Production Engg Gate Question

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Production
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Common Data for

Questions Q.1 to Q.3
In an orthogonal machining operation :

Uncut thickness = 0.5 mm
Cutting speed = 20 m/min
Rake angle = 150
Width of cut = 5 mm
Chip thickness = 0.7 mm
Thrust force = 200 N
Cutting force = 1200 N
Assume merchant’s theory.
Q.1 The value of shear angle and shear strain, respectively, are
(A) 30.30 and 1.98 (B) 30.30 and 4.23 (C) 40.20 and 2.97 (D) 40.20 and 1.65
Q.2 The coefficient of friction at the tool-chip interface is
(A) 0.23 (B) 0.46 (C) 0.85 (D) 0.95
Q.3 The percentage of total energy dissipated due to friction at the tool chip interface is
(A) 30% (B) 42% (C) 58% (D) 70%
Q.4 In an orthogonal cutting test on mild steel, the following data were obtained
Cutting speed 40 m/min
Depth of cut 0.3 mm
Tool rake angle + 50
Chip thickness 1.5 mm
Cutting force 900 N
Thrust force 450 N
Using merchant’s analysis, the friction angle during the machining will be
(A) 26.60 (B) 31.50 (C) 450 (D) 63.40
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Common Data for

Questions Q.5 & Q.6
A cylinder is turned on a lathe with orthogonal machining principle. Spindle rotates at 200 rpm. The axial
feed rate is 0.25 mm per revolution. Depth of cut is 0.4 mm. The rake angle is 100 . In the analysis it is
found that the shear angle is 27.750 .
Q.5 The thickness of the produced chip is
(A) 0.511 mm (B) 0.528 mm (C) 0.818 mm (D) 0.846 mm
Q.6 In the above problem, the coefficient of friction at the chip tool interface obtained using Ernst and
merchant theory is
(A) 0.18 (B) 0.36 (C) 0.71 (D) 0.98
Common Data for

Questions Q.7 & Q.8
A low cabon steel bar of 147 mm diameter with a length of 630 mm is being turned with uncoated carbide
insert. The observed tool lives are 24 min and 12 min for cutting velocities of 90 m/min and 120 m/min
respectively. The feed and depth of cut are 0.2 mm/rev and 2 mm respectively. Use the unmachined
diameter to calculate the cutting velocity.
Q.7 When tool life is 20 min, the cutting velocity in m/min is
(A) 87 (B) 97 (C) 107 (D) 114
Q.8 Neglect over-travel or approach of the tool. When tool life is 20 min, the machining time in min for a
single pass is
(A) 5 (B) 10 (C) 15 (D) 20
Common Data for

Questions Q.9 & Q.10
In a machining experiment, tool life was found to vary with cutting speed in the following manner :
Cutting speed (m/min) Tool life (minutes)
60 81
90 36
Q.9 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 = 1.155
Q.10 What is the percentage increase in tool life when the cutting speed is halved?
(A) 50% (B) 200% (C) 300% (D) 400%
Q.11 Tool life equations for two tools under consideration are as follows :
HSS : VT 0.2 = 150
Carbide : VT 0.3 = 250
Where V is the cutting speed in m/min and T is the tool life in mm. The breakeven cutting speed above
which the carbide tool will be beneficial is
(A) 57 m/min (B) 150 m/min (C) 194 m/min (D) 250 m/min
Q.12 A 600 mm × 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 mm/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
Q.13 In a shaping process, the number of double strokes per minute is 30 and the quick return ratio is 0.6. If the
length of the stroke is 250 mm, the average cutting velocity in m/min.
(A) 300 (B) 4.5 (C) 7.5 (D) 12.0
Q.14 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 0.2mm/rev and drill point angle is 1180 . 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
Q.15 A hole of 20 mm diameter is to be drilled in a steel block of 40 mm thickness. The drilling is performed
at rotational speed of 400 rpm and feed rate of 0.1 mm/rev. The required approach and over run of the
drill together is equal to the radius of drill. The drilling time (in minute) is
(A) 1.00 (B) 1.25 (C) 1.50 (D) 1.75
Q.16 Taylor's tool life equation is used to estimate the life of a batch of identical HSS twist drills by drilling
through holes at constant feed in 20 mm thick mild steel plates. In test 1, a drill lasted 300 holes at 150
rpm while in test 2, another drill lasted 200 holes at 300 rpm. The maximum number of holes that can be
made by another drill from the above batch at 200 rpm is______ (correct to two decimal places).
Q.17 A milling cutter having 8 teeth is rotating at 150 rpm. If the feed per tooth is 0.1 mm, the speed in mm per
minute is
(A) 120 (B) 187 (C) 125 (D) 70
Q.18 Two separate slab milling operations, 1 and 2, are performed with identical milling cutters. The depth of
cut in operation 2 is twice that in operation 1. The other cutting parameters are identical. The ratio of
maximum uncut chip thicknesses in operations 1 and 2 is ________.
Q.19 The length, width and thickness of a steel sample are 400 mm, 40 mm and 20 mm, respectively. Its
thickness needs to be uniformly reduced by 2 min in a single pass by using horizontal slab milling. The
milling cutter (diameter : 100 mm, width : 50 mm) has 20 teeth and rotates at 1200 rpm. The feed per
tooth is 0.05 mm. The feed direction is along the length of the sample. If the over travel distance is the
same as the approach distance, the approach distance and time taken to complete the required machining
task are
(A) 14 mm, 21.4 s (B) 21 mm, 39.4 s (C) 14 mm, 18.4 s (D) 21 mm, 28.9 s
Q.20 The standard specification of a grinding wheel is A-46-M-6-V-21. It means a wheel of
(A) Aluminum oxide of mesh size 6 (B) Boron carbide of mesh size 46
(C) Alumina oxide of mesh size 46 (D) Silicon carbide of mesh size 6

