PRESS TOOL QUESTIONS

SECTION-A
1. The thickness of a sheet metal ranges from
a) 5-10 mm
b) 0.6-0.8mm
c) 0.4-6mm- ANS
d) 0.5-1.5mm

2. What are the advantages of sheet metal working

a) good dimensional accuracy
b) economical mass production
c) good surface finish
d) all of these- ANS

3. The normal value of angular clearance is

a) 3.5° per side
b) 0.5° per side
c) 1.5° per side- ANS
d) 2.5° per side

4. Which of these is not a stage in the shearing action

a) fracture
b) plastic formation- ANS
c) plastic deformation
d) penetration

5. To prevent distortion on the stock material for blanking operation shear angle should be given on
a) the die member- ANS
b) the punch member
c) both punch & die
d) none of these

6. Which of the following is not a bending operation

a) seaming
b) hemming
c) flanging
d) none of these- ANS

7. Arrange the steps of a basic drawing process:

i) friction and compression
ii) bending
iii) initial contact
iv) final shape
v) straightening

a) ii,i,iii,iv,v
b) iii,ii,v,i,iv - ANS
c) i,ii,v,iii,iv
d) none of these

8. The time interval in a press cycle during which there is no movement of a press member is known as
a) dwell- ANS
b) null time
c) rest time
d) all of these

9. Forming is a
a) shearing process
b) non shearing process- ANS
c) both
d) none of these

10. A wavy condition formed in the walls of deep drawn parts

a) hemming
b) lancing
c) redrawing
d) puckering- ANS

11. The formula of cutting clearance is 0.01x T x Ts, here ‘Ts’ stands for
a) sheet thickness
b) shearing strength- ANS
c) cutting strength
d) cutting force

12. It is always preferred to bend a sheet

a) Across its grain direction
b) Opposite to its grain direction
c) along to its grain direction- ANS
d) All of these are possible.

13. When the press ram is up, blank holder underneath should be_____below the drawing punch face.
a) 8-10mm
b) 3-4mm- ANS
c) 10-12mm
d) 5-7mm

14. The stripping force is__________ of vertical shearing force.

a) 10%-ANS
b) 20%
c) 5%
d) 12-15%

15. __________ is used for shedding used strip for simplifying handling of the strip.
a) strip cutter
b) scrap cutter-ANS
c) sheet cutter
d) metal cutter

16. The spring back value increases with

a) tensile strength of the material bent
b) bend radius
c) angle of bend& material hardness
d) all of these- ANS

17. Bending force depends on

a) width of the blank
b) thickness of the blank
c) tensile strength of the blank material
d) all of these-ANS

18. Ironing reduces the thickness of the drawn component by

a) 10-15%
b) 30-35%-ANS
c) 45-50%
d) 20-25%

19. Which of the following is not a shearing process

a) notching
 b) piercing
c) beading-ANS
d) perforating

20. Thrust plate is necessary in a press tool because

a) it distributes the cutting thrust to a wider area of the top bolster
b) it prevents digging of the punch into the top bolster
c) both a) and b)-ANS
d) none of these

21. Thrust plate is not required if the pressure on the contact area do not exceeds
a) 60 N/mm2
b) 20 N/mm2
c) 100 N/mm2
d) 80 N/mm2-ANS

22. When the required blank is bigger than the fall through hole in the press table, it is necessary to use
a) progressive tool
b) compound tool
c) inverted blanking tool-ANS
d) combination tool

23. ____________ combines two cutting operations in a single stroke in a press tool.
a) combination tool
b) compound tool- ANS
c) piercing tool
d) all of these

24. this formula of developed length is applicable when

e) R> T
f) R<T
g) R<2T
h) R≥2T-ANS

25. This image depicts

a) bending across grain direction-ANS

b) bending along grain direction
c) bending above grain direction
d) bending through grain direction

26. Corrundum is a/an

a) Diamond
b) Abrasive-ANS
c) Ceramic
d) None of the above

27. The cutting tool wears due to

 a) Edge wear
b) Crater wear
c) Flank wear
d) All of the above-ANS

28. The built up edge in cutting tools can be eliminated by

a) Fast cutting speed
b) Higher rake angles
c) High pressure cutting fluid
d) All of the above-ANS

