st Crack al Attempt 2016 WOrKbOOK Tete Tie) | Production Engineering Engineering R= Ee MADE EASY Publications (© Copyright: Sbjct matt to MADE EASY Pubcatos, Now Deh No pao hisbook may be reproduced or utsed in ay em wither te wren permission.O16 \ MADE EASY | Production Engineering | WOPKDOOK | Production Engineering Sl. Unit Mechanics of Basic Machining Operation Cutting Tool, Too! life and Cutting Fluid. 1 2 3. Economics of Machining Operation... 4 Lathe 5, Shaping and Planning 6 Drilling Boring and Reaming 7. Milling & — Gear and Screw Thread Manufacturing 9. Grinding 10. Non-conventional Machining Operation. 11. NC, CNC, Robotics... 12. Jigs and Fixture 13. Metrology. 14, Rolling 15. Forging... 16. Drawing. 17. Extrusion 18. Sheet Metal Forming. 19. Powder Metallurgy. 20. Welding se 21. Conventional Casting Process 22. Special Casting Process .. No part ofthis book may be reproduced cr utlisedin any form without the written permission,Mechanics of Basic Machining Operation [Vf Multiple Choice Questions oy/ine angle between the face and the flank of the single point cutting tool is known as (@) rakeangle —_(p) clearance angle (2) pointangle rip angle [IES : 1995] OF te angle of inclination of the rake face with respect to the tool base measured in a plane perpendicular to the base and parallel to the width of the tool is called: (a) Back rake angle (b) Side rake angle ) Side cutting edge angle (d) End cutting edge angle —[IES: 2003] aes the following characteristics: “The cutting edge is normal to the cutting velocity, The cutting forces occur in two directions only. _& The cutting edges wider cut. than the depth of sip StS The characteristics applicable to orthogonal cutting would include (@) 1and2 (b) 1 and 3 (©) 2and3 1, 2and3 [IAS : 1994] The primary too! force used in calculating the total power consumption in machining is the (@) racial force tangential force (©) axialforce ——_(¢) frictional force [IES : 1995) ©Copyright | pandar60 Fmanvoa sia URGON RISC RaW BUOTTPDIGNG ASE SOM GH RNB PRIaRS REO @ a z ‘oseniued canna FEN Publications. a acas G75 [ge single point turning tool, the side rake angle ind orthogonal rakg angle are equal. ¢ is the rincipal outtimy'édyje angle and its range is 0 <6 < 90°. The chip flows in the orthogonal plane. The value of ¢ is closest to @o (b) 45° ©) we [GATE : 2008] lop Cansie ‘the following statements: The strength of a single point cutting tool depends upon Take angle 2. clearance angle 3. lipangle ~ Which of these statements are correct? (a) 1and3 (b) 2and3 (c) 1and2 LO 2and 3 [IES : 2002] Inmetal cutting operation, the approximate ratio heat distributed among chip, tool and work, in that order is: 78:10:10 (b) 33:33:33 (©) 20:60:10. (d) 10: 10:80 [ES : 1998] ~ ‘Consider the following statements about nose. radius: T. Itimproves tool life 0% Span ue 2, Itreduces the cutting force > 3. Itimproves the surface finish v- he A Of these staternents @ky (a) 1and2are correct (0) 2and3are correct (Oana are correct 45) O (@) 1,2and3 are correct [IES : 1995] isonMechanical Engineering 4 Q.9 During machining, excess metal is removed in the form of chip as in the case of turning on a lathe. Which of the following are correct? Continuous ribbon like chip is formed when turning 1. Atahigher cutting speed 2. Atalower cutting speed 3. Abritle material 4, Aductile material Select the correct answer using the code given. below? (@ 1and3 (0) tanga (©) 2and3 (@) 2and4 [les : 2007] to relief angle of cutting tool 1. This affects the direction of chip flow 2. This reduces excessive friction between the tool and work piece. This affects tool life. This allow better access of coolant the tool-workpiece interface. 4fot tool Opp: Which of following statements given are correct (a) 1and2 \by2 ands (© 2and4 (0) Sand 4 [IES : 1997] 3. 4 Sal In orthogonal turning of a low carbon steel bar of diameter 150 mm with uncoated carbide tool, the cutting velocity is 90 m/min. The feed is 2 0.24 mm/rev and the depth of cut is2 mm. The & chip thickness obtained is 0.48 mm. If the orthogonal rake angle is zero and the principal “7 9.2, la.grtogonal tying of medium carbon steel, x92 lag n : The specific machining energy is 2.0 Jimm®, The f cutting velocity, feed and depth of cut are 120 in/min, 0.2 mm/rev and 2mm respectively. The main cutting force in Nis (a) 40 (0) 8 (c) 400 (d) 800 oh ¢ cutting edge angle is 90°, the shear angle in 57, — degresis 4% @ 2086 26.56 a5 ©) 9056 (d) 36.56 [GATE : 2007] 2 [GATE +2007] 13d ON TueG WON "SUOTPOIENG ABV SOYA) Jo pasnpoides eq Kew ¥000 Si ‘orssiaied vaniim qi Wouiim wi0} AUB UI pa ve signatures wo tools P and Q Nel Two 10088 7-0 and S°-S°-77-77-8°-15°-0 (both ASA) respectively. They are used {© i" same machining nder thy components unde aon Conditions. If Mp and No de ED tne peak-to-valley heights of surfaces Pre" by the tools Pand Q, the ratio Mala Wil Be tant5* +0018? (©) {an30r + cots 13 tang® + cot 15° ©) jane 60190" tan7°+cot1S? ) tan7= + cot30" [GATE : 2005] (©) tan30"+ cot? (orthogonal cutting test, the cutting force = 900 N, the thrust force = 600 N anc chip shear angle is 30°. Then the chip shear force is (@ 1079.4N (©) 479.4N (b) 969.6N (d) 69.6N [IES : 2003] 0.15 When depth of cut is increased, the specific cutting energy (@) Increases (©) Decreases (©) Remains same (a) Reaches an optimum value Q.16 Amedium carbon steel workpiece is tured on alathe at 50 m/min cutting speed, 0.8 mmirev feed and 1.5 mm depth of cut. What is the rate of metal removal? (@) 1000 mm/min (©) 60,000 mm/min (€) 20,000 mm®/min 7 (d) Cannot be calculated with the given data IES : 2004] 2.17£onsider the following the statements: nan orthogonal cutting the cutting ratio is found to be 0.75, The cutting speed is 60 m/min and depyprof cut 2.4 mm. an velocity will be 45 mimin. 2. Chip velocity Will be 80 m/min. 3. Chip thickness will be 1.8 mm. 4, Chip thickness will be 3.2 mm. MADE EASY Publications.Roe > sabe > Publications Which of the following are correct? (@) 1and3 (b) tand4 (¢) 2and3. (0) 2and4 [IES : 2008] Q.18 In turing operation, the feed could be doubled to increase the metal removal rate. To keep the same level of surface finish, the nose radius of the tool should be: (a) Halved (c) Doubled (b) Keptunchanged (d) Made four times [IES : 1999] of 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-' during the process is (a) 0.1781 x 10° (c) 1.0104 x 108 (b) 0.7754 x 10° (d) 4.397 x 108 [GATE (PI) : 2012] 10 7he main cutting force acting on a tool during the turning (orthogonal cutting) operation of a metal is 400 N, The turning was performed using iw” 2mm depth of cut and 0.1 mm/rev. feed rate. 2a” The specific cutting pressure (in Nimm?) is (@) 1000 (o) 2000 FI Awe (c) 3000 (a) 4000 [GATE : 2014] aes surface finish is obtained with alarge rake angle because (@) the area of shear plane decreases resulting in the decrease in shear force and cutting force (bythe tool becomes thinner and the cutting force is reduced (c) less heat is accumulated in the cutting zone (@) the friction between the chip and the tool is Carthy dy nds — Tet Ce —Cs = NH Workbook 5 0.20% instrument or device used to measure the Cutting forces in machining is. (@ Tachometer (b) Comparator (©) Dynamometer (d) Lactometer (IES : 2011] | 23%6uine orthogonal cutting, an increase in cutting speed causes (@) Aninorease in longitudinal cutting force (©) Aniincrease in radial cutting force (©) Anincrease in tangential cutting force at Cutting forces to remain unattected [IES : 2012] aFricn one of the following statements is correct about an oblique culling? (a) Direction of chip flow velocity is normal to the cutting edge of the tool {b) Only two components of cutting forces act on the toot (©) Cutting edge of the tool is inclined at an acute angle to the direction of tool feed (¢) Cutting edge clears the width of the workpiece [IES : 2014) PS turning of a mild stee! tube with a tool of rake angle 10° carried out at a feed of 0.14 mmlrev. If the thickness of the chip produced is 0.28 mm, the values of shear angle and shear strain will be respectively (a) 28°20’ and 2.19 (b) 22°20" and 3.53, (©) 24°30’ and 3.53 (d) 37°20" and 5.19 a long BOUND IGATE : 2015] Q.26 A cutting too! has major cutting edge angle of 30°, minor cutting edge angle of 8° and nose radius of 1.8mm. During turning a carbon steel rod with feed 0.2 mmirev. What willbe the peak to valley height of surface produce? (@) 2.7 x 103mm (b) 26.0 x 10 mm. (©) 106,806 x 10% mm oysequlned wannim dui TmouiTw w10) us i passin 70 peanperde; gl Feu yoou suhyo ued ON WeG MeN #UO]E0/0Ng ASV AGW ED! less [GATE : 2014] (a) 1.6 x 10-3 mm 6; ee MADE EASY Publications} 6 . Mechanical Engineering .27 If the friction angle of the tool chip interface is 580’ the the cutting force components measured by a dynamometer are 600 N and 200N, the power loss due to trition (in KNmvimin) is approximately (a) 20 © 6 (o) 18 (¢) 350 [GATE : 2005] rh ‘Which pair of following statements is correct for orthogonal cutting using a single-point cutting tool? P. Reduction in friction angle increases cutting force Reduction intriction angle decreases cutting force R. Reduction in friction angle increases chip thickness ‘eduction in friction angle decreases chip thickness (@) PandR (b) Pands. (c) QandR L9Gands [GATE : 2014] Q.29 What is the approximate % change in the life, t, of the tool with zero rake angle used in orthogonal cutting when its clearance angle, a, is changed from 10 to 7 deg? (Hints : Flank wear rate is proportional to cot a) (@) 30% increase (b) 30% decrease (©) 70% increase (d) 70% decrease [GATE : 1999] Numerical Data Type Questions 0.30A straight turning operation is carried out using i single point cutting tool on an AISI 1020 steel rod. The feed is 0.2 mmirev and the depth of Production Engineering ° 3 z 70d ON WIG MEN 00 Thowinm 9} Aue ul posiian 70 paonpaida eq Kew yo9a Publ thickness of the chip produced is 0.5 mm. The feed given to the zero degree rake angle tool is 0.2 mmirev. The shear strain produced during the