Machine Tools Theory and Q&A PDF

NeedforUnconventionalProcesses
y New materials having high strength and hardness, such as
nimonic alloys and alloys with alloying elements such as
NTMM
tungsten, molybdenum, and columbium are difficult to

machine by the traditional methods.
y By conventional machining the MRR reduces with an
increase in the work material hardness.

hardness
y Need
BySKMondal
NeedforUnconventionalProcesses
y Complex shapes.
y A very high accuracy is desired besides the complexity of
the
h surface
f
to be
b machined.
hi d
1.ThermalEnergyMethods
h
l
h d
InUnconventionalMachining
y Different
forms
off energy directly
Diff
f
di
l applied
li d to the
h
workpiece to have shape transformation or material

removal from work surface.
y No chips,
chips No lay pattern on work surface,
surface no direct
physical contact between the tool and the workpiece .
y The
h tooll materiall does
d
not have
h
to be
b harder
h d than
h the
h
work material.
y Tool forces do not increase as the work material gets
harder.
harder
y Economic metal removal rate does not decrease as the
work material gets harder.
2.Electro ChemicalEnergyMethod
y Electricaldischargemachining(EDM)
y ElectroChemicalMachining(ECM)
y LaserbeamMachining(LBM)
y ElectroChemicalgrinding(ECG)
y PlasmaArcMachining(PAM)
y ElectronBeamMachining(EBM)
(
)
y IonBeamMachining(IBM)
I B
M hi i (IBM)
For-2013 (IES, GATE & PSUs)
for development
p
of
processes
which
utilize
nontraditional
other
methods
y ElectroChemicalDeburring (ECD)
Page 1
such
as
electrochemical processes for the material removal.
ClassificationofNTMM
l
f
f
The
Methods
Th Nontraditional
N
di i
l Machining
M hi i
M h d are classified
l ifi d
according to the major energy sources employed in
machining.
1.ThermalEnergyMethods
Th
lE
M h d
2.Electro
El t ChemicalEnergyMethod
Ch i lE
M th d
3 ChemicalEnergyMethods
3.ChemicalEnergyMethods
4 MechanicalEnergyMethods
4.MechanicalEnergyMethods
3. ChemicalEnergyMethods
h
l
h d
These
methods
controlled
off the
Th
h d involve
i
l
ll d etching
hi
h
workpiece material in contact with a chemical solution.
y Chemical Machining Method (CHM).
(CHM)
y ElectroChemicalHoning(ECH)
machining
g
4. MechanicalEnergyMethods
h
l
h d
y UltraSonicMachining(USM)
y AbrasiveJetMachining(AJM)
y WaterJetMachining(WJM)
SomeObservations
b
y EDM has
h the
th lowest
l
t specific
ifi power requirement
i
t and
d can
achieve sufficient accuracy.

y ECM has the highest metal removal rate, MRR.
y USM and AJM
J have low MRR and combined with high
g
tool wear, are used for nonmetal cutting.
y LBM and EBM have high penetration rates with low
MRR and, therefore, are commonly used for micro
drilling sheet cutting,
drilling,
cutting and welding.
welding
y CHM is used for manufacturing PCB and other shallow
components.
t
y PAM can be used for clean, rapid cuts and profiles in
almost all plates upto 20 cm thick with 5o to 10o taper.
LimitationsofNTMM
f
ECM
y The NTMM which have not been proved commercially
economical are: USM, AJM,

J CHM, EBM and PAM.
BySKMondal
ElectrochemicalMachining
l
h
l
h
y Variation
in
V i i
i the
h current density
d i will
ill result
l in
i work
k
taking the electrodes shape.

y The electrode is fed with a constant velocity, and the
electrolyte is fed through the tool.

tool
Fig- Electrochemical Machining process

1. Micromachining and Drilling : LBM and EBM

2. Cavity sinking and standard Hole Drilling: EDM and
USM
3. Fine hole drilling and Contour Machining: ECM
4. Clean, rapid Cuts and Profiles: PAM
5. Shallow Pocketing: AJM
y Electrochemical
is
El
h i l machining
hi i
i the
h reverse off electro
l
y The limitation of electrical machining methods is that
consumption of electrical energy is very large.

large
The
NTMM have
some special
cutting
Th various
i
h
i l shape
h
i
capability as given below:
l
h
l
h
y Expensive set up, low MRR and skilled labour required.
the
h work
k material
i l must be
b an electrical
l
i l conductor.
d
Al
Also,
ShapesCuttingCapability
h
bl
Page 2
plating
y The workpiece is made the anode, which is placed in
close proximity to an electrode (cathode),
(cathode) and a high
high
amperage direct current is passed between them through
an electrolyte,
electrol te such as salt water,
ater flowing
flo ing in the anode
anode
cathode gap.
y Metal is removed by anodic dissolution and is carried
away in the form of a hydroxide in the electrolyte for
recycling or recovery.
y MRR in
i ECM depends
d
d on atomic
t i weight
i ht off work
k material
t i l
ECMEquipment
ECMEquipment
ECMEquipment
Electrolyte
l
l
y Supply
2 to 35 V DC and
500 to 40,000 A
S
l Voltage
V l
d Current
C
y The
consists
off the
Th electrolyte
l
l
i
h metall debris
d b i removed
d
y The tooltowork g
gap
p needs to be maintained at a veryy
from the anode, which will have to be filtered before it is

repumped into the system.
y Also a large amount of heat is generated during the
electrolysis, which heats up the electrolyte, and hence it
needs to be cooled.
cooled
The
that
Th electrolyte
l t l t is
i so chosen
h
th t the
th anode
d (workpiece)
(
k i )
is dissolved but no deposition takes place on the cathode
(t l)
(tool).
Properties electrolyte should be
1. High electrical conductivity
2 Low viscosity
2.
3. High specific heat
4. Chemical
h
l stability
bl
55. Resistance to formation of p
passivating
g film on
workpiece surface
6 Non
6.
Noncorrosive
corrosive and non
nontoxic
toxic
7. Inexpensive and readily available
small value 0.1 to 0.25 mm. A servo drive is provided on

the tool axis for this purpose.
purpose
y The electrolyte needs to be pumped through this gap at
h h pressures ranging from
high
f
0.70 to 3.00 MPa. This
h
introduces a large amount of load on the machine,
because of the large working areas involved. Hence the
machine structure will have to be made rigid to a
withstand such forces.
T l
Tool
The
Th properties
ti off tool
t l materials
t i l should
h ld be:
b
ForECMofsteelNaCl isusedastheelectrolyte.
1.
High
g electrical and thermal comductivityy
2.
Easy machinability
3.
Good shiffness
4.
High corrosion resistance
y Tool materials: Copper,

Copper brass,
brass bronze,
bronze Al,
Al Stainless
Steel, Cupro nickel, etc.

y Material wear / Tool wear: Infinite
Disadvantages
1.
2.
3.
4.
55.
6.
77.
Use
U off corrosive
i media
di as electrolytes
l t l t makes
k it difficult
diffi lt to
t
handle.
Sh
Sharp
i
interior
i edges
d
and
d corners (<
( 0.2 mm radius)
di ) are
difficult to produce.
V expensive
Very
i machine.
hi
Forces are large with this method because of fluid pumping
forces.
Veryy high
g specific
p
energy
gy consumption
p
(about 150
5 times
that required for conventional processes),
Not applicable
pp
with electricallyy nonconducting
g materials
and jobs with very small dimensions
Lower fatigue
g strength
g
Advantages
1. Complex threedimensional surfaces can be machined
accurately.
y Good for low machinabilityy or complicated
p
shapes.
2 As ECM leads to atomic level dissolution,
2.
dissolution the surface
finish is excellent (Ra 0.2 to 0.6 m) with almost stress
f
free
machined
hi d surface
f
and
d without
ih
any thermal
h
l
damage.
3. The tool wear is practically nil which results in a large
number of components produced per tool.
tool
3
4. MRR is highest (1600 mm /min) among NTMM and
comparable
bl with
h conventionall machining.
h
Applications
l
y Any electrically conductive work material irrespective
y
y
y
y
y
y
y
y
y
of their hardness, strength or even thermal properties.

The machining surface can be situated at any
inaccessible.
Shape application blind complex
comple cavities,
ca ities curved
cur ed
surfaces, through cutting, large through cavities.
It is
i used
d for
f the
th machining
hi i off the
th gas turbine
t bi blades.
bl d
Die sinking
Profiling and contouring
Trepanning
p
g
Grinding
Drilling
Micromachining
Page 3
ECMCalculations
l l
Faradays
state
F d laws
l
t t that,
th t
m=
Where
It E
F
m
I
t
E
F
=weight(g)ofamaterial
g
g
=current(A)
=time(sec)
=gramequivalentweightofthe
material
t i l
=constantofproportionality
Faraday(96,500coulombs)
ECMCalculations
l l
yMRR =
EI
F
AI
g/s =
F. V
ECMCalculations
l l
ECMCalculations
l l
y MRR for
f pure metall
g/s
3
IfyouputE=equivalentweightinCGSi.e.g/mole
Ii A
IinAmpere(A)
(A)
F=96500columb/molei.e.As/mole
9 5
/
/
TheMRRwillbeing/s
AI cm3 EI cm3
vF sec F sec
y MRR for Alloy
y
Eeq I cm3
eq F sec
100
x
= i
eq
i i
Flowanalysis
l
l
Overvoltage
y To
the
required,
T calculate
l l
h fluid
fl id flow
fl
i d match
h the
h heat
h
generated to the heat absorbed by the electrolyte.
and
100
x v
= i i
Eeq
i Ai
DynamicsofElectrochemicalMachining
y If the total over voltage at the anode and the cathode is
V and the applied voltage is V, the current I is given

by,
by
I=
V V
R
y Neglecting
g
g all the heat losses
y Schematic representation of the ECM process with no
l2R = q e ce (B o )
ffeed to the tool
ElectrochemicalGrinding(ECG)
l
h
l
d (
)
ElectrochemicalGrinding(ECG)
y In
metal
I ECG,
ECG the
th tool
t l electrode
l t d is
i a rotating,
t ti
t l bonded,
b d d
y The process is used for shaping and sharpening
diamond grit grinding wheel.

A the
As
h electric
l
i current flows
fl
b
between
the
h workpiece
k i
and
d the
h
wheel, through the electrolyte, the surface metal is changed
to a metal oxide,
oxide which is ground away by the abrasives.
abrasives As
the oxide film is removed, new surface metal is oxidized and
removed.
removed
ECG is a lowvoltage highcurrent electrical process.
Th purpose off the
The
h abrasive
b i is
i to increase
i
the
h efficiency
ffi i
off the
h
ECG process and permit the continuance of the process.
The
h abrasive
b
particles
l are always
l
nonconductive
d
materiall
such as aluminum oxide, diamond, or borazon (CBN). Thus
they
h act as an insulating
i
l i spacer maintaining
i i i a separation
i off
from 0.012 to 0.050 mm between the electrodes.
carbide cutting tools, which cause high wear rates on

expensive
i
di
diamond
d wheels
h l in
i normall grinding.
i di
Electrochemical grinding greatly reduces this wheel
wear.
y Fragile parts (honeycomb structures), surgical needles,
and tips of assembled turbine blades have been ECG
processed successfully.
p
y
y The lack of heat damage, burrs, and residual stresses is
very beneficial,
beneficial particularly when coupled with MRRs
that are competitive with conventional grinding but
with far less wheel wear.
wear
y
y
y
Equipmentsetupandelectricalcircuitforelectrochemicalgrinding.
Page 4
PhysicalPrinciple
h
l
l
OtherElectrochemicalprocesses
Other Electrochemical processes
y Basic
B i process
y Electrochemicalpolishing
El
h i l li hi
y Electrochemicalholedrilling
y ElectrochemicalDeburring
PhysicalPrinciple
h
l
l
PhysicalPrinciple
h
l
l
PhysicalPrinciple
h
l
l
y An
between
two points
along
the
A arc jumps
j
b
i
l
h path
h off least
l
y The
Th energy off the
h arc is
i so concentrated
d that
h it
i causes the
h
y The
Th metall and
d dielectric
di l
i fluid
fl id is
i partly
l vaporized,
i d
resistance.
electrode, and the work to melt. But the electrode

material is chosen so that it melts less.
causing sudden expansion.
PhysicalPrinciple
h
l
l
CharacteristicsofEDM
h
f
CharacteristicsofEDM
h
f
y The
from
the
vapors knocks
Th blast
bl
f
h expanding
di
k
k some
y Mechanics
off material
and
M h i
i l removall melting
li
d
y Uses
Voltage
off 60
arc lasting
U
V l
6 to 300 V to give
i a transient
i
l i
molten particles loose, and the remaining molten metal

hardens.
evaporation aided by cavitation.

y The process is based on melting temperature, not
hardness so some very hard materials can be machined
hardness,
this way.
y The
h arc that
h jumps heats
h
the
h metal,
l and
d about
b
1 to 10%
% off
the molten metal goes into the fluid. The melted metal
then recast layer is about 1 to 30 m thick, and is
generally hard and rough.
y The electrode workpiece gap is in the range of 10 m to
100 m.
Page 5
from 0.1 s to 8 ms.

y Typical cycle time is 20 ms or less, up to millions of
cycles may be required for completion of the part.

part
y Rotating the wire in an orbital direction will,
Increase accuracy in form and surface finish
Decrease electrode wear
y Surface finish obtained 0.25 m
EDMTool
Prime
requirements
EDM tooll Material
P i
i
M
i l
It should be electricallyy conductive.
2. It should have good machinability, thus allowing
easy manufacture of complex shapes.
shapes
3. It should have low erosion rate or good work to tool
wear ratio.
4 It should have low electrical resistance.
4.
resistance
5. It should have high melting point.
6. It should have high electron emission.
1.
Theusualchoicesfortool(electrode)materialsare
Th
l h i f
l( l
d )
i l
y Copper,
pp ,
y brass,
y alloysofzincandtin,
ll f i d i
y hardenedplaincarbonsteel,
p
,
y coppertungsten,
y silvertungsten,
l
y tungstencarbide,
y coppergraphite,andgraphite.
ServoMechanism
h
y The gap between the tool and work has a critical
importance. As the
h workpiece
k
is machined,
h d this
h gap
tends to increase.
increase For optimum machining efficiency,
efficiency
this gap should be maintained constant. This is done by
servo mechanism which controls the movement of the
electrode.
DielectricFluid
l
l d
2.
3.
4.
5.
6.
Hardness,
toughness
or brittleness
off the
H d
t
h
b ittl
th material
t i l poses no
problems. Due to this EDM can be used for machining
materials that are too hard or brittle to be machined by
conventional methods.
The method does not leave any chips or burrs on the work
piece.
C tti forces
Cutting
f
are virtually
i t ll zero, so very delicate
d li t and
d fine
fi
work can be done.
Th process dimension
The
di
i
repeatability
bili and
d surface
f
fi i h
finish
obtained in finishing are extremely good.
The
h characteristic
h
surface
f
obtained,
b
d which
h h is made
d up off
craters, helps in better oil retention. This improves die life.
Because the forces between the tool and the workpiece and
virtually zero,
very delicate
work&can
be done.
For-2013
(IES, GATE
PSUs)
y One
O major
j drawback
d
b k off EDM is
i the
h wear that
h occurs on
the electrode at each spark. Tool wear is given in terms of

wear ratio which is defined as,
Wear ratio =
Volume of metal removed work

Volume of metal removed tool
y Wear ratio for brass electrode is 1: 1.

1 For most other
metallic electrodes, it is about 3: 1 or 4: 1.

y With
h graphite
h (with
( h the
h highest
h h
melting
l
point, 3500C),
)
the wear ratio mayy range

g from 55: 1 up
p to 550: 1.
Relaxationcircuit
l
y Fluid
Fl id is
i used
d to
t actt as a dielectric,
di l t i and
d to
t help
h l carry away
debris.
y If the fluid is pumped through and out the end of the
electrode, particles will push out, and mainly collect at

the edges. They will lower the dielectric resistance,
resulting in more arcs. As a result the holes will be
conical.
y If fluid
u d iss vacuu
vacuum pu
pumped
ped into
to tthee eelectrode
ect ode ttip,
p, st
straight
ag t
holes will result.
y Quite often kerosenebased oil.
oil
y The dielectric fluid is circulated through the tool at a
pressure off 0.35 N/m
N/ 2 or less.
l
T free
To
f
it from
f
eroded
d d
metal particles, it is circulated through a filter.
Fig-Relaxation circuit used for generating the pulses in EDM process
Di d
Disadvantages
Advantages
d
1.
WearRatio
EDMTool
1. Only
O l electrically
l t i ll conductive
d ti materials
t i l can be
b machined
hi d
2.
3.
4.
5.
6.
by EDM. Thus non metallic, such as plastics, ceramics

or glass,
l
cannott be
b machined
hi d by
b EDM.
EDM
Electrode wear and overcut are serious problems.
A rehardened, highly stressed zone is produced on the
work surface byy the heat g
generated during
g machining.
g
This brittle layer can cause serious problems when the
partt iss put into
pa
to se
service.
v ce.
Perfectly square corners cannot be made by EDM.
Hi h specific
High
ifi energy consumption
ti (about
( b t 50 times
ti
th t
that
in conventional machining)
MRR is quite low
Page 6
Applications
l
y EDM can be used for machining any material that is
electrically
l
ll conductive,
d
thus
h including
l d
metals,
l alloys
ll
and
d
most carbides.
carbides
y EDM is widely used for machining burr free intricate
shapes,
p , narrow slots and blind cavities etc.,, for example,
p ,
sinking of dies for moulding, die casting, plastic
moulding, wire drawing, compacting, cold heading,
forging, extrusion and press tools.
Applications
Applications
l
WireEDM
y EDM is particularly useful when dealing with internal
y The method is also employed for blanking parts from sheets,
y Wire EDM is a special form of EDM wherein the
cuts that
h are hard
h d to get tools
l into. Machining
h
tends
d to
cutting off rods of materials,

materials flat or form grinding and
work best with external cuts.

cuts
y Almost any geometry (negative of tool geometry) can be
sharpening of tools, cutters and broaches.

y In EDM method, small holes, about 0.13 mm, in
diameter and as deep as 20mm diameters can be drilled
electrode
l t d is
i a continuously
ti
l moving
i conductive
d ti wire.
i
y A thin wire of brass,
brass tungsten,
tungsten or copper is used as an
electrode.
generated on a workpiece
g
p
if a suitable tool can be
with virtually no bending or drifting of hole.

hole Due to this,
this
y The electrode wire is typically

yp
y made with a 0.055 to 0.25
5
fabricated (the use of punch as a tool to machine its own
EDM is particularly useful for machining of small holes,
mm diameter, which is wire electrode wound between
mating die is commonly employed in EDM method).
orifices or slots in dieselfuel injection nozzles, or in aircraft
the two spools.
engines, air brake valves and so on.
y Deionized water is used as the dielectric.
WireEDM
y This process is much faster than electrode EDM.
y This process is widely used for the manufacture of
punches,
h
di
dies,
and
d stripper
i
plates,
l
with
i h modern
d
machines capable of cutting die relief,
relief intricate
openings,
p
g , tight
g radius contours,, and corners routinely.
y
y Geometrically accurate but moderately finished straight
toothed metallic spur

p g
gears,, both external and internal
type, can be produced by wire type Electro discharge
Machining (EDM).
(EDM)
ElectricDischargeGrinding(EDG)
l
h
d (
)
ElectricDischargeGrinding(EDG)
l
h
d (
)
y EDG is
i similar
i il to EDM except that
h the
h electrode
l
d is
i a
y The
Th spark
k gap is
i normally
ll held
h ld at 0.013 to 0.076
6 mm
rotating wheel (usually graphite).

y Positively charged work pieces are immersed in or
flooded by a dielectric fluid and fed past the negatively
charged wheel by servocontrolled machine table.
y Metall is removed
d by
b intermittent high
h h frequency
f
electrical discharges passing through the gap between
wheel and workpiece.
y Each spark discharge melts or vaporizes a small amount
of metal from the workpiece surface, producing a small
crate
t att the
th discharge
di h
sit,
it as in
i EDM.
EDM
y The g
graphite
p
wheel is rotated at 0.55 to 3 m/s
/
The method can be used for