Q.21 A grinding wheel A 27 K 7 V is specified for finish grinding of a HSS cutting tool. What do you understand
about the wheel from the above code? Is this an appropriate choice?
(A) Yes (B) No, because abrasive is not correct
(C) No, grain size is not correct (D) No, because grade is not correct choice
Q.22 A grinding ratio of 200 implies that the
(A) Grinding wheel wears 200 times the volume of the material removed
(B) Grinding wheel wears 0.005 times the volume of the material removed
(C) Aspect ratio of abrasive particles used in the grinding wheel is 200
(D) Ratio of volume of abrasive particle to that of grinding wheel is 200
Q.23 The base of a brass bracket has to be rough ground to remove the unevenness. The 4 wheels available in
the store. The appropriate wheel is
(A) A 30 K 12 V (B) C 90 M 4 B (C) C 30 Q 12 V (D) C 50 G 8 V
Q.24 In a grinding wheel marked with A-48- L-7-V-25, L refers to
(A) Abrasive type (B) Wheel structure
(C) Wheel hardness (D) Manufactures code
Q.25 Grinding ratio is defined as
Volume of wheel wear Volume of work material removed
(A) (B)
Volume of work material removed Volume of wheel wear
Cutting speed Longitudinal feed
(C) (D)
Feed Transverse feed
Q.26 In a rolling process, sheet of 25 mm thickness is rolled to 20 mm thickness. Roll is of diameter 600 mm
and it rotates at 100 rpm. The roll strip contact length will be
(A) 5 mm (B) 39 mm (C) 78 mm (D) 120 mm
Q.27 A 4 mm thick sheet is rolled with 300 mm diameter rolls to reduce thickness without any change in its
width. The friction coefficient at the work-roll interface is 0.1. The minimum possible thickness of the
sheet that can be produced in a single pass is
(A) 1.0 mm (B) 1.5 mm (C) 2.5 mm (D) 3.7 mm
Q.28 In a slab rolling operation, the maximum thickness reduction (Δhmax ) is given by Δhmax = μ 2 R, where R
is the radius of the roll and μ is the coefficient of friction between the roll and the sheet. If μ = 0.1, the
maximum angle substended by the deformation zone at the centre of the roll (bite angle in degree) is
______.
Q.29 In a rolling operation using rolls of diameter 500 mm, if a 25 mm thick plate cannot be reduced to less
than 20 mm in one pass, the coefficient of friction between the roll and the plate is _____.
Q.30 In a rolling process, thickness of a strip is reduced from 4 mm to 3 mm using 300 mm diameter rolls
rotating at 100 rpm. The velocity of the strip (in m/sec) at the neutral point is
(A) 1.37 (B) 3.14 (C) 47.10 (D) 94.20
Q.31 A strip of 120 mm width and 8 mm thickness is rolled between two 300 mm diameter rolls to get a strip
of 120 mm width and 7.2 mm thickness. The speed of the strip at the exit is 30 m/min. There is no front
or back tension. Assuming uniform roll pressure of 200 MPa in the roll bits and 100% mechanical
efficiency, the minimum total power (in kW) required to drive the two rolls is ______.
Q.32 A metal rod of initial length L0 is subjected to a drawing process. The length of the rod at any instant is
given by the expression, L(t ) = L0 (1 + t 2 ), where t is the time in minutes. The true strain rate (in min −1 )
at the end of one minute is ________ .
Q.33 The true stress (in MPa) versus true strain relationship for a metal is given by σ = 1020 ε 0.4 . The cross-
sectional area at the start of a test (when the stress and strain values are equal to zero) is 100 mm 2 . The
cross-sectional area at the time of necking (in mm 2 ) is _____ (correct to two decimal places).
Q.34 The true stress true curve is given by σ = 1400 ε0.33 , where the stress σ is in MPa. The true stress
maximum load (in MPa) is
(A) 971 (B) 750 (C) 698 (D) 350
Q.35 A brass billet is to be extruded from its initial diameter of 100 mm to a final diameter of 50 mm. The
working temperature of 7000 C and the extrusion constant is 250 MPa. The force required for extrusion
is
(A) 5.44 MN (B) 2.72 MN (C) 1.36 MN (D) 0.36 MN
Q.36 In a wire drawing operation diameter of a steel wire is reduced from 10 mm to 8 mm. The mean flow
stress of the material is 400 MPa. The ideal force required for drawing (ignoring friction and redundant
work) is
(A) 4.48 kN (B) 8.97 kN (C) 20.11 kN (D) 31.41 kN
Q.37 In a two stage wire drawing operation, the fractional reduction (ratio of change in cross sectional area to
initial cross sectional area) in the first stage is 0.4. The fractional reduction in the second stage is 0.3. The
overall fractional reduction is
(A) 0.24 (B) 0.58 (C) 0.60 (D) 1.00
Q.38 A φ 25 mm hole is pierced in a t = 2.5 mm thick steel sheet having shear strength τ = 350 MPa . If the
diametral clearance is given by the expression c = 0.0064 t τ , the die diameter (in mm), punch diameter
(in mm) and punch force in (kN) respectively are
(A) 25.0, 25.3, 171.8 (B) 25.0, 24.7, 68.75
(C) 24.7, 25.0, 171.8 (D) 25.3, 25.0, 68.75
Q.39 A hole of 40 mm diameter is pierced in a steel sheet of 4 mm thickness without shear on the tool. Shear
strength of steel is 400 N / mm 2 and penetration is 25 %. What is the expected percentage load reduction
if a shear of 1 mm is provided on the punch?
(A) 25.00 (B) 33.33 (C) 50.00 (D) 66.67
Q.40 The percentage scrap in a sheet metal blanking operation of a continuous strip of sheet metals as shown
in the figure is –––––– (correct to two decimal places).
D/5 D/5 D/5
D
Feed D/5 D/5
D
D/5 D/5 D/5