operation is [GATE : 2014] aay ange point cutting too! with 0° rake angle is used in an orthogonal machining process. At ‘a culling speed of 180 m/min, the thrust force is 490 N, Ifthe coefficient of friction between the tool’and the chip is 0.7, then the power consumption (in kW) for the machining operation is 2:\ me [GATE : 2015] ronkhink Gone") 2.33 An orthogonal turning operation is carried out 307 under the following conditions; rake angle = 5°, spindle rotational speed = 400 rpm; axial feed Lea = 0.4 mimin and radial depth of cut = 5 mm, iz Thechip thickness t, is found to be 3mm. The ag shear angle (in degree) in this turning process is_ peat?” 2.34 uring turning a carbon steel rod of 160. mm diameter by a carbide tool of geometry 0°, 0°, 40°, 8°, 15°, 75°, 0 (mm) at speed of 400 rpm, feed of 0.32 mm/rey. and 4.0 mm depth of cut, the following observations were made Tangential component of the cutting force, P, = 1200N Axial component ofthe cutting force, P, = 800N. Chip thickness (after cut), = 0.8mm For the above machining condition determine the values of (i) Friction force, Fand normal force, Nacting 7a cutis 0.5 mm. The tool has a side cutting edge | 3 atthe chip-tool interface. angle of 60°. The uncut chip thickness (in mm) 3 (ii) Yield shear strength of the work.material is Auth 2 under this machining condition. > [GATE : 2014] | 3 (ii) Cutting power consumption in kW. 5@41 During pure orthogonal turning operation of a | (iv) Specific energy consumption. hollow cylindrical pipe, it is found that the [IES : 2003] MADE EASY yt Publications NCOPMADE EASY Publications Workbook | 7 0.38 Mid steelis being machined ata cutting speed (of 200 mimin with a tool rake angle of 10°. The | © Try Yourself width of cut and uncut thickness are 2mm and | 8 0.2 mm respectively. If the average value of |S coetcient of ction between the tool and the | ,| T1- A Bet of 70 mm es chip is 0.5 and the shear stress of the work | & ‘orthogonally and Is reduced to 68 mm by a material is 400 Nimmr2, determine (i) shear angle | 2 ea eee ee ve ee s and (if) culting and thrust components of the | 2 angie scot ee sie tae aa machining force. e [Ans : 0.318 and 18.34" (ES ; 2005) | = : ; 8] 72, In aorthogonal cutting test, the following data 0.36 While turing a C'S steel of 160 mm diameter |] Tn orhogenst cuting i ° at 215 rpm, 2.5 mm depth of cut and feed of | 2 Uncut chip thickness = 0.25 mm 0.16 mmjrev by a tool of geometry |& Cuting speed = 60 min 0-10-8-9-15-75-0 mm, the folowing observations Tool ake angle = 0° were made, Tangential component f the cutting Chip thickness = 0.75 mm force = 500 N. Axial component of the cutting Cutting force = 900 N force = 200 N, chip thickness = 0.48 mm. Thrust force = 450N Determine the dynamic shear strength of the Caloulate the shear angle, total power in making work piece material. the cut, coefficient of friction between the chip tool interface, percentage shearing power and percentage frictional power. 3] [Ans : 18.43", 900 W, 0.5, , 69.33% & 16.67%] =| T3. While machining steel with zero rake angle, 2 prove the folowing expression whose t, is shear z strength, P, is specific cutting power and ris 8 chip reduction coefficient (t/t) 3 te _r(t-nr) & Ans, |= = LET 8 [: +r peor ds tor (G0 3a p= 58° Io! + (aye 8 sae = tok G8 sua Are? eI ele 3 stel-6) > 9A = 2 3 ato |? MADE EASY Fawr [x6 m, Publications See > 200 te 2 aikw. wy | Multiple Choice Questions (ahd ASV BOW UN DeTaN BIAGIO Q.1/Consider the following tool materials: 1. HSS 2. Cemented carbide 3. Ceramics v 4. Diamond ~ The correct sequence of these materials in decreasing order of their cutting speed is: *@43.42 ¥(b) 43,21 x(d) 3, 4, 1, 2[IES : 2000} Cutting Tool, Tool Life and Cutting Fluid a4 Qs Which one of the following is the hardest cutting tool material next only to diamond? (a) Cemented carbides (b) Ceramics (@) Silicon (d) Cubic boron nitride [IES : 2002] Consider the following statement: ‘An increase in the cobalt content in the straight carbide grades of carbide tools 1. increases the hardness 3421 3 2, decreases the hardness Q.2. The correct sequence of cutting tools in the | 2 3. increases the transverse rupture strength ascending order of their wear resistance is: g 4, lowers the transverse rupture strength (@) HSS-Cast nonferrous alloy (Stellite)-Carbide- | > Which of the statements given above are Nitride i correct? (b) Castnon-ferrous alloy (Stelite)HSS-Carbide- | (@) tand3 (0) 2and4 Nitride i (©) 1and4 (@) 2and3 (0) HSS-Cast non-ferrous alloy (Stelite)-Nitride- | £ [IES : 2005] Carbide 4 (8) Cast non-ferrous alloy (Stellte)-Carbide- | ¥ | @.6 Whatis the safe operation temperature for HSS. Nitrde-HSS a tools? [IES : 2003] | 3 (a) 850°C (b) 750°C 3 Consider the following statements: oe ee For precision machining of non-ferrous alloys, |&|Q.7 Consider the following statements: diamond is preferred because it has: 3 Chipping of a cutting tool is due to 1. Lowcoefficient of thermal expansion 3 4. tool material being too brittle 2. High wear resistance \ 5 2. hot hardness of the tool material 3. High compression strength a 3. high positive rake angle of the tool 4. Low fracture toughness : Which of these statements are correct? ‘Which of these statements are correct? 3 (@)1,2and3 (6) tand3 (a) tand2 (b) tand4 3 (©) 2and3 (a) 1and2 () 2and3 (een § AS : 2003] [les : 1999] |2 : bia MADE EASY a)mApDE EASY Publications | —=————~ Q.8 Consider the following work materials: 4. Titanium 2. Mild steel 3, Stainless steel 4. Grey castiron The correct sequence of these materials in terms of increasing order of difficulty in machining is: (2) 4.2.31 (0) 4,2,1,3 (c) 2,4, 3,1 () 2.4,1,3 [IES : 1995] Q.9 Machinability depends on (@) Microstructure, physical and mechanical properties and composition of workpiece material (©) Cutting forces, + © Types of Chips (@) Too! life [ISRO : 2007] Q.10 Which of the following indicate better machinability? 1. Smaller Shear angle 2. Higher cutting forces 3. Longer tool life 4, Better surface finish (a) 1and3 (b) 2and4 (c) tand2 (@) 3and4 [IES : 1996] Q.11 The type of wear that occurs due to cutting action of the particles in the cutting fluid is referred toas (a) attrition wear (0) erosive wear (b) diffusion wear (A) corrosive wear [IAS : 1999] Q.12 Flank wear occurs mainly on which of the following (@) Nose part and top face (b) Cutting edge only (c) Nose part, front relief face, and side relief face of the cutting too! (d) Face of the currying tool at a short distance ng WwBAIOD jad ASVS SOWA 0128 (20 maw "evar ed on 70 posnpoider aq Keun yoo #4 aved UsTiaa een Frou sey Lae pal Workbook | gy Q.13 Crater wear is predominant in (a) carbon steel tools (b) tungsten carbide tools (©) high speed steel tools (A) ceramic tools, [IES : 1995] Q.14 Consider the following elements: 1. Noseradius 2. Cutting speed 3. Depthofout 4. Feed The correct sequence of these elements in decreasing order of their influence on too! life is (@) 2,4,3,1 (b) 4.2.34 ©2413 (0) 4.2.1.3 [IES : 1997] Q.45 Consider the following statement: During third stage of tool-wear, rapid deterioration of tool edge takes place because 4. Flank wears only marginal 2. Flank wear is large 3, Temperature of tool increase gradually 4, Temperature of tool increase drastically (a) 1and3 (b) 2and4 (©) tand4 (d) 2and3. [IES : 1998] Q.16 Amachinist desires to turn a round steel stock of outside diameter 100 mm at 1000 rpm. The material has tensile strength of 75 kg/mm®. The depth of cut chosen is 3 mm at a feed rate of 0.3 mmirev. Which one of the following tool materials will be suitable for machining the component under the specified cutting conditions? (a) Sintered carbides (©) Ceramic (©) HSS (4) Diamond [IES : 1996) Q.17 Whats the variation of cutting speed with tool life on Log-Log scale? (@) Parabolic variation (b) Straightline variation (©) Hyperbolic variation from the cutting edge 5 we rf : 3 (d) Elliptical variation IES : 2007] t 1 [IAS : 2006) i nf MADE EASY ey Publeatone10 Mechanical Engineering © Produ 2.18 The too! life curves for two tools A and 8 are ‘shown in the figure and they follow the tool life equation VT" = C. Consider the following statements: Cutting speed 1. Value of n for both the tools is same 2. Value of Cfor both the tools is same 3, Value of Cor tool Awill be greater than that for the tool B 4. Value of Cfor B will be greater than that for the tool A Which of these statements is/are correct? (@) 1and3 (b) tand4 (©) 2only (A) 4only [IAS : 2003] Q.19 Which of the following values of index n is associated with carbide tools when Taylor's tool life equation V7" = constant is applied? (2) 0.110015 —(b) 0.2t00.4 (0) 0.451006 —(d) 0.651009 [Es : 2006] Q.20 The following tool-life equation represents the effect of cutting variables viz. speed (v), feed (A and depth of cut (d) on tool life T: VI" f" d@=C. Where n, n,, n, are exponents and C.is a constant, For most of the cutting conditions, which one of ———the followings generally observed? n Engineering MADE EASY Q.21 In the given figure, for which of the following does the curve °C’ hold good? ° = log (cutting speed) lg (Tool fe) —> ind ASV SQV) BU (@) HSS. tools (0) Cemented carbide tool (©) Ceramic tools (@) Ideal material tools, [IAS : 2006) Q.22 In a too! life test, doubling the cutting speed reduces the tool life to 1/8" of the original. The Taylor's too! life index is: (o) (20 mon uDHD on @ © @) leateroies ale wis [IES : 2000] Q.23 What are the reasons for reduction of tool life in machining operation? 