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Me6402 PIT - QB-with Two Marks
Me6402 PIT - QB-with Two Marks
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9. Briefly explain the effect of rake angle during cutting?
10. How do you classify tool wear?
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11. What are the factors responsible for built-up edge in cutting tools?
12. What is electrochemical wear in tools?
13. List out the essential characteristics of a cutting fluid.
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14. Name the various cutting tool materials.
15. Give two examples of orthogonal cutting.
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16. What arte the four important characteristics of materials used for cutting tools?
17. What is the function of chip breakers?
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18. Name the factors that contribute to poor surface finish in cutting.
19. When will be the negative rake angles are used?
22. Why is neither lubrication nor required while machining cast iron? rin
23. What is meant by buildup edge?
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24. What are the advantages of diamond tools?
25. How is metal removed in metal cutting?
PART-B
1. a)Discuss about orthogonal cutting?
b) Explain various cutting tool materials?
2. In an orthogonal cutting operation on a work piece of width 2.5mm, the uncut chip thickness was
0.25mm and the tool rake angle was zero degree. It was observed that the chip thickness was
1.25mm.The cutting force was measured to be 900N and the thrust force was found to be 810 N.
(a) Find the shear angle.
(b) If the coefficient of friction between the chip and the tool was 0.5, what is the machining
constant Cm?
3. What is a chip Describe the different types of chips produced during metal machining with neat
sketches?
6. List the various tool materials used in industry. State the optimum temperature of each of the tool
materials.
7. The Taylor tool life equation for machining C-40 steel with a HSS cutting tool at a feed of
0.2mm/min and a depth of cut of 2mm is given by VTn= C, Where n and C are constants. The
following V and T observations have been noted V , m/min 25,35 T , min 90,20 Calculate (1) n and
C (2) Hence recommend the cutting speed for a desired tool life of 60min.
8. a)State the parameters that influence the life of tool and discuss?
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9. Explain “merchant force circle” along with assumptions.
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10. Explain the geometry of a single point t cutting tool with suitable sketches?
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12. What is orthogonal rake system? Show the ORS of the tool analysis with the help of a sketch.
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13. What is the use of chip breaker? Discuss the various types of chips produced during metal
machining process.
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14. Explain the conditions that promote the formation of the following types of chip
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a) Continuous chips without buildup edge.
(b) Continuous chip with buildup edge.
(c) Discontinuous chips.
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15. What are the standard angles of cutting tool? Illustrate with an example.
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16. Describe an expression for the determination of shear angle in orthogonal metal cutting.
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22. Mention any four shaper specifications?
23. What is center gauge that is used in threading?
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24. What are programmed automatic lathes?
25. What is the purpose of tumbled gear mechanism of a lathe?
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1.
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a) Explain the various taper turning methods?
b) Discuss about special attachments of lathe.
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c) Describe the turret indexing mechanism.
2.
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a)Discuss about the bar feed mechanism.
b) Describe the holding devices in a lathe
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3. Explain the following with a neat sketch
(i) Taper turning by swiveling the compound rest
(ii) Taper turning attachment method
(iii) Taper turning with tail stock set over method.
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4. Mention the specifications of lathe with a neat sketch.
5. Calculate the change gears to cut a single start thread M16 of 2mm pitch on a Centre lathe, having
a lead screw of 6mm pitch. Calculate the depth of cut and number of passes preferred.(A typical set
contains the following change gears with number of teeth : 20,25,30,35,40,45,50,55,60,65and 70 .
6. Draw neat sketches of steady and follower rests and brief their applications.
8. Explain the working of Swiss type auto lathe with a neat sketch
10. a)Discuss the features of ram type and saddle type Turret.
b) Explain the feature of multi- spindle automatics.
11. Describe some of the methods and equipment’s for holding work on a lathe.
12. Briefly explain the principle of working of the sliding head type single spindle automatic
Machine
ww b) Calculate the time taken for one complete cut on a work piece of 500mm long and 50mm
diameter. The cutting speed is 30m/min and the feed rate is 0.5mm/rev.
14.w.E a)Describe the working principle of multi spindle automatics. Give its advantages and
application.
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b) Explain the construction and working principle of a lathe with a sketch.