1. External
E
l cylindrical
li d i l grinding,
i di
i
internal
l grinding
i di
and
d
Fig- Electric Discharge Grinding (EDG)
Page 7
surface grinding.
2. Grinding carbide and steel at the same time without
wheel loading.
loading
3. Grinding thin sections where abrasive wheel pressures
might
h cause distortion.
d
4. Grinding brittle materials or fragile parts where
abrasive materials might cause fracturing.
UltrasonicMachining
l
h
UltrasonicMachining
g
y In
a tooll off desired
vibrates
at an
I ultrasonic
l
i machining,
hi i
d i d shape
h
ib
ultrasonic frequency (19 ~ 25 kHz) with an amplitude of

around
d 15 50 m over the
h workpiece.
k
y Generally
y the tool is p
pressed downward with a feed force,, F.
Between the tool and workpiece, the machining zone is
flooded with hard abrasive p
particles g
generallyy in the form of
water based slurry.
y As the tool vibrates over the workpiece,
workpiece the abrasive particles
act as the indenters and indent both the work material and
the tool.
tool The abrasive particles,
particles as they indent,
indent the work
material, would remove the same, particularly if the work
material is brittle,
brittle due to crack initiation,
initiation propagation and
brittle fracture of the material.
BySKMondal
y
UltrasonicMachining
l
h
UltrasonicMachining
l
h
y USM is
brittle
i mainly
i l used
d for
f machining
hi i
b i l materials
i l
y At
the
depth
A full
f ll indentation,
i d
i
h indentation
i d
i
d h in
i the
h work
k
{which are poor conductors of electricity and thus

cannot be processed by Electrochemical and Electro
discharge
g machining
g ((ECM and EDM)}.
)}
material is characterized by w. Due to the indentation,

as the work material is brittle, brittle fracture takes place
leading
g to hemispherical
p
fracture of diameter 2x under
the contact zone.
y If at any
an moment of time,
time there are an average
a erage n
n of grits
and the tool is vibrating at a frequency f then material
removall rate can be
b expressed
d as
y MRRw
EffectofmachiningparametersonMRR
ProcessParameters
2
( w db )3/2 nf
3
UltrasonicMachine
l
h
UltrasonicMachine
l
h
y The
Th basic
b i mechanical
h i l structure off an USM is
i very similar
i il
Feedforce(F)
to a drill press.
A lit d f ib ti ( o)
Amplitudeofvibration(a
y It has additional features to carry out USM of brittle
work material.
material
y The workpiece is mounted on a vice, which can be
l
located
d at the
h desired
d
d position under
d the
h tooll using a 2
axis table.
y The table can further be lowered or raised to
accommodate work of different thickness.
thickness
y Slurry delivery and return system
averagegritdiameter,d
g g
g
Frequencyofvibration(f)
q
y
( )
Volumeconcentrationofabrasive
inwaterslurry C
UltrasonicMachining
l
h
Page 8
UltrasonicMachine
l
h
y Feed
to provide
on
F d mechanism
h i
id a downward
d
d feed
f d force
f
y The
Th
the tool during machining

y The transducer, which generates the ultrasonic vibration
y The horn or concentrator,
concentrator which mechanically amplifies
the vibration to the required amplitude of 15 50 m and
accommodates
d
the
h tooll at its tip.
ToolholderorHorn
l h ld
Tooll
y Its function is to increase the tool vibration amplitude
y Tools should be constructed from relatively ductile
y It
I must be
b constructed
d off a material
i l with
i h good
d acoustic
i
properties and be highly resistant to fatigue cracking.

cracking
ultrasonic
are produced
the
l
i vibrations
ib i
d d by
b
h
transducer. The transducer is driven by suitable signal
generator followed by power amplifier. The transducer
for USM works on the following
gp
principle
p
Piezoelectric effect
Magnetostrictive effect
ff
Electrostrictive
ect ost ct ve eeffect
ect
y Magnetostrictive transducers are most popular and
robust
b t amongstt all.
ll
and
d to match
h the
h vibrator
b
to the
h acoustic load.
l d
Transducer
d
SubsystemsofUSM
Subsystemsof
USM
materials.
l
Li i i
Limitations
y LowMRR
L MRR
y Ratherhightoolwear
g
y Lowdepthofhole
y The
Th harder
h d the
h tooll material,
i l the
h faster
f
i wear rate will
its
ill
be.
be
y Monel and titanium have good acoustic properties and
are often used together

g
with stainless steel, which is
cheaper.
Applications
l
Note
y Used
hard
U d for
f machining
hi i
h d and
d brittle
b i l metallic
lli alloys,
ll
y The
Th following
f ll i material
i l is
i generally
ll machined
hi d by
b USM
semiconductors, glass, ceramics, carbides etc.

y Used for machining round, square, irregular shaped
holes and surface impressions.
impressions
y Machining, wire drawing, punching or small blanking
dies.
()
(i)
Glass
(ii)
Silicon
(iii)
G
Germanium
i
y Tool in USM is g
generallyy made of Steel
Ch i l M hi i
ChemicalMachining
y Chemicals are used to dissolve material
y Masks are used to control attack
y Most common use is circuit boards and plates for
printing.
i ti
y Cutting speed of 0.00250.1
0 0025 0 1 mm/minute very slow
Page 9
Ch i l M hi i
ChemicalMachining
Ph
PhotoChemicalMachining
Ch i l M hi i
Ph
PhotoChemicalMachining
Ch i l M hi i
y PCM is
chemicals
i a material
i l removall process using
i
h i l
(etchants) to produce high precision parts.

y This process is also known as Photo Etching, Chemical
Blanking and Photo Chemical Milling.

Milling
y Coat both sides of the plate with photoresist.
( h
(photoresist
is a polymer
l
that
h adheres
dh
to the
h metall when
h
exposed to UV light).
y Spray metal with etchant or dip it in hot acidic solution
to etch all material other than part covered with
photoresist (115 min.).
y Rinse the plate to ensure photoresist and etchant
removal.
LaserBeamMachining
LaserBeamMachining
LaserBeamMachining
y Direct
laser
beam
against
surface
off workpiece,
as in
Di
l
b
i
f
k i
i
y Produceslargeremelt zone
laser welding
y Canproduceholesassmallas0.0005mmdiameter
y Success
Successive
ve pu
pulses
ses from
o laser
ase gu
gun vapo
vaporizee ttinyy b
bits
ts o
of
y Canproducedeepholes
workpiece
y Usedtoproducecoolingholesinblades/vanesforjet
y Location of laser beam controlled by computer
engines
y Workpiece need not be conductive

y Cuts are tapered
y Gotta trap overshoot from laser beam
85
ElectronBeamMachining
86
PlasmaArcCutting
ElectronBeamMachining
y Plasma is a stream of ionized gas
y Workpiece placed in vacuum chamber

y Highvoltage
electron
beam
directed
y Typical
T i l temperatures
t
t
are very high
hi h
toward
y Same process as plasma welding,

welding without filler metal
workpiece
y Torch movement controlled by

y computer
p
y Energy
e gy o
of eelectron
ect o bea
beam melts/
e ts/ vaporizes
apo es se
selected
ected
y Power requirements depend on material being cut,
region of workpiece
plus depth of cut
y Electron beam moved by deflection coils
y Recast layer
l
i deeper
is
d
than
h with
i h other
h processes
y Similar process to EB welding
87
88
Page 10
89
90
Abrasive Jet Machining (Dry)

AbrasiveJetMachining(Dry)
WaterJetMachining
WaterJetMachining
y It is similar to sand blasting, except that a very narrow jet of
gas and abrasive particles achieves localized cutting.

cutting
y Narrowjetofwaterdirected,athighpressureand
y It removes material through the eroding action of a high
velocity
l it stream
t
off abrasiveladen
b i l d gas.
velocity,againstsurfaceofworkpiece
y The gas is first compressed and mixed with the abrasive
y Jetofwatererodessurfaceofworkpiece,thereby
J t f t d f f
k i
th b
cuttingworkpiece
g
p
y
y
y
y
y
y
y
y Computercontroltoachieveshape
91
powder
d in
i a mixing
i i
chamber
h b and
d passed
d through
h
h outlet
l
nozzle.
Computer is used
d to position the
h jet.
Gas Pressure about 7 atm
Velocity of jet about 300 m/s
Jet Diameter 0.12 mm to 1.25 mm
Abrasive used: Al2O3 , SiC with particle size 10 to 50 m
Tool (nozzle) material tungsten
g
carbide or sapphire
pp
Tool(nozzle)Life about30hours
92
AdvantagesofAJM
AbrasiveJetMachining
y Can be used in any material, conductive, non
conductive, ductile or brittle

y Good
d dimensional
d
l accuracy (0.05
(
mm))
y Good
G d Surface
S f
fi i h 0.25 to
finish
t 1.25 m
93
DisadvantagesofAJM
y LowMRR
y Possibilityofstraycutting
y Embeddingofabrasiveparticlesinsoftworkpiece
y Dustcontrolneeded
y Due to cooling action of gas stream no thermal damage
on the work surface

y Due to negligible force delicate workpiece can be
94
ApplicationofAJM
y Cutting and drilling on metal foils and thin
sections of ceramics and glass

y Intricate holes
h l in electronic
l
components such
h as
resistor paths in insulation

y Engraving of characters on toughened glass
automobile windows
y Cleaning, polishing and deburring the surface
machined.
AbrasiveWJCutting
y Used to cut much harder materials
y Water is not used directly to cut material as in Pure,
Pure
instead water is used to accelerate abrasive particles which

do the cutting
y 80mesh
8
h garnet (sandpaper)
( d
) is
i typically
i ll used
d though
h
h 50
and 120mesh is also used

y Standoff distance between mixing tube and workpart is
typically 0.0100.200 important to keep to a minimum to

keep a good surface finish
Page 11
AbrasiveWJCuttingg
y Evolution
of mixing tube
technology
y Standard Tungsten Carbide
lasts 46 hours (not used much
anymore)
y Premium Composite Carbide
lasts 100150 hours
y Consumables include water,,
abrasive, orifice and mixing
tube
Ch10:NonConventionalMachiningOperation
Q.No
1
2
3
4
5
6
7
Option
D
B
B
D
D
B
A
Q.No
8
9
10
11
12
13
14
NC,CNC&Robotics
WhatisNC/CNC?
h
/
?
y NC is an acronym for Numerical Control and CNC is an
Option
D
A
B
D
A
A
B
acronym for
f Computer Numericall Control.
l
BySKMondal
WhatisthedifferencebetweenNCandCNC?
WhatisthedifferencebetweenNCandCNC?
WheredidCNCgetstarted?
h
dd
d?
y The
between
NC and
Th difference
diff
b
d CNC is
i one off age and
d
y Some of the enhancements that came along with CNC
y 1940 Jhon Parson developed first machine able to drill
include:
l d
Canned
d Cycles,
l
Sub
b Programming, Cutter
h l at specific
holes
f coordinates
d
programmed
d on punch
h
Compensation Work coordinates,

Compensation,
coordinates Coordinate system
cards.
cards
capability.
y The earliest NC machines performed limited functions
and movements controlled by punched tape or punch
cards.
y As the
h technology
h l
evolved,
l d the
h machines
h
were equiped
d
with increasingly powerful microprocessors (computers)
with the addition of these computers, NC machines
become CNC machines.
y CNC machines have far more capability than their
predecessor.
d
contd..
td
rotation, automatic corner rounding, chamfering, and B

B
y 1951 MIT developed servomechanism
spline interpolation.
y 1952 MIT developed first NC machines for milling.

milling
y 1970 First CNC machines came into picture
Nowadays
y modified 1970s
97 machines are used.
DoallmachinesspeakthesameCNC
D
ll
hi
k th
CNC
language
y CNC machine tool builders offer an option what is
y No, while there is fairly standard set of G and M codes,
k
known
as the
h conversationall control.
l This
h controll lets
l
WhatisaConversationalControl
h
l
l
th
there
i some variation
is
i ti in
i their
th i application.
li ti
F example
For
l
the
operator/programmer
use
a G0 or G00 command is universally regarded as the
language to program the part. The control then
command for rapid

p travel. Some older machines do not
displayed a graphical representation of the instructions
have a G00 command. On these machines, rapid travel is
so the operator/programmer can verify the tool path.
commanded by using the F (feed) word address.

Page 12
simple
descriptive
AreCNCmachinesfasterthan
conventionalmachines?
l
h
y Yes, No, Sometimes. When it comes to making a single,
simple part it is hard to beat a conventional mill or lathe.

CNC machines move faster in rapid travel than
conventional
i
l machines.
hi
AreCNCmachinesmoreaccurate
thanconventionalmachines?
h
l
h
NC/CNCMachinesAdvantages
NC/CNCMachinesDisadvantages
y High Repeatability and Precision e.g. Aircraft parts
y Costlysetup,skilledoperators
y Volume of production is very high

y Yes, they
y can be. But like anything
y
g else it depends
p
on
who is running the machine, how well the machines has

been maintained, quality of setup and so on.
y Complex contours/surfaces need to be machined. E.g.
Turbines
y Flexibility in job change,
change automatic tool settings,
settings less
y Computers,programmingknowledgerequired
y Maintenanceisdifficult
scrap
y More
M
safe,
f higher
hi h productivity,
d i i better
b
quality
li
y Less p
paper
p work,, faster p
prototype
yp p
production,, reduction
in lead times
NC/CNC/DNC
y Direct Numerical Control is a system that uses a
Directnumericalcontrol
Direct numerical control
DNC
central computer
p
to control several machines at the same
time
y Distributed Numerical Control (DNC): the central
computer downloads complete programs to the CNC
machines,
hi
which
hi h can be
b workstations
k
i
or PCs,
PC and
d can get
the information for the machine operations.
y The speed of the system is increased, large files can be
handled and the number of machine tools used is
expanded.
112
StepperMotor
113
BasicCNCPrinciples
p
BasicLengthUnit(BLU)
h
(
)
y In
the
length
I NC machine,
hi
h displacement
di l
l
h per one pulse
l
y The stepper motor is special type of synchronous motor
output from machine is defined as a Basic Length Unit

(BLU).
y In the CNC computer each bit (binary digit) represents 1
BLU.
Bit = BLU
y Example:
a p e: If o
onee pu
pulse
se makes
a es a se
servo
vo motor
oto rotate
otate by o
onee
degree and the servo motor moves the table by 0.0001
mm one BLU will be 0.0001
mm,
0 0001 mm.
mm
y The lead of a ball screw is related to the displacement
unit of the machine tool table.
which
h h is designed
d
d to rotate through
h
h a specific
f angle
l
(Called step) for each electrical pulse received from the
control unit.
114
Page 13
ControlSystemspossibleinCNCMachine
Pointtopointstraightlinemode
y Point
P i to point
i mode:
d
Coordinatesystem
d
y All the
system.
h machine
hi tooll use Cartesian
C
i Coordinate
C
di
y The first axis to be identified is the Z axis,, This is
followed by X and Y axes respectively.
Righthandcoordinatesystems
Page 14
Absolute and Incremental Coordinate System
Absolute Coordinate System
5axesCNCverticalaxismachiningcentreconfiguration
Incremental Coordinate System
PartProgramming
Thefollowingarethestepstobefollowed
whiledevelopingtheCNCpartprograms.
while developing the CNC part programs
y FANUCCONTROLL
y Processplanning
p
g
y SIEMENSCONTROLL
y Axesselection
y Toolselection
T l l ti
y Cuttingprocessparametersplanning
gp
p
p
g
y Jobandtoolsetupplanning
y Machiningpathplanning
M hi i th l
i
y Partprogramwriting
p g
g
y Partprogramproving
CNC
i
CNCprogramming
Importantthingstoknow:
y For a CNC machine

h
controll unit (MCU)
(
) decides
d d cutting
speed,
p
feed, depth
p of cut, tool selection , coolant on off
and tool paths. The MCU issues commands in form of
numeric data to motors that position slides and tool
accordingly.
TableofImportantGcodes
p
ProgrammingKeyLetters
y O Programnumber(Usedforprogramidentification)
CoordinateSystem
y N
N Sequencenumber(Usedforlineidentification)
y G Preparatoryfunction
Units,incrementalorabsolutepositioning
Meaning
RapidTransverse
p
LinearInterpolation
CircularInterpolation,
CW
G03
CircularInterpolation,
CCW
N__G03 X___Y___Z__R__F___
G04
Dwell
N__G04P___
G17
G8
G18
G19
XY Plane
XZPl
XZPlane
y X Xaxisdesignation
g
y Y Yaxisdesignation
Coordinates:X,Y,Z,RX,RY,RZ
, , ,
, ,
Code
G00
G01
G02
y Z Zaxisdesignation
g
y R Radiusdesignation
Feedrateandspindlespeed
p
p
y F Feedratedesignation
y S Spindlespeeddesignation
CoolantControl:On/Off,Flood,Mist
CoolantControl:On/Off Flood Mist
ToolControl:Toolandtoolparameters
y H Toollengthoffsetdesignation
y D Toolradiusoffsetdesignation
y T ToolDesignation
y M Miscellaneousfunction
Page 15
YZPlane
Format
N__G00X___Y___Z___
N__G01X___Y___Z___F___
N__G02X__Y__Z___R___F___
N G X
N__G02X___Y__Z__I___J__K__F__
Y Z I J K F
N__G03 X__Y__Z__I__J__K__F__
p
Code
G20/G70
7
G21/G71
G28
G40
G
G41
G42
G43
p
Meaning
Format
InchUnit
MetricUnit
AutomaticReturntoReference
Point
Cuttercompensationcancel
C tt
Cuttercompensationleft
ti l ft
N G D
N__G41D__
Cuttercompensationright
N__G42D__
Toollengthcompensation
(plus)
N__G43H__
p
Linearinterpolation:G01
y G00:
y tomakethemachinemoveatmaximumspeed.
y Itisusedforpositioningmotion.
Itisusedforpositioningmotion
G90G00X20.0Y10.0
End
G90:
absolute
coordinates
Start
Circularinterpolation:G02,G03
Circular interpolation: G02, G03
(20,10)
(10,10)
(0,0)
y G02,G03:
y G01:
y Forcircularinterpolation,thetooldestinationandthecircle
Forcircularinterpolation thetooldestinationandthecircle
y linearinterpolationatfeedspeed.
centerareprogrammedinoneblock
y G02isclockwiseinterpolation,G03iscounterclockwise
i
interpolation
l i
G91G0lX200.0Y100.0F200.0
G91:
9
incremental
coordinates
Y
End
100.0
200.0
Start
Circular interpolation: G02 G03
Y
p
Rapidtraverse:G00
Code Meaning
Format
G44 Toollengthcompensation N__G44H__
(minus)
G49 Toollengthcompensation
cancel
G80 Cancelcannedcycles
N G81Z R F
N__G81Z__R__F__
G81
Drillingcycle
G90 Absolutepositioning
G91
Incrementalpositioning
Absolutepreset,changethe N__G92X__Y__Z__
G92
datumposition
y I,J,Karetheincremental
J
distancefromthestartof
thearc;
X
Start
j
Center
y Viewingthestartofarcas
theorigin,I,J,Khave
positiveornegativesigns.
ii
i i
F __;;
J __
F __;;
K __
G 02
R
G19
Y __ Z __
G 03
J __
F __;;
K __
End
point
Start
N0010G92X200.0Y40.0Z0
N0020G90G03X140.0Y100.0R60.0F300
N0030G02X120.0Y60.0R50.0
Y
100
60
40
Page 16
R=50mm
>180 R
Circular interpolation: G02 G03
y I0.0,J0.0,andK0.0canbeomitted.
y IfX,Y,Zareallomittedintheprogram,thatmeans
IfX Y Zareallomittedintheprogram thatmeans
startandendofarcaresamepoints.
N0020G02I20 0(afullcircle)
N0020G02I20.0(afullcircle)
y IfI,J,K,andRallappearsincircularinterpolation
i t ti Ri lid dI J dK i
instruction,RisvalidandI,J,andKareinvalid
lid
R50
R60
X
SpecifyRwith
S
if R i h
signbeforeit:
AnnotationforCircularInterpolation
p
G92:
Todefineworking
T
d fi
ki
coordinate
G
G90:
absolute
coordinates
End
G91G02X60.0Y20.0R50.0 F300.0
G91G02X60.0Y20.0R50.0 F300.0
Circlecenter,radius
,
N0010G92X200.0Y40.0Z0;
N0020G90G03X140.0Y100.0I60.0F300
N0030G02X120.0Y60.0I 50.0
Or
R=-50mm
180 +R
y SpecifyCenterwithI,J,K
End
G 02
R
G17
X __ Y __
G 03
I __
G 02
R
G18
X __ Z __
G 03
I __
90 120 140
200
p
ToolCompensation
y ToolRadiusCompensation
oo Rad us Co pe sat o
y LefthandG41
p
ToolRadiusCompensation
y Toolradiuscompensationsmakeitpossibleto
programdirectlyfromthedrawing,andthuseliminate
programdirectlyfromthedrawing
andthuseliminate
thetooloffsetcalculation
y RighthandG42
y CanceltoolradiuscompensationG40
y ToolHeightCompensation
y PositiveG43
os e G43
G (G )D
G41(G42)D
p
CancelToolCompensation:G40
y Notethedifferencebetweentwoways
N0060G01 X2.000Y1.700
X2 000Y1 700
N0070G40 M02
N0060G40G01 X2.000Y1.700M02
y D:theradiusoftooltocompensateissavedinamemoryunitthat
isnamedD
y G41/G42isdirectlyrelatedwithdirectionoftoolmovementand
whichsideofpartiscut.
y NegativeG44
y CanceltoolheightcompensationG49
Canceltool heightcompensationG49
rampoffblock
g
p
ToolHeightCompensation
G43(G44)H
y H:specifiedmemoryunitusedtosaveheight
compensationoftool.
y Positivecompensation(G43):
realposition=specifiedposition+valuesavedinH
y Negativecompensation(G44):
realposition=specifiedposition
p
p
p
valuesavedinH
ToolHeightCompensation
ToolHeight Compensation
y Example:
effectivetotheendpoint
TableofImportantMcodes
y M00Programstop
y M01Optionalprogramstop
y N0010G91G00X12.0Y80.0
y N0020G44Z32.0H02
N
G Z
H
G91:
iincremental
t l
coordinates
y M03Spindleonclockwise
y M04Spindleoncounterclockwise
M S i dl
t l k i
y M05Spindlestop
y Ifweput0.5mmintoH02,
y M06Toolchange
y realposition=32.0
p
3
0.5=32.5
5 3 5
y M08Coolanton
y M09Coolantoff
y Canceltoolheightcompensation:G49
y M10Clampson
y M11Clampsoff
y M02orM30Programstop,resettostart
M M P
Rulesforprogramming
R l f
i
Block Format
ExampleofCNCProgramming
E
l f CNC P
i
Top
View
N135 G01 X1.0 Y1.0 Z0.125 F5