29. The cutting speed of High speed steels is ___ times faster than Carbon steel
a) 2
b) 4-ANS
c) 6
d) 8
30. Which of the following cutting tool has highest hot hardness?
a) Ceramics-ANS
b) Cast alloys
c) High speed steels
d) Carbon tool steel
31. Which of the following cutting conditions greatly affects the tool wear?
a) Cutting speed-ANS
b) Feed
c) Depth of cut
d) None of the above
32. The ascending order of evolution of materials used for making the cutting tools is
a) bronze – stone – steel – iron
b) iron – steel – bronze – stone
c) stone – bronze – iron – steel-ANS
d) bronze – stone – steel – iron
33. The materials are added to cutting tools to increase their properties. Match the following
1. Tungsten a) Hardness
2. Carbon b) Hot hardness
3. Vanadium c) Wear resistance
The correct order is

a) 1-b, 2-a, 3-c-ANS

b) 1-c, 2-a, 3-b
c) 1-b, 2-c, 3-a
d) 1-a, 2-b, 3-c
34. Which of the following is second hardest substance known?
a) Ceramics
b) Cermets
c) Cubic Boron Nitride (CBN) -ANS
d) Diamond
35. Which of the following tools are generally manufactured by Powder metallurgy?
a) Low carbon steel
b) Abrasives
c) High carbon steel
d) Cemented carbides -ANS
36. Which of the following is hardest known material?
a) Cemented carbide
b) Ceramics
c) Cubic boron nitride (CBN)
d) Diamond -ANS
37. Which of the following is not a constituent of High speed steel?
a) V
b) Cr
 c) W
d) Ni -ANS
38. In a single point turning operation with a cemented carbide and steel combination having a Taylor exponent of
0.25, if the cutting speed is halved, then the tool life will become
a) Half
b) Two times
c) Eight times
d) Sixteen times -ANS
39. A drill bit of 20mm diameter rotating at 500 rpm with a feed rate of 0.2 mm/revolution is used to drill a through
hole in Mild Steel plate of 20mm thickness. The depth of cut in this drilling operation is
a) 100 mm
b) 20 mm
c) 10 mm -ANS
d) 0.2 mm 
40. The tool life increases with the
a) Increase in side cutting edge angle -ANS
b) Decrease in side rake angle
c) Decrease in nose radius
d) Decrease in back rake angle 

SECTION-B

41. Which of the following is not a tool of grounded theory?

a. Theoretical sampling
b. Coding
c. External validity -ANS
d. Constant comparison
42. Match list I and II and select the correct answer using the codes given below the lists:

List I (Cutting tools) List II (Major constituent)

a. Stellite 1. Tungsten
b. HSS 2. Cobalt
c. Ceramic 3. Alumina
d. UCON 4. Columbium
  5. Titanium

a. a-5, b-1, c-3, d-4

b. a-2, b-1, c-4, d-3
c. a-2, b-1, c-3, d-4 -ANS
d. a-2, b-5, c-3, d-4 
43. In the Taylor’s tool life equation, VT^n = C, the value of n=0.5. The tool life has a life of 180 minutes at a cutting
speed of 18 m/min. If the tool life is reduced to 45 minutes, then the cutting speed will be
a. 9 m/min
b. 18 m/min
c. 36 m/min -ANS
d. 72 m/min
44. Match list-I (Cutting tool material) with List-II (Typical value of tool life exponent ‘n’ in the Taylor’s equation
V.T^n=C) and select the correct answer using the codes given below the lists:

List I List II
a. HSS 1. 0.18
b. Cast alloy 2. 0.12
c. Ceramic 3. 0.25
d. Sintered carbide 4. 0.5

a. a-1, b-2, c-3, d-4

b. a-2, b-1, c-3, d-4
 c. a-2, b-1, c-4, d-3 -ANS
d. a-1, b-2, c-4, d-3 
45. The cutting velocity in m/sec, for turning a work piece of diameter 100 mm at the spindle speed of 480 rpm is
a. 1.26
b. 2.51 -ANS
c. 48
d. 151 
46. Which of the following tool materials have cobalt as a constituent element?

1. Tungsten carbide          2. CBN         3. Stellite       4. UCON

Select the correct answer using the codes given below

a. 1 & 2
b. 1 & 3 -ANS
c. 1 & 4
d. 2 & 3 
47. The approximately variation of the tool life exponent ‘n’ of cemented carbide tools is
a. 0.03 to 0.08
b. 0.08 to 0.20
c. 0.20 to 0.48 -ANS
d. 0.48 to 0.70
48. The coating materials for coated carbide tools, include
a. TiC, TiN and NaCN
b. TiC and TiN -ANS
c. TiN and NaCN
d. TiC and NaCN
49. Consider the following cutting tool materials used for metal-cutting operation at high speed:

1. Tungsten carbide
2. Cemented titanium carbide
3. High speed steel
4. Ceramet

The correct sequence in increasing order of the range of cutting speeds for optimum use of these materials is

a. 3, 1, 4, 2
b. 1, 3, 2, 4
c. 3, 1, 2, 4 -ANS
d. 1, 3, 4, 2 
50. Match List-I (Cutting tool materials) and List-II (Fabrication processes) and select the correct answer using the
codes given below the lists:

