceramics have very poor
y Developing SIALON – deriving beneficial effects of Al2O3
means which include; and Si3N4 thermal shock resistance. Else, it can be machined
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 with no coolant.
coolant
toughness of Al2O3 ceramics were improved to impart toughness and thermal conductivity y Ceramic tools are used for machining work pieces,
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 which have high hardness, such as hard castings, case
y Transformation toughening
g g byy addingg appropriate
pp p enhanced strength, toughness and life of the tool and thus hardened and hardened steel.
productivity
d i i spectacularly.
l l
amount of partially or fully stabilised zirconia in y Typical products can be machined are brake discs,
y Toughening Al2O3 ceramic by adding suitable metal like
Al2O3 powder,
powder brake drums,
drums cylinder liners and flywheels.
flywheels
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.
43
Page 152 of 203 Contd…
44
Rev.0 45
Page 153
IES 2016
IES‐2016 IES‐2013
Statement (I): Ceramics withstand very high High Performance ceramics (HPC)
temperatures that range from 1000°C to 1600°C. Sialon ceramic is used as:
Statement ((II):
) Silicon carbide is an exceptionp from
among ceramics that cam withstand high ( )
(a) Cutting tool material
p
temperatures.
(b) C
(b) Creep resistant
i
(a) Both Statement (I) and Statement (II) are
individually true and Statement (II) is the correct ( ) F
(c) Furnace linens
li
explanation of Statement (I).
(b) Both Statement (I) and Statement (II) are Silicon Nitride
Sili Nit id Alumina toughned
Al i t h d byb (d) High strength
individually true but Statement (II) is not the correct (i) Plain (i) Zirconia
explanation
l ti off Statement
St t t (I).
(I)
(ii) SIALON (ii) SiC whiskers
(iii) Whisker toughened (iii) Metal (Silver etc)
46 47 48
IES 2010 IAS‐1996 IES‐1997

Constituents
C tit t off ceramics i are oxides
id off Match List I with List II and select the correct answer Assertion (A): Ceramic tools are used only for light,
different materials, which are using the codes given below the lists: g p
smooth and continuous cuts at high speeds.
List I (Cutting tools)
( l ) List II (Major constituent)
( )
(a) Cold mixed to make ceramic pallets Reason (R): Ceramics have a high wear resistance and
A. Stellite l. Tungsten high temperature resistance.
(b) Ground, sintered and palleted to make ready B. H.S.S. 2. Cobalt
ceramics C. Ceramic 3. Alumina correct explanation of A
D. DCON 4. Columbium
(c) Ground, washed with acid, heated and cooled (b) Both A and R are individually true but R is not the
55. Titanium correct explanation of A
(d) Ground, sintered, palleted and after calcining Codes: A B C D A B C D
((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
A i f l b R i
49 50 51
IES‐1996 IES 2007 IAS‐2000

A machinist desires to turn a round steel stock of Which one of the following is not a ceramic? Consider the following cutting tool materials used for
outside diameter 100 mm at 1000 rpm The
outside diameter 100 mm at 1000 rpm. The g p
metal‐cutting operation at
( ) Alumina
(a) Al i
material has tensile strength of 75 kg/mm2. The high speed:
((b)) Porcelain 1
1. Tungsten carbide
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 2. Cemented titanium carbide
materials will be suitable for machining the (d) Pyrosil
P il 3. High‐speed steel
Hi h d l
component under the specified cutting
p p g 4. Ceramic
conditions? The correct sequence in increasing order of the range of
cutting speeds for optimum use of these materials is
(a) Sintered carbides (b) Ceramic
(a) 3,1,4,2 (b) 1,3,2,4
(c) HSS (d) Diamond (c) 3,1,2,4 (d) 1,3,4,2

Page 153 of 203 53
Rev.0 54
Page 154
IAS‐2003 Coated Carbide Tools y The coatings

g must be fine g
grained, & free of binders
At room temperature, which one of the following y Coated tools are becoming the norm in the metalworking and porosity.
is the correct sequence of increasing hardness of industryy because coating g , can consistentlyy improve,
p , tool y Naturally,
Naturally the coatings must be metallurgically bonded
life 200 or 300% or more.
the tool materials? to the substrate.
y In cutting tools, material requirements at the surface of the
(a) Cast alloy‐HSS‐Ceramic‐Carbide tool need to be abrasion resistant, hard, and chemically y Interface coatings are graded to match the properties
(b) HH
HH‐Cast alloy‐Ceramic‐Carbide
Cast alloy Ceramic Carbide inert to pprevent the tool and the work material from of the coating
g and the substrate.
interacting chemically with each other during cutting. y The coatings must be thick enough to prolong tool life
(c) HSS‐Cast alloy‐Carbide‐Ceramic
y A thin, chemically stable, hard refractory coating of TiC, but thin enough to prevent brittleness.
brittleness
(d) Cast alloy‐HSS‐Carbide‐Ceramic TiN, or accomplishes this objective.
y The bulkAlof
2 O3the tool is a tough, shock
shock‐resistant
resistant carbide that y Coatings should have a low coefficient of friction so
can withstand high‐temperature plastic deformation and that the chips do not adhere to the rake face.
resist breakage.g y Multiple coatings are used,
used with each layer imparting
55 Contd…
56
its own characteristic to the tool. Contd…
57
y The most successful combinations are

IAS‐1999
TiN/TiC/TiCN/TiN and TiN/TiC/ Al2O3 . The coating materials for coated carbide tools,
y Chemical
h l vapour deposition
d (
(CVD)
) is the
h technique
h includes
used to coat carbides. (a) TiC, TiN and NaCN (b) TiC and TiN
(c) TiN and NaCN (d) TiC and NaCN
Contd…
58 59 60
TiN‐Coated High‐Speed Steel C t
Cermets
y Physical
y p
vapour p
deposition (PVD) has p
proved to be the y These sintered hard inserts are made by combining ‘cer’
cer from
y Coated high‐speed steel (HSS) does not routinely best process for coating HSS, primarily because it is a ceramics like TiC, TiN or TiCN and ‘met’ from metal (binder)
provide as dramatic improvements in cutting speeds as relatively low temperature process that does not likee Ni,, Ni‐Co,
Co, Fee etc.
do coated carbides, with increases of 10 to 20% being exceed the tempering point of HSS. y Harder, more chemically stable and hence more wear resistant
typical.
i l y Therefore,
Th f no subsequent
b t heat
h t treatment
t t t off the
th y More brittle and less thermal shock resistant
cutting tool is required. y Wt% of binder metal varies from 10 to 20%.
y In addition to hobs,, ggear‐shaper
p cutters,, and drills,,
y The advantage of TiN‐coated HSS tooling is reduced y Cutting edge sharpness is retained unlike in coated carbide
HSS tooling coated by TiN now includes reamers, taps,
inserts
chasers spade
chasers, spade‐drill
drill blades,
blades broaches,
broaches bandsaw and tool wear.
y Can machine steels at higher cutting velocity than that used for
circular saw blades, insert tooling, form tools, end y Less tool wear results in less stock removal during tool tungsten carbide, even coated carbides in case of light cuts.
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 y Modern cermets with rounded cutting edges are suitable for
reground more times. finishing and semi‐finishing of steels at higher speeds, stainless
steels but are not suitable for jerky interrupted machining and
61
Page 154 of 203 62 machining of aluminium and similar materials. Rev.0 63
Page 155
IES 2010 IES‐2000 IES – 2003

The
Th cutting
tti tool
t l material
t i l required
i d to
t Cermets are
The
Th correct sequence off cutting i tools
l ini theh
sustain high temperature is ascending order of their wear resistance is
( ) Metals for high temperature use with ceramic like
(a) M l f hi h i h i lik
(a) HSS‐Cast non‐ferrous alloy (Stellite)‐Carbide‐
((a)) High
g carbon steel alloys
y properties
Nitride
(b) Ceramics with metallic strength and luster
(b) Composite of lead and steel (b) Cast non‐ferrous alloy (Stellite)‐HSS‐Carbide‐
(c) Coated tool materials Nitride
d
(c) Cermet (d) Metal‐ceramic composites (c) HSS‐Cast
SS Cast non‐ferrous
o e ous aalloy oy (Ste
(Stellite)‐Nitride‐
te) t de
(d) Alloy of steel, zinc and tungsten Carbide
(d) Cast
C t non‐ferrous
f alloy
ll (St llit ) C bid Nit id
(Stellite)‐Carbide‐Nitride‐
HSS
64 65 66
Di d
Diamonds y Diamond tools have the applications in single point turning and
y Diamond is the hardest of all the cutting
y Diamond has the following properties:
g tool materials.
GATE –
GATE – 2009 (PI)
2009 (PI) boring
b i tools,
t l milling
illi cutters,
tt reamers, grinding
i di wheels,
h l honing
h i
tools, lapping powder and for grinding wheel dressing.
y extreme hardness,
hardness Di
Diamond
d cutting
tti t l are nott recommended
tools d d for
f y Due
D to their
h i brittle
b i l nature, the h diamond
di d toolsl have
h poor
y low thermal expansion, resistance to shock and so, should be loaded lightly.
y high
hi h heat
h conductivity,
d i i and d machining of ferrous metals due to
y Polycrystalline diamond (PCD) tools consist of a thin layer (0.5
y a very low co‐efficient of friction. to 1.5 mm) of'fine grain‐ size diamond particles sintered
(a) high tool hardness
y This is used when good surface finish and dimensional accuracy together
h and d metallurgically
ll ll bonded
b d d to a cemented d carbide
bd
are desired. substrate.
((b)) high
g thermal conductivityy of work material
y The work‐materials on which diamonds are successfully employed y The main advantages of sintered polycrystalline tools over
are the non‐ferrous one, such as copper,
pp brass, zinc, aluminium ((c)) p
poor tool toughness
g natural single‐crystal tools are better quality, greater toughness,
and magnesium alloys. and improved wear resistance, resulting from the random
y On ferrous materials,, diamonds are not suitable because of the (d) chemical affinity of tool material with iron orientation of the diamond grains and the lack of large cleavage
diffusion of carbon atoms from diamond to the work‐piece planes.
l
material. 67
Contd…
68 Contd…
69
y Diamond tools offer dramatic performance IES‐1995 IES‐2001

improvements over carbides. Tool life is often greatly Assertion (A): Non‐ferrous materials are best Assertion (A): Diamond tools can be used at high
improved, as is control over part size, finish, and
p p machined with diamond tools. p
speeds.
surface integrity. Reason (R): Diamond tools are suitable for high speed Reason (R): Diamond tools have very low coefficient
y Positive rake tooling is recommended for the vast machining. of friction.
majority of diamond tooling applications. (a) Both A and R are individually true and R is the (a) Both A and R are individually true and R is the
correct explanation of A correct explanation of A
y If BUE is a problem, increasing cutting speed and the
(b) Both A and R are individually true but R is not the (b) Both A and R are individually true but R is not the
use of more positive rake angles may eliminate it.
p g y correct explanation of A correct explanation of A
y Oxidation of diamond starts at about 450oC and (c) A is true but R is false (c) A is true but R is false
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 (d) A is false but R is true
A i f l b R i
diamond tool is kept flooded by the coolant during
cutting, and light feeds are used.
i d li h f d d
Page 155 of 203 71
Rev.0 72
Page 156
IES – 1999 IES‐1992 IAS – 1999

C id h f ll i Assertion (A): During cutting, the diamond tool is
A i (A) D i i h di d l i
Which of the following given the correct order of
p g y,
For precision machining of non‐ferrous alloys, diamond kept flooded with coolant.
increasing hot hardness of cutting tool material?
is preferred because it has Reason (R): The oxidation of diamond starts at
(a) Diamond, Carbide, HSS
1 Low coefficient of thermal expansion
1. about 4500C
(b) Carbide, Diamond, HSS
2. High wear resistance (a) Both A and R are individually true and R is the
(c) HSS, carbide, Diamond
HSS carbide Diamond correct explanation of A
l f
3. High compression strength
(d) HSS, Diamond, Carbide (b) Both A and R are individually true but R is not
ot a d R a e d v dua y t ue but R s ot tthe e
4. Low fracture toughness
L f t t h
(a) 1 and 2 (b) 1 and 4
( ) 2 and 3
(c) d (d) 3 and 4
d
73 74 75
Cubic boron nitride/Borazon y The operative speed range for cBN when machining

grey castt iron
i is
i 300 ~400 m/min/ i
y Next to diamond, cubic boron nitride is the hardest y CBN is less reactive with such materials as hardened
y Speed
p ranges
g for other materials are as follows:
material presently available.
available steels, hard‐chill cast iron, and nickel‐
steels hard chill cast iron and nickel and cobalt‐
and cobalt
y Hard cast iron (> 400 BHN) : 80 – 300 m/min based superalloys.
y It is made by bonding a 0.5 – 1 mm layer of
polycrystalline cubic boron nitride to cobalt based y Superalloys
S ll ( 35 RC) : 80
(> 8 – 140 m/min
/ i y CBN can be used efficiently and economically to
carbide substrate at veryy high g temperature
p and y Hardened steels ((> 45 RC) : 100 – 3 300 m/min machine these difficult‐to‐machine materials at higher
g
pressure. y It is best to use cBN tools with a honed or chamfered speeds (fivefold) and with a higher removal rate
y It remains inert and retains high hardness and fracture edge preparation,
preparation especially for interrupted cuts.
cuts Like (fivefold) than cemented carbide and with superior
(fivefold) than cemented carbide, and with superior
toughness at elevated machining speeds. ceramics, cBN tools are also available only in the form accuracy, finish, and surface integrity.
y It shows excellent performance in grinding any off indexable
i d bl inserts.
i
material of high
g hardness and strength.
g y The only y limitation of it is its high
g cost.
Contd…
76 Contd…
77 78
IES‐1994 IES‐2002 IES‐1996

Consider the following tool materials: Which one of the following is the hardest cutting Cubic boron nitride
1. Carbide
C bid 2. C
Cermet tool material next only to diamond? ( ) Has a very high hardness which is comparable to
(a) H hi h h d hi h i bl
33. Ceramic 4.
4 Borazon. (a) Cemented carbides that of diamond.
Correct sequence of these tool materials in increasing (b) Ceramics (b) Has a hardness which is slightly more than that of
order of their ability to retain their hot hardness is (c) Silicon HSS
(a) 1,2,3,4 (b) 1,2,4,3 (d) Cubic boron nitride (c) Is used for making cylinder blocks of aircraft
(c) 2, 1, 3, 4 (d) 2, 1, 4, 3 engines
i
((d)) Is used for making optical glasses.
g p g

Page 156 of 203 80
Rev.0 81
Page 157
IES‐1994 IAS‐1998 C it
Coronite
y Coronite is made basically by combining HSS for strength and
Cubic boron nitride is used Which of the following tool materials have cobalt toughness and tungsten carbides for heat and wear resistance.
( ) As lining material in induction furnace
(a) A li i i l i i d i f as a constituent element? y Microfine TiCN particles are uniformly dispersed into the matrix.
matrix
1. Cemented carbide 2. CBN y Unlike a solid carbide, the coronite based tool is made of three
((b)) For making optical quality glass.
g p q yg layers;
(c) For heat treatment 3. Stellite 4. UCON y the central HSS or spring steel core
(d) For none of the above.
F f h b Select the correct answer using the codes given below: y a layer of coronite of thickness around 15% of the tool
Codes: diameter
(a) 1 and 2 (b) 1 and 3 y a thin (2 to 5 μm) PVD coating of TiCN
y The coronite tools made by y hot extrusion followed byy PVD‐
(c) 1 and 4 (d) 2 and 3 coating of TiN or TiCN outperformed HSS tools in respect of
cuttingg forces, tool life and surface finish.
82 83 84
IES‐1993 IES‐2003 IES‐2000

Match List I with List IT and select the correct answer using the Which one of the following is not a synthetic Consider the following tool materials:
codes given below the lists:
Li I (Cutting tool Material)
List ‐ I (C i l M i l) List ‐
Li I I(Major
I I(M j abrasive material? 1. HSS 2. C
Cemented carbide
d bid
characteristic constituent)
A. High speed steel 1. Carbon (a) Silicon Carbide (b) Aluminium Oxide 33. Ceramics 4.
4 Diamond
B. Stellite 2. Molybdenum (c) Titanium Nitride (d) Cubic Boron Nitride The correct sequence of these materials in decreasing
C. Diamond 3. Nitride
D. Coated carbide tool 4. Columbium order of their cutting speed is
5. Cobalt (a) 4, 3, 1, 2 (b) 4, 3, 2, 1
C d A
Codes: B C D A B C D
(a) 2 1 3 5 (b) 2 5 1 3 (c) 3, 4, 2, 1 (d) 3, 4, 1, 2
(c) 5 2 4 3 (d) 5 4 2 3
85 86 87
IES‐1999 IAS‐2001 Attrition wear

Match List‐I with List‐II and select the correct answer Match. List I (Cutting tool materials) with List II y The strong bonding between the chip and tool material at
using the codes given below the Lists: (Manufacturing methods) and select the correct answer high temperature is conducive for adhesive wear.
List I List II using the codes given below the Lists:
i th d i b l th Li t y The adhesive wear in the rough region is called attrition
(Materials) (Applications) List I List II wear .
A Tungsten carbide
A. bid 1. Ab i h l
Abrasive wheels A HSS
A. 1
1. Casting y In the rough region, some parts of the worn surface are still
B. Silicon nitride 2. Heating elements B. Stellite 2. Forging covered by molten chip and the irregular attrition wear
C Aluminium
C. Al i i oxide
id 3. Pi f
Pipes for conveying
i C Cemented carbide
C. 3
3. Rolling occurs in this region .
liquid metals D. UCON 4. Extrusion y The irregular attrition wear is due to the intermittent
D Silicon carbide
D. 4
4. Drawing dies 5
5. Powder metallurgy adhesion during interrupted cutting which makes a
Code: A B C D A B C D Codes:A B C D A B C D periodic attachment and detachment of the work material
(a) 3 4 1 2 (b) 4 3 2 1 (a) 3 1 5 2 (b) 2 5 4 3 on the tool surface.
(c) 3 4 2 1 (d) 4 3 1 2 (c) 3 5 4 2 (d) 2 1 5 3 y Therefore, when the seizure between workpiece to tool is
broken, the small fragments of tool material are plucked
and
d brought
b h away byb the
h chip.
h
Page 157 of 203 89
Rev.0 90
Page 158
IES‐1996 IES‐2005
The limit to the maximum hardness of a work Consider the following statements: An increase in
material which can be machined with HSS tools the cobalt content in the straight carbide grades
g g
even at low speeds is set by which one of the of carbide tools
following tool failure mechanisms? 1 Increases the hardness.
1. Increases the hardness
(a) Attrition 2. Decreases the hardness.
(b) Abrasion 3. Increases the transverse rupture strength
I h h
4. Lowers the transverse rupture strength.
4 p g
(c) Diffusion
Which of the statements given above are correct?
(d) Plastic deformation under compression.
(a) 1 and 3 (b) 2 and 4
(c) 1 and 4 (d) 2 and 3
91 92 93

Page 159

IES-2012 Page No.5 Slide No.30 Ans. (b)Both are correct. We have used negative rake angles for
different purpose but not for the direction of chip.In turning positive back rake angle takes the chips away from
Ch-1 Basics of Metal Cutting: Answers with Explanations the machined surface, Whereas negative back rake angle directs the chip on to the machined surface.
IES-2013 Page No.2 SlideNo.8 Ans.(c) IES-2003 Page No.5 Slide No.31 Ans. (b)
S DN S u 30 u1000 IES-2015 Page No.5 Slide No.32 Ans. (b)