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15. What is lathe carriage? Explain the various parts of a lathe carriage with a neat diagram. .
Enumerate the purpose of various attachments used on a center lathe.
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16. What is a Swiss- type automatic screw machine? How it functions and what are its main
applications?
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UNIT – III: SHAPER, MILLING AND GEAR CUTTING MACHINES rin
PART-A g.n
1. Mention the differences between shaper and planer.
2. What are the differences between drilling and reaming?
3. Briefly describe the importance of quill mechanism.
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4. Define the cutting speed, feed and machining time for drilling.
5. What is the difference between up milling and down milling?
6. How do you classify milling cutters?
7. What do you know about straight fluted drill and fluted drill?
8. What is meant by up milling and down milling?
9. State the differences between a vertical shaper and slotters.
10. Write the differences between drilling and tapping.
11. What are the common work holding devices used on milling machines?
12. What is a shell mill?
13. Give the functions of flutes on taps.
14. List some of the materials of broaching tools.
15. How are work piece held in shaper?
16. What are the various types of end mills used in milling?
17. What is the difference between a plain milling machine and a universal milling machine?
18. What is gear hobbing?
PART-B
1. a)Explain various milling cutters with neat sketches?
b) Discuss various hole making processes.
2. a)Write short notes on gear forming.
b) Write short notes on gear shaping &. List the advantages and limitations of gear shaping
4. With a neat sketch explain the column and knee type milling machine and name its main parts.
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5. With a line diagram, describe the construction of radial drilling machine.
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6. Sketch and explain the hydraulic drive of a horizontal shaper.
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7. How will you cut the following types of surfaces on milling machines?
(a) Flat surfaces (b) Slots and splines
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8. Sketch the Quill mechanism .write its main parts and their functions?
10.
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9. Describe gear cutting by forming and shaping.
11. Discuss the common work holding devices used in shapers, slotters and planners.
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12. With simple sketches explain the features of the major elements of twist drill.
PART-A
1. What are the specifications of grinding wheel?
2. What is honing?
3. Narrate the working principle of abrasive jet machining.
4. What is broaching?
5. What are the specifications of grinding wheel?
6. What is honing?
7. Narrate the working principle of abrasive jet machining.
8. What is gear super finishing?
9. Define hardness of the grinding wheel.
10. Define lapping.
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11. What is meant by “grade” and “structure” of a grinding wheel?
12. What are all the parameters that would affect the MRR in abrasive jet machining?
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13. Mention four important factors that influence the selection of grinding wheel.
14. What is roller burnishing process?
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15. State the abrasives used in manufacture of grinding wheels.
16. What are the types of surfaces that can be produced using plain cylindrical grinders?
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17. What do you mean by loading of grinding wheels?
18. Name two artificial abrasive materials
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19. Distinguish between the polishing and buffing process
20. List the some of the materials of broaching tools.
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24. List the gear generating process
25. Write any four applications of Abrasive jet machining g.n
26. List four applications of broaching machines.
27. Define broaching. et
PART-B
1. Explain the working mechanism of cylindrical and surface grinding.
2. Explain the working principle and various methods of Centre less grinding with a neat sketch.
3. Discuss the various bonding materials used for making grinding wheels
4. Sketch and explain the three methods of external cylindrical Centre less grinding
7. Explain the salient features of a center less grinding machine and discuss different operations that
can be carried in it. Mention some advantages.
8. Briefly discuss about the different types of abrasives used in a grinding wheel.
9. Explain the gear shaving, gear honing and gear lapping processes.
13. With the help of a neat sketch, discuss the working of a surface broaching machine.
14. Discuss various types of broaches. Give out their advantages and disadvantages.
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1. List the differences between NC and CNC.
2. What are linear bearings?
3. Mention the type of ball screws.
4. What are feed drives?
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5. What are the types of motion control system used in NC machines?
6. What is meant by APT language?
En
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7. Compare a closed loop NC system with open loop system.
8. What is a preparatory function? How is it important in CNC programming?
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12. Name the major elements of NC machines.
13. Name the major elements of CNC machines.
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14. What are the classifications of NC machines?
15. What is the difference between incremental and absolute system
16. What is the role of computer for NC machine tool?
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17. What is point –to – point (PTP) system?