Sample Block
Restrictions on CNC blocks
Each mayy contain onlyy one tool move
Each may contain any number of non-tool move G-codes
Each may contain only one feed rate
Each may contain only one specified tool or spindle speed
The block numbers should be sequential
Both the program start flag and the program number must be
independent of all other commands (on separate lines)
The data within a block should follow the sequence shown
in the above sample block
y WhatMustBeDoneToDrillAHoleOnACNC
VerticalMillingMachine
Front
View
O0001
N005G54G90S600M03
N
N010G00X1.0Y1.0
G X Y
N015G43H01Z.1M08
5 43
N020G01Z.75F3.5
N025G00Z 1M09
N025G00Z.1M09
N030G91G28X0Y0Z0
N035M30
M30
3
Page 17
EndofProgram
g
W d
Words
APTLanguage
y APT (Automatically
(A
i ll Programmed
P
d Tools)
T l )
y The APT language consists of many different types of
statements made up of the following valid letters, numerals

and p
punctuation marks.
y Letters:
ABCDEFGHIJKLMNOPQRSTUVWXYZ
y Numerals: 0123456789
/
Aslashdividesastatementintotwosections.eg.,
GO/PAST,
,, Acommaisusedasaseparatorbetweentheelementsin
p
astatementgenerallytotherightoftheslash.
= Anequalsisusedforassigninganentitytoasymbolic
name,e.g.,P1=POINT/25,50,30.
ThecompleteAPTpartprogramconsistsof
thefollowingfourtypesofstatements
the following four types of statements
y Motion
y Postprocessor
y
y
y
programming system for smaller computers

AUTOSPOT (AUTOmatic
(AUTO ti Sytem
S t
f POsitioning
for
PO iti i
T l ) was
Tools)
developed by IBM and first introduced in 1962
EXAPT (EXtended subset of APT) was developed jointly in
German in about 1964 by several universities to adapt APT for
European
p
use. It is compatible
p
with APT and thus can use the
same processor as APT
COMPACT was developed
p byy Manufacturing
g Data Systems,
y
Inc.
(
(MDSI)
)
SPLIT (Sundstrand Processing Language Internally Translated)
was developed
d l
d by
b Sundstrand
S d
d Corporation,
C
i
i
intended
d d for
f its
i own
machine tools
MAPT (MicroAPT)
(Mi
APT) is
i a subset
b t off APT,
APT to
t be
b run on the
th
microcomputers
158
Point (POINT)
(
)
PTA = POINT/ 3,4,5
letter No special character is allowed in the words.

letter.
words
OtherPartProgrammingLanguages
y
Point (POINT)
one to six letters

l
or numerals
l with
h the
h first
f
one being
b
a
APTLanguage
APT Language
y ADAPT (ADaptation
(AD
i APT) was the
h first
fi
attempt to adapt
d
APT
y Geometry
y Compilationcontrol
y The words to be used in the statements are built up from
Additionalstatements:
MACHIN/DRILL, 2
COOLNT/
Forexample: COOLNT/MIST COOLNT/FLOOD COOLNT/OFF

FEDRAT/
SPINDL/
Forexample: SPINDL/ON SPINDL/1250, CCLW
TOOLNO/
TURRET/
END
159
Point (POINT)
(
)
PTB = POINT/ INTOF, LIN1, LIN2
PTD = POINT/ YSMALL, INTOF, LIN3, C1

PTD = POINT/ XSMALL, INTOF, LIN3, C1
PTC = POINT/ YLARGE, INTOF, LIN3, C1
PTC = POINT/ XLARGE, INTOF, LIN3, C1
PTC
(3, 4, 5)
LIN2
PTA
z
LIN3
PTB
C1
LIN1
PTD
Page 18
Point (POINT)
(
)
PTE = POINT/ YLARGE, INTOF, C1, C2
PTE = POINT/ XLARGE, INTOF, C1, C2
PTF = POINT/ YSMALL, INTOF, C1, C2
PTF = POINT/ XSMALL, INTOF, C1, C2
Point (POINT)
Line (LINE)
PT7 = POINT/ CENTER, C6
LIN1 = LINE/ P1, P2
y
y
C1
y
C6
PTE
P2
PT7
PTF
P1
C2
LIN1
Line (LINE)
(
)
Line (LINE)
Line (LINE)
(
)
L12 = LINE/ PT4, ATANGL, 20, XAXIS

L14 = LINE/ PT1, ATANGL, 40
L15 = LINE/ 32, -3, 2, ATANGL, -15, XAXIS
L16 = LINE/ PT3, ATANGL, 40, YAXIS
LIN4 = LINE/ PT6, 15, -30, 3
LIN = LINE/ POINT,

POINT ATANGL,
ATANGL ANGLE (in degrees),
degrees) LINE
y
LINE2
PT6
PT3
L14
P1
40
L4
L12
PT1
L16
30
PT4
LINE1
(15,30,3)
LINE2=LINE/P1,ATANGL,30,LINE1
3
20
40
x
L15
15
(32,3,2)
Line (LINE)
(
)
Line (LINE)
(
)
Line (LINE)
(
)
LIN = LINE/ SLOPE,

SLOPE SLOPE VALUE,
VALUE INTERC,
INTERC MODIFIER,
MODIFIER d
where the slope value is y/x. The modifier options are [XAXIS,
YAXIS] and d is the corresponding intercept value on the selected
YAXIS],
axis (i.e., modifier).
LIN = LINE/ ATANGL,

ATANGL DEGREES,
DEGREES INTERC,
INTERC MODIFIER,
MODIFIER d
The modifier options are [XAXIS, YAXIS], and d is the
corresponding intercept value on the selected axis (i.e., modifier).
The LEFT & RIGHT modifier indicates whether the line

is at the left or right
g tangent
g
point,, depending
p
p
g on how
one looks at the circle from the point.
L1 = LINE/ PT51, LEFT, TANTO, C11
LINE1
L1
LINE1
LINE1=LINE/SLOPE,1,INTERC,XAXIS,6
PT51
=30
x
(6,0)PointofX Intercept
(6,0)PointofXIntercept
C11
LINE1=LINE/ATANGL,30,INTERC,d
x
Page 19
Line (LINE)
(
)
Line (LINE)
(
)
Line (LINE)
(
)
L6 = LINE/ LEFT, TANTO, C3, LEFT, TANTO, C4

L2 = LINE/ PT51,
PT51 RIGHT,
RIGHT TANTO,
TANTO C11
L3 = LINE/ PT40, RIGHT, TANTO, C11
L4 = LINE/ PT40, LEFT, TANTO, C11
L6
L6 = LINE/ RIGHT, TANTO, C4, RIGHT, TANTO, C3

C4
Left
L3
C3
Right
L6
Right
Right
L8
L9
Left
Left
C3
L7
L4
Left
The descriptive words LEFT and RIGHT are used by

looking from the first circle written towards the
second
d circle.
i l
PT51
Right
C4
PT40
L1
L2
Line (LINE)
(
)
L8
L9
L7
Plane (PLANE)
(
)
Line
LN5 = LINE/ INTOF, PLAN1, PLAN2
LN3 = LINE/ PNT6, PARLEL, LN15

LN4 = LINE/ PNT5
PNT5, PERPTO,
PERPTO LN13
PLAN10 = PLANE/ PT6, PT12, PT15
LN5
PLAN10
PT15
y
PNT6
PNT5
LN3
PT6
PT12
LN4
LN15
LN13
3.0
PLAN1
PT4
z
PLAN2
PLAN14
x
x
Plane (PLANE)
(
)
Circle (CIRCLE)
PLAN14 = PLANE/ PT4, PARLEL, PLAN10

PLAN14 = PLANE/ PARLEL,
PARLEL PLAN10,
PLAN10 YSMALL,
YSMALL 3.0
30
PLAN10
PT15
C1 = CIRCLE/ 3, 6, 5, 4.3
C1 = CIRCLE/ CENTER, PT3, RADIUS, 4.3
y
Circle (CIRCLE)
C3 = CIRCLE/ CENTER, PT6, TANTO, LN4
C7 = CIRCLE/ CENTER, PT8, PT5
y
C1
PT6
LN4
PT12
PT5
3.0
4.3
PT3
(3,6,5)
PT4
4
PT6
PT8
C7
C3
z
PLAN14
4
x
Page 20
The Machining Plan

Contouring:
The Machining
g Plan
The Machining Plan
y Part surface: the surface on which the end of the
Checksurface
Drivesurface
CS
CS
CS
tool is riding.
riding
y Drive surface: the surface against
g
which the edge
g of
the tool rides.
Directionof
cuttermotion
cutter
x
DS
DS
DS
y Check surface: a surface at which the current tool
motion is to stop.
GOUP
The Machining Plan

Motion commands:
GOLFT/
: Move left along the drive surface
GORGT/
: Move right along the drive surface
GOUP/
: Move upp along

g the drive surface
ON
PAST
FROM/PTARG
GO/TO,L1,TO,PL2,TOL3
GORGT/L3,PAST,L4
GOLFT
GOFWD
Present tool
position
p
GOBACK
GODOWN/ : Move down along the drive surface

GOFWD/
TO
Partsurface
GORGT
: Move forward from a tangent position
GODOWN
GOBACK/ : Move
M
b k d from
backward
f
a tangent
t
t position
iti
Previous
tool position
Machining Specifications
Postprocessor commands for a particular machine tool are:
MACHIN/ : used
d to
t specify
if the
th machine
hi
t l and
tool
d call
ll the
th
postprocessor for that tool:
MACHIN/ DRILL, 3
COOLNT/ : allows the coolant fluid to be turned on or off:
FEDRAT/ : specifies the feed rate for moving the tool along the
part surface
f
i inches
in
i h per minute:
i
FEDRAT/ 4.5
SPINDL/ : gives the spindle rotation speed in revolutions per
minute:
i
COOLNT/ MIST
SPINDL/ 850
COOLNT/ FLOOD
TURRET/ : can be used to call a specific tool from an automatic

t l changer:
tool
h
COOLNT/ OFF
TURRET/ 11
Page 21
TOLERANCE SETTING: Nonlinear motion is accomplished in
straight-line
straight
line segments,
segments and INTOL/ and OUTTOL/ statements
dictate the number of straight-line segments to be generated.
INTOL/ 0.0015
OUTTOL/ 0.001
PARTNO: identifies the part program and is inserted at the start of
the program.
program
APTLanguage
APT Language
FINI: specifies the end of the program.
OtherMotionstatements:
GO/{TO}, Drive surface, {TO} Part surface, {TO},
Check surface
CLPRNT: indicates that a cutter location printout is desired.
Or
GO/{TO}, Drive surface, {TO} Part surface, {TANTO},
CUTTER: specifies a cutter diameter for offset (rough versus finish

g) If a milling
g cutter is 0.5 in. in diameter and we have
cutting).
Check surface
AndthesamewithPASTorONinsteadofTO
GOLFT/
GORGT/
GOUP/
GODOWN/
GOFWD/
GOBACK/
Forexample:
GO/TO, L1, TO, PS, TANTO, C1
GO/PAST L1,
GO/PAST,
L1 TO,
TO PS
PS, TANTO
TANTO, C1
CUTTER/ 0.6
then the tool will be offset from the finish cut by 0.05 in.
192
IES2008
Name the four types of statements in a complete APT
IES2007
Prepare part using APT language for milling the contour
part program. Prepare part program for geometry

description
p
of the contour shown in the figure
g
below:
Y
[15Marks]
shown in Fig. in a single pass.

B
[20Marks]
R30
Q
40
30
110
20
L2
L3
135
20
C1
110
120
E
R40
L4
L1
20
20
100
+ 40
L5
P1
P
Material : M S.
8 mm
Contd.
CUTTER/25.0
TOLER/0.1
INTOL/0.05
OUTTOL/0.05
FEDRAT/200
SPINDL/500, CLW
COOLNT/ON
FROM/P0
GO/TO, LAB, TO, PL1, TO, LAF
GOLFT/LAB, TANTO, CBC
GOFWD/CBC, PAST, LCD
GORGT/LCD PAST,
GORGT/LCD,
PAST LDE
GORGT/LDE, PAST, CEF
GORGT/CEF PAST,
GORGT/CEF,
PAST LAF
GORGT/LAF, PAST, LAB
40
C2
P2
80
Answer:
PARTNO CONTOUR
MACHIN/MILL, 2
CLPRNT
UNITS/MM
P0 = POINT/0.0, 0.0, 10.0
PTA = POINT/0.0, 0.0, 0.0
PTB = POINT/0.0, 120.0, 0.0
PTC = POINT/30.0,
POINT/30 0 150.0,
150 0 0
0.0
0
PTD = POINT/140.0, 150.0, 0.0
PTE = POINT/140.0, 40.0, 0.0
PTF = POINT/100.0, 0.0, 0.0
PTQ = POINT/30.0, 120.0, 0.0
PTP = POINT/140.0, 0.0, 0.0
LAB = LINE/PTA, PTB
LCD = LINE/PTC, PTD
LDE = LINE/PTD,
LINE/PTD PTE
LAF = LINE/PTA, PTF
CBC = CIRCLE/CENTRE, PTQ, RADIUS, 30.0
CEF = CIRCLE/CENTRE, PTP, RADIUS, 40.0
PL1=PLANE/PTA, PTB, PTC
Contd.
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
IES2006
Prepare part program to machine the contour shown in

the figure using APT on CNC milling machine.
[15Marks]
5
R30
R20
100 mm
80
50
60
200 mm
Page 22
Material: MS
Thickness: 8.0 mm
HomeWork
Write a complete part program in APT for machining
the product which is given in the diagram. Thickness of
th workpiece
the
k i
i 6 mm. All dimensions
is
di
i
are in
i mm.
[15]
REMARKMOTIONSTATEMENTFOLLOW
FROM/P0
GO/TO,L1,TO,PL1,TANTO,C1
GORGT/L1,TANTO,C3
GORGT/L TANTO C
GOFWD/C3,TANTO,C4
GOFWD/C4,TANTO,C2
GOFWD/C2,PAST,L2
GOFWD/L2,TANTO,C1
GOFWD/C PAST L
GOFWD/C1,PAST,L1
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
Ad t
fR b t
AdvantagesofRobots
y Robotics and automation can, in many situation, increase

y
y
y
y
y
y
y
y
productivity,
safety,
efficiency,
quality,
and
off
d i i
f
ffi i
li
d consistency
i
products
Robots can work in hazardous environments
Robots need no environmental comfort
Robots work continuously without any humanity needs and
illnesses
Robots have repetable
p
precision at all times
p
Robots can be much more accurate than humans, they may have
mili or micro inch accuracy.
R b
Robots
and
d their
h i sensors can have
h
capabilities
bili i beyond
b
d that
h off
humans
Robots can process multiple stimuli or tasks simultaneously,
simultaneously
humans can only one.
Robots replace
ep ace human
u a workers
o e s who
o ca
can ccreate
eate eco
economic
o c
problems
PARTNOCONTOUR
/
,
MACHIN/MILL,1
CLPRNT
UNITS/MM
P0=POINT/25.0,25.0,25.0
P1=POINT/0.0,0.0,6.0
P2=POINT/117 0 32 0 6 0
P2=POINT/117.0,32.0,6.0
P3=POINT/117.0,32.0,6.0
C1=CIRCLE/CENTER,P1,RADIUS,10.0
/
, ,
, 5
Robotics
Di d t
fR b t
DisadvantagesofRobots
y Robots lack capability to respond in emergencies, this can cause:

Inappropriate and
d wrong responses
A lack of decisionmaking power
A loss of power
Damage to the robot and other devices
Human injuries
y Robots
b
may have
h
l
limited
d capabilities
bl
in
Degrees of Freedom
Dexterity
Sensors
Vision systems
Realtime Response
y Robots are costly, due to
Initial cost of equipment
Installation Costs
Need for peripherals
Need for training
Need for Programming
Page 23
L1=LINE/RIGHT,TANTO,C1,RIGHT,TANTO,C3
L2=LINE/LEFT,TANTO,C1,LEFT,TANTO,C2
C4=CIRCLE/XLARGE,OUT,C2,OUT,C3,RADIUS,62
PL1 PLANE/P1,P2,P3
PL1=PLANE/P1,P2,P3
REMARKPOSTPROCESSORSTATEMENTFOLLOW
CUTTER/50 0
CUTTER/50.0
TOLER/0.01
INTOL/0.05
OUTTOL/0.05
FEDRAT/200
SPINDL/1000,CLW
COOLNT/ON
Whatisanindustrialrobot?
A robot is a reprogrammable, multifunctional
manipulator
p
designed
g
to handle material,, p
parts,, tools or
specialized devices through variable programmed
motions for the performance of a variety of tasks.
tasks
WhatCanRobotsDo?
IndustrialRobots
Material handling
Material transfer
Machine loading and/or unloading
Spot welding
Continuous
C ti
arc welding
ldi
Spray coating
Assembly
Assembly
Inspection
MaterialHandling
Manipulator
Assembly
Manipulator
SpotWelding
Manipulator
Ai
Asimov'sthreelawsofrobotics
' h
l
f b i
First law (Human safety):
y A robot may not injure a human being,
being or,
or through
inaction, allow a human being to come to harm.
S
Second
d law
l
(R b
(Robots
are slaves):
l
)
y A robot must obey
y orders g
given it byy human beings,
g,
except where such orders would conflict with the First
Law.
Law
Third law (Robot survival):
y A robot must protect its own existence as long as such
protection does not conflict with the First or Second
Law.
E d Eff
EndEffectors
y Thespecialtoolingforarobotthatenablesitto
Allrobotshavethefollowingbasiccomponents:
ll b
h
h f ll
b
1. Manipulators: the mechanical unit, often called the
2.
33.
4.
5.
"arm," that does the actual work of the robot. It is

p
of mechanical linkages
g and jjoints with actuators
composed
to drive the mechanism directly or indirectly through gears,
chains, or ball screws.
Feedback devices: transducers that sense the positions of
various linkages
g and jjoints and transmit this information to
the controllers in either digital or analog Form.
End effectors: the "hand" or "gripper"
g pp
portion of the
p
robot, which attaches the end of the arm and perform the
p
of the robot.
operations
Controller: the brains of the system that direct the
p
movements of the manipulator.
Power supply
WristConfigurations
y Wristassemblyisattachedtoendofarm
Wristassemblyisattachedtoend of arm
y Endeffector isattachedtowristassembly
yF
Functionofwristassemblyistoorientendeffector
i f i
bl i i d ff
y Bodyandarmdeterminesglobalpositionofend
effector
y Twoorthreedegreesoffreedom:
g
y Roll
y Pitch
y Yaw
DegreesofFreedom
GrippersandTools
Grippers and Tools
y The degree of freedom or grip of a robotic system can be
compared to the way in which the human body moves.
performaspecifictask
y Twotypes:
y For each degree of freedom a joint is required.
y Grippers tograspandmanipulateobjects(e.g.,
tograspandmanipulateobjects(e g
y The degrees of freedom located in the arm define the
parts)duringworkcycle
y Tools
Tools toperformaprocess,e.g.,spotwelding,spray
toperformaprocess e g spotwelding spray
configuration.
fi
ti
painting
y Each of the five basic motion configurations utilizes three
degrees of freedom in the arm.

y Three degrees of freedom located in the wrist give the end
effector all the flexibility.
D
DegreesofFreedom(contd.)
fF d
( td )
y A total of six degrees of freedom is needed to locate a
robots hand at any point in its work space.

