Machining E Book

Tailor made module for various exams like HPCL, ISRO, BARC etc.
PRODUCTION TECHNOLOGY
(Machining and Machine tool Operations)
1. Which is the property of a tool that prevents plastic deformation at its cutting edge
during machining process?
(a) High value of fracture toughness (b) High value of hardness under heating
(c) Chemical stability (d) Adhesion resistance
2. The difference between (i) a horizontal borer and (ii) a lathe is
(a) In (i) the spindle is horizontal; in (ii) it is vertical
(b) In (i) the tool rotates; in (ii) the object rotates
(c) In (i) the object rotates; in (ii) tool rotates
(d) (i) produces a plain surface; (ii) produces a cylindrical surface
3. The chip thickness during slab milling process is directly proportional to
(a) Cutter's rotational speed (b) Angle of contact of the tooth
(c) Number of teeth of the cutter (d) Feed rate of work piece
4. HSS tool is used to machine a 20 mm diameter steel shaft, at a spindle speed of 1000
revolutions per minute. What is the cutting speed?
(a) π m/min (b) 20 π m/min (c) π mm/min (d) 20 π mm/min
5. In turning operation, the typical ratio of heat generated in chip, tool and work piece is
in the order of:
(a) 70: 20: 10 (b) 10: 70: 20 (c) 10: 20: 70 (d) 70: 10: 20
6. In which of the following operations performed on lathe machine, chips does not
occur?
(a) Knurling (b) Boring (c) Reaming (d) Threading cutting
7. The cutting speed of the tool in turning operation is:
(a) Directly proportion to diameter of the workpiece
(b) Inversely proportional to the workpiece
(c) Inversely proportional to the square of the workpiece
(d) Directly proportional to the square of the diameter of the workpiece
8. In a turning tool, crater wear occur on _____.
(a) Base (b) Flank face (c) Rake face (d) Shank
9. Tool dynamometers are used to:
(a) Determine the tool angle
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(b) Determine the tool hardness

(c) Determine the tool nose radius
(d) Determine the cutting forces
(e) Determine the tool material composition
10. Which of the following is not the characteristics of cutting tool material?
(a) High hot hardness (b) High wear resistance
(c) High toughness
(d) High coefficient of friction at tool chip interface
(e) High thermal conductivity
11. Cutting fluid used in machining operation should:
(a) Have high heat absorbing capacity (b) have low flash point
(c) Have good lubricating property (d) wash-off the chips
(e) Be non-toxic
12. Why does crater wear start at some distance from the tool tip?
(a) Tool strength is minimum at that region
(b) Cutting fluid cannot penetrate that region
(c) Tool temperature is maximum in that region
(d) Stress on rake face is maximum at that region
13. The process of removing the burrs or flash from a forged component in drop forging
is called -
(a) Swaging (b) Perforating (c) Trimming (d) Fettling
14. In which of the following milling operation the surface finish is better
(a) Climb (b) up (c) Drop (d) Face
15. The thickness of the chip is minimum at the beginning of the cut and maximum at the
end of the cut is case of
(a) climb milling (b) Up milling (c) Down milling (d) Face milling
16. The best machine tool to cut an internal spline in steel is
(a) Milling machine (b) Slotting machine
(c) Lathe (d) Grinding machine
17. One of the disadvantages of a hydraulic shaper compared to the mechanical shaper is
(a) Stopping point of the cutting stroke can vary depending upon the resistance
offered to cutting
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(b) Less strokes per minute

(c) Power available varies during the cutting stroke
(d) Cutting speed remains constant throughout the cutting stroke
18. A steel workpiece is to be milled. Metal removal rate is 40 cm3/min. Depth of cut is
10 mm and width of cut is 200 mm. Find the Table feed?
(a) 20 mm/min (b) 30 mm/min (c) 40 mm/min (d) 50 mm/min
19. Among the following for which operation, the slowest speed is selected in lathe?
(a) Facing (b) Taper turning
(c) Thread cutting (d) Straight Turning
20. In which method the gear cutting can be done faster?
(a) Milling (b) Shaping (c) Hobbing (d) Turning
21. 119 divisions can be indexed by using
(a) Differential indexing (b) Simple indexing
(c) Double indexing (d) Direct indexing
22. In radial drilling machine, large and odd shaped workpieces are hold by using
(a) V-block (b) Machine
(c) Strap clamps and T-bolts (d) Three jaw chuck
23. When the grinding wheels loose their geometry, the original shape is restored by
(a) Burnising (b) Truing (c) Buffing (d) Honing
24. The gear is manufactured on generating principle in
(a) Milling (b) Hobbing (c) Forming (d) Broaching
25. Gear shaving in the operation pertaining to
(a) Gear cutting (b) Gear tooth cutting
(c) Gear finishing (d) Gear tooth correction
26. The name Carborundum refers to
(a) Silicon Carbide (b) Silicon Oxide (c) Silicon Nitrate (d) Silicon Acid
27. Which of the following is not a natural abrasive?
(a) Garnet (b) Emery (c) Carborundum (d) Diamond
28. A taper job of length 90 mm, has a taper length of 42 mm. The larger diameter of
taper is 73 mm and the smaller diameter is 63 mm. Determine the tail-stock setting
over.
(a) 10.51 mm (b) 10.61 mm (c) 10.71 mm (d) 10.81 mm
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29. In lathe, which work holding device is used if the job is complex and irregular shape,
which is inconvenient (or) even impossible to clamp/hold in chucks.
(a) Collets (b) Mandrels (c) Lathe dogs (d) Face plate
30. The size of shaper is specified by
(a) Length of stroke (b) Height of table
(c) Maximum size of tool (d) Ratio of forward to return stroke
31. Which of the following is true for grinding wheel?
(a) Hard grinding wheel is used to grind hard steel
(b) 'A' denotes the hardest abrasive wheel
(c) Grade of grinding wheel is related to its hardness
(d) Soft grinding wheel is used to grind the soft steel
32. A slot is to be milled by a side and face milling cutter with 12 teeth and 100 mm
diameter. Feed rate is 0.2 mm/tooth and cutting speed is 100 rpm. Table feed will be:
(a) 240 mm/min (b) 600 mm/min (c) 260 mm/min (d) 300 mm/min
33. Which of the following is not a part of carriage in lathe mechanism?
(a) Tail stock (b) Saddle (c) Cross slide (d) Tool post
34. What will be step ratio of headstock spindle for a lathe machine of following data?
Maximum speed = 2100 rev/min
Minimum speed = 70 rev/min
No. of speeds = 21
1/22 1/19 1/21 1/20
(a) (30) (b) (30) (c) (30) (d) (30)
35. Finishing of existing hole is known as:

(a) Boring (b) Counter boring (c) Counter sinking (d) Reaming
36. An exact centering can be done on a lathe by
(a) Four jaw chuck (b) Three jaw chuck (c) Dog clutch (d) Face plate
37. Knurling operation is performed on
(a) Shaper machine (b) Milling machine (c) Grinding machine (d) Lathe machine
38. The surface finish of a cylindrical hole is maintained by
(a) Honing (b) Lapping
(c) Internal cylindrical grinding (d) Boring
39. In shaping process
(a) Tool reciprocates and feed is given to job
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(b) Job reciprocates and feed is given to job

