Grinding Test Paper

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Q.1 Incase of Cylindrical Grinder, the depth of cut for roughing cut is normally.

a. 0.05mm

b. 0.01mm

c. 0.005mm

d. 0.001mm

Q.2 Incase of Cylindrical Grinder, the depth of cut for finishing Cut is normally.

a. 0.05mm

b. 0.01mm

c. 0.005mm

d. 0.001mm

Q.3 The process of removing surface roughness, tool marks, surface Cracks from grinding, slight
distortion and other minor defect from previous operation is known as

a. honing

b. lapping

c. brazing

d. milling

Q.4 When grinding with silicon carbide wheel, the coolant should be

a. water
b. paraffin

c. paraffin with equal quantity with water

d. soluble oil

Q.5 The process of changing the shape of grinding wheel as it become worn out is

a. honing

b. truing

c. lapping

d. dressing

Q.6 Which of the following statement is correct

a. In wet condition Hard wheel is required

b. In wet condition soft wheel is required

c. In dry condition soft wheel is required

d. Both a & c

Q.7 The grinder used for grinding irregular, curved, tapered, concave & convex surfaces should be

a. Internal grinder

b. surface grinder

c. cylindrical grinder

d. all of the above

Q.8 The wheel will apper __________ if the depth of cut is decreased

a. Harder

b. softer
Q.9 Surface grinding machines are employed to finish

a. plane or flat surface

b. cylindrical, tapered and formed surface on work piece

c. cylinder, cam and crank shaft

d. None of above

Q.10 Truing is the process of

a. surface finishing

b. changing the shape of grinding wheel

c. metallic coating

d. None of above
Q.1.    Write the purposes of grinding.

Answer.    

Grinding is mainly used for the following purposes:

1. It is used for sharpening the cutting tools.

2. It is used for grinding threads in order to have close tolerances and better finish.
3. It is used to produce surfaces with a higher degree of smoothness.
4. It is used to machine materials which are too hard for machining by other methods using
cutting tools.
5. Sometimes, it is also used for higher material removal rate.

Q.2.    Name different bonds used in the manufacturing of grinding wheels

Answer:

The bonds commonly used for manufacturing of grinding wheels are as follows:

(i)     Vitrified bond (denoted by V),

(ii)    Silicate bond (denoted by s),

(iii)    Shellac bond (denoted by E),

(iv)    Rubber bond (denoted by R),

(v)    Bakelite or resinoid bond (denoted by B),

(vi)    Oxychloride bond.

Q.3.    Write the advantages of built up wheels.

Answer.    

Built up wheels are mainly used in surface grinding and have following advantages:

1. It is easier to manufacture these wheels in large sizes in comparison to the solid wheels of
same sizes.
2. These cut intermittently and hence cool grinding is the result.
Q.4.    Explain testing of grinding wheels.

Answer.    

The grinding wheels should be first examined for any flaw, and other defect before it is fastened
to the spindle. If any crack or serious flaw is observed, it should never be used as it may get
fractured under stressed condition. Thus the grinding wheel has to be examined for cracks by
sound test.

Vitrified and silicate wheels when freely suspended must give a clear sound on knocking with a
mallet. Small wheels can be held freely with the hole in finger and tapped gently with a plastic
hammer or handle of screw driver etc. at a point approximately 45 deg from the vertical centre
line.

Q.5.    Explain balancing of grinding wheels.

Answer.    

If the centre of gravity of a grinding wheel and its axis of rotation coincide, the grinding wheel is
said to be balanced.

The process of ensuring uniform distribution of the mass on the grinding wheel around its axis so
that no unbalanced force acts on it during its rotation is called balancing of the grinding wheel.

A balanced grinding wheel operates reliable at high peripheral speeds. An unbalanced grinding
wheel produces chatter and leaves undue strain on the machine. The problem becomes serious in
the wheels of large diameter and needs attention. The unbalancing of grinding wheels occurs due
to following reasons:

1. Non-uniform density of the wheel material.

2. Incorrect mounting of the grinding wheel.
3. Incorrect shape of the wheel.
4. Eccentricity in the wheel hole with reference to the wheel surface.

Q.6.    Name different types of rough grinders.

Answer.    

Most commonly used rough grinders are as follows:

1. Floor stand and bench grinder.

2. Portable and flexible shaft grinder.
3. Swing belt grinder.
 4. Abrasive belt grinder.

Q.7.    Write the advantages of internal centreless grinding.

Answer.    