18. What are G-Codes and M-Codes? Give examples.
19. List the commonly used coordinate systems of CNC machine tools.
20. Write down the types of statements in APT language.
21. List the main elements of a NC machine tool
22. What do you understand by „canned cycle‟ in manual part programming?
23. Mention the advantages of stepping motor
24. Define subroutine
25. With reference to CNC manual part programming, state what is linear interpolation?
26. A stepping motor of 200 steps per revolution is mounted on the lead-screw of a NC machine
table. The pitch of the screw is 2.5mm/rev. if the stepping motor receives pulses at a frequency of
2000 Hz, What is the linear speed of the table?
PART-B
1. a)Narrate the design considerations of CNC machines.
b) Discuss about slide ways used in CNC machine tools.
c) Describe the spindle drives used in CNC machine tools.
2. List the difference between manual and computer assisted part programming.
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6. Write the part program for drilling holes in the part shown below. The plate thickness is 20mm.
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7. Under what conditions of production the numerically controlled machine tools are employed.
8. Explain the various elements of NC machine with closed loop control system.
9. a)Explain the main difference between point to point and continuous path of numerically
controlled machine tools.
b) List any five motions and control statements of computer assisted NC programming and
explain.
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14. a)Define CNC and DNC. With a help of a diagram explain the working of NC machine tool.
b) How is manual programming of a NC machine done?
15.
w.E c) Describe in brief basic components of a tape operated NC machine tool.
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b) State a few typical applications where the use of numerical control would be justified.
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Compiled by,
C.VELMURUGAN - M.E
Assistant Professor / Mechanical Engineering
Chennai-123.
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methods, special attachments, machining time and power estimation. Capstan and turret lathes- tool
layout – automatic lathes: semi-automatic – single spindle: Swiss type, automatic screw type – multi
Spindle:
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UNIT III SHAPER, MILLING AND GEAR CUTTING MACHINES 9
Shaper - Types of operations. Drilling, reaming, boring, and Tapping. Milling operations - types of milling
cutter, Gear cutting – forming and generation principle and construction of gear milling, hobbing and
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gear shaping processes –finishing of gears
UNIT IV ABRASIVE PROCESS AND BROACHING 9
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Abrasive processes: grinding wheel – specifications and selection, types of grinding process– cylindrical
grinding, surface grinding, Centre less grinding and internal grinding- Typical applications – concepts of
broaching machines
UNIT V CNC MACHINING gin
surface integrity, broaching machines: broach construction – push, pull, surface and continuous
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Numerical Control (NC) machine tools – CNC types, constructional details, special features, machining
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center, part programming fundamentals CNC – manual part programming – micromachining – wafer
machining
OUTCOMES:
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TOTAL: 45 PERIODS
Upon completion of this course, the students can able to understand and compare the functions
machining.
TEXT BOOKS
1. Hajra Choudhury, "Elements of Workshop Technology", Vol.II., Media Promoters
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and applications of different metal cutting tools and also demonstrate the programming in CNC
2. Rao. P.N Manufa turing Te hnology - Metal Cutting and Machine Tools", Tata McGraw-Hill,
New Delhi, 2003.
REFERENCES:
1. Ri herd R Ki e, John E. Neely, Roland O. Merges and Warren J.White Ma hine Tool Pra ti es ,
Prentice Hall of India, 1998
3. Geofrey Boothroyd, "Fundamentals of Metal Machining and Machine Tools", Mc Graw Hill, 1984
4. Roy. A.Lind erg, Pro ess and Materials of Manufa ture, Fourth Edition, PHI/Pearson
Education 2006.
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3. What is tool signature?
The various angles of tools are mentioned in a numerical number in particular
order. That order is known as tool signature.
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4. What is effect of back rake angle &mention the types?
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Back rake angle of tool is increases the strength of cutting tool& cutting action. It
can be classified in to two types
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1. Positive rake angle
2. Negative rake angle
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5. What is side rake angle & mention its effects?