(c) Both tool and job reciprocate relative to each other
(d) Both tool and job remain static
40. For taper turning, a work piece having r- as radius at the small end, and R- as the
radius at the big end with L- as the length of the taper will have a taper angle α given
by:
 Rr   Rr 
(a) tan     (b) tan 2   
 L   L 
 Rr   Rr 
(c) tan     (d) tan 2   
 2L   2L 
 Rr 
(e) tan   2  
 L 
41. Which of the following lathes is suitable for a small engineering workshop involved
in repair work?
(a) Centre lathe (b) Tool-room lathe
(c) Special purpose lathe (d) Hollow spindle lathe
(e) Capstan lathe
42. In a shaper, let N be the rotational speed of the bull gear and L be the length of the
stroke, then the time T for completing one stroke is given by:
2L L L L
(a) T  (b) T  (c) T  (d) T  2  
N 2N N N
1 L 
(e) T   
2 N 
43. Suggest a suitable machine from the following options for cutting T- slots on a very
long and heavy apparatus table:
(a) Slotting machine (b) Planer machine
(c) Shaper machine (d) Vertical lathe
(e) Horizontal milling machine
44. A 16 mm hole is to be drilled through a mild steel plate of 25 mm thickness. The

over-travel of the drill is 5 mm. What will be the drilling time if the feed rate is 150
mm/min?
(a) 0.2 min (b) 0.02 min (c) 2.0 min (d) 2.2 min
(e) 2.22 min
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45. ______ is not an abrasive used in grinding wheels.

(a) Aluminum oxide (b) Silicon carbide
(c) Cubic boron nitride (d) Sodium silicate (e) Diamond
46. The binding material used in cemented carbide tools is
(a) Nickel (b) Cobalt (c) Chromium (d) Carbon
47. Gang milling is
(a) Process of cutting gears
(b) Milling process for gearing hexagonal surfaces
(c) Process in which two or more cutters are used simultaneously
(d) High speed milling
48. If is number of strokes per minute, L is stroke length is mm, C is cutting ratio (cutting
time/total time) the cutting speed of shaper in meters/min is given by
(a) NL/1000C (b) NLC/1000 (c) 1000/NC (d) 1000 LC/N
49. In centre less grinding the work piece advances by
(a) Push given by operator (b) Hydraulic force
(c) Force exerted by grinding wheel (d) Remains stationary
50. Size of a shaper is generally specified by
(a) The area of machined surface per hour
(b) Maximum travel of cutting tool
(c) Length, breadth and height of machine
(d) Quick return ratio
51. In a machine operation on free cutting mild steel the cutting speed is mentioned as 70
m/min. What should be material of cutting tool
(a) Carbon steel (b) High speed steel
(c) Carbide (d) Diamond
52. The maximum peripheral speed a grinding wheel is limited by
(a) The work material (b) The diameter of the wheel
(c) The drive limitations (d) The kind of bond used in the wheel
53. On a triple thread screw
(a) Lead = Pitch (b) Lead = 3 Pitch
(c) Lead = 1/3 Pitch (d) Lead = 9 Pitch
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54. Which machine can be used in for grinding the ball bearing outer races
(a) Cylindrical grinding machine (b) Centre less grinding machine
(c) Magnetic grinding machine (d) Surface grinding machine
55. Which of the following is gear finishing process?
(a) Gear lapping (b) Gear shaving
(c) Gear grinding (d) All of the above
56. Quick return mechanism is associated with
(a) Lathe (b) Milling (c) Shaping (d) None
57. When the dia of work piece changes from one end to the other, it is called
(a) Straight turning (b) Taper turning (c) Knurling (d) facing
58. Boring operation is used to
(a) Drill a hole (b) Correct the hole
(c) Enlarge the existing hole (d) Finish a drilled hole
59. Reaming operation is used to
(a) Make a hole (b) Enhance the finish of a hole
(c) Enlarge the hole (d) Obtain correct diameter
60. Standard taper generally used on milling machine spindles is
(a) Morse (b) Brown and Sharpe (c) Chapman (d) Seller's
61. The usual ratio of forward and return stroke in shaper is–
(a) 2 : 1 (b) 1 : 2 (c) 2 : 3 (d) 3 : 2
62. While machining a brass casting on a lathe, the type of chuck used is–
(a) Collect chuck (b) Magnetic chuck (c) Three jaw chuck (d) Four jaw chuck
63. In machined components,
(a) Fiber lines are arranged in a predetermined way
(b) Fiber lines of rolled stock are broken
(c) There are no fiber lines
(d) Fiber lines are scattered
64. Abrasive grain size of 10 on grinding wheel refers to :
(a) Fine grain wheel (b) Coarse grain wheel
(c) Medium grain wheel (d) Very fine grain wheel
65. Which of the following is an artificial abrasive used in grinding wheel?
(a) Sandstone (b) Corundum (c) Silicon carbide (d) Emery
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66. Consider the units in following operations

1. Turning-mm/rev 2. Shaping-mm/stroke
3. Drilling-mm/rev 4. Milling-mm/min
Out of the above which are correct?
(a) 1, 2 and 3 (b) 1, 2 and 4 (c) 1, 3 and 4 (d) 1, 2, 3 and 4
(e) 1 and 3
67. Consider the following machines
1. Shaping machine 2. Planing machine
3. Slotting machine
Internal keyway in gears can be cut by which of the above
(a) 1 and 2 (b) 2 and 3 (c) 3 (d) 1
(e) 2
68. Characteristic features of a universal cylindrical grinder not possessed by plain
cylindrical grinder are:
1. Swiveling wheel head 2. Swiveling wheel head slide
3. Swiveling head stock 4. Rotation of grinding wheel
(a) 1, 3 and 4 (b) 1, 2 and 3 (c) 1, 2 and 4 (d) 1, 2, 3 and 4
(e) 2 and 3
69. Tool-life criterion normally used is:
(a) Flank wear (b) Crater wear
(c) Crater wear and flank wear (d) Flank wear and nose radius
70. Cutting tool is much harder than the work piece. Yet the tool wears out during the tool
work interaction, because
(a) Extra hardness is imparted to the work piece due to coolant used
(b) Oxide layers formed on the work piece surface impart extra hardness to it
(c) Extra hardness is imparted to the work piece due to severe rate of strain
(d) Vibration is induced in the machine tool
71. The lead screw of a lathe with nut forms a
(a) Sliding pair (b) Rolling pair (c) Screw pair (d) Turning pair
72. Blade in the back saw cuts during the
(a) Forward stroke (b) Backstroke
(c) Both stroke (d) Pressure applied
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73. Friction at the tool chip interface can be reduced by