1. Temperature rise of cutting edge 2. Chipping of tool edge due to mechanical impact 3. Gradual wear at tool point 4, Increase in feed of cut at constant cutting force Select the correct answer using the cod given below: (@)1,2and3 —(b) 2,3and4 (©) 1,3and4 —(¢) 1,2anda [IES : 2008] uotssiu9d veiiim ou Rout wy Kae w pestinn se poOnpoNdar Ba feu vooa (a) 45m, 2 (b) = > a 25 Q.24 Dry and compressed air is used as cutting fluid ne for machining: 1, &yl,m @) steel (0) aluminum Onn thy. On nn (©) castiron (d) brass LIES : 1995) MADE EASY Publications:maApDE EASY Publications 0.25 Typical coolants used for machining aluminium are: 1. Kerosene oil 2. Soda water 3. Air 4. Paraffin oil (a) 1,2,3and4 (b) 2and3 (©) 1and2 (@) Banda {IES : 2014] Q.26 For tool A, Taylor's tool life exponent (n) is 0.45 and constant (K) is 90. Similarly for tool B, n=0.3and K= 60. The cutting speed (in m/min) above which tool A will have a higher tool life than tool Bis (a) 26.7 (0) 42.5 (©) 807 (a) 1429 [GATE : 2010] Q.27 Inaccelerated too fe tests, the three main types. of quick and less costly tool life testing are (@) extrapolation on the basis of steady wear; conventional measurement of flank and crater wear; comparative performance against tool chipping measurement of abrasive wear; mulli-pass turning; conventional measurement of diffusion wear extrapolation on the basis of steady wear; multi-pass turning; taper turning comparative performance against tool chipping; taper turning; measurement of abrasive wear (b) (c) (a) [IES : 2014] Q.28 During machining, the wear land (h) has been plotted against machining time (T) as given in the following figure Workbook 41 (@) 52.00 (c) 51.50 (b) 51.67 (@) 50.00 [GATE (PI): 2008} Q.29 Crater wear always starts at some distance from the tool tip because at that point (@) cutting fluid does not penetrate (6) chip tool interface temp is maximum (©) normal stress on rake face is maximum (A) tool strength is minimum [GATE : 1989] jeu yoatang WOUKIOD © Q.30 Cutting tool is much harder than the workpiece. Yet the tool wears out during the tool-work interaction, because (@) extra hardnessis imparted to the workpiece due to coolant used (©) oxide layers on the workpiece surface impart extra hardness to it (c) extra hardnessis imparted to the workpiece due to severe rate of strain (d) vibration of induced in the machine too! [GATE : 2014] jana ASWa SOV OF z 3 | Q.31 For increasing the material removal rate in 2 turning, without any constraints, what is the right I sequence to adjust the cutting parameters? A 1. Speed 3 2. Feed 5 3, Depth of cut I Select the correct answer using the code given below: (a) 1-2-3 (bo) 2-3-1 () 3-2-1 (@ 1-3-2 [IES : 2007] Direction for Assertion & Reasoning Questions: The following items consists of two statements, one labelled as ‘Assertion 4’ and the other labelled as 3 5 7 ‘Reason A’. You are to examine these two statements 3 | carefully and select the answers to these items using t 3 | the codes given belo 0 T (minute) 0 § (@) Both Aand Rare individually true and Ris For a critical wear land of 1.8 mm, the cutting 3 Comacteaplanationof A i ; eae 8 (b) Both A and Rare individually true but Ris tool iia Qnimnin) is not correct explanation of A (@ copys | MADE EASY se PulcationsMADE EASY 12 | Mechanical Engineering @ Production Engineering Numerical Data Type (©) Ais true but Fis false Questions (d) Ais false but Ris true Q.32 Assertion (A): The characteristics feature of High Speed Steel is its red hardness. Reason (A): Chromium and cobalt in High ‘Speed Steel promote martensite formation when the tools is cold worked @.38 Under certain cutting conditions, doubling the » cutting speed reduces the tool life to (35) UAS:: 1994] of the original. Taylors tool ite index(n) for this tool-workpiece combination will be [GATE : 2015] Q.33 Assertion (A): During cutting, the diamond tool is kept flooded with coolant. Reason (A): The oxidation of diamond starts at about 450°C [IAS : 1999] gy : Conventional Questions Q.34 Assertion (4): Ceramic tools are used only for light, smooth and continuous cuts at high speeds, Reason (A): Ceramics have a high wear resistance and high temperature resistance, [IES : 1997] Q.39 An HSS tool is used for turning operation. The tool life is 1 hour when turning is carried at 30mimin. The tool lfe will be reduced to 2.0min ifthe cutting speed is doubled. Find the suitable speed in RPM for turning 300 mm diameter so that life is 30 min, © paanpoides oq Kou yeaq sho We ON WWlba MON SUDLTOOHGna ASV SOWW 01 BNEW ToTaNS Q.35 Assertion (A): Cemented carbide tool tips produced by powder metallurgy. [IES : 2006] Reason (R): Carbides cannot be melted and cast. [IAS : 1994) Try Yourself Q.36 Assertion (A): Negative rake is usually provided = on carbide tipped tools. T1. _Inadrilling operation under a given condition, Reason (A): Carbide tools are weaker in the tool life was found to decrease from compression’ 20 min to 5 min due to increase in drill speed from 200 rpm to 400 rpm. What will be the tool [IES : 2002] life of that drill under the same condition if the drill speed is 300 rpm? Q.37 Assertion (A): Non-ferrous materials are best machined with diamond tools. [Ans : 8.89 min] Reason (A): Diamond tools are suitable for high speed machining. T2, If under a condition of plain turning the life of the cutting too! decreases by 50% due to increase in the cutting velocity by 20%, then what is the % increase in tool life due to reduction in the cutting velocity by 20% from its original value. [IES : 1995] [Ans : 133%] ‘oIssiwuied uatium ou) inom we) Aue Uy pea PublicationsEconomics of Machining Operation Multiple Choice Questions Q.1 Consider the following approaches normally applied for the economic analysis of machining: 1, Maximum productions rate 2. Maximum profit eriterion 3. Minimum cost criterion The correct sequence in ascending order of optimum cutting speed obtained by these approaches is: (a) 1.2.3 () 1 (©) 3.2.1 (d) 3, IES : 1999] Q.2 Which one of the following does not affect the selection of optimum cutting speed for minimum cost? (@) Labour cost (0) Machine maintenance cost (6) Tool cost (d) Job handling cost IAS : 2006] Q.3 In economics of machining, which one of the following costs remains constant? (@) Machining cost per piece (b) Tool changing cost per piece (©) Toot handling cost per piece (6) Too! cost per piece [IES : 2002] Q.4_ Consider the following statements: 1. Asthe cutting speed increases, the cost of Production initially reduces, then after an optimum cutting speed it increases. Syn on ena elans WENECD MADE EASY blications 2. As the cutting speed increases the cost of production also increases and atter a critical value to reduces. 3. Higher feed rate for the same cutting speed reduces cost of production. 4, Higher feed rate for the same cutting speed increases the cost of production Which of the statements given above is/are correct? (@) 1and3 (©) tand4 (6) 2and3 (d) 3only [IES : 2004] Inturning, the ratio of the optimum cutting speed for minimum cost and optimum cutting speed for maximum rate of produstion is always (2) equal to 1 (©) in the range of 0.6 to 1 (0) inthe ranges of 0.1 0.0.6 (A) greater than 1 [IAS : 1997} The figure below shows a graph which qualitatively relates cutting speed and cost per Piece produced. Total cost 8 3 x 8 3 1 Cutting speed The three curves 1, 2 and 3 respectively represent 5 (a) machining cost, non-productive cost, tool changing cost “wwewemadeeasypublications.org }a4 Q2 Match List-I (Part) with List-Il (Method of holding) and select the correct answer using the codes given below the lists: List-1 . Cylindrical parts Non-cylindrical parts . Very complicated shapes |. Material in bar form on small lathes List-Il 1. Circular face plate 2. Collet 3. Three jaw chuck 4. Four jaw chuck Codes: 9Om> @ (b) (c) ) Consider the following statements associated with the lathe accessories: 1. Steady rest is used for supporting a long job in between head stock tail stock. 2. Mandrel is used for turning small cylindrical job. 3. Collets are used for turning disc-shaped job, Of these statements: (@) 1and 2are correct (b) 2and3 are correct (c) 3alone is correct c 4 1 1 onengd VoeneDd B 1 4 4 1 4 [IAS : 2005] (d) 1 alone is correct [IAS ; 1998] Uuerssuod uanyin nok uy Axe pas 1 padnpoxda! 69 Kew yOOG sa OVE ON WRC NaN SUOTEO| aha AGva SMW A avEUTDOTaNS NETO © a3 a4 The indexing of the turret in a single-spindle automatic lathe is done using: (@) Genevamechanism (b) Ratchet and Paw! mechanism (©) Rack and pinion mechanism (d) Whitworth mechanism [IES : 2001] The figure shows an incomplete schematic of a conventional lathe to be used for cutting threads with different pitches. The speed gear box U, is shown and the feed gear box U, is to be placed. P, Q, A and $ denote locations and have no other significance. Changes in U, should NOT affect the pitch of the thread being cut and changes in U, should NOT affect the cutting speed, Spindle (waar Joo, Publications: Pa The correct connections and the correct placement of U, are given by (a) Qand Eare connected. U, is placed between PandQ. (b) Sand Eare connected. U, is placed between Rand S. (c) Qand Eare connected. U, is placed between Qand E (d) Sand Eare connected. U, js placed between Sand E. [GATE : 2008]16 Q.5 The spindle speed range in a general-purpose lathe is divided into steps which approximately follow: (@) arithmetic progression (b) geometric progression (©) harmonic progression () logarithmic progression [IES : 2001] Q.6 A 400 mm long shaft has a 100 mm tapered step at the middle with 4° included angle. The tailstock offset required to produce this taper ona lathe would be: (@) 400sin 4° (©) 100sin 4 (b) 400 sin 2° (0) 100 sin 2° [IES : 1998] Q.7 Estimate the boring time to enlarge a spindle bore from diameter 30 mm to diameter 40 mm for a length of 100 mm taking cutting speed as 30 m/min, feed 0.01 cm/rev. All cuts are 2mm deep. (@) 3.2min (b) 10.7 min (©) 3.7 min (d) 4.2 min Q.8 A through hole of diameter 20 mm has to be drilled in a lathe in a rectangular plate of size 500 x 400 x 50 mm. Drills of diameter 10 mm and 20 mm are available. Assuming that the cutting speed is 10 m/min and the feed for drill is 0.2mmfev, calculate the driling time. Neglect, approach and over travel. Maximum material cut at a time cannot exceed 10 mm. (@) 1.6min (b) 13min (©) 16min (a) 2.4 min Q.9 Asquare plate of size 300 x 300 mm has to be faced on both sides to reduce its thickness from 50 mm to 40 mm in two cuts per side. Cross feed is 0.05 cm/rev