Speed V m / min m / min 94.2 m / min
1000 1000
GATE(PI)-1990 Page No.5 Slide No.33 Ans. (c)
IES-2001 Page No.2 Slide No.9 Ans. (c)For cutting brass recommended rake angle is -5 to +5 No of chattering per cycle 360/30 = 12
No of cycle per second = 500 /60
degree. Therefore chattering frequency is 12 x 500/60 = 100 Hz
IAS-1996 Page No.5 Slide No.34 Ans. (a)
IES-1995 Page No.3 Slide No.10 Ans. (a) It is true form-cutting procedure, no rake should be
ground on the tool, and the top of the tool must be horizontal and be set exactly in line with the axis of IAS-1995 Page No.5 Slide No.35 Ans. (a) Fy Ft cos O Ft sin CS
rotation of the work; otherwise, the resulting thread profile will not be correct. An obvious disadvantage
of this method is that the absence of side and back rake results in poor cutting (except on cast iron or
brass). The surface finish on steel usually will be poor.
IES-2010 Page No.5 Slide No.36 Ans. (c) Fy n Ft cos O Ft sin CS n (radial force)
Fx p Ft sin O Ft cos CS n (axial force)andSCEA has no influence on cutting force i.e. tangential force. But
GATE-1995;2008 Page No.3 Slide No.11 Ans. (a)Increasing rake angle reduces the cutting force
on the tool and thus power consumption is reduced. this question is not for Orthogonal Cutting it should be turning.
IES-1993 Page No.3 Slide No.12 Ans. (d) Negative rake angle increases the cutting force i.e. IES-1995 Page No.6 Slide No.37 Ans. (c)
Cutting force
specific pressure. Specific pressure = IES-2006 Page No.6 Slide No.38 Ans.(c) Smaller point angle results in higher rake angle.
feed×depth of cut
IES-2005 Page No.3 Slide No.13 Ans.(b)Carbide tips are generally given negative rake angle it is IES-2002 Page No.6 Slide No.41 Ans. (d)Strength of a single point cutting tool depends
very hard and very brittle material. Negative rake is used as carbides are brittle not due to hardness. on lip angle but lip angle also depends on rake and clearance angle.
Hardness and brittleness is different property
IES-2012 Page No.6 Slide No.43 Ans. (b)
IES-2015 Page No. 3 Slide No.14 Ans.(b)
IES-2009 Page No.6 Slide No.44 Ans. (c)Large nose radius improves tool life. A sharp
IES-2002 Page No.3 Slide No.15 Ans.(c)Carbide tools are stronger in compression. point on the end of a tool is highly stressed, short lived and leaves a groove in the path of cut. There is an
improvement in surface finish and permissible cutting speed as nose radius is increases from zero value.
IES-2011 Page No.3 Slide No.16 Ans. (b)The rake angle does not have any effect on flank But too large a nose radius will induce chatter.
but clearance anglehas to reduce the friction between the tool flank and the machined surface.
IES-1995 Page No.6 Slide No.45 Ans. (c) It will increase tool cutting force.
GATE-2008(PI) Page No.3 Slide No.17 Ans. (c) Brittle workpiece materials are hard
and needs stronger tool. Tools having zero or negative rake angle provides adequate strength to cutting IES-1994 Page No.7 Slide No.46 Ans. (b)
tool due to large lip angle.
IAS-1994 Page No.4 Slide No.20 Ans. (d)
IES-1993 Page No.7 Slide No.48 Ans. (b)The second item is the side rake angle. Thus 6°
IES-2014 Page No.4 Slide No.21 Ans. (c) is theside rake angle.
ISRO-2011 Page No.7 Slide No.49 Ans. (b)
IES-2012 Page No.4 Slide No.22 Ans.(d)When cutting velocity is increased, it will lead to
increase in power and temperature, and cutting force will be slightly reduce so we take as cutting forces will not
IES-2018 Page No.7 Slide No.50 Ans. (a)
be affected by the cutting velocity.Common sense will say force will increase, but if you think deeply there
is no reason for increasing the force, same material same hardness, same tool same sharpness.
Therefore the force will remain unaffected. But in actual practice it will reduce due to high
GATE-2008 Page No. 7 Slide No.51 Ans.(d) We may use principal cutting edge angle or
temperature. As velocity increases power consumption will increase and temperature will increase. approach angle = 90 - CS . When, principal cutting edge angle =90;then D S D . Don’t confuse with
IES-2006 Page No.4 Slide No.27 Ans. (d)All other tools are multi-point. side cutting edge angle. Side cutting edge angle is not principal cutting edge angle.
GATE-2017(PI) Page No.5 Slide No.28 Ans. (c)

1|P a g e 2|P a g e


Page 160

r cos D 0.4 cos10 D 10o
GATE-2001Page No.7 Slide No.52 Ans.(c) I tan 1
tan 1
22.944
1 r sin D 1 0.4sin10 t 0.5 mm
t 0.81 tc 1.125 mm
GATE-2011Page No.7 Slide No.53 Ans. (b) r 0.45
tc 1.8 t 0.5
r 0.444
tc 1.125
r cos D 0.45cos12 o
I tan 1 tan 1 25.90o r cos D 0.444 cos10
1 r sin D 1 0.45sin12o tan I
1 r sin D 1 0.444 sin10
GATE-2018 Page No.7 Slide No.54 Ans. 23.32 I 25.35o
J cot I tan(I D ) cot 25.35o tan(25.35o 10o ) 2.385
t 0.5
D = 15° , t = 0.5 mm, t c = 1.25 mm, r = 0.4
tc 1.25 IES-2009 Page No.8 Slide No.61 Ans. (d) as rake angle is zero. shear strain (H ) = cot I tan I
r cos D 0.4 cos15°
tanI = I = 23.3155° = 23.32° GATE-1990(PI) Page No.8 Slide No.62 Ans. (a)
1 r sin D 1 sin15°
GATE-2017Page No.8 Slide No.55 Ans. 1.494 H cot I tan I 12

dH
IES-1994 Page No.8 Slide No.56 Ans. (b)Shear angle does not depends on cos ec 2I sec 2 I 12 0 gives I 51o
dI
velocity. If we double the velocity it will double the chip velocity so r will remain
same. Shear angle will remain same. True feed means feed. V Vs Vc
IES-2016 Page No.8 Slide No.63 Ans.(a)
cos I D cos D sin I
IES-2014 Conventional Page No.8 Slide No. 57
GATE-2012 Page No.9 Slide No.64 Ans. (c)
lc 68.9 r cos D
Ans. 18.3o r and tan I r 0.4; D
10
l S u 69 1 r sin D
r cos D 0.4 cos10
I tan 1 tan 1 22.94
GATE-2014 Page No.8 Slide No.58 Ans. 2.8 to 3.0 1 r sin D 1 0.4sin10
from the velocity triangle;
t f sin O 0.2 u sin 90o V VS
r (for turning) = 0.4
tc tc 0.5 sin 90 I D sin 90 D
r cos D r cos 0 2.5 VS
I tan 1 tan 1 tan 1 r tan 1 0.4
1 r sin D 1 r sin 0 sin 90 22.94 10 sin 90 10
I 21.80o
VS 2.526m / s
Shear strain(H )= cot I tan I D cot 21.80o tan(21.80 0)o 2.9
VS 2.526 m / s
Shear strain rate(H < ) 1.0104 u105 / s
tS 25 u106 m
IES-2004 Page No.8 Slide No.59 Ans.(d)
IES-2004 Page No.9 Slide No.65 Ans. (b) actually 2,3 and 4 are correct.But best choice is (b)
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-2006 Page No.9 Slide No.66 Ans. (c)Cutting torque decreases with increase in rake angle.
o
shear strain (H ) = cot I tan I D cot17.31o tan 17.31 10 3.34
IES-2004 Page No.9 Slide No.67 Ans. (c)
Without using calculator we can’t solve this question.
IES-2004,ISRO-2009 Page No.9 Slide No.68 Ans. (a)
IAS-2015 Main Page No.8 Slide No.60
VC V
sin I sin 90 D I
35 u sin 45
VC 28.577m / min
sin 90 15 45
3|P a g e 4|P a g e


Page 161

IES-2008 Page No.9 Slide No.69 Ans. (b) IES
S-2015 Pa
age No.11 Slide No.84 An
ns. (c)
Cutting ratio means chip thickness ratio, r 0.75; V 60 m / min IAS

S-1997 Pa
age No.11 Slide No.85 An
ns. (a)
t 2.4
r tC 3.2 mm ATE-2002 Page No..11 Slide No.86 An
GA ns. (b)Low cutting speeed means llong chip toool contact time.
t
tC 0.75
And
d long contacct time will sufficient
s to form bond between
b chip
p and tool.
VC sinI
r 0.75
V sin(90 D I ) GA
ATE-2009 Page No
o.11Slide No.87 An
ns. (d)Low cutting speeed means llong chip toool contact time.
t
VC 0.75 u 60 45 m / min Andd long contacct time will sufficient too form bondd between ch hip and tooll. This microo-weld have to break du
ue to
ative motion between chiip and tool. It will increease co-efficient of frictioon.
rela
IES-2014 Page No.9 Slide No.70 Ans. (c) f = f sinǌ = 0.2 sin 90 = 0.2 mm ; tc= 0.32 mm;
cutting ratio = chip thickness ratio = t / tc = 0.2/0.32 = 0.625 But examiner has given reciprocal value = 1.6 IES
S-1997Pag
ge No.11 Slide No.88 An
ns. (d) Caast iron means
m brittlee material and will form
disccontinuous chip. So chip breaker is not
n needed.
IES-2001 Page No.9 Slide No.71 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 Ch
h-2: An
nalysis of Mettal Cuttting: Answer
A rs with
h Expla
anation
ns
along rake face is chip velocity (Vc ).
ESE
E-2000(co onvention nal) Pagge No.12 Slide No
o.91
IES-2003 Page No.9 Slide No.72 Ans. (d) Ans.
V t 0.5 D 10q, r 0.335, t 0.51 mm
m , b=3mm
m,
t 0.5 mm , tc 0.6 mm, C r
V tc 0.6 Wy m2 , P
285 N / mm 0.655
2 u 0.5 r cos D 0.35 u cos10
or VC 1.66 m / s tan I 0.3669
0.6 1 r sinn D 1 0.35sin10
IAS-2003 Page No.10 Slide No.73 Ans. (a)
I tan 1 0.36669 20.152q
IAS-2002 Page No.10 Slide No.74 Ans. (a) bt 3 mm u 0.51 mm
FS Wy m2
285 N / mm
sin I sin 20.1152q
IAS-2000 Page No.10 Slide No.75 Ans. (d) 12265.7 N
IAS-1998Page No.10 Slide No.76 Ans. (b) P tan E , ? E tan 1 P tan 1 0.65 33.023q
S DN S u100 u 480 Froom Merchannt Circle:
V m/s m/s 2.51 m / s
1000 u 60 1000 u 60 ? Fs R cos I E D
IAS-1995 Page No.10 Slide No.77 Ans. (b) It is orthogonal cutting means depth of cut FS
R 1735.6N
equal to uncut chip thickness. As depth of cut halved, uncut chip thickness is also halved and hence chip cos I E D
thickness will be halved. (i) Cutting
C force (Fc ): Fc R cos E D 1597.3N
GATE-2009 (PI -common data S-1) Page No.10 Slide No.78 Ans.(c) (ii) Radial forcee (Fy ) =0 [Thhis force is present in turning
t but it
i is orthogonnal cutting]
t 0.2 mm; tc 0.4 mm; D 15q (iii)) Normal forrce on tool (N): N c E
R cos 1455.2 N
t r cos D 0.5cos15q (iv))Shear forcee (Fs ):1265.77 N
?r 0.5; I tan1
tan 1
29.02q
tc 1 r sin D 1 0.5sin15q Notte : Shear foorce on tool face
f is fricttion force ( F ) R sin E 945.86 N
Nearest option is c GA
ATE-2010 (PI) linke ed S-1 Paage No.12 Slide No.95 Ans.(a)
GATE-2009 (PI- common data S-2) Page No.10 Slide No.79 Ans. (b)
V
V 20 m / min; C r 0.5 orVC 10 m / min
V
GATE-1995 Page No.11 Slide No.82 Ans. (b)It is multi-point cutter and mild steel is ductile
material. Ductile material with multipoint cutter will produce regular shaped discontinuous chip.
5|P a g e Page
6|P


Page 162

' Friction force is perpendicular to the Ussing Merchaant Analysiss:
cutting velocity vector that means D = 0q D E
I = 45q +
F 2 2
F 402.5 N ; and P 1( given) ? N 402.5 N 10 q
Eq
N 20q 45q E 60q
t 0.2 2 2
t 0.2 mm; tc 0.4mm, r 0.5 ESE
E-2005(co
onvention nal)Page No.13 Slide No.107
tc 0.4
P 0.55; ? E tan 1 P tan 1 0.5 26.5665q
r cos D r cos 0
tan I r 0.5.......('D = 0q) using Merchant
M An
nalysis:
1 r sin D 1 r sin 0
or I tan r tan 0.5 26.565q
1 1 D E
I = 45q +
tan E P 1; E 45q 2 2
266.565q
or I 4 q 5q
45 36.717q
From merchant circle: 2
bt 2 mm u 0.22 mm
F R sin E or R 402.5 N 569.22 N FS W y m2
400 N / mm 2677.61N
sin 45q sin I sin 36.7717q
In FS and FC triangle: Froom merchant circle:
Fs =Rcos E D I 569.22 u cos 45 0 26.565 N 180.0 N Fs R cos I E -D
GATE-2010 (PI) linked S-2 Page No.12 Slide No.96 Ans. (d) or 267.61
2 N R cos(36.717q 26.5655q 10q )
V 2m ; or R 447.6 N
s
From the velocity triangle , applying sine rule; andd Fc R cos E -D
V VS FC 447.6 cos(26.565q 10
1 q) 429.002 N
sin ^90 I D ` sin 90 D Ft 447.6sin(226.565q 10
0q ) 127.611N
2 VS
sin 90 26.565 sin 90
GA
ATE-2008 (PI) Link
ked S-1 Page No..13 Slide No.108 Ans. ((d)
VS 2.2361 m Forr minimum cutting
c forcee we have too use mercha
ant Theory
s D 10q , P 0.7 tan E or E tan 1 P 34.99q
? Heat generation at the primary shear zone
Using Merchant
M A
Analysis
will be because of shear velocity and shear force
D E
Heat =FS u VS 180.0 N u 2.2361 m / s 402.5W I 45q
2 2
GATE-2013 linked question S-1 Page No.12 Slide No.97 Ans. (a) 10 34.99q
q
From Merchant Circle if cutting force ( FC ) is perpendicular to the friction force ( F ) then the rake
I 45q 32.5q
2 2
angle will be zero GA
ATE-2008 (PI) Linkked S-2 Page No..14 Slide No.109 Ans. ((b)
GATE-2013 linked question S-2 Page No.12 Slide No.98 Ans. (b) b 3.6 mm
From merchant circle; Calculaating shear force
f Fs :
' D = 0, then F, N, FC , Ft will form a rectangle. bt 3.6 mm u 0.25
0 mm
Fs Wy u 60 N / mm 2
46 7
770.52 N
Fc N 1500 N sin I sin 322.5q
Ft F Using Merchant
M C
Circle:
GATE-2015 Page No.12 Slide No.99 Ans. 2.1 In trianngle formed by Fs , Fn annd R;
GATE-2017(PI) Page No.13 Slide No.101 Ans. (d) Fs c I E D
R cos
IAS-1999 Page No.13 Slide No.105 Ans. (b)
D E or 770.52 N R N u cos(32.5q 34.99q 10q ) R 1433.7 N
I =45 +
q
2 2 In trianngle formed by Ft , Fc annd R;
20q 25.5q
I 45 q
42.25q Fc =Rcoos E D 1433.7 u coos(34.99q 10
1 q ) 1299..5 N
2 2
GATE-1997 Page No.13 Slide No.106 Ans. (c) 1500
=FC <V
Power= 12999.5 N u m / s 32448.8W | 3.2
25 KW
60
7|P a g e Page
8|P


Page 163

GATE-2014 Page No.14 Slide No.110 Ans. (d) GATE-2007 (PI) Linked S-2 Page No.15 Slide No.125 Ans. (b)
D Ep Orthogonal machining, t = depth of cut = 0.8 mm,
Using Merchant Analysis, I n 45 q

2 2 t c =1.5 mm, V =1m/s
As shear angle increases cutting force will decrease and length of shear plane decreased results chip t 0.8 Vc Vc
thickness decrease. r
tc 1.5 V 1
GATE-2014 Page No.14 Slide No.111 Ans. (a)
D Ep Vc 0.53 m / s
Using Merchant Analysis, I n 45 q
GATE-2011 (PI) linked S-1 Page No.15 Slide No.126 Ans. (b)
2 2
As shear angle increases area of the shear plane decreased, it results cutting force hence improve t 0.25 mm; tc 0.75 mm; D 0q; b 2.5 mm; N 950 N ; Ft 475 N
surface finish. Here option (b) is also correct but best one is option (a).
t 0.25
IES-2010 Page No.14 Slide No.113 Ans. (b) Merchant Analysis r 0.33333
tc 0.75
r cos D r cos 0
IES-2003 Page No.15 Slide No.119 Ans.(c) tan I r 0.33333
1 r sin D 1 r sin 0
Fs Fc cos I Ft sin I 900cos30 600sin 30 479.4 N
I 18.435q
To calculate shear force;
Fs Fc cos M Ft sin M 900 cos11.31q 810sin11.31q 723 N
as D = 0, N = Fc 950 N
But we have to calculate without using calculator
Fs Fc cos I Ft sin I 950 cos18.435q 475sin18.435q 751.04 N
sin11.31q = 0.2 given ? cos 11.31q 1 sin 2 11.31q 1 0.22 0.98
GATE-2011 (PI) linked S-2 Page No.16 Slide No.127 Ans. (d)
900 cos11.31q 810sin11.31q 900 u 0.98 810 u 0.2 720 N bt
We know, FS W y ;
IES-2000 Page No.15 Slide No.121 Ans. (a) sin I
F Fc sin D Ft cos D 2.5 mm u 0.25 mm
751.04 N W y N / mm 2
N Fc cos D Ft sin D sin18.435q
'D 0; W y 379.90 N
mm 2
. so F= F 500 N
t IFS-2012 Page No.16 Slide No.128 Ans.
N Fc 1000 N d t 0.1 mm, tc 0.2mm, b 5 mm, Fc 500 N , Ft 200 N , D 10q
F 500 1 To calculate co-efficient of friction:
P
N 1000 2 Using relations:
IES-2016 Page No.15 Slide No.122 Ans. 0.5 F Fc sin D Ft cos D 500 sin10q 200 cos10q 283.79 N
F Fc sin D Ft cos D 500 sin 0 250 cos 0
P 0.5 N Fc cos D Ft sin D 500 cos10q 200sin10q 457.67 N
N Fc cos D Ft sin D 500 cos0 250sin 0
F 283.79
IES-2018 Page No.15 Slide No.123 Ans. (a) P 0.62
N 457.67
Let us assume principal cutting edge ¬angle 90o
To calculate shear strength;
Fc 3000 N , Ft 1200 N
t 0.1 mm
F Fc sin D Ft cos D 3000sin 32o 1200 cos32o r= 0.5
P 1.37 tc 0.2 mm
N Fc cos D Ft sin D 3000 cos32o 1200sin 32o r cos D 0.5cos10
GATE-2007 (PI) Linked S-1 Page No.15 Slide No.124 Ans. (a)
I tan 1 tan 1 28.334q
1 r sin D 1 0.5sin10
FC 1200 N ; Ft 500 N ;D 0q Using relation;
Using the relations: Fs Fc cos I Ft sin I 500 cos 28.334q 200sin 28.334q 345.18 N
F FC sin D Ft cos D 1200sin 0 500 cos 0 500 N § bt ·
Shear force(FS ) shear strength(W y ) u shear area ¨ ¸
N FC cos D Ft sin D 1200 cos 0 500sin 0 1200 N © sin I ¹
F 500 bt 5 u 0.1
P tan E Fs W y 345.18 W y u
N 1200 sin I sin 28.334q
500 W y 327.65 N / mm 2
?E tan 1 22.6q
1200
GATE-2006 common data Q-1 Page No.16 Slide No.129 Ans. (b)
9|P a g e 10|P a g e


Page 164

D 15; t 0.5mm; tc 0.7 mm; Fc 1200 N ; Ft 200 N t f sin O
t 0.5 O 90q CS 90q 60q 30q
r 0.7142
tc 0.7 t 0.2sin 30q 0.1 mm
r cos D 0.7142 cos15q ESE-2003(conventional) Page No.17 Slide No.142 Ans.
I tan 1 tan 1 40.24q
1 r sin D 1 0.7142sin15q D 0;f 0.2mm / rev, d 4mm, tc 0.8mm, dia ( D ) 160mm, speed 400rpm
F Fc sin D Ft cos D 1200sin15q 200 cos15q 503.77 N ' it is a turning operation,
N Fc cos D Ft sin D 1200 cos15q 200sin15q 1107.3 N Fc 1200 N
F 503.77 Fx 800
?P 0.455 | 0.46 Ft 828.22 N
N 1107.3 sin O sin 75q
Alternatively (i) Using the force relations
Using Merchant Theory: F=FC sin D Ft cos D 1200sin 0 828.22 cos 0 828.22 N
D E N Fc cos D Ft sin D 1200 cos 0 828.22sin 0 1200 N
I 45q
2 2 (ii ) ' it is a turning operation,
15q
E 45q 40.24q 24.5q t f sin O 0.32sin 75q 0.3091 mm
2
P tan E tan 24.5q 0.456 | 0.46 d 4
b 4.1411 mm,
sin O sin 75q
GATE-2006 common data Q-2 Page No.16 Slide No.130 Ans.(a)
V 20m / min; Fc 1200 N ; Ft 200 N ( given) t 0.3091 mm
Now , r 0.38638
tc 0.8 mm
Vc t Vc 0.5
r or r cos D r cos 0
V tc 20 m / min 0.7 I tan 1 tan 1 tan 1 r tan 1 0.38638 21.13q
1 r sin D 1 r sin 0
orVC 14.286 m / min
Fs Fc cos I Ft sin I 1200 cos 21.13 828.22sin 21.13 820.76 N
20
Total power Fc u V 1200 N u
m / s 400 W bt
60 Fs Wy u
sin I
14.286
Frictional power=F u VC 503.77 N u m / s 119.95W Fs 820.76
60 or W y 230.93 N / mm 2
Percentage of total energy dissipated as frictional power is bt 4.1411u 0.3091
F u VC 119.95 sin I sin 21.13
u 100% u 100% 29.988% | 30% S DN S u 0.160 u 400
Fc u V 400 (iii ) V 3.351 m / s
GATE-2006 common data Q-3 Page No.16 Slide No.131 Ans. (d) 60 60
H cot I tan(I D ) cot 40.24q tan(40.24q 15q ) 1.653 Power consumption(P)=Fc u V 1200 u 3.351W 4.021kW
GATE-2018 Page No.16 Slide No.132 Ans. Ans.(0.4408) GATE-1995(conventional) Page No.17 Slide No.143 Ans.
t = 0.010 mm, V = 130 m/min, D = 15°, b = 6 mm, t c = 0.015 mm Given : D =100 t f sin O 0.15455mm
t
Fc = 60 N, Ft = 25 N O 750 r 0.32197
tc
F= Fc sinD + Fcos
t D r cosD
tc 0.48 mm tanI = 0.33586
= 60 sin 15° + 25 cos 15° = 39.6773 N 1 r sinD
Ratio of frictional energy to total energy f = 0.16 mm/rev or I =18.5650
F .Vc F t 39.6773 0.010 ª t Vc º