y Although
g six degrees
g
of freedom are needed for
maximum flexibility, most robot employee only three to
g
of freedom.
five degrees
y The more the degrees of freedom, the greater is the
complexity of motions encountered.
encountered
y The three degrees of freedom located in the arm of
a robotic
b i system are:
The
e rotational
otat o a reverse:
eve se: iss tthee movement
ove e t o
of tthee aarm
assembly about a rotary axis, such as leftandright
swivel of the robot
robotss arm about a base.
base
D
DegreesofFreedom(contd.)
fF d
( td )
The radial traverse: is the extension and retraction
of the arm or the inandout motion relative to the

base.
The vertical traverse: provides the upanddown
motion
ti off the
th arm off the
th robotic
b ti system.
t
y The three degrees of freedom located in the wrist,
which bear the names of aeronautical terms, are
Pitch or bend: is the up
upanddown
and down movement of the
wrist.
Yaw:
Y
i the
is
h rightandleft
i h
d l f movement off the
h wrist.
i
Roll or swivel: is the rotation of the hand.
Page 24
TypesofRobot
y Cartesian
C t i
or
Gantry
G t
robot:
y It's
I ' a robot
b whose
h
arm
has
three
prismatic
joints whose axes are
joints,
coincident
with
a
Cartesian coordinator.
coordinator
y Used for pick and place
work
work,
application of
sealant,
assembly
operations
operations,
handling
machine tools and arc
welding.
TypesofRobot
R robot
obot
y SC
SCARA
y The
SCARA
acronym
stands
ffor Selective
S l ti
C
Compliant
li t Assembly
A
bl
Robot Arm or Selective Compliant
Articulated Robot Arm.
y It
It'ss a robot which has two parallel
rotary joints to provide compliance
in a plane
y Used for pick and place work,
application of sealant, assembly
operations
p
and handling
g machine
tools
y Spherical
S h i l or
y Cylindrical
C li d i l robot:
b
Polar robot:
y It's a robot whose axes
y It's a robot whose axes
form a cylindrical
coordinate system.
system
y Used for assembly
operations, handling
h dl
at
machine tools, spot
welding, and handling
at
die
casting
machines.
Types of Robot
TypesofRobot
TypesofRobot
polar coordinate
form a p
system.
y Used for handling at
machine tools, spot
welding
welding,
diecasting
diecasting,
fettling machines, gas
welding
and
arc
welding.
TypesofRobot
y Articulated
A i l d
TypesofRobot
y Parallel
P ll l robot
b
or
Revolute Robot:
y It's a robot whose arm
has at least three rotary
joints.
y Used
d for
f
assembly
bl
operations, die casting,
fettling machines, gas
welding, arc welding
and spray painting.
One use is a mobile

platform
handling
cockpit
flight
simulators. It's a robot
whose
hose
arms
ha e
have
concurrent prismatic
or rotary joints.
R b tC t lS t
RobotControlSystems
JointDriveSystems
Joint Drive Systems
y Electric
y Useselectricmotorstoactuateindividualjoints
y Preferreddrivesystemintoday'srobots
y
y
y Hydraulic
y Useshydraulicpistonsandrotaryvaneactuators
y Notedfortheirhighpowerandliftcapacity
y Pneumatic
y Typicallylimitedtosmallerrobotsandsimplematerial
yp
y
p
transferapplications
RobotControlSystem
Robot Control System
q
p
p
y Limitedsequencecontrol
pickandplace
operationsusingmechanicalstopstosetpositions
y Playbackwithpointtopointcontrol
Playbackwithpoint to pointcontrol records
workcycleasasequenceofpoints,thenplaysback
th
thesequenceduringprogramexecution
d i
ti
y Playbackwithcontinuouspathcontrol
y
p
greatermemorycapacityand/orinterpolation
p
y
p
(
p
)
capabilitytoexecutepaths(inadditiontopoints)
y Intelligentcontrol exhibitsbehaviorthatmakes
itseemintelligent e g respondstosensorinputs
itseemintelligent,e.g.,respondstosensorinputs,
makesdecisions,communicateswithhumans
Page 25
Joint1
Joint2
Cell
Supervisor
Level2
Controller
&Program
Level1
Joint3
Joint4
Joint5
Joint6
Sensors
Level0
W ki E l
WorkingEnvelope
R b i A W ldi C ll
RoboticArcWeldingCell
y Work cycle is taught to robot by moving the
y Robotperforms
fluxcoredarc
fl
d
welding(FCAW)
operationatone
i
workstation
whilefitter
hil fi
changespartsat
theother
workstation
Leadthrough Programming
1. Poweredleadthrough
y Commonforpointto
C
f i
pointrobots
y Usesteachpendant
2. Manualleadthrough
g
y Convenientfor
continuouspath
controlrobots
y Humanprogrammer
physicalmoves
manipulator
CAM
ComputerAidedManufacturing(CAM):
d d
f
(
)
y ComputerAidedProcessPlanning(CAPP)
p
g(
)
y ComputerizedmaterialResourcePlanning(MRP)
y NCpartprogramming
y RobotProgramming
y ComputerizedScheduling
y Computerizedprocesscontrol
y ComputerizedManufacturingControlbyFMS
y Shopfloorcontrol
Sh fl
t l
y ComputerAidedQualityControl(CAQC)
y ComputerAidedInspection
R b tP
i
RobotProgramming
eadt oug p
og a
g
y Leadthrough
programming
manipulator
i l t through
th
h the
th required
i d motion
ti
cycle
l and
d
simultaneously entering the program into controller
memory for later playback
y Robot programming languages
y Textual programming language to enter commands
i t robot
into
b t controller
t ll
y Simulation and offline programming
p g
g
y Program is prepared at a remote computer terminal
and downloaded to robot controller for execution
without need for leadthrough methods
Leadthrough ProgrammingAdvantages
y Advantages:
Ad
t
y Easilylearnedbyshoppersonnel
y Logicalwaytoteacharobot
y Nocomputerprogramming
y Disadvantages:
y Downtimeduringprogramming
d
y Limitedprogramminglogiccapability
p g
g g
p
y
y Notcompatiblewithsupervisorycontrol
CAD
Computer Aided Design (CAD): Used for creating the
product database
y
Geometric Modeling
Engineering Analysis
l
D i Review
Design
R i
and
d Evaluation
E l i
A t
Automated
t d Drafting
D fti
Automation
y Automation is the process of following a predetermined
sequence of operations with little or no human intervention,

intervention
using specialized equipment and devices that perform and
control the manufacturing
gp
process.
Why go for Automation?
1. Increased productivity
p
y
2. Reduced cost of labour
3. Improved quality
4. Reduced inprocess inventory
5 Reduce Manufacturing time
5.
6. Increased safety
There are three types of Automation
1. Fixed Automation
2 Programmable Automation
2.
3. Flexible Automation
Page 26
Automation
Fixed Automation
y It is also known as hard automation.
y Used to produce a standardized product.
y Used for very large quantity production of one or few
marginally different components.

components
y Highly specialized tools, devices, equipment, special
purpose machine tools, are utilized to produce a

product.
y Very efficient, high production rate , low unit cost.
Automation
Automation
WhatisanFMS?
Programmable
g
Automation
Flexible Automation
y A flexible manufacturing system (FMS) is a
y Can change
g the design
g of the p
product or even change
g the
y If is also known as FMS,, and uses CAD/CAM
manufacturing system in which there is some

amount off flexibility
fl ibili that
h allows
ll
the
h system to
react in the case of changes.
g
y Two categories of flexibility
product by changing the program.

y Used for the low quantity production of large number of
y Produce different p
products on the same equipment
q p
in
any order or mix.
y Machine
M hi flexibility,
fl ibilit covers the
th system's
t ' ability
bilit to
t be
b
different components.
changed to produce new product types, and ability to

change
h
the
h order
d off operations
i
executed
d on a part.
y Routing
g flexibility,
y which consists of the abilityy to
use multiple machines to perform the same operation
part, as well as the system's
y
abilityy to absorb
on a p
largescale changes, such as in volume, capacity, or
capability.
y Equipment are designed to be flexible or programmable.

y Used for batch production.
FMSComponents
y
Most FMS systems comprise of three main

systems
y
y Work machines (typically automated CNC
machines) that perform a series of operations;
y An integrated material transport system and a
computer that controls the flow of materials,
tools,, and information ((e.g.
g machining
g data
and machine malfunctions) throughout the
system;
y Auxiliary work stations for loading and
unloading,
l d
cleaning,
l
inspection, etc.
FMSGoals
y Reduction in manufacturing cost by lowering direct
labor cost and minimizing scrap, rework, and material

wastage.
t
y Less skilled labor required.
q
y Reduction in workinprocess inventory by eliminating
the need for batch processing.
processing
y Reduction in production lead time permitting
manufacturers to respond more quickly to the variability
of market demand.
y Better process control resulting in consistent quality.
DisadvantagesofFMS
y Limited
to changes
in
or product
Li i d ability
bili to adapt
d
h
i product
d
d
mix (e.g., machines are of limited capacity and the

tooling necessary for products, even of the same family,
is not always
y feasible in a g
given FMS))
y Substantial preplanning activity
y Expensive, costing millions
ll
off dollars
d ll
y Technological
ec o og ca p
problems
ob e s o
of eexact
act co
component
po e t pos
positioning
to g
and precise timing necessary to process a component
y Sophisticated
S hi ti t d manufacturing
f t i systems
t
ReferenceBook
y CAD/CAM:ComputerAidedDesignand
ManufacturingByGroover
y CNCMachines ByB.S.Pabla,M.Adithan
y Machinetooldesignandnumericalcontrol
Machinetooldesignandnumericalcontrol By
Mehta
y ComputerControlOfManu.Systems
C
C
lOfM
S
ByKoren
B K
Page 27
AdvantagesofFMS
y Faster,
lower
costt changes
from
one partt to
F t
l
h
f
t another
th
which will improve capital utilization

y Lower direct labor cost, due to the reduction in number
of workers
y Reduced
inventory, due to the planning and

p g
programming
gp
precision
y Consistent and better quality, due to the automated
control
y Lower cost/unit of output, due to the greater
productivity
d ti it using
i the
th same number
b off workers
k
y Savings from the indirect labor, from reduced errors,
rework, repairs and rejects
Ch 11: NC CNC Robotics

Ch11:NC,CNC,Robotics
Q
Q.No
1
2
3
4
5
6
7
8
p
Option
A
B
A
A
D
A
A
A
Q
Q.No
9
10
11
12
13
14
15
16
17
p
Option
B
D
A
C
D
A
C
B
A
Lathe
BySKMondal
Lathe
h
y A lathe
machine
l th is
i a large
l
hi that
th t rotates
t t the
th work,
k and
d
cutting is done with a nonrotating cutting tool. The

shapes
h
cutt are generally
ll round,
d or helical.
h li l The
Th tool
t l is
i
typically moved parallel to the axis of rotation during
cutting.
tti
y headstock thisendofthelathecontainsthedriving
motorandgears.Powertorotatethepartisdelivered
fromhere.Thistypicallyhasleversthatletthespeeds
andfeedsbeset.
y ways thesearehardenedrailsthatthecarriagerides
on.
y tailstock thiscanbeusedtoholdtheotherendofthe
part.
Lathe
h
Generalclassificationsusedwhendescribinglathes
y Bed
B d this is a bottom pan on the lathe that catches chips,
y Swing
diameter
off work
S i the
h largest
l
di
k that
h can be
b rotated.
d
cutting fluids, etc.
y If n number of spindle
p
speed
p
is required
q
with N1 is the
y Length of Bed Related to the Distance Between
Turning
Th di
Threading
y Turning
T i producesasmoothandstraightoutsideradius
d

h d
i h
id di
onapart.
Centres
y Power The range of speeds and feeds, and the
horsepower
o sepo e ava
available
ab e
y Threading
Th di Thecuttingtoolismovedquicklycutting
Th
i li
d i kl
i
threads.
minimum speed then
N1 , N1r , N1r 2 , N1r 3 ,.............N1r n1

N1 = N min and N1r n1 = N max
1
N n1
Therefore, Step Ratio ( r ) = max
N min
y The values of step ratios are 1.06, 1.12, 1.26, 1.41, 1.58 and 2
workpiece
moves based on the rotation of the lead screw or rod.

rod
y Lead screw A large screw with a few threads per inch used
f cutting
for
i threads.
h d It
I has
h ACME threads
h d with
i h included
i l d d angle
l
of 29o for easy engagement and disengagement of half nut.
y Lead rod a rod with a shaft down the side used for driving
normal cutting
g feeds.
y The critical parameters on the lathe are speed of rotation
(speed in RPM) and how far the tool moves across the work
for each rotation (feed in IPR)
NumberofSpindleSpeed
y Number
N b off spindle
i dl speed
d is
i in
i a geometric
i progression.
i
y Distance Between Centres the longest

g
length
g
of
y carriage this part of the lathe carries the cutting tool and
Page 28
Threading
y Inonerevolutionofthespindle,carriagemusttravel
I
l i f h i dl
i
F i
Facing
y Facing
F i The
Th end
d off the
h part is
i turned
d to be
b square.
thepitchofthescrewthreadtobecut.
N s Pz s = N L Lz L
P = Pitch
Pit h off the
th screw thread
th d to
t be
b cutt
L = Pitch of the lead screw
z s = Number of start of the screw thread to be cut
z L = Number
b off start off the
h lead
l d screw
(N s ) to carriage
icg = g
gear ratio of spindle
p
g (N L ) g
gear train
T
Tapering
i
y Tapering
T
i thetoolismovessoastocutataper(cone
h li

(
Parting/Slotting/Grooving
/ l
/
Drilling/Boring
ll /
y A tooll is
off the
i moved
d in/out
i /
h work.
k shallow
h ll cut will
ill leave
l
y Drilling/Boring
the
D illi /B i a cutter or drill
d ill bit
bi is
i pushed
h d into
i
h
a formed cut, a deep cut will cut off the unsupported

part.
shape).
Knurling
l
Spinning
y Knurling
is
process whereby
K
li
i a manufacturing
f
i
h b a
y Metal
M l Spinning
S i i is
i a process by
b which
hi h circles
i l off metall are
visuallyattractive diamondshaped (crisscross)

pattern is cut or rolled into metal.
y This pattern allows human hands or fingers to get a
better grip on the knurled object than would be
provided by the originallysmooth
originally smooth metal surface.
surface
shaped over mandrels (also called forms) while mounted

on a spinning lathe by the application of levered force
with various tools.
Page 29
end to create an internal feature.
Reamingg
y A reamer enters the workpiece axially through the end
and enlarges an existing hole to the diameter of the

tool Reaming removes a minimal amount of material
tool.
and is often performed after drilling to obtain both a
more accurate diameter and a smoother internal
finish.
WorkholdingDevicesforLathes
k h ld
f
h
pp g
Tapping
y A tap enters the workpiece axially through the end and
cuts internal threads into an existing hole.

hole The
existing hole is typically drilled by the required tap
d ill size
drill
i that
th t will
ill accommodate
d t the
th desired
d i d tap.
t
Lathechucks
h h k
y Lathe
L th chucks
h k are used
d to
t supportt a wider
id variety
i t off
y Held
centers
H ld between
b
y 3 jjaw self centering
g chuck ((Disc type
yp jjobs being
g held
in chucks )
y 4 jaw independently adjusted chuck
y Held in a collet (Slender rod like jobs being held in
collets )
y Mounted on a face plate (Odd shape jobs,
jobs being held
in face plate)
y Mounted
d on the
h carriage
y Mandrels
y Magnetic chuck for thin job
workpiece shapes and to permit more operations to be

performed
f
d than
th can be
b accomplished
li h d when
h the
th work
k is
i
held between centers.
y Threejaw, selfcentering chucks are used for work that
has a round or hexagonal cross section.
y Each jaw in a fourjaw independent chuck can be moved
a d aand
d out
outward
a d independent
depe de t o
of tthee ot
others
e s by means
ea s
inward
of a chuck wrench. Thus they can be used to support a
wide variety of work shapes.
y Combination fourjaw chucks are available in which each
jaw can be moved independently or can be moved
simultaneously by means of a spiral cam.
Turning
Collets
MagneticChuck
4JawChuck
33JawChuck
J
FacePlate
FormulaforTurning
l f
D D2
mm
y Depth
D h off cut, d = DOC = 1
2
y Average diameter of workpiece
Davg =
TurningTapersonLathes
h
D1 + D2
mm
2
y Cutting Time,CT = L + A + O
MRR =
y Cutting Speed, V =
y Usingformtools,
g
y Offsettingthetailstock,and
Offsettingthetailstock and
fN
y Metal Removal Rate
y Usingacompoundslide,
(D
2
1
D 22
4 / fN
)=
D a v g d fN
y Usingtaperturningattachment.
U i t
t
i tt h
t
D1N
,m / min
1000
Page 30
Ui
UsingaCompoundSlide
C
d Slid
ted movement
ove e t o
pou d sslide
de
y Limited
of tthee co
compound
y Feeding is by hand and is nonuniform. This is
responsible
ibl for
f
l
lowproductivity
d ti it and
d poor surface
f
finish.
y Can be employed for turning short internal and
external tapers with a large angle of (steep) taper.
UsingaCompoundSlidecontd..
y The angle is determined by
Offsettingthetailstock
y It
I is
i necessary to measure the
h tailstock
il
k offset
ff when
h using
i
Dd
2l
this method.
y This method is limited to small tapers (Not exceeding 8o
) over long lengths.
lengths
y By offsetting the tailstock, the axis of rotation of the job
is inclined
l d by
b the
h half
h lf angle
l off taper.
Formtooll
T
TaperTurningAttachment
T i A
h
y Special
tooll for
S i l form
f
f generating
i the
h tapers is
i used.
d The
Th
y Additional
is
Addi i
l equipment
i
i attached
h d at the
h rear off the
h lathe.
l h
tan =
= Half taper angle
D = Diameter of stock
d = smaller diameter
l = length of the taper
feed is given by plunging the tool directly into the work.

This method is useful for short external tapers, where
the steepness
p
is of no consequence,
q
, such as for
chamfering.
Errorsintoolsettings
l
y Tailstock
T il
k offset
ff (h) can be
b determined
d
i d by
b
h=
L(D d )
or h = L tan
2l
y The cross slide is disconnected from the cross feed nut.

y The cross slide is then connected to the attachment.
y As
A the
h carriage
i
i engaged,
is
d and
d travels
l along
l
the
h bed,
b d the
h
attachment will cause the cutter to move in/out to cut

the taper.
y For turning tapers over a comprehensive range is the use
of taper turning attachment.
TurretLathe
h
A turret lathe,
l h a number
b off tools
l can be
b set up on the
h
machine and then quickly be brought successively into
working position so that a complete part can be
machined without the necessityy for further adjusting,
j
g,
changing tools, or making measurements.
y Setting the tool below the centre decrease actual rake angle,
while clearance angle increases by the same amount. Thus

cutting force increased.
increased
y Setting the tool above the centre causes the rake angle to
increase while
increase,
hile clearance angle reduces.
reduces More rubbing with
ith
flank.
OffsettingthetailstockContd..
Page 31
Turret Lathe
TurretLathe
Capstan Lathe
CapstanLathe
Capstan lathe
Turret lathe
Sh t slide,
lid since
i
th saddle
ddl iis Saddle
S ddl moves along
l
th bed,
b d
Short
the
the
clamped on the bed in position.
thus allowing the turret to be of
large size.
size
Light duty machine, generally for Heavy duty machine, generally
components whose diameter is for components with large
less than 50 mm.
diameters, such as 200 mm.
Too much overhang of the turret Since the turret slides on the
when it is nearing cut.
bed, there is no such difference.
Ramtype turret lathe, the ram and
the turret are moved up to the
cutting position by means of the
capstan Wheel.
Wheel As the ram is
moved toward the headstock, the
turret is automatically locked into
position.
AutomaticLathe
h
y The
Th term automatic
i is
i somewhat
h loosely
l
l applied,
li d but
b is
i
normally restricted to those machine tools capable of

producing identical pieces without the attention of an
operator,
p
, after each p
piece is completed.
p
Thus,, after
setting up and providing an initial supply of material,
further attention beyond replenishing the material
supply is not required until the dimensions of the work
pieces
i
change
h
owing
i to
t tool
t l wear.
y A number of types
yp of automatic lathes are developed
p
that can be used for large volume manufacture
application, such as single spindle automatics, Swiss type
automatics, and multispindle automatics.
MultiSpindleAutomaticLathe
Saddletype lathes, the main

turret is mounted directly on the
saddle, and the entire saddle
and
turret
assembly
reciprocates.
Turretindexingmechanism
y The hexagonal turret is rotated (for indexing) by a
Geneva mechanism where a Geneva disc having six

radial
di l slots
l
i driven
is
di
b a revolving
by
l i pin.
i Before
B f
starting
i
rotation the locking pin is withdrawn by a cam lever
rotation,
mechanism. The single
g rotation of the disc holding
g the
indexing pin is derived from the auxiliary shaft with the
help of another single revolution clutch as indicated.
y For automatic lathe: Ratchet and Pawl mechanism
SwisstypeAutomaticLatheOrSlidingHeadstockAutomatics
y Headstock travels enabling axial feed of the bar stock
against the cutting tools.

y There
h
is no tailstock
l
k or turret
y High spindle speed (2000 10,000 rpm) for small job
diameter
y The
Th cutting
tti tools
t l (upto
( t five
fi in
i number
b including
i l di two
t
on
the rocker arm) are fed radially
y Used for lot or mass production of thin slender rod or
tubular jobs, like components of small clocks and wrist
watches, by precision machining.
N
NortontypeTumblergearquickchangeGearbox
T bl
i k h
G
b
NortontypeTumblergearquickchangeGearbox
y It comprises
i a cone off gears 1 to
t 8 mounted
t d on shaft
h ft S2.
S
y For increase in rate of production of jobs usually of
y The tumbler gear can slide on shaft S1. It can mesh with any
smaller
ll size
i and
d simpler
i l geometry.
t
gear on shaft S2 through an intermediate gear which is
y Having four to eight parallel spindles are preferably used.

used
located on a swinging and sliding lever so that it can engage
y Multiple spindle automats also may be parallel action or
gears 1 to
t 8 off different
diff
t diameters,
di
t
on shaft
h ft S2.
S
progressively
p
g
y working
g type.
yp
y The lever can be fixed in any desired ratio position with the
help of a stop pin.

y The drive is usually from the driving shaft S1 to the driven
shaft S2.
Page 32
Ch 2:Lathe
Q. No
Option
Q. No
Option
10
TYPESOFDRILLPRESSES
Drilling
Drilling
ll
y Drilling
D illi is
i a operation
i that
h cuts cylindrical
li d i l holes.
h l
B SKM d l
BySKMondal
DrillingOperations
ll
Chip formation
of a drill
y Verticalorpillartype
y RadialArmtype
y Gangdrill
y MultiSpindledrill
y NumericalControldrill
N
i lC
ld ill
Drill
y The twist drill does most of the cutting with the tip of
Drillll
the
th bit.
bit
There are flutes
to carry the chips
up
from
the
cutting edges to
the top of the
hole where they
are castt off.
ff
Drillll
y Axial rake angle is the angle between the face and the line
parallel to the drill axis.