(a) Decreasing the rake angle (b) Increasing the depth of cut
(c) Decreasing the cutting speed (d) Increasing the cutting speed
74. The factor responsible for the formation of discontinuous chips is
(a) Low cutting speed and small rake
(b) High cutting speed and small rake angle
(c) High cutting speed and large rake angle
(d) Low cutting speed and large rake angle
75. Which of the following abrasive will be used for grinding tool steel and high speed
steel
(a) Diamond (b) SiC (c) Al2O3 (d) Boron Carbide
76. When the space between two consecutive abrasive is less in griding upon machining
ductile materials, how chips weld these abrasives and after some time wheel is
rubbing over work without cutting. This phenomenon is called
(a) Glazing (b) Loading (c) Dressing (d) Trueing
77. Spinning operation is carried out on a
(a) Lathe machine (b) Milling machine
(c) Hydraulic press (d) Mechanical press
78. In 4 high roll mill, the bigger rolls are called
(a) Back up rolls (b) Guide rolls (c) Support rolls (d) Main rolls
79. Point angle in drills are kept low for machining ductile materials to take advantage of
(a) Thinner chips (b) Thicker chips
(c) Low head developed (d) Lesser cutting forces
80. Very accurate screw threads can be manufactured by
(a) Milling (b) Grinding (c) Rolling (d) Chasing
81. When machining parameters are kept constant, tool life will be less in
(a) Down milling (b) Up milling (c) Face milling (d) End milling
82. What is the purpose of inscribing the concentric circles on the face of the chuck in
lathe
(a) To improve the appearance (b) To facilitate lubrication in the chuck
(c) To minimize the weight of the chuck
(d) To facilitate quick centering of work pieces
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83. A steel shaft of 25 mm diameter is turned at a cutting speed of 50 m/min. Find the
RPM of the shaft.
(a) 637 (b) 159 (c) 6280 (d) 1570
84. Process of shaping thin metal sheets by processing them against a form tool is called
(a) Upsetting (b) Spinning (c) Reaming (d) Deep drawing
85. Dressing is
(a) The process of changing the shape of the grinding wheel
(b) The process of removing the metal loading and breaking away the glazed surface
of the grinding wheel
(c) The process of disposing the grinding wheel as it no longer useful
(d) The process of adding excess abrasive grains on the grinding wheel
86. Hobbing process is not suitable for cutting following type of gear
(a) Spur (b) Helical (c) worm (d) Bevel
87. In centreless grinding work piece, centre will be
(a) Above the line joining the two-wheel centres
(b) Below the line joining the two-wheel centres
(c) On the line joining the two-wheel centres
(d) At the intersection of the line joining the wheel centres with the plane of the
workpiece
88. Internal gears can be made by
(a) Hobbing (b) Shaping with pinion cutter
(c) Shaping with rack cutter (d) Milling
89. The correct sequence of tool materials in increasing order of their ability to retain
their hot hardness is
(a) Carbide, ceramic, cermet, borazon (b) Ceramic, carbide, borazon, cermet
(c) Cermet, carbide, ceramic, borazon (d) Borazon, ceramic, carbide, cermet
90. The cutting speed of a tool is
(a) Directly proportional to the diameter being out
(b) Inversely proportional to the diameter being cut
(c) Directly proportional to the square of the diameter being cut
(d) Independent of the diameter being cut
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91. The most common type of drill is

(a) Step drill (b) Twist drill (c) Spot drill (d) Spade drill
92. Which of the following processes results in the best accuracy of the hole made?
(a) Reaming (b) Tapping (c) Broaching (d) Boring
93. Which of the following grinding processes is used for high production run?
(a) Surface grinding (b) Cylindrical grinding
(c) Centreless grinding (d) internal grinding
94. Which of the following operations is also known as internal turning?
(a) Milling (b) Facing (c) Tapping (d) Boring
95. The correct sequence of operations for hole making is
(a) Centering, boring, drilling, reaming
(b) Centering, drilling, boring, reaming
(c) Reaming, drilling, boring, centering
(d) Boring, drilling, reaming, centering
96. The correct sequence of operations for making alloy steel gears is
(a) Turning, hobbing, heat treatment, shaving
(b) Heat treatment, turning, hobbing, shaving
(c) Shaving, turning, hobbing, heat treatment
(d) Turning, hobbing, shaving, heat treatment
97. The correct sequence in increasing hardness of tool materials is
(a) HSS, tungsten carbide, cubic boron nitride, diamond
(b) HSS, cubic boron nitride, tungsten carbide, diamond
(c) Cubic boron nitride, HSS, tungsten carbide, diamond,
(d) Tungsten carbide, cubic boron nitride, HSS, diamond
98. Which of the following is not the function of a cutting fluid?
(a) Removal of heat (b) Lubrication
(c) Protection against corrosion (d) Abrasion of workpiece
99. A built up edge is formed white machining :
(a) Ductile material at high speed (b) Ductile material at low speed
(c) Brittle material at high speed (d) Brittle material at low speed
100. Trepanning is performed for :
(a) Finishing a hole (b) Producing large hole without drilling
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(c) Enlarging hole (d) Threading

101. Abrasive are not used in :
(a) Buffering process (b) Burnishing process
(c) Polishing process (d) Super finishing process
102. A milling cutter is having 8 teeth rotating at 100 rpm. Workpiece feed is set at 40
mm/min. So feed per tooth is :
(a) 5 mm (b) 0.05 mm (c) 0.4 mm (d) 0.2 mm
103. In HSS, tungsten can be substitute by :
(a) Chromium (b) Nickel (c) Molybdenum (d) Cobalt
104. Cutting speeds for Turning with HSS on cast iron is about
(a) 20 m/min (b) 30 m/min (c) 35 m/min (d) 15 m/min
105. Which of the following is a chipless machining process?
(a) Metal spinning (b) Knurling (c) Hobbing (d) Lapping
106. The recommended average cutting speed in meters per minute for HSS tool for
cutting mild steel is
(a) 15 (b) 30 (c) 60 (d) 90
107. Cutting tool material 18 - 4 - 1 HSS has which one of the following compositions?
(a) 18% W, 4% Cr, 1% V (b) 18% Cr, 4% W, 1% V
(c) 18% W, 4% Ni, 1% V (d) 18% Cr, 4% Ni, 1% V
108. Choose the correct order of tool materials arranged, according to the decreasing order
of their hot hardness.
(a) Ceramics, Cermets, Tungsten Carbide, HSS
(b) Cermets, Ceramics, Tungsten Carbide, HSS
(c) Tungsten Carbide, Ceramics, Cermets, HSS
(d) Cermets, Tungsten Carbide, Ceramics, HSS
109. A step cone pulley is provided on a lathe to
(a) Reverse the direction of spindle rotation
(b) Change the spindle speed
(c) Drive the lead screw
(d) Give desired direction of movement of lathe carriage
110. Which of the following method cannot be used for manufacturing internal gears?
(a) Casting (b) Die casting (c) Broaching (d) Hobbing
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111. HSS has the property to–

