SEMESTER END REGULAR EXAMINATIONS (AR20), JUNE - 2022

U.G. MECHANICAL ENGINEERING Degree Bachelor of Technology

Academic Year 2021-2022 Sem. 4th
Course Title
Course Code 20ME403
Metal Cutting and Machine Tools
Duration 3 Hours Maximum Marks 60 (SIXTY)
Remember % 9 Understand % 11 Apply % 80 Analyze % -
SECTION-I
6 x 2 = 12 Marks
1.
No. Questions (a to f) RBT Level COs
What is ASA system? Remember
The ASA Physical Status Classification System has
a been in use for over 60 years. The purpose of the 1
system is to assess and communicate a patient's pre-
anesthesia medical co-morbidities.
List out the various work holding devices used in the lathe Remember
machine?
There is the following work holding devices in the lathe
machine:
Chuck.
b Centers. 2
Steady Rest.
Carriers.
Driving Plate.
Face Plate.
Mandrel.
List out any four operations performed on drilling machine? Remember
The operations that are commonly performed on
drilling machines are drilling, reaming, lapping, boring,
c counter-boring, counter-sinking, Spot facing, and 3
tapping. This is the operation of making a circular hole
by removing a volume of metal from the job by a
rotating, cutting tool called drill.
How do you specify a planning machine? understand
The principle of the planner machine is the concept of relative tool-work
d motions. Reciprocation of the tool or job and the slow, intermittent 3
transverse feed motions are imparted to the job or tool by the fast straight
path cutting motion.
e Classify the milling machine. Remember 4
Milling machines can generally be classified
into horizontal and vertical milling machine based on
the axis of the machine spindle. These machines can
also be divided into knee type milling machines, ram-
 type milling machines, bed-type milling machines,
planer-type milling machines,
What is super finishing? Write any two features of it. Remember
Superfinishing, also known as micromachining, microfinishing,
[1]
 and short-stroke honing, is a metalworking process that improves surface
f finish and workpiece geometry. This is achieved by removing just the 5
thin amorphous surface layer left by the last process with an abrasive stone or
tape; this layer is usually about 1 μm in magnitude. Superfinishing,
unlike polishing which produces a mirror finish, creates a cross-hatch pattern
on the workpiece.
SECTION-II
4 x 12 = 48 Marks
No. Questions (2 to 9) RBT Level COs Marks
In an orthogonal turning operation on a lathe the
following data were obtained. Cutting speed =
120m/min; diameter of the work piece is 100 mm;
cutting force =180kg; feed force = 60kg; back rake
angle = 100; feed rate = 0.3mm/rev; chip thickness =
0.4mm; depth of cut = 0.3mm. calculate chip thickness
ratio, shear plane angle, co-efficient of friction, friction
angle, shear stress, shear strain and chip flow thickness
The following data was observed during orthogonal cutting a steel
work piece of 60 mm diameter.
Cutting speed = 90 m/min,
Feed= 0.15 mm/rev,
Depth of cut 5 mm,
Length of chip /rev = 80.8 mm,
Rake angle = 10∘,
2 Clearance angle = 8∘ Apply 1 12
Tangential force = 2200 N.
Thrust force 1200 N
Length of chip/rev =80.8mm,

Length of uncut chip =πd

=π×60=188.49=188.5 mm

r=L2L1=80.8188.5=0.428

tanϕ=rcosα1−rsinα=0.455

ϕ=24.48∘

Vf=Vcsinϕcos(ϕ−α)
 =90sin24.48cos14.48=38.51 m/min=0.643 m/sec

Energy lost in friction:

R=√ (2200)2+(1200)2 =2506 N

β=α+tan−1(FTFc)

=10+tan−1(12002200)=38.61∘

Friction power=F×Vf

=Rsinβ×0.643 m/sec
=2506sin(38.61)×0.643
=1005.3 W

OR
List the common methods of chip breaking and
explain
The chip breakers break the
produced chips in to small
pieces. The work hardening of
the material of the chip makes
the work of the chip breakers
easy.
3
a Understand 1 6M

The common methods used for

chip breaking are:
i) By control of tool geometry
i.e. grinding proper back rake
and side rake angles according
to the speeds and feeds used.
ii) By obstruction method i.e. by
inters posing a metallic
obstruction in the path of the
coil.
The following types of chip
breakers are commonly used:
a) Groove type:
It consists of a grinding groove
on the face of the tool, behind
the cutting edge, leaving a small
land near the tip.
b) Step type:
It consists of a grinding a step
on the face of the tool, adjacent
to the cutting edge.
c) Secondary rake type:
It consists of providing a
secondary rake on the tool,
through grinding, together with
a small step.
d) Clamp type:
 This type of chip breaker is very
common with the carbide tipped
tools. The chip breaker is a thin
and small plate, which is either
brazed to or held mechanically
on the tool face.
r cosα
b Prove that tan ∅= Understand 1 6M
1−rsinα
4 a How does the apron mechanism of a lathe works? Understand 3 6M
Explain with the help of a neat diagram.

