GATE-2001

During orthogonal cutting of mild steel with a 10°

rake angle tool, the chip thickness ratio was
obtained as 0.4. The shear angle (in degrees)
evaluated from this data is
(a) 6.53 (b) 20.22
(c) 22.94 (d) 50.00
 GATE 2011
A single – point cutting tool with 12° rake angle is used
to machine a steel work – piece. The depth of cut, i.e.
uncut thickness is 0.81 mm. The chip thickness under
orthogonal machining condition is 1.8 mm. The shear
angle is approximately
(a) 22°
(b) 26°
(c) 56°
(d) 76°
 GATE-2014
During pure orthogonal turning operation of a hollow
cylindrical pipe, it is found that the thickness of the
chip produced is 0.5 mm. The feed given to the zero
degree rake angle tool is 0.2 mm/rev. The shear strain
produced during the operation is ……………….
 GATE (PI)-1990
A single point cutting tool with 120 rake angle is
used for orthogonal machining of a ductile material.
The shear plane angle for the theoretically minimum
possible shear strain to occur

(a) 51 (b) 45

(c) 30 (d) None of these

 GATE -2012
Details pertaining to an orthogonal metal cutting process
are given below.
Chip thickness ratio 0.4
Undeformed thickness 0.6 mm
Rake angle +10°
Cutting speed 2.5 m/s
Mean thickness of primary shear zone 25 microns
The shear strain rate in s–1 during the process is
(a) 0.1781×105 (b) 0.7754×105
(c) 1.0104×105 (d) 4.397×105
 IES-2004, ISRO-2009
The rake angle of a cutting tool is 15°, shear angle 45° and
cutting velocity 35 m/min. What is the velocity of chip
along the tool face?

(a) 28.5 m/min (b) 27.3 m/min

(c) 25.3 m/min (d) 23.5 m/min

Linked Answer Questions GATE-2013 S-1
In orthogonal turning of a bar of 100 mm diameter with a
feed of 0.25 mm/rev, depth of cut of 4 mm and cutting
velocity of 90 m/min, it is observed that the main
(tangential)cutting force is perpendicular to friction force
acting at the chip-tool interface. The main (tangential)
cutting force is 1500 N.

• The orthogonal rake angle of the cutting tool in degree is

(a) zero (b) 3.58 (c) 5 (d) 7.16

Linked Answer Questions GATE-2013 S-2
In orthogonal turning of a bar of 100 mm diameter with a
feed of 0.25 mm/rev, depth of cut of 4 mm and cutting
velocity of 90 m/min, it is observed that the main
(tangential)cutting force is perpendicular to friction force
acting at the chip-tool interface. The main (tangential)
cutting force is 1500 N.

• The normal force acting at the chip-tool interface in N is

(a) 1000 (b) 1500 (c) 20oo (d) 2500

 GATE-2015

A single point cutting tool with 0° rake angle is used in an

orthogonal machining process. At a cutting speed of 180
m/min, the thrust force is 490 N. If the coefficient of
friction between the tool and the chip is 0.7, then the
power consumption(in kW) for the machining operation
is _____
 IAS – 1999
In an orthogonal cutting process, rake angle of the tool is
20° and friction angle is 25.5°. Using Merchant's shear
angle relationship, the value of shear angle will be

(a) 39.5° (b) 42.25°

(c) 47.75° (d) 50.5°

 GATE-2006 Common Data Questions(1)
In an orthogonal machining operation:
Uncut thickness = 0.5 mm
Cutting speed = 20 m/min
Width of cut = 5 mm Chip thickness = 0.7 mm
Thrust force = 200 N Cutting force = 1200 N
Assume Merchant's theory.
The coefficient of friction at the tool-chip interface is
(a) 0.23 (b) 0.46
(c) 0.85 (d) 0.95
 GATE-2006 Common Data Questions(2)
In an orthogonal machining operation:
Uncut thickness = 0.5 mm
Cutting speed = 20 m/min
Width of cut = 5 mm Chip thickness = 0.7 mm
Thrust force = 200 N Cutting force = 1200 N
Assume Merchant's theory.
The percentage of total energy dissipated due to friction at
the tool-chip interface is
(a) 30% (b) 42%
(c) 58% (d) 70%
 GATE-2006 Common Data Questions(3)
In an orthogonal machining operation:
Uncut thickness = 0.5 mm
Cutting speed = 20 m/min
Width of cut = 5 mm Chip thickness = 0.7 mm
Thrust force = 200 N Cutting force = 1200 N
Assume Merchant's theory.
The values of shear angle and shear strain, respectively,
are
(a) 30.3° and 1.98 (b) 30.3° and 4.23
(c) 40.2° and 2.97 (d) 40.2° and 1.65
 GATE-2009 Linked Answer Questions (1)
In a machining experiment, tool life was found to vary with
the cutting speed in the following manner:
Cutting speed (m/min) Tool life (minutes)
60 81
90 36
The exponent (n) and constant (k) of the Taylor's tool life
equation are
(a) n = 0.5 and k = 540 (b) n= 1 and k=4860
(c) n = -1 and k = 0.74 (d) n-0.5 and k=1.15
 GATE-2009 Linked Answer Questions (2)
In a machining experiment, tool life was found to vary with
the cutting speed in the following manner:
Cutting speed (m/min) Tool life (minutes)
60 81
90 36
What is the percentage increase in tool life when the
cutting speed is halved?
(a) 50% (b) 200%
(c) 300% (d) 400%
GATE-2005
 GATE - 2005
Two tools P and Q have signatures 5°-5°-6°-6°-8°-30°-0 and
5°-5°-7°-7°-8°-15°-0 (both ASA) respectively. They are used
to turn components under the same machining conditions.
If hp and hQ denote the peak-to-valley heights of surfaces
produced by the tools P and Q, the ratio hp/hQ will be