= u = u = 0.4408 «' r»
Fc .V Fc tc 60 0.015 ¬ tc V ¼
IES-1995 Page No.16 Slide No.134Ans. (b) Tangential force accounts for 99% of
the power consumption.
GATE-2014 Page No.17 Slide No.141 Ans.0.08to0.12
11|P a g e 12|P a g e


Page 165

Fc 500N
N
Fx 200 GATE-2015 Page No.18 Slide No.147 Ans. 18.88
Ft 207N
sin O sin75 GATE-2015 Page No.18 Slide No.148 Ans. (a)
F = Fc sin D Ft cos D 500sin10 207 cos10 290.68N GATE-2016 Page No.18 Slide No.149 Ans.(b)
N Fc cos D Ft sin D 500 cos10 207sin10 456.56N For an Orthogonal Turning (Orthogonal Cutting)
F 29 90.68 This question is somehow confusing,data given
P 0.633667
N 45 56.56 for orthogonal turning but written orthogonal cutting
E tan 1 P 32.484 o
Fn n I Ft cos I
Fc sin 565 207 coss18.565
500 sin18.5 355.42 N
Principal cutting edge angle O 90 o
Fs Fc cos I Ft sin I 565 207 sin 18.565 408
500 cos18.5 8.08 N t f sin O or t 0.4 sin 90o 0.4 mm
tc 0.8 mm
IASS-2003(ma
ain exam
m) Page No.17
N Slide No.144
4 Ans. t 0.4
r 0.5
Givven : tc 0.8
Db 7; CS 300;? O 90q 30q 60q r cos D 0.5 cos 22
Now,tan I or I 29.7o
t 2mm; b 2..5mm; Fc 1
1177 N ; Ft 560 N 1 r sin D 1 0.5sin 22
Usiing relationss: GATE-2007 Page No.18 Slide No.150 Ans.(c)
O 90q ; D 0q ;I 25q ; Fc 1000 N
tan D tan D s sin O taan D b cos O
Fx 800
t D
or tan tan D s sin 60q tan 7q cos 60q...........(i ) We know; Ft 800 N
sin O sin 90q
tan D b tann D cos O sin O tan i Using relations:
or ttan 7q tan D cos 60q sin 60q tan 0q F Fc sin D Ft cos D 1000sin 0 800 cos 0 800 N
or D 13.79q N Fc cos D Ft sin D 1000 cos 0 800sin 0 1000 N
Froom (i ) D s 12q
1 F 800
Usiing force relaations P 0.8
N 1000
F = FC sin D Ft cos D GATE-2003(common data)S-1 Page No.18 Slide No.151 Ans. (a)
1177 sin13.79 560 coss13.79 8224.44 N f 0.25 mm / rev, d 0.4 mm, D 10q, I 27.75q
NFC cos D Ft sin D 1177
1 cos13.779 560sinn13.79 10009.6 N t f sin O 0.25sin 90q 0.25 mm
F 824.444 r cos D r cos10q
P 0.816 E tann 1 P tan 1 0.816 39..214q tan I
N 1009..6 1 r sin D 1 r sin10q
Usiing Merchannt Theory r cos10q
tan 27.75q
1 r sin10q
D E 3.79q 39.2214q
13
I = 45q+ 45q 32.288q t 0.25
2 2 2 2 r 0.4888
tc tc
Usiing force rellation:
tc 0.51138 mm
Fs Fc cos I Ft sin I 1177
1 cos 32..288q 560 sin 32.288q 695.87 N
GATE-2003(common data)S-2Page No.18 Slide No.152 Ans. (d)
Fs 6695.87 using Merchant Analysis;
Sheear strength (W y ) 74.34 N / mm 2
bt 2 u 2.55
sinn I sin 32.288 D E
I =45q+
GA
ATE-2007 Pag ge No.18 Slide No.146 6 An
ns. (b) 2 2
O 90q ; D 0q 10q E
E 44.5q
27.75q 45q
t f sinn O f sin 90
9 q 0.24 mm
m 2 2
P tan E tan 44.5q 0.9826
tc 0.448 mm
GATE-2008(common data)S-1 Page No.18 Slide No.153 Ans. (d)
t 0.24 mm
r 0.5
tc 0.48 mm
r cos D r cos 0
I tan 1 tan 1 tann 1 r tan 1 0.5 26.566q
1 r sin D 1 r sin 0
13|P a g e 14|P a g e


Page 166

Wy 250 MPa;V 180 m / min; FC 200
Specific cutting energy J / mm3 2 J / mm3
f 0.20 mm / rev; d 3 mm; r 0.5; D 7q 1000 fd 1000 u 0.1u 1
GATE-2014 Page No.20 Slide No.168 Ans. (b)
r cos D 0.5cos 7q
I tan 1 tan 1 27.85q | 28q FC FC 400
1 r sin D 1 0.5sin 7q Specific pressure 2000 N / mm 2
bt fd 2 u 0.1
We know;
d b sin O º GATE-1993 Page No.20 Slide No.171 Ans. (b)
.........(O 90); d b&t f
t f sin O »¼ IES-2000 Page No.21 Slide No.172 Ans. (a)
bt 0.20 u 3 IES-2004 Page No.21 Slide No.173 Ans. (b)
Fs Wy 250 u 321.09 N | 320 N IES-2002 Page No.21 Slide No.175 Ans. (d)
sin I sin 27.85q
chip : work piece : tool = 80 : 10 : 10
GATE-2008(common data)S-2 Page No.19 Slide No.154 Ans. (b)
Using Merchant Theory: IAS-2003 Page No.21 Slide No.177 Ans. (b)
IAS-2003 Page No.21 Slide No.180 Ans. (c)
7 E 7q E IES-2011 Page No.22 Slide No.182 Ans. (c)
I 45q 28q 45q 41q
2 2 2 2 IES-1993 Page No.22 Slide No.183 Ans. (b)
Using Merchant Circle: IES- 1996 Page No.22 Slide No.184 Ans. (b)
Fs R cos I E D 'R
IES- 1998 Page No.22 Slide No.187 Ans. (b) GH
320 R cos(28q 41q 7q) R 681.62 N R
IES- 2018 Page No.22 Slide No.188 Ans. (b)
Fc R u cos E D 681.62 cos(41 7) 565.09 N R 50 :, H 0.001
Ft R u sin E D 681.62sin(41 7) 381.16 N 'R
GH
IES-2004 Page No.19 Slide No.156 Ans.(b) R
MRR Vfd 'R RGH
50 u 2.1u 0.001 0.105 :
50 u 10 u 0.8 u 1.5mm
3 3
/ min IAS- 2001 Page No.22 Slide No.189 Ans. (c)
60000mm3 / min FOR PSU & IES Page No.23 Slide No.190 Ans.(a) For higher sensitivity, two
gauges are used for tensile strain, while two others are for compressive strain, total of which adds up to four
GATE-2013 Page No.19 Slide No.157 Ans.(d) gauges.All the four gauges in each bridge are active gauges, and the bridge fully compensates for temperature
S DN S u 200 u 160 changes. For 3-D lathe dynamometer total 12 strain gauge is needed, 4 for main cutting force, 4 for Radial force
MRR fdV fd u mm / s 0.25mm u 4 mm u mm / s 1675.5mm3 / s
60 60 and 4 for feed force.
IES-2016 Page No.19 Slide No.158 Ans.(c)
MRR Cross Section u AxialVelocity
S
D1
2

D22 u F ChǦ3ToolLife:AnswerswithExplanation
4
S IES-2014 Page No.23 Slide No.194 Ans. (b) Think only the parameters which can produce cyclic
4
10 2

92 u 175 mm3 / min 2611.45 mm3 / min stress on tool material.
Or MRR fdV fd S DN S dDaverage fN S dDaverage F IES-2007, IES-2016 Page No.23 Slide No.198 Ans.(c)
IES-1994 Page No.24 Slide No.199 Ans.(b) Flank wear directly affect the component dimensions.
S u 0.5 u 9.5 u 175 mm3 / min 1611.45 mm3 / min
GATE-2014 Page No.24 Slide No.201 Ans.(c)Strain hardening don’t confuse with oxide layers because
GATE(PI)-2018 Page No.19 Slide No.161 Ans. 630to641 if workpiece is clean then also tool will wear.
GATE(PI)-1991 Page No.20 Slide No.163 Ans. (d) IES-2004 Page No.24 Slide No.207 Ans.(b)
GATE-2007 Page No.20 Slide No.164 Ans. (d) GATE-2008(PI) Page No.25 Slide No.208 Ans.(b)
The energy consumption per unit volume of material removal, commonly known as specific energy. Solving using straight line equation:
Power (W ) Fc y2 y1
e y y1 < x x1
x2 x1

MRR mm3 / s 1000 fd
2 0.8
Fc 1.8 0.8
60 10
x 10
or 2.0 Fc 800 N
1000 u 0.2 u 2 x 51.666
GATE-2016(PI) Page No.20 Slide No.165 Ans.0.001
GATE-2013(PI) common data question Page No.20 Slide No.166 Ans. (b)
15|P a g e 16|P a g e


Page 167

IES-2002 Page No.25 Slide No.213 Ans.(c)For crater wear temperature is main culprit and tool Using Taylor's Tool Life Equation, VT n C
defuse into the chip material & tool temperature is maximum at some distance from the tool tip that so
why crater wear start at some distance from tip. V1T1n V2T2 n
IAS-2007 Page No.25 Slide No.214 Ans.(c) § V1 · 0.25
IES-2000 Page No.25 Slide No.215 Ans.(d) or V1T10.25 ¨ 2 ¸ T2
IES-1995 Page No.25 Slide No.216 Ans.(b)Crater wear occurs due to temperature mainly. And high © ¹
carbon tool steel withstands least temperature 250oC. 250oC is too low for diffusion. HSS will withstand § 1 ·
¨ ¸
600 C it is also low for diffusion. WC (Tungsten Carbide) tool contains cobalt as binder which can diffuse
o or T2 2© 0.25 ¹ T1 16T1
as temperature is 800oC to 900oC. Ceramics are carbide or oxides of metal it will not diffuse.
IAS-2002 Page No.26 Slide No.219 Ans.(c) IAS-2016 Page No.29 Slide No.245 Ans.(d)
IAS-1999 Page No.26 Slide No.221 Ans.(c)Chemical reaction between abrasive and workpiece IAS-1995 Page No.29 Slide No.246 Ans.(d)
material at elevated temperature and in the presence of grinding fluid.
IAS-2003 Page No.26 Slide No.223 Ans.(b) Using Taylor's Tool Life Equation, VT n C
IES-1996 Page No.26 Slide No.225 Ans.(b)
IES-2015 Page No.27 Slide No.229 Ans.(d) V1
V1T1n V2T2 n or n 0.25;V2
IES-1992 Page No.27 Slide No.231 Ans.(d) 2
IES-2012 Page No.28 Slide No.235 Ans.(a) V1
IES-2008 Page No.28 Slide No.236 Ans. (c) or V1 u T10.25 u T20.25 or T2 16T1
In Taylor’s tool life equation is
2
n = 0.08 – 0.20 o for H.S.S.
GATE-2015 Page No.29 Slide No.247 Ans.0.25
n = 0.20 – 0.60 o for Carbides.
n = 0.60 – 0.80 o for Ceramics.
IAS-2002 Page No.29 Slide No.248 Ans.(a)
IAS-1998 Page No.28 Slide No.239 Ans.(d) Using Taylor's Tool Life Equation,VT n C
IES-2016 Page No.28 Slide No.240 Ans.(c) ª V1 º
GATE-2009(PI) Page No.28 Slide No.241 Ans.(a) V1T1n V2T2 n «Where, n 0.5;V2
¬ 2 »¼
Using Taylor's Tool Life Equation VT n C
V1T1n V2T2 n § V1 · 0.5
or V1T10.5 ¨ 2 ¸ T2
or 100 u 10 n
75 u 30 n © ¹
or n 0.2616 can be solved using solve function on calculator or T2 20.5 T1 4T1
ISRO-2011 Page No.28 Slide No.242 Ans.(c) T2 T1 4T1 T1
D 50mm; %change u100% u 100% 300%
T1 T1
S D u 284
N1 284rpm; T1 10 min;V1 m / min
1000 GATE-2018 Page No.29 Slide No.247 Ans.(a)
S D u 232
N 2 232rpm; T2 60 min;V2 m / min IES-2015 Page No.29 Slide No.250 Ans.(c)
1000
Using Taylor's Tool Life Equation,VT n C IES-2013 Page No.29 Slide No.251 Ans.(b)
V1T1n V2T2 n
Using Taylor's Tool Life Equation, VT n C
S D u 284 S D u 232
or u 10n u 60 n
or n 0.1128 n 0.25;V 60m / min; T 1 hr 21min 81min
1000 1000
In the question straight line relation is mentioned which is wrong. 60 u 810.25 C 180
GATE-2004, IES-2000 Page No.28 Slide No.243 Ans.(c)
IAS-1997 Page No.29 Slide No.252 Ans.(c)
Using Taylor's Tool Life Equation, VT n C Using Taylor's Tool Life Equation, VT n C
V1T1n V2T2 n V1T1n V2T2 n
n n 0.5; V1 18 m / min; T1 180 min; T2 45 min;V2 ?
§T · 1
or V u T n 2V u ¨ ¸ or 8n 2 or n Putting in equation:
©8¹ 3
or 18 u1800.5 V2 u 450.5
IES-1999,ISRO-2013 Page No.29 Slide No.244 Ans.(d) or V2 36m / min
IES-2006 (conventional) Page No.30 Slide No.253 Ans.
17|P a g e 18|P a g e


Page 168

Given:V1=30m/min;T1=1hr=60min,V2=2V1,T2=2min,T3=30min, Using Taylor's Tool Life Equation:
Taylortoollifeequationgives V1T1n V2T2 n
VTn C or 100 u 120n 130 u 50n
or V1 T1n V2 T2n or n 0.2997 | 0.3
n
§ T1 · § V2 · NowC 100 u1200.3 420.49
or ¨ ¸ ¨ ¸
© T2 ¹ © V1 ¹ Tool life when cutting speed is 2.5 m/s = 2.5 u 60 m/min
taking log on both side we get
§T · §V · 2.5 u 60 T 0.3 420.49
n ln ¨ 1 ¸ ln ¨ 2 ¸
© T2 ¹ © V1 ¹ or T 31.06 min
§ V2 · § 2V1 · Velocity when tool life is 80 min
ln ¨ ¸ ln ¨ ¸
or n = © V1 ¹ © V1 ¹ 0.204
V u 800.3 420.49
§T · § 60 · or V 112.94 m / min
In ¨ 1 ¸ ln ¨ ¸
© T2 ¹ © 2 ¹ GATE-2010 Page No.30 Slide No.257 Ans.(a)
Now for = T3 30 min, V3 ? for Carbide o n1 1.6, K1 90
Here V1 T1n V3 T3n for HSS o n2 0.6, K 2 60
VT n
§T ·
n
§ 60 ·
0.204 Using Taylor's Tool Life Equation:VT n =C
1 1
or V3 n
V1 x ¨ 1 ¸ 30 u ¨ ¸ 34.55 m/min
T3 © T3 ¹ © 30 ¹ let cutting speed is x m/min
V3 = ǑdN 1
0.45
§ 90 ·
V 34.55 x×TA 0.45 =90 TA = ¨ ¸
or N = 3 =
Ǒd Ǒ×0.3
=36.66 rpm © x ¹
1
GATE-2009 Linked Q-1 Page No.30 Slide No.254 Ans.(a) § 60 · 0.30
VTn C V1 T1n V2 T2n and x×TB0.3 = 60 TB = ¨ ¸
© x ¹
60 u 81n 90 u 36n
n
for TA >TB
§ 81 · 90 1 1
or ¨ ¸ 1.5
© 36 ¹ 60 § 90 · 0.45 § 60 · 0.30
¨ x ¸ !¨ ¸
n=
In1.5
n = 0.5
© ¹ © x ¹
§ 81 · Solve for x using calculator, x = 26.7 m/min
In ¨ ¸
© 36 ¹ GATE-2013 Page No.30 Slide No.258 Ans.(b)
C =60 u 810.5 90 u 360.5 540 K for A o n1 0.45, K1 3000
GATE-2009 Linked Q-2 Page No.30 Slide No.255 Ans.(c) for B o n2 0.3, K 2 200
V1 60
Now, according to the given question V = 30m / min; Using Taylor's Tool Life Equation:VT n =C
2 2
1/n let cutting speed is x m/min
§C·
T1 ¨V ¸ 1
1.6
© 1¹ § 3000 ·
x×Tc1.6 =3000 Tc = ¨ ¸
§ C·
1/n © x ¹
T2 ¨V ¸ 1
0.6
© 2¹ § 200 ·
and x×TH 0.6 = 200 TH = ¨ ¸
T2 T1 § V1 ·
1/n
1/0.5 © x ¹
T1 ¨V ¸ 1 2 1 300% for Tc >TH
© 2¹
1 1
IFS-2013 Page No.30 Slide No.256 Ans. § 3000 · 1.6 § 200 · 0.60
¨ x ¸ !¨ x ¸
© ¹ © ¹
Solve for x using calculator, x = 39.389 m/min
GATE-2017 Page No.30 Slide No.259 Ans.(b)
Ans. 106.066
Let us assume the speed is x m/min.
19|P a g e 20|P a g e


Page 169

1 we know : V S DNm / min
§ 150 · 0.1
xT10.1 150 T1 ¨ ¸ For the 1st case:
© x ¹
1
N 50rpm, f 0.25mm / rev
0.3 § 300 · 0.3 L
and xT 2 300 T2 ¨ ¸ Let t1 be the time to produce 1 component in 1st case,t1 min
© x ¹ fN
NowT2 ! T1 L
Tool life(T1 ) 50components u t1 50 u min
1 1 f u 50
§ 300 · § 150 ·
0.3 0.1
10 cutting tools produce 122 components
or ¨ ¸ !¨ ¸
© x ¹ © x ¹ Therefore, 1 cutting tool will produce 12.2 components
For solving inequality For the 2nd case:
1 1 N 80rpm, f 0.25mm / rev
§ 300 · 0.3 § 150 · 0.1 L
¨ ¸ ¨ ¸ Let t2 be the time to produce 1 component in 2nd case,t 2 min
© x ¹ © x ¹ fN
0.1 0.3
§ 300 · § 150 · L
or ¨ ¸ ¨ ¸ Tool life(T2 ) 12.2components u t2 12.2 u min
© x ¹ © x ¹ f u 80
x 0.3
150 0.3
Using Taylor's Tool Life Equation:VT n C V1T1n V2T2 n
or 0.1
x 3000.1 § L ·
n
§ L ·
n
or S D u 50 u ¨ 50 u S D u 80 u ¨ 12.2 u
or x 106.066 m / min © 0.25 u 50 ¸¹ © 0.25 u 80 ¸¹
EXAMPLE Page No.30 Slide No. 260 Ans.
This can be solved using regression analysis:
or n 0.2499 | 0.25
Using Taylor's Tool Life Equation:VT n C For 3rd case : N 60rpm, f 0.25mm / rev
taking log on both sides: log V n log T log C L
Let t3 be the time to produce 1 component in 3rd case,t 3 min
or log V log C n log T fN
On comparing with straight line equation,in Casio Calculator: L
Tool life(T3 ) ( x )components u t2 xu min
y A Bx f u 60
y log V ; x log T ; A log C ; B n now, V1T10.25 V3T30.25
0.25 0.25
T V X=logT Y=logV § L · § L ·
or S D u 50 u ¨ 50 u S D u 60 u ¨ x u
2.94 49.74 X1= log2.94 Y1= log49.47
© 0.25 u 50 ¸¹ © 0.25 u 60 ¸¹
3.90 49.23 X2= log3.90 Y2= log49.23
0.25
4.77 48.67 X3= log4.77 Y3= log48.67 § x ·
9.87 45.76 X4= log9.87 Y4= log45.76 or 50 60 u ¨ ¸
28.27 42.58 X5= log28.27 Y5= log42.58 © 60 ¹
Now on calculator, or x 28.926 | 29components
Press mode – 2 times-then press ‘2’(Reg-2) GATE-2018 Page No. 31Slide No. 262 Ans.(253.53)
Then select the type –(lin-1)
Then start entering the values as below;
x1 ,y1 i.e. log2.94, log49.47 then press DT(M+) it will display n =1 then press AC
After entering all values then press shift then S-VAR(on number 2),then press the right arrow 2 times
then A (1) press 1 then = it will give A = 1.732
Again press the right arrow 2 times then B(2) press 2 and = it will give B = -0.07
From y A Bx; A log C C 10 A 54
B n 0.07 n 0.07
? equation becomes:VT n C VT 0.07 54
GATE-2003 Page No.30 Slide No.261 Ans.(a)
10 cutting tools produce 500 components
Therefore, 1 cutting tool will produce 50 components
21|P a g e 22|P a g e