Apron Mechanism:

Apron is attached to the carriage and hangs over the front

side of the lathe bed. It is useful in providing power and hand

feed to both carriage and cross-slide. It is also used to

provide power feed to the carriage during thread cutting

through two half nuts. The construction of apron is shown in

Fig.

Fig - Apron Mechanism

Construction

Power is transmitted from the spindle to the lead screw and

feed rod through the spindle gear and tumbler gear

arrangement. A worm is mounted on the feed rod by a

sliding key. The worm meshes with a worm gear on whose

axis another gear G1 is attached. Gear G1 is attached to a

small gear G2 by a bracket as shown in the diagram. Gear G4

is positioned to be in mesh with the rack gear always.

Another gear G3 is mounted on the same axis of gear G4. The

carriage hand wheel meant for longitudinal feed is attached

to the gear G5 on the same axis. The gears G3 and G5 are

always in mesh. The gear G6 is attached to the cross slide

screw.

The feed selection lever can be kept in neutral, up and down

positions to obtain the following movements.

1. Hand feed and power feed to the carriage

2. Hand feed and power feed to the cross slide

Hand feed to the carriage

Feed selection lever is kept in neutral position and the

carriage hand wheel is rotated. The gear G4 attached to the

rack gets rotation through the gears G5 and G3. The carriage

moves longitudinally.

Power feed to the carriage

When feed selection lever is kept in up position (U), the gear

 G2 will mesh with gear G3. Gear G4 gets rotation through

gear G3 and the carriage gets automatic (power) feed.

Hand feed to the cross slide

Feed selection lever is kept in neutral position. The cross

slide will move on rotation of the cross slide hand wheel.

b What is a twist drill? make a neat sketch of it and Understand 3 6M

show different parts on it
The following Nomenclature of Twist Drill are:
Body
Shank
Dead Center
Point
Lips
Body clearance
Chisel edge
Chisel edge corner
Face
Flank
Flutes
Heel
Neck
Tang

Line diagram of Twist Drill

 Body: The portion between the shank and the drill bit tip is
called ‘Body. The body is mostly fluted and relieved.
Shank: The part of the drill bit that holds into the holding is
called the ‘shank’.
Dead Centre: The sharp edge at the extreme tip end of the
drill is formed by the intersection of the cone-shaped
surfaces of the point. The dead center is always at the
exact center of the axis of the drill.
Point: The entire cone-shaped surface at the cutting end of
the tool.
Lips: The main cutting edges of the drill are formed by the
intersection of the flank and the flute surfaces. For a good
cutting, it should be straight, symmetrical with the axis of
the shaft and equal in length.
Body clearance: To provide diameter clearance the body
surface diameter is reduced.
Chisel edge: The chisel edge is the point. Here two cutting
lips meet at extreme tip.
Chisel edge Angle: The chisel edge angle is the angle
between the chisel edge and cutting lip measured plane
normal to the axis.
Face: The flute surface portion adjacent to the lip, when it
is cut from the work the chip impinges.
Flank: Drill surface which extends behind the lip to flute.
Flutes: The Twist Drill body has grooves and it is known as
flutes.
Heel: The Heel is the intersection of the flute surface and
the body clearance.
Neck: Neck is the portion of the body with reduced
diameter between body and shank.
Tang: The tang is flattened end of the taper shank.
Now moving to different types of Twist Drill,

OR
5 a Analyze the ideal properties of cutting tool. List out Understand 2 6M
different types of cutting tool materials.

There are many types of cutting process done in different

conditions. In such conditions along with the
general requirements of the cutting tool, they need some
unique properties. To achieve this properties the cutting
tools are made up of different material. The material
chosen for a particular application depends on the material
to be machined, type of machining, quantity and quality of
production.
According to the material used the tools are classified into
 1. Carbon tool steel
2. High speed steel tool (HSS)
3. Cemented carbide
4. Ceramics tool
5. Cubic boron nitride Tool (CBN)
6. Diamond tool

With the help of a neat diagram discuss the

constructional features of a radial drilling machine.
The radial drilling machine is intended for drilling medium
to large and heavy work pieces.

b Understand 3 6M

The machine consists of a heavy, round, vertical column

mounted on a large base. The column supports a radial
arm which can be raised and lowered to accommodate
work pieces of different height. The arm …

What is indexing? Briefly discuss about dividing

head.
HomeManufacturing ProcessIndexing in Milling Machine: Head, Part,
Method, Calculation
6
a Understand 3 6M
Indexing in Milling Machine:
Head, Part, Method, Calculation
Kamal DwivediDecember 16, 2021
Hello, friends today's topic is related to "Indexing in
Milling Machine" in which you will learn what is
indexing in milling machines, types of indexing
heads, different indexing methods as well as their
formula and calculation.

Indexing in a milling machine is mainly used to

cut gear teeth accurately and equal spacing of the
teeth of the gear.