(a) Withstand high temperature (b) Provide lubrication by itself
(c) Become hard during machining (d) Reduce impact of the tool
112. A work piece of 100 mm diameter is to be machined at a cutting speed of 1000 meters
per minute. The rpm of the work piece should be–
(a) 1000 (b) 1590 (c) 2000 (d) 3183
113. The metal in machining operation is removed by :
(a) Tearing chips (b) Distortion of metal
(c) Shearing the metal across a zone (d) Cutting the metal across a zone
114. Feed rate in milling operation is equal to :
(a) RPM (b) RPM × No. of teeth
(c) RPM × Feed per tooth × No. of teeth (d) None of the above
115. Machinability depends on :
(a) Microstructure, physical and mechanical properties and composition of workpiece
Material
(b) Cutting forces (c) Type of chip
(d) Tool life
116. Time taken to drill a hole through a 25 mm thick plate at 300 r.p.m. at a feed rate of
0.25mm/revolution will be :
(a) 10 sec (b) 20 sec (c) 40 sec (d) 50 sec
117. A mild steel rod having 50mm diameter and 500 mm length is to be turned on a lathe.
Determine the machining line to reduce the rod to 45mm in one pass when cutting
speed is 30m/min and a feed of 0.7 mm/rev is used :
118. For producing more accurate holes, the sequence of operations to be followed is :
(a) Centering, drilling, boring , reaming (b) Centering, boring , drilling, reaming
(c) Drilling, centering, boring , reaming (d) Drilling, reaming, boring, centering,
119. The angle which is found between the face of the cutting tool and the normal to the
machined surface at the cutting edge is called:
(a) Rake angle (b) Relief angle
(c) Clearance angle (d) Cutting angle
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120. The hardness with which the bond holds the cutting points or abrasives in place
defined by the term :
(a) Structure (b) Grit size (c) Grain size (d) Grade
121. Which of the following is not part of Capstan lathe ?
(a) Chuck (b) Tailstock (c) Spindle (d) Tool post
122. When the tool moves parallel to the lathe axis, it is called:
(a) Cross feed (b) Sellar's taper
(c) Chapman's taper (d) Brown and Sharpe taper
123. In order to grind soft material:
(a) Fine grained grinding wheel is used
(b) Medium grained grinding wheel is used
(c) Coarse grained grinding wheel is used
(d) None of these
124. The size of a lathe is expressed by
(a) Diameter of chuck (b) Maximum speed of chuck
(c) Swing of lathe (d) Height of centers from ground
125. A sprue hole is
(a) An eccentric hole (b) A blind hole
(c) An opening is a mould into which molten metal is poured
(d) A thorough hole drilling through two mating parts
126. Power is transmitted by lead screw to carriage through
(a) Gear system (b) Pulley drive
(c) Rack and pinion arrangement (d) Half nut
127. Knurling is an operation
(a) Of cutting smooth collars (b) Of under cutting
(c) Of generally roughing the surface for hand grip
(d) Done prior to screw cutting
128. The operation performed on a shaper is
(a) machining horizontal surface (b) machining vertical surface
(c) machining angular surface (d) All of these
129. The method of grinding used to produce a straight of tapered surface on a work-piece
is
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(a) Internal cylindrical grinding

(b) Form grinding
(c) External cylindrical grinding (d) Surface grinding
130. The process of removing metal by a cutter which is rotating in the same direction of
travel of work-piece is called
(a) Up milling (b) Down milling (c) Face milling (d) End milling
131. A broach has the following teeth:
(a) Rough teeth (b) Semi-finishing teeth
(c) Finishing teeth (d) All of the above
132. The broaching operation in which either the work or tool moves across the other is
known as
(a) Pull broaching (b) Push broaching
(c) Surface broaching (d) Continuous broaching
133. Which of the following is not the assumption in Merchant’s theory :-
(a) Tool is perfectly sharp (b) Shear is occurring on a plane
(c) Uncut chip thickness is constant
(d) A continuous chip with built up edge (BUE) is produced
134. In machining processes, the percentage of heat generated in shear action is carried
away by the chips to the extent of:-
(a) 10% (b) 25% (c) 50% (d) 90%
135. Which of the following are the reasons for reduction of tool life in a 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 answer from the following :
(a) 1, 2 & 4 (b) 1, 2 & 3 (c) 1, 3 & 4 (d) 1, 2, 3 & 4
136. With high speed steel tools, the maximum safe operating temperature is of the order
of
(a) 200oC (b) 540oC (c) 760oC (d) 870oC
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137. While machining a brass casting on a lathe, the type of chuck used is
(a) Collect chuck (b) Magnetic chuck
(c) Three jaw chuck (d) Four jaw chuck
138. Consider the following statements about desirability of High velocity in grinding
because of
1. To reduce force per grit 2. To increase overall grinding force
3. To offset effect of high negative rake angle
4. To decrease overall grinding force
(a) 1 and 3 (b) 2 and 3 (c) 3 and 4 (d) 1, 3 and 4
(e) 1, 2 and 3
139. The different speeds on a lathe are provided in:
(a) Arithmetic progression (b) Binary numbers
(c) Geometric progression (d) None of these
140. High speed steel contains carbon
(a) 0.15 to 0.3% (b) 0.6 to 1.0% (c) 4 to 6% (d) 6 to 10%
141. Milling cutter is mounted on the part of a milling machine called
(a) Dividing head (b) Spindle (c) Bracket (d) Arbor
142. A plate of 600 × 900 mm is to be machined on a shaper. Cutting speed is 6 m/min,
return time to cutting time ratio is 1 : 4 and the feed is 2 mm/stroke. Clearance at each
end is 75 mm. The time required in minutes on shaper to complete one cut would be :
(a) 45 (b) 60 (c) 80 (d) 90
143. In which milling operation, the cutting force tends to lift the work piece?
(a) Climb (b) Down (c) Conventional ( d) Face
144. Which of the following operation is required for making a chamfer on the edge of a
hole?
(a) Spot facing (b) Countersinking (c) Counter boring (d) Reaming
145. Which one of the following methods is used for turning internal tapers only?
(a) Compound rest (b) Tailstock offset
(c) Form tool (d) Taper attachment
146. The time taken to face a work piece of 80 mm diameter for the spindle speed of 90
rpm and cross feed of 0.3 mm/rev will be
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147. A feed f for the lathe operation is

N L
(a) mm / rev (b) mm / rev
L × Tm N × Tm
Tm Tm  L
(c) mm / rev (d) mm / rev
N×L N
Where : Tm = Machining time t in min. N = Speed in rpm
L = Length of cut in mm
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MACHINING AND MACHINE TOOL OPERATIONS

SOLUTIONS
1. Solution. (b) : Hot hardness is the properly of a tool that prevents plastic deformation
at its cutting edge during machining process.
2. Solution. (b) : In a horizontal borer, the tool rotates where as in a lathe, the object
rotates.
3. Solution. (d) : The chip thickness during slab milling process is directly proportion to
feed rate of work piece.:
4. Solution. (b) : Cutting speed = πDN = π × 20 × 1000 = 20000 π mm/min = 20 π
m/min
5. Solution. (d) : (1 given by CIL)
It is clear from the figure that at high speed, maximum heat is carried away by the
chip, then work piece and least is carried by tool. So the ratio 70: 10: 20 will be
correct.
6. Solution. (a) : Knurling: Knurling is a manufacturing process whereby a visually-
attractive diamond-shaped (crisscross) pattern is cut or rolled into metal. This pattern
allows human hands or fingers to get a better grip on the knurled object than would be
provided by the originally-smooth metal surface.
Boring: Boring always involves the enlarging of an existing hole, which may have
been made by a drill or may be the result of a core in a casting.
Reaming: Reaming removes a small amount of material from the surface of holes. It
is done for two purposes: to bring holes to a more exact size and to improve the finish
of an existing hole.
Threading: It is the process of making internal or external threads on the workpiece.
Out of above four processes except knurling all other involves the chips. So Knurling
is right option.
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7. Solution. (a) : Cutting speed (also called surface speed) may be defined as the rate (or
speed) at the workpiece surface, irrespective of the machining operation used. Cutting
speed = r × ω = πDN mm/min Where D is in mm and N is in RPM. So cutting speed
is directly proportion to diameter of the workpiece.
8. Solution. (c) : Crater wear occur on the rake face. For crater wear temperature is the
main culprit and tool diffuse into the chip material and tool temperature is maximum
at some distance from the tool tip. So crater wear starts at some distance from tool tip.
9. Solution. (d) : Tool dynamometers are used to determine cutting forces.