Page 170

L IAS-1995 Page No.32 Slide No.271 Ans. (a) It is comparing, if we increase speed it will increase maximum
Time required for drilling a hole, t = min temperature and depth of cut increase temperature least. That so why tool life affected mostly by velocity
fN and least by depth of cut.
Here 'L' is const. 't' is const, N is variable. ESE-1991,IAS-2010(conventional) Page No.32 Slide No.272 Ans.
L given;VT 0.3 f 0.6 d 0.3 C
V1 = S D x 150 m/min, T1 = 300 u min
f u150 V 40m / min; T 60 min; f 0.25mm / rev; d 2mm
L Putting in equation : 40 u 600.3 u 0.250.6 u 20.3 C C 36.49
V2 = S D x 300 m/min, T2 = 200 u min When speed, feed & depth of cut are together increased by 25%; tool life will be
f u 300
Now when V, f and d are increased by 25%
L
V3 = S D x 200 m/min, T3 = x u min [No. of hole is 'x'] New V,f and d are:V 40 0.25 u 40 50 m / min
f u 200
f 0.25 0.25 u 0.25 0.3125mm / rev
V1T1n V2T2n
n n
d 2 0.25 u 2 2.5mm
§ L · § L · putting in given equation:VT 0.13 f 0.6 d 0.3 36.49
S D x 150 u ¨ 300 u ¸ S D x 300 u ¨ 200 u ¸
© f u150 ¹ © f u 300 ¹ 50 u T 0.13 u 0.31250.6 u 2.50.3 34.99
or n 0.63093 T 2.29 min
Now V1T1n V3T3n When only speed is increased by 25%, rest parameters remain same; then
0.63093 0.63093 Now when V is increased by 25%
§ L · § L ·
S D x 150 u ¨ 300 u ¸ S D x 200 u ¨ x u ¸ New V,f and d are:V 40 0.25 u 40 50m / min, f 0.25mm / rev, d 2mm
© f u 150 ¹ © f u 200 ¹
putting in given equation: VT 0.13 f 0.6 d 0.3 34.99
or x = 253.53
or 50 u T 0.13 u 0.250.6 u 20.3 34.99
GATE-2017 Page No. 31 Slide No. 263 Ans. (b)
or T 10.779 min
V1 S D u 400 m / min, T1 20 min When only feed is increased by 25% , rest parameters remain same; then tool life
Now when f is increased by 25%
V2 S D u 200 m / min, T2 60 min
New V,f and d are:V 40m / min, f 0.25 0.25 u 0.25 0.3125mm / rev, d 2mm
Now using Taylor's equation
n n putting in given equation:VT 0.13 f 0.6 d 0.3 36.49
VT
1 1 VT
2 2
n
or 40 u T 0.13 u 0.31250.6 u 20.3 36.49
or S D u 400 u 20 S D u 200 u 60n or T 21.41min
or n 0.6309 When only depth of cut is increased by 25%, rest parameters remain same; then
And , V3 S D u 300 m / min, T3 ? Now when d is increased by 25%
VT n
VT n
V3 T n New V,f and d are:V 40m / min, f 0.25mm / rev, d 2 0.25 u 2 2.5mm
1 1 2 2 3
0.6309 putting in given equation:VT 0.13 f 0.6 d 0.3 36.49
S D u 400 u 20 S D u 300 u T30.6309
or 40 u T 0.13 u 0.250.6 u 2.50.3 36.49
?T3 31.55 min | 32 min or T 35.844 min
' flank wear v cot D
45 u 300.14 u 0.350.7 u 20.4 C 45.84
? tool life v tan D V1 45 u 1.25 56.25 m / min
tan D 2 tan D1 tan 7 tan10 T1 ?
% change in life u 100% u 100% 30%
tan D1 tan10 f1 0.35 u 1.25 0.4375 mm
? % change in life = 30% decrease d1 2.0 u 1.25 2.5 mm
IES-2010 Page No.31 Slide No.266 Ans.(d) 45.84
0.14
ISRO-2012 Page No.31 Slide No.267 Ans.(d) T 1 1.007538
56.25 u 0.43750.7 u 2.50.4
IES-1994,2007 Page No.31 Slide No.269 Ans.(c) T1 1.055 | 1.06
We know that cutting speed has the greatest effect on tool life followed by feed and depth of cut GATE-2017(PI) Page No.32 Slide No. 274 Ans. Range (80 to 84)
respectively. For maximizing tool life we will adjust 3- 2- 1 respectively. IES-2016 Conventional Page No.32 Slide No. 275 Ans. n = 0.160964, C = 72.43
IES-2008 Page No.31 Slide No.270 Ans.(a)If we increase feed rate it must increase cutting force and IES-2010 Page No.32 Slide No.279 Ans.(a)
temperature. Therefore statement ‘4’ is wrong. IAS-2003 Page No.33 Slide No.280 Ans.(a)
23|P a g e 24|P a g e


Page 171

IES-2014 Page No.33 Slide No.286 Ans. TotalCost Ct MetalCutting Cost Cm Tooling Cost Ct
IES-1996 Page No.34 Slide No.289 Ans.(b) 1
18C 270C ª § 150 · 0.25
§ 150 · º
4
IES-2009(conventional) Page No.34 Slide No.294 Ans. « Now T
Ct
V

VT ¨ V ¸ ¨ V ¸ »
Tc 3min, Tool regrind time(Tr ) 3min, Cm Rs.0.50 / min ¬« © ¹ © ¹ »¼
Depriciation cost Rs.5.0, n 0.2; C 60 18C 270C

Ct 4
V § 150 ·
Using the equation for optimum tool life for minimum cost V¨ ¸
© V ¹
§ Ct · § 1 n · dCt 18C 270C u 3V 2
To ¨ Tc C ¸ ¨ n ¸ 2 0 orV 57.91 m / min
© m ¹© ¹ 4
dV V 150
Ct Cm u Tr Depriciation cost GATE-2005 Page No.35 Slide No.302 Ans.(a)
IAS-2007 Page No.35 Slide No.303-304 Ans.(b)
Ct Rs.0.50 / minu 3min Rs.5.0 Rs.6.5 / regrind
Putting in equation: IES-1999 Page No.36 Slide No.307 Ans.(c)
§ 6.5 · § 1 0.2 · IAS-2002 Page No.36 Slide No.309 Ans.(c)
To ¨ 3 0.50 ¸ ¨ 0.2 ¸ 64 min
© ¹© ¹ The minimum cost criterion will give a lower cutting speed i.e. lower prodeuction rate, while the
maximum production rate criteria will result higher cutting speed i.e. higher cost per piece as it reduces
Using Taylor's Tool Life Equation:VoTon C
tool life.
0.2
Vo 64 60 orVo 26.11 m / min IAS-1997 Page No.36 Slide No.310 Ans.(b) it is less than one but very close to each other so 0.1 is not
possible.
GATE-2014 Page No.34 Slide No.295 Ans. 5.9 to 6.1min IES-2000 Page No.36 Slide No.311 Ans.(a)
Tc 1.5 min; n 0.2 IES-2004 Page No.36 Slide No.312 Ans.(a) To improve MRR = fdv i.e. productivity we can increase
Using optimum tool life equation for maximum productivity: velocity or feed. but increase in velocity will reduce the tool drastically so will increase cost more than
feed.
§ 1 n · § 1 0.2 · IES-2002 Page No.36 Slide No.313 Ans.(c)
To Tc ¨ ¸ or To 1.5 ¨ ¸ 6 min
© n ¹ © 0.2 ¹ IAS-2007 Page No.36 Slide No.314 Ans.(a)At optimum cutting speed for the minimum cost of
machining gives low production rate.
ESE-2001(conventional) Page No.34 Slide No.296
IES-2010 Page No.36 Slide No.315 Ans.(d) After some time cutting speed will be so that tool
V1 50m / min; T1 45 min;V2 100m / min; T2 10 min; Tc 2 min changing time will be significant.
Using Taylor's Tool Life Equation:VT n C V1T1n V2T2 n IES-2012 Page No.37 Slide No.320 Ans.(d)
IAS-1996 Page No.37 Slide No.321 Ans.(d)Machinability is a comparative measure not absolute.
50 u 45n 100 u10n or n 0.46, C 50 u 450.46 288 IES-1992 Page No.38 Slide No.327 Ans.(a) large grain means soft workpiece material.
Using equation of optimum tool life: IAS-2000 Page No.38 Slide No.329 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.
§ 1 n · § 1 0.46 · IES-1992 Page No.38 Slide No.333 Ans.(a)
To Tc ¨ ¸ 2 ¨ 0.46 ¸ 2.34
© n ¹ © ¹ IES-2007,2009 Page No.39 Slide No.334 Ans.(a)Machinability: Machinability can be tentatively defined as
‘ability of being machined’ and more reasonably as ‘ease of machining’.
Again Using Taylor's Tool Life Equation:VoTon C Such ease of machining or machining characters of any tool-work pair is to be judged by:
Vo u 2.340.46 288 orVo 195m / min • Magnitude of the cutting forces
• Tool wear or tool life
IAS-2011(main) Page No.34 Slide No.297 Ans.
• Surface finish
Tc 9 min; n 0.5; C 100 • Magnitude of cutting temperature
Using optimum tool life equation for max productivity: • Chip forms
ISRO-2007 Page No.39 Slide No.335 Ans.(a)But All of the above are machinability criteria. We have to
§ 1 n · § 1 0.5 · select best option that so why chosen (a)
To Tc ¨ ¸ or To 9 ¨ ¸ 9 min
© n ¹ © 0.5 ¹ IES-2003 Page No.39 Slide No.336 Ans.(c)Free-machining steels are basically carbon steels that
have been modified by an alloy addition to enhance machinability. Sulfur, lead, bismuth, selenium,
Using Taylor's Tool Life Equation:VoTon C , Vo u 90.5 100 orVo 33.33 m / min tellurium, and phosphorus have all been added to enhance machinability. Sulfur (0.08 to 0.33%)
GATE-2016 Page No.35 Slide No.301 Ans. 57.91 m/min combines with manganese (0.7 to 1.6%) to form soft manganese sulfide inclusions. These act as
discontinuities in the structure which serve as sites to form broken chips. The inclusions also provide a
built-in lubricant that prevents formation of a built-up edge on the cutting tool and imparts an altered
cutting geometry.
IES-2009 Page No.39 Slide No.337 Ans.(a) Sulphur, Lead and Phosphorous are added to steel which
when added to Manganese forms Manganese sulphide etc. which has low shear strength.
IES-1998 Page No.39 Slide No.338 Ans.(c) It is CNC machine, dimensional accuracy and surface
finish are prime factor.
IES-1996 Page No.39 Slide No.339 Ans.(d) smaller shear angle means higher force.
25|P a g e 26|P a g e


Page 172

IES-1992 Page No.40 Slide No.343 Ans. (b) Titanium is very reactive and the chips tend to weld to For PSU PageNo.43 Slide No.9 Ans.(b)
the tool tip leading to premature tool failure due to edge chipping. Almost all tool materials tend to react ISRO-2010 Page No.44 Slide No.10 Ans.(b)
chemically with titanium. GATE-2010,ISRO-2012 Page No.44 Slide No.13 Ans.(d)
Titanium’s work-hardening characteristics are such that titanium alloys demonstrate a complete absence upper limit = 35-0.009 = 34.991mm
of “built-up edge”. Because of the lack of a stationary mass of metal (BUE) ahead of the cutting tool, a
high shearing angle is formed. This causes a thin chip to contact a relatively small area on the cutting lower limit = 35-0.025 = 34.975 mm

tool face and results in high loads per unit area. These high forces, coupled with the friction developed by Fundamental Deviation = basic size-nearer limit = 35-34.991= 0.009 mm
the chip as it passes over the cutting area, result in a great increase in heat on a very localized portion of
the cutting tool. All this heat (which the titanium is slow to conduct away), and pressure, means that tool Tolerance = upper limit-lower limit = 34.991 - 34.975 = 0.016 mm
life can be short, especially as titanium has a tendency to gall and weld to the tool surface. GATE-1992 Page No.44 Slide No.14 Ans.(a)
IES-1995 Page No.40 Slide No.345 Ans. (a) Titanium high cost and need 10 times much energy than Tolerance of shaft A=100.1-99.9=0.2
steel to produce.Light weight, strong, corrosion resistant, properties between steel and aluminium.
Tolerance of shaft B=0.1001-0.0999=0.0002
IAS-1996 Page No.40 Slide No.348 Ans. (d) So, tolerance of shaft A > tolerance of shaft B
IES-1999 Page No.40 Slide No.349 Ans. (d) Never confused with relative errors because we even don’t know the actual dimensions of all product. we
f 2 can’t calculate error.
we know : hc GATE-2004 Page No.44 Slide No.15 Ans.(c)
8R
Maximum clearance = Higher limit of hole – lower limit of shaft
f2 f12 f2 4f = 25.020-24.990 = 0.03 mm = 30 microns
When f1 2 f , and hc remains the same; or R1 4R
8R 8 R1 8R 8 R1 IES-2005 Page No.44 Slide No.16 Ans.(c)
GATE-1997 Page No.40 Slide No.350 Ans. (a) Since basic size is 20mm so, minimum rejection will be of the batch having mean diameter 20mm. Due to
h 5P m 5 u106 m; R 1.8mm 1.8 u 103 m natural variations dimensions of the component will increase and decrease same from basic size.
GATE-2007 Page No.45 Slide No.20 Ans.(c)
f2 f2
we know : h or 5 u106 or f 2.68 u104 m / rev 0.268mm / rev
8R 8 u1.8 u103
GATE-2007(PI) Page No.40 Slide No.351 Ans.(a)
f 1mm / rev; SCEA 30q; ECEA 10q
f 1
Using formula: h 0.16mm
tan SCEA cot ECEA tan 30 cot10
GATE-2018(PI) Page No.41 Slide No.352 Ans. (8.4 to 8.7)

f
Using formula:h
tan SCEA cot ECEA
f f
hP and hQ
tan 30 cot 8 tan15 cot 8 max clearance = upper limit of hole - lower limit of shaft = 40.50-39.95 = 0.1 mm
? P
h tan15 cot 8 GATE-2015 Page No.45 Slide No.21 Ans.(b)This being an clearance fit , so minimum clearance will
be
hQ tan 30 cot 8
Min C= LL of hole –UL of Shaft
IES-1993,ISRO-2008 Page No.41 Slide No.354 Ans. (c) Surface roughness is directly dependent on Min C = 25.020-25.005 mm = 0.015 mm
square of feed. Slow cutting results in formation of built-up edge, but after certain speed the finish
remains same.Rake angle has noticeable effect at slow speeds, but its effect is small at speeds, used for
finish machining. So f has maximum effect.
IES-2006 Page No.41 Slide No.355 Ans. (a) refer previous question
GATE-2014(PI) Page No.41 Slide No.356 Ans.
GATE-2010(PI) Page No.41 Slide No.357 Ans. (b)
For increasing surface finish means reduce roughness we have to increase nose radius and reduce feed.
Here MRR remains same therefore feed remains same only nose radius can be changed.
For triangular surface profile
h 20
Ra 5 Pm
4 4 IES-2015 Page No.45 Slide No.22 Ans.(a)
IES-2001 Page No.42 Slide No.361 Ans. (c) IES-2015 Page No.45 Slide No.25 Ans.(c)Allowance is the minimum clearance between shaft and hole.
IES-2012 Page No.42 Slide No.362 Ans. (b) IES-2011 Page No.45 Slide No.27 Ans.(a)
Ch-4: Limit, Tolerance & Fit: Answers with Explanations
27|P a g e 28|P a g e


Page 173

IES-2015 Page No.4
47 Slide No
o.42 An
ns. (d)
It is
i thick cylin
nder under external
e preessure.
Disstribution of
o radial and
a circumfferential strresses with
hin the
cyllinder wall when
w only ex
xternal pressure acts
IES-2014 Page No.46 Slide No.30 Ans. (c) IES

S-2004 Page No.47
7 Slide No.43
N Anss.(b)
IES-2015 Page No.46 Slide No.31 Ans. (c) GATTE-2001 Page No.48
8 Slide No.46
N Anss.(b)
IES-2017 Page No.46 Slide No.32 Ans. (c) GATTE-1998 Page No.48
8 Slide No.47
N Anss.(c)
GATE-2011 Page No.46 Slide No.33 Ans.(c) IES
S-2012 Page No.48
8 Slide No.48
N Anss.(b)
ISR
RO-2010 Page No.48
8 Slide No.50
N Anss.(c)
It is trannsition fit, Using
U formuula of minimmum clearannce
Min cleearance = up pper limit of
o shaft - low
wer limit off hole = -0.022 mm
Here Minimum
M cleearance is nnegative i.e. maximum inteference
i occur.
Actuallyy in transitioon fit no min
n clearance is there. Theoretically minimum
m cleearance is negative
n of
maximu um interfereence.
GATE -2012 Same Q in GATE-2012 (PI) Page No.46 Slide No.34 Ans.(c) ISRRO-2008 Page No.49 9 Slide No.56
N Anss.(c)
IES
S-2005 Page No.49 9 Slide No.57
N Anss.(c)
Maximum Interference = Maximum size of shaft – Minimum size of hole
= (25 + 0.04) – (25 + 0.02) mm = 20 μm IES
N Anss.(c)
IAS-2011(main) Page No.46 Slide No.35 Ans. GATTE-2014 Page No.51 1 Slide No.73
N Anss.(d)
IES
N Anss.(a) All stattements are wrong. 50 m mm is not ho ole diameterr it
is basic size. And ex
xaminer ask k INCORREC CT not correect options. Therefore
T alll options arre incorrect.
IES
S-2006(convventional) Page No.51
N Slid
de No.75 Ans.
Bassic size =1000 mm; D D1 u D2
80 u1200 97.97 mm
m
Funndamental deviation
d off shaft
= 5.5D 0.41 36 P m
? Fundamentall deviation of
o hole 3 Pm
36
1
i 0 D 0..001D 2.1711P m
0.45 3
Using unilateral hole base system; IT 8 25i 25 u 2.17 P m 54 P m

Min clearance = 0.03mm; Max clearance = 0.09 mm; Basic size = 20 mm 1 64i 644 u 2.17 P m 139 P m
IT 10
Refering the figure:2 x 0.03 x 0.09 or x 0.02 mm Alloowance = min
n clearance = 36 μm
? size of hole: lower limit = 20 mm
upper limit =20+2x 20+2 u 0.02=20.04 mm IES
S-2015(conv
ventional) Page No.51
N Slid
de No.76 Ans.
size of shaft:Lower limit = 20.04+0.03= 20.07 mm
upper limit = 20.07+ x =20.07+0.02=20.09 mm
GATE -2018 (PI) Page No.46 Slide No.36 Ans.(d) For interference fit Lower limit of shaft will be
greater than upper limit of hole. Therefore value of x should be less than 0.03 mm and only one option are there
(d).
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.47 Slide No.38 Ans.(c)
An interference fit creates stress state in the shaft therefore “2” is wrong.
29|P a g e 30|P a g e