o o o o
tan 8  cot15 tan15  cot 8
(a) o o
(b) o o
tan 8  cot 30 tan 30  cot 8
tan15o  cot7o tan7o  cot15o
(c ) o o
(d ) o o
tan 30  cot7 tan7  cot 30
 Types of chip
• Continuous chip

• Discontinuous chip

• Continuous chip with BUE

 Conditions for forming Discontinuous chip
Discontinuous chips are always formed when the work material is brittle.
Discontinuous chips might also be formed in ductile materials under following
conditions:
feed – large
Depth of cut – large
tool rake – small or negative
cutting fluid – absent or inadequate
For all the above conditions higher forces are needed hence more
energy is needed which will lead to propagation of cracks with
higher energy leading to the formation of discontinuous chips.
Velocity-low ; low cutting velocity leads to curling of chip which leads
to discontinuous chips.
 Built – up – Edge (BUE) formation
• During machining, lot of stress and temperature develops at the chip
tool interface.
• Under such high stress and temperature in between micro chips and
the tool, strong bonding may locally take place due to adhesion
similar to welding.
• Such bonding will be encouraged and accelerated if the chip tool
materials have mutual affinity or solubility.
• The weld material starts forming as an embryo at the most favorable
location and thus gradually grows.
Contd….
 Built – up – Edge (BUE) formation
• With the growth of the BUE, the force also gradually increased due to wedging
action of the tool tip along with the BUE formed on it.

• Whenever the force exceeds the bonding force of the BUE, the BUE is broken or
sheared off and taken away by the flowing chip. Then again starts forming and
grow.

• Low cutting speed also contributes to the formation of BUE.

 Conditions for forming Continuous chip without
BUE
• work material – ductile

• Cutting velocity – high

• Feed- low

• Rake angle – positive and high

• Cutting fluid – both cooling and lubricating

• Discontinuous chips are preferred over continuous chips as they are
easy to dispose.
• Hence to convert continuous chips into discontinuous chips, chip
breaker will be used.
• Chip breakers bend the continuous chips and curl them thus forming
discontinuous chips.
 IAS-1997
Consider the following machining conditions: BUE will form in

(a) Ductile material. (b) High cutting speed.

(c) Small rake angle. (d) Small uncut chip thickness.

 GATE-2002
A built-up-edge is formed while machining

(a) Ductile materials at high speed

(b) Ductile materials at low speed

(c) Brittle materials at high speed

(d) Brittle materials at low speed

 Effects of BUE formation
Harmful effect
• Poor surface finish.
• It unfavourably changes the rake angle at the tool tip causing increase of cutting
force i.e. power consumption.
• Induce vibration.

Good effect
• BUE protects the cutting edge of the tool i. e. increases tool life.
 Machinability-Definition
Machinability can be tentatively defined as ‘ability of being machined’ and
more reasonably as ‘ease of machining’.
Such ease of machining or machining characters of any tool-work pair is to
be judged by:
• Tool wear or tool life
• Magnitude of the cutting forces
• Surface finish
• Magnitude of cutting temperature
• Chip forms.
 For IES Only