and plate rotates at 200 rpm. (i) Estimate the machining time neglecting the comer lengths. (a) 1.5 min (b) 6min (©) 3min (d) min Mechanical Engineering © Production Engineering (ang ASV SAVW 01 Tone jaalang WBUAGID @ ‘UOISS/A00 UeHum au InOUIM UO) AUB Ul PASIIIN 70 paanpoldel aq Kew ood sill 10118 ON THAD NEN “SUO) MADE EASY Public (i) Estimate the machining time including the comer lengths. (@) 85min (0 43min (b) 2.1 min (@) 12.7 min Q.10. Lathe machine with turret can turn a work piece of limited length only because (@) Cross slide motion is obstructed by turret (b) Turret cannot work on a long job (©) Chuck cannot be replaced by a face plate (d) Turret replaced the loose centre [IES : 2012] Q.11 The diameter and rotational speed of a job are 400 m and 500 rpm respectively. The high spots (chatter marks) are found at a spacing of 30 deg on the job surface. The chatter frequency is (a) 5 Hz (c) 100 Hz (b) 12 Hz (@) 500 Hz [GATE (PI) : 1990] Q.12 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 the taper is made by tailstock set over method, the taper angle and the set over respectively are (a) 15°32’ and 12.16 mm (b) 15°32’ and 15.66 mm (0) 11°22’ and 10.26 mm (@) 10°32" and 14.46 mm [GATE : 2015] Q.13 A job of the shape shown in the figure below is to be machined on a lathe. The tool best suited for machining of this job must have (2) positive side rake angle (©) positive back rake angle PublicationsmrApDE EASY Publications (c) positive cutting edge inclination angle (a) negative cutting edge inclination angle [GATE (PI) : 2014) Q.14 A lead screw with half nuts in a lathe, free to rotate in both directions has (a) V-threads (b) Withworth threads (c) Butteress threads (a) Acme threads [GATE : 2002] Numerical Data Type Questions Q.15 For cutting double start screw threads of pitch 2mm on alathe, the thread cutting tool should have a feed of mmjrev. Q.16 A medium carbon steel work piece is turned on a lathe at 50 m/min cutting speed, 0.8 mm/rev feed and 1.5 mm depth of cut. The MRR is mm/min, &y | Conventional Questions Q.17 Find the time required to turn a 60 mm diameter rod into the dimensions shown, take cutting speed as 20 m/ min. f= 1.2 mmirev. All cuts are 3 mm deep -— 10 ——-+—— 11s ——+| jane wuB0kG0 @ jeon@ha ASS 3OVH 01 HU ToISS|ued UOT Buy IRON Woy AUB Ul PesIITIN 70 peonnosdel oq Kew HOON Si yo ved ON WAG MEN "SUE 17 Workbook Q.18 Find the time for threading on 3 cm spindle of M.S. for length of 18 cm. The number of threads to be cut are 3/em, The lathe runs at 88 rpm. Assume Approach and over travel are 0.5 cm each and number of cuts for M.S. are 7. Q19 Determine the transformation ratio (TR) of the gear train connecting the spindle and the lead screw of 4TPI required to out 1.0 mm pitch screw threads in a centre lathe. [GATE : 1995] Q.20 Estimate the machining time to turn MS Rod from 4 cm diameter to 3.5 cm diameter for a length of 15 cm ina single cut. Assume cutting speed 30 m/min. Feed 0.4 mm/rev. Try Yourself T1. Asize speed gear box has to be designed for the head stock of centre lathe for tuning mild steel and cast iron rods of diameter ranging from 100 mm to 200 mm by carbide tools. If the maximum and minimum cutting speeds permissible as 120 m/min and 40 m/min respectively. What should be the value of the 6" spindle speed [Ans : 1200 rpm] 2. Cylindrical bars of 100 mm diameter and 576 mm length are tured in a single pass operation. The spindle speed used is 144 rpm and the feed is 0.2 mmirev. Tailor tool life equation is VT®75 = 75, where V = cutting speed in m/min and T = tool life in min, Calculate (i) The tool life is (ii) Ifittakes 3 minutes to change the tool each time, the time required to produce one piece [Ans: (i) 1.96 min, (i) 50 min] MADE EASY PublicationsShapping and Planning Multiple Choice Questions Q.1, Which of the following is not correct about shaper and planer (@) planer is heavier and more rigid than shaper (©) in shaper the indexed feed is given to work during the idle stroke of the ram (©) planner is used for machining small flat surfaces (A) the return motion in the shaper is faster Q.2 Which of the following are the advantages of a hydraulic shaper over a mechanically driven shaper? 1. More strokes per minute can be obtained at a given cutting speed. The cutting stoke has a definite stopping point. Itis simpler in construction Cutting speed is constant throughout most of the cutting stroke. Select the correct answer using the codes given 3 4. below: (@) tand2 (b) tand4 (c) 2and4 (d) 1,3and4 [IES : 1997] Q.3 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 250mm, the average cutting velocity in m/min. (a) 30 (b) 45 (©) 75 (d) 120 8|.a.4 A600mm x30 mm fat surface of a plate is to \s be finish machined on a shaper. The plate has ¢ been fixed with the 600 mm side along the le tool travel direction. If the tool over-travel at E each end of the plate is 20 mm, average cutting & speed is 8 m/min, feed rate is 0.3 mm/stroke g and the ratio of return time to cutting time of R the tool is 1:2, the time required for machining 5 will be 2 (@) 8 minutes (0) 12minutes (c) 16 minutes (d) 20 minutes [GATE : 2005] 5 _ Inashaper machine, the mechanism for tool feed is (@) Genevamechanism (b) Withworth mechanism (©) Ratchet and Paw! mechanism (d) Ward-Leonard system [GATE (PI) : 2005] Q.6 A cast iron block of 200 mm length is being shaped in a shaping machine with a depth of Cut of 4 mm, feed of 0.25 mmistroke and the too! principal cutting edge angle of 30°. Number Of cutting strokes per minute is 60. Using specific energy for cutting as 1.49 Jimm®, the average power consumption (in watt) is 7 penpoidei 99 feu yooq sia OTST ON TSC MAN SUB Numerical Data Type Questions ‘UOISSNANSd UBM BURROIA Luo AUB Uae [GATE : 2014] [GATE (PI) : 2012] (Press ypblestonsog MADE EASY Publications,mADE EASY Publications Conventional Questions Q.7 Ina shaper work, the length of the stroke is 200 mm. Number of double strokes per minute is 30 and ratio of return time to cutting time is 2:3. Find the cutting speed. Q.8 Find the time required for taking a complete cut on a plate 600 x 900 mm, if the cutting speed is 9 mimin, The retum time to cutting 1@ ratio is 1:4, feed is 8 mm, clearance at each end is 75 mm. 75 600 75 Q9 A planer has maximum stroke length of 2metres. Return stroke occurs at twice the speed of the forward stroke. Six rectangular blocks of 900 mm x 300 mm are to be planned in one pass with three tools equi-spaced arranged. On the cross slide as shown in wa oslang sen kd09 © orang AVA SW OF I ToIssiuied Uaniim sip NOUN UO) Aue G| PABIIIN 10 peonpordas eq eu yooq SiN) Jo VEG ON WISG MEN ‘SU Workbook | 4.9 figure (the triangles in the figure represents inal poston of the tools) cuting speed is 1 m/sec and feed is 1 mm/stroke. Over travel on either side lengthwise is 50 mm and widthwise is 5 mm on either side. The machining time per piece is 900 100 900,59, wre ee 00,40 300 40.200, Co (eee, L sa [GATE (PI) : 1995] \ 2 @ Try Yourself ‘hydraulic shaping machine is set for 60 double strokes per minute, while machining a job of 90 mm length. The ratio of the cutting and idle speeds 1: 2, Assume a 5 mm approach and 5 mm overrun. If the lateral feed per stroke is 0.6 mm and the width of job is 36 mm, calculate the machining time, [Ans : 4 min.] PubilDrilling Borin Multiple Choice Questions The rake angle in a twist drill: (@) varies from minimum near the dead centre to a maximum value at the periphery. (b) is maximum at the dead centre and zero at the periphery. (©) isconstantat every pointof the cutting edge. (d) is a function of the size of the chisel edge. [IES : 1997] Q.2 The depth of cut in drilling is measured at right angles to the axis of the drill and is numerically Qt equal to da d @s $ @d (d) 20 Where dis diameter of drill? Q.3. The arm of a radial drilling machine is being raised at a speed of 3.9 m/min by single start square threads of 6mm pitch and 30mm diameter. The speed of the screw: (a) is650rpm ——_(b) is 180rpm (©) is 130 rpm —(d) datainsutficient [IES : 2002] Q.4 Through holes of 10mm 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 overtravel ‘of 2mm, the time for producing a hole will be (a) 4seconds (b) 25 seconds (c) 100seconds (d) 110 seconds [GATE : 2004] “uossaized usulim ta ynoUgn la) Aue peBHRA 29 PONE am Rae Pas 6 PaoN POA! oq ROU yOON SW OE ON MBO MONT SUOTIESTIaN ASV JONG /ONEW DaIgRS WONG @ Qs a6 Q7 g and Reaming ‘The purpose of helical grooves in 2 twist dri isto: 4, Improve the stiffness 2, Save a tool material 3. Provide space for chip removal 4. Provide rake angle for the cutting edge Select the correct answer using the codes given below: (@) 1and2 (b) 2and3 () and4 (d) 1and4 [IES : 2004] Match List-I with List-II and select the correct answer using the codes given below the lists: List-I Reaming Counter-boring Countersinking Spot facing List-I Smoothing and squaring surface around the hole for proper seating 2. Sizing and finishing the hole 3. Enlarging the end of the hole 4. Making a conical enlargement at the end of the hole Codes: A (@) 3 (b) 2 © 3 () 2 9ODPF oneno Baano aana0 [IES : 1995] For reaming operation of a blind hole, the type of reamer required is PublicationsMADE EASY as ag Publications — (@) straight flute reamer (0) righthand spiral fluted reamer (0) left hand spiral fluted reamer (d) none of the above LIAS : 1999] Which one of the following sets of tools or tools and processes are normally employed for making large diameter holes? (@) Boring tool (©) BTA tool (Boring and Trepanning Association) and gun drill (6) Gun drill and boring toll (6) Boring too! and trepanning [IES : 2000] Which drill is good for inverted drilling operation? (a) Oithole dil (b). Straightlute dri (©) Taper-shank dil (d)_ High-helix dri [IES : 2014] Q.10 Reamer is designed to have even number of ant flutes to (a) Balance the cutting forces (b) Conform to shop floor standard (c) Enable measurementof the reamer diameter (@) Help in regrinding of reamer [GATE (PI) : 1990] The effects of setting a boring