10. Solution. (d) : Characteristics of cutting tool material-
1. High hot hardness
2. High wear resistance
3. High toughness
4. High thermal conductivity
5. Low coefficient of friction at tool chip interface.
11. Solution. (b) : Common properties of cutting fluid-
1. High heat absorbing capacity
2. High flash point
3. Non corrosive to tool and work mateiral.
4. It should be harmless to operate and bearing
5. It has good lubrication properties to reduce frictional force and to reduce the power
consumption.
6. Wash-off the chips easily.
7. Also be non-toxic.
12. Solution. (c) : Crater wear start at some distance from the tool tip because of tool
temperature is maximum in that region.
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Crater wear—
• Crater wear occur on the rake face.
• At very high speed crater wear predominates
• For crater wear, temperature is main culprit and
tool defuse into chip material and tool temperature is
maximum at some distance from the tool tip.
13. Solution. (c) : Trimming—Trimming is the process of removing the burrs or flash
from a forged component in drop forging.
Swaging—Swaging is a forging process in which the dimension of an item are altered
using dies into which the item is forced.
Perforating—A perforation is a small hole in thin material. There is usually more
than one perforation in organized fashion, where all of the holes collectively are
called a perforation. The process of creating perforations is called perforting.
14. Solution. (a) : Climb milling is generally the best way to machine parts today since it
reduces the load from the cutting edge, leaves a better surface finish and improves
tool life. During conventional milling, the cutter tends to dig into the work piece and
may cause the part to be cut out of tolerance.
15. Solution. (b) : The thickness of the chip is minimum at the beginning of the cut and
maximum at the end of the cut is case of up milling. Up milling also know as
conventional milling.
16. Solution. (b) : The slotting machine can be used to cut slots, splines keyways for both
internal and external job such as machining internal and external gears.
17. Solution. (a) : One of the disadvantages of a hydraulic shaper compared to the
mechanical shaper is stopping point of the cutting stroke can vary depending upon the
resistance offered to cutting.
18. Solution. (a) : mrr = d × f × b
3
40 × 10 = 10 × f × 200
f = 20 mm/min.
19. Solution. (c) : For thread cutting among the following operation, the slowest speed is
selected in lathe.
20. Solution. (c) : Hobbing machines provide gear manufacturers a fast and accurate
method for cutting parts. This is because of the generating nature of this particular
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cutting process. Gear hobbing is not a form cutting process, such as gashing or milling
where the cutter is a conjugate form of the gear tooth. The hob generates a gear tooth
profile by cutting several facets of each gear tooth prolife through a synchronized
rotation and feed of the work piece and cutter.
21. Solution. (a) : 119 divisions can be indexed by using differential indexing.
22. Solution. (c) : In radial drilling machine, large and odd shaped workpieces are hold
by using strap clamps and T-bolts.
23. Solution. (b) : The purpose of truing is to bring every point of the grinding surface
concentric with the machine spindle and to introduce a form into a wheel.
24. Solution. (b) : The gear is manufactured on generating principle in hobbing.
25. Solution. (c) : Gear shaving in the operation pertaining to gear finishng.
26. Solution. (a) : The name Carborundum refers to Silicon Carbide.
27. Solution. (c) : Carborundum is not a natural abrasive where as Gamet, Emery and
Diamond are a natural abrasive.
28. Solution. (c) : Given, L = 90 mm, D = 73 mm lr = 42 mm, d = 63 mm
 x D  d 73  63
tan  , x 
2 lr 2 2
x = 5 mm
 5
tan    13.578o
2 42
Where α is tapper angle then, tail stock setting (y) is given as
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
y  L  sin
2
y  90  0.1182
y  10.639mm
29. Solution. (d) : Face plate is used as a work holding device in lathe when the job is
complex and irregular shape.
30. Solution. (a) : Specification of shaper machine–
1. The maximum length of stroke ram.
2. Types of the drive.
3. Power input of the machine.
4. Floor space required to establish the machine.
5. Weight of the machine in ton.
6. Feed.
7. Cutting to return stroke ratio.
8. Angular moment of the table.
31. Solution. (c) : Hard grinding wheel is used to grind soft steel. Grade of grinding
wheel is related to its hardness. Soft grinding wheel is used to grind the hard steel.
From A (soft) to Z (hard), determines how tightly the bond holds the abrasive. A to H
for softer structure, I to P for moderately hard structure and Q to Z for hard structure.
32. Solution. (a) : We know that, table feed of milling machine
fm = f t × z × N
ft = 0.2 mm/tooth
z = 12, D = 100 mm
N = 100 rpm
fm = 0.2 × 12 × 100
fm = 240 mm/min
33. Solution. (a) : Tool post, saddle, cross slide these are parts of carriage in lathe
mechanism whereas tail stock is another important part of lathe machine.
34. Solution. (d) : Maximum speed = 2100 rev/min Minimum speed = 70 rev/min
No. of speeds = 21 then step ratio (r) =?
We know that
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N max
 ( r ) n 1
N min
 2100 
( r ) 211     30
 70 
1
(r )   30  20
35. Solution. (d) : Reaming process—Reaming is a cutting operation with a multi-edge

