MANUFACTURERING TECHNOLOGY-II

KATHIR COLLEGE OF ENGINEERING

(Approved By AICTE, New Delhi, Affiliated to Anna University,Chennai).

WISDOM TREE, NEELAMBUR, COIMBATORE 641062.

Web : www.kathir.ac.in
Phone : 0422-6554778 Fax:0422-2625777

DEPARTMENT OF MECHANICAL ENGINEERING

Subject Name: ME 2252 MANUFACTURING TECHNOLOGY II Staff name: Prof.P.SENTHILKUMAR
UNIT- I THEORY OF METAL CUTTING Part A -2 Mark Questions & Answers 1. What are the different types of chips ? 1. Continuous chips 2. Discontinuous chips 3. Discontinuous with built up chip 2. What is Rake angle ? The angle made by the cut chip with the tool face is called rare angle. 3.What is shear angle ? The angle made by the tool more cutting edge with the uncut chip is called shear angle. 4.What is orthogonal cutting ? The angle made by the tool to the cutting directions of the metal is 90 is called orthogonal cutting. 5.What is chip thickness ratio ? Chip thickness ratio is defined as the ratio of uncut chip thickness to cut chip thickness t r = ------tc 6. What are fore acting as the cutting of a metal ? 1. Horizontal cutting fore Fc 2. Tangential cutting fore Ft 3. Shear fore Fs 4. Normal fore Fn 7. What are the properties required for cutting tool material. 1. 2. 3. 4. 5. 6. Higher hardness Hot hardness Wear resistance Toughness Low friction Better thermal characteristics

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8.What are the tool materials? 1. 2. 3. 4. 5. 6. 7. Carbon tool stretch H.S.S. Cast cobalt Alloys Cemented carbides Ceramic tools Diamond Cubic boron

9.What are the types of tool wear ? 1. 2. Flank wear Crater wear

10. What is flank wear ? Wear as the flank fare. 11. What is orater wear ? The wear on the fond face of the tool 12.What is tool life ? Useful life of the tool experienced in time units. 13. What is tool life equations ? VT = C

14. What is machinobility ? It is the characteristics of work material enpressing its ease of machining. 15. What are the variables that affects tool life ? 1. 2. 3. 4. 5. Cutting conditions Tool geomentry Tool material Ware materials Cutting fluid

16. What are the factors that affects surface finish ? 1. 2. Geomentry of the machining operations no of uncomfortable factors

17. What is the functions of a cutting fluids 1. 2. 3. 4. 5. 6. Cool the tool and workpiece reduce friction protect the work against mushing improve surface finish to prevent the formations of surface finish wash away the chips

18. How will you select a cutting fluid ? 1. 2. 3. Work piece material Machining operations Cutting tool material

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19. How are the ceramic tools are made ? Ceramic tools are moulded as powder metallogy principle. 20. What are the points from which cutting fluid may be applied ? Tool are to be engaged in cutting. PART-B 1. Explain orthogonal cutting and oblique cutting with its neat sketches and compare. (16) 2. What is the tool life equation and state the factor affecting the tool life. 3. What is machinability? And explain. 4. Explain the various tool materials. 5. Write short notes on surface finish. 6. What are the different types of cutting fluids used in machining process? 7. Write short notes tool wear. (16)

UNIT- II CENTRE LATHE & SPECIAL PURPOSE LATHES Part A -2 Mark Questions & Answers 1.What is centre lathe ? The center of the head shock and tail shock are in the same centre that is why it is called as center lathe. 2.Mentions the Lathe parts ? 1. 2. 3. 4. Head shock Tail shock Carriage Tool post

3.What are the types of lathes ? 1. 2. 3. 4. 5. Center lathe Tool room lathe Special pumps lathe Capstan and Automatic lathe

4.What is the function of a lead It will guides the carriage. 5.What is the use of Bed way (or) Guide way ? It gives straight line accuraly to the tail shock and carriage etc., 6.What are the work holding devices ? 1. 2. 3. Three jaw chuck Four jaw chuck Fare plate

7.What is the tool holding device available in center lathe ? Tool post is the tool holding device.