tool above centre height leads to a/an (a) increase in the effective rake angle and a decrease in the effective clearance angle (b) increase in both effective rake angle and effective clearance angle (©) decrease in effective rake angle and an increase in the effective clearance angle (d) decrease in both effective rake angle and effective clearance angle [GATE (PI) : 2005] 2 in10 peanporder ea few 9000 #1 3 z z 3 Workbook | 21 Q.12 Helix angle of fast helix drill is normally (a) 35 deg (c) 90 deg a (b) 60 deg (d)5 deg [GATE : 1997] Numerical Data Type Questions Q.13 Blind holes of diameter 10 mm are to be drilled up toa depth of 50 mm at a speed of 600 rpm and feed 0.2 mm/rev. Point angle of drill is 120°. Machining time per hole is min. Conventional Questions Q.14 A20mm diameter through hole is to be drilled in a 30 mm thick plate using a double fluted, 120° lip angle drill. The drill tip is at a distance ‘of 3mm from the plate surface when cutting is started and an overtravel of 2 mm is recommended as a margin to ensure drilling through the full thickness of the plate. If the drill rotates at 500 rpm and feed per tooth is 0.01 mm, the machining time of the operation (insec). [GATE (PI) : 2004] 2 Try Yourself T. Publications ‘A 20 mm diameter drill with point angle 120 degrees is used to drill a through hole in a plate 30 mm thick, assume the length of approach and over travel as 2mm and 3 mm. respectively. The time required for drilling if the feed is 0.1 mmv/rev and the material is cut with a velocity of 20 m/min [Ans : 1.28 min.]A Milling ") Multiple Choice Questions Q.1. Which of the following statements are true of face milling? 1. Face milling cutter is held on an arbor, 2. Ithas two rake angles-axial rake and radial rake. 3. The maximum chip thickness equals the feed per tooth. 4. The chip thickness varies from a minimum at the start of cut toa maximum at the end of cut. Select the correct answer using the codes given below: (@) 1and2 (b) 2and3 (©) 2and4 (@) 3and4 (IAS : 1998] Q.2 Gang milling isa (@) milling process for generating hexagonal surfaces. (b) process of cutting gears. (c) process in which two or more cutters are used simultaneously. (6) milling operation combined with turning [IES : 2008] Q.3 A hexagonal prism is to be made in a milling machine from a round bar of diameter 60 mm and 100 mm length. The feed is 30 mm/min and set up time is 2 min per face. Estimate, the machining time. Assume added table travel 10mm (a) 24min (0) 20 min (¢) 32min (d) 34min 2 EGON "MEO NEN SUONBO| Ana ASVASGUWOI NEU IAS WANNA? 1 Ben aeaeT oa Fea oO Ha ‘eed waa ma IN A UB a4 Qs Q6 ion of producing grooves around the The operat perbhery of a cylindrical or conical work piece is called. \ (@) Profilemiling (b) Gang a ina Sawmilling (0) Helical milling 2 [IES : 2004] Which of the following statements are correctin respectof up-milling and down-milling? 4. Inup-miling the cutter rotates in a direction opposite to that of workpiece travel whereas in down-milling the cutter rotates in a direction similar to that of workpiece travel 2. In down-milling chip will be thin at the beginning and increase to a maximum at the end of the cut and reverse will be the case of a chip formed by up-milling 3. Down-miling is desirable with milling cutters having a high radial rake angle when compared to up-milling 4, Down-milling forces the work-piece against the milling table to exert more pressure while up-milling tends to lift the workpiece from the table. Select the correct answer using the codes given below: (—)1,2and3——(b) 4, 2and4 (0) 3and4 (@) 1,3and4 [IAS : 2001] Amiling cutter of 70 mm diameter with 12 teeth is operating at a cutting speed of 22 mymin and a feed of 0.05 mmvtooth. The feed per minute is (2) 110mm/min—(b) 35 mmimin (©) 6mmimin ——(d) 6Ommimin [IAS : 2003]MADE EASY a7 Qs Qg Publications ~ A straight teeth slab milling cutter of 100 mm diameter and 10 teeth rotating at 200 r.p.m. is used to remove a layer of 3 mm thickness from assteel bar. Ifthe table feed is 400 mm/minute, the feed per tooth in this operation will be: (2) 0.2mm (b) 0.4mm (0) 0.5mm (6) 0.6mm [IES : 1999] Consider the following statements: In Up milling process, 1. the cutter starts the cut from the machined surface and proceeds upwards. 2. the cutter starts the cut from the top surface and proceeds downwards 3. the job is fed in a direction opposite to that of cutter rotation. 4. the job is fed in the same direction as thet of cutter rotation Of these statements: (a) 1 and3are correct (©) 1 and 4 are correct (©) 2and3are correct (d) 2and 4 are correct [IES : 1997] Consider the following statements regarding miling machine: 1. Inthe vertical miling machine. Itis possible tomachine dovetail recesses. 2. Inuniversal milling machine, the worktable can be swivelled 3. In rotary milling machine, motion imparted to work is rotary. 4. Planer milling machine is provided with several horizontal and vertical heads. Which of the above statements are correct? (@)1,2and3—(b) 1, anda ()1,2and4 — (¢) 2, 3and4 Q.10 A work piece of 100 x 50 x 25 mm has to be machined using a face miling cuter of diameter 60 mm and 20 teeth to reduce the thickness to 1 mm. The feed per tooth is 0.03 mm/tooth The cutter rotates at 180 rpm. The depth of cut cannot exceed 5 mm. The machining time is (2) 252min (b) 1.26min (6) 1.4 min (@) None of these [ha ABV SVN 1 onew WoalaNG WBNAdOD © Teed ON TuIeG MON BU a feu yooa To pooped Tojssuved van sip WOUTA taIO) Aue U1 PORT ant Workbook | 93 Data for the plain milling operation are given below: Length of the workpiece = 10mm Cutter diameter = 10mm No. of teeth =4 Cutter speed = 100rpm Feed = 200 mm/min Depth of cut = 2mm Total clearance (entry and exit) = § mm Determine mean undeformed chip thickness (in microns) is (@) 142 (b) 100 (71 (d) 50 [GATE (PI) : 2002] Direction for Assertion & Reasoning Questions: The following items consists of two statements, one labelled as ‘Assertion A’ and the other labelled as ‘Reason A’. You are to examine these two statements carefully and select the answers to these items using the codes given below: a.t2 a13 (2) Both A and Rare individually true and Ris correct explanation of A (b) Both A and Pare individually true but Fis not correct explanation of A (0) Ais true but Ris false (¢) Ais false but Ris true Assertion (A): Virtually all modern milling machines are capable of doing down-milling. Reason (A); In down-milling the cutter tends to push the work along and lift it upward from the table. This action tends to eliminate any effect in looseness in the feed screw and nut of the milling machine table and results'in smooth cut [IES : 2002] Assertion (A): Climb or down milling operation ‘ensures smoother operation of the machine tool and longer tool life as compared to the conventional up milling operation, Reason (A): In climb or down miling operation, the rotational motion of the cutter as well as the feed motion of the work-piece are in the same direction, and the depth of cutis maximum at MADE EASY Publications.24 the entry point as the cutter engages the workpiece, [IES : 2010) Numerical Data Type Questions Q.14 A CNC vertical milling machine has to cut 2 straight slot of 10 mm width, 2 mm depth between (0,0) and (100,100) on XY plane (Dimensions in mm) with a cutter of diameter 10 mm. Feed rate is 50 mm/min. Milling time in seconds is Q.15 Two separate slab milling operations 1 and 2, are performed with identical miling 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 [GATE : 2014] F Conventional Questions Q.16 Estimate the milling time to cut 60 teeth on a gear blank of 60 mm thick, feed 35 mm /minute and take set up time as 10 min, Assume table travel =10 mm, a7 A slot is to be made on a milling machine with the help of a peripheral cutter, revolving at 120rpm. Find the time required to prepare | the slot in two cuts, ifit is 2 cm deep and 10 cm long with a cutter of 8 cm diameter. Assume feed as 0.5 mmirev. Neglect Over travel and assume clearance at exit is 0.5 cm Mechanical Engineering @ Production Engineering _ — ing AGWS SOW 81 HEU Balan WOUAEED @ Dojss|uied ualilam Bin InSUITm wo) AUB | PERNA 70 peonpolde: 8a few A004 Sa MADE ERAsy the fallowing data wag ling operation Q.18 Insiab mil observed. No. of teeth ter : 90. mM, eth on, jiameter of cul _ mime ae 40 , Cutting of speed = 30 m/min 0 mm/min, Depth of Cut = 3 mm Table fc: 18 im and average Calculate the maximu thickness in milling chip [GATE : 1989) 0.19 One brand of miling machine has following index plates, Plate |: 15, 16, 17, 18, 19. 20 hole circles Plate Il; 21, 23, 27, 29, 31, 33 hole circles, Jo make 28 teeth by simple indexing, which plate is suitable? (x When miling a slot 20 mm wide 10. cm longina rectangular plate 10 cm x 20 cm the cutting conditions used were Cutting speed = 60 m/min Diameter of the end mill = 20 mm Number of flutes = 8 Feed = 0.01 mmyflute Depth of cut = 3mm Find the cutting time for this operation. [Ans : 1.44 min] 72. Asurlace 80 x 160mmis rough machined using 150 mm diameter face milling cutter having 10 teeth. The cutter centre is offset by 15 mm from the line of symmetry of the surface Estimate the time to rough machine the surface, if @ feed per tooth of 0.25 mm and a cutting speed of 20 mm/min are employed. [Ans : 1.73 min/cut] MADE EASY PublicatiGear and Screw Thread Manufacturing | Q.5 Consider the folowing mations and settingin a Multiple Choice Questions | |? hobbing machine: & 1. Hob rotation g 2. Job rotation Q.1 Which one of the following processes of gear | 3. Axial reciprocating job rotation manufacture results in best accuracy of the | 3 involute gear tooth profile? : 4, Tilting of hob to its helix angle (a) Miling g Which of these motions and setting ina hobbing (b) Hobbing machine are required to machine a spur gear? (c) Rotary gear shaper g (a) 4,2and3 (pb) 2,3and4 (d) Rack type gear shaper z (© 12and4 — (¢) 1,3and4 {1s : 2000) |= [IAS : 2001} Q.2_ Internal gears can be made by: 8|Q.6 External threads can be produced by: (a) hobbing g 1. Rolling (b) gear shaping with rack cutter g 2. Grinding (©) gear shaping with pinion cutter z 3. Milling (d) gang milling B (@) 1and3 [IES : 1996] | 3 (b) 1and 2 g (c) 2and3 Q.3. Gear shaping is a process of manufacturing | § (@)1,2end3 gears. Which one of the following principles is a {les : 2011] employed by it? ei (@) From cutting with cutter §|.