Common Data for

Questions 41 & 42
In shear cutting operation, a sheet of 5 mm thickness is cut along a length of 200 mm. The cutting blade
is 400 mm long (see figure) and zero shear (S = 0) is provided on the edge. The ultimate shear strength of
the sheet is 100 MPa and penetration to thickness ratio is 0.2 Neglected friction.
400
Q.41 Assuming force vs displacement curve to be rectangular, the work done (in J) is
(A) 100 (B) 200 (C) 250 (D) 300
Q.42 A shear of 20 mm (S = 20 mm) is now provided on the blade. Assuming force vs displacement curve to
be trapezoidal, the maximum force (in kN ) exerted is
(A) 5 (B) 10 (C) 20 (D) 40
Q.43 Determine the load required to punch a 20 mm diameter hole in 2 mm thick sheet. The properties of the
material of the sheet are :
Tensile strength = 580 MPa
Yield strength in tension = 410 MPa
Shear strength = 350 MPa
Yield strength in shear = 250 MPa
The load in kN is
(A) 31.40 (B) 43.98 (C) 64.40 (D) 91.10
Q.44 In a electrochemical machining (ECM) operation, a square hole of dimensions 5 mm × 5 mm is drilled in
a block of copper. The current used is 5000 A. Atomic weight of copper is 63 and valence of dissolution
is 1. Faradays constant is 96500 coulomb. The material removal rate (g/s) is
(A) 0.326 (B) 3.26 (C) 3.15 ×103 (D) 3.15 ×105
Q.45 During the electrochemical machining (ECM) of iron (atomic weight = 56, valency = 2) at current of 1000
A with 90% current efficiency, the material removal rate was observed to be 0.26 gm/s. If titanium (atomic
weight = 48, valency =3) is machined by the ECM process at the current of 2000 A with 90% of current
efficiency, the expected material removal rate in gm/s will be
(A) 0.11 (B) 0.23 (C) 0.30 (D) 0.52
Q.46 A researcher conducts electrochemical machining (ECM) on a binary alloy (density 6000 kg/m 3 ) of iron
(atomic weight 56, valency 2) and metal P (atomic weight 24, Valency 4). Faraday’s constant = 96500
coulomb/ mole. Volumetric materal removal rate of the alloy is 50 mm 3 /s at a current of 2000 A. The
percentage of the metal P in the alloy is closest to
(A) 40 (B) 25 (C) 15 (D) 79
Q.47 While removing material from iron (atomic weight = 56, Valency = 2 and density = 7.8 g/cc) by
electrochemical machining, a metal removal rate of 2 cc/min is desired. The current (in A) required for
achieving this material removal rate is
(A) 896.07 (B) 14.93 (C) 448.03 (D) 53764.29
Q.48 In an electrochemical machining of aluminium with plane parallel electrodes, the current density is
70 A/cm 2 . Cross sectional area of each electrode is 3cm 2 . The current efficiency (i.e., the fraction of
current used for dissolution of metal) is 80%. Atomic weight, valency and density of aluminium are 27
gram, 3 and 2700 kg/m3 , respectively. Take Faraday’s constant as 96500 coulomb. The volumetric
material removal rate (in mm 3 / min) is ______.
Common Data for