Free Cutting steels

• Addition of lead in low carbon re-sulphurised steels and also in aluminium,
copper and their alloys help reduce their τs. The dispersed lead particles act as
discontinuity and solid lubricants and thus improve machinability by reducing
friction, cutting forces and temperature, tool wear and BUE formation.
• It contains less than 0.35% lead by weight .
• A free cutting steel contains
C-0.07%, Si-0.03%, Mn-0.9%, P-0.04%, S-0.22%, Pb-0.15%
 Machinability Index
Or Machinability Rating
The machinability index KM is defined by
KM = V60/V60R
Where V60 is the cutting speed for the target material that ensures tool life of 60
min, V60R is the same for the reference material.
If KM > 1, the machinability of the target material is better than that of the
reference material, and vice versa
 IES - 2012
The usual method of defining machinability of a material is by an index based on
(a) Hardness of work material
(b) Production rate of machined parts
(c) Surface finish of machined surfaces
(d) Tool life
LATHE
• A lathe is a large machine that rotates the work, and cutting is done
with a non-rotating cutting tool. The shapes cut are generally round,
or helical. The tool is typically moved parallel to the axis of rotation
during cutting.
• Head stock - this end of the lathe contains the driving motor and
gears. Power to rotate the part is delivered from here. This typically
has levers that let the speeds and feeds be set.
• Guide ways - these are hardened rails that the carriage rides on.
• Tail stock - this can be used to hold the other end of the part.
LATHE
• Bed - this is a bottom part of the lathe that catches chips, cutting
fluids, etc.
• Carriage - this part of the lathe carries the cutting tool and moves
based on the rotation of the lead screw or rod.
• Lead screw - A large screw with a few threads per inch used for
converting the rotational motion of spindle into linear motion of
carriage. It has ACME threads with included angle of 29 degree for
easy engagement and disengagement of half nut.
• Lead rod - a rod with a shaft down the side used for driving normal
cutting feeds.
Turning
 IES 2010
In turning a solid round bar, if the travel of the cutting tool in
the direction of feed motion is 1000 mm, rotational speed of
the workpiece is 500 rpm, and rate of feed is 0.2
mm/revolution, then the machining time will be
(a) 10 seconds (b) 100 seconds
(c) 5 minutes (d) 10 minutes
 GATE-2013 (PI) Common Data
A disc of 200 mm outer and 80 mm inner diameter is faced of 0.1 mm/rev with
a depth of cut of 1 mm. The facing operation is undertaken at a constant cutting
speed of 90 m/min in a CNC lathe. The main (tangential) cutting force is 200 N.
Assuming approach and over-travel of the cutting tool to be zero, the
machining time in min is
(a) 2.93 (b) 5.86 (c) 6.66 (d) 13.33
 Turning Tapers on Lathes
• Using a compound slide,

• Using form tools,

• Offsetting the tailstock, and

• Using taper turning attachment.

 Using a Compound Slide
• Limited movement of the compound slide
• Feeding is by hand and is non-uniform. This is responsible for low-productivity
and poor surface finish.
• Can be employed for turning short internal and external tapers with a large
angle of (steep) taper.
 Using a Compound Slide contd..
• The angle is determined by
Dd
tan  
2l
  Half taper angle
D  Diameter of stock
d  smaller diameter
l  length of the taper
 IES - 2006
For taper turning on centre lathes, the method of swiveling the compound rest
is preferred for:
(a) Long jobs with small taper angles
(b) Long jobs with steep taper angles
(c) Short jobs with small taper angles
(d) Short jobs with steep taper angles
 Offsetting the tailstock
• It is necessary to measure the tailstock offset when using this method.
• This method is limited to small tapers (Not exceeding 8o ) over long lengths.
• By offsetting the tailstock, the axis of rotation of the job is inclined by the half
angle of taper.
 Offsetting the tailstock Contd..
• Tailstock offset (h) can be determined by
LD  d 
h or h  L tan 
2l
 GATE-2015
A shaft of length 90 mm has a tapered portion of length 55 mm. The diameter of
the taper is 80 mm at one end and 65 mm at the other. If taper is made by tail
stock set over method, the taper angle and set over respectively are
a) 15°32´ and 12.16 mm
b) 18°32´ and 15.66 mm
c) 11°22´ and 10.26 mm
d) 10°32´ and 14.46 mm
 IES - 1992
Tail stock set over method of taper turning is preferred for
(a) Internal tapers
(b) Small tapers
(c) Long slender tapers
(d) Steep tapers
 Form tool
• Special form tool for generating the tapers is used. The feed is given by plunging
the tool directly into the work. This method is useful for short external tapers,
where the steepness is of no consequence, such as for chamfering.
 Taper Turning Attachment
• Additional equipment is attached at the rear of the lathe.
• As the carriage is engaged, and travels along the bed, the attachment will cause
the cutter to move in/out to cut the taper.
• For turning tapers over a comprehensive range is the use of taper turning
attachment.
 GATE - 2005
A 600 mm x 30 mm flat surface of a plate is to be finish machined on a shaper.
The plate has been fixed with the 600 mm side along the tool travel direction. If
the tool over-travel at each end of the plate is 20 mm, average cutting speed is
8 m/min, feed rate is 0.3 mm/stroke and the ratio of return time to cutting time
of the tool is 1:2, the time required for machining will be
(a) 8 minutes (b) 12 minutes
(c) 16 minutes (d) 20 minutes
 Cutting Speed in Drilling
• The cutting speed in drilling is the surface speed of the twist drill.

 DN
V  m / min
1000
 Drilling Time
• Time for drilling the hole

L
T  , min
fN
 MRR in Drilling
  D2 
MRR   3
 fN , mm / min
 4 
 GATE- 2004
Through holes of 10 mm diameter are to be drilled in a steel plate of 20 mm
thickness. Drill spindle speed is 300 rpm, feed 0.2 mm/ rev and drill point angle
is 120°. Assuming drill over travel of 2 mm, the time for producing a hole will be
(a) 4 seconds (b) 25 seconds
(c) 100 seconds (d) 110 seconds
 GATE- 2012
In a single pass drilling operation, a through hole of 15 mm diameter is to be
drilled in a steel plate of 50 mm thickness. Drill spindle speed is 500 rpm, feed
is 0.2 mm/rev and drill point angle is 118°. Assuming 2 mm clearance at
approach and exit, the total drill time (in seconds) is

(a) 35.1 (b) 32.4

(c) 31.2 (d) 30.1