@.7_Bywhich one ofthe folowing mactines the teeth (b) Generating tooth from with a reciprocating | 3 of anintemal spur gear can be cut accurately? cutter 8 (@) Miling machine (c) Generating tooth from by a rotating cutter (6) Slotting machine (d) Generating tooth from a reciprocating and 3 (c) Hobbing machine revolving cutter 2 (d) Gearshaping machine [IES : 2009] [les ; 2004] | 3 2|Q.8 Forproducing both internal and external screw Q.4 Quality screw threads are produced by t threads, the method used is (@) thread milling H (@) thread chasing with multiple-rib chasers (b) thread chasing : (b) threads milling with multiple-thread cutters (0) thread cutting with single point tool z (c) thread tapping with taps (d) thread casting i (d) die threading with self-opening die heads [GATE : 2003] |* [IES : 2010] MADE Ase | wiewmadeeasypublictions. orgGear bobbing produces more accurate gears ¢ e because in hobbing (2) There is @ continous indexing operation (b) Pressure angle is larger than milling (c) Hod and work piece beth are rotating (@) Asoherica! mult-tooth cutter (heb) is used. aa Pa SruneS Vaibim Bui MOGuM a1, Fuk wi BORIS 10 POTBOIER) WG FEL HOG Hal OED OH WARE MAI] SUDIETIANG ISVS BOVIV@I TAIRA Publications Numerical Data Type Questions @.10 A spur gear of 40 teeth is machined in a gear hobbing machine using a double start hob cutter. The speed ratio of the hob to the blank is ____.Grinding {¥{__ muttipte Choice Questions Q.1 Specific energy requirements in a grinding process are more than those in turning for the same metal removal rate because of the (@) specific pressures between wheel and work being high. (b) size effect of the larger contact areas between wheel and work. (©) high cutting velocities (d) high heat produced during grinding. [IES : 1996] Consider the following statements in respect of grinding? 1. The pitch of the grit cutting edges is larger than the pitch of the milling cutter. 2. The cutting angles of the grits have arandom a2 geometry 3, The size of the chip cuts is very small for grinding Which of the statements given above are correct? (a) tand2 (b) 2and3 (©) tand3 (d) 1,2and3 [IES : 2005] Q3. Which one of the following is not a synthetic abrasive material? (@) Silicon Carbide (b) Aluminium Oxide (0) Titanium Nitride (0) Cubic Boron Nitride [IES : 2003) “rsried vauan 2 YA uy Aue pas 79 paorpendov oa Keunyoo" suo VEER HOG MOR SURI as Qs a7 Publications. Consider the following statements in respect of a grinding wheel of specification, 51-A-36-L-7-A-23, using the standard alphanumeric codification 4. Abrasive used in the wheel is: aluminium oxide 2. The grain size of abrasive ismedium 3. Ithas an open structure 4, Ithas resinoid as bonding agent ‘Which of these statements are correct? (a) 1,2and3 (b) 1,3and4 (©) 2,3and5 (d) 1,4andS [AS : 2000] Which of the following materials are used in Grinding wheel? 4. Aluminium oxide 2, Cubic boron nitride 3. Silicon carbide Select the correct answer using the codes given below: (a) 1,2and3 (©) 2and3 (b) 1and2 (@) 1and3 [IES : 2002] Soft material cannot be economically grounded due to: (@) the high temperature involved (©) frequent whee! clogging (©) rapid wheel wear (d) low work piece stiffness [IES : 1995] Consider the following statements: The set-up for internal centreless grinding consists of a regulating wheel, a pressure roll and support roll, between which the tubular workpiece is supported with the grinding wheel within the tube, wherein28 Mechanical Engineering # 1. the grincling wheel, workpiece and regulating Wheel centres must line on one line. 2. the directions of rotation of workpiece and, grinding wheel are same. 3. the directions of rotation of pressure roll, Support roll and regulating wheel are same. 4. the directions of rotation of grinding whee! and regulating wheel are same. Which of these statements are correct? (@)1,2and3—(b) 1, 3and4 (©) 2and3 (6) 3and4 [IAS : 2001] Q.8 Grinding wheel is said to be loaded when the: (a) Metal particles get embedded in the wheel surface blocking the interspaces between cutting grains. (b) bonding material comes on the surface and the wheel becomes blunt. (©) work piece being ground comes toa stop in cylindrical grinding, (@) grinding wheel stops because of very large depth of cut (IES : 1996] Q.9° Consider the following reasons: 1. Grinding wheel is soft 2. RPMof grinding wheel is too low 3. Cutis very fine 4, An improper cutting fluid is used A grinding wheel may become loaded due to reasons stated at (@) tand4 (b) 1and3 (c) 2and4 (d) 2and3. [IES : 1999) Q.10 Consider the following statements with reference to grinding wheel characteristics: 1. Aluminium oxide and silicon carbide are used for making the grinding wheels. 2. Rubber bonds are used for making flexible wheels, 3. The grade of a wheel is determined by the strength of the bonding materials. 4, Negative rake angles are used for grinding of high-strength materials Production Engineering ‘Volssuured Uanum oui inouri™ wid) Aue ul Pesylin 70 poonporde) a Anu yoo Si JO ed ON "UIeG MON “SUOTEDTIGNg ASva JOWW OI NEW I9AIaNS AOUKGOO MADE EASY mADE EAsy rich of the above statements are correct? wrsms Grates (1.3end4 (een Q.11 Grinding ratio is defined as Volume of wheel wear (®) Youmeof work material removed Volume of work material removed Volume of wheel wear Cutting speed feed Longitudinal feed Transverse feed eo Q.12 Toollife in the case of a grinding wheel is the time (@) between two successive regrinds of the whet (©) taken for the wheel to be balanced (c) taken between two successive wheel dressings (@) taken for a wear of 1 mm on its diameter [GATE (Pl) : 2005) Q.1 The hardness of a grinding wheel is determined by the (a) hardness of abrasive grains (b) ability of the bond to retain abrasives (c) hardness of the bond (d) ability of the grinding wheel to penetrate the workpiece [GATE : 2002] Q.14 Asurface grinding operation is performed ona ‘ow carbon steel work piece using a grinding wheel of diameter 220 mm that rotates at 3600 rpm. The width of cut is 22 mm, depth of Cut is 0.04 mm and the feed rate of the work plece is 1180 mmimin. Then the cutting force (the force tangential to the wheel) is N. (For low carbon steel take the specific Numerical Data Type Questions energy as 40 W-s/mm?)Non-conventional Machining Operation aD a4 Consider the following statements: Inelectrochemical grinding, 1, arubber bonded alumina grinding wheel acts as the cathode and the workpiece as the anode. Q.1. Consider the following statements in retation to | 5 the unconventional machining processes: | f 2. a copper bonded alumina grinding wheel 1. Different forms of energy directly applied to | & acts as the cathode and the workpiece as work piece to have shape transformation of | 8 the anode. material removal from work surface g 3, metal removal takes place due to the 2. Relative motion between the work and the | 2 pressure applied by the grinding wheel. tool is essential g 4, metal removal takes place due to 3, Cutting tool is not in physical contact with |3 electrolysis. work piece. # Which of these statements are correct? Which of the statements given above are |= (@) Vand 3 (b) 2and4 correct? i (c) 2and3 (@) 1and4 (@) 1and2only — (b) 1, 2and3 7 [IES : 2000) (c) 2and3 only — (d) 1 and 3 only 2|Q.5_ As tool and work are not in contact in EDM [IES : 2007] : process 2 Which one of the following processes does not | 3 (@) no relative motion occurs between them a (0) no wear of tool occurs causetoolwear? g (©) nopoweris consumed during metal cutting (o) reson ee fe (a) no force between tool and work occurs (b) Electrochemical machining : eT (0) Electric discharge machining g (a) Anode mechanical machining 2 |Q6 A researcher conducts electrochemical [les : 1997] |& machining (ECM) on a binary alloy (density 3 6000 kglm?) of iron (atornic weight 56, valency 2) 3. In electrodischarge machining (EDM), if the |= and motal P (atomic welght 24, valoncy 4), thermal conductivity of tools Is high and the | 5 Faraday’s constant = 96500 coulomb/mole. specic heat of work piece is low, then the tol | B Volumetric material removal rate ofthe alloy is wear rate and material removal rate are expected | ¢ so mrsfsata currentof 2000 A. The percentage tobe respectively i of the metal Pin the alloy is closest to {a) high and high (b) lowand low: 2 (@) 40 (b) 5 (c) highandiow — (d) lowandhigh 3 6 (72 [@ate : 2007) | [GATE : 2008] (Benen mace Eas! eee~N 30 Mechanlcal Engineering ¢ Production En: Q.7_ During ullrasonic machining the motal removal affected by the (a) hammering action of abrasive particios (©) rubbing action between tool and workplace (©) high frequency sound waves (d) high frequency eddy currents Qs ag [IAS ; 1996, IES : 2005] Match List-I (Machining process) with List-I! (Associated medium) and select the correct answer using the codes given below the lists: List-1 List A. Ultrasonic machining 1. Kerosene B. EDM 2. Abrasive slurry Cc. ECM 3, Vacuum D. EBM 4, Salt solution Codes: ABCD @23a41 (O)2eai 473 () 4eul 2) 3 @43 214 [IES : 1998] Typical machining operations are to be performed on hard-to-machine materials by Using the processes listed below. Choose the best set of Operation- Process combinations Operation P. Deburring (internal surface) Q. Die sinking R. Fine hole driling in thin sheets S. Tool sharpening Process 1. Plasma Arc Machining 2. Abrasive Flow Machining 3. Electric Discharge Machining 4, Ultrasonic Machining 5, Laser beam Machining 6. Electrochemical Grinding Codes: P @1 (o) 1 () 5 (@) 2 wsnao anon Donan [GATE : 2004] 19 paanpeidos og Ae Wood siqi jo Wed ON WiOG NON “GuONeONana ASYS SN OID Pasi ‘Uo}ssjused vonum aug Inuilm WO) RUB gineering MADE Ensy grial $1011 TON (atone ne rornoving 1 P om a 0.10 wie 56, valoncy «2nd de! aly Tk oe paola rabrnachinings 2 M0%Al remy) byaoc mopmin is dosed INO CUED (ap routed ror actin tiomateril ovata (p) 14.93 196,07 (! ree f fas (d) 63764.29 a [GATE (PI) 2011 att Tho principio of material removal in : Electrochemical machining is (a) Fick's law (p) Foraday’s laws (6) Kirchhot's laws Ohm's law eon [GATE : 2014] Q.12 Ultrasonic machines used in material removal process, requites ultrasonic transducers. The transducers work on different working principles, ‘One of the working principles of such ultrasonic transducers is based on (@) Eddy current effect (b) Seeback effect (0) Piezoresistive effect (d) Piezoelectric effect [GATE (Pl) : 2010] Q.13 In abrasive jet machining, as the distance between the nozzle tip and the work surface increases, the material removal rate (@) increases continuously (0) decreases continuously (©) decreases, becomes stable and then increases (9) increases, becomes stable and then decreases [GATE : 2012] Q.14 Consider the following statements in relation to the unconventional machining processes 1. Different forms of energy directly applied to work piece to have shape transformation o! material removal from work surface, 2, Relative motion between the work and the tool is essential. 