Question 49 & 50
In an EDM process using RC relaxation circuit, a 12 mm diameter through hole is made in steel plate of
50 mm thickness using a graphite tool and kerosene as dielectric assume discharge time to be negligible.
Machining is carried out under the following condition :
Resistance = 40 Ω
Capacitance = 20 μF
Supply voltage = 220 V
Discharge voltage = 110 V
Q.49 The time for one cycle, in milliseconds, is
(A) 0.55 (B) 0.32 (C) 0.89 (D) 0.24
Q.50 Average power input (in kW) is
(A) 0.373 (B) 0.137 (C) 0.218 (D) 0.5
Q.51 A resistance-capacitance relaxation circuit is used in an electrical discharge machining process. The
discharge voltage is 100 V. At a spark cycle time of 25 μs . The average power input required is 1 kW.
The capacitance (in μF ) in the circuit is
(A) 2.5 (B) 5.0 (C) 7.5 (D) 10.0
Q.52 A circular hole of 25 mm diameter and depth of 20 mm is machined by EDM process. The Material
removal rate (in mm3 /min) is expressed as 4 ×104 IT −1.23 where I = 300 A and the melting point of the
material, T = 16000 C . The time (in minutes) for machining this hole is ___ (correct to two decimal
places).
Q.53 The surface irregularities of electrodes used in an electrochemical machining (ECM) process 3 μm and
6 μm as shown in the figure. If the work-piece is of pure iron and 12 volt DC is applied between the
electrodes, the largest feed rate is _____ mm/min.
Conductivity of the electrolyte 0.02 ohm -1mm -1
Over potential voltage 1.5 V
Density of iron 7860 kg/m3
Atomic weight of iron 55.85gm
Assume the iron to be dissolved as Fe+2 and the Faraday’s constant to be 96500 coulomb.
Tool
6mm
Nominal Gap
3mm
Work piece (Iron)
Q.54 In a DC arc welding operation, the voltage arc length characteristic was obtained as Varc = 20 + 5 L where
the arc length L was varied between 5 mm and 7 mm. Here Varc denotes between the arc voltage in Volts.
The arc current was varied from 400 A to 500 A. Assuming linear power source characteristic, the open
circuit voltage and short circuit current for the welding operation are :
(A) 45 V, 450 A (B) 75 V, 750 A (C) 95 V, 950 A (D) 150 V, 1500 A
Q.55 The voltage-length characteristic of a direct current arc in an arc welding process is V = (100 + 40 l ) ,
where l is the length of the arc in mm and V is arc voltage in volts. During a welding operation, the arc
length varies between 1 and 2 mm and the welding current is in the range 200-250 A. Assuming a linear
power source, the short circuit current is _______ A.
Q.56 The voltage arc length characteristics of a DC arc is given by V = 20 + 40 L , where L = arc length in cm.
The power source characteristics can be approximated by a straight line. Open circuit is 80 V and short
circuit current 1000 Amps. The optimum arc length in mm
(A) 0.5 (B) 1 (C) 5 (D) 10
Q.57 A DC welding power source has a linear voltage-current (V-I) characteristic with open circuit voltage of
80 V and a short circuit current of 300 A. For maximum arc power, the current (in amperes) should be set
as ______.
Q.58 In arc welding of a butt joint, the welding speed is to be selected such that highest cooling rate is achieved.
Melting efficiency and heat transfer efficiency are 0.5 and 0.7, respectively. The area of weld cross section
is 5 mm and the unit energy required to melt the metal is 10 J/mm3 . If the welding power is 2 kW, the
welding speed in mm/s is closest to
(A) 4 (B) 14 (C) 24 (D) 34
Q.59 In an arc welding process, the voltage and current are 25 V and 300 A respectively. The arc heat transfer
efficiency is 0.85 and welding speed is 8 mm/sec. The net heat input (in J/mm) is
(A) 64 (B) 797 (C) 1103 (D) 79700
Q.60 Two aluminum alloy plates each 10 mm thick and 1 m long are welded without crowning by multipass
tungsten inert gas butt welding.
The joint configuration is V-type with 600 angle and root gap is maintained at 5 m. if electrode of 5 mm
diameter with 500 mm length is used for welding, then the number of electrodes required is
(A) 7 (B) 9 (C) 11 (D) 13
Q.61 Resistance spot welding is performed on two plates of 1.5 mm thickness with 6 mm diameter electrode,
using 15000 A current for a time duration of 0.25 sec. Assuming the interface to be 0.0001 Ω, the heat
generated to form the weld is
(A) 5625 W-sec (B) 8437 W-sec (C) 22500 W-sec (D) 33750 W-sec