6. What are all the conditions for using positive rake angle? rin
g.n
1. To machine the work hardened material 3. To machine low strength ferrous/non-ferrous metals
2. To turn the long shaft of small diameter 4. Small machine with low power capacity
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Machinability index I= Cutting speed of metal investigated for 20 minute tool life
Cutting speed of standard steel for 20 minutes tool life
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15. How tool life is defined?
Tool life is defined as time elapsed between two consecutive tools re-
sharpening. During this period tools serves effectively and efficiently.
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16. What are the factors affecting tool life?
1. Cutting speed
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2. Feed & depth of cut
3. Tool geometry
4. Tool material gin
Tailors tool life equation:
VTn=C
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17. Express the tailor's tool life equation?
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V=Cutting speed in m/min
T=Tool life in minutes g.n
C=Constant
n=Index depends upon tool & work. et
18. What is the function of cutting fluids?
1. It is used to cool the cutting tool & the work piece.
2. It improves the surface finish as stated earlier.
3. It causes the chips to break up into small parts.
4. It protects the finish surface from corrosion.
5. It prevents the corrosion of work & machine.
Orthogonal cutting
The cutting edge of the tool is perpendicular to the cutting velocity vector. The chip flows over the
tool face and the direction of chip-flow velocity is normal to the cutting edge. The cutting edge
clears the width of the work piece on either ends. (i.e. No side flow) The maximum chip thickness
occurs at its middle.
Oblique cutting
The cutting edge is inclined at an acute angle with normal to the cutting velocity vector. The chip
flows on the tool face making an angle with the normal on the cutting edge. The cutting edge may or
may not clear the width of the work piece. The maximum chip thickness may not occur at the
middle.
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22. Name any four tools material?
i. Carbon tool steel
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iv. Ceramics
v. Diamonds
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23. What are the factors should be considered for selection of tool materials?
i. Volume of production
ii. Tool design
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iii. Type of machining process
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iv. Physical & Chemical properties
v. Rigidity and condition of machine.
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24. What are the ways of representing tool life?
The following are some of the ways of expressing tool life.
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1. Volume of metal removed per grind,
2. Number of work piece machined per grind,
3. Time unit.
26. What are the assumptions made in lee and Shaffer's theory?
a. The work ahead of the tool behaves as ideal plastic mass
b. There exists a shear plane which separates the chip and work piece
c. No hardening in chip occurs
27. What are the cuttings forces acting on the cutting tool?
During the cutting process, the following three component of cutting forces acting mutually at right
angles
a. Feed force Fx acts in a horizontal plane, but in the Direction opposite to feed.
b. Thrust force Fy acts in a direction perpendicular to the generated surface.
c. Cutting force Fz in the direction of the main cutting motion
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4. Chip does not flow to either side
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31. Define the following: cutting ratio, Lip angle
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Cutting ratio: The ratio of depth of cut to the thickness of the chip after cutting
Lip angle: The angle between tool face and the ground end surface of the flank
4. Cutting oils
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5. Gaseous fluids
1. What is a lathe?
Lathe is a machine, which removes the metal from a piece of work to the
required shape &size
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4. What are the types of headstock?
Back geared type, all geared type
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5. State the various parts mounted on the carriage?
Saddle, compound rest, cross slide, tool post
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6. What are the four types of tool post?
1. Single screw
2. Open side
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3. Four bolt
4. Four way
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7. What is an apron?
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The integral part of several gears, levers clutches mounted with the saddle for
moving the carriage along with lead screw while thread cutting
16. State any two specifications of capstan lathe & turret lathe?
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1. Number of spindle speed
2. Number of feeds for the turret or saddle
En
17. Compare the advantage of capstan lathe & turret lathe?
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1. Heavier & larger work piece chucking can be done
2. More rigid hence it withstand heavy cuts
21. What are the components that can be turned on a copying lathe?
1. Camshaft
2. Crank shat
3. Journal bearings
25. State the purpose of providing lead cam in single automatic screw cutting machine?
The turret slide travel is controlled by a lead cam gives a slow forward and fast return
movement to slide.
26. Mention the applications of single spindle automatic screw cutting machine.
ww It is used for producing small jobs, screws, stepped pins, pins, bolts etc.
w.E The advantage of a sliding head automatic lathe is that long, slender work pieces can be
machined with very good surface finish, accuracy and concentricity in sliding head automatic
lathes.