axis At the periphery of the drill,
drill it is
equivalent to the helix angle.
y The lip clearance angle is the angle formed by the portion of
the flank adjacent to the land and a plane at right angles to

the drill axis measured at the periphery of the drill.
drill
y Lead of the helix is the distance measured p
parallel to the drill
axis, between corresponding point on the leading edge of the

Page 33
land in one complete revolution.
Drillll
PointAngle(2)
g is selected to suit the hardness and brittleness of

y The p
point angle
y Drill sizes are typically measured across the drill points with
the material being drilled.

y Harder materials have higher
g
point angles,
p
g , soft materials have
a micrometer
i
t
lower point angles.
y Most widely used material is High Speed Steel

y The
ed
drill b
blanks
a s aaree made
ade by forging
o g g aand
d tthen
e aaree ttwisted
sted to
y An increase in the drill p

point angle
g leads to an increase in the
provide the torsional rigidity. Then the flutes are machined

and hardened before the final grinding of the geometry.
y Deep hole drilling requires special precautions to take care of
th removall off large

the
l
volume
l
off chips.
hi
y
y
y
y
y
thrust force and a decrease in the torque due to increase of the

orthogonal rake angle.
This angle (half)
(
) refers to side cutting edge angle of a single point
tool.
S d d Point
Standard
P i Angle
A l is
i 118
8
It is 116 to 118 for medium hard steel and cast iron
It is 125 for hardened steel
It is 130 to 140 for brass and bronze
It is only 60 for wood and plastics
C i S
CuttingSpeedinDrilling
d i D illi
y Thecuttingspeedindrillingisthesurfacespeedofthe
Th
i
di d illi i h f
d f h
twistdrill.
V=
DN
1000
m / min
DrillingTime
ll
y Time
for
Ti
f drilling
d illi the
h hole
h l
T=
HelixAngle()
y Helix angle is the angle between the leading edge of the
land and the axis of the drill. Sometimes it is also called

as spiral
i l angle.
l
y The helix results in a p
positive cutting
g rake
y This angle is equivalent to back rake angle of a single
point cutting tool.
tool
y Usual 20 to 35 most common
y Large helix : 45 to 60 suitable for deep holes and softer
work materials
y Small helix : for harder / stronger materials
y Zero helix : spade drills for high production drilling
microdrilling and hard work materials
MRRinDrilling
ll
D2
3
MRR =
fN , mm / min
4
L
, min
fN
S
SomeFormulaeforDrilling
F
l f D illi
Cone height (h) =
D
2 tan
Uncut chip thickness (t ) =
f
sin
2
D
Width of cut (b) =
2sin
Reaming,Boring,Broaching
( 2r / D ) tan
O th
Orthogonal
l rake
k angle
l ( ) = tan
t 1
sin
BySKMondal
Page 34
Reaming
Reaming
Reamer
y Reaming
removes a small
the
R
i
ll amountt off material
t i l from
f
th
surface of holes.
y It
I is
i done
d
f two purposes: to bring
for
b i holes
h l to a more exact
size and to improve the finish of an existing hole.

y Multiage
M li
cutting
i
tools
l that
h has
h many flutes,
fl
which
hi h may be
b
straight or in a helix are used.

y No special machines are built for reaming. The same
machine that was employed for drilling the hole can be used
f reaming
for
i by
b changing
h
i the
h cutting
i tool.
l
y Only a minimum amount of materials should be left for
removall by
b reaming. As little
l l as 0.1 mm is desirable,
d
bl and
d in
no case should the amount exceed 0.4 mm.
y A properly reamed hole will be within 0.025 mm of the
correct size and have a fine finish.
Reamer Flutes
ReamerFlutes
y The reamer flutes are either straight or helical.
y The helical flutes promote smoother cutting and should be
y
y
used specifically for holes that are not continuous, such as

those with keyways parallel to the axis of the hole.
The cutting
g action of the helical flutes is smoother and helps
in preventing chatter.
The reamers are termed as left hand or right
g
hand,,
depending upon the direction in which they are moved,
looking from the shank to the cutting portion.
The righthand reamer with righthand helix is used for
g g cuts, since the tool tends to g
go into the workpiece
p
roughing
more efficiently and thereby promotes the material removal.
A righthand
g
reamer with lefthand flutes is used for
finishing cuts.
Reaming
y Reamers,
like
dull.
R
lik drills,
d ill should
h ld nott be
b allowed
ll
d to
t become
b
d ll
The chamfer must be reground long before it exhibits

excessive wear.
wear Sharpening is usually restricted to the
starting taper or chamfer. Each flute must be ground exactly
evenly or the tool will cut oversize.
oversize
y Reamers tend to chatter when not held securely, when the
work or work holder is loose,
loose or when the reamer is not
properly ground.
y Irregularly spaced teeth may help reduce chatter.
chatter Other cures
for chatter in reaming are to reduce the speed, vary the feed
rate chamfer the hole opening,
rate,
opening use a piloted reamer,
reamer reduce
the relief angle on the chamfer, or change the cutting fluid.
y Any misalignment between the work piece and the reamer
will cause chatter and improper reaming.
TypesofReamers
f
Theprincipaltypesofreamersare:
Th i i l
f
1. Handreamers
a.
Straight
b
b.
T
Taper
g
2. Machineorchuckingreamers
a.
Rose
b
b.
Fluted
l d
3. Shellreamers
4. Expansionreamers
5. Adjustablereamers
RoseReamer
Rose Reamer
Rose chucking reamers
are ground cylindrical
and have no relief
behind the outer edges
off the
h teeth.
h All cutting
i
is done on the beveled
ends of the teeth
Page 35
Reaming
y To
including
T meet quality
li requirements,
i
i l di both
b h finish
fi i h and
d
accuracy (tolerances on diameter,

roundness,
straightness, and absence of bellmouth at ends of
holes).
) Reamers must have adequate
q
support
pp
for the
cutting edges, and reamer deflection must be minimal.
y Reaming speed is usually
usuall twothirds
t o thirds the speed for
drilling the same materials. However, for close tolerances
and
d fine
f
f
finish,
h speeds
d should
h ld be
b slower.
l
y Feeds are usually much higher than those for drilling
and depend upon material.
y Recommended
R
d d cutting
tti fluids
fl id are the
th same as those
th
f
for
drilling.
ChuckingReamer
Chucking Reamer
Fluted
chucking
reamers have relief
behind the edges of the
teeth as well as beveled
ends.
d They
Th can cut on
all portions of the teeth.
Their
flutes
are
relativelyy short and theyy
are intended for light
finishing cuts.
cuts
Boring
g
Trepanning
p
g
ShellReamer
Shell Reamer
Shell reamers often are
used for sizes over 20
mm to save cuttingtool
cutting tool
material. The shell,
made
d off HSS for
f smaller
ll
sizes and with carbide
edges for larger sizes or
for
massproduction
p
work.
y Trepanning is a annular groove producing operation
which leaves a solid cylindrical core in the centre.

centre In
trepanning a cutter consisting of one or more cutting
edges placed along the circumference of a circle is used
to produce the annular groove.
TrepanningTool
B i
Boring
Boring
y Boring
always
involves
the
off an existing
hole,
B i
l
i
l
h enlarging
l i
i i
h l
y The
Th same principles
i i l are used
d for
f boring
b i as for
f turning.
i
which may have been made by a drill or may be the result of a

core in a casting.
y An equally
q
y important
p
and concurrent p
purpose
p
of boring
g mayy
be to make the hole concentric with the axis of rotation of
the workpiece
p
and thus correct anyy eccentricityy that mayy
have resulted from the drill drifting off the centerline.
Concentricity is an important attribute of bored holes.
y When boring is done in a lathe, the work usually is held in a
chuck or on a faceplate.
faceplate Holes may be bored straight,
straight
tapered, or to irregular contours.
y Boring is essentially
ll internall turning while
h l feeding
f d
the
h tooll
parallel to the rotation axis of the workpiece.
y The tool should be set exactly

y at the same height
g as the
Boring
axis of rotation. Slightly larger end clearance angles

sometimes have to be used to prevent the heel of the tool
from rubbing on the inner surface of the hole.
FormulaforBoring
l f
y Because
the
will
B
h tooll overhang
h
ill be
b greater, feeds
f d and
d
depths of cut may be somewhat less than for turning to

prevent tool vibration and chatter.
y In some cases,
cases the boring bar may be made of tungsten
carbide because of this material's greater stiffness.
y The
h boring
b
tooll is a singlepoint
l
cutting tool.
l
y Hole
o e qua
quality,
ty, finish
s bo
boring
g ca
can typ
typically
ca y ac
achieve
eve holes
o es
within tolerances of IT9.
y Surface
S f
fi i h better
finishes
b tt than
th Ra
R 1 micron
i
can be
b achieved.
hi d
y Average diameter of workpiece
Davg =
D1 + D2
mm
2
Broaching
y Cutting Time, CT = L + A + O
fN
y Metal Removal Rate

MRR =
(D
2
1
D 22
4 / fN
Page 36
)=
D a v g d fN
B
Broaching
hi
Broaching
y Broaching
B
hi is
i a multipletooth
lti l t th cutting
tti operation
ti with
ith the
th
y The
Th material
i l removall using
i the
h broach
b
h teeth
h is
i shown
h
tool reciprocating.
y Since in broaching the machining operation is
completed in a singlestroke as the teeth on the cutting
tool, called broach, are at gradually increasing height
corresponding to the feed per tooth of a milling cutter.
y The shape of the broach determines the shape of the
ac ed pa
part.
t.
machined
y Broaching was originally developed for machining
internal keyways,
keyways but looking at the advantages,
advantages it has
been extensively used in the mass production of
automobile component manufacture for various other
surfaces as well.
BroachConstruction
h
schematically in Fig. shown in below. The dotted line in

the figure indicates the amount of material being
removed byy successive individual teeth.
BroachConstruction
h
BroachConstruction
h
BroachConstruction
h
y The
Th broach
b
h is
i composed
d off a series
i off teeth,
h each
h tooth
h
y The
Th last
l set off teeth
h is
i called
ll d the
h finishing
fi i hi or sizing
i i teeth.
h
y The
the
Th rear pilot
il helps
h l to keep
k
h broach
b
h to remain
i square
standing slightly higher than the previous one. This rise

per tooth is the feed per tooth and determines the
material removed byy the tooth.
y There are basically three sets of teeth present in a broach
as shown
sho n in Fig.
Fig shown
sho n above.
abo e
y The roughing teeth that have the highest rise per tooth
remove bulk of the material.
y The semifinishing teeth,
teeth whose rise per tooth is smaller,
smaller
remove relatively smaller amounts of material compared
t the
to
th roughing
hi teeth.
t th
Very little material will be removed by these teeth.

y The necessary size will be achieved by these teeth and
hence all the teeth will be of the same size as that
required finally. With the progress of time, when the
first set of teeth wear
ear out,
out the next
ne t set of teeth will
ill be
able to provide the sizing function.
y The pull end of the broach (Fig. shown in above) is
attached to the pulling mechanism of the broaching
machine with the front pilot aligning the broach
properly with respect to the workpiece axis before the
actual cutting starts.
with the workpiece as it leaves the workpiece after

broaching.
y Broaching speeds are relatively low,
low of the order of 6 to 15
m/min. However, the production rate is high with the
c cle times being about 5 to 30 seconds,
cycle
seconds including the
workpiece and tool handling times. The low cutting
speeds
d are conducive
d
to very high
h h tooll life
l f with
h very
small tool wear rates.
BroachConstruction
h
BroachConstruction
h
y Broaches
B
h are generally
ll made
d off high
hi h speed
d steell in
i view
i
of its high impact strength. Sometimes, the titanium

nitride coating helps to improve the tool life further.
Also,, the carbide inserttype
yp broaches are used more for
surface broaching of cast iron for very large volume
production to reduce the frequent resharpening of the
broach, which is a very difficult operation.
y Standard
d d broaches
b
h are available
l bl for
f common and
d more
often used forms, such as round and square
q
holes,
keyways, etc.
y For
it
two or
F smooth
h operation,
i
i is
i essential
i l that
h at least
l
three teeth be simultaneously engaged.

y The thumb rule for tooth spacing, s =1.75 l , mm
y The cut per tooth f is kept in the range 0.05
0 05 mm 0.09
0 09
mm.
y In the normal speed BUE may be a problem. To avoid
tthiss a cop
copious
ous supp
supplyy o
of tthee cutt
cutting
g fluid
u d iss p
provided.
ov ded.
Page 37
Advantagesofbroaching
d
fb
h
1.
1 It is the fastest way of finishing an operation with a single
stroke.
2 Since all the machining parameters are built into the
2.
broach, very little skill is required from the operator.
3 Broaching machine is simple since only a single
3.
reciprocating motion is required for cutting.
4. Final cost of the machining
4
g operation
p
is one of the lowest
for mass production.
55. Anyy type
yp of surface, internal or external, can be g
generated
with broaching.
6. Many surfaces, which are very difficult or impossible by
other
h means, can be
b done
d
b broaching.
by
b
hi
F example,
For
l square
hole and internal splines.
7. Good
G d surface
f
fi i h and
finish
d fine
fi dimensional
di
i
l tolerances
t l
can be
b
achieved by broaching, often better than boring or reaming
Limitationsofbroaching
fb
h
1. Custom
made
C t
d broaches
b
h are very expensive
i and
d can
therefore be justified only for very large volume
production.
d ti
2. A broach has to be designed for a specific application
and can be used only for that application. Hence, the
lead time for manufacture is more for custom designed
broaches.
3. Broaching,
oac g, be
being
g a ve
veryy heavy
eavy metal
eta removal
e ova
operation, requires that the workpiece is rigid and
capable of withstanding the large forces.
4. Broaching can only be carried out on the workpiece
whose geometry is such that there is no interference for
the broach movement for the cutting.
Ch6:Drilling,Boring&Reaming
Q.No
1
2
3
4
5
6
7
Option
A
D
A
B
C
B
D
Q.No
8
9
10
11
12
13
Option
D
A
B
C
C
B
Milling
ll
Milling
ll
Milling
machines
off various
types are widely
Milli
hi
i
id l used
d
for the following purposes using proper cutting
tools called milling cutters:
y Flat surface in vertical,
vertical horizontal and inclined planes
y Making slots or ribs of various sections
y Slitting or parting
y Often producing surfaces of revolution
y Making helical grooves like flutes of the drills
y Long thread milling on large lead screws, power screws,
worms etc and short thread milling for small size
fastening screws, bolts etc.
y 2D contouring like cam profiles, clutches etc and 3D
Upmillinganddownmilling
ll
dd
ll
AdvantagesofDownMilling
d
f
ll
y In
milling,
though
I down
d
illi
h
h the
h cut starts with
i h a full
f ll chip
hi
thickness, the cut gradually reduces to zero. This helps in

eliminating the feed marks present in the case of up
milling
g and consequently
q
y better surface finish.
y Climb milling also allows greater feeds per tooth and
longer cutting life between
bet een regrinds than the
conventional milling.
y Up milling needs stronger holding of the job and down
milling needs backlash free screw
screwnut
nut systems for
feeding.
Milling
BySKMondal
Upmillinganddownmilling
contouring like
l k die
d or mould
ld cavities
y Cutting
C i teeth
h in
i piece
i
or batch
b h production
d i off spur gears,
straight toothed bevel gears,

gears worm wheels,
wheels sprockets,
sprockets
clutches etc.
y Producing
g some salient features like g
grooves, flutes,
gushing and profiles in various cutting tools, e.g., drills,

taps, reamers, hobs, gear shaping cutters etc.
1. Suited
S i d to machine
hi thin
hi and
d hardtohold
h d
h ld parts since
i
the workpiece is forced against the table or holding
device by the cutter.
2 Work need not be clamped as tightly.
2.
tightly
3. Consistent parallelism and size may be maintained,
particularly
l l on thin
h parts.
4. Itt may
ay be used where
ee b
breakout
ea out at tthee edge o
of tthee
workpiece could not be tolerated.
5. It requires
i upto
t 20%
% less
l
power to
t cutt by
b this
thi method.
th d
g off stock or when milling
g
6. It mayy be used when cutting
deep, thin slots.
Page 38
DisadvantagesofDownMilling
d
f
ll
1. It cannot be used unless the machine has a backlash
eliminator and the table jibs have been tightened.
2 It cannot be used for machining castings or hot rolled
2.
steel since the hard outer scale will damage the cutter.
steel,
cutter
Classificationofmillingmachines
l
f
f ll
h
Classificationofmillingmachines
l
f
f ll
h
Classificationsofmillingcutters
l
f
f ll
(a)
( ) According
A
di to nature off purposes off use:
y
General purpose
p p
y
Single purpose
y
S
Special
i l purpose
((b)) According
g to configuration
g
and motion of the
workholding table / bed
y
K
Knee
t
type
y
Bed type
yp
y
Planer type
y
R t
Rotary
t bl type
table
t
(c)
( ) According
A
di to
t the
th orientation
i t ti off the
th spindle(s).
i dl ( )
y Plain horizontal knee type
y Horizontal axis (spindle) and swiveling bed type
y Vertical spindle
p
type
yp
y Universal head milling machine
(d) According to mechanization / automation and
production rate
y Hand mill (milling machine)
y Planer and rotary table type vertical axis milling machines
y Tracer
T
controlled
ll d copy milling
illi machine,
hi
y Milling machines for short thread milling
y Computer Numerical Controlled (CNC) milling machine
(a)
the
( ) Profile
P fil sharpened
h
d cutters where
h
h geometry off
the machined surfaces are not related with the tool
shape, viz;
i
i.
Slab or plain milling cutter: straight or helical
fluted
ii. Side
S d milling
ll
cutters single
l side
d or both
b h sided
d d type
Slotting
ott g cutte
cutter
iii.. S
iv. Slitting or parting tools
v. End
d milling
ll
cutters with
h straight
h or taper shank
h k
vi. Face milling cutters.
Classificationsofmillingcutters
l
f
f ll
SlaborPlainmillingcutters
l b
l
ll
Sideandslotmillingcutters
d
d l
ll
EndmillingcuttersorEndmills
d ll
d ll
Facemillingcutters
ll
(b) Form
relieved
the
F
li
d cutters where
h
h job
j b profile
fil
becomes the replica of the
Toolform, e.g., viz.;
i
i.
Form cutters
ii. Gear (teeth) milling cutters
iii. Spline shaft cutters
i
iv.
T l form
Tool
f
cutters
tt
v. Tslotcutters
vi. Threadmillingcutter
Slittingsaworpartingtool
l
l
Page 39
T slotcutter
l
Useofformrelievedcutters(milling)
Toolformcutters
Gearteethmillingcutters
h ll
Spline
l
shaftcutters
h f
Straddlemilling
ddl
ll
Gangmilling
ll
Turningbyrotarytools(millingcutters)
Indexing
d
Page 40
SimpleorPlainIndexing
l
l
d
MillingVelocity
ll
l
y Plain
to the
Pl i indexing
i d i is
i the
h name given
i
h indexing
i d i method
h d
y The
speed
Th cutting
i speed
d in
i milling
illi is
i the
h surface
f
d off the
h
carried out using any of the indexing plates in

conjunction with the worm.
MRRinMilling
ll
Consideringtheparametersdefinedinthediscussionof
C
id i h
d fi di h di
i f
speedsandfeeds,etc,theMRRisgivenbelow,
Where,
milling cutter.
V=
y Time for one p

pass =
DN
1000
Some Formulae for Milling

SomeFormulaeforMilling
Maximum uncut chip thickness (t max ) =
d=depthofcut
2f
NZ
d
D
d
D
f2
Peak to valley surface roughness (h max ) =
4 DN 2 Z 2
4DN
ManufactureofGears
f
f
GearManufacturing
g
Manufacture of gears needs several processing operations in

sequential stages depending upon the material and type of the
gears and q
g
qualityy desired. Those stages
g g
generallyy are:
D D
A = d = d (D d )
2 2
Ch 7 Milli
Ch7:Milling
QNo
Option
Q.No
Option
10
11
12
FormingandGeneration
d
Gear teeth are produced by machining based on
y Preforming the blank without or with teeth

y Annealing
g of the blank,, if required,
q
, as in case of forged
g or
Forming where the profile of the teeth are obtained as
y Preparation of the gear blank to the required dimensions
milling, broaching etc.
cast steels
BySKMondal
L + 2 A minutes
fZN
2
y Approach
A
h distance,
di
f
A
Average
uncut chip
hi thickness
hi k
((t a vg ) =
NZ
wd F
MRR =
where,w=widthofcut,
MillingTime
ll
by machining
b
h
y Producing teeth or finishing the preformed teeth by
machining
hi i
y Full or surface hardening of the machined gear (teeth), if
required
y Finishing teeth, if required, by shaving, grinding etc
y Inspection
I
ti off the
th finished
fi i h d gears
Page 41
the replica of the form of the cutting tool (edge); e.g.,

eg
Generation where the complicated

p
tooth p
profile are
provided by much simpler form cutting tool (edges)
through rolling type, tool work motions, e.g., hobbing,
gear shaping etc.
Sunderlandmethodusingracktypecutter
Sunderlandmethodusingracktypecutter
Gearshaping
h
y The
rake
Th rack
k type HSS cutter (having
(h i
k and
d
y Applicationsofthismethod(andmachine)include:
y Gear
shaping
G
h i is
i similar
i il to the
h rack
k type cutting
i process,
clearance angles) reciprocates to accomplish the