It is also used for milling gears, splines, squares,

cutting of flutes in reamers, drills and milling
cutters, racks, grinders, etc.

So without wasting time let's get started.

What is Indexing in Milling Machine?

It is an operation to divide the circumference of a

workpiece into equally spaced divisions.

This operation is performed on the milling

machine by means of an indexing attachment called
an indexing head or dividing head.

But nowadays CNC type milling machine is most

widely used in the industry because this type of
milling machine is fully automatic.

What is Indexing Head or Dividing Head?

A dividing head is an attachment used to rotate the

job through a given angle, which is often equal
divisions of a circle.

It works by converting the work to an angular

position with respect to the cutter.

Types of Indexing Heads

Generally, the following types of dividing heads or

indexing heads are used.
 Simple Indexing Heads
Direct Indexing Heads
Universal Indexing Heads

Sketch and describe a vertical milling machine.

Vertical Milling Machine: Vertical Milling Machine is one of
the most used  operation method. In Vertical Milling
Machine, there is a multi-point cutting tool called milling
cutter. this machine has vertical spindle which is
perpendicular to the work piece. In Vertical Milling Machine,
the head is used to swiveled or it can be fixed. this can move
in upward and downward directions and can move in any
directions. Vertical Milling Machine is used to make a
different type of operations like a flat surface, grooves, slots
etc.

B Understand 4 6M

Working of Vertical Milling Machine:

In this milling machine workpiece is fixed without any

movement, this used to feed against the cutting tool. metal
removed from the workpiece is done in the form of chips, we
can move the head in up and down direction or any angles.
by this, we can perform many operations like grooves, slots

Main parts of Vertical Milling Machine:

 Base:

 The base is the bottom part of a machine used to

support the machine and it contains coolant in it.
Column:

 The column is mounted on the top of the base, this is

used to support the knee by the help of guide ways
and on the top of it, ram is located.
Saddle:

 This is present at the front of the column. this is used

to carry the table on which work is done.
Knee:

 The knee is present at the bottom of the saddle this is

used to support the table and can adjust its position
according to the operation.

Table:
 The table is used to hold the workpiece on it and this
can make the longitudinal motion.
Ram:

 This on the top of the column to make an angle at the

time of cutting.
Tool Head:

 This is to hold the tool holder in which the tool is

fixed.
Spindle:

 This is located in the head which is used to make the

rotation with the help of motors present in the
column.

OR
7 a Explain the working of a slotted disc mechanism for Understand 3 6M
driving the ram of a slotting machine.
The position of the stroke is adjusted with the
help of hand lever provided for the stroke
adjustment. Slotting machine is usually
provided with horizontal circular work table,
but co-ordinate tables are also provided
sometimes. The table is mounted directly
over a bed casting and fairly heavy work may
be placed.

Depending upon the functions for

which slotters are designed, they could
be classified as:

(i) Puncher Slotter:

It is of rugged construction, equipped with a

powerful motor and can machine cut metal at
a very high speed, on it without serious
distortion. Circular table can be revolved by
hand or power teed. It is graduated round its
outer edges, and work can thus be mounted
and turned to predetermined position.

(ii) Production Slotter.

(iii) Tool-Room Slotter.

In this case circular table is mounted on a

pair of slides arranged on a saddle, and this
saddle itself moves on another pair of slides
on the bed casting. Thus, work can be
revolved and also moved in two directions at
right angles to each other.

Relieving tool used with slotters. Fig. 14.30

shows a relieving tool used to produce large
 internal surfaces from drilled holes. This
tool, circular in section, nibbles at the hole
and can cut in every direction at right angles
to its axis

Write short note on the following milling operations

b Understand 4 6M
i) end milling ii) profile milling iii) gang milling
What is the use of cylindrical grinders? Explain the
principle of cylindrical grinding.
When you want to achieve a fine finish on a metallic
surface, you can use cylindrical grinding. Most commonly,
cylindrical grinding is used for grinding pieces with a
central axis of rotation, like rods and cylinders. This
process involves using a cylindrical grinder, which is a type
of machinery categorized by rotation style and wheel
a device. Understand 5 6M
There are several kinds of cylindrical grinders, each one
serving different purposes. However, all of them
accomplish a similar goal — to remove tiny bits of excess
metal from aluminum, steel and other metal objects as the
8 final step in a project. As a result, you have a smooth
piece of metal for your specific application.

What are the different types of bonds used in the

manufacture of abrasive wheels? Explain.
Standard grinding wheel bonds are vitrified,
resinoid, silicate, shellac, rubber and metal.
b Vitrified bond. Vitrified bonds are used on more Understand 5 6M
than 75 percent of all grinding wheels. Vitrified
bond material is comprised of finely ground
clay and fluxes with which the abrasive is
thoroughly mixed
OR
What is lapping? How is it done? How many types of
a Understand 6 6M
lapping operations are there? Explain.
9
Explain with neat sketches: i) centreless grinding
b Understand 5 6M
and ii) internal centreless grinding
***********