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28. What are the four major parts of Swiss type automatic lathes?
En
1. Sliding headstock
2. Cam shaft
3. Tool bracket
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4. Auxiliary attachments
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29. State the advantages of Swiss type screw cutting machine
1. Wide range of speed
2. Rigid construction rin
3. Micrometer tool setting
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4. Simple design of cams & 5. Tolerance : 0.005-0.0125mm
36. What are three types of rotary systems in rotary indexing transfer machines?
1. The machining heads located outside and around a circular table and operates
at its periphery.
2. The heads are fixed around a central column of the machine and operate the
components located on the table below them.
ww 3. The components are carried on platens, which are fixed on a drum rotating on
a horizontal axis, and machine heads operate from the sides.
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37. State the advantages of rotary transfer machines
1. A rotary transfer machine is very compact.
2. It is used in presses for peening over rivets, nut running heads for assembling nuts to screws
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3. Electric brazing heads for assembly.
En
38. What are the, different machining operations performed on in-line transfer machines?
Machining operations at each station are tapping, reaming, boring, counter boring,
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chamfering, countersinking, milling and grooving.
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40. Describe tumbler gear mechanism
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It is a feed mechanism which is used to give the desired direction for the feed shaft. It
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moves carriage via lead screw, in forward, neutral and reverse.
42. Write the following: Eccentric turning, taper boring and grinding
Eccentric turning: A cylindrical work piece has two separate axis of rotation. One being out of
centre to the other, the work piece is termed as eccentric and turning of different surface of the work
piece is known as eccentric turning
Taper Boring: It is similar to the external taper turning operation and is accomplished by rotating
the work on a chuck or a face plate and feeding the tool at an angle to the axis of rotation of the work
piece.
Grinding: It is the operation of removing metal in the form of minute chips by feeding the work
against a rotating abrasive wheel known as grinding wheel.
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In planner-the work reciprocate while the tool is stationary. In shaper-the tool reciprocate
while the work is stationary
drill
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Drilling is the process of producing hole on the work piece by using a rotating cutter called
10. List any four machining operations that can be performed on a drilling machine?
1. Drilling
2. Counter sinking
3. Tapping
4. Trepanning
11. What are the different ways to mount the drilling tool?
1. Fitting directly in the spindle
2. By using a sleeve
3. By using a socket
4. By means of chucks
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16. What is counter boring?
It is used to enlarge the end of the hole cylindrically and the enlarge hole forms the
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square shoulders with original hole. .
17. List the types of drill.
1. Flat or spade drill
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2. Straight fluted drill.
3. Two lip twist drill
4. Centre drill.
18. What is the advantage of flute? En
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The flute is the helical groove. It is used to remove the chip through the helical groove
and the cutting fluid will enter through the flute surface.
24. What are the parts used in the column and knee type milling machine?
1. Base 2.Column 3. Knee 4.Table 5.Over hanging arm 6.Front brace 7.Arbour
It is the operation of dividing the periphery of a work piece into any number of equal parts.
In cutting spur gears, equal spacing of teeth on the blank is performed by indexing.
A bevel gear is one in which the tooth are cut so that they radius from the apex of a cone
and lie on the conical surface.
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w.E The milling cutter may be made of high speed steel, super high speed steel, non-ferrous cast
alloys or cemented carbide tipped.
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29. Name the various milling processes
1. Peripheral milling
2. Face milling En
3. End milling
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4. Down milling and
5. up milling ee
30. What are the specifications of the milling machine? rin
1. The table length &width.
2. Number of spindle speeds &feeds. g.n
3. Power of driving motor.
32. State any two comparisons between plain &universal milling machine?
1. In plain milling machine the table is provided with three movements, longitudinal,
Cross & vertical. In universal milling machine in addition to these three movements, there is a forth
movement to the table. The table can be swiveled horizontally & can be fed at angles to the milling
machine spindle.
2. The universal milling machine is provided with auxiliaries such as dividing head,
vertical milling attachment, rotary table etc. Hence it is possible to make spiral, bevel gears, twist
drills, reamers etc on universal milling machine.
ww 1. Cutter with higher rake angle can be used. This reduces power requirements.
