ME3493 - Manufacturing Technology: Q&A Compilation
Question 1: What is a chip? How is it formed? What are the 4 types of chips?
A chip is a small piece or fragment of metal removed from the workpiece during machining. It is formed when
the cutting tool applies shear stress exceeding the metal's shear strength, causing plastic deformation and
separation of material. Four types of chips are:
1. Continuous Chip
2. Discontinuous Chip
3. Serrated Chip
4. Continuous Chip with Built-up Edge
Question 2: What is metal cutting? Explain orthogonal metal cutting and oblique metal cutting.
Metal cutting is the process of removing material from a workpiece using a sharp cutting tool to obtain a
desired shape and size.
**Orthogonal metal cutting:**
- Cutting edge is perpendicular (90 degrees) to the cutting velocity.
- Simpler to analyze.
- Produces a shear plane where the chip forms.
**Oblique metal cutting:**
- Cutting edge is inclined at an angle less than 90 degrees to the cutting velocity.
- Chip flows at an angle to the cutting velocity.
- More complex chip formation and tool forces.
Question 3: Explain tool life, tool wear, cutting fluids, machinability, and relief angle.
1) Tool Life:
- Duration or amount of machining that a cutting tool can perform before it needs replacement or
reconditioning.
2) Tool Wear:
- Gradual failure of the cutting tool due to mechanical, thermal, and chemical effects during cutting.
3) Cutting Fluids:
- Liquids or gases applied to the cutting zone to cool and lubricate, reducing friction, heat, and tool wear.
ME3493 - Manufacturing Technology: Q&A Compilation
4) Machinability:
- Measure of how easily a material can be machined, affecting tool life, surface finish, and cutting forces.
5) Relief Angle:
- The angle between the tool flank surface and the machined surface, allowing clearance to avoid rubbing.
Question 4: Explain the tool layout and working principle of capstan and turret lathes.
Capstan and turret lathes have a rotating turret holding multiple tools, allowing sequential machining without
retooling.
- Tools are mounted on the turret.
- The turret rotates to bring the required tool into the cutting position.
- The workpiece is held stationary or rotated (capstan lathe generally for small batch, turret for larger).
- The carriage feeds the tool into the workpiece for cutting.
- This arrangement increases productivity by reducing tool change time.
Question 5: Explain what is thread cutting and the thread cutting methods.
Thread cutting is the process of producing screw threads on a workpiece using a cutting tool.
Methods include:
1) Single-point threading on lathe
2) Thread rolling
3) Thread milling
4) Thread grinding
5) Die threading
6) Tap threading
Each method varies based on application, thread type, and precision required.
Question 6: Explain and compare the single automatic (screw type) lathes and multiple spindle auto
Single spindle automatic lathe:
- Has one spindle holding one workpiece at a time.
- Operations are done sequentially.
- Suitable for low to medium production.
ME3493 - Manufacturing Technology: Q&A Compilation
Multiple spindle automatic lathe:
- Has multiple spindles arranged on a rotating drum.
- Allows simultaneous machining of multiple parts.
- Used for high production.
Comparison:
- Multiple spindle offers higher production rate but complex setup.
- Single spindle is simpler and flexible.
Question 7: What is milling and explain the types of milling operations.
Milling is a machining process using rotary cutters to remove material from a workpiece.
Types of milling operations:
1) Face Milling
2) Plain Milling
3) Slot Milling
4) Angular Milling
5) Form Milling
6) Profile Milling
7) Gang Milling
8) Straddle Milling
Question 8: Explain finishing of gears.
Gear finishing improves surface finish, accuracy, and durability.
Common finishing methods:
1) Grinding
2) Honing
3) Lapping
4) Shaving
5) Burnishing
These processes remove minor surface irregularities and enhance gear performance.
ME3493 - Manufacturing Technology: Q&A Compilation
Question 9: Explain precision grinder, surface grinder, centerless grinder, internal grinder.
Precision grinder:
- Used for accurate grinding with tight tolerances.
Surface grinder:
- Grinds flat surfaces using a rotating abrasive wheel.
Centerless grinder:
- Grinds cylindrical surfaces without centers.
- Workpiece supported between a grinding wheel and regulating wheel.
Internal grinder:
- Grinds internal surfaces like holes or bores.
Question 10: Explain work holding methods in turning and machining centres.
In turning:
- 3-jaw chucks
- 4-jaw chucks
- Collet chucks
- Faceplates
In machining centres:
- Machine vice
- Clamps and fixtures
- Magnetic chucks
- Vacuum fixtures
- Hydraulic chucks
Work holding ensures accurate positioning and stability during machining.
Question 11: Explain open and closed CNC control systems.
**Open Loop Control System:**
- No feedback from output to input.
- Simple and cheaper.
ME3493 - Manufacturing Technology: Q&A Compilation
- Less accurate.
**Closed Loop Control System:**
- Feedback from output (position, speed) used to adjust input.
- More accurate and stable.
- Used in modern CNC machines.
Question 12: Explain coolant systems.
Coolant systems supply cutting fluids to the tool-workpiece interface to reduce heat and friction.
Components include coolant tank, pump, nozzles, filters, and return lines.
Types of delivery: flood, mist, through-tool, high-pressure, minimum quantity lubrication.
Benefits include improved tool life, surface finish, and chip removal.
Question 13: A) Types of interpolation B) Loops C) Subroutine D) Macros
**A) Types of Interpolation:**
- Linear (G01)
- Circular (G02/G03)
- Helical
- Parabolic
- Cubic/Spline
**B) Loops:**
- Repeating blocks of code (WHILE, FOR loops)
**C) Subroutine:**
- Separate program blocks called from main program (M98/M99)
**D) Macros:**
- User-defined programs using variables, logic, and arithmetic
- Highly flexible automation
Question 14: How to set up a CNC machine for machining? Explain.
Steps to set up a CNC machine:
1) Understand machining requirements and review drawings.
ME3493 - Manufacturing Technology: Q&A Compilation
2) Load and verify the CNC program.
3) Install and secure the workpiece using appropriate fixtures.
4) Install and set cutting tools in tool holders.
5) Set workpiece zero or work coordinate system.
6) Set tool length and radius offsets.
7) Check coolant and lubrication systems.
8) Perform dry run to check for errors or collisions.
9) Start machining operation and monitor process.
10) Inspect first piece and adjust as necessary.
Proper setup ensures accuracy, safety, and efficiency.