cutting tool which is constantly in action. Reaming is applied to finish drilled holes
accurately to size and with a good surface finish.
Boring—Boring, also called internal turning, is used to increase the inside diameter
of hole. The original hole is made with drill, or it may be a cored hole in a casting.
Counter boring—counter boring is the operation of enlarging one end of an existing
hole concentric with the original hole with square bottom. It is done to accommodate
the heads of bolts, studs and pins.
Counter sinking—a countersink is a core-shaped hole that is cut into PCB to allow
the flat head of a socket cap screw to fit flush with the surface of the board.
36. Solution. (a) : An exact centering can be done on a lathe by four jaw chuck.
Type of Chuck in Lathe machine are as follows:
• Four jaws independent chuck.
• Three jaws universal chuck.
• Combination chuck.
• Magnetic chuck.
• Collet chuck.
• Air or hydraulic operated chuck.
37. Solution. (d) : Knurling–Knurling is a process of impressing a diamond shaped or
straight line pattern into the surface of workpiece by using specially hardend metal
wheels to improve its appearance and provide a better gripping surface. Knurling
operation is performed on lathe machine.
38. Solution. (a) : Honing process–Honing is a finishing process, in which a tool called
hone carries out a combined rotary and reciprocating motion while the work piece
does not perform any working motion. The Honning process is carried out by
mechanically rubbing the honing stone (cutting tool) against the workpiece surface
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(normally internal) along the controlled path. The surface finish of cylindrical hole is
maintained by honing.
39. Solution. (a) : In shaping process, The shaper holds the single point cutting tool in
ram and workpiece is fixed in the table and feed is given to job. During the forward
stroke, the ram is holding the tool is reciprocating over the workpiece to cut into the
required shape. During the return stroke, no metal is cutting in the shaper machine,
the rotary motion of the drive is converted into reciprocating motion of ram holding
the tool.
40. Solution : (e)
 (R  r) R r 
tan    2 tan 1  
2 L  L 
41. Solution. (a) : Centre-Lathe Machine–A centre lathe is amachine tool that carries
out many machine shop tasks. It can cut and smooth the face of a work piece. It can
make holes to an exact size and position. It can also make external or internal
threaded parts on a work piece. This ability to do different tasks makes it an important
tool. In most tasks a lathe use is only limited by the size of the work piece. The five
most common tasks on a centre lathe that you will be perform are:
_ Facing
_ Turning
_ Drilling
_ Boring
_ Threading
_ Knurling
_ Chamfering
42. Solution . (c) : Time for completing one stroke
L
T
N
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43. Solution. (b) : Planer Machine–A planer is a type of metal working machine tool
that uses linear relative motion between the workpiece and a single-point cutting tool
to cut the workpiece. A planer is similar to a shaper, but larger, and with workpiece
moving, whereas in a shaper the cutting tool moves. The workpiece is securely fixed
on a table called platen, and it reciprocates horizontally against a single edged cutting
tool. The surface machined may be horizontal, vertical or at an angle.
Operations of Planer Machine–
_ Planning flat horizontal, vertical and curved surface.
_ Planning at an angle and machining dovetails.
_ Planning slots, T-slots and grooves.
44. Solution. (a) : Data given t = 25 mm
Over-travel (x) = 5 mm
f × N = 150 mm/min
D = 16 mm
Then drilling time T = ?
Le (t  x) (25  5)
T    T  0.2 min
f N f N 150
45. Solution. (d) : Aluminum oxide, silicon carbide, CBN and Diamond are used to an
abrasive in grinding wheel whereas sodium silicate is not used as abrasive in grinding
wheel.
46. Solution. (b) : The binding material used in cemented carbide is cobalt. Cobalt acts as
a binder & also reduces the brittleness of the carbides tool. In cemented carbide
composition are 82% tungsten carbide, 10% titanium carbide and 8% cobalt.
47. Solution. (c) : It is an operation of producing many surfaces of a work-pieces
simultaneously by feeding the table against a number of required cutters. (Gang
Milling).
NLC
48. Solution. (b) : Shaper, cutting speed (m/min) (V) = C = cutting ratio.
1000
49. Solution. (c) : In centre less grinding the work piece advances by the force exerted by
grinding wheel. Grinding wheel are statationary wheel, which rotate on a fixed axis, at
high speed.
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50. Solution. (b) : The size of a shaper is generally specified by the maximum travel of
cutting tool.
51. Solution. (b) : For, cutting mild steel, in machining operation, the cutting tool of high
speed steel material is used for cutting, at speed 70 m/min
52. Solution. (d) : The maximum peripheral speed of a grinding wheel is limited by the
kind of bond used in the wheel.
53. Solution. (b) : On a triple thread screw, lead is three times the pitch.
Lead = 3 × pitch
54. Solution. (b) : Center less grinding machines is used for grinding the ball bearing
outer races. Center less grinding may be external or internal.
55. Solution. (d): For gear finishing process :- gear lapping, gear shaving, gear grinding
all are used for fine finishing process.
56. Solution. (c) : Shaping
57. Solution. (b) : When the diameter of work-piece changes from one-end to the other, it
is called taper turning.
58. Solution. (c) : Boring operation is used after the drilling take place it help to enlarge
the existing hole by means of a single point cutting tool.
59. Solution. (c) : A reamer is a type of rotary cutting tool used in metal working.
Precision reamers are designed to enlarge the size of a previously formed hole by a
small amount but with a high degree of accuracy, to leave smooth sides.
60. Solution. (b) : Standard taper generally used on milling machine spindles is Brown
and Sharpe.
61. Solution. (d) : The usual ratio of forward & return stroke in shaper is 3:2
62. Solution. (d) : Four jaw chuck used in machining a brass casting on a lathe.
63. Solution. (b) : In machined component fiber lines of rolled stock are broken.
64. Solution. (b) : Abrasive grain size of 10 on grinding wheel refers to coarse grain
wheel.
65. Solution. (c) : Silicon carbide is an artificial abrasive used in grinding wheel.
66. Solution. (d) : 1, 2, 3 and 4.
67. Solution. (c) : Internal keyways usually require a slotted busing or horn to fit the
hole, with the keyway broach pulled through the horn, guided by the slot.
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68. Solution. (b) : Characteristic features of a universal cylindrical grinder not possessed
by plain cylindrical grinder are
(i) Swiveling wheel head
(ii) Swiveling wheel head slide
(iii) Swiveling wheel stock.
69. Solution. (b) : Crater wear is used normally for tool life criterion.
70. Solution. (d) : Due to extra hardness is imparted to the work piece due to severe rate
of strain, cutting tool which is much harder than the work piece wears out during the
tool - work interaction.
71. Solution. (c) : The lead screw of a lathe with nut forms a screw pair.
72. Solution. (a) : A backsaw is any hand saw which has a stiffening rib on the edge
opposite the cutting edge, enabling better control and more precise cutting than with
other types of saws.
73. Solution. (d) : Friction at the tool chip interface can be reduced by increasing the
cutting speed.
74. Solution. (a) : Discontinuous types of chips are formed when hard and brittle metals
like brass, bronze and cast iron is machined.
Condition which one responsible for the formation of discontinuous chips are :
1. Low feed rate.
2. Small rake angle of the tool.
3. High friction force at the chip tool interface.
4. Too much depth of cut.
75. Solution. (c) : Al2O3 abrasive will be used for grinding tool steel and high speed
steel.
76. Solution. (b) : In grinding process this phenomenon is called "wheel loading" which
can be defined as the state of a grinding wheel when particles of a work-piece
material either adhere to the grits or become embedded in the spaces between abrasive
grains on grinding wheels.
77. Solution. (a) : Spinning operation is carried out on a lathe machine.
78. Solution. (a) : In 4 high roll mill, the bigger rolls are called Back up rolls.
79. Solution. (a) : For thinner chips, point angle in drills are kept low for machining of
ductile materials.
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80. Solution. (b) : With the help of grinding, very accurate screw threads can be
manufactured.
81. Solution. (b) : In up-milling tool life will be less.
82. Solution. (d) : To facilitate quick centering of work pieces
83. Solution. (a) : Data given- D = 25 mm, V = 50 m/min
We know that
 DN 3.14  25  N
V ,50 
1000 1000
N = 636.94  637(RPM)
84. Solution. (b) : Metal spinning, also known as spin forming or spinning or metal
turning most commonly, is a metal working process by which a disc or tube of metal
is rotated at high speed and formed into an axially symmetric part. Spinning can be
performed by hand or by a CNC Lathe.
85. Solution. (b) : Dressing is the process of removing the metal loading and breaking
away the glazed surface of the grinding wheel.
86. Solution. (d) : Hobbing process– Hobbing process is carried out on gear hobbing
machine using hob as tool.
–Hob is a cylinder on the surface of which a continuous thread has been cut having
the cross section of involute gear teeth.
So, hobbing process is not suitable for cutting bevel type of gear.
87. Solution : (a) : Centreless grinding- The centreless grinding is the process of
grinding the diameter of a workpiece not mounted on centres or otherwise held. The
centreless grinding may be external or internal. In centreless grinding workpiece,
centre will be above the line joining the two-wheel centres.
88. Solution : (b : Internal gears can be made by shaping with pinion cutter.
89. Solution : (c) : The correct sequence of tool materials in increasing order iscermet,
carbide, ceramic, borazon
90. Solution : (a)
 DN
cutting speed (v c ) 
1000
Cutting speed of a tool is directly proportional to the diameter being
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91. Solution: (b) : It is an end cutting tool with two, three or four cutting lips. It has a
cylindrical body on which the grooves are cuts. These grooves are called flutes while
drilling, the drill is held by a shank.
92. Solution: (a) : Reaming- It is an operation of slightly enlarging a machined hole to
proper size with a smooth finish.
93. Solution: (a) : Surface grinding is used to produce that surface in a horizontal
position.
94. Solution: (d) : Boring is also known as internal turning.
95. Solution : (b) : The correct sequence of operations for hole making is-
• Centering, drilling, boring, reaming.
96. Solution : (d) : The correct sequence of operations for making alloy steel gears is
• Turning, hobbing, shaving, heat treatment.
97. Solution : (a) : HSS, tungsten carbide, cubic boron nitride, diamond
98. Solution : (d) : Function of cutting fluid:
• Cooling of the job and the tool.
• Lubrication at the chip-tool interface.
• Cleaning the machining zone by washing away the chip particles and debris.
• Protection of the nascent finished surface.
99. Solution : (b) : Chips with built-up edge-
_ Ductile materials
_ Low speed
_ High feed
_ High depth of cut
100. Solution: (b) : Trepanning is performed for producing large hole without drilling.
They are used just for through holes, not for blind holes. Mainly used in making gun
barrels.
101. Solution: (b) : In burnishing process, the jig-jag edges of material gets converted into
straight and smooth edges, which is not required any of abrasive. So, abrasives are not
used in burnishing process.
102. Solution : (b) : Number of teeth (Z) = 8
Speed (N) = 150 rpm
Workpiece feed f = 40 mm/min
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Feed per tooth ft = ?
Workpiece feed (f) = ftZN
40 = ft × 8 × 100
ft = 0.05 mm
103. Solution: (c): In HSS, tungsten can be subsite by molybdenum.