The advantages of internal centreless grinding are as follows:

1. The main advantage of centreless grinding is its high productivity.

2. There is no need of centering and use of fixtures is totally avoided.
3. It can be applied for both internal as well as external grinding.
4. The work is rigidly supported and hence there is no chatter or deflection of the work.
5. The operation is easy and hence less skilled worker is required.
6. Size of work is easily controlled.
7. Large grinding wheels are used and hence errors due to wheel wear are reduced.
8. Maintenance required is very less.

Q.8.    Write the disadvantages of internal centreless grinding.

Answer.    

The main disadvantages of internal centreless grinding are as follows:

1. Work with flats and keyways cannot be ground.

2. In hollow work, there is no assurance that the outer diameter wil be concentric to the
inner one.
3. Work having several diameters is not easily handled.

Q.9.    Explain Roll Grinder.

Answer.    

A roll grinder is a cylindrical grinder of 500 to 900 mm swing by 2.5 to 5 m length between
centres.

It is built either with work traversing past the grinding wheel and the wheel in a fixed position or
with the wheel traversing past the work.

The table carries the roll, roll driving and the roll supporting equipments. This type of machine is
used for smaller diameter and shorter length rolls.
 

Figure: A Roll Grinder (Source)

Q.10.    Explain thread grinder.

Answer.

Thread grinder, which is used to generate threads, belongs to the family of cylindrical grinding
machines. The traversing motion of the workpiece is obtained by means of lead screw so that the
grinding wheel follows a desired helix or thread form. The wheel itself is shaped to the thread
profile and the wheel spindle is inclined to the helix angle of the thread. Thread grinders are
shown in fig.
Figure: A Thread Grinder (Source)
Previous Years GATE Questions on Engineering Materials 2002-2011
Solved Gate Questions on Engineering Materials

Question 1. The ductility of a material with work hardening

(A) Increases

(B) Decreases

(C) Remains unaffected

(D) Unpredictable

GATE-ME-2002

Hint 1. (Ans B)

Question 2. Hardness of steel greatly improves with

(A) Annealing

(B) Cyaniding

(C) Normalizing

(D) Tempering

GATE-ME-2003

Hint 2. (Ans D)

Question 3. During heat treatment of steel, the hardness of various structures in

increasing order is

(A) Martensite, fine pearlite, coarse pearlite,spherodite

(B) Fine pearlite, coarse pearlite, spherodite, martensite

(C) Martensite, , coarse pearlite, fine pearlite, spherodite

(D) Spherodite, coarse pearlite, fine pearlite, martensite

GATE-ME-2003

Hint 3. (Ans D)

ROCKWELL HARDNESS STRUCTURE

RC 15 Coarse Pearlite

RC 25 Fine Pearlite

RC 65 Martensite

Question 4. From the list given below, choose the most appropriate set of heat
treatment process and the corresponding process characteristics

Process Characteristics

P. Tempering 1. Austenite is converted into bainite

Q. Austempering 2. Austenite is converted into martensite

R. Martemperin
3.Cementite is converted into globular structure
g

  4. Both hardness and brittleness are reduced

  5. Carbon is absorbed into the metal

(A) P-3, Q-1,  R-5

(B) P-4, Q-3,  R-2

(C) P-4, Q-1,  R-2

(D) P-1, Q-5,  R-4

GATE-ME-2004
Hint 4. (Ans C)

Question 5. Grey cast iron blocks   are to be cast in

sands moulds. Shrinkage allowance for pattern making is 1 %. The ratio of the
volume of pattern to that of casting will be

(A) 0.97

(B) 0.99

(C) 1.01

(D) 1.03

GATE-ME-2004

Hint 5. (Ans D)

Given L=200 mm; B=100 mm; H=10 mm

Volume of the casting,

Shrinkage allowance =1%

Hence, shrinkage allowance given along length

Shrinkage allowance given along breadth

Shrinkage allowance given along height

Volume of the pattern,

Question 6. The percentage of carbon in grey cast iron is in the range  of

(A) 0.25 to 0.75 percent

(B) 1.25 to 1.75 percent

(C) 3 to 4 percent

(D) 8 to 10 percent

GATE-ME-2004

Hint 6. (Ans C)

Question 7. When the temperature of a solid metal increases.

(A) Strength of the metal decreases but ductility increases.

(B) Both strength and the ductility of the metal decreases.

(C) Both strength and the ductility of the metal increases.

(D) Strength of the metal increases but ductility decreases.

GATE-ME-2005

Hint 7. (Ans A)

Question 8. Match the items in column I and II.