machining (cutting) action while rolling type
i t
interaction
ti with
ith the
th gear blank
bl k like
lik a pair
i off rack
k
and pinion.
p
y Moderatesizestraightandhelicaltoothedexternal
spurgearswithhighaccuracyandfinish
i hhi h
dfi i h
excepting that, the linear type rack cutter is replaced by a

circular cutter where both the cutter and the blank
rotate as a p
pair of spur
p
gears in addition to the
g
reciprocation of the cutter.
y Cuttingtheteethofdoublehelicalorherringbone
C tti th t th fd bl h li l h i b
gearswithacentralrecess(groove)
y Cuttingteethofstraightorhelicalflutedclustergears
y Howeverthismethodneeds,thoughautomatic,few
,
g
,
External gear teeth generation by rack type cutter (Sunderland method)
indexingoperations.
Gearshaping
h
GearHobbing
bb
y Generation
method
G
ti
th d is
i characterised
h
t i d by
b automatic
t
ti indexing
i d i
y The HSS or carbide cutter having teeth like gear milling
and ability of a single cutter to cover the entire range of

number of teeth for a given combination of module and
pressure angle and hence provides high productivity and
economy.
economy
y The gear type cutter is made of HSS and possesses proper
rake and clearance angles.
angles
y The additional advantages of gear shaping over rack type
cutting are:
Separate indexing is not required at all
Straight
h or helical
h l l teeth
h off both
b h externall and
d internall
spur gears can be produced with high accuracy and
fi i h
finish
Productivity is also higher.
AdvantagesofGearHobbing
d
f
bb
(a)
( ) The
Th method
h d is
i versatile
il and
d can generate spur,
helical, worm and worm wheels.
(b) Since gear hobbing is a continuous process, it is
rapid; economical and highly productive.
productive
(c) The method produces accurate gears and is suitable
f medium
for
d
and
d large
l
b h production.
batch
d
(d) Thee cutte
cutter iss u
universal,
ve sa , because itt ca
can cut aall gea
gearss o
of
same module, irrespective of number of teeth on the
gear.
gear
cutter and the gear blank apparently interact like a pair

of worm and worm wheel.
wheel
y The hob (cutter) looks and behaves like a single or
multiple start worms.
worms
y Having lesser number (only three) of tool work
motions, hobbing
h bb
machines
h
are much
h more rigid,
d strong
and productive than gear shaping machine.
machine
y But hobbing provides lesser accuracy and finish and is
used onlyy for cutting

g straight
g or helical teeth ((single)
g ) of
external spur gears and worm wheels.
(a)Straight(b)helicaltoothand(c)wormwheel
DisadvantagesofgearHobbing
d
f
bb
(a) Gear hobbing cannot generate internal gears and
bevel gears.
(b) Enough space has to be there in component
configuration for hob approach.
Milling
ll
y Gear
teeth
G
t th can be
b produced
d d by
b both
b th disc
di and
d end
d mill
ill type
t
form milling cutter.
ApplicationsofHobbing
y The gears produced by gear hobbing are used in
automobiles, machine tools, various instruments, clocks

and
d other
h equipments.
i
GearHobbing
bb
Page 42
Fi
Fig.
( ) disc
(a)
di type and
d end
d mill
ill type for
f
(b) single helical and
(c) double helical teeth
Milling
ll
Shaping,PlanningandSlotting
h
l
d l
Production
off gear teeth
milling
are characterised
P d ti
t th by
b form
f
illi
h
t i d
by:
y Use
U off HSS form
f
milling
illi cutters
y Use of ordinary milling machines
y Low production rate for
y Straight
S i h toothed
h d spur gear can be
b produced
d d in
i shaping
h i
Need of indexing after machining each tooth gap

Slow speed and feed
y Low
L accuracy and
d surface
f
fi i h
finish
y Inventory problem due to need of a set of eight cutters for
each
h module
d l pressure angle
l combination
bi ti
machine.
y Both productivity and product quality are very low in
this process which therefore,

therefore is used,
used if at all,
all for making
one or few teeth on one or two pieces of gears as and
when
hen required for repair and maintenance purpose.
purpose
y Planning and slotting machines work on the same
principle. Planning machine is used for making teeth of
large gears whereas slotting for internal gears.
y End mill type cutters are used for teeth of large gears and / or
module.
d l
Fig gearteethcuttinginordinaryshapingmachine
Fastproductionofteethofspurgears
Parallel
teeth
P ll l multiple
li l
h
shaping
y It is similar to ordinary
shaping but all the tooth gaps
are made simultaneously,
without
ithout requiring indexing,
inde ing
by a set of radially in feeding
single
l point form
f
tools.
l
y This old process was highly
productive but became almost
obsolete for very high initial
and running costs.
Fastproductionofteethofspurgears
Manufactureofgearsbyrolling
Broaching
B
hi
y Teeth of small internal and external spur
p g
gears;; straight
g
or single helical, of relatively softer materials are
produced in large quantity by broaching.
broaching
y This method leads to very high productivity and quality
b cost off machine
but
h
and
d broach
b
h are very high.
h h
y The
Th straight
i h and
d helical
h li l teeth
h off disc
di or rod
d type externall
P d M ll
PowderMetallurgy
steel gears of small to medium diameter and module are

generated by cold rolling by either flat dies or circular
dies.
y Such rolling imparts high accuracy and surface integrity
of the teeth which
hich are formed by
b material flow
flo unlike
cutting.
y Gear rolling is reasonably employed for high productivity
and high quality though initial machinery costs are
relatively high.
y Larger
L
size
i gears are formed
f
d by
b hot
h t rolling
lli
and
d then
th
finished by machining.
Wi EDM
WireEDM
y Small
S ll size
i high
hi h quality
li externall or internal
i
l spur, bevel
b l or
y Geometrically
G
i ll accurate but
b moderately
d
l finished
fi i h d straight
i h
spiral gears are also produced by powder metallurgy

process.
y Large size gears are rolled after briquetting and sintering
for more strength and life.
y Powder
d metallurgically
ll
ll produced
d d gears hardly
h dl require
any further finishing work.
toothed metallic spur gears, both external and internal

type, can be produced by wire type Electrodischarge
Machining
g ((EDM).
)
Page 43
C i
Casting
y BlankinginPresstool
y Sandcasting
S d
i
y Plasticmoulding
y Diecasting
y Extrusionprocess
Gearfinishingprocess
f h
y One
O off the
th goals
l off the
th gear finishing
fi i hi process in
i gears is
i
to obtain a certain level of toughness in the gear teeth to

reduce
d
and/or
d/ eliminate
li i t bending
b di
and
d contact
t t fatigue
f ti
failures.
y Reduction of index undulation errors associated with
helical gear teeth caused by the grinding process during
the manufacture of the gears without degrading other
gear accuracies (e.g. profile, tooth spacing) below levels
required for precision (AGMA16 or DIN1) gears.
y A mold of the space between several gear teeth is
obtained, with the mold having a length equal to or
greater than the wavelength of the undulation error to be
reduced.
y Metalmouldcasting
g
y Investmentcasting
I
i
y Shellmouldcasting
g
y Centrifugalcasting
Gearshaving
h
y A micro
finishing
film
i
fi i hi
fil is
i affixed
ffi d to the
h mold
ld and
d the
h
mold is placed relative to a gear tooth so that the micro

finishing film rests against a tooth surface having the
undulation error.
y The grit size of the micro finishing film is such as to
remo e approximately
remove
appro imatel 2 to 3 millionths of gear material
with each pass through the teeth by the mold. Multiple
passes are made
d by
b hand
h d untill the
h undulation
d l
error is
reduced to an acceptable
p
value. During
g the p
process the
micro finishing film is replaced after approximately 3 or
4 passes and the process is repeated for each tooth of the
gear.
GearLapping
y Gear lapping is used to finish hardened gears by
correcting
ti
small
ll errors in
i spacing,
i
profile,
fil helix
h li
angle and eccentricity.
angle,
eccentricity
y The operation is performed with all forms of gears
running together with mating gears, and cast iron

toothed laps, under a flow of fine oil mixed with
an abrasive compound.
Gearburnishing
b
h
y Gear
shaving
is
operation
with
G
h i
i a gear finishing
fi i hi
ti
ith high
hi h
efficiency and high precision.

y When a work gear has been shaved by a shaving cutter
with a true involute profile, the ''midconcave''
phenomena inevitably exist around the pitch points of
the work gear tooth flanks.
y Aiming at this problem, a newstyle shaving cutter with
unequal
u
equa dept
depth gas
gashes
es iss des
designed
g ed aand
d manufactured.
a u actu ed.
y This paper analyses the forming of the gash on the basis
of the slotting principle,
principle and proposes a gashdesigning
method.
y Experiment
E
i
t has
h proven that
th t the
th shaved
h d gear has
h a better
b tt
surface finish that achieves the anticipated effect.
y It is designed to remove or reduce gear tooth nicks and
burrs, along with improving the smoothness of the

tooth's active profile finish.
y The action of the burnishing dies on the tooth surface
allows the machine to accomplish these quality

improvements without altering the tooth profile or lead.
y Both internal and external gears are possible to burnish.
Ch8:GearandScrewthreadManufacturing
Q.No
1
2
3
4
5
6
7
Option
A
B
C
D
C
A
D
Q.No
8
9
10
11
12
13
Page 44
Option
D
C
C
D
B
D
ScrewThread
Manufacturing
BySKMondal
,
Processes,MachinesandTools
UsedForProducingScrewThreads
( )
(a)Machining
g
( )
(b)Rolling
g
(c)Grinding
g
Thread Cutting
ThreadCutting
External
Internal
Threading on a lathe
Threading
h di on a NC lathe
l h
With a die held in a stock
(manual)
With an automatic die
(turret lathe or screw
machine) or NC lathe
By milling
By
B Grinding
G i di
Threading (on a lathe or

NC lathe)
l h )
With a tap and holder
(manual NC, machine,
semiautomatic,
or
automatic)
With a collapsible tap
(turret
lathe,
screw
machine,
hi
or
special
i l
threading machine)
By milling
CuttingThreadswithDies
ThreadTapping
h d
y Straight and tapered external threads can be cut quickly
y Cutting internal thread by a multiplepoint

multiple point tool is called
manually by means of threading dies.

y Dies are made of carbon or highspeed tool steel
thread tapping, and the tool is called a tap.

y A hole of diameter slightly larger than the minor
diameter of the thread must alreadyy exist.
( )S lid h di di (b) lid dj

(a)Solidthreadingdie;(b)solidadjustablethreadingdie
bl h di di
y Grinding
ThreadGrinding
can produce
very accurate threads, and
it also permits threads to
be produced in hardened
materials.
materials
y A singleribbed grinding
wheel is employed,
employed but
multipleribbed
wheels
are used occasionally.
occasionally
y Centerless
thread
grinding
i di
i
is
used
d for
f
making headless sets
screws.
The flutes on tap create cutting

edges
d
on the
h thread
h d profile
f l and
d
provide space
p
p
for the chips
p and
the passage of cutting fluid.
Taps are made of either carbon
or highspeed steel and coated
with TiN.
Th d C tti
ThreadCuttingonLathe
L th
y Can cut both external and
Internal thread
y Thread
h d cutting is a form
f
cutting
g operation
p
an
accurately shaped tool is
used (with zero rake)
y The lead screw and the
split
lit nut,
t which
hi h provide
id
positive motion of the
carriage relative to the
rotation of the spindle.
p
Thread Milling
ThreadMilling
g y accurate threads,
y Highly
particularly in larger
sizes, are often form
form
milled. Either a single or
a multipleform
multiple form Cutter
may be used.
y The milling cutter is
tilted at an angle
g equal
q
to the helix angle of the
thread and is fed inward
radially to full depth
while the work is
stationary.
ThreadRolling
y Thread rolling is used to produce threads in substantial
quantities.
y Coldforming process operation in which the threads are
formed byy rolling
g a thread blank between hardened dies
that cause the metal to flow radially into the desired
shape.
shape
y Chip less process,
fast and economical.
y Mechanical properties
are good.
Page 45
Sh
Shaper,Planner,Slotter
Pl
Sl
BySKMondal
Shaper
h
Q i k t
ti M h i
QuickreturnmotionMechanism
RamDrive
Ram Drive
FeedMechanism
Feed Mechanism
y Themechanicalramdriveisaslottedarmquickreturn
y Table feed is intermittent and is accomplished on the
Shaper
h
y The
between
the
Th relative
l i motions
i
b
h tooll and
d the
h workpiece,
k i
shaping and planing use a straightline cutting motion with a

singlepoint
l
cutting tooll to generate a flat
fl surface.
f
y In shaping,
p g, the workpiece
p
is fed at right
g angles
g to the cutting
g
motion between successive strokes of the tool.
y For either shaping or planing,
planing the tool is held in a clapper box
which prevents the cutting edge from being damaged on the
return stroke of the tool.
tool
y Relatively skilled workers are required to operate shapers and
planers,
l
and
d most off the
h shapes
h
that
h can be
b produced
d d on
them also can be made by much more productive processes,
such
h as milling,
ll
b
broaching,
h
or grinding.
d
QuickreturnmotionMechanism
k
h
y In
the
tooll is
I shaping,
h i
h cutting
i
i held
h ld in
i the
h tooll post
located in the ram, which reciprocates over the work

with a forward stroke, cutting at velocity V and a quick
return stroke at velocityy VR.
y The rpm rate of the drive crank (Ns) drives the ram and
determines the velocity
elocit of the operation.
operation
y The stroke ratio, Rs
motionmechanism,
return ((non cutting)

g) stroke when the tool has cleared
the workpiece.
y The cross feed is given to the table with the help of a
cutting
tti g stroke
t k angle
gl
=
0
360
cross feed screw which is actuated by a pawl which

engages a notched wheel (ratchet) keyed to the screw.
screw
ClassificationofShaperMachine
l
f
f h
h
Shapers,asmachinetoolsusuallyareclassified
Sh

hi l
ll l ifi d
accordingtotheirgeneraldesignfeaturesasfollows,
1. Horizontal
a
a.
Push cut
Pushcut
b.
Pullcutordrawcutshaper
2. Vertical
a.
R
Regularorslotters
l l tt
y
b.
Keyseaters
3. Specialpurpose
Formula
l
NL(1 + m)
1000
w
y Numberofstrokes,
, Ns =
f
y Cuttingspeed, V =
y Timeofonestroke,
Timeofonestroke t =
y Totaltime,T =
L(1 + m)
min
1000V
L(1 + m)
Lw(1 + m)
Ns =
min
1000v
1000vf
Page 46
HydraulicShaper
g
y
p g
Advantagesofhydraulicshaping
y 1. Cutting speed remains constant throughout most of the cutting
stroke,
t k unlike
lik the
th crank
k shaper
h
where
h
th speed
the
d changes
h
continuously.
ti
l
y 2. Since the p
power available remains constant throughout,
g
, it is p
possible
to utilise the full capacity of the cutting tool during the cutting stroke.
y 3.
3 The ram reverses quickly without any shock due the hydraulic
cylinder utilised. The inertia of the moving parts is relatively small.
y 4. The
Th range and
d number
b off cutting
i strokes
k possible
ibl are relatively
l i l large
l
in hydraulic shaper.
y 5. More strokes per minute can be achieved by consuming less time for
Planer
Pl
Slotter
Sl
y Planing
horizontal,
Pl i can be
b used
d to produce
d
h i
l vertical,
i l or
y Slotting
Thus
Sl i machine
hi is
i basically
b i ll a vertical
i l axis
i shaper.
h
Th
inclined flat surfaces on workpieces that are too large to

be accommodated on shapers.
y Planing is much less efficient than other basic
machining processes, such as milling, that will produce
such surfaces.
surfaces
y Planing and planers have largely been replaced by planer
milling machines or machines that can do both milling
and planing.
the workpieces, which cannot be conveniently held in

shaper, can be machined in a slotter.
y Generally,
Generally keyways,
keyways splines,
splines serrations,
serrations rectangular
grooves and similar shapes are machined in a slotting
machine.
machine
y The stroke of the ram is smaller in slotting machines
than in shapers to account for the type of the work that
is handled in them.
Slotter
Slotter
reversal and return strokes.
y The
are very similar
Th types off tools
l used
d in
i a slotter
l
i il to
those in a shaper, except that the cutting actually takes

place in the direction of cutting.
y However,
However in view of the type of surfaces that are possible
in the case of slotter, a large variety of boring bars or
single point tools with
singlepoint
ith long shanks are used.
used
AbrasiveMachiningProcesses
Ch5:ShapingandPlanning
Q.No
1
2
3
4
5
6
Option
C
A
C
B
B
C
P
Process
F
Features
Grinding
Useswheels,accuratesizing,finishing,lowMRR;
Useswheels accuratesizing finishing lowMRR;
canbedoneathighspeeds.
Useswheelswithlongcuttingarc veryslowfeed
Useswheelswithlongcuttingarc,veryslowfeed
rateandlargedepthofcut
Creepfeed
grinding
G d g&
s
g
Grinding&Finishing
BySKMondal
Page 47
Abrasive
machining
Abrasivewater
jjetMachining
g
Honing
Lapping
HighMRR,toobtaindesiredshapesand
approximatesizes
Waterjetswithvelocitiesupto1000m/seccarry
abrasiveparticles(silicaandgarnet)
p
(
g
)
"Stones"containingfineabrasives;primarilya
hole finishingprocess
hole
Fineparticlesembeddedinsoftmetalorcloth;
primarilyasurfacefinishingprocess
G i di
Grinding
Whyishighvelocitydesiredingrinding?
y Grinding
is
off abrasive
G i di
i the
th mostt common form
f
b i
y It
effect
off very high
I is
i desired
d i d to off
ff set the
h adverse
d
ff
hi h
machining.
y It is a material cutting process which engages an abrasive
tool whose cutting elements are grains of abrasive
material known as grit.
y These g
grits are characterized byy sharp
p cutting
g p
points,,
high hot hardness, and chemical stability and wear
es sta ce.
resistance.
y The grits are held together by a suitable bonding
material to give shape of an abrasive tool.
tool
y Grinding can be compared with milling with an infinite
number
b off cutting
tti edge.
d
negative rake angle of the working grit, to reduce the

force per grit as well as the overall grinding force.
Fi cutting
Figtti action
ti off abrasive
b i grains
i
Ad
AdvantagesofGrinding
f G i di
A li i
ApplicationsofGrinding
f G i di
Grinding
d
y Dimensionalaccuracy
y Surfacefinishing
y If each
tooll then
in
h abrasive
b i grain
i is
i viewed
i
d as a cutting
i
h
i
y Goodsurfacefinish
y Slittingandparting
High
y Goodformandlocational accuracy
y Descaling,deburring
y Applicabletobothhardenedandunhardenedmaterial
y Stockremoval(abrasivemilling)
(
)
grinding operation.
y Rake angle can be positive,
positive zero,
zero or negative ranging from
y Finishingofflataswellascylindricalsurface
Fi i hi ffl ll li d i l f
y Grindingoftoolsandcuttersandresharpening
G i di ft l d tt d h
i ofthe
fth
+45o to 60o, dull, rounded grits has large negative rake angle
y Cutting
C i speed
d is
i very high
hi h
y Very
y high
g specific
p
energy
gy of cutting
g
Low
y Low
L shear
h
angle
l
y Low feed rate
same
y Low depth of cut
Interactionofthegritwiththeworkpiece
y Grit
chip
G i with
i h favourable
f
bl geometry can produce
d
hi in
i shear
h
Howischipaccommodationvolumeis
relatedtomaterialremovalrate?
l t dt
t i l
l t ?
mode.
y However, grits having large negative rake angle or
rounded cutting edge do not form chips but may rub or

make a groove by ploughing leading to lateral flow of the
workpiece
orkpiece material.
material
Fig Grits engage shearing, ploughing and rubbing

y Volume of chip accommodation space ahead of each grit
must be g
greater than the chip
p volume p
produced byy each
grit to facilitate easy evacuation of the chip from the
grinding wheel.
wheel
Page 48
Specificenergyconsumptioningrinding
GRatio
Parametersforspecifyagrindingwheel
y The
h grinding
d
ratio or G ratio is defined
d f d as thee
h cubic
b mm
1)) The
Th type off grit
i material
i l
2)) The g
grit size
3) The bond strength of the wheel, commonly known
as wheel hardness
4) The structure of the wheel denoting the porosity i.e.
the amount of inter grit spacing
5) The type of bond material
6) Other than these parameters, the wheel
manufacturer
f
may add
dd their
h
own identification
d
f
code
d
prefixing
p
g or suffixing
g (or both) the standard code.
of stock removed divided by the cubic mm of wheel lost.