104. Solution: (a) : Cutting speeds for turning with HSS on cast iron is about 20 m/min.
105. Solution : (a) : Metal spinning also known as spin forming or spinning or metal
turning most commonly, is a metal working process by which a disc or tube of metal
is rotated at high speed and formed into an axially symmetric part. Spinning can be
performed by hand or by a CNC lathe.
106. Solution. (b) :
Material speed (m/min)
Diamond 200 - 2000
CBN 30 - 310
Ceramic 150 - 650
Carbides 30 - 150
High speed steel 10 - 60
107. Solution. (a) : High speed steel is a subset of tool steels, commonly used as cutting
tool material.
18 - 4 - 1 (HSS)
18% - Tungsten (W)
4% - Chromium (Cr)
1% - Vanadium (V)
High speed steel properties and applications—The well balanced composition
produce both excellent toughness and cutting power and makes this economical
molybdenum high speed steel a standard grade for all types or roughness and
finishing tools, as well as for all tools demanding a high degree of toughness.
108. Solution. (a) : The correct order of decreasing hot hardness is Ceramics, Cermets,
Tungsten Carbide and HSS. Ceramics are essentially alumina based high refractory
materials introduced specifically for high speed machining of difficult to machine
materials and cast iron. These can withstand very high temperatures, are chemically
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more stable, and have higher wear resistance than the other cutting tool materials.
Cermets are aluminium oxide based material containing titanium carbide, titanium
nitride and titanium carbo nitride. Cermets have higher hot hardness and higher
oxidation resistance over cemented carbides. Carbides, which are nonferrous alloys,
are also called, sintered (or cemented ) carbides because they are manufactured by
powder metallurgy techniques. These tool materials are much harder, are chemically
more stable, have better hot hardness, high stiffness, and lower friction, and operate at
higher cutting speeds than do HSS.
109. Solution : (b) A step cone pulley is provided on a lathe to change the spindle speed.
110. Solution. (d) : Hobbing method here not used for manufacturing internal gear
111. Solution. (d) : HSS has the property to reduce impact of the tool.
112. Solution. (d) : Given, D = 100 mm, V = 1000 m/min, N=?
1000  V 1000 1000
N   3183.00 R.P.M
 D   100
113. Solution: (c) The metal in machining operation is removed by shearing the metal
across a zone. To remove metal by machining the tool first penetrate the surface once
the tool has penetrated the surface, the chip formed should readily break. The ideal
method of breaking the chip is to provide a built in breaker. It is wrong to assume that
because a metal is soft it is easy to machine. In steel a completely spheroidized
structure is considered to be easiest to machine.
114. Solution : (c) Feed rate in milling operation is equal to RPM Feed per tooth × no. of
teeth
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cutter speed
(i) RPM of cutter =
D
(ii) Feed/min = feed/teeth × no. of teeth × RPM
Length
(iii) Time for milling =
feed / mt
(iv) feed rate = RPM × feed per tooth × No of teeth.
115. Solution : (a) Factor affecting the machinability
(i) The type of work - piece
(ii) Type of tool material
(iii) Size and shape of tool
(iv) Size, shape and velocity of cut
(v) Type and quality of machine used
(v) Co efficient of friction between chip and tool
(vi) Shearing strength of work-piece material
116. Solution : (b) Time take in Drilling
Length of drilled hole
rpm  feed / revolution
25
T
300
 0.25
60
25  60
T
300  0.25
T  20 sec
117. Solution : (c) Given data : Rod diameter = 50 mm
Length = 500 mm Cutting speed = 30 m/min
Feed = 0.7 mm/rev.
L V  1000 30 1000
Time for machining (t) = N  N  191 rpm
f N  D 3.14  50
500
t  t  3.738 min
0.7  191
118. Solution : (a) For producing more accurate holes, the sequence of operations to be
followed is centering, drilling, boring , reaming
119. Solution: (a) Angle between the face of the cutting tool and the normal to the
machined surface at the cutting edge is called rake angle.
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120. Solution: (d) The bond holds the cutting points or abrasive in place defined by the
grade. Grade of a grinding wheel: The grade of a wheel indicates the strength of the
grains, and the holding power of the bond. It is usually referred to as hardness of the
wheel. The thickness of the bonding layer holding abrasive Controls the grade of the
grinding wheel. Hard wheel is used for precision grinding.
Very Soft - A to G
Soft - H to K
Medium - L to O
hard - P to S
Very hard - T to Z
121. Solution : (b) Principal parts of Capstan lathe
(i) Head stock
(ii) Cross Slide and tool post
(iii) Hexagonal turret
(iv) Saddle for Cross slide
(v) Saddle for auxiliary Slide
(vi) Lathe bed.
122. Solution: (b) When the tool moves parallel to the lathe axis, it is called Sellar's taper.
123. Solution: (c) The hardness of a grinding wheel is specified by a letter of alphabet.
The alphabets A to H are soft grades. I to P are medium grades and Q to Z are hard
grades. The soft grade grinding wheels are used for grinding hard materials and hard
grade grinding wheels for softer materials. A soft grade grinding wheel is one in
which the abrasive grains can be easily dislodged and in hard grade grinding wheel,
the abrasive grains are held more securely.
124. Solution : (c) Specification of a lathe:- A lathe is generally designated by
(i) Swing, i.e the largest work diameter that can be swiung over the lathe bed.
(ii) Distance between head stock and tail stock centre. Some manufactures designate
the lathes by the swing and length of the bed. Bar automatic lathes are specified by
the maximum diameter of the bar which can be accommodated.
125. Solution: (c) A sprue hole is an opening in a mould into which molten metal is
poured. The sprue cross-section may be circular, square or rectangular. The size of the
sprue usually varies from 10 mm square for small casting to about 20mm square for
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heavy casting. The size of the sprue should be so enough that it is kept full during the
entire pouring operation, and the metal does not enter the mould cavity with high
velocity causing splattering and turbulence.
126. Solution: (d) Power is transmitted by lead screw to carriage through half nut. The
apron is fitted to the front position of the saddle facing the operator. It consists of a
hand wheel for saddle movement, pinion to engage with the rack for saddle
movement, a lever to engage the automatic feed for the saddle automatic feed
clutches, split nut (half nut) and lead screw.
127. Solution : (c) Knurling is an operation of generally roughing the surface for hand grip
Knurling:- It is the process of embossing a diamond shaped regular pattern on the
surface of a work piece using a special knurling tool. This tool consists of a set of
hardened steel rollers in a holder with the teeth cut on their surface in a definite
pattern.
128. Solution : (d) The operation performed on a shaper is
(i) Machining horizontal surface
(ii) Machining vertical surface
(iii) Machining angular surface.
129. Solution: (c) The method of grinding used to produced a straight or tapered surface
on a work-piece is external cylindrical grinding.
130. Solution: (b) The process of removing metal by a cutter which is rotating in the same
direction of travel of work-piece is called down milling.
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131. Solution : (d) A broach has:-