List I List II
a. HSS 1. Casting
b. Stellite 2. Powder metallurgy
c. Carbide 3. Forging
d. UCON 4. Extrusion
  5. Rolling

a. a-3, b-1, c-2, d-4

b. a-1, b-5, c-3, d-4
c. a-2, b-4, c-3, d-5
d. a-3, b-1, c-2, d-5 -ANS
51. Which one of the following grinding wheels (with grade, grit and bond) is suitable for cutter grinding?
a. K 60 vitrified -ANS
b. K 320 vitrified
c. T 60 resinoid
 d. T 320 resinoid 
52. Using the Taylor equation VT^n=c, calculate the percentage increase in tool life when the cutting speed is reduced
is reduced by 50% (n=0.5 and c=400)
a. 300%
b. 400% -ANS
c. 100%
d. 50% 
53. Match List-I (Alloying elements for tool steel) with List-II (Improved mechanical property) and select the correct
answer using the codes given below the lists:

List I List II
a. Carbon 1. Hardness
b. Manganese 2. Hot Hardness
c. Chromium 3. Low critical Temperature
d. Vanadium 4. Toughness

a. a-1, b-3, c-4, d-2

b. a-2, b-4, c-3, d-1 -ANS
c. a-1, b-4, c-3, d-2
d. a-2, b-3, c-4, d-1 
54. Consider the following actions:

1. Mechanical abrasion
2. Diffusion
3. Plastic deformation
4. Oxidation

Which of the above are the causes of tool wear?

a. 2 & 3
b. 1 & 2
c. 1, 2 & 4 -ANS
d. 1 & 3 
55. Match List-I (Material) with List-II (Related Cutting Speed in m/min) and select the correct answer using the
codes given below the lists:

List I (Material) List II (Related cutting speed in m/min)

a. Plastics 1. 305
b. Cast Iron (medium) 2. 15
c. Stainless steel 3. 20-30
d. Aluminium 4. 450
  5. 220

a. a-1, b-3, c-2, d-4

b. a-4, b-2, c-5, d-1
c. a-1, b-2, c-5, d-4 -ANS
d. a-4, b-3, c-2, d-1 
56. Tool material not suited to resistance welding is
a. Aluminium oxide
b. Stellite -ANS
c. High speed steel
d. Masonite 
57. Consider the following statements:

Chipping of a cutting tool is due to

1. Tool material being too brittle

2. Hot hardness of the tool material
 3. High positive rake angle of the tool

Which of these statements are correct?

a. 1, 2 & 3
b. 1 & 3 -ANS
c. 2 & 3
d. 1 & 2 
58. A milling cutter of 70 mm diameter with 12 teeth is operating at a cutting speed of 22 m/min and a feed of 0.05
mm/tooth. The feed rate per minute is
a. 110 mm/min
b. 35 mm/min
c. 6 mm/min
d. 60 mm/min
59. Which of the following is a press tool operation?
a. Blanking
b. Piercing
c. Deep drawing
d. All of the above -ANS

60. Bulging involves local deformation to

a. Increase the size of a part of a drawn cup -ANS
b. Decrease the size of a part of a drawn cup
c. For the hardening of the materials
d. For the softening of the materials

61. Shaving is used to

a. Finish the blank/holes to high surface finish. -ANS
b. Making a component as per customers requirement
c. Decrease the size of the drawn cups.
d. For considerable metal distribution

62. Maximum clearance between die and punch per side is

a. 0.01mm
b. 0.015mm -ANS
c. 0.020mm
d. 0.030mm

63. The minimum radius to which a blank can be bend without cracking depends upon the
a. Material and its hardness
b. Direction of rolling
c. Both a and b -ANS
d. Grain direction