2. Cutter wear is less because chip thickness is maximum at the start of cut.
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38. List out the various milling operations?
1. Plain or slab milling. 4. Face milling.
2. Angular milling.
3. End milling.
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6. Gear cutting.
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40. What are the three types dividing heads?
1. Plain or simple. 2. Universal. 3. Optical.
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dividing head & a vertical milling attachment.
43. What are the other forming methods for manufacturing gears?
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1. Gear cutting by single point form tool.
2. Gear cutting by shear speed shaping process.
3. Gear broaching.
4. Template method.
5. Gear milling using a formed end mill.
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50. What are the purposes of gear grinding process?
1. To improve the surface Finish of teeth.
2. To increase the accuracy of the teeth.
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52. Write the formula for calculating index change gears in gear Hobbing?
For Index change gear:
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Driving Teeth - Indexing constant X Number of teeth of hob Driven Teeth Number
of teeth to be cut.
56. Give any three differences between gear hobbing and gear milling?
Gear Hobbing:
a) Hob operates on several teeth at a time.
b) It is not necessary to disengage cutter and work before indexing.
c) Gear hobbing is faster process than gear milling.
Gear Milling:
a) Milling machine can cut only one tooth at a time.
b) It requires cutter and work to get disengaged before indexing can occur.
c) It is slower process compared to gear hobbing process.
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En
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3. What are the specifications of grinding wheel?
o Type of bond
o Grit or grain size
o Grade
o Structure
o Abrasive
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o Manufacturer’s Code
Structure denotes the spacing between the abrasive grains or in other words the density of the
wheel.
5. What is meant by dressing &truing?
The process of loading & breaking away the glazed surface so that, new sharp abrasive
particles are again present to work for efficient cutting is called dressing.
Truing is a process of trimming the cutting surface of the wheel to run true with the axis.
9. What is broaching?
Broaching is a process of machining a surface with a special multipoint cutting tool called
broach which has successfully higher cutting edges in a fixed path
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11. What are the advantages and limitation of broaching?
Advantages:
1. Roughing, semi finishing & finishing cuts are completed in one pass of the broach
w.E 2. Broaching can be used for either external or internal surface finish
Limitation:
1. High initial cost of the broach tool compare to other tools
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2. Job work or batch work is not advisable due to the high tool cost..
En
12. What are the different operations that can be performed on a broaching machine?
1. Broaching splines
2. Broaching a key way
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13. Give some applications of broaching.
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By internal broaching, splined holes, key ways internal gear serration, square and
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hexagonal holes and holes with different shapes are broached. By surface broaching, flat surface
and surface different contour, external splines.
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broach comes under tensile load. So it is not bending during machining. So the broach can be made
longer. Also, more amount of material can be easily removed by the broach.
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20. Name some broaching operations.
The broaching operations are
1. Surface broaching
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2. Hole broaching
3. Key way broaching
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4. Spline broaching
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21. List the various parts of pull type broach.
The various parts of pull type broach are
1) Pull end
5) Rear pilot 6) Land
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2) Front pilot 3) Roughing and semi finishing teeth 4) Finishing teeth
7) Clearance angle 8) Rake (or) face angle 9) Pitch
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22. Give a summary of the abrasive of their application for different operation?
ABRASSIVE APPLICATION
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(1) Aluminum Cleaning, Cutting and Deburring
(2) Silicon Carbide. Faster cleaning, Cutting.
(3) Glass Heads Matt polishing, cleaning
(4) Rushed glass Peening and cleaning.
1. Define NC machine
Numerical control machine cane be defined as a form of programmable machine in which
the process are controlled by a program of numbers, letters, and symbols.
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7. Mention the main difference between CNC and DNC
CNC system can do operations on only one machine at a time. But Direct Numerical
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control involves that at a time a large central computer to direct the operations of a number
of separate NC machines.
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8. State any four applications of CNC.