Page 174

Geometric mean diameter(D) = 18 u 30 23.238mm For IT 8 25i 0.0326mm
Standard tolerance unit (i) = 0.45 u 3 D 0.001 u D 1.3074 Pm upper limit of hole = basic size + tolerance = 25+0.0326=25.032mm
Tolerance of hole = 25i = 33Pm 0.033mm ' hole base system so, lower limit = basic size=25mm
Tolerance of shaft = 40i = 52Pm 0.052mm GATE-2000 Page No.51 Slide No.81 Ans.(d)
Fundamental deviation of shaft d = -16D0.44 64 Pm 0.064mm Hole: Lower limit = Basic size = 25 mm
Higher limit = lower limit + tolerance = 25 + 0.033 = 25.033 mm
Fundamental deviation of hole H = zero
Shaft: Higher limit = basic size – fundamental deviation = 25 – 0.04 = 24.96 mm
LL of hole = BS =25mm Lower limit = Higher limit – tolerance = 24.96 – 0.033 = 24.927 mm
UL of hole = BS + Tolerance = 25.033mm Therefore Maximum clearance = Higher limit of hole – lower limit of shaft
UL of shaft = BS +FD = 25- 0.064mm = 24.936mm = 25.033 – 24.927 = 0.106 mm = 106 microns
LL of shaft = UL - tolerance = 24.936-0.052 = 24.884 mm
' diametric steps are not given we take given dia as the basic diameter only.
Selected Question Page No.51 Slide No.77 Ans. i 0.45 3 D 0.001D 1.34P m 1.34 u 103 mm
Geometric mean diameter (D) =ξͷͲ ൈ ͺͲ = 63 mm For IT 7 16i 16 u1.34 u103 0.021 mm
య య
Standard tolerance unit (i) = ͲǤͶͷξ‫ ܦ‬൅ ͲǤͲͲͳ‫ ܦ‬ൌ ͲǤͶͷξ͸͵ ൅ ͲǤͲͲͳ ൈ ͸͵ ൌ ͳǤͺͷ͵ߤ݉
' it is a shaft base system:
Tolerance for hole H8 (IT8) = 25 i = ʹͷ ൈ ͳǤͺͷ͵ߤ݉ ൌ Ͷ͸ߤ݉ ൌ ͲǤͲͶ͸݉݉
Upper limit = basic size=25.00 mm
Tolerance for shaft g7 (IT7) = 16 i = ͳ͸ ൈ ͳǤͺͷ͵ߤ݉ ൌ ͵Ͳߤ݉ ൌ ͲǤͲ͵Ͳ݉݉
)XQGDPHQWDOGHYLDWLRQRIVKDIW¶J·LV െʹǤͷ‫ܦ‬଴Ǥଷସ ൌ െʹǤͷ ൈ ͸͵଴Ǥଷସ ߤ݉ ൌ െͲǤͲͳͲ݉݉ Lower limit = Upper limit tolerance = 25.00 - 0.021=24.978 mm
GATE-2010(PI) Page No.52 Slide No.83 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
IT IT
Use formula 10 u 1.6 n 6
GATE-2016(PI) Page No.52 Slide No.84 Ans.(b)Allareshaftbasissystem.
GATE-1996,IES-2012 Page No.52 Slide No.86 Ans.(d)
Remember
H7 with p6, s6: Interference fit
H7 with k6, n6: Transition fit
All other fits are clearance fit.
Lower limit of hole = Basic size = 75 mm IES-2000 Page No.52 Slide No.87 Ans.(b)
ISRO-2008 Page No.52 Slide No.90 Ans.(a)
Upper limit of hole = LL of hole + Tolerance of hole = 75 + 0.046 mm =75.046 mm GATE-2003 Page No.53 Slide No. 94 Ans.(b)
Upper limit of shaft = Basic size ² fundamental deviation = 75 ² 0.01 =74.99 mm P 35+0.08mm
Lower limit of shaft = UL of shaft ² Tolerance of shaft = 74.99 ² 0.03 = 74.96 mm Q 12.00+0.02mm
Maximum clearance = UL of hole ² LL of shaft = 75.046 ² 74.96 mm = 0.086 mm R 13.00.04
0.02 13.01 r 0.03
Minimum clearance = LL of hole ² UL of shaft = 75 ² 74.99 = 0.01 mm Now all have same bilateral tolerance, so
As minimum clearance is positive it is a clearance fit. P QWR
IES-2002 Page No.51 Slide No.78 Ans.(c) Considering dimension
35 12 W 13.01
60 mm diameter lies in the diameter step of 50-80mm. Therefore
w 9.99mm
Geometric mean diameter,D Dmin ×Dmax 50 u 80 63.246 mm
Tolerance are probabilities and not the absolute value on any part, at
Fundamental tolerance unit i (0.45D1/3 +0.001D) ǍP
least one section must be there that treated as sink, and tolerance of
[0.45(63.246)1/3 0.001(63.246)] 1.859 ǍP .00186 mm sink will be cumulative sum of all tolerances.
For IT8 25i 25 u 0.00186 0.04646 mm ? Tolerance 0.08 0.02 0.03 0.13
Fundamental deviation for 'f'shaft, 5.5D0.41 5.5[63.246]0.41 0.030115mm GATE-1997 Page No.53 Slide No. 95 Ans.(d)
GATE-2008(PI) Page No.51 Slide No.80 Ans.(c)Without calculating we can choose option (c) as S P Q R T or T S P Q R or Tmin Smin Pmax Qmax Rmax
fundamental deviation is zero therefore LL = Basic size = 25.000 mm GATE-2015 Page No.53 Slide No. 96 Ans.(d)
But proper calculation is
D D1 u D2 18 u 30 23.23 mm LL of L4 = LL of L1 –UL of L2 –UL of L3
1
= 21.99-10.005-10.005=1.98mm
i 0.45D 0.001D 1.3076P m 1.3076 u 103 mm
3 UL of L4 = UL of L1 –LL of L2 –LL of L3
31 | P a g e 32|P a g e


Page 175

= 22.01-9.995-9.995=2.02mm
GATE-2007(PI) Page No.53 Slide No.97 Ans.(d)
Before plating the hole size will be bigger ,
Maximum limit will correspond to min thickness;so,
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.53 Slide No.98 Ans. (d)
Upper limit of pin = 25.020 mm ISRO-2008 Page No.54 Slide No.103 Ans.(c)
GATE-2014 Page No.55 Slide No.109 Ans.(d)
Lower limit of pin = 25.010 mm Lower limit of hole = 25-0.015=24.958 mm
Max thickness of plating =2 u 0.032=0.064 mm lower limit of GO-Guage = 24.985 mm
Min thickness of plating =2 u 0.028=0.056 mm Work tolerance = 10% of guage tolerance = 10% of (2 u 0.015) = 0.003mm
Minimum size will correspond to max thickness Upper limit of GO- Guage = 24.9850+0.003 mm
Size of GO-Guage = Lower limit of pin Max thickness of plating GATE-2004 Page No.55 Slide No.110 Ans. (None)
Higher limit of hole = 20.05 mm
Size of GO-Guage 25.020+ 2x0.032 = 25.084 mm
Lower limit of hole = 20.01 mm
GATE-2017 Page No.53 Slide No.99 Ans. 29.030 Work tolerance = 20.05 – 20.01 = 0.04 mm
Gauge tolerance = 10% of work tolerance = 0.004 mm
GO ring gauge will inspect maximum metal conditions i.e. UL of shaft i.e. Largest size after platting. 0.004
UL after platting = 25.02 + 2.005 + 2.005 mm = 29.030 mm Therefore, Dimension of ‘GO’ gauge 20.01 mm
0
0.004
Dimension of ‘NOT GO’ gauge 20.05 mm
0
GATE-2015 Page No.55 Slide No.111 Ans.(b, c and d are correct.)
GATE – 2006, VS-2012Page No.55 Slide No.113 Ans.(c)
PSU Page No.56 Slide No.118 Ans.(c)
Ch-5 Measurement of Lines & Surface: Answers with Explanations

GATE-2017(PI) Page No.57 Slide No.130 Ans. (c)
ISRO-2010 Page No.58 Slide No.139 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.58 Slide No.140 Ans.(c)Least count = 0.5/25 = 0.02 mm
ISRO-2009, 2011 Page No.58 Slide No.143 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.59 Slide No.147-148 Ans.(c)If there is axial intersection Rp must not
equal to RQ
GATE-2014(PI) Page No.59 Slide No.149-150 Ans. (d)

GATE-2000 Page No.54 Slide No.100 Ans.(a) It is a case of tolerance sink. Final product will be
tolerance sink because due to the errors in the block and due to the errors in the cutter locations both ISRO-2010 Page No.60 Slide No.157 Ans.(c)A measuring device of a standard size that is used
errors will affect. to calibrate other measuring instruments.
GATE-2017 Page No.54 Slide No.101 Ans.5 ISRO-2008 Page No.60 Slide No.158 Ans.(d)Primary standards are used for calibration only.
According to Root Sum Square or RSS model In workshop it has no use.
33|P a g e 34|P a g e


Page 176

GATE-2007(PI) Page No.60 Slide No.161 Ans.(d)During the measurement, a comparator is able to
give the deviation of the dimension from the set dimension. Cannot measure absolute dimension but can only
compare two dimensions. (Rest all the options will give reading of the dimension measured it will not compare)
ISRO-2011 Page No.62 Slide No.176 Ans.(c)A sine bar is specified by the distance between the centre
of the two rollers

L 250 mm; H r 100 mm ;( Diameter d 20 mm or r 10 mm) or H 90 mm GATE-2016 Page No.70 Slide No.245 Ans.675
The distance of air gap between two successive
§H· § 90 ·
T sin 1 ¨ ¸ sin 1 ¨ ¸ 21.1o nO
©L¹ © 250 ¹ fringes is given by
GATE-2018 Page No.62 Slide No.178 Ans.(57.782)
2
o For1mm fringe gap we need 450 nm
§ 32 · ½
T 27o 32 ' ®27 ¨ ¸ ¾ 27.533q ?For1.5 mm fringe gap we need 450×1.5 nm = 675 nm
¯ © 60 ¹ ¿
In sine bar , nOl
'h
H 2
sin T
L n u 0.0058928 u 101 cm u 101 cm
(1.002 1.000) u 101 cm
H 2
sin 27.533q
125 n 0.678 / cm
H 57.782 mm So for both fringes=2 u n 1.357 | 2 fringes
GATE-2011(PI) Page No.71 Slide No.255 Ans.(c)
Parallelism Error
14 10 u 0.5086 Pm 0.5086 Pm
p D 2.5 § 60 · 4
Best Wire Size : d sec sec ¨ ¸ 1.443 mm
2 2 2 © 2 ¹
GATE-2013 Page No.63 Slide No.189 Ans.(none) refer formula Ch-6 Miscellaneous of Metrology: Answers with Explanations
IES-2017(Pre) Page No.64 Slide No.190 Ans(c) GATE-1998 Page No.72 Slide No.263 Ans. (c)Autocollimator isan optical instrument for non-contact
GATE-2011(PI) Page No.64 Slide No.191 Ans.(None) measurement of small angles or small angular tilts of a reflecting surface
IES-2012 Page No.65 Slide No.201 Ans. Refer slides for theory GATE-2009(PI) Page No.72 Slide No.264 Ans. (a)
GATE-2017(PI) Page No.65 Slide No.205 Ans.(b) GATE-2014 Page No.72 Slide No. 265 Ans. (b)Autocollimator is also measure flatness.
IES-1992 Page No.66 Slide No.210 Ans.(b) ISRO-2010 Page No.72 Slide No.268 Ans. (b)In optical square two mirrors are placed at an angle of
GATE-2018(PI) Page No.66 Slide No.214 Ans. (b) 45o to each other and at right angles to the plane of the instrument. Angle between the first incident ray and
GATE-2007(PI) Page No.66 Slide No.215 Ans. (d) Concentricity will refer centre. Runout need datum. the last reflected ray is 90o.Two mirrors may be replaced by two prisms.
Runout is the total variation that the reference surface can have, when the part is rotated around the datum’s IES-1998 Page No.73 Slide No.271 Ans. (d)
true axis. Perpendicularity need one reference surface from where it can be checked. GATE-2014 Page No.73 Slide No. 274 Ans. (c) Laser interferometer is widely used to check and
GATE-2016(PI) Page No.67 Slide No.220 Ans.Ans. 2 Ǎm (Range 2.0 to 2.0) calibrate geometric features of machine tools during their assembly
ISRO-2011 Page No.67 Slide No.222 Ans.(d) GATE-1992 Page No.74 Slide No.282 Ans. (b)
IES-2006 Page No.67 Slide No.223 Ans.(d) GATE-2004 Page No.74 Slide No. 285 Ans. (b)
IES-2007 Page No.67 Slide No.224 Ans.(c)Lay direction: is the direction of the predominant surface GATE-1995 Page No.74 Slide No. 287 Ans. (b)
pattern produced on the workpiece by the tool marks. GATE-2010 Page No.75 Slide No.291 Ans. (a)
IES-2008 Page No.67 Slide No.225 Ans.(b)Lay – directional of predominant surface texture produced
by machining operation is called Lay.
35|P a g e 36|P a g e


Page 177

10 AB ( R r )2 ( D R r )2
tan T
30
T 18.434 ( R r D R r )( R r D R r )
Also, 2 D( R r ) D 2
x H R AB r
tan T
10
R r 2 D( R r ) D 2
x
tan18.434
10
x 3.334
? diameter at z 0 is (20 2 x )
? diameter (20 2 u 3.334) 13.336
GATE-2008(PI) Page No.75 Slide No. 292 Ans. (d)
T C2 A 3 GATE-2018(PI) Page No.75 Slide No.295 Ans. 1.7

tan
2 5 15.54 8 28.54
T
6.006
2 Ch-7 Metal Forming: Answers with Explanations
T 12.001 GATE-1995 Page No. 76 Slide No.9 Ans. (b)If the specimen is stressed slightly beyond the yield point
and unloaded then the phenomena of strain hardening takes place as a result of which strength
increases.
IES-2013 Page No.77 Slide No. 10 Ans. (b)
GATE-2014 Page No.75 Slide No. 293 IES-2016 Page No.77 Slide No. 14 Ans. (a)
IES-2016 Page No.78 Slide No. 27 Ans. (a)
BC = (H2 + d2/2) – ( H1 Mechanical properties of the material is depends on grain size.
+ d1/2) = 35.55 + 60/2 - Due to plastic deformation grain gets elongated.
20.55 – 40/2 = 25 mm IES-2011 Page No.79 Slide No. 31 Ans. (b) If cold worked it will improve mechanical properties.
GATE-2003 Page No.79 Slide No. 32 Ans. (c)If working below Rx temp then it is cold-working process
AC = 60/2 + 40/2 = 50 GATE-2002, ISRO-2012 Page No. 79 Slide No. 33 Ans. (d)
mm ISRO-2010 Page No. 79 Slide No. 34 Ans. (d)Annealing is used to induce ductility,
soften material, relieve internal stresses, refine the structure by making it homogeneous, and
improve cold working properties.Normalization is an annealing process in which a metal is cooled in
AB 50 2
252 43.3 air after heating.
IES-2006 Page No.79 Slide No.35 Ans. (c)When a metal is heated & deformed under mechanical
D = 60/2 + 43.30 + 40/2 force, an energy level will reached when the old grain structure (which is coarse due to previous cold
= 93.30 mm working) starts disintegrating. Simultaneously, an entirely new grain structure (equi-axed, stress free)
with reduced grain size Starts forming. This phenomenon is known as “recrystallisation”. Never be
confused with Annealing because in the last stage of annealing grain growth takes place. So no reduction
in grain size.
IES-2004 Page No. 79 Slide No. 36 Ans. (b) For cold working metal should have high ductility.
IES-2009 Page No. 80 Slide No.37 Ans. (d) Strength increases due to grain refinement.
IES-2008 Page No. 80 Slide No. 38 Ans. (b)
IES-2008 Page No. 80 Slide No. 39 Ans. (a)
GATE-2016 Page No.75 Slide No.294 Ans. (d) Advantages of Cold Forming vs. Hot Working:
• Better accuracy, closer tolerances
• Better surface finish
• Strain hardening increases strength and hardness
• Grain flow during deformation can cause desirable directional properties in product
• No heating of work required (less total energy)
Dis-advantages of Cold Forming
• Equipment of higher forces and power required
• Surfaces of starting work piece must be free of scale and dirt
• Ductility and strain hardening limit the amount of forming that can be done
• In some operations, metal must be annealed to allow further deformation
• In other cases, metal is simply not ductile enough to be cold worked
37|P a g e 38|P a g e


Page 178

IES-2004 Page No. 80 Slide No.40 Ans. (c) During deformation, a portion of the deformation energy 0.002 inch larger than the thread-pitch diameter. If it is desired to have the body of a bolt larger than the
becomes stored within the material in the form of additional dislocations and increased grain boundary outside diameter of the rolled thread, the blank for the thread is made smaller than the body.
surface area. IAS-2007 Page No.85 Slide No.87 Ans.(d)
IES-2003 Page No. 80 Slide No. 41 Ans. (a) IAS -2003 Page No.85 Slide No.88 Ans.(b)
IES-2000 Page No. 80 Slide No. 42 Ans. (d) Annealing required. IAS-2000 Page No.85 Slide No.89 Ans.(b)Rolling with smaller diagram rolls requires lower force.
ISRO-2009 Page No. 80 Slide No. 43 Ans. (a) IES-1993 Page No.86 Slide No.93 Ans.(a)In order to get uniform thickness of the plate by rolling
IES-1997 Page No. 80 Slide No. 44 Ans. (c) process, one provides camber on the rolls to take care of unavoidable tool bending. Cylindrical rollers
x Phenomenon where ductile metals become stronger and harder when they are deformed plastically is would result in production of plate with convex surface. Because of the limitations in the equipment and
called strain hardening or work hardening. workability of the metal, rolling is accomplished progressively in many steps. Plate, sheet and strip are
x During plastic deformation, dislocation density increases. And thus their interaction with each other rolled between rolls having a smooth, cylindrical, slightly cambered (convex) or concave working surface.
resulting in increase in yield stress. IAS-2004 Page No.86 Slide No.95 Ans.(c) Rolling means hot rolling where no lubricant is used.
IES-1996 Page No. 80 Slide No. 45 Ans. (c)Cold working increases the strength and hardness of the GATE -2009(PI) Page No.86 Slide No.98 Ans.(d) Due to directional granule deformation.
material due to strain hardening. Strength, fatigue, and wear properties are improved through strain IES-2003 Page No.87 Slide No.100 Ans. (c) Wavy edges due to roller deflection.
hardening. GATE -2007 Page No.87 Slide No.105 Ans.(d)
IES-2006 Page No. 81 Slide No. 46 Ans. (d) Should be above the recrystallisation temperature.
ho 16 mm ; h f 10 mm ;D 400 mm;R=200 mm?'h 6 mm;
IES-1992 Page No. 81 Slide No. 47 Ans. (c)
• Annealing relieves the stresses from cold working – three stages: recovery, recrystallization and grain 'h D(1 cos D )
growth.
• During recovery, physical properties of the cold-worked material are restored without any observable 6 400(1 cos D ) D 9.936q
change in microstructure. GATE – 2012 Same Q in GATE – 2012 (PI) Page No.87 Slide No.106 Ans.(c)
• Grain growth follows complete crystallization if the material is left at elevated temperatures. ho 8 mm ; h f 8 x 1 – 0.1 7.2 mm; D 410 mm;
• Grain growth does not need to be preceded by recovery and recrystallization; it may occur in all
polycrystalline materials. 'h 10% of 8 mm 0.8 mm ª¬ alternative : ho h f 8 7.2 0.8 mm º¼
IAS-1996 Page No. 81 Slide No. 48 Ans. (c)For Mild Steel, recrystallisation temp is of the order of
10000C We know that, 'h D(1 cos D ) or 0.8 410 (1 cos D )
IAS-2004 Page No. 81 Slide No. 49 Ans. (a) S
IAS-2002 Page No. 81 Slide No. 50 Ans. (b)Ulta hai. Assertion reason me hona chahiye. or D 3.58o 3.58 u rad 0.062 rad
IES-2008 Page No. 81 Slide No. 51 Ans. (d)Malleability- It is a special case of ductility which permits
180
GATE -2017(PI) Page No.87 Slide No.107 Ans.(b)
materials to be rolled or hammered into thin sheets. A malleable material should be plastic but it is not
essential to be so strong. Lead, soft steel, wrought iron, copper and aluminium are some materials in GATE -1998 Page No.87 Slide No.108 Ans.(d) For strip rolling sheet rolling width remains same.
order of diminishing malleability. Initial thickness (h1) = 4.5 mm.
GATE -2017 Page No.81 Slide No.52 Ans.(c)In metal forming mechanical properties of materials will As width constant therefore 20% reduction in area means 20% reduction in thickness also.
Final thickness (h2 = 0.8 x 4.5 = 3.6 mm
increase due to improvement in grain.
'h D 1 cosT or 4.5 3.6 450 1 cosT or T 3.62q 0.063radian
GATE -2018(PI) Page No.88 Slide No.109 Ans. 7.27(7.1to7.4)
GATE -2004 Page No.88 Slide No.111 Ans.(b)
Ch-8 Rolling: Answers with Explanations Roll strip contact length, L = R ǂ
GATE -2013 Page No.82 Slide No.55 Ans.(c)Bi axial compression and frictional force between roller 'h D(1 cos D ) or 25 20 600 1 cos D or D 7.402q 0.129 rad
and workpiece produces shear stress Therefore L RD 300 x 0.129 38.76 mm | 39 mm
IAS-2001 Page No.82 Slide No.60 Ans.(c)Rolling means hot working it will not show work
hardening GATE -2011 Page No.88 Slide No.114 Ans.(a)Maximum possible draft. 'hmax P2R
ISRO-2006 Page No.82 Slide No.63 Ans.(c) You may confused with Forging but forging is hot
GATE -2014 Page No.88 Slide No.115 Ans.(b)Maximum possible draft. 'hmax P 2 R
working, but Cold rolling (cold working) is mentioned therefore answer will be (c). In cold working
product will be stronger. If we compare cold forging and cold rolling then cold forging produce stronger GATE -2018 Page No.88 Slide No.116 Ans. (b)Maximumpossibledraft. 'hmax P 2 R
components. GATE -2016 Page No.88 Slide No.117 Ans. 1.92
IES-2006 Page No.83 Slide No.71 Ans.(c) A continuous form of three-point bending is roll bending, R 300 mm, and 'hmax P 2 R 0.082 u 300 1.92 mm
where plates, sheets, and rolled shapes can be bent to a desired curvature on forming rolls. GATE -2015 Page No.89 Slide No.118 Ans.0.1414
IES – 1992, GATE-1992(PI) Page No.84 Slide No.78 Ans.(b)Since brittle materials cannot handle GATE -2015 Page No.89 Slide No.119 Ans. 5.71
plastic deformation. IES-1999 Page No.89 Slide No.120 Ans.(b) Actually metal will get hardened in every pass due to
IES – 1993, GATE-1989(PI) Page No.84 Slide No.79 Ans.(d) strain hardening. Therefore in actual practice the reduction in second pass is less than in the first pass.
• Thread rolling is used to produce threads in substantial quantities. This is a cold-forming process GATE-2006 Page No.89 Slide No.122 Ans.(c)
operation in which the threads are formed by rolling a thread blank between hardened dies that cause 'h max ho h f ,min P 2 R 0.12 u150 mm 1.5 mm
the metal to flow radially into the desired shape. Because no metal is removed in the form of chips, less
material is required, resulting in substantial savings. In addition, because of cold working, the threads or 4 h f ,min 1.5 or h f ,min 2.5 mm
have greater strength than cut threads, and a smoother, harder, and more wear-resistant surface is GATE – 2011 (PI) Page No.89 Slide No.124 Ans.(d)
obtained.
• One obvious characteristic of a rolled thread is that its major diameter always is greater than the
diameter of the blank. When an accurate class of fit is desired, the diameter of the blank is made about
39|P a g e 40|P a g e