Q.62 Two 1 mm thick steel sheets are to be spot welded at a current of 5000 A. Assuming effective resistance
to be 200 micro-ohms and current flow time of 0.2 second, heat generated during the process will be
(A) 0.2 Joule (B) 1 Joule (C) 5 Joule (D) 1000 Joule
Q.63 Spot welding of two 1 mm thick sheets of steel (density = 8000 kg/m3 ) is carried out successfully by
passing a certain amount of current for 0.1 second through the electrodes. The resultant weld nugget
formed is 5 mm on diameter and 1.5 mm thick. If the latent head of fusion of steel is 1400 kJ/kg and the
effective resistance in the welding operation is 200 μΩ , the current passing through the electrodes is
approximately
(A) 1480 A (B) 3300 A (C) 4060 A (D) 9400 A
Q.64 Two metallic sheets, each of 2.0 mm thickness, are welding in a lap joint configuration by resistance spot
welding at a welding current of 10 kA and welding time of 10 millisecond. A spherical fusion zone
extending up to the full thickness of each sheet is formed and properties of the metallic sheets are given
as :
Ambient temperature = 293 K
Melting temperature = 1793 K
Density = 7000 kg/m 3 ,
Latent heat of fusion = 300 kJ/kg
Specific heat = 800 J/kgK
Assume :
1. Contact resistance along sheet interface is 500 micro ohm and along electrode sheet interface is zero.
2. No conductive heat loss through the bulk sheet materials; and
3. The complete weld fusion zone is at the melting temperature.
The melting efficiency (in %) of the process is
(A) 50.37 (B) 60.37 (C) 70.37 (D) 80.37
Q.65 Two flat steel sheets, each of 2.5 mm thickness, are being resistance spot welded using a current of 6000
A and weld time of 0.2 s. The contact resistance at the interface between the two sheets is 200μΩ and
the specific energy to melt steel is 10 × 109 J/m 3 . A spherical melt pool of diameter 4 mm is formed at the
interface due to the current flow. Consider that electrical energy is completely converted to thermal
energy. The ratio of the heat used for melting to the total resistive heat generated _____.
Q.66 Two metallic sheets are spot welded by passing a current of 8000 A for 0.2 s. Assume that a cylindrical
nugget of 8 mm diameter and 3 mm depth is formed. The density of nugget is 7500 kg/m 3 , effective
resistance of the total system is 222 micro-Ohm and heat required to produce 1.0 gram of nugget is 1400
J. The percentage of heat actually utilized in producing the nugget is _______.
Q.67 A cubic casting of 50 mm side undergoes volumetric solidification shrinkage and volumetric solid
contraction of 4% and 6% respectively. No riser is used. Assume uniform cooling in all directions. The
side of the cube after solidification and contraction is
(A) 48.32 mm (B) 49.90 mm (C) 49.94 mm (D) 49.96 mm

Q.68 Gray cast iron blocks 200 × 100 × 10 mm are to be cast in sand moulds. Shrinkage allowance for pattern
making is 1%. The ratio of volume of pattern to that of the casting will be
(A) 0.97 (B) 0.99 (C) 1.01 (D) 1.03
Q.69 A 200 mm long down sprue has an area of cross section of 650 mm 2 where the pouring basin meets the
down sprue (i.e. at the beginning of the down sprue). A constant head of molten metal is maintained by
the pouring basin. The molten metal flow rate is 6.5 × 105 mm3 /s . Considering the end of down sprue to
be opened to atmosphere and an acceleration due to gravity of 104 mm/s 2 , the area of the down sprue in
mm 2 at its end (avoiding aspiration effect)
Pouring basin
650 mm2
200 mm
Area of down
sprue at its end
(A) 650.0 (B) 350.0 (C) 290.7 (D) 190.0

Q.70 Schematic diagram of pouring basin and sprue of a gating system is shown in the figure. Depth of molten
metal in the pouring basin is 100 mm and the height of the sprue is 1500 mm.
Pouring
d2 100 mm
basin
Sprue 1500 mm
d1
Considering the cross-section of the sprue is circular, the ratio d1 : d 2 to avoid aspiration is
(A) 3:2 (B) 5:6 (C) 15:16 (D) 1:2
Q.71 A mould has down sprue whose length is 20 cm and the cross sectional area at the base of the down sprue
is 1 cm 2 . The down sprue feeds a horizontal running leading into the mould cavity of volume 1000 cm3 .
The time required to fill the mould cavity will be
(A) 4.05 s (B) 5.05 s (C) 6.05 s (D) 7.25 s
Q.72 The figure shows a pouring arrangement for casting of a metal block. Frictional losses are negligible. The
acceleration due to gravity is 9.81 m/s 2 . The time (in s, round off to two decimal place) to fill up the
mould cavity (of size 40 cm × 30 cm ×15 cm ) is ______.
1 Atmospheric
pressure
2
Filling height Diameter 2 cm
20 cm
3 30 cm
Volume to be casted
Open to (mold cavity) 15 cm
atmosphere
40 cm