1. Welding machines
En
2. Press working machine tools
3. Assembly machines
4. Inspection machines
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b) Bridge construction
c) Column construction
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9. State the various types of CMM in practical applications.
a) Cantilever construction
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d) Gantry construction
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10. List the methods of creating part programming.
a) Manual part programming
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b) Computer-assisted part programming (CAD/CAM based programming system)
c) Manual data input
d) Computer automated part programming
11. What are the data essentially needed to prepare a part program?
1. Job dimension/work piece
2. Work holding (damping, chucking)
3. Feed /Cutting speed
4. Finished dimension with tolerance
5. Sequence of operation
6. Types of tools
7. Mounting of tools.
12. Define absolute and incremental programming.
In absolute programming the distance at any point at any instant will be from the
origin(X=0, Y=0) whereas in incremental programming the instant point will be noted as
(X=0, Y=0). Further measurement will be made from the particular point only.
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16. What is FTP NC?
The objective of machine tool control system to move the cutting tool to a predefined
location.
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17. What do you mean by machining center?
The machining center in a control machines is an automatic tool changing arrangement that is
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designed to perform a variety of machining operations, with large number of cutting tools and provided
with a continuous path CNC system.
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18. Where is the common path contouring used?
Common path contouring is used in grinding machine and routes.
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program into computer language.
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one of the above operation is required.
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Feed motor; DC Servo Motor, AC Servo Motor and Stepper Motor
Compiled by,
K.ELAVARASAN – B.E, M.Tech
Chennai – 123
Additional Questions
1. Comparison of single spindle and multi spindle automatic lathes (Any 4-Points)
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Capstan lathe
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2. Comparison between the capstan and turret lathe. (Any 4-Points)
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Turret lathe
Maximum size of bar that a capstan lathe Turret lathes are capable of turning bars
can accommodate is 60 mm in diameter. 125 to 200 mm in diameter and absorbing
up to 50h.p. in the main drive.
Capstan lathes are suitable for bar work. Larger and heavier chucking works are
usually handled on a turret lathe.
In capstan lathe hand feeding is easy as the In case of turret lathe hand feeding is a
hexagonal turret can be moved forth and laborious process due to the movement of
back more rapidly without moving saddle the entire saddle unit.
unit.
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Difference between gear shaping and gear hobbing
Gear tooth is cut one by one All teeth of gear are cut simultaneously till the
1.
completion of process
2. Accuracy is good but it is a slow process Accuracy is good and the process is fast
Only spur and bevel gears can be cut. Worm All type of gears such as spur, helical and worm
3.
gears cannot be cut gears can be cut
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1.
Size, thickness and mass of
features
Large size Small size
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2. Use of wafers Used on both sides Used on one side
3.
Vertical dimensions
4.
Wafer bonding
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bonding
6.
Critically
process
towards end of
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Thinned wafers may be fragile Utmost
required
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structure
cleanliness
to protect
is
the
Metal cutting or machining is the process of by removing unwanted material from a block of
metal in the form of chips.
In the ASA system, the angles of tool face, that is, its slope, are defined in two orthogonal
planes, one parallel to and the other perpendicular to, the axis of the cutting tool, both planes being
perpendicular to the base of the tool.
All processes including loading and Both loading and unloading are done manually
1.
unloading are done automatically
3. Production time and cost are less Production time and cost are more
Number of machines can be controlled Only one or two machines can be controlled by
4.
by single operator at a time single operator at a time
5. Initial cost of the machine is high Initial cost of the machine is low
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How the feed and depth of cut is given to the shaper? Justify your answer (6)
Depth of cut:
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Feed:
It is given by rotating the down feed screws of tool head or by raising or elevating the
table.
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In shaper, there are three types of feeds.
1. Vertical feed it is given by rotating the down feed screws of tool
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head or by raising or elevating the table at the end of return stroke
after tilting the apron to some angle.
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2. Cross feed it is given by moving the table perpendicular to ram
movement by rotating the cross feed screw at the end of the return
stroke.
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3. Angular feed it is given by rotating the down feed screw at the end
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of the return stroke after tilting the tool head to the required angle and
tilting the apron to some angle.
Give the functions of flutes on taps
It conducts the cutting fluid to the cutting region et
It periodically reverse the rotation to break the chip formed to avoid breakage during cutting
process
If the taper shank of drill is smaller than the taper in the spindle hole, a sleeve is used. The
sleeve with drill is fitted in the hole of the spindle. The sleeve has outside taper surface. This fits into
the tapered hole of the spindle.