Page 179

2 This question is wrong. For proper calculation we need velocity of neutral plane or velocity of roller. But in this
'h max P 2 R 0.1 u 300 mm 3 mm
question velocity of exit is given. From velocity of exit we may assume the velocity of neutral plane but can’t
Therefore we cannot reduce more than 3 mm in a single pass but we have calculate correctly.
to reduce total, 30 mm -10 mm = 20 mm Projected length Lp R sin D | R'h , mm 150 u (8 7.2) 10.954 mm
? Number of pass needed =

20
|7 Projected Area Ap Lp u b , mm 2
10.954 u120 1314.48 mm 2
3 RollSeparating Force ( F ) V o u Lp u b , N 200 u1314.48 N 262.9 KN
2
R 150 mm; ho 30 mm; h f 15 mm [V o in N / mm i.e. MPa]
'h 15
1 1 Arm length a in mm 0.5L p for hot rolling = 0.5 u10.954 mm =5.477 mm
'h P 2 R or P | | 0.3something
R 10 3.something
150 0.45 L p for cold rolling
In IESobjective exam calculators are not allowed, we have to use above apporx.calculation a
GATE-2014(PI) Page No.89 Slide No.126 Ans.(b) same as above Torque per roller T Fu , Nm =262.9 KN u 5.477 mm 1439.9 Nm
1000
GATE-1990(PI) Page No.90 Slide No.128 Ans.(b)
IES-2014 Page No.90 Slide No.129 Ans. (b) 2S N
Total power for two roller P 2T Z , inW 2T u
GATE-2008(PI) Page No.90 Slide No.130 Ans.(a) 60
The velocity at neutral point is equal to the velocity of roller, as there is no slip occur Assuming velocity of neutral plane velocity at exit V 30 m / min 0.5 m / s
S DN S u 0.300m u 100rpm V 0.5 m / s
V= 1.57 m / s Z 3.3333 rad / s
60 60 R 0.150 m
Selected Questions Page No.90 Slide No.132 Ans.(c & d) ? Total power for two roller P
GATE-2014 Page No.90 Slide No.134 Ans.14.6 to 14.8 m/min
2T u Z 2 u1439.9 u 3.3333, W 9.6 kW
The inlet and outlet volume rates of material flow must be the same, that is,
IAS-2017 Main. Page No.91 Slide No.142
h o bo vo h f b f v f
F V 0 R'h u b 400 400 u 4 u 300 4.8 MN
2 IES – 2000, GATE-2010(PI) Page No.91 Slide No.143 Ans.(a)The roll-separating force which separates
hf h ; b 1.02bo ; vo 10m / min
3 o f the two rolls apart can be obtained by multiplying the average roll pressure with the total contact area.
2 The average roll pressure can be decreased by reducing the maximum pressure, which is a function of
h o b o u10 h u1.02bo v f v f 14.706 m / min the contact length. Smaller contact lengths means lesser friction forces acting. Thus, by reducing the
3 o
GATE-1992(PI) Page No.91 Slide No.136 Ans.(d) contact length, it is possible to decrease the roll-separating force. This in turn, can be achieved by
reducing the roll diameter, since; smaller rolls would have less contact length than larger rolls for the
Ao
Elongation factor = E = 1.22...........( given) same reduction.
A1 IAS-2007 Page No.91 Slide No.144 Ans.(c)Use small dia rolls to reduce Roll force.
Ao 750 u 750 IES-2001 Page No.92 Slide No.146 Ans.(a)Coefficient of friction is constant over the arc of contact
En or 1.22n or 11.04 and But does not acts in one direction throughout the arc of contact.
An 250 u 250 IFS-2010 Page No.92 Slide No.149 Ans. Rolling analysis needed. Not needed for mechanical GATE
GATE-2016(PI) Page No.91 Slide No.139 Ans. 2000 (Range 1990 to 2010) and IES Prelims. Only for IES Conventional.
F V o L p b V o u R 'h u b IAS-1998 Page No.92 Slide No.150 Ans.(d)
500 u 100 u 4 u 200 N 2000 KN

GATE-2008 Page No.91 Slide No.140 Ans.(a) Ch-9 Forging: Answers with Explanations
'h 20 mm 18 mm 2mm 0.002m IES-2013 Page No.93 Slide No. 155 Ans.(a)
R 250mm 0.250m IES-1996 Page No.93 Slide No. 159 Ans.(d)
IES-2013 Page No.93 Slide No. 160 Ans.(c) Forging components poses high reliability i.e. point3. is
Pr ojected Length (L p ) R'h 0.250 u 0.002 0.02236 m
wrong, means (a), (b) and (d) wrong.
Arm length (a) O R'h 0.5 0.250 u 0.002 0.01118 m IES-2005 Page No.93 Slide No. 161 Ans.(b)
IES-2012 Page No.93 Slide No. 162 Ans.(b) If undercut is present it is not moldable means can’t be
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
withdrawn from die.
Torque(T) Fua [Force F on both roller] IES-2016 Page No.94 Slide No. 163 Ans.(a)
• Forging means hot working it will increases strength and ductility both.
670.8 u 10 u 0.01118
3
7.5 kNm
• Hot working reduced or eliminates porosity of the metal and increase resistance toshock and vibrating.
2S N 2S u 10 • Forging pressure is not uniform so it can’t guarantee uniformly and forging has poordimensional accuracy and
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
surface finish.
GATE-2017 Page No.91 Slide No.141 Ans. ISRO-2013 Page No.94 Slide No. 164 Ans.(b)
IES-2012 Page No.94 Slide No. 166 Ans.(c)
41|P a g e 42|P a g e


Page 180

IES-2006 Page No.94 Slide No. 168 Ans.(c) The draft provided on the sides for withdrawal of the elongation
forging. Engineering strain or Conventional Strain(H E )
original length
IES-2016 Page No.95 Slide No.172 Ans. (a) elongation
IAS-2002 Page No.95 Slide No. 173 Ans.(b)Amount of flash depends on the forging size not on forging
True Strain(H T )
instantaneous length
force.
IES – 1993, GATE-1994(PI) Page No.95 Slide No.176 Ans.(a)Closed die forging requires the provision of If suppose x is the length; dx is the elongation which is infinitely small
gutters to provide space for excess material and ensure complete closure of die and defect free forged L dx L
part. HT ³ ln
Lo x Lo
IES-1997 Page No.95 Slide No.177 Ans.(c) The provision of gutters to provide space for excess
material and ensure complete closure of die and defect free forged part. L Lo 'L 'L
GATE-1989(PI) Page No.95 Slide No. 178 Ans. Gutter
as 1 1 H E
Lo Lo Lo
IES-1998 Page No.96 Slide No. 182 Ans.(c) HT ln 1 H E
IES-2001 Page No.96 Slide No. 183 Ans.(a)
' volume change will not be there so,Ao Lo AL
IES-2011 Page No.96 Slide No. 185 Ans.(a) L Ao S / 4 d o 2

IES-2002 Page No.96 Slide No. 187 Ans.(b)
Lo A S / 4 d 2
IES-2003 Page No.96 Slide No. 188 Ans.(d) L Ao do
IAS-2001 Page No.96 Slide No. 189 Ans.(b) ln ln 2 ln
Lo A d
IES-2012 Conventional Page No.97 Slide No. 190 Ans. refer theory slides
IAS-2003 Page No.97 Slide No. 191 Ans.(a) The term swaging is also applied to processes where GATE-1992, ISRO-2012, VS-2013 Page No.101 Slide No. 231 Ans.(c)
material is forced into a confining die to reduce its diameter. § L· § 2L ·
IES – 1994, ISRO-2010 Page No.97 Slide No. 194 Ans.(c)The drop forging die consists of two halves. HT ln ¨ ¸ ln ¨ 0 ¸ ln 2 0.693
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
L
© o¹ © Lo ¹
stock is kept in the lower die while the ram delivers four to five blows on the metal, in quick succession so that GATE-2016 Page No.101 Slide No. 232 Ans.(c)
the metal spreads and completely fills the die cavity. When the two die halves close, the complete cavity is § 0.100 ·
formed. HT ln(1 H ) ln ¨1 u 100% 0.09995
IAS-2000 Page No.97 Slide No. 195 Ans.(a) Due to low toughness. © 100 ¸¹
IES-2011 Page No.97 Slide No. 198 Ans.(b) GATE-2007 Page No.101 Slide No. 233 Ans.(c)
IES-2005 Page No.98 Slide No. 206 Ans.(c) L
dx L¬ A ¬ D ¬ 200 ¬
IES-2008 Page No.98 Slide No. 207 Ans.(a) True strain T
¨ ln ln o 2 ln o 2 ln 1.386
x Lo ® A ® D ® 400 ®
Lo
IES-2013 Page No.99 Slide No. 209 Ans.(a)As K.E V2, high energy is delivered to the metal with
relatively small weights (ram and die). negative¬sign indicates compressive strain.
IES-2008 Page No.99 Slide No. 213 Ans.(None) Correct sequence is 2 – 1 – 3 - 4 GATE-2017(PI) Page No.101 Slide No. 234 Ans. 1.833 Range (1.80 to 1.85)
IAS-1998 Page No.100 Slide No. 218 Ans.(b)
IES-2011 Page No.100 Slide No. 219 Ans.(c) Bonding between the inclusions and the parent material is GATE-2016 Page No. 101 Slide No. 235 Ans.(b)
throughphysicalbondingnochemicalbondingpossible.
GATE-2008(PI) Page No.100 Slide No. 220 Ans.(c) §L· §L /2·
IES-2013 Page No.100 Slide No. 223 Ans.(b) HT ln ¨ ¸ ln ¨ o ¸ ln 2 0.69
GATE-2010(PI) Page No.100 Slide No. 225 Ans.(c)Low thermal conductivity because low heat loss © Lo ¹ © Lo ¹
from workpiece. GATE-2018 Page No. 102 Slide No. 236 Ans. 0.693
GATE-2014 Page No.101 Slide No. 230 Ans.(c) Initial length = L 0
L0
Final length L =
2
ª § L0 · º
L «¨ 2 ¸ »
True strain = H T = ln = ln « © ¹ » = - 0.693
Lo « L0 »
«¬ »¼
As examiner mentioned "magnitude" only magnitude will be given 0.693
GATE-2017 Page No.102 Slide No. 237 Ans.(b)
For calculating true strain we have to know initial and final length only.
Initial length Lo 20 mm
Final length ( L ) 10 mm
43|P a g e 44|P a g e §L· §A · §d ·

True strain (H T ) ln(1 H ) ln ¨ ¸ ln ¨ o ¸ 2 ln ¨ o ¸
© Lo ¹ © A ¹ ©d¹
§L· § 10 ·
For-2019(IES, GATE & PSUs) Page 180 of 203 True strain (H T ) ln ¨ ¸ ln ¨ ¸ 0.693 Rev.0
©L ¹ © 20 ¹
Page 181

We know that, Slope of AB line is E
AC
E=
BC
200 x 103 MPa =

500 100 MPa
BC
GAT
TE-2018 Page No. 102
1 N 239 Anss..(67.032)
Slide No. 400
BC = =0.002
Given, V = 1020 u H 0.4 200 x 103
at UTS, H T = n = 0.4
0 H B = 0.5 - 0.002 = 0.498
mation starts, Let, Af is cross-sectioon area at thhe time of neecking,
at UTS, neak form
GATE-2000(PI) Page No.103 Slide No.249 Ans. 7068 J , 0.6968 m
§A · § 100 ·
H T = 0.4 =ln ¨ 0 ¸ ln ¨
Ä ¸ ¨ A ¸¸
© f ¹ © f ¹
or A f 67.032 mmm 2
GAT
TE-2006 Page No.10
02 Slide No.
N 242 Anss.(b)

Sdo2 Sd 2f
u ho u hf
4 4
Su 1002 u 50 Su d 2f u 40
or or d f 111.8 mm
4 4
Sdo2 Su1002
Initial Force( Po ) u Vo u 80 628.3 KN
4 4
Sd 2f Su 111.82
GAT
TE-2015 Page No.1002 Slide No.
N 243 Anss.(c)
Final Force( Pf ) u Vo u 80 785.35 KN
4 4
GAT
TE-2017 Page No.1003 Slide No.
N 244 Anss.(b)
GAT
TE-2012 Sa
ame Q GATE -2012 (PII) Pag
ge No.103 Slide No. 245
2 Ans.(d))
Po Pf 628.3 785.35
Average Force( Pavg ) 706.8 KN
Volumee of materiaal will remainn same due to
t incompressibility 2 2
S d12
u h1
S d 22
u h2
Workdone(W ) Pavg u ho h f
706.8 u (50 40) J 7068 J
4 4
h1 50 mg(h x ) W [x ho h f ]
d2 d1 100 u 1411.42 mm
h2 25
10 u 10 h 0.010 7068 or h 0.6968 m
3
d 2 d1 GATE-2000(PI) Page No.103 Slide No.251 Ans. (c)

Percenttage change in diameterr u 100% 41..42%
d1
GAT
TE-2016(PII) Pag ge No.103 Slide No. 246
2 Ans. 1.0
0 (Range 1.0
0 to 1.0)
GAT
TE-2015 Page No.10 03 Slide No.247
N Anss. 95.19 mmm
100
0
True strain = ln 0.5129
5
95
V 0 u (0.5129)0.1
500 371.51
Upto elastic limits using Hookee's Law
V ul 371.51 u 106 u 100
E= or 200 u 109
'l 'l
'l 18575mm (co
0.1 his for elasttic recovery)
onsidering th
This is elastic comp
ponent and after
a releasee of the compressive loa
ad this
amountt of recoveryy takes placee.
This wiill be added to 95mm. Therefore,
T nal dimensioon = 95.1857
fin 75mm Ch-10 Extrusion and Drawing: Answers with Explanations
GAT
TE-2018 Page No.10 03 Slide No.248
N Anss.
IES-2007 Page No.104 Slide No. 256 Ans. (d)
45|P a g e 46|P a g e


Page 182

The equipment consists of a cylinder or container into which the heated metal billet is loaded. IES-2000 Page No.111 Slide No.317 Ans.(c)
On one end of the container, the die plate with the necessary opening is fixed. From the other end, a plunger or IAS-1995 Page No.111 Slide No. 318 Ans. (d)The correct sequence for preparing a billet for extrusion
ram compresses the metal billet against the container walls and the die plate, thus forcing it to flow through the process is pickling, alkaline cleaning, phosphate coating, and lubricating with reactive soap.
die opening, and acquiring the shape of the opening. The extruded metal is then carried by the metal-handling IES-1996 Page No.111 Slide No. 319 Ans. (d)
system as it comes out of the die. IES-2014 Page No. 111 Slide No. 321 Ans. (b)
DRDO-2008 Page No.104 Slide No. 258 Ans.(b) IES-1993; GATE-1994(PI), 2014(PI) Page No. 112 Slide No. 326 Ans. (b)
IES-2012 Page No.104 Slide No. 260 Ans.(c) IAS-2006 Page No.112 Slide No. 327 Ans. (b)
Advantages: 1. Material saving 2. Process time saving 3. Saving in tooling cost IES-2015 Page No.112 Slide No. 330 Ans. (a)
All are correct but only a die change can change the product therefore (c) is most appropriate. IES-1993 Page No.112 Slide No. 331 Ans. (a) Tandem drawing of wires and tubes is necessary because
IES-2009 Page No.104 Slide No. 261 Ans.(c) it is not possible to reduce at one stage.
IES-1994 Page No.105 Slide No. 264 Ans.(c)Metal extrusion process is generally used for producing IES-2000 Page No.112 Slide No. 332 Ans. (d)
constant solid and hollow sections over any length. IES-1999 Page No.112 Slide No. 333 Ans. (d)
GATE-1994 Page No.105 Slide No. 265 Ans. (a) IES-1996 Page No.113 Slide No. 334 Ans.(c)
IES-1999 Page No.105 Slide No. 267 Ans.(c) IES-1994 Page No.113 Slide No. 335 Ans. (d)
IES-2009 Page No.105 Slide No. 270 Ans. (b) IES-1993, ISRO-2010, Page No. 113 Slide No. 336 Ans. (b)since malleability is related to cold rolling,
IES-1993 Page No.106 Slide No. 272 Ans. (b) Both A and R are true but R is not correct explanation of A. hardness to indentation, resilience to impact loads, and isotropy to direction.
Zinc phosphate coating is used to prevent metal contact.In direct extrusion, friction with the chamber opposes IES-2002 Page No.113 Slide No. 337 Ans. (a)
forward motion of the billet. For indirect extrusion, there is no friction, since there is no relative motion. IAS-2001 Page No.113 Slide No. 338 Ans. (a)
IES-2000 Page No.106 Slide No.273 Ans.(c)As diameter decreases therefore for same mass flow rate GATE-2015 Page No.113 Slide No. 339 Ans. (b)
the speed of travel of the extruded product must be greater than that of the ram. IAS-2002 Page No.113 Slide No. 340 Ans. (b)
IES-2012 Page No.106 Slide No. 276 Ans.(c) The force required on the punch is less in comparison to IES-2011 Page No.113 Slide No. 341 Ans. (b)
direct extrusion. GATE-2018 Page No.113 Slide No. 342 Ans. (c)
IES-2007 Page No.106 Slide No. 277 Ans. (b)In direct extrusion, friction with the chamber opposes IAS-1994 Page No.114 Slide No.345 Ans. (b) Extrusion and skew rolling produce seamless metallic
forward motion of the billet. tubes.
IAS-2004 Page No.106 Slide No. 278 Ans. (d) Only ram movement is there. GATE-2003 Page No.114 Slide No. 350 Ans. (b)
IES-2016 Page No.106 Slide No. 279 Ans. (a) In the direct extrusion a significant amount of energy is Extrusion constant k = 250MPa
used to overcome frictional resistance between workpiece and cylinder wall.
IES – 2008, GATE-1989(PI) Page No.107 Slide No.283 Ans. (a)Impact Extrusion is used for manufacture S do 2 Sdf 2
of collapsible toothpaste tubes Initial area A o and Final area A f
4 4
IES-2003 Page No.107 Slide No. 284 Ans. (d)
IES-2014 Page No.107 Slide No.285 Ans. (c) Force required for extrusion:
IAS-2000 Page No.108 Slide No. 293 Ans. (d)Hydrostatic extrusion suppresses crack formation by §A · S § S / 4 u 0.12 ·
pressure induced ductility. Relative brittle materials can be plastically deformed without fracture. And materials P kA0 ln ¨ o ¸¸ 250 u u 0.12 ln ¨ 2 ¸
2.72219 MN
with limited ductility become highly plastic. Ä 4 © S / 4 u 0.05 ¹
© f ¹
IES-2006 Page No.108 Slide No.294 Ans. (a) It is pressure induced ductility.
GATE-2009(PI) Page No.114 Slide No.351 Ans. (a)
GATE-1990(PI) Page No.108 Slide No. 295 Ans.(c)
IES-2001 Page No.108 Slide No.296 Ans. (d) §A ·
Pressure (V ) V o ln ¨ o ¸¸ V o ln r 300 ln 4 416 MPa
IES-2009(conventional) Page No. 109 Slide No. 298 Ans. Ä
For sketches refer slides. © f ¹
(i)Direct Extrusion-curtain rods GATE-2006 Page No.115 Slide No. 352 Ans. (b)
(ii) Indirect Extrusion- Given : Do 10 mm; Df 8 mm; V 0 400 MPa; Ignore friction and redundant work means
(iii) Hydrostatic Extrusion-Cladding of metals, Extrusion of nuclear fuel reactor fuel rod §r · S u 82
§5·
(iv) Impact Extrusion-Collapsible tubes for toothpastes, creams etc. 2V 0 A f ln ¨ o ¸
Ideal Force 2 u 400 u ln ¨ ¸ 8.97 kN
IES-2014 Page No.109 Slide No.300 Ans. (d) For high extrusion pressure, the initial temperature of © rf ¹ 4©4¹
billet should be low. GATE -2008 (PI) Linked S-1 Page No. 115 Slide No.353 Ans. (b)
IES-2018(PI) Page No.109 Slide No.302 Ans. (d) do 10 mm, d f (1 0.2) u d o (1 0.2) u 10 8 mm
IES-2016 Page No.109 Slide No.3030 Ans. (b) Bamboo defects at low temperature due to
sticking of metals in die land. §A · §d · § 10 ·
Stress V d V o ln ¨ o ¸ 2 u V o u ln ¨ o ¸¸ 2 u 800 u ln ¨ ¸ 357 MPa
JWM-2010 Page No.109 Slide No. 304 Ans. (a) Ä ¸ ¨d © 8 ¹
GATE-2014 Page No.109 Slide No. 306 Ans. (b) © f ¹ © f ¹
IES-2007 Page No.110 Slide No. 310 Ans.(c) GATE -2008 (PI) Linked S-2 Page No.115 Slide No. 354 Ans. (a)
IES-2009 Page No.110 Slide No. 311 Ans. (b)The wire is subjected to tension only. But when it is in Power Drawing force u Velocity
contact with dies then a combination of tensile, compressive and shear stresses will be there in that portion only.
Stress V d u area Af uVelocity
IES-2005 Page No.110 Slide No. 312 Ans. (a)
GATE-1987 Page No.110 Slide No. 313 Ans. (a) S u 82
IES-2016 Page No.110 Slide No. 314 Ans.(c) 357 u u 0.5W 8.97 KW
IES-2010 Page No.111 Slide No. 316 Ans.(c) 4
Cleaning is done to remove scale and rust by acid pickling. IES-2014 Conv. Page No.115 Slide No. 355 Ans. 190 N
Lubrication boxes precede the individual dies to help reduce friction drag and prevent wear of the dies. GATE-2001, GATE -2007 (PI) Page No.115 Slide No. 356 Ans. (b)
It is done by sulling, phosphating, electroplating.
47|P a g e 48|P a g e