3. Cutting tool is not in physical contact with work piece. |MADE EASY Which of these statements are correct? (@) 1and2only —(b) 1,2and3 (©) Zand 3only —(¢) tand3 only (IES : 2007) Q.15 USM has good machining performance for (Al (b) Steel (c) Super alloys (d) Refractory material [IES : 2011] Q.16 The primary mechanism of material removal in electrochemical machining (ECM) is (@) chemical corrosion (b) etching (©) ionic dissolution (d) spark erosion [GATE : 2015} Q.17 A resistance-capacitance relaxation circuit is used in an electrical discharge machining process. The discharge voltage is 100 V. Ata spark cycle time of 25 ys, the average power input required is 1 kW. The capacitance (in uF) in the circuit is (@) 25 (75 (b) 50 (d) 10.0 [GATE : 2015} Q range the processes in the increasing order of their maximum material removal rate cu’ @) USM, LBM, EBM, EDM, ECM a (b) EBM, LBM, USM, ECM, EDM ™ (©) LBM, EBM, USM, ECM, EDM * v (@) LBM< EBM, USM, EDM, ECM * [GATE (PI) : 2005] Q.19 Machining of injector Nozzle in diesel engine is done by (@) AJM (b) EDM () EBM (d) ECM Direction for Assertion & Reasoning Questions: The following items consists of two statements, one labelled as ‘Assertion A’ and the other labelled as ‘Reason f’’. You are to examine these two statements carefully and select the answers to these items using the codes given below: Publications MADE EASY Workbook | 34 (@) Both A and Rare individually true and Ris correct explanation of A (0) Both 4 and Rare individually true but Ris ot correct explanation of A (0) Ais true but Ris false (6) Ais false but Ris true Q.20 Assertion (A): Water jet machining uses high pressure and high velocity water stream which acts like @ saw and cults a narrow groove in the material Reason (R): The force required for cutting is generated from sudden change in the momentum of the water stream. [IES : 2003] Q.21 Assertion (A): In electrolytic process of producing metal powders, Metal plates placed in a tank of electrolyte acts as anode and cathode. Reason (A): High electric current produces powdery deposit on anode, CMON SuONBOTTana AWS SQW 01 Jone I2alanS WABIKGOD © [IES : 2013] | Numerical Data Type Questions Q.22 During the electrochemical machining (ECM) of iron (atomic weight = 56, valency = 2) at current of 1000 A with 90% current efficiency, the MRR was observed to be 0.26 gmvs. If Titanium (atomic weight = 48, valency = 3) is machined by the ECM process at the current 3 of 2000 A with 90% current efficiency, the 3 expected MAR in gm/s will be 3 For the following condition in electro-chemical 2 i machining, ex sbfr=28 E Ps 3 AV MRR= et 5 Ff z fe 2arH60 3 Tool gap = 0.6 mm (aae— i Atomic weight = $6 AERO T z Valency 8 p = 7.6g/cm? the material removal rate in cm*/g.is __. PublicationsQ.24 Calculate the MRP and electrode feed rate in the ECM of an iron surface that is 25mm x 25mmin cross section using NaC! in water as electrolyte. The gap between tool and work piece is 0.25 mm. Supply voltage is 12 V DC. Specific resistance of electrolyte is 3 2-om Valency of iron = 2, Atomic weight = 55.85, Density = 7860 kg/m’. Q.25 In ECM operation of pure iron, an equilibrium gap of 2 mm is kept. Determine the supply voltage, if the over voltage is 2.5 V, resistivity of electrolyte is 50 Q-mm, Set feed rate is 0.25 mm/min, p = 7.86 gmlem’, A = 56 and Za, Q.26 For a RC type generator in EDM to get maximum power dissipation during charging V, = V, x 0.716. Determine idle time for R= 10 Q and C = 200 pF. 0 pesnpeise) 8a Kew yoo Suny ued ONT Jo Wed ON UIeG NON “sUONED|IGNE ASWA SOW Ol TeNeW WelanS WBUAGOD @ orssiwied vstiam Bu TROUT WiO} Aue Uy Pa 11. T2. Publications, maAvpeE EASY a Pulications om*s) of an alloy ate the MAR (in sentanind 1g % cobalt, 62% Nickel, 20 % Shromin during ECM with a current of 500A Density of alloy IS 3.28 giem®. The following data is available [Ans using AC relaxation circuit, a rough hole is made in steel hickness using a graphite too! dielectric. Assume discharge time is negligible, Machining is carried under In EDM process 42mm diameter t plate of 50 mm t and kerosene as following conditions. Resistance = 40 9 Capacitance = 20 nF, Supply voltage = 220V, Discharge voltage = 110 V. (The time for one cycle in milli sec is (ii) Average power input in KW is [Ans. (i) 0.55 and (ii) 0.22] ___.__ fepac NC, CNC, Robotics 1. Match List-I(A function connected with NC me tool) with List-II (Associated parameter) and select the correct answer using the codes given below the lists: List-I A. Interpolation B. Parity check . Preparatory function D. Point to point control List-II 1. Tape preparation 2. Canned cycle 3. Drilling 4, Contouring 8. Turing Codes: A SEs Aoee asso eonno VyNaod = [IES : 1995] During the execution of a CNC part program block’ NO20 GO2 X45.0 ¥25.0 A5.0 the type of too! motion will be (@) circular interpolation - clockwise (b) circular Interpolation - counterclockwise (©) linear Interpolation (@) rapid feed (ang ASV IGUW A NEI DaGNS OUGOD © [GATE : 2004] ‘rsd anim aa aoqnn uboy Aue W paSinn 10 paonpardas eq ABLyoOG puny Wed ON IBC MON SU) Q.3 The tool of an NC machine has to move along a circular arc from (5,5) to (10, 10) while pertorming 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) NO10 G02 X10 Y10.X5 Y5 RS (b) NO10 GO3 X10 Y10 X5 YS AS (c) NO10 GO1 X5 Y5 X10 Y10 RS; (d) NO10 G02 XS YS X10 Y10 RS [GATE : 2005] Q.4 Match List-I (Track numberson paper tape) with List-I (Holes on those tracks represent) and select the correct answer using the codes given below the lists: List-! List-tI A. Track No. 1to4 1. Alphabets B. TrackNo.5 2, Numerals C. Track No.6&7 3. End of block D. TrackNo.8 4, Blocknumber 5. Parity check Codes: ABCD @25 13 )1 425 @241 3 @15 23 UES: 1997] Q.5 NC contouring is an example of (@) continuous path positioning (b) point-to-point positioning (0) absolute positioning (A) incremental positioning [GATE : 2006] Q.6 Which type of motor is not used in axis or spindle drives of CNC machine tools? (@) induction motor (b) de servo motor motor (d) linear servo motor (0) epee [GATE : 2007]34 | Mechanical Engineering @ Production Eng) aes Q7 Match List-I (Components) with List-I! (Functions) and select the correct answer using the code given below the lists List-l Control unit Arithmetic unit . Memory . Output device List-II Logical checks and calculations Stores instructions and data Converts results and presents to the user Convert instructions to codes Receives instructions and performs operations Codes: A (a) 2 (b) 5 (©) 2 @s In APT language, .the cutter motion in incremental coordinate mode is addressed as: (a) GO/TO)... (b) GO/TO. (©) GO DLA... (d) GO FWD). [IES : 1995] com> B 1 3 3 Fi hanno oe tale [IES : 2008) as Q9 Which of the following are the rules of programming NC machine tools in APT language? 1. Only capital letters are used 2. A period is placed at the end of each statement 3. Insertion of space does not affect the APT word. Select the correct answer using the codes given below: (@) tand2 (b) 2and3 (©) 1and3 (d) tonly [IES : 1995) Q.10 Ina 2-D CAD package, clockwise circular are of radius 5, specified from P, P, (10, 15) will have its center at (b) (18, 10) (A) (10, 18) [GATE : 2004] (15, 10) to (a) (10, 10) (c) (15, 15) MADE EASY MADE En, Sy @.11 Match List-I (NC machine t00l systems) y, List-ll (Features) and select the correct an using the codes given below the lst List-I NC system CNCsystem DNCsystem Machining centre List-II Ithas anintegrated automatic oo changeg unit and a component indexing devicg 2. A number of machine tools ate controleg by a computer. No tape reader, the nay programme is transmitted directly to thy machine tool from the computer memory The controller consists of sottavireg computer and hard-wired logic system, Graphic display of ool path is also possitie The instructions on tapes preparedintinay decimal form and operated by a series o coded instructions ity ANS, S aBuhdOD © pom> 0 Wed ON 1WIeG MON “SUOHBOIaRa ASYS TOWN OI Codes: 3 A BCD 3 @42 3 1 3 ) 1 3 2 4 g @4 3 21 3 @12 3 4 8 TIES : 2002] ©] Q.12 If the z-axis and x-axis of CNC lathe are provided with straight line controls, itis possible to carry out (@) Turning and facing only (b) Turning, facing and taper turning (c) Turning, facing and thread cutting (d) Turning, facing and drilling IGATE (PI) : 20081 Q.13 Arobotarm PQwith end coordinates P(0.0)a"4 Q(2,5) rotates counter clockwise about Pinte 3 = g 3 3 XY plane by 90°. The new coordinate pair ofthe end point Qis (@) (2,5) (b) (-5.2) (c) (5,-2) (d) (2,-5) PublicationsMADE EASY Publications Q.14 Whatis the correct order of the development of the following? 