Column I Column II

(P) Charpy test (1) Fluidity

 (2) Microhardnes
(Q) Knoop test
s

(R) Spiral test (3) Formability

(S) Cupping test (4) Toughness

(5) Permeability

(A) P-4, Q-5, R-3, S-2

(B) P-3, Q-5, R-1, S-4

(C) P-2, Q-4, R-3, S-5

(D) P-4, Q-2, R-1, S-3

GATE-ME-2006

Hint 8. (Ans D)

Question 9. The ultimate tensile strength of a material is 400 MPa and the

elongation up to maximum load is 35%. If the material obeys power law of
hardening, then the rue stress –true strain relation (stress in MPa) in the plastic
deformation range is :

(A) 

(B) 

(C)

(D)

GATE-ME-2006
Hint 9. (Ans B)

Question 10. The main purpose of spheroidising treatment is to improve

(A) Hardenability of low carbon steels

(B) Machinability of low carbon steels

(C) Hardenability of high carbon steels

 (D) Machinability of high carbon steels

GATE-ME-2006

Hint 10. (Ans D)

Spherodising improves machinability of high carbon steels.

Question 11. If a particular Fe-C alloy contains less than 0.83 % carbon, it is
called

(A) High speed steel

(B) Hypoeutectoid steel

(C) Hypereutectoid steel

(D) Cast iron

GATE-ME-2006

Hint 11. (Ans B)

Question 12. The effective number of lattice points in the unit cell of simple
cubic, body centered cubic, and face centered cubic  space lattices, respectively
are

(A) 1,2,2

(B) 1,2,4

(C) 2,3,4

(D) 2,4,4
 GATE-ME-2009

Hint 12. (Ans B)

For a simple cubic unit cell

8 corners have 8 atoms and each atom at one corner contributes to 8 unitcells.

For FCC,

Hence answer is (1,2,4)

Question 13. The material property which depends only on the basic crystal
structure is

(A) Fatigue strength

(B) Work hardening

(C) Fracture strength

(D) Elastic constant

GATE-ME-2010

Hint 13. (Ans C)

Question 14. The operation in which oil is permeated into the pores of a powder
metallurgy product is known as

(A) Mixing

(B) Sintering

(C) Impregnation
(D)Infiltration

GATE-ME-2011

Hint 14. (Ans C)

Question 15. The crystal structure of austenite is

(A) Body centered Cubic

(B) Face centered Cubic

(C) Hexagonal closed packed

(D) Body centered tetragonal

GATE-ME-2011

Hint 15. (Ans B)

Austenite has FCC Crystal Structure.

Answer Keys

1. (B)     2. (D)     3. (D)     4. (C)     5. (D)     6. (C)     7. (A)     8. (D)     9. (B)     10. (D)   

11. (B)   12. (B)   13. (C)   14. (C)   15. (B)

Q.2.    Explain piston grinder.

Answer.    

The grinding of piston of high speed i.c. engines is basically cylindrical grinding, but it deviates
slightly from the plain cylindrical grinding.

Many such pistons are not ground truly cylindrical, but slightly elliptical and sometimes, they are
slightly tapered. On a piston grinder, a mechanism is attached to move the revolving piston
alternately toward and away from the wheel, thus grinding in elliptical form.

At the same time, the work moves progressively away from the wheel during its longitudinal
movement, thus grinding the desired taper.

Piston Grinder

Source: http://lovick.com.au
Q.3.    Explain way grinder.

Answer.    

These are large and heavy single-purpose grinder intended mainly to grind the various surfaces
of the ways and beds of machines. The wheel used is cup, ring or segment type mounted on a
vertical spindle which can be usually titled at an angle. All sorts of angles may be produced on
this machine as shown in fig.

Q.4.    Explain tool post grinder.

Answer.   

Tool post grinder, sometimes called lathe grinder, is used for miscellaneous and small grinding
work on a lathe. It is held on the tool post and fed across the work, longitudinal and cross-wise
whenever necessary.
Q.5.    Write the functions of cutting fluids used in grinding.

Answer.    
Cutting fluids are used in grinding for the following reasons:

1. To reduce the excessive heat generated during the operation and to avoid its extreme
localization.
2. To maintain uniform temperature I order to prevent distortion of the job and breakage of
the wheel.
3. To drive away the broken abrasive grains and chips, so that they may not scratch against
the finished surface and spoil it.
4. To prevent the metal chips from clogging into the grain spaces and thus to avoid loading
the wheel face.

Q.6.    Write safety precautions to be taken in grinding.

Answer.    

Safety Precautions to be taken in Grinding are:

1. Inspect grinding wheel for cracks before mounting.

2. Test grinding wheel for concentricity.
3. Check whether all safety guards and hoods are in their place.
4. Make a trial run before initial use.
5. Use safety goggles.
6. Do not exceed the permissible peripheral speed.
7. While grinding on the pedestal grinding machine, the tool rest must have a distance of 1-
2 mm from the wheel, otherwise the workpiece may get between tool rest and the wheel
and break the wheel.
8. Do not touch the running grinding wheel.
9. Do not remove the protecting covers.
10. Clothing of the operator should not come in contact with the wheel and work.
10 Short Answer Questions on Grinding Operation

Q.1.    Write the purposes of grinding.