(i) Rough teeth
(ii) Semi- finishing teeth
(iii) Finishing teeth.
Broaching is a method of removing metal by a tool that has successively higher
cutting edges in a fixed path. Each tooth removes a predetermined amount of material.
132. Solution : (c) The broaching operation in which either the work or tool moves across
the other is known as surface broaching
133. Solution. (d) : A continuous chip with built up edge (BUE) is produced, not a
assumption in merchant's theory.
134. Solution. (d) : 90%
135. Solution. (b) : 1, 2 & 3
136. Solution. (b) : 540oC
137. Solution. (d) : While machining a brass casting on a lathe four jaw chuck is used.
Four jaw chuck is known as independent chuck. Chuck used in lathes for holding &
rotating the work-piece.
138. Solution. (d) : Desirability of high velocity in grinding because, it is desired to offset
the adverse effect of very high negative rake angle of the working grit, to reduce the
force per grit as well as the overall grinding force.
139. Solution: (c) (i) The different speed on a lathe are provided in geometric progression.
(ii) A feed gear box for a screw cutting lathe is designed on the basis of geometric
progression.
140. Solution : (b) High Speed Steel (HSS)
* Speed range 30–15 m/min
* Temperature–6500C
* Toughness of HSS is highest among all cutting tool materials.
* The rake angle required for machining aluminum by carbides tool is 150
141. Solution: (d) Milling cutter is mounted on the part of a milling machine called arbor.
Arbor:- The arbor is an accurately machined shaft for holding and driving the arbor
type cutter. It is tapered at one end to fit the spindle nose and has two slots to fit the
nose keys for locating and driving it.
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142. Solution : (b)

6000
V mm / sec
60
Let length = 900 mm
Width = 600 mm
2 mm stroke
600
 300
2
 900  150  1  900  150 
   
 100  4  100 
(10.5 + 2.625) sec = 13.125 sec
= 300× 13.125 sec
 totel time required = number of stroke × time return
stroke
= 300 × 13.125 sec = 3937.5 sec or 65.625 minutes
Ans is near about 60 mintues.
143. Solution : (c) Conventional milling (Up milling) and climb milling (down milling)
are two distinct ways to cut material. The difference between these two techniques is
the relationship of the rotation of the cutter to the direction of feed. In conventional
milling, the cutter rotates against the direction of the feed so the cutting force tends to
lift the workpiece.
144. Solution : (b) Countersinking operation is required for making a chamfer on the edge
of a hole.
145. Solution. (b) : Tailstock offset method is used for turning internal tapes only.
146. Solution. (d) : Given,
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d = 80 mm
N = 90 rpm
f = 0.3 mm /rev
L = d/2
L
Tm 
fN
80
L  40 mm
2
40
Tm  Tm  1.48 mm
90  0.3
147. Solution. (b) : Machining time,
L
Tm 
fN
Where L = Length of cut
f = feed
N = rpm
L
f =
N× Tm
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Tailor made module for various exams like HPCL, ISRO, BARC etc.

(b) Determine the tool hardness

(b) Less strokes per minute

35. Finishing of existing hole is known as:

(b) Job reciprocates and feed is given to job

44. A 16 mm hole is to be drilled through a mild steel plate of 25 mm thickness. The

45. ______ is not an abrasive used in grinding wheels.

66. Consider the units in following operations

73. Friction at the tool chip interface can be reduced by

(a) Diamond (b) SiC (c) Al2O3 (d) Boron Carbide

91. The most common type of drill is

(c) Enlarging hole (d) Threading

111. HSS has the property to–

(a) Internal cylindrical grinding

147. A feed f for the lathe operation is

MACHINING AND MACHINE TOOL OPERATIONS

9. Solution. (d) : Tool dynamometers are used to determine cutting forces.

28. Solution. (c) : Given, L = 90 mm, D = 73 mm lr = 42 mm, d = 63 mm

35. Solution. (d) : Reaming process—Reaming is a cutting operation with a multi-edge

Feed per tooth ft = ?

Workpiece feed (f) = ftZN

103. Solution: (c): In HSS, tungsten can be subsite by molybdenum.

131. Solution : (d) A broach has:-

142. Solution : (b)

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