4. Numerical control 2. Computer numerical control 3. Directnumerical control 4, Distributed numerical control (@1,2,3and4 —(b) 4,2,3and1 (9) 1,3,2and4 (d) 4,3,2and1 [IES : 2013] 15 In NC machines, slides are positioned by hydraulic ram and are influenced by (@) length of stroke and mass to be displaced (0) feed and spindle speed (c) length of stroke and feed (d) spindle speed and mass to be displaced [IES : 2014] Q.16 The geometric transformation specified by 05 0 0 ik y T=[x y 1] 0 025 Ofna 1 21 In a 2D CAD system represents (a) Scaling and translation (b) Scaling and rotation (c) Rotation and translation (d) Rotation [GATE (Pl) : 2007] Q.17 Match the following Group-! P. Q. R. s. Group-II 1. Linear interpolation 2. Retardation 3. Circular interpolation 4. Cutter radius compensation PQres @3 1 4 2 )4 13 2 3 41 2 @24 13 [GATE (PI) : 1994] Workbook | 35 Q.18 In finish machining of an island on a casting with CNC milling machine, an end mill with 10 mm diameteris employed. The corner points, of the island are represented by (0, 0), (0, 30), (60, 30) and (50, 0). By applying cutter radius ‘compensation, the trajectory of the cutter will be (@) (-5, 0), (-5, 35), (55, 35), (65, -5), (-5, 5) (b) (0, 5), (65, -5). (55, 35), (-5, 35), (-5, -5) (©) (6, 5), (5, 25), (45, 25), (45, 5), (5, 5) (0) (6, 5), (45, 5), (45, 25), (5, 25), (5, 5) [GATE : 2000] Q.19 A rill is positioned at point P and its has to proceed to point Q. The coordinates of point Qin the incremental system of defining position of a point in CNC part program will be [GATE : 2015] 0 The function of interpolator in a CNC machine controller is to (a) control spindle speed f coordinate feed rates of axes (©) contro! too! rapid approach speed (@) perform Miscellaneous (M) functions (tool change, coolant control etc.) [GATE : 2015] 4 A triangular facet in a CAD model has vertices: P1(0, 0, 0); P2(1, 1, 1)and P(t, 1, 1), Thearea of the facet is (a) 0500 (0) 1.414 se or07 (a) 1.732 [GATE : 2015] ‘UoSanwIed Voynm Sip NOUN W/O) KuB G| Paslpn Je paOAROIMA! aq FaUlyoOa 7 TROUT wd) UB | paBTp Jo pasnpeldes 6g ABU yoDd Si) JO HES ON TSG MeN 'SUOTBDTAG AOVS SGWN OF TRU BOIGRS TEINS @ IDE EASY Publications.36 | Mechanical Engineering © Production En; al Data Type Questions Q.22 Ina CNCteed drive, a stepper motor with step angle of 1.8° drives a lead screw with pitch of 2 mm. The BLU for this drive is microns, S WBNhIOD © 2 0.23 Astepper motor has 180 steps. The output shaft ofthe motor is directly coupled toa lead screw Of pitch 4 mm which drives the table. If the frequency of pulse supply to the motor is 200 Hz, the speed of the table (mmimin) is & Conventional Questions PESTEN] Q.24 Inapointtopointcontrolof NCmachine, the slides are positioned by an integrally mounted stepper Motor drive. If the specification of the motor is 1 degipuise and pitch ofthe lead screwis 3.6 mm, ‘What is the expected positional accuracy. Q.25 Acylinder of 155mm diameter is to be reduced to 150 mm dia in one turning cut with a feed of 0.15 mnvrev and cutting speed of 150 m/min ‘ona NClathe. What are the programmed feed rate and MAR. Q.26 Prepare a part program for machining a rectangular contour of 200 mm x 100 mm size from a suitable MS blank of § mm thickness. Also, a reamed hole of 16 mm has to be made centrally n the rectangular contour. Take speed and feeds arbitrarily. in 78 paanpoides 8a Feu yooa su jo WEG ON TWIG WON FU [IES : 2005] Q.27 Prepare part program to machine the contour, ‘shown in the figure using APT on CNC milling machine. Material : MS, Thickness : 8.0 mm. wig) hue vi por ‘worsened ui $200 mm ———+j (vo winadeeasypublications 7g : im a ina MADE EAsy Publications .28 Inthe given figure define the line L,, Lo, Le ang Lyin the APT language. Prepare part program using APT language for milling the contour shown in figure in a single pass, TH 2 t +10 zl ef 0 ce 10 — I" | 4 HO a) Pp Material: M.S. a T2. Name the four types of staternents in a complete APT part program. Prepare part program for geometry description of the contour shown in figure below: EASY Publications a)Jigs and Fixtures Multiple Choice Questions Qa a2 a3 Inthe 3-2-1 principle of fixture design, 3 refers tonumber of: {@) Setups possible (©) Clamps required (©) Positions on primary face (d) Locating positions IES : 2011] Diamond pin location is used in a fixture because: (@) It does not wear out (b) It takes care of any variation in centre distance between two holes (€) Itis easy to clamp the part on diamond pins (A) Its easy to manufacture [IES : 1999] _TaSSamSe Tam Soa oy Fae pam peoTpoTTr ea Feu OG BAO URGON 1400 MON SUOTTED|/Gnd ASVESONILOL OHBUTEEIANS WEMICO Q.4 Match List-l (Components used in jigs and fixtures) with List-II (Their functions) and select the correct answer using the codes given below the lists: List-| Jack pin VAocator . Bushes Ejectors List-I1 To guide the dill bit during machining For easy removal of the work piece from the jig or fixture after the machining operation is over 3. Tolocate the circular or semicircular objects in a jig or fixture 4, Tolocate work pieces whose dimensions are subject to variations gomp> po Codes: Match List-I (An Element of Jigs and Fixtures) ABCD with List-Il (Associating System) and select the @3 412 correct answer using the code given below the 3 4214 lists: @4 3 1 2 List-I Ust-HI @4 324 [IES : 2000} ie aes , ee Q5_ Asine bar has a length of 250 mm, each roller ©. Diamond pin 3. Radiallocation has a diameter of 20 m, during taper angle D. Viblock ‘4. Cylindrical location measurement of a component, the height from 5. Drill igs the surface plate to the centre of arolleris 100 Codes: mm. The calculated taper angle (in degrees) is ABCD (a) 214 (b) 228 (0) 236 (@ 689 ® 3 1 : , [GATE (Pl) : 2012] @5 13 4 awe @3 4214 [IES : 2005] (Cceerahe MADE EASY Jarmadeeaspubieatons or)Metrology Qt Consider the following statements: Anomenclature @50 H8/p8 denotes that 1. hole diameter is 50 mm. 2. itis a shaft base system 3. Bindicates fundamental deviation. Which of the statements given above is/are correct? (@) 1,2and3 (©) 1and 3 only (b) 1 and 2 only (d) 3only [IES ; 2002] Q.2. Which one of the following is not correct in hole basis system of fits? (a) The hole size is kept constant. (b) The basic size of the hole is taken as the low limit of size of the hole. (c) The actual size of a hole that is within the tolerance limits always less than the basic size. (d) The high limit of the size of the hole and the two limits of size of the shaft are selected to give desired fit [IES : 1995] Q.3 Inthe tolerance specification 25 D6, the letter Drepresents' (@) type of fit (b) upper deviation (c) lower deviation (d) grade of tolerance [IES : 2002] i i i : SoSSniScl am Be ROL Ly Ku a SBI 0 PaONpONTA ea Ke WSO SO ved ON THC MEN SUI a4 Qs6 Q7 40.015 con oot? ‘A hole is of dimension @2°" mm The corresponding shaft is of dimension 40.010 49°01 mm. The resulting assembly has .gfit (b) close running fit (d) interference fit [GATE : 2011] (@) loose runnin: (©) transition fit Aholeis specified as 408% mm. The mating shafthas a clearance fitwith minimum clearance of 0.01 mm. The tolerance on the shaft is 0.04 mm, The maximum clearance in mm between the hole and the shaft is (@) 0.04 (b) 0.05 (© 0.10 @ on [GATE : 2007] For the following hole and shaft sizes of mated Parts according to basic hole system Hole: 37.60mm Shaft: 37.47mm 37.52mm 37.45mm What is the value of allowances (in mm)? (a) 0.02 (b) 0.03 (©) 0.05 (@) 0.07 [JWM : 2008] Aring gauge is used to measure (2) outside diameter but not roundness (b) roundness but not outside diameter (c) both outside diameter and roundness (d) only external threads [GATE : 2006) ===mADE EASY ——— Publications — @.8 GO and NO-GO plug gauges are to be 20050 designed for a hole 2.000001 mm. Gauge tolerances can be taken as 10% of the hole tolerance. Following ISO system of gauge design, sizes of GOand NO-GOgauge will be respectively (a) 20.010 mmand 20.050 mm (b) 20.014mmand 20.046 (©) 20,006 mm and 20.054 mm (6) 20.014mmand 20.054 [GATE: 2004] Q.9 A part shown in the figure is machined to the sizes given below P= 35,00 + 0.08 mm Q= 12.00 +0.02mm o bre. R= 13.0033%mm pel With 100% confidence, the resultant dimension Wwill have the specification (@) 9.99 + 0.03mm (b) 9.99 + 0.14 mm (6) 10.00 + 0.03 mm (4) 10.00 + 0.13mm GON 1aI8G RON SuONBOTaNG ASWA SOWA OF [GATE : 2003] Q.10 Which of the following is an interference fit? {@) Push fit (b) Running fit (c) Sliding fit (6) Shrink ft [IES : 2006] Q.11 Two slip gauges of 10 mm width measuring 1,000 mm and 1.002 mm are kept side by side in contact with each other lengthwise. An optical flat is kept resting on the slip gauges as shown inthe figure. Monochromatic ight of wavelength 0,0058928 mm is used in the inspection. The total number of straight fringes that can be observed on both slip gauges is To poonpoider 2@ Feu 7008 ‘Uorssywied anim eu noun GHIO} AUB Ul POE Optical lat Slip gauges (a2 (b) 6 os (¢) 13 [GATE : 2003] Workbook | 39 Q.12 Match List-I (Measuring Device) with List-II (Parameter Measured) and select the correct answer using the codes given below the lists: List-I Diffraction grating Optical flat Auto collimators Laser scan micrometer List Small angular deviations on long flat surfaces. 2, On-line measurement of moving parts 3. Measurement of gear pitch 4, Joining hydraulic piston rods for agricultural machinery 5. Measurement of very small displacements pop> Codes: ABCD @5 421 ) 3 5 1 2 @3 5 4 1 @5 412 [IES : 1998] Q.13 The Mand E systemin metrology are related to measurement of (@) screwthreads (©) angularity (©) flatness (d) surface finish [IES : 2006] Q.14 What symbol is used to indicate surface roughness? fa) = (be) ©) or @a {IES : 2008) Q.15 Whatis the dominant direction of the tool marks or scratches in a surface texture having a directional quality, called? (a) Primary texture (b) Secondary texture (c) Lay (@) Flaw {IES : 2007] Q.16 A threaded nut of M16, ISO metric type, having 2mm pitch with a pitch diameter of 14.701 mm is to be checked for its pitch diameter using MADE EASY Publications, |onnade