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8.What is the difference between three jaw chuck and Four jaw chuck ? Three jaw is a independent chuck Four jaw is a self dependent chuck

9.What is line center and deed center of center lathe ? Head shock is the line center because power is used to rotate spindle. 10.What is a Mandrel ? Mandrel is an element used in lathe by turning hallow tubes. 11. What is single point cutting tool ? The cutting tip of a point is single edge. 12. What is nose radius ? The radius of the cutting tip is called nose radius. 13. What is relief angle ? The recess provided in all the sides of the cutting edge is called relief angles. 14. What is back rake angle ? The recess provided in the flank of the tool face is called back rake angle. 15. What are the tools used in lathe ? 1. 2. 3. 4. 5. Parting off tool Turning tool Radius tool Thread cutting tool Chamfering tool

16. What are the operations performed on a lathe ? 1. 2. 3. 4. Turning Facing Chamfering Threading

17. How drilling operation is performed on lathe ? The drill bit is held in tail shock and the wall piece is chuck. The drilling operation can be held. 18.How taper turning can be done is lathe ? By using compound rest. 19. What is formula for cutting speed ? TDN V = ---------1000

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20. What is formula for machining time calculation in lathe ? L + Lo t = --------FN L = Length of job Lo = Over travel of the tool F = feed rate mm / N = rpm PART-B 1. Sketch a center lathe and mention various parts. 2. List various types of feed mechanisms and explain briefly about tumbler gear reversing mechanism with a sketch. 3. Explain taper turning operation in a lathe by a taper turning attachment. Discuss its advantages. 4. Explain the following methods of taper turning in a lathe. 5. (i) By swiveling the compound rest. (ii) By a taper turning attachment. 6. Explain the Working principle of capstan and turret lathes. 7. Explain the tooling layout for the production of a Hexagonal bolt in a capstan lathe. 8. Discuss the tooling layout for the production of a Hexagonal nut in Turret lathe. 9. Classify transfer machines. Sketch and explain the working of Swiss type automatic screw machine.What is the advantages of automatic machines. 10. Describe a typical single spindle automatic chucking machine. 11. Describe a typical single spindle automatic bar machine. 12. Differentiate between parallel action and progressive action multi-spindle automatics.

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UNIT-III OTHER MACHINE TOOLS Part A -2 Mark Questions & Answers 1.What are Reciprocating machines ? 1. 2. 3. Shaper Planner Shotter

2.What is cutting shock of a shaper ? The forward shock is called cutting shock. 3.What is quide return mechanism ? The reversal of the ram is faster than the cutting shock. 4.What is principle of shaper ? The tool reciprocates against fired job. 5.What is work holding device used in sneper ? Machine vice 6.What are the operations can be done on shaper ? 1. 3. Squaring V groove cutting 2. 4. Angle machining dovetail cutting

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7.Whare the types of planner ? 1. 2. 3. Double housing planner Pit planner Single housing planner

8.What are the operations can be performed on the planner ? 1. 2. 3. Angle machining Dovetail machining Vgroove machining

9.What is the principle of planner ? The work reciprocates and tool fixed. 10. What is the principle of shorter ? Vertical reciprocation of tool and fixed job. 11. What are the operations can be done on shorter ? 1. 2. 3. Internal key ways Slot Polyson cutting etc.,

12. What are milling operations ? 1. 2. 3. 4. Slab milling Face milling end milling form milling

13. What are the drilling machines available ? 1. 2. 3. Bench drilling Radial drilling Crang drilling

14. What is Boring operation ? Enlarging a hole is called boring. 15. What is Reaming operation ? It is finishing of holes. 16. What is tapping ? Cutting threads is the hole by using a die. 17. What is the difference between Lack saw and Circular saw ? The Lack saw reciprocates and cuts the job. Circular saw rotates to cut the job. 18. What is Broaching ? It is finishing of holes, keyways etc.,

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19. What are the types of broaching ? 1. Push type 2. Pull type 20. What is spot facing ? Finishing of holes face in the top of the hole.

PART-B 1. With a simple sketch, explain the working of the crank and slotted link quick return motion mechanism used in shaper. 2. Write down any four differences between shaper and planer. 3. Explain the Working principle of planer with a neat sketch. 4. How do you specify a planer? 5. Describe the working mechanism of a universal dividing head, with neat diagram. 6. With a neat sketch, indicate the various parts of an arbor assembly. 7. With a simple sketch, explain the principal parts and angles of a plain milling cutter .Explain them. 8. Explain the twist drill nomenclature and define various elements of twist drill. 9. With a simple sketch, explain the working of a vertical boring machine. 10. Explain the counter boring and counter ringing operation. 11. Explain the Working principle of a Jig boring machine with a neat sketch.