Q.73 A cube shaped casting solidifies in 5 minute. The solidification time in min for a cube of the same material,
which is 8 times heavier than the original casting, will be
(A) 10 (B) 20 (C) 24 (D) 40
2
V 
Q.74 The solidification time of a casting is proportional to   , where V is the volume of the casting and A
 A
is the total casting surface area losing heat. Two cubes of same material and size are cast using sand casting
process. The top face of one of the cubes is completely insulated. The ratio of the solidification time for
the cube with top face insulated to that of the other cube is
25 36 6
(A) (B) (C) 1 (D)
36 25 5
Q.75 The dimensions of a cylindrical side riser (height = diameter) for a 25 cm × 15 cm × 5 cm steel casting are
to be determined. For the tabulated shape factor values given below, diameter of the riser (in cm) is
______.
Shape factor Riser volume/casting volume
2 1.0
4 0.70
6 0.55
8 0.50
10 0.40
12 0.35
+ 0.020 + 0.010
Q.76 The hole 40 + 0.000 and shaft 40 − 0.010 when assembled will result in
(A) Clearance fit (B) Interference fit (C) Transition fit (D) Drive fit
Q.77 In an engineering drawing one finds the designation of 20G7f8. The position of tolerance of the hole is
indicated by
(A) Letter G (B) Letter f (C) Number 7 (D) Number 8
+0.00
Q.78 A bush was turned after mounting the same on a mandrel. The mandrel diameter in millimeter is 40 −0.05
+0.06
and bore diameter of bush is 40 −0.010 . The maximum eccentricity of the bush, in mm will be
(A) 0.01 (B) 0.055 (C) 0.1 (D) 0.11
Q.79 The fit on a hole-shaft pair system is specified as H7-s6. The type of fit is
(A) Clearance fit (B) Running fit (sliding fit)
(C) Push fit (transition fit) (D) Force fit (interference fit)
Q.80 A part shown in the figure is machined to the sizes given below
P = 35.00+−0.08 +0.02 +0.04
0.08 mm , Q = 12.00−0.02 mm , R = 13.00 −0.02 mm
Q R
W
P
With 100% confidence, the resultant dimension W will have the specification
(A) 9.99 ± 0.03 mm (B) 9.99 ± 0.13 mm
(C) 10.00 ± 0.03 mm (D) 10.00 ± 0.13 mm
Q.81 In the assembly shown below, the part dimensions are :
L1 = 22.0± 0.01 mm, L2 = L3 = 10.0± 0.005 mm
Assuming the normal distribution of part dimensions, the dimension L4 in mm for assembly condition
would be :
L2 L3 L4
L1
(A) 2.0± 0.008 (B) 2.0± 0.012 (C) 2.0± 0.016 (D) 2.0± 0.020
Q.82 A circular shaft having diameter 65.00++0.01
0.05 mm is manufactured by turning process. A 50 μm thick
coating TiN is deposited on the shaft. Allowed variation in TiN film thickness is ±5 μm. The minimum
hole diameter (in mm) just to provide clearance fit as
(A) 65.12 (B) 65.01 (C) 65.10 (D) 64.95
+0.050
Q.83 GO and NO-GO plug gauges are to be designed for a hole 20.000 +0.010 mm . Gauge tolerances can be taken
as 10% of the hole tolerance. Following ISO system of gauge design, sizes of GO and NO-GO gauge will
be respectively
(A) 20.010 mm and 20.050 mm (B) 20.014 mm and 20.046
(C) 20.006 mm and 20.054 mm (D) 20.014 mm and 20.054
Common Data for

Questions 84 & 85
In the feed drive of a point to point open loop CNC drive, a stepper motor rotation at 200 steps/rev drives
a table through a gear box and lead screw nut mechanism (pitch = 4 mm , number of starts = 1). The gear
1
ratio (output rotational speed/ Input rotational speeds) is given by U = . The stepper motor (driven by
4
voltage pulses from a pulse generator) executes 1 step/pulse of the pulse generator. The frequency of the
pulse train from the pulse generator is f =10,000 pulses per minute .
Table
f
Pulse Stepper Gear Box
Generator motor U Nut
Lead screw