y In conventional grinding,
grinding the G ratio is in the range 20: 1
to 80: 1.
y The G ratio is a measure of grinding production and
reflects
fl
the
h amount off work
k a wheel
h l can do
d during
d i its
i
useful life.
y As the wheel losses material,
material it must be reset or
repositioned to maintain workpiece size.
Abrasive
Material
CommentsandUses
Aluminium oxide
g
Softer and tougher
than silicon
carbide; use on steel, iron, brass
Sili
Siliconcarbide
bid
Used
d
f
for
b
brass,
b
bronze,
aluminum, stainless steel and
cast iron
For grinding hard,
hard tough tool
steels, stainless steel, cobalt and
nickel
i k l based
b
d superalloys,
ll
and
d
hard coatings
Used
to grind
nonferrous
materials, tungsten carbide and
ceramics
cBN (cubicboron
nitride)
Diamond
Whyisaluminium oxidepreferredto
siliconcarbideingrindingsteel?
ili
bid i
i di
t l?
y Al2O3 is tougher than SiC. Therefore it is
preferred to grind material having high tensile

strength like steel. Moreover, Al2O3 shows higher
chemical
h
l inertness than
h SiC towards
d steell leading
l d
to much improved wear resistance during
grinding.
G d
Grade
S
Structure/concentration
/
i
y The
the
Th worn out grit
i must pull
ll out from
f
h bond
b d and
d make
k
y The
grinding
wheels
Th structure should
h ld be
b open for
f
i di
h l
room for fresh sharp grit in order to avoid excessive rise

of grinding force and temperature.
y A soft wheel should be chosen for grinding hard
material.
y A hard
h d wheel
h l should
h ld be
b chosen
h
f
for
grinding
d
soft
f
material.
engaged in high material removal to provide chip

accommodation space.
y The space between the grits also serves as pocket for
holding grinding fluid.
y Dense structured
d wheels
h l are used
d for
f longer
l
wheel
h l life,
lf
for holding precision forms and profiles.
Page 49
Gi i
Gritsize
y The
material
Th grain
i size
i affects
ff
i l removall rate and
d the
h
surface quality of workpiece in grinding.

y Large grit big grinding capacity, rough workpiece
surface
y Fine grit small grinding capacity, smooth workpiece
surface
f
Whyiscoarsegrainandopenstructuredwheel
ispreferredforstockremovalgrinding?
f
df
k
l
d
y Coarse grit allows large grit protrusion and open
structure p
provides large
g inter g
grit chip
p space.
p
Thus in
combination those two provide large space for chip
accommodation during stock removal grinding and risk
of wheel loading is minimized.
BondingMaterialsforGrindingwheels
Type
off Bond
T
B d
Attributes
A ib
Vitrified bonds Composed of clays and other ceramic

substances, porous, strong, rigid, and
unaffected
ff
d
b
by
oils,
il
water,
or
temperature. Brittle and can not be used
for high wheel speed.
Resinoid
Resinoid,
or Plastic bond,
bond replaced shellac and
phenolic
rubber wheels, not with alkaline
resins
i
grinding
i di fluid.
fl id
Shellac bond
For flexible cut off wheels, replaced
p
byy
resin bond.
Bonding Materials for Grinding wheels

BondingMaterialsforGrindingwheels
Glazing
l
Type of Bond
Attributes
y With
use a grinding
dull
Wi h continuous
i
i di wheel
h l becomes
b
d ll with
ih
Rubber bond
For use in thin wheels,, replaced

p
byy resin
bond.
Li it d use.
Limited
y This condition of a dull grinding wheel with worn out
Oxychloride
O
hl id
bond
Metal bond
Electroplated
El
t
l t d
bond
the sharp abrasive grains becoming rounded.

grains is termed as glazing.
glazing
Extensively used with super abrasive

wheels, high toughness, high accuracy,
large stock removal.
U d for
Used
f small
ll wheel,
h l form
f
wheel
h l and
d
thin super abrasive wheels, for abrasive
milling and ultra high speed grinding.
Replace by electroplated bond
Loading
d
D
Dressing
i
T i
Truing
y Some
grinding
the
S
i di chips
hi get lodged
l d d into
i
h spaces between
b
y Dressing
which
D
i is
i the
h conditioning
di i i off the
h wheel
h l surface
f
hi h
y Truing
T i is
i the
h act off regenerating
i the
h required
i d geometry
the grits resulting in a condition known as loaded wheel.

y Loading is generally caused during the grinding of soft
and ductile materials.
materials
y A loaded grinding wheel cannot cut properly and need
dressing.
ensures that grit cutting edges are exposed from the

bond and thus able to penetrate into the workpiece
material.
y In dressing attempts are made to splinter the abrasive
grains to make them sharp and free cutting and also to
remove any residue left by material being ground.
y Dressing therefore produces microgeometry.
on the grinding wheel.

y Truing is also required on a new conventional wheel to
ensure concentricity with specific mounting system.
system
y Truing and dressing are commonly combined into one
operation for
f conventionall abrasive
b
grinding
d
wheels,
h l but
b
are usually two distinctly separate operation for super
abrasive wheel.
BalancingGrindingWheels
y Because of the high rotation speeds involved, grinding
wheels must never be used unless theyy are in g

good
balance.
y Grinding wheel must be balanced Statically and
Dynamically.
y A slight imbalance will produce vibrations that will cause
waviness in the work surface. It mayy cause a wheel to
break, with the probability of serious damage and injury.
C
Creepfeedgrinding
f d i di
y Thismachineenablessinglepassgrindingofasurface
Thi
hi
bl i l
i di f f
withalargerdownfeedbutslowertablespeedthanthat
adoptedformultipassconventionalsurfacegrinding.
y Increep
Increepfeedgrinding
feedgrinding,theentiredepthofcutis
theentiredepthofcutis
completedinonepassonlyusingverysmallinfeed
rates.
rates
Page 50
Statethebasicadvantageofacreepfeed
grinderoveraconventionalsurface
i d
ti
l
f
y Productivityisenhancedandlifeofthegrindingwheelis
extended.
CylindricalGrinding
l d
l
d
Centerless
l
Grinding
d
y Centertype
cylindrical
is
C
li d i l grinding
i di
i commonly
l used
d far
f
y Centerless
grinding
makes
C
l
i di
k it
i possible
ibl to grind
i d both
b h
producing external cylindrical surfaces.

y The grinding wheel revolves at an ordinary cutting
speed and the workpiece rotates on centers at a much
speed,
slower speed.
y Grinding
G d
machines
h
are available
l bl in which
h h the
h workpiece
k
is held in a chuck for grinding both external and internal
cylindrical surfaces.
external and internal cylindrical surfaces without

requiring the workpiece to be mounted between centers
or in a chuck.
y This eliminates the requirement of center holes in some
workpieces
orkpieces and the necessity
necessit for mounting the
workpiece, thereby reducing the cycle time.
y Two wheels are used. The larger one operates at regular
grinding speeds and does the actual grinding. The
smaller wheel is the regulating wheel. It is mounted at
an angle to the plane of the grinding wheel.
wheel
Centerless Grinding
Centerless
l
Grinding
d
Centerless
l
Grinding
d
y The
Th regulating
l i
wheel
and
h l controls
l the
h rotation
i
d
longitudinal motion of the workpiece and usually is a
plastic or rubberbonded wheel with a fairly wide face.
y Theworkpieceisheldagainstthework
Theworkpieceisheldagainsttheworkrestbladebythe
restbladebythe
cuttingforcesexertedbythegrindingwheelandrotates
atappro imatel thesamesurfacespeedasthatofthe
atapproximatelythesamesurfacespeedasthatofthe
regulatingwheel.
The axial feed is calculated by the equation

F = dN sin
where
F = feed (mm/min)
d = di
diameter off the
h regulating
l i wheel
h l ((mm))
N = revolutions
evo u o s pe
per minute
u e oof thee regulating
egu a g wheel
w ee
= angle of inclination of the regulating wheel
Centreless
l
internalGrinding
l
d
Statethedisadvantagesofcentreless
cylindricalgrindingmachine?
li d i l i di
hi ?
y This
is
grinding
cylindrical
Thi machine
hi
i used
d for
f
i di
li d i l and
d
tapered holes in cylindrical parts (e.g. cylindrical liners,

various bushings etc).
y The workpiece is rotated between supporting roll,
roll
pressure roll and regulating wheel and is ground by the
grinding wheel.
heel
Itdoesnotgrindconcentricallywithcentres.
Largediametershortworkpiecearedifficultto
controlintheprocess
I
Itmaynotimproveworkpieceperpendicularity.
i
k i
di l i
Page 51
SurfaceGrindingMachines
y Surface grinding machines are used primarily to
g
grind
flat surfaces.
y However formed, irregular surfaces can be
produced on some types of surface grinders by use
of a formed wheel.
Four basic types of surface grinding machines are:
1. Horizontal spindle and reciprocating table
2. Vertical spindle and reciprocating table
3. Horizontal spindle and rotary table
4. Vertical spindle and rotary table
Lapping
Characteristicsoflappingprocess
h
fl
y Lappingisbasicallyanabrasiveprocessinwhichloose
L
i i b i ll b i
i hi hl
y Useoflooseabrasivebetweenlapandtheworkpiece
U fl
b i b
l d h
k i
abrasivesfunctionascuttingpointsfindingmomentary
supportfromthelaps.
y Materialremovalinlappingusuallyrangesfrom.003to
Materialremovalinlappingusuallyrangesfrom 003to
.03mmbutmanyreach0.08to0.1mmincertaincases.
y Usuallylapandworkpiecearenotpositivelydrivenbut
y p
p
p
y
Abrasivesoflapping
b
fl
Vehiclematerialsforlapping
h l
l f l
areguidedincontactwitheachother
y Relativemotionbetweenthelapandtheworkshould
changecontinuouslysothatpathoftheabrasivegrains
ofthelapisnotrepeatedontheworkpiece.
f h l
d
h
k
y Castironisthemostlyusedlapmaterial.However,soft
Cast o s t e ost y used ap ate a . o eve , so t
steel,copper,brass,hardwoodaswellashardenedsteel
andglassarealsoused.
andglassarealsoused
Technicalparametersaffectinglappingprocessesare
y Al2O3 andSiC,grainsize5~100m
y Machineoil
y unitpressure
y Cr2O3,grainsize1~2m
y Rapeside oil
y thegrainsizeofabrasive
y B4C3,grainsize5 60m
y grease
y concentrationofabrasiveinthevehicle
y Diamond,grainsize0.5~5m
y lappingspeed
Honing
y Honing
H i is
i a finishing
fi i hi process, in
i which
hi h a tooll called
ll d hone
h
carries out a combined rotary and reciprocating motion

while the workpiece does not perform any working
motion.
y Most honing is done on internal cylindrical surface, such
as automobile cylindrical
c lindrical walls.
alls The honing stones are
held against the workpiece with controlled light
pressure. The
h honing
h
h d is not guided
head
d d externally
ll but,
b
instead, floats in the hole, being
g g
guided byy the work
surface.
Honing
Honing
y It
I is
i desired
d i d that
h
g stones should not leave the work surface

1. Honing
2. Stroke length must cover the entire work length.
3. In
I honing
h i
rotary and
d oscillatory
ill
motions
i
are
combined to produce a cross hatched lay pattern.
The honing
g stones are g
given a complex
p
motion so as
to prevent every single grit from repeating its path
over the work surface.
Page 52
Fig.Honingtool
Fig.Laypatternproducedbycombinationofrotaryand
oscillatorymotion
B ffi
Buffing
Thecriticalprocessparametersare
y Buffing
B ffi is
i a polishing
li hi operation
ti in
i which
hi h the
th workpiece
k i
y 1.rotationspeed
is brought into contact with a revolving cloth wheel that

has been
h
b
charged
h
d with
ith a fine
fi abrasive,
b i such
h as polishing
li hi
rough.
y The wheels are made of disks of linen, cotton,
broadcloth, or canvas, and achieve the desired degree of
firmness through the amount of stitching used to fasten
the layers of cloth together.
y Negligible amount of material is removed in buffing
while a very high luster is generated on the buffed
surface.
y The dimensional accuracy of the parts is not affected by
the buffing operation.
y 2.oscillationspeed
y 3.lengthandpositionofthestroke
y 4.honingstickpressure
SuperFinishing
SuperFinishing
h
Statethespecificapplicationofaplanetary
internalgrinder.
i t
l i d
y Planetary
a eta y internal
te a g
grinders
de s find
d app
application
cat o for
o g
grinding
d g
holes in workpieces of irregular shape or large heavy

workpieces.
workpieces
Fig. super finishing of end face
of a cylindrical work piece in radial mode
In this both feeding and oscillation of the super

finishing stone is given in the radial direction.
Q.No
1
2
3
4
5
6
Ch9:Grinding
Option Q.No
D
7
D
8
A
9
A
10
B
11
B
12
Fi super finishing
Fig.
fi i hi operation
ti iin plunge
l
mode
d
In this case the abrasive stone covers the section of the

workpiece requiring super finish. The abrasive stone is
slowly fed in radial direction while its oscillation is
imparted in the axial direction. It reduce surface
roughness and increase bearing load capacity.
capacity
Option
A
A
A
C
A
D
Page 53
Lathe
BySKMondal
IES 2001
IES 1992
Thespindlespeedrangeinageneralpurposelathe
Th i dl
d
i
l
l h
isdividedintostepswhichapproximatelyfollow
(a) Arithmeticprogression
(b) Geometricprogression
(c) Harmonicprogression
(d) Logarithmicprogression
Feedgearboxforascrewcuttinglatheisdesigned
F d
b f
i l h i d i
d
onthebasisof
(a) Geometricprogression
(b) Arithmeticprogression
(c) Harmonicprogression
(d) None.
IES 1998
IES 1993,ISRO2009
A single
i l start thread
h d off pitch
i h 2 mm is
i to be
b produced
d
d
on a lathe having a lead screw with a double start
thread of pitch 4 mm. The ratio of speeds between
the spindle
p
and lead screw for this operation
p
is
(a) 1 : 2 (b) 2: 1
( ) 1: 4 (d) 4: 1
(c)
Example
It
I is
i required
i d to cut screw threads
h d off 2 mm pitch
i h on
a lathe. The lead screw has a pitch of 6 mm. If the
spindle speed is 60 rpm, then the speed of the lead
screw will be
(a) 10 rpm
(b) 20 rpm
( ) 120 rpm
(c)
(d) 180 rpm
How much machining time will be required to reduce

the diameter of a cast iron rod from 120 mm to 116 mm
over a length
l
h off 100 mm by
b turning
i
using
i
a carbide
bid
insert Cutting velocity is 100 m/min and feed rate = 0.2
insert.
02
mm/rev.
/
IES2010
In
I turning
t
i a solid
lid round
d bar,
b if the
th travel
t
l
of the cutting tool in the direction of
feed motion is 1000 mm, rotational
speed of the workpiece is 500 rpm, and
rate of feed is 0.2
0 2 mm/revolution,
mm/revolution then
the machining
g time will be
(a) 10 seconds
(b) 100 seconds
(c) 5 minutes
(d) 10 minutes
D
IES 2003
IAS 2002
The
taken
to face
a workpiece
off 72 mm
Th time
i
k
f
k i
diameter, if the spindle speed is 80 r.p.m. and cross
feed is 0.3 mm/rev, is
(a) 1.5
1 5 minutes (b) 3.0
3 0 minutes
(c) 5.4 minutes (d) 8.5 minutes
A 150 mm long,
12 mm diameter
304 stainless
steell
l
di
i l
rod is being reduced in diameter to 115 mm by
turning on a lathe. The spindle rotates at N = 400
rpm
p and the tool is travelling
g at an axial speed
p
of
200 mm/min. The time taken for cutting is given by
(a) 30 s
(b) 36 s
(c) 1 minute (d) 45 s
A
D
Page 54
IES 2004
A medium
carbon
steell workpiece
is
di
b
k i
i turned
d on a
lathe at 50 m/min. cutting speed 0.8 mm/rev feed
and 1.5 mm depth of cut. What is the rate of metal
removal?
(a) 1000 mm3/min
(b) 60,000 mm3/min
/
(c) 20,000
0,000 mm3//min
(d) Can not be calculated with the given data
IES 2006
Example
l
For
on centre lathes,
the
F taper turning
i
l h
h method
h d off
swiveling the compound rest is preferred for:
(a) Long jobs with small taper angles
(b) Long jobs with steep taper angles
(c) Short jobs with small taper angles
(d) Short jobs with steep taper angles
Find
Fi d the
h angle
l at which
hi h the
h compound
d rest should
h ld
be set up to turn taper on the workpiece having a
length of 200 mm, larger diameter 45 mm and the
smaller 330 mm.
IES 1992
Tailstocksetovermethodoftaperturningis
T il
k
h d f
i i
preferredfor
(a) Internaltapers
(b) Smalltapers
(c) Longslendertapers
(d) Steeptapers
C
IAS 2002
The
off tail
Th amount off offset
ff
il stock
k for
f turning
i taper
on full length of a job 300 mm long which is to have
its two diameters at 50 mm and 38 mm respectively
is
(a) 6 mm
(b) 12 mm
( ) 25 mm
(c)
(d) 44 mm
A
IES2010
The effect of centering error
when the tool is set above the
center line as shown in the figure
results effectively in
1 Increase in rake angle.
1.
angle
2. Reduction in rake angle.
3. Increase in clearance angle.
4. Reduction in clearance angle.
Which of these statements is/are
correct?
(a) 1 only
(b) 1 and 4 only
(c) 2 and 4 only
(d) 1,
1 2,
2 3 and 4
B
IES 1998
A 400 mm long
shaft
l
h f has
h a 100 mm tapered
d step at
the middle with 4 included angle. The tailstock
offset required to produce this taper on a lathe
would be
(a) 400 sin 4 (b) 400 sin 2
( ) 100 sin 4 (d) 100 sin 2
(c)
B
IES 2012
GATE 2002
Lathe
with
off
L h machine
hi
i h turret can turn a work
k piece
i
limited length only because,
(a) Cross slide motion is obstructed by turret
(b) Turret cannot work on a long job
(c) Chuck cannot be replaced by a face plate
(d) Turret replaces the loose centre
A leadscrew with half nuts in a lathe, free to rotate

in both
b h directions
d
h
has
( ) Vthreads
(a)
V h d
(b) Whitworth
Whit
th threads
th d
(c) Buttress threads
(d) ACME threads