Page 183

2B 2B
§A ·
V d V o ln ¨ o ¸ For Maximum reduction,V d V o V o 1 B ª §r · º §r ·
Vd «1 ¨ f ¸ » ¨ f ¸ .V b
© Af ¹ B r r
§ Ao · Ao
¬« © o ¹ »¼ © o ¹
A Af § 1·
V o V o ln ¨ ¸ or e 2.71828 ? o u 100 ¨1 e ¸ u 100 63% 2u1.7145 2u1.7145
© Af ¹ Af Ao © ¹ 400(1 1.7145) ª § 5 · º § 5 ·
Vd «1 ¨ ¸ »¨ ¸ u 50 361.26 MPa
GATE-2018 Page No.115 Slide No. 357 Ans. (d) 1.7145 «¬ © 6.25 ¹ »¼ © 6.25 ¹
GATE-1996 Page No.115 Slide No. 359 Ans. (b) For maximum possible reduction;V o Vd
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 2B 2B
V o 1 B ª §r · º §r ·
(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 Vo «1 ¨ f min ¸ » ¨ f min ¸ .V b
B «¬ © ro ¹ ¼» © ro ¹
(c) 5 stage reduction final dia 2u1.7145 2u1.7145
=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 400(1 1.7145) ª § rf min ·
º § rf min ·
400 «1 ¨ »¨
¸ ¸ u 50 rf min 4.78 mm
GATE-2015 Page No.115 Slide No. 360 Ans. (b) 1.7145 «¬ © 6.25 ¹»¼ © 6.25 ¹
GATE-2018(PI) Page No.116 Slide No. 361 Ans. 58
d o d f min
IES-2011(conventional) Page No. 116 Slide No.364 Ans. Max possible % reduction in diameter = u 100% 23.5%
d o 12.5mm; d f 10mm;V 100m / min; D 5q; P 0.15; V o 400MPa do
B P cot D 0.15cot 5 1.7145 Ao Af min
Max possible % reduction in area = u 100% 41.5%
2B Ao
V o 1 B ª
§r · º
Vd «1 ¨ f ¸ » GATE – 2018 Page No. 116 Slide No. 365 Ans. (316.25)
B r
¬« © o ¹ »¼ di 10 mm, d f 7.5 mm, D 5q, P 0.1, ª¬V y º¼ 350 MPa
2u1.7145 avg
400(1 1.7145) ª § 5 · º 2 P cot D
Vd «1 ¨ ¸ » 338.653MPa 1 ½ª § df · º
1.7145 6.25
«¬ © ¹ »¼ Vf V
y avg ®1 ¾ «1 ¨ ¸ »
¯ P cot D ¿ «¬ © di ¹ »¼
S 2
Force P 338.653 u 10 N 2u0.1ucot 5q
4 1 ½ ª § 7.5 · º
S 100 Vf 350 u ®1 ¾ «1 ¨ ¸ » 316.25 MPa
Power P u V 338.653 u 102 u m / s 44.329 kW ¯ 0.1 u cot 5q ¿ ¬« © 10 ¹ ¼»
4 60
IFS-2016 Page No. 116 Slide No. 366 Ans (i) 5.594 KW and (ii) 73.24 MPa
Maximum possible reduction;V o V d
2B 2u1.7145 GATE – 2011 (PI) Common Data-S1 Page No. 116 Slide No. 367 Ans.(c)
V o 1 B ª
§r · º 400(1 1.7145) ª § rf min · º
Vo «1 ¨ f min ¸ » or 400 «1 ¨ ¸ » or rf min 4.67mm S d o2 S u102
B «¬ © ro ¹ »¼ 1.7145 «¬ © ro ¹ »¼ Initial area A o mm 78.54 mm 2
2
4 4
d d f min r r After first pass area A1 1 0.35 Ao 1 0.35 u 78.54 mm2 51 mm 2
Max possible reduction in dia = o u100% o f min u100% 25.3%
do ro 2
After second pass area A 2 1 0.35 Ao and then ........
If the rod is subjected to a back pressure of 50 N/mm2
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
§ L· §A · § 78.54 ·
True strain ln ¨ ¸ ln ¨ o ¸ ln ¨ ¸ 3.02
© Lo ¹ © A¹ © 3.85 ¹
and Ao Lo A7 L7 or 78.54 u100 3.85 u L7 L7 2040 mm
GATE – 2011 (PI) Common Data-S-2 Page No. 116 Slide No. 368 Ans. (d)
§A · §A · § 78.54 ·
P V o Af ln ¨ o ¸¸ V o A1 ln ¨ o ¸ 200 u 51u ln ¨ ¸N 4.40 KN
¨ Af A © 51 ¹
© ¹ © 1¹
GATE-2014 Page No.116 Slide No. 369 Ans. = 0.9 to 1.1
49|P a g e 50|P a g e


Page 184

t
dL dL 2tdt
True strain at any instant t H T ³L ³ L 1 t2 ln ª¬1 t 2 º¼

0 ³
0 1 t2
as, L
L0 1 t 2 ,? dL L0 2tdt
dHT 2t 2 u1
HT 1.0
dt 1 t 2
1 12
IAS-1997 Page No.117 Slide No. 370 Ans.(c)
IES-2012 Page No.117 Slide No. 371 Ans. Refer slides
IAS-2006 Page No.117 Slide No. 373 Ans. (c)
Ch-11 Sheet Metal Operation: Answers with Explanations

GATE-2018 Page No.118 Slide No. 383 Ans. 53.25

Punching Force(F) LtW
F 2(a b)tW 2(100 50) u 5 u 300 450 kN
IAS-2011(main) Page No.119 Slide No. 395 Ans.
For punching operation 10 mm circular hole
d 10 mm; t 1 mm;W 240 MPa
(i) Punch size size of hole 10 mm
ii Die size Punch size 2 C 10 2(0.0032t W )=10 2(0.0032 u1u 240)= 10.09914 mm
(iii) Punching Force(F) LtW S dtW S u10 u1u 240 N 7.54 KN
This rectangle ABCD will be repeated again and again.
For blanking 50×200 mm rectangular blank
7 6 42 2
A t = Total Area = D u D D (i) Punch size size -2C
5 5 25
Length will be = 200-2C =200 - 2(0.0032 u1u 240) =199.90 mm
S D2
A u = Area of blanking Disc =
4 Width will be = 50 -2C =50 - 2(0.0032 u 1u 240) = 49.90 mm
ª §S ·º ii Die size correct size
At Au « ¨ 4 ¸»
% of scrap = u 100% «1 © ¹ » u 100% 53.25% Length will be = 200 mm
At « 42 » Width will be = 50 mm
«¬ 25 »¼
(iii ) F 2(a b)tW 2(200 50) u 1u 240 120 kN
Example Page No.119 Slide No. 389 Ans.
The clearance to be provided is given by, C = 0.0032 u t u ¥W
Shear strength of annealed C20 steel = 294 MPa GATE-2016(PI) Page No.119 Slide No. 396 Ans.0.25(Range0.24to0.26)
Hence, C = 0.0032 u1.5 u 294 = 0.0823 mm f 3
IES-1999 Page No.120 Slide No.398 Ans.(b) min dia =4t s 4 u 20 u 30 mm
Since it is a blanking operation, fc 6
Die size = blank size = 20 mm IES-2014 Page No.120 Slide No.399 Ans. (c)
Punch size = blank size – 2 C = 20 – 2 u 0.0823 = 19.83 mm
Now when it is punching operation, Sd2 4tW 4tW
ISRO-2008, 2011 Page No.120 Slide No. 400 Ans.(c) S dtW d Vc u or d t t
Punch size= size of hole = 20 mm 4 Vc 4W
Die size = Punch size +2 C = 20 +2 u 0.0823 = 20.1646 mm IES-2013 Page No.120 Slide No. 401 Ans.(c)same as previous question
GATE-2003 Page No.119 Slide No.390 Ans.(a) EXAMPLE Page No.121 Slide No. 406 Ans.
It is blanking operation Maximum force without shear = 550 x 100 x Ǒ x 5.6 N = 968 kN
Therefore Diameter of die = metal disc diameter = 20 mm Capacity of press, F = 30 T = 30 x 9.81 KN = 294 KN
3% clearance (c) = 0.06 mm on both side of the die (of sheet thickness)
Fmax u pt 968 u 0.4 u 5.6
Therefore Diameter of punch = 20 – 2c = 20 – 2 x 0.06 = 19.88 mm F or 294 or s 5.13mm
Example Page No.119 Slide No. 393 Ans. s pt s 0.4 u 5.6
Angle of shear, tanǉ = 5.13/100 or ǉ = 2.9o
EXAMPLE Page No.121 Slide No. 407 Ans.
51|P a g e 52|P a g e


Page 185

d1 25.4 mm; d 2 12.7 mm; t 1.5 mm;W 280 N / mm 2 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.124 Slide No. 439 Ans.(c)
Total cutting force when both punches act at the same time and no shear is C = 6% of t = 0.06×2.5 mm = 0.15 mm
applied to either the die or punch; Punch size = die size - 2C = 50 - 2×0.15 mm = 49.70 mm
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 Die size = 50.00 mm
The cutting force if the punches are staggered, so that only one punch acts at a time: GATE-2002 Page No.124 Slide No.440 Ans.(c)
Fmax S d outsidetW S u 25.4 u 1.5 u 280 33.515 kN GATE-2001 Page No.124 Slide No. 441 Ans.(b)
GATE-1996 Page No.125 Slide No. 442 Ans.(d) Clearance only on punch for Blanking operation. Due to
Taking 60% penetration and shear on punch of 1 mm, insufficient data we cant calculate.
The cutting force if both punches act together; IES-1994 Page No.125 Slide No. 443 Ans.(a)
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 u 1.5 23.81KN
S pt 1 0.6 u1.5 IES-2006 Page No.125 Slide No. 446 Ans.(c)
GATE-2010 Statement Linked 1 Page No.121 Slide No. 408 Ans.(a)
p IAS-2000 Page No.125 Slide No. 449 Ans.(d)
t 5 mm; L 200 mm;W 100MPa; 0.2
t It is blanking operation so clearance must be provided on punch.
Fmax LtW 200 u 5 u100 100 kN Therefore, Die size = blank size = 30 mm
Punch size = blank size – 2C = 30 -2 x 0.06 x t = 30 – 2 x 0.06 x 10 = 28.8 mm
Work Done Fmax u ( pt ) 100 u (0.2 u 5) 100 J GATE-2007(PI) Page No.125 Slide No. 450 Ans.(c)
C 40 microns 0.040 mm; 2C 0.08 mm
It is blanking operation : Punch size 35 0.080 mm and Die size 35 mm
GATE-2010 Statement Linked 2 Page No.121 Slide No. 409 Ans.(b)
For 400mm length shear is 20mm; therefore for IAS-1994 Page No.126 Slide No. 451 Ans.(a)
200mm length it becomes10mm. Only 200 mm length Work done = Fmax u pt 200 kN u 0.25 u 4 200 J [2 u 105 N 200kN ]
is effective. IAS-2002 Page No.126 Slide No. 452 Ans.(a) In punching usable part is sheet so punch size is
Fmax ( pt ) Correct and clearance on die. In blanking usable part is punched out circular part so die size is correct
F and clearance on punch
S
IAS-2007 Page No.126 Slide No. 453 Ans.(b)In punching useable part is punched sheet so size of hole
100 must be accurate i.e. size of punch must be accurate. Clearance have be given on Die only.
F 10kN
10 IAS-1995 Page No.126 Slide No. 454 Ans.(a)Both A and R are true and R is the correct explanation of A
IAS-2003 Page No.122 Slide No. 419 Ans.(a) IES-2002, GATE(PI)-2003 Page No.126 Slide No. 455 Ans.(c)
ISRO-2013 Page No.122 Slide No. 420 Ans.(a) Higher the modulus of elasticity higher will be the spring IAS-2003 Page No.126 Slide No. 456 Ans.(c)
back. IES-2000 Page No.126 Slide No. 457 Ans.(b)
GATE-2011 Page No.123 Slide No. 431 Ans.(c) IES-1999 Page No.126 Slide No. 458 Ans.(d) In blanking operation clearance is always given on the
Blanking Force(F) LtW S dtW S u100 u1.5 u 300 141.371kN punch . Die size is always the exact dimension
GATE-2016 Page No.123 Slide No. 432 Ans. 5.026 KN IES-1994 Page No.127 Slide No. 464 Ans.(c)
F S dtW S u 10 u 2 u 80 5026 N 5.026 KN d 25mm; h 15mm;We know D d 2 4dh 252 4 u 25 u15 46 mm
GATE-2009(PI) Page No.124 Slide No.433 Ans.(b)
GATE-2003 Page No.127 Slide No. 465 Ans.(c)
Blanking Force(F) LtW S dtW S u 200 u 3.2 u150 301.592kN d 100
GATE-2013(PI) Page No.124 Slide No. 434 Ans.(c) Here 250 For d t 20r ; D d 2 4dh 1002 4 u 100 u 100 224 mm
r 0.4
Blanking Force(F) LtW S dtW S u10 u 2 u 80 5.026kN
ISRO-2009 Page No.124 Slide No. 435 Ans.(b) GATE-2017 Page No.127 Slide No. 466 Ans.(28.723mm)
Blanking Force(F) LtW S dtW S u 25 u10 u 500 392.69kN ISRO-2011 Page No.127 Slide No. 467 Ans.(a)
GATE-2007 Page No.124 Slide No. 436 Ans.(a) IAS-2013(mains) Page No.128 Slide No. 472 Ans.
Blanking Force(F) LtW S dtW d 50 mm; h 100 mm; BlankDia D d 2 4dh 502 4 u 50 u 100 150 mm
F1 5 S dtW and F2 S u1.5d u 0.4t uW d d
Reduction 1 ; 1st Reduction; 0.4 1 d 90 mm
F1 S dtW 5 1 D 150
or or F2 3
F2 S u1.5d u 0.4t uW F2 1.5 u 0.4 So, it can't be draw in a single draw.
GATE-2004 Page No.124 Slide No.437 Ans.(a) IFS-2013 Page No.128 Slide No. 473 Ans.
The blanking force (Fmax ) =S dtW S u 10 u 3 u 400 37.7 kN
Fmax u pt 37.7 u 0.40 u 3
F 22.6 kN
S 2
GATE_2012 Page No.124 Slide No. 438 Ans.(a)
Punch size without allowance = Die size – 2 x radial clearance = 25 – 2 x 0.06 = 24.88 mm
53|P a g e 54|P a g e


Page 186

d 40 mm; h 60 mm; r 2 mm (iv)Internal combustion of gaseous mixtures.
(v) Electro-magnetic (the use of rapidly formed magnetic fields)
D d 2 4dh 402 4 u 40 u 60 105.83mm IES-2009 Page No.134 Slide No. 530 Ans.(b)
First draw 50% reduction, d1 0.5D=52.415mm IES-2005 Page No.134 Slide No. 531 Ans.(c)
Second draw 30% reduction, d 2 0.6d1 31.44mm (possible) li1 li 2
For bi-axial strectching of sheets: H1 ln and H 2 ln
It is not possible to draw the cup in single step.we have to use double step. lo1 lo 2
IES-2008 Page No.128 Slide No. 475 Ans.(c) A cylindrical vessel with flat bottom can be deep drawn initial thickness(t )
by double action deep drawing Final thickness =
eH 1 u e H 2
1.5
2
D = d 4dh = 15 cm t 1.5mm; H1 0.05; H 2 0.09 ?Final thickness 1.304 mm
e0.05 u e0.09
First draw 50% reduction, d1 = 7.5 cm
Second draw 30% reduction, d2 = 5.25 cm
EXAMPLE Page No. 136 Slide No. 548 Ans.
Third draw 25% reduction, d3 = 3.94 cm possible
IES-1998 Page No.129 Slide No. 480 Ans.(d) KlV ut t 2
F
d § d· w
0.5; Reduction ¨1 ¸ u100% 50%
D © D¹ 1.33 u1200 u 455 u1.62
N 145.24 kN
Thumb rule: 12.8
First draw:Reduction 50 % GATE-2005 Page No.136 Slide No. 549 Ans.(c)
D 1 radian; R 100mm; k 0.5; t 2mm
Second draw:Reduction 30 %
Lb D (R kt) 1(100 0.5 u 2) 101 mm
Third draw:Reduction 25%
GATE-2007 Page No.137 Slide No. 553 Ans.(d)
Fourth draw:Reduction 16 % GATE -2012 Same Q in GATE-2012 (PI) Page No.123 Slide No.554 Ans.(a)
Fifth draw:Reduction 13%
IAS-1999 Page No.137 Slide No. 556 Ans.(d)
IAS-1996 Page No.130 Slide No.487 Ans. (a) IAS-1997 Page No.137 Slide No. 557 Ans.(c)
IAS-2007 Page No.130 Slide No. 490 Ans.(d) In drawing operation, proper lubrication is essential for IES-2010 Page No.137 Slide No. 558 Ans.(d)
1. To improve die life.
2. To reduce drawing forces. Ch-12 Powder Metallurgy: Answers with Explanations
3. To reduce temperature.
IAS-2003 Page No.138 Slide No.562 Ans. (c)It is for low melting point temperature metals.
4. To improve surface finish.
IAS-2007 Page No.138 Slide No.563 Ans. (c)In atomization process inert gas or water may be used as
a substitute for compressed air.
GATE-2008 Page No.131 Slide No. 499 Ans.(a)An insufficient blank holder pressure causes wrinkles to
develop on the flange, which may also extend to the wall of the cup.
• Molten metal is forced through a small orifice and is disintegrated by a jet of compressed air, inert gas or
water jet.
GATE-1999 Page No.131 Slide No. 501 Ans.(b)It is without a blank holder, so no stress.
• In atomization, the particles shape is determined largely by the rate of solidificationand varies from
GATE-2006 Page No.131 Slide No. 502 Ans.(d)
spherical, if a low-heat-capacity gas is employed, to highly irregularif water is used. By varying the
design and configurations of the jets pressure andvolume of the atomizing fluid, thickness of the stream
IAS-1994 Page No.131 Slide No. 504 Ans.(d)
of metal, etc, it is possibleto control the particle size distribution over a wild range.
GATE-1992 Page No.132 Slide No. 510 Ans.(a)
IES-1999 Page No.138 Slide No.565 Ans. (c)An oxide film is formed in the case of air atomization and
tc 1.5mm;D 30q now tc tb sin D ; or 1.5 tb sin 30 tb 3 mm that film can be avoided by using an inert gas.
IES-1994 Page No.132 Slide No. 511 Ans.(d)Mode of deformation of metal during spinning is bending GATE-2017(PI) Page No.138 Slide No.566 Ans. (a)
and stretching. GATE-2011(PI) Page No.139 Slide No.568 Ans. (b)In reduction Metal oxides are turned to pure
IES-2016 Page No.134 Slide No. 525 Ans.(a) metal powder when exposed to below melting point gases results in a product of cake of sponge metal.
IES-2011 Page No.134 Slide No. 526 Ans.(b) IES-2012 Page No.139 Slide No.573 Ans. (b)
Option (b) Magnetic pulse forming and (d) Eletro-hydraulic formingboth are High Energy Rate GATE -2014 (PI) Page No.139 Slide No.575 Ans. (b) Compaction is used for making product.
Forming (HERF). But Question is "usedfor forming components form thin metal sheets or deform IAS-2000 Page No.139 Slide No.576 Ans. (b)Sintering used for making bond
thin tubes"it is done by Magnetic pulse forming only. IES-2010 Page No.140 Slide No.577 Ans. (d)
JWM-2010 Page No.134 Slide No. 527 Ans.(c) IES-1999 Page No.140 Slide No.578 Ans. (a)
IES-2010 Page No.134 Slide No. 528 Ans.(c) IES-2013(conventional) Page No.140 Slide No.582 Ans. Lubricants such as graphite or stearic acid
IES-2007 Page No.134 Slide No. 529 Ans.(b) improve the flow characteristics and compressibility at the expense of reduced strength.
High-Energy-Rate-Forming is metal forming through the application of large amount of energy in a very sort GATE-2016(PI) Page No.141 Slide No.589 Ans. (c)
time interval. GATE-2010(PI) Page No.141 Slide No.590 Ans. (b)Due to formation of bonding brittleness reduces.
High energy-release rate can be obtained by five distinct methods: IES-2002 Page No.141 Slide No.591 Ans. (c)
(i) Underwater explosions. IAS-1997 Page No.142 Slide No.597 Ans. (d)A is false. Closed dimensional tolerances are possible
(ii) Underwater spark discharge (electro-hydraulic). with iso-static pressing of metal power in powder metallurgy technique.
(iii)Pneumatic-mechanical means. ISRO-2013 Page No.143 Slide No. 605 Ans. (b& c)Best choice will be ( c)
55|P a g e 56|P a g e