Answer.    

Grinding is mainly used for the following purposes:

1. It is used for sharpening the cutting tools.

2. It is used for grinding threads in order to have close tolerances and better finish.
3. It is used to produce surfaces with a higher degree of smoothness.
4. It is used to machine materials which are too hard for machining by other methods using
cutting tools.
5. Sometimes, it is also used for higher material removal rate.

Q.2.    Name different bonds used in the manufacturing of grinding wheels

Answer:

The bonds commonly used for manufacturing of grinding wheels are as follows:

(i)     Vitrified bond (denoted by V),

(ii)    Silicate bond (denoted by s),

(iii)    Shellac bond (denoted by E),

(iv)    Rubber bond (denoted by R),

(v)    Bakelite or resinoid bond (denoted by B),

(vi)    Oxychloride bond.

Q.3.    Write the advantages of built up wheels.

Answer.    

Built up wheels are mainly used in surface grinding and have following advantages:

1. It is easier to manufacture these wheels in large sizes in comparison to the solid wheels of
same sizes.
2. These cut intermittently and hence cool grinding is the result.

Q.4.    Explain testing of grinding wheels.

Answer.    

The grinding wheels should be first examined for any flaw, and other defect before it is fastened
to the spindle. If any crack or serious flaw is observed, it should never be used as it may get
fractured under stressed condition. Thus the grinding wheel has to be examined for cracks by
sound test.

Vitrified and silicate wheels when freely suspended must give a clear sound on knocking with a
mallet. Small wheels can be held freely with the hole in finger and tapped gently with a plastic
hammer or handle of screw driver etc. at a point approximately 45 deg from the vertical centre
line.

Q.5.    Explain balancing of grinding wheels.

Answer.    

If the centre of gravity of a grinding wheel and its axis of rotation coincide, the grinding wheel is
said to be balanced.

The process of ensuring uniform distribution of the mass on the grinding wheel around its axis so
that no unbalanced force acts on it during its rotation is called balancing of the grinding wheel.

A balanced grinding wheel operates reliable at high peripheral speeds. An unbalanced grinding
wheel produces chatter and leaves undue strain on the machine. The problem becomes serious in
the wheels of large diameter and needs attention. The unbalancing of grinding wheels occurs due
to following reasons:

1. Non-uniform density of the wheel material.

2. Incorrect mounting of the grinding wheel.
3. Incorrect shape of the wheel.
4. Eccentricity in the wheel hole with reference to the wheel surface.

Q.6.    Name different types of rough grinders.

Answer.    

Most commonly used rough grinders are as follows:

1. Floor stand and bench grinder.

2. Portable and flexible shaft grinder.
3. Swing belt grinder.
4. Abrasive belt grinder.

Q.7.    Write the advantages of internal centreless grinding.

Answer.    

The advantages of internal centreless grinding are as follows:

1. The main advantage of centreless grinding is its high productivity.

2. There is no need of centering and use of fixtures is totally avoided.
3. It can be applied for both internal as well as external grinding.
4. The work is rigidly supported and hence there is no chatter or deflection of the work.
5. The operation is easy and hence less skilled worker is required.
6. Size of work is easily controlled.
7. Large grinding wheels are used and hence errors due to wheel wear are reduced.
8. Maintenance required is very less.

Q.8.    Write the disadvantages of internal centreless grinding.

Answer.    

The main disadvantages of internal centreless grinding are as follows:

1. Work with flats and keyways cannot be ground.

2. In hollow work, there is no assurance that the outer diameter wil be concentric to the
inner one.
3. Work having several diameters is not easily handled.

Q.9.    Explain Roll Grinder.

Answer.    
A roll grinder is a cylindrical grinder of 500 to 900 mm swing by 2.5 to 5 m length between
centres.

It is built either with work traversing past the grinding wheel and the wheel in a fixed position or
with the wheel traversing past the work.

The table carries the roll, roll driving and the roll supporting equipments. This type of machine is
used for smaller diameter and shorter length rolls.

Figure: A Roll Grinder (Source)

Q.10.    Explain thread grinder.

Answer.

Thread grinder, which is used to generate threads, belongs to the family of cylindrical grinding
machines. The traversing motion of the workpiece is obtained by means of lead screw so that the
grinding wheel follows a desired helix or thread form. The wheel itself is shaped to the thread
profile and the wheel spindle is inclined to the helix angle of the thread. Thread grinders are
shown in fig.
Figure: A Thread Grinder (Source)