A shell mill is a large type of face or end mil that mounts on to a arbor, rather than having an
integral shank. Typically there is a hollow or recess in the centre of the shell mill for mounting
hardware on to a separate arbor.
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What is the difference b/w plain and universal milling machine?
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It is provided with four table movements:
movements: Longitudinal, Cross,
Vertical. g.n
Longitudinal, Cross, Vertical, swiveling
of the table horizontally.
Fixed zero point is the reference point for CNC machine, which is set by the manufacturer. It
cannot be changed.
Floating zero point is the reference point on the work piece, which is set by the programmer.
It can be set at any point on the work piece by the programmer.
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on the machine. Small wheels may be balanced by milling a short recess on the inside
of the flanges and filling with lead. Large wheels should be placed on a balancing
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stand and balanced by moving weights around a recessed flange.
Now-a-days, grinding wheel mounts are provided with devices to enable balancing to
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be done whilst the wheel is running and between grinding operations.
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What are the conditions that would allow a continuous chip to be formed in metal cutting?
o Ductile material
o Smaller depth of cut gin
o High cutting speed
o Large rake angle ee rin
o Sharp cutting edge
o Proper cutting fluid g.n
o Low friction between tool face and chips
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What are the methods of external cylindrical Centre less grinding?
i. Through feed center less grinding
ii. Plunge or in-feed center less grinding
iii. End feed center less grinding
Describe: Sputtering
Sputtering is achieved by bombarding a target with energetic ions and knocking off the atoms
from a target material and transporting them to the wafer where they get deposited
i. Wet etching
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List some of the canned cycle and mention its use
G81 – Drill cycle
G82 – Dwell cycle
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G79 – Basic mill cycle
G83 – Peck drill cycle gin
G85 – Bore cycle
G80 – Cancel Cycle
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List out some of the important NC languages
APT - Compact II
ADAPT - PROMPT
EXAPT - CINTURN II
Define DNC
Direct numerical control is also called distributive numerical control. It is a technology that
permits a single computer to be networked with one or more machines that use CNC
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for automatic selection and positioning. ATC can be:
i. Drum type – for holding small number of tools store in periphery of drum
ii. Chain type – for more number of tools (30 – 40 or more tools can be used)
i.
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What are the desirable characteristics of tool magazines?
Tool magazines must be capable of holding enough tools needed for performing complete
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operation for work pieces on the machining centers
ii.
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As the magazine gets larger, the space needed is more and more expensive and hence the
magazine has to be compact and as simple as possible
iii.
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Interchange of tools should not interfere with the work piece space and tool space. This
means that the tool magazine should be located outside the working space of the machine
iv.
tool
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Easier and safer manual exchange of tools in the tool magazine during loading and unloading
should be facilitated
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All preparatory works for tool exchange should be made during machining
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List some of the materials of broach tools
i.
ii.
HSS (Alloy steel and Stainless steel)
Tin coated carbides
iii.
iv.
Aluminum
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v. 12L14
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List any four applications of broaching machines
Straight and helical slots
ii.
iii.
iv.
External and internal gearsee
External surface of various shape
The loaded wheel has particles of the metal being ground adhering to it. They prevent the
wheel from cutting freely due to openings and pores of the wheel-face filled up with metal.
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Axial load carrying capacity
Running accuracy
Thermal stability
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It is the origin of the co-ordinate system with the lathe. It is on the mounting flange of the
main spindle and the turning axis. It cannot be changed by the user of the machine. It is fixed by the
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manufacturer and programmed into the computer. The point generally has the coordinates X=0, Z=0
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What is orthogonal rake system?
Orthogonal rake system is one of the methods to describe the tool signature or tool
designation. It consists of seven parameters to describe the tool. As per this system, the tool
signature is designated in the following sequence. For example, if the tool signature is 5 10 6 6 5
90 1
Angle of inclination--5˚
Normal rake angle--10˚
Side relief angle--6˚
End relief angle--6˚
End cutting edge angle--5˚
Approach angle--90˚
Nose radius—1mm
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----------------ALL FOR THE BEST-------------------
Compiled by,
K.ELAVARASAN – B.E, M.Tech.
Chennai – 123