64. The plane (layer) which is neither compressed nor stretched is called neutral plane.
a. true -ANS
b. false

65. What causes spring back?

a. tensile stress (toughness)
b. bend radius
c. bend angle
d. all of the above -ANS
66. What is the hardness of cutting punches & dies in a press tool?
a) 60-64HRC
b) 48-52HRC
c) 58-62HRC -ANS
d) 50-54HRC
67. What is the advantage of using presstool?
a) High productivity
 b) Use of unskilled labour
c) High degree of possible precision can be achieved
d) All of the above -ANS
68. What do you mean by SDAU?
a) Slide down adjustment up -ANS
b) Stroke down adjustment up
c) Shank down adjustment up
d) None of these
69. The cutting force is depend upon
a) Material of the sheet
b) Thickness of the sheet
c) The length is to be cut
d) All of the above -ANS
D
70. The formula for drawing force is Vd=π dT [ d ]
−0.6 f y
a) true
b) false -ANS
71. Which of the methods by which we can overcome springback?
a) corner setting
b) over bending
c) both a and b -ANS
d) none of the above
72. The distance between top of the top plate and bottom of the bottom plate after the stroke has finished is called die
shut height.
a) True -ANS
b) False
73. The increase in die clearance
a) increases tool life -ANS
b) decreases tool life
c) does not effects its utilization
d) doubles its tool life
74. Tool shut height must be kept ________ than the press shut height
a) Lesser -ANS
b) More
c) Equal
d) both a and c
75. Why stepped punches are provided?
a) To increase the pressure on the punch
b) To reduce back pressure on the punch -ANS
c) for optimum tool shut height
d) for height adjustment
76. Design of a press tool involves
a) determination of force
b) Selection of press for requisite force
c) determination of shut height of tool
d) All of the above -ANS
77. Progressive tool combines a number of press tools into a single long tool producing one finish component per
stroke.
a) True -ANS
b) False
78. The other use of stripper plate is to
a) Support and guide the punches -ANS
b) Guides the strip.
c) both a & b
d) none of these
79. What is an idle station ?
a) where there is no punch only die -ANS
 b) where there is no profile on the die
c) both a& b
d) none of these
80. What are the effects of high cutting clearances between die and punch?
a) More formation of burrs. -ANS
b) Less formation of burrs.
c) no effect
d) none of these

SECTION- C
81. Why stepped punches are provided?
a) cheaper compared to other punches
b) helps in locating holes for the sequensive operation
c) both a & b -ANS
d) none of these
82. What is piercing?
a) The cut out material or slug will be the component.
b) The cut out material will be waste. -ANS
c) Double line cutting material in between the line.
d) None of these.
83. What is cutting off?
a) Process of making opening on sheet metal.
b) Material is going to cut in a single line, there won’t be any waste. -ANS
c) Double line cutting material in between the line
d) None of these.
84. What is extrusion?
a) Operation to produce collapsible tubes, shell etc. -ANS
b) External forming operation.
c) Internal forming operation to expand portions.
d) Process of making cup or vessel.
85. What is bulging?
a) Rolling the edge of sheet metals.
b) Removing small amount of material from the previously blanked part.
c) Internal forming operation to expand portions. -ANS
d) Removing large amount of material from the edge of the piece part.
86. What is perforating?
a) Making no. of holes at a time. -ANS
b) The cut out material or slug will be the component.
c) External forming operation.
d) None of these
87. What is lancing?
a) Series of teeth profile removes metal from blanked part.
b) Combination of cutting and bending. -ANS
c) Removing large amount of material from the edge of the piece part.
d) Removing small amount of material from the previously blanked part.
88. What is forming?
a) Process of making cup or vessel.
b) Rolling the edge of sheet metals.
c) Non cutting operations in which material is formed into different shapes. -ANS
d) Shaping of material around straight line axis.
89. What is clinking?
a) Cutting operation for soft materials like paper, leather, wood etc. -ANS
b) Series of teeth profile removes metal from blanked part.
c) Process of making cup or vessel.
d) Internal forming operation to expand portions.
90. Normal stripping force is?
a) 10 to 20% of cutting force. -ANS
b) 30 to 40% of cutting force.
c) 5 to 8% of cutting force.
d) None of these.
91. What is tensile load?
a) Load which is acting on same direction but not in same axis.
b) Force acting on opposite direction in same axis. -ANS
c) Load acting on a material per unit area.
d) All of these.
92. What is the equation to calculate press force?
a) Press force =10 to 20 %of cutting force.
b) Press force = load /area.
c) Press force = cutting force + stripping force. -ANS
d) None of these.
93. What is compressive load?
a) Forces acting on same direction in same axis. -ANS
b) Force acting on opposite direction in same axis.
c) Load which is acting on same direction but not in same axis.
d) None of these.
94. What is shear load?
a) Forces acting on same direction in same axis.
b) Force acting on opposite direction in same axis.
c) Load which is acting on same direction but not in same axis. -ANS
d) None of these.
95. Result of optimum cutting clearance will be................................?
a) Maximum cut band. -ANS
b) Maximum break edge.
c) Maximum edge radius.
d) None of these.
96. Result of excessive cutting clearance will be................................?
a) Maximum cut band.
b) Maximum break edge.
c) Maximum edge radius. -ANS
d) None of these.
97. Result of insufficient cutting clearance will be................................?
a) Maximum cut band.
b) Maximum break edge. -ANS
c) Maximum edge radius.
d) None of these.
98. What is the shear strength?
a) Maximum force due to torsion and compression. -ANS
b) Ability of material to resist shear stress.
c) Maximum amount of force can be given on.
d) None of these.
99. For blanking cutting clearance is provided on?
a) Punch. -ANS
b) Die inserts.
c) Punch plate.
d) All of these
100.Punch determines………………… and Die determines…………………….
a) Piercing size & Blanking size. -ANS
b) Blanking size & Piercing size.
c) Both (a) and (b) are correct.
d) None of these.