Q.84 The Basic Length Unit (BLU), i.e., the table movement corresponding to 1 pulse of the pulse generator,
is
(A) 0.5 microns (B) 5 microns (C) 50 microns (D) 500 microns
Q.85 A customer insists on a modification to change the BLU of the CNC drive to 10 microns without changing
the table speed. The modification can be accomplished by
1 f 1
(A) Changing U to and reducing f to . (B) Changing U to and increasing f to 2 f.
2 2 2
1
(C) Changing U to and keeping f unchanged. (D) Keeping U unchanged and increasing f to 2 f .
2
Q.86 In a CNC feed drive, a stepper motor with step angle of 1.8 degree drives a lead screw with pitch of 2 mm.
The basic length unit (BLU) for this drive is
(A) 10 microns (B) 20 microns (C) 40 microns (D) 100 microns
Q.87 Each axis of NC machine is driven by a stepper motor drive with a lead screw. The pitch of lead screw is
p mm. The step angle of stepper motor per pulse input is α degrees/pulse. The ratio of gear drive in
stepper motor drive is g (number of turns of the motor for each single turn of the lead screw). The number
of pulses required to achieve a linear movement of x mm is
αg 360g g 360g
(A) x (B) x (C) x (D) x
360 p p 360 p pα
Q.88 In an NC machining operation, the tool has to be moved from point (5, 4) to point (7, 2) along a circular
path with center at (5, 2). Before starting the operation, the tool is at (5, 4) . The correct G and M code
for this motion is
(A) N010 G03 X7.0 Y2.0 I5.0 J2.0 (B) N010 G02 X7.0 Y2.0 I5.0 J2.0
(C) N010 G01 X7.0 Y2.0 I5.0 J2.0 (D) N010 G00 X7.0 Y2.0 I5.0 J2.0
Q.89 The tool of an NC machine has to move along a circular arc from (5, 5) to (10, 10) while performing an
operation. The centre of the arc is at (10, 5). Which one of the following NC tool path commands performs
the above mentioned operation?
(A) N010 G02 X10 Y10 X5 Y5 R5 (B) N010 G03 X10 Y10 X5 Y5 R5
(C) N010 G01 X5 Y5 X10 Y10 R5 (D) N010 G02 X5 Y5 X10 Y10 R5
Q.90 Circular arc on a part profile is being machined on a vertical CNC milling machine. CNC part program
using metric units with absolute dimensions is listed below,
---------------------------------
N60 G01 X30 Y55 Z-5 F50
N70 G02 X50 Y35 R20
N80 G01 Z5
---------------------------------
The coordinates of the center of the circular arc are :
(A) (30, 55) (B) (50, 55) (C) (50, 35) (D) (30, 35)
Q.91 A robot arm PQ with end coordinates P(0, 0) and Q(2, 5) rotates counter clockwise about P in the XY
plane by 900. The new coordinate pair of the end point Q is
(A) (− 2,5) (B) (− 5, 2) (C) (− 5, − 2) (D) (2, − 5)
Q.92 A point P (1, 3, − 5) is translated by 2iˆ + 3 ˆj − 4 kˆ and then rotated counter clockwise by 900 about the z -
axis. The new position of the point is
(A) (− 6, 3, − 9) (B) (− 6, − 3, − 9) (C) (6, 3, − 9) (D) (6, 3, 9)
Q.93 The figure below represents a triangle PQR with initial coordinates of the vertices as P (1, 3), Q (4, 5) and
R (5, 3.5). The triangle is rotated in the X-Y plane about the vertex P by angle θ in clockwise direction. If
sin θ = 0.6 and cos θ = 0.8 , the new coordinates of the vertex Q are
y
Q(4, 5)
R(5, 3.5)
P(1, 3)
O x
(A) (4.6, 2.8) (B) (3.2, 4.6) (C) (7.9, 5.5) (D) (5.5, 7.9)
Q.94 In a binary system of A and B, a liquid of 20% A (80% B) is coexisting with a solid of 70% A (30% B).
For an overall composition having 40% A, the fraction of solid is
(A) 0.40 (B) 0.50 (C) 0.60 (D) 0.75
Q.95 The binary phase diagram of metals P and Q is shown in the figure. An alloy X -containing 60% P and
40% Q (by weight) is cooled from liquid to solid state. The fractions of solid and liquid (in weight percent)
at 12500 C , respectively, will be
Liquidus
1500
Liquid X
1250
Temperature (0C)
Solidus
1000
Solid
100%P 20 32 40 60 68 80 100%Q
Concentration of Q (in weight%)
(A) 32.0% and 68.0% (B) 22.2% and 77.8% (C) 68.0% and 32.0% (D) 77.8% and 22.2%
MSQ : Multiple Select Question
Q.96 During machining, the wear land (h) has been plotted against machining time (T) as given in the following
figure.
h(mm)
0.8
10 60 T (minute)

Which of the following options is/are correct?