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UNIT-IV ABRASIVE PROCESSES & GEAR CUTTING Part A -2 Mark Questions & Answers 1.What are the abrasives used in grinding ? 1. 2. 3. Aluminium oxide Silicon carbide Cubic Nitride (LBN)

2.What is Grain size ? The abrasive used in grinding wheel is relatively small. The size of the abrasive grain is called grain size. 3.What is Bond ? The barding of abrasive grains is called bond. 4.What are types of bond ? 1. 2. 3. 4. 5. Vetrified Silicate Synthetic resin Rubber Shellac and Metal

5.What are the Grades of Grinding wheel ? 1. 2. 3. Very soft Medium hard

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6.How are grinding wheels are balanced ? The grinding wheels are Static balancing Dynamic balancing

7.What are the difference shapes of grinding wheel ? 1. 2. 3. 4. 5. 6. Straight Cutoff Recessed one side Recessed two side Dish Saucer

8.What is dressing and Truing ? The grinding wheel is consumed to the operation on a job. Because of this the wheel is tuned to certain diameter. 9.What are the types of Grinding machines ? 1. 2. 3. Cylinderical grinding machines Surface grinding machines Centerless grinding machines

10. What are the parameters that affects Grinding process ? 1. 2. 3. 4. Wheel speed Work speed In feed Area of contract

11. What are the super finishing operations available ? 1. 2. 3. Honing Lapping Buffing etc.,

12. What is super finishing ? Finishing the component by removing micron level materials. 13. What is abrasive jet machining ? The abrasive with water jet is used to machine plastic, leather components. 14. Why gears are important ? The power transmiting belt has ship and gears are no ship positive drive. 15. How gears are cut ? 1. 2. Gear shaping Gear generation

16. What is gear shaping ? The cutting of gear by form tool.

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17. What is gear hobbing ? Cutting gears with the help of a hob called cutter. 18. What is module of a gear ? D M= ------Z D = Dia of blank Z = no of teeth M = Module 19. What is gear forming ? The gear cut by the form cutters is called gear forming. 20. What for gears are used ? 1. 2. Power transmissions Motion transmission

PART-B 1. What are the various methods of centerless grinding and each briefly? (16) 2. Explain the external cylindrical grinding process and surface grinding process. 3. Explain the vitrified and resinoid bonding process. 4. Explain the operations of horizontal broaching machine with neat sketch. 5. Explain the gear cutting by a formed tool. 6. Differentiate between gear forming and generating. 7. Explain the principle of operation of gearing hobbing operation what are the advantages of gear hobbing. 8. Give advantages and limitations of gear hobbing.

UNIT- V CNC MACHINE TOOLS & PART PROGRAMMING Part A -2 Mark Questions & Answers 1.What is NC machines ? Numerically controlled machines are called NC Machines 2.What is the difference between NC and CNC machines ? NC Machines tape header is available CNC - Computer memory is available 3.What are the steps to be followed while developing the CNC program ? 1. 2. 3. 4. Process planning Tool selection Job, Tool setup Part program

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4.What are the process plans content ? 1. 2. 3. 4. 5. Machine tool used Fixture required Sequence of operation Cutting tools used Process parameters

5.What is point programming The drilling operations can be carried on point by point it is called point programming. 6.What is curve forming programming ? The program to trace a path is called curve programming. 7.What is preparatory function ? The G codes are called as preparatory functions. 8.What is misselenous function ? The M codes which controls machines. 9.What is the function o GOO ? Rapid traverse. 10. What is GO1 stand for ? Liner interpolation 11. What is GO2 stands for ? Circular interpolation. 12. What is G41 stands for ? Cutter compensation left. 13. What is G40 stands for ? Cutte compensation. 14. What is G76, G70, G71 ? G76 Thread Cutting cycle G70 Finishing cycle G71 Roughing cycle 15. How many axis available is lathe ? Only two X, Z

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16. How many axis available in milling? X,Y,Z Three axis. 17. What are the core machines available ? 1. 2. 3. Horizontal machining center Vertical machining center Multi axis machining center

18. Why core machines are preferred ? 1. 2. Accuracy Productivity etc.

19. What are the parts of core machines ? 1. 2. 3. 4. Slide way Linear bearings Servo motor Fanure systems

20. What are the types of system available ? 1. 2. 3. 4. Fanure system Hinumeric system Sinumeric system Siemens system PART-B 1. List the various drive systems explain the principle of any two drive system. 2. Explain open loop and closed loop system. 3. What is machining centers explain in detail. 4. Explain various types of CMM. 5. Explain the part programming procedure with a good example. 6. List and explain G and M code for turning milling operations. 7. Explain NC axis conventions.

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