Page 187

GATE-2009(PI) Page No.143 Slide No.610 Ans. (d) IES-1996 Page No.153 Slide No.51 Ans.(b)
IES-2007 Page No.143 Slide No.611 Ans. (b)Disadvantage of PM is relatively high die cost. S D(mm) N S u100 u1000
IES-2012 Page No.144 Slide No.613 Ans. (b) V m / min 314.15m / min
1000 1000
IES-2006 Page No.144 Slide No.613 Ans. (c)No wastage of material.It may be automated though it is Cutting speed in this case is 314 m / min, at which ceramic is suited.
difficult for automation. this is not true IES-2007 Page No.153 Slide No.52 Ans.(d)
IES-2004 Page No.144 Slide No.613 Ans. (a) IAS-2000 Page No.153 Slide No.53 Ans.(c)
IES-2010 Page No.144 Slide No.618 Ans. (c) H.S.S < Cast alloy < Carbide < Cemented carbide < Cermets < ceramics
IAS-1998 Page No.144 Slide No.619 Ans. (c) IAS-2003 Page No.154 Slide No.54 Ans.(c)
IES-2009 Page No.144 Slide No.620 Ans. (c) IAS-1999 Page No.154 Slide No.59 Ans.(b)
GATE-2011(PI) Page No144 Slide No.621 Ans. (d) IES-2010 Page No.155 Slide No.63 Ans.(c)
IAS-2003 Page No.145 Slide No.622 Ans. (a) IES-2000 Page No.155 Slide No.64 Ans.(d)CermetsareMetal-ceramic composites
IES-1997 Page No.145 Slide No.623 Ans. (d)
GATE-2009(PI) Page No.155 Slide No.67 Ans.(d)On ferrous materials, diamonds are not suitable
because of the diffusion of carbon atoms from diamond to the work-piece material.
IAS-2003 Page No.145 Slide No.627 Ans. (d)
IES-1995 Page No.155 Slide No.70 Ans.(b)Nonferrous materials are best to work with diamond
GATE-2011 Page No.146 Slide No.633 Ans. (c)
because ferrous materials have affinity towards diamond and diffusion of carbon atoms takes place.
IAS-1999 Page No.156 Slide No.74 Ans.(a)“Oxidation of diamond starts at about 450oC and
thereafter it can even crack. For this reason the diamond tool is kept flooded by the coolant during cutting, and
IES-2001 Page No.146 Slide No.639 Ans. (d)
light feeds are used.” - Book B L Juneja and Nitin seth page 88
GATE-2008(PI) Page No.147 Slide No.640 Ans. (d)
IES-1996 Page No.156 Slide No.80 Ans.(a)Hardness of CBN is comparable to diamond
Ch-xx Tool Materials: Answers with Explanations IES-1994
IAS-1998
Page No.157 Slide No.81 Ans.(d)None of the uses is true for CBN.
Page No.157 Slide No.82 Ans.(b)
IAS-1997 Page No.148 Slide No.7 Ans.(a)Carbon steel tools have Limited tool life. Maximum
High speed steel, in addition to W, Cr & V, has Mo as the most influencing constituent. Thus A matches with 2.
cutting speeds about 8 m/min. dry and used upto 250oC
Non ferrous alloys (stellites) are high in cobalt. Thus B matches with 5.
IES-2013 Page No.149 Slide No.11 Ans.(b) Addition of large amount of cobalt and Vanadium to
The major constituent of diamond is carbon. Thus C matches with 1.
increase hot hardness and wear resistance respectively
Coated carbide tools are treated by nitriding. Thus D matches with 3
IAS-1997 Page No.149 Slide No.12 Ans.(a)Coating if TiC and TiN on HSS is done by by Chemical
IES-2003 Page No.157 Slide No.85 Ans.(b)This is one of the natural abrasives found, and is also
Vapour Deposition (CVD) or Physical Vapour Deposition (PVD)
called corundum and emery. However, the natural abrasives generally have impurities and, as a result, their
IES-2003 Page No.149 Slide No.14 Ans.(a)18-4-1 High speed steel- contains 18 per cent tungsten, 4
performance is inconsistent. Hence the abrasive used in grinding wheels is generally manufactured from the
per cent chromium and 1 per cent vanadium
aluminium ore, bauxite,Silicon carbide (SiC) Silicon carbide is made from silica sand and coke with small
amounts of common salt.
IES-1993 Page No.149 Slide No.16 Ans.(b)The blade of a power saw is made of high speed steel.
IES-2000 Page No.157 Slide No.86 Ans.(b)Cutting speed of diamond is very high but small feed rate
with low depth of cut. Degarmo and Kalpakjian both book written this.
x 18-4-1 High speed steel- contains 18 per cent tungsten, 4 per cent chromium and 1 per cent vanadium
IES-1999 Page No.157 Slide No.87 Ans.(d)WC is used for drawing dies, silicone nitride for pipes to
x Molybdenum high speed steel contains 6 per cent tungsten, 6 per cent molybdenum, 4 per cent
carry liquid metal, Al2O3 for abrasive wheels, and silicon carbide for heating elements.
chromium and 2 per cent vanadium.
IAS-2001 Page No.157 Slide No.88 Ans.(d)
IAS-1994 Page No.150 Slide No.23 Ans.(b)
Creamics tool is sued upto 1300°C SiC can with stand upto 2700°C that so why we
can use it for furnace part also. But statement-I and statement-II has no relation.
IES-2010 Page No.153 Slide No.48 Ans.(b)Constituents of ceramics are oxides of different materials,
which areGround, sintered and palleted to make ready ceramics
IAS-1996 Page No.153 Slide No.49 Ans.(c)
IES-1997 Page No.153 Slide No.50 Ans.(b)Ceramic tools are used only for light, smooth and
continuous cuts at high speeds.This is because of low strength of ceramics
57|P a g e 58|P a g e


Page 188
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):


Page 189
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

Page 190
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

Page 191
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

Page 192
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.

Page 193
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

Page 194
( 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

Page 195
2K
C V0 R
h
IES–2007Conventional or
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

Page 196
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)

Page 197
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

Page 198
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

Analysis of Rolling For sliding friction, τ x =Page 199
μp Simplifying and neglecting Due to cold rolling, σ 0' increases as h decreases,
terms sin θ ≅ θ and cos θ = 1,
second order terms, 1 wee get thus σ 0' h nearly a constant and itsderivative zero.
d (σ x h )
dθ
= 2 pR (θ ∓ μ ) d
dθ
( p / σ 0' ) 2R
2 = (θ ∓ μ )
p −σ x = σ 0 = σ 0' p / σ 0' h
3
h = h f + 2 R (1 − cos θ ) ≈ h f + Rθ 2
⎡ h ( p − σ 0' ) ⎤ = 2 pR (θ ∓ μ )
d
dθ ⎣ ⎦ d ( p / σ 0' ) 2R
= (θ ∓ μ ) dθ
Considering the thickness of the element perpendicular to the
d ⎡ ' ⎛ p ⎞⎤
⎢σ 0 h ⎜ ' − 1 ⎟ ⎥ = 2 pR (θ ∓ μ )
( p /σ )'
0
h f + Rθ 2
dθ ⎣ ⎝σ0 ⎠⎦
plane of paper to be unity,
unity We get equilibrium equation in xx‐ Integrating both side
direction as, - σ x h + (σ x +dσ x ) (h + dh) - 2pR dθ sin θ d ⎛ p ⎞ ⎛ p ⎞ d 2 Rθ dθ 2 Rμ
+ 2 τ x R dθ cos θ = 0
σ 0' h ⎜
d θ ⎝ σ 0'
⎟ + ⎜ ' − 1⎟
σ θ
(σ 0' h ) = 2 pR (θ ∓ μ ) ln ( p / σ 0' ) = ∫ ∓ ∫h dθ = I ∓ II ( say )
⎠ ⎝ 0 ⎠ d h f + Rθ 2 f + Rθ
2
2Rθdθ 2Rθdθ 2θdθ ⎛h⎞ ⎛h⎞ R ⎛ R ⎞ ⎛h ⎞

I= ∫h f + Rθ
2
= ∫ h
= ∫h/R = ln ⎜ ⎟
⎝R⎠
∴ ( )
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
⎝ hf ⎠ ⎝R⎠
hf ⎛h⎞
Now h / R = + θ2 ∴ p = C σ '0 ⎜ ⎟ e∓ μH R μHo
R
⎝R⎠ and C = .e
d ⎛h⎞ ho
or = 2θ
θ\ R ⎛ R ⎞
dθ ⎜⎝ R ⎟⎠ where H = 2 .tan −1 ⎜⎜ .θ ⎟ h
⎟ . e ( 0 )
μ H −H
hf ⎝ hf ⎠ p = σ '0
2Rμ
R h0
II = ∫ dθ Now at entry ,θ = α
h f + Rθ2
Hence H = H0 with θ replaced by ∝ in above equation I the eexit
In it zone
o e
2μ
= ∫ h f / R + θ2 dθ At exit θ = 0 ⎛ h ⎞
'
p = σ '0 ⎜ ⎟ .eμH
Therefor p = σ
R ⎛ R ⎞ 0 ⎝ hf ⎠
= 2μ .tan −1 ⎜ .θ
θ⎟
hf ⎜ h ⎟ At the neutral po int above equations
⎝ f ⎠
will give same results
hn h
. e ( 0 n ) = n . eμ Hn
μ H −H
If back tension σ b is there at Entry,
Entry
h0 hf
h
ho p = ( σ ′o − σ b ) . e ( 0 )
μ H −H
= e ( 0 n)
μ H − 2H
or h0
hf
1⎡ 1 ⎛ h0 ⎞ ⎤ If front tension σ f is there at Exit,
or Hn = ⎢H0 − ln ⎜ ⎟ ⎥
2 ⎣⎢ μ ⎝ h f ⎠ ⎦⎥ h
p = ( σ ′o − σ f ) . eμ H
⎛ R ⎞ hf
R
From H = 2 .tan −1
⎜⎜ .θ ⎟
hf ⎟
⎝ hf ⎠
hf ⎛ h f Hn ⎞
∴ θn = .tan ⎜ . ⎟⎟
R ⎜
⎝ R 2 ⎠
and h n = h f + 2R (1 − cos θn )
Page 200
or σ x 2rdr + dσ x r + 2rτ x dx + Px 2rdx tan α = 0
2 dσ x 2σ o 2 μ (σ o − σ x )
Wire Drawing Analysis (Home Work)
Wire Drawing Analysis (Home Work) + + 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 + τ x cos α ⎜ 2π r
2
⎟ Both Tresca's and Von-Mises criteria will ggive
⎝ 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
B.C s at r = ro ,σ x = σ b
1
⎡ Bσ b − (1 + B ) σ o ⎤⎦ 2 B
∴C = ⎣
ro
σ o (1 + B ) ⎡ ⎤ ⎛ r ⎞2 B
2B
⎛r⎞
or σ x = ⎢1 − ⎜ ⎟ ⎥ + ⎜ ⎟ .σ b
B ⎢⎣ ⎝ ro ⎠ ⎥⎦ ⎝ ro ⎠
σ o (1 + B ) ⎡ ⎛r ⎞ ⎤ ⎛r ⎞
2B 2B
∴ Drawing stress (σ d ) = ⎢1 − ⎜ f ⎟ ⎥ + ⎜ f ⎟ .σ b
B ⎢⎣ ⎝ ro ⎠ ⎥⎦ ⎝ ro ⎠
at r = ro
Extrusion Analysis (Home Work)
Extrusion Analysis (Home Work) If effect of container friction is considered
σ o (1 + B ) ⎡ ⎤
2B
⎛r ⎞
For a round bar both wire drawingg and extrusion will ggive σ xo = ⎢1 − ⎜ o ⎟⎟ ⎥ p f = ram pressure required by container friction
B ⎢ ⎜r ⎥
same equation except B.C s ⎣ ⎝ f ⎠ ⎦ τ i = uniform interface shear stress between
2
∴ Bσ x − (1 + B ) σ o = ( rC )
2B
Ao ⎛ ro ⎞ billet and container wall
Extrusion ratio,, R = = ⎜ ⎟ for round bar
Af ⎜⎝ rf ⎟⎠ 2τ i L
B.C s at r = rf , σ x = 0 (at exit stress is zero) p f .π r0 2 = 2π r0τ i L or p f =
ro
1 ⎛h ⎞
⎡ − (1 + B ) σ o ⎤⎦ 2 B =⎜ o
⎟⎟
for flat stock ∴ Total Extrusion Pressure(Pt ) = σ xo + p f
∴C = ⎣ ⎜h
⎝ f ⎠
rf and Extrusion Load = pt .π r0 2
σ o (1 + B )
σ o (1 + B ) ⎡ ⎛ ⎤ ⎞
2B σ xo = ⎣⎡1 − R ⎦⎤
2B
or σ x = ⎢1 − ⎜ r⎥ ⎟⎟
B
B ⎢ ⎝⎜ rf ⎥ ⎠
⎣ ⎦ & PSUs)
For-2019(IES, GATE Page 200 of 203 Rev.0
Page 201
d) Transform Theory
e) Numerical Methods
GATEǦ2019:Mechanical f)
g)
h)
Calculus, Gradient, Multiple Integrals
Complex Variables
Matrix Algebra
i) Fourier Series
j) Partial Derivatives
FollowingTopicsareveryimportantforGATEExamination 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
GradeǦASubjects………….morethan10revisionsarerequired e) Lathe, drilling, milling, shaping cutting time calculations, all numericals
x Mathematics (2011 By IIT Madras-13%) f) Grinding and finishing
x Production (2011 By IIT Madras-12%) g) ECM MRR, feed calculations, EDM theory, comparison of all NTMM
x SOM (2011 By IIT Madras-12%) h) NC/CNC Machine, BLU calculations, upto M & G code
i) Limit, tolerance, fit
x TOM (2011 By IIT Madras-7%)
j) Jig & Fixture, 3-2-1 principle
x Thermodynamics (2011 By IIT Madras-7%)
k) Welding: V-I Characteristics calculations, Resistance welding calculations, Special welding
x Powerplant (2011 By IIT Madras-7%) theory
x FluidMechanics&Machines (2011 By IIT Madras-5%) l) Casting: allowances, Riser Design, Sprue Design, Pouring time calculations, Special
Castings, Casting Defects.
GradeǦBSubjects………….morethan5revisionsarerequired
3.SOM
x IndustrialEngineering (2011 By IIT Madras-5%)
x HeatTransfer (2011 By IIT Madras-5%) a) Principal Stress and Principal Strain, Mohr Circle(VIMP)
b) Stress and Strain (VIMP)
x EngineeringMechanics (2011 By IIT Madras-5%)
c) Bending Moment and Shear Force Diagram (VIMP)
GradeǦCSubjects………….lessthan5revisionsarerequired d) Deflection of Beam
e) Torsion
x Design (2011 By IIT Madras-2%) f) Theories of Column (Euler method, end conditions)
x RAC (2011 By IIT Madras-1%) g) Strain Energy Method (Castigliano’s theory)
h) Theories of failure
GradeǦDSubjects………….1or2revisionsaresufficient i) Thin cylinder
j) Riveted and Welded Joint
x ICEngine (2011 By IIT Madras-2%) k) Spring
x EngineeringMaterials (2011 By IIT Madras-1%)

4. TOM
DetailedTopics a) Mechanism (VIMP)

b) Linear Vibration Analysis of Mechanical Systems (VIMP)
c) Gear train (VIMP)
1. Mathematics d) Flywheel (Coefficient of Fluctuation of speed, Coefficient of Fluctuation of energy), mass
a) Probability and Statistics calculation,
b) Eigen Values and Eigen Vectors e) Critical Speed of Shafts
c) Differential Equations f) Gyroscope
By:SKMondal(GATE99.96Percentile)EǦMail:swapan_mondal_01@yahoo.co.inPage1 By:SKMondal(GATE99.96Percentile)EǦMail:swapan_mondal_01@yahoo.co.inPage2

Page 202
5.Thermodynamics 10.EngineeringMechanics
a) Basic Concepts a) Equilibrium
b) Application of First law b) Truss
c) Entropy, Availability c) Friction
d) Pure Substance (VIMP)
e) Gases and Gas mixture
11.Design
6.Powerplant
a) Fluctuating Load Consideration for Design
a) Steam Cycle (VIMP) b) Rolling Contact Bearings, Load-life Relationship
b) Gas Cycle c) Sliding contact bearing, Modes of Lubrication, Sommerfeld Number
c) Compressor d) Clutch , Brake
7.FluidMechanics&FluidMachines
12.RAC
a) Properties of fluid
b) Pressure measurement, manometers a) Heat engine, heat pump, refrigerator (VIMP)
c) Fluid kinematics (VIMP) b) Psychrometry (VIMP)
d) Bernoulli’s Equation ( Fluid Dynamics) c) Vapour Compression Systems
e) Venturimeter
f) Flow ( Laminar and Turbulent) 13.ICEngine
g) Boundary Layer, Thermal Boundary Layer a) Gas Power Cycles (All) (VIMP)
h) Compressible Flow b) IC Engine Performances
i) Hydraulic Turbine c) Octane number, cetane number
j) Centrifugal Pump
14.Engineeringmaterials
a) Crystal structure & crystal defects
8.IndustrialEngineering
b) Iron-carbon Equilibrium diagram, TTT diagram,
a) EOQ Models (VIMP) c) Heat treatment
b) PERT & CPM (VIMP)
c) Queuing Model (VIMP)
d) Forecasting (VIMP)
e) LPP
f) Work Study & Work Measurement (standard time calculations, theriblings symbol)
g) Break even Analysis
h) The Scheduling Problem and Johnson’s Rule
i) Assembly line balancing
9.HeatTransfer
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)

Page 203
x TOM (Class note + Question set GATE,IES,IAS)

GeneralGuidelines 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)
needed to solve the question remains same. So you don’t need to remember the questions 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 GATE papers are set by Professors of IITs and they check student’s fundamentals of the x Power plant (Class note + Only 20 Years GATE Questions)
subject. So we must be prepared with fundamentals. That’s why funda is repeated. 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.
Forselfpreparingstudents
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 )
ForStudents’whoareattendingcoaching 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)

2019 Metal Cutting Metal Forming Metrology PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2019 Metal Cutting Metal Forming Metrology PDF

Uploaded by

Copyright:

Available Formats

Page 1

Metal Cutting, Metal Forming & Metrology

Section‐II: Metrology Questions Answer & Explanations

Section‐III: Metal Forming Questions Answer & Explanations

Section‐IV: Cutting Tool Materials Page‐148 Page-187

For-2019(IES, GATE & PSUs) Page 1 of 203 Rev.0

accepted as a machine tool? Independent Variables Dependent Variables

Ans. In spite of having all other major features of •Starting materials •Force or power requirements

machine tools, the sharpener is of low value. (tool/work) •Maximum temperature in b

IES‐1995 GATE‐1995; 2008 IES‐1993

IES – 2005 IES‐2015 IES – 2002

Types of Machining IAS – 1994 IES ‐ 2014

IES ‐ 2012 Chip formation

For-2019(IES, GATE & PSUs) 25

GATE‐2017(PI) A Single Point Turning Tool IES ‐ 2012

IES‐2003 IES‐2015 GATE(PI)‐1990

IAS – 1996 IAS – 1995 IES 2010

IES ‐ 2012 IES‐2009 IES‐1995

For-2019(IES, GATE & PSUs) 43

IES‐1994 IES‐2009 IES‐1993

GATE‐2001 GATE 2011 GATE‐2018

IAS 2015 Main

IES ‐ 2009 GATE (PI)‐1990

IES‐2004 IES‐2004, ISRO‐2009 IES‐2008

IES ‐ 2014 IES‐2001 IES‐2003

For-2019(IES, GATE & PSUs) 70

IAS‐2003 IAS‐2002 IAS‐2000

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

(c) Quadrupled (d) Unchanged

GATE – 2009 (PI) Common Data S‐2 Mechanism of chip formation in Mechanism of chip formation in

The chip velocity (in m/min) is

(a) 8 (b) 10 (c) 12 (d) 14

GATE‐1995 IES 2007 IES‐2015

IAS‐1997 GATE‐2002 GATE‐2009

GATE 2017 (PI)

φ= + − angle means smaller shear plane which means

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

103 104 105

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

(i) shear angle and Shear p

GATE 2008 (PI) Li k d S 2

Modified Merchant Theory IES 2010 IES‐2005

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

Fn = Fc sin φ + Ft cos φ ( ) 1079.4 N

121 122 123

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°

For-2019(IES, GATE & PSUs) 151

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

154 155 156

GATE‐2013 IES 2016

157 158 159

Power Consumed During Cutting GATE‐2018 (PI) Specific Energy Consumption

c 390 N, respectively. Assume a shear angle of 35°.

GATE(PI)‐1991 GATE‐2007 GATE‐2016 (PI)

163 164 165

For-2019(IES, GATE & PSUs) 169

IES‐2002 IES‐1998 IAS – 2003

175 176 177

181 182 183

IES‐1996 Types of Dynamometers Strain Gauge Dynamometers