(A) For wear land of 1.8 mm, cutting tool life will be 39.16 minutes.
(B) For wear land of 1.8 mm, cutting tool life will be 51.67 minutes.
(C) For wear land of 1.5 mm, cutting tool life will be 51.67 minutes.
(D) For wear land of 1.5 mm, cutting tool life will be 39.16 minutes.
Q.97 Two different tools A and B having nose radius of 0.6 mm and 0.33 mm respectively are used to machine
C-45 steel employing feed rates of 0.2 mm/rev and 0.1 mm/rev respectively. Which of the following
options is/are correct?
(A) Surface roughness for tool A is 8.33 μm
(B) Surface roughness for tool B is 3.78 μm
(C) Tool B will give better surface finish than tool A
(D) Tool A will give better surface finish than tool B
Q.98 In an orthogonal cutting of C35 steel with HSS tool, the following conditions were noted.
Uncut chip thickness = 0.25 mm
Shear angle = 13.70
Width of cut = 2.5 mm
Cutting force = 1800 N
Thrust force = 1000 N
(A) Area of shear plane is 2.63 mm 2
(B) Mean shear strength for work material is 574.88 MPa
(C) Shear force for work material is 1511.95 N
(D) Mean shear strength for work material is 274.88 MPa
Q.99 In a limit system, the following limits are specified to give a clearance fit between a shaft and a hole.
Shaft 30−−0.005
0.018 mmφ
Hole 30+−0.020
0.000 mmφ

(A) Maximum clearance will be 0.038 mm
(B) Minimum clearance will be 0.038 mm
(C) Ratio of maximum to minimum clearance will be 7.6
(D) Minimum clearance will be 0.005 mm
Q.100 The power source characteristics is given by I 2 = −350(V − 90) and the voltage-length characteristics of
a DC arc is expressed by V = 25 + 5l , where ' l ' is the arc length in mm, and 'V ' is the arc voltage in Volt
and ‘I’ is the welding current in Amp. Which of the following options is/are correct?
(A) For arc length l = 5 mm , welding current I will be 118.32 Amp
(B) For arc length l = 7 mm , welding current I will be 118.32 Amp
(C) For arc length l = 5 mm , welding current I will be 102.47 Amp
(D) For arc length l = 7 mm , welding current I will be 102.47 Amp
Q.101 A cylindrical cup of diameter 10 mm and height 15 mm having a corner radius of 0.4 mm has to be made
out of a 3 mm thick metal sheet blank. Yield strength of material is 250 MPa. If the draw reduction ratio
for first and subsequent draws are 35% and 20% respectively, then which of the following options is/are
correct?
(A) Diameter of metal sheet blank will be 22.45 mm
(B) Number of draws required to draw the desired cup will be 2
(C) Diameter of metal sheet blank will be 26.45 mm
(D) Number of draws required to draw the desired cup will be 4
Q.102 During orthogonal machining with a cutting tool having a 100 rake angle, the chip thickness is measured
to be 0.4 mm and the uncut chip thickness is 0.15 mm. Then, which of the following options is/are correct?
(A) Chip thickness ratio is 0.375 and shear angle is 21.550
(B) Chip thickness ratio is 0.573 and shear angle is 20.220
(C) Shear strain induced is 4.27
(D) Shear strain induced is 2.74
Q.103 A copper bar of 60 mm diameter is to be turned over a length of 170 mm with a depth of cut of 1.5 mm
and feed of 0.2 mm/rev at 230 rpm by HSS. If the modified tool life equation is given by
VT 0.2 f 0.3d 0.12 = 60, then which of the following options is/are correct?
 m mm 
 Where V = min , T = min, f = rev , d = mm 
(A) Time required for turning one job will be 3.6956 min
(B) Time required for turning one job will be 6.9356 min
(C) Number of jobs to be turned before regrinding the tools will be 21
(D) Number of jobs to be turned before regrinding the tools will be 12
I
Q.104 In Gas Metal arc welding the power source characteristics is V p = 36 − and the arc characteristic is
60
Va = 2la + 27, where 'V p ' and 'Va ' are voltages in Volt, ‘I’ is current in Amp and la is arc length in mm.
(A) For arc length la = 3 mm , power of the arc will be 9540 Volt-Amp
(B) For arc length la = 3 mm , power of the arc will be 5940 Volt-Amp
(C) For arc length la = 4 mm , power of the arc will be 2100 Volt-Amp
(D) For arc length la = 2 mm , power of the arc will be 9300 Volt-Amp


ANSWERS
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Common Data for

In an orthogonal machining operation :

Common Data for

Common Data for

Common Data for

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D/5 D/5 D/5

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Common Data for

Common Data for

Work piece (Iron)

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(A) 650.0 (B) 350.0 (C) 290.7 (D) 190.0

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Common Data for

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Which of the following options is/are correct?

Which of the following options is/are correct?

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