D
Page 55
GATE 2008
GATE2008Contd.
The
shows
an incomplete
schematic
Th figure
fi
h
i
l
h
i off a
conventional lathe to be used for cutting threads
with different pitches. The speed gear box Uv, is
shown and the feed g
gear box Us, is to be p
placed. P,, Q
Q.
R and S denote locations and have no other
significance Changes in Uv, should NOT affect the
significance.
pitch of the thread being cut and changes in Us,
should
h ld NOT affect
ff t the
th cutting
tti speed.
d
C td
Contd..
IES 1996
IES 2009
Inturningofslenderrods,itisnecessarytokeep
I
i f l d d i i
k
thetransverseforceminimummainlyto
(a) Improvethesurfacefinish
(b) Increaseproductivity
(c) Improvecuttingefficiency
(d) Reducevibrationsandchatter.
D
To
finish
T get good
d surface
f
fi i h on a turned
d job,
j b
one should use a sharp tool with a ..feed
and speed of rotation of the job.
( ) Minimum, minimum
(a)
(b) Minimum,
Minimum maximum
((c)) Maximum,, maximum
(d) Maximum, minimum
B
IES 1999
Match
tools)
M h List
Li I (Cutting
(C i
l ) with
i h List
Li II (Features)
(F
)
and select the correct answer using the codes given
below the Lists:
List I
List II
A. Turning tool
1.
Chisel edge
B. Reamer
2.
Flutes
C Milling cutter
C.
3
3.
Axial relief
4.
Side relief
C
Codes: A
B
C
A
B
C
(a) 1
2
3
(b) 4
3
2
(c) 4
2
3
(d) 1
3
2
Th
ThecorrectconnectionsandthecorrectplacementofU
i
d h
l
fUsare
givenby
( ) QandEareconnected.
(a)
Q dE
t d Us,isplacedbetweenPandQ.
i l db t
P dQ
(b) SandEareconnected.Us isplacedbetweenRandS.
( ) QandEareconnected.U
(c)
Q dE
d Us,isplacedbetweenQandE.
i l db
Q dE
(d) SandEareconnected.Us,isplacedbetweenSandE.
GATE1994
Which
sets off forces
are
Whi h one off the
h following
f ll i
f
encountered by a lathe parting tool while groove
cutting?
(a) Tangential,
Tangential radial and axial
(b) Tangential and radial
(c) Tangential and axial
(d) Radial and axial
A
IES 2004
Whatisthenumberofjawsinselfcentred
Wh i h
b fj
i lf
d chuck?
h k?
((a)) Eight
g
(b) Six
( ) Four
(c)
F
((d)) Three
D
IES 2009
IES 1992
Whichoneofthefollowingmethodsshouldbeused
Whi h
f h f ll i
h d h ldb
d
forturninginternaltaperonly?
(a) Tailstockoffset
(b) Taperattachment
(c) Formtool
(d) Compoundrest
Whichofthefollowingstatementisincorrectwith
Whi h f h f ll i
i i
i h
referenceoflathecuttingtools?
(a) Theflankofthetoolisthesurfacebelowand
adjacenttothecuttingedges
(b) Thenoseisthecorner,orchamferjoiningtheside
cuttingandtheendcuttingedges
d h
d
d
(c) Theheelisthatpartofthewhichisshapedto
e ee s t at pa t o t e
c s s aped to
producethecuttingedgesandface
(d) Thebaseisthatsurfaceoftheshankwhichagainst
Th b i th t f fth h k hi h i t
thesupportandtakestangent
Page 56
IES 2006
IES 1997
It
I is
i required
i d to cut screw threads
h d with
i h double
d bl start
and 2 mm pitch on a lathe having lead screw pitch
of 6 mm. What is the speed ratio between lathe
spindle
p
and lead screw?
(a) 1 : 3 (b) 3: 1
( ) 2 : 3 (d) 3: 2
(c)
Consider
C
id the
h following
f ll i operations:
i
g
2.
Plain turning
g
1. Under cutting
3. Taper turning
4.
Thread cutting
Th correct sequence off these
The
h
operations
i
i machining
in
hi i a
product is
(a) 2, 3, 4, 1
(b) 3, 2, 4, 1
( ) 2, 3, 1, 4
(c)
(d) 3, 2, 1, 4
D
C
IES 2007
Assertion
(A):
A
i
(A) In
I a multispindle
l i i dl automatic
i lathe,
l h the
h
turret tool holder is indexed to engage the cutting tools
one by
b one for
f successive machining
h
operations.
Reason ((R):
) Turret is a multiple
p tool holder so that for
successive machining operation, the tools need not be
changed.
g
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation
l
i off A
(c) A is true but R is false
(d) A is false but R is true
A
IES 2009
A capstan lathe
in
l h is
i used
d to massproduce,
d
i batches
b h
of 200, a particular component. The direct material
cost is Rs 4 per piece, the direct labour cost is Rs 3
per p
p
piece and the overhead costs are 4
400% of the
labour costs. What is the production cost per piece?
(a) Rs 19 (b) Rs 23
(c) Rs 16 (d) Rs 15
A
IES 1995
IES 1996
Consider
C
id the
th following
f ll i characteristics:
h
t i ti
1. Multiple operations can be performed
2. Operator's fatigue is greatly reduced.
3 Ideally suited for batch production
3.
4. A breakdown in one machine does not affect the
flo of products.
flow
products
5. Can accommodate modifications in design of
components, within
h certain limits.
l
The characteristics which can be attributed to special
p
purpose machines would include
(a) 1,
1 3 and 4 (b) 1,
1 2 and 4
(c) 2, 3 and 5 (d) 1, 2 and 5
C
IES 2003
Assertion
(A):
tools
A
i
(A) Special
S
i l purpose machine
hi
l and
d
automatic machine tools are quite useful for job
shops
Reason (R): Special purpose machine tools can do
special types of machining work automatically
( ) Both
(a)
h A and
d R are individually
d d ll true and
d R is the
h
correct explanation of A
D
IES 2009
Which
following
mechanisms
is
Whi h one off the
h
f ll i
h i
i
employed for indexing of turret in an automatic
lathe?
(a) Whitworth
(b) Rack and pinion
(c) Ratchet and pawl
(d) Geneva wheel
IES 2001
For
off screw fasteners
on a mass
F the
h manufacture
f
f
scale, which is the most suitable machine tool?
(a) Capstan lathe
(b) Singlespindle
Single spindle automatic lathe
(c) CNC turning centre (lathe)
(d) CNC machining centre
The
off the
Th indexing
i d i
h turret in
i a singlespindle
i l
i dl
automatic lathe is done using
(a) Geneva mechanism
(b) Ratchet and Pawl mechanism
(c) Rack and pinion mechanism
(d) Whitworth mechanism
C
B
Page 57
IES 1995
Assertion
(A):
automatic
A
ti
(A) In
I a Swiss
S i type
t
t
ti lathe,
l th the
th
turret is given longitudinal feed for each tool in a
specific
ifi order
d with
ith suitable
it bl indexing.
i d i
Reason (R): A turret is a multiple tool holder to
facilitate machining with each tool by indexing
without the need to change the tools.
(a) Both A and R are individually true and R is the
correct
co
ect eexplanation
p a at o o
of A
( ) A is false but R is true
(d)
D
IES 1992
Maximum
production
off small
M i
d
i
ll and
d slender
l d parts is
i
done by
(a) Watch maker's lathe
(b) Sliding head stock automatic lathe
(c) Multispindle automatic lathe
(d) Capstan lathe
C
IAS 2002
Consider
C
id the
h following
f ll i statements related
l d to Turret
T
lathe:
1. Turret is mounted directly on the saddle.
2 Turret is mounted on an auxiliary slide.
2.
slide
3. Much heavier and larger jobs than Capstan lathe can
be produced.
Which of the above statements is/are correct?
(a) 1 and 3
(b) 2 and 3
(c) 1 only
(d) 2 only
A
IAS 2001
Consider
the
following
operations
and
C
id
h
f ll i
i
d time
i
required on a multi spindle automatic machine to
produce a particular job
1 Turning
1.
1.2
1 2 minutes
2. Drilling
1.6 minutes
3. Forming
0.2 minute
4 Parting
4.
0.6
0 6 minute
The time required to make one piece (cycle time) will be
(a) 0.6 minutes
(b) 1.6 minutes
(c) 3.6
3 6 minutes
(d) 0.9
0 9 minute
B
IAS 2007
Which
is
Whi h one off the
h following
f ll i
i the
h characteristic
h
i i for
f
capstan lathe?
(a) Rate of production is low
(b) Labour cost is high
(c) Used for handling jobs of varying shapes and sizes
(d) Capstan head is mounted on a slide
D
IAS 1996
Apart
from
hexagonal
(s)
A
f
h
l turret, the
h elements
l
( ) in
i a
turret lathe include (s)
(a) Crossslide tool post
(b) Crossslide
Cross slide tool post and rear tool post
(c) Crossslide tool post and tail stock
(d) Teal tool post and tail stock
IAS 2004
Swiss
have
S i type screw machines
hi
h
((a)) Turrets
((b)) Radial slides
(c) Spindle carriers (d) Tool posts
C
IAS 1995
Assertion
A
ti (A):
(A) In
I a multispindle
lti i dl automat,
t
t the
th turret
t
t
is indexed to engage each of the cutting tool
mounted
t d on it.
it
Reason(R): Turret is a multiple tool holder so that
the machining can be continued with each tool
without the need to change the tool.
correct
co
ect eexplanation
p a at o o
of A
(d)
D
Page 58
IAS 1994
A multispindle
four
operations
l i i dl automat performs
f
f
i
with times 50, 60, 65 and 75 seconds at each of its
work centers. The cycle time (time required to
manufacture one work p
piece)) in seconds will be
(a) 50 + 60 + 65 + 75
(b) (50
( + 60 + 65 + 75)) /4
/
(c) 75/4
(d) 75
D
IAS 1998
Assertion
(A):
the
A
i
(A) For
F thread
h d cutting,
i
h spindle
i dl speed
d
selected on a lathe, is very low.
Reason (R): The required feed rate is low in
threading operation.
operation
correct explanation
l
off A
(b) Both
ot A aand
d R aaree individually
d v dua y ttrue
ue but R iss not
ot tthee
( ) A is
(c)
i true
t
b t R is
but
i false
f l
C
IAS 1998
Drilling
Consider
C
id the
h following
f ll i features:
f
p
operate
p
simultaneously,
y,
1. All spindles
2. One piece is completed each time the tools are
withdrawn and the spindles are indexed
3. The tool slide indexes or revolves with the spindle
carrier
Which of these features are characteristics of a multi
spindle automatic machine used for bar work?
( ) 1, 2 and
(a)
d 3 (b) 1 and
d2
(c) 2 and 3
(d) 1 and 3
A
IES 2004
Consider
C
id the
h following
f ll i statements:
provides the necessaryy
The helical flute in a twist drill p
1. Clearance angle for the cutting edge
2. Rake
R k angle
l for
f the
h cutting
i edge
d
33. Space
p
for the chip
p to come out during
g drilling
g
4. Guidance for the drill to enter into the workpiece
Which
h h off the
h statements given above
b
are correct?
(a) 1 and 2
(b) 2 and 3
(c) 3 and 4
(d) 1 and 4
B SKM d l
BySKMondal
B
IES 2003
GATE 1996
IES 1997
The
Th rake
k angle
l in
i a drill
d ill
((a)) Increases from centre to p
periphery
p y
(b) decreases from centre to periphery
( ) Remains
(c)
R
i constant
((d)) Is irrelevant to the drilling
g operation
p
The
Th rake
k angle
l in
i a twist
i drill
d ill
((a)) 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
(c) Is constant at every point of the cutting edge
(d) Is a function of the size of the chisel edge.
edge
A
A
C
In Norton type feed

f d gearbox
b
for
f cutting Whitworth
h
h
standard threads with a standard TPI Leadscrew, power
flows from:
((a)) Spindle
p
to Tumbler g
gear to Norton cone to Meander
drive to Leadscrew
(b) Spindle to Norton cone to Tumbler geat to Meander
drive to Leadscrew
(c) Spindle t o Tumbler gear to Meander drive to Norton
cone to Leadscrew
(d) Spindle
dl to Norton cone to Meander
d drive
d
to Tumbler
bl
gear to Leadscrew
A
IAS 2000
The
Th purpose off helical
h li l grooves in
i a twist
i drill
d ill is
i to
p
the stiffness
1. Improve
2. Save a tool material
3. Provide
P id space for
f chip
hi removall
4. Provide rake angle
4
g for the cutting
g edge
g
Select the correct answer using the codes given below:
Codes:
d
(a) 1 and 2
(b) 2 and 3
(c) 3 and 4
(d) 1 and 4
IES2011
Consider
statements associated
C
id the
h following
f ll i
i d with
ih
the lathe accessories:
1. Steady rest is used for supporting a long job in
between head stock and tail stock.
stock
2. Mandrel is used for turning small cylindrical job.
3. Collects are used for turning discshaped job.
Of these statements:
(a) 1 and 2 are correct
(b) 2 and 3 are correct
(c) 3 alone is correct
(d) 1 alone is correct
Page 59
IES 1992
GATE 1997
A drill
deep
holes
should
d ill for
f drilling
d illi
d
h l in
i aluminum
l
i
h ld
have
(a) High helix angle
(b) Taper shank
(c) Small point angle
(d) No lip
Helix
helix
H li angle
l off fast
f
h li drill
d ill is
i normally
ll
((a)) 35o
(b) 60o
( ) 90o
(c)
((d)) 5o
IES 1992
Low
helix
drilling
L
h li angle
l drills
d ill are preferred
f
d for
f
d illi
holes in
(a) Plastics
(b) Copper
(c) Cast steel
(d) Carbon steel
D
Example
l
IFS2011
The
taken
Th time
i
k to drill
d ill a hole
h l through
h
h a 25 mm thick
hi k
plate with the drill rotating at 300 r.p.m. and
moving at a feed rate of 0.25 mm/revolution is
(a) 10 sec
(b) 20 sec
(c) 60 sec
(d) 100 sec
A hole with 40mm diameter and 50mm depth is to
Discuss deephole
deep hole drilling keeping in mind speed and
b drilled
be
d ll d in mild
ld steell component. The
h cutting
feed,, mentioning
g the technique
q of applying
pp y g coolant.
speed can be taken as 65 m/min and the feed rate as
[5marks]
0.25 mm/rev. Calculate the machining time and the

material removal rate.
GATE 2004
Through
are to be
Th
h holes
h l off 10 mm diameter
di
b drilled
d ill d
in a steel plate of 20 mm thickness. Drill spindle
speed is 300 rpm, feed 0.2 mm/ rev and drill point
angle
g is 120. Assuming
g drill over travel of 2 mm,, the
time for producing a hole will be
(a) 4 seconds
(b) 25
2 seconds
(c) 100 seconds
(d) 110 seconds
B
GATE 2002
GATE 2012
IES 2002
The
Th arm off a radial
di l drilling
d illi machine
hi is
i being
b i raised
i d
at a speed of 3.9 m/min by single start square
threads of 6 mm pitch and 30 mm diameter. The
speed
p
of the screw
(a) Is 650 rpm
(b) Is 180 rpm
(c) Iss 130
30 rpm
p
(d) Cannot be determined as the data is insufficient
In a single pass drilling operation, a through hole of

15 mm diameter
d
is to be
b drilled
d ll d in a steell plate
l
off 50
mm thickness.
thickness Drill spindle speed is 500 rpm,
rpm feed
is 0.2 mm/rev and drill point angle is 118
118.. Assuming
2 mm clearance at approach and exit, the total drill
time (in seconds) is
(a) 35.1
(b) 32.4
(c) 31.2
(d) 30.1
Page 60
IES 1994
IES 2009
The
two consecutive
Th ratio
i between
b
i spindle
i dl speeds
d
for a sixspeed drilling machine using drills of
diameter 6.25 to 25 mm size and at a cutting velocity
of 18 m/min
/
is
(a) 1.02 (b) 1.32
( ) 1.62 (d) 1.82
(c)
What
for
Wh is
i the
h drilling
d illi time
i
f producing
d i a hole
h l in
i an
MS sheet of 25 mm thickness using an HSS drill of
20 mm diameter? The cutting speed and feed for
drill are 20 m/min
/
and 0.255 mm/revolution
/
respectively, Neglect time taken for setting up,
approaching and travelling of tools.
tools
(a) 0.314 min (b) 0.236 min
(c) 0.438 min (d) 0.443 min
IES 2002
A 31.8
8 mm H.S.S.
H S S drill
d ill is
i used
d to drill
d ill a hole
h l in
i a cast
iron block 100 mm thick at a cutting speed 20
m/min and feed 0.3 mm/rev. If the over travel of
drill is 4 mm and approach
pp
9 mm,, the time required
q
to drill the hole is
(a) 1 min 40 s (b) 1 min 44 s
(c) 1 min 49 s (d) 1 min 53 s
D
IAS 1999
GATE 2007(PI)LinkedS1
( ) k d
Blind
50 mm deep
are
Bli d holes
h l 10 mm diameter,
di
t
d
g drilled in steel block. Drilling
g spindle
p
being
speed is 600 rpm, feed 0.2 mm/rev, point angle of
drill is 120o.
g time ((in minutes)) p
per hole will be
Machining
(a) 0.08
(b) 0.31 (c) 0.44 (d) 0.86
To
hole
T drill
d ill a 10 mm diameter
di
h l through
h
h a 20 mm
thick M.S. plate with a drill bit running at 300 rpm
and a feed of 0.25 mm per revolution, time taken
will be
(a) 8 s (b) 16 s
( ) 24 s (d) 32 s
(c)
B
IAS 1994
The
(in
by
Th time
i
(i minutes)
i
) for
f drilling
d illi a hole
h l is
i given
i
b
t=
Depth of the hole + h

Feed RPM
where
h
'h' is
i the
h
((a)) Length
g of the drill
(b) Drill diameter
( ) Flute
(c)
l
l
length
h off the
h drill
d ll
(d) Cone height of the drill.
D
( ) k d
Blind
50 mm deep
are
Bli d holes
h l 10 mm diameter,
di
t
d
g drilled in steel block. Drilling
g spindle
p
being
speed is 600 rpm, feed 0.2 mm/rev, point angle of
drill is 120o.
g the above operation,
p
, the drill wears out
During
after producing 200 holes. Taylors tool life
0 3 = C,
equation is of the form VT0.3
C where V =
g speed in m/minute and T = tool life in
cutting
minutes. Taylors constant C will be
( ) 15
(a)
(b) 72
( ) 93
(c)
(d) 490
B
IES 1999
Match
M t h ListI
Li t I (Drill
(D ill bits)
bit ) with
ith ListII
Li t II (Applications)
(A li ti
) and
d select
l t the
th correctt
answer using the codes given below the Lists:
ListII
List
ListII
List
II
A. Core drill
1.
To enlarge a hole to a certain depth so as to
accommodate the bolt head of a screw
B.
Reamer 2.
To drill and enlarge an already existing hole in a
g
casting
C.
Counter bore drill 3.
To drill a hole before making internal
thread
D.
Tap drill
4.
To improve the surface finish and dimensional
accuracy of the already drilled hole [C]
Code:A
B
C
D
A
B
C
D
(a) 1
3
2
4
(b)
2
3
1
4
(c) 2
4
1
3
(d)
3
2
4
1
Page 61
Reaming,Boring,Broaching
BySKMondal
IES 1999
IFS2011
IES 1999
Which
Whi h one off the
h following
f ll i processes results
l in
i the
h
best accuracy of the hole made?
(a) Drilling
(b) Reaming
(c) Broaching (d) Boring
Wh t is
What
i the
th main
i difference
diff
b t
between
rose reamer
and chucking reamer ? Write in short about shell
Consider
the
following
statements regarding
C
id
h
f ll i
di
reaming process:
1. Reaming generally produces a hole larger than its
own diameter
2. Generally rake angles are not provided on reamers.
3. Even numbers of teeth are preferred in reamer
des g .
design.
Which of these statements are correct?
( ) 1 and
(a)
d2
(b) 2 and
d3
(c) 1 and 3
(d) 1, 2 and 3
B
reamer.
[5marks]
IES 1998
Match
the
M h ListI
Li I with
i h ListII
Li II and
d select
l
h correct answer
using the codes given below the lists:
ListI
ListII
A. Reaming
1. Smoothing and squaring surface
around the hole for proper seating
B Counterboring
B.
Counter boring 2.Sizing
2 Sizing and finishing the hole
C. Countersinking 3. Enlarging the end of the hole
D. Spot facing
4. Making a conical enlargement at the
end of the hole
[ ]
[D]
Code:A
B
C
D
A
B
C
D
(a) 3
2
4
1
(b) 2
3
1
4
(c) 3
2
1
4
(d) 2
3
4
1
IES 1993
A hole
is
di
i to be
b produced
d
d by
b reaming.
i
The minimum diameter permissible is 30.00 mm while
the
h maximum diameter
d
permissible
bl is 30.05 mm. In this
h
regard, consider the following statements about the
reamer size:
1. The minimum diameter of the reamer can be less than 30 mm.
2. The minimum diameter of the reamer cannot be less than 30 mm.
33. The maximum diameter of the reamer can be more than 330.055 mm.
4.The maximum diameter of the reamer must be less than 30.05 mm.
Of these statements
[D]
(a)
1 and 4 are correct
(c)
2 and 3 are correct
(d) 2 and 4 are correct
IES 1994
GATE 2007(PI)
( )
In
I reaming
i process
((a)) Metal removal rate is high
g
(b) High surface finish is obtained.
( ) High
(c)
Hi h form
f
accuracy is
i obtained
b i d
((d)) High
g dimensional accuracyy is obtained.
D
Reaming
R
i is
i primarily
i
il used
d for
f achieving
hi i
((a)) Higher
g
MRR
(b) Improved dimensional tolerance
( ) Fine
(c)
Fi surface
f
fi i h
finish
((d)) Improved
p
positional tolerance
p
B
IES 1998
A component requires
a hole
i
h l which
hi h must be
b within
i hi
the two limits of 25.03 and 25.04 mm diameter.
Which of the following statements about the
reamer size are correct?
1. Reamer size cannot be below 25.03 mm.
2. Reamer size cannot be
b above
b
25.04 mm.
3. Rea
Reamer
e ssizee ca
can be 25.04
5.04 mm..
4. Reamer size can be 25.03 mm.
Select
l
the
h correct answer using the
h codes
d given below:
b l
(a) 1 and 3
(b) 1 and 2
(c) 3 and 4
(d) 2 and 4
B
Page 62
IAS 1999
For
operation
off blind
F reaming
i
i
bli d hole,
h l the
h type off
reamer required is
(a) Straight flute reamer
(b) Right hand spiral fluted reamer
(c) Left hand spiral fluted reamer
(d) None of the above
B
IAS 2003
Match
M t h List
Li t I (Operation)
(O
ti ) with
ith List
Li t II (Application)
(A li ti ) and
d select
l t
the correct answer using the codes given below the lists:
List I
ListI
List II
ListII
(Operation)
(Application)
(A) Reaming
R
i
1. Used
U d for
f enlarging
l i the
th end
d off a hole
h l to
t give
i it a
conical shape for a short distance
(B) Boring
B i
2. Used
U d for
f enlarging
l i only
l a limited
li i d portion
i off the
h
hole
[C]
(C) Counter boring
3.
Used for finishing a hole
(D) Counter sinking
4.
Used for enlarging a hole
Codes:A
B
C
D
A
B
C
D
(a) 3
2
4
1
(b)
1
4
2
3
(c) 3
4
2
1
(d)
1
2
4
3
IES 1992
[ ]
[C]
IES 1993
The
as compared
Th main
i purpose off boring
b i operation,
i
d
to drilling is to:
(a) Drill a hole
(b) Finish the drilled hole
(c) Correct the hole
(d) Enlarge the existing hole
IES2009
IES 2009
Shell
Sh ll reamers are mounted
d on
((a)) Tool holders
((b)) Amour p
plates
(c) Arbor
(d) Shanks
IES 1994,ISRO2008
IES 1992,ISRO2010
Enlarging
an existing
circular
E l i
i i
i
l hole
h l with
i h a rotating
i
single point tool is called
(a) Boring
(b) Drilling
(c) Reaming (d) Internal turning.
turning
Which
Whi h off the
h machine
hi tools
l can be
b used
d for
f boring
b i
1. Lathe
2. Drilling machine
3. Vertical
V i l milling
illi machine
hi
4. Horizontal milling
4
g machine
(a) 1, 2, 3
(b) 1, 3, 4
( ) 2 and
(c)
d4
(d) 1, 2, 3, 4
D
A
IES 2000
IES 1996
Which
Whi h one off the
h following
f ll i sets off tools
l or tools
l and
d
processes are normally employed for making large
diameter holes?
(a) Boring tool
(b) BTA tools (Boring and trepanning association) and
gun drill
d ll
(c) Gu
Gun d
drill aand
d bo
boring
g too
tool
(d) Boring tools and trepanning
Which
Whi h off the
h following
f ll i statements are correct??
1. A boring
g machine is suitable for a jjob shop.
p
2. A jig boring machine is designed specially for doing
more accurate work when compared to a vertical
milling machine.
3. A vertical precision boring machine is suitable for
boring
bo
g holes
o es in cy
cylinder
de b
blocks
oc s aand
d liners.
e s.
(a) 1, 2 and 3 (b) 1 and 2
( ) 2 and
(c)
d3
(d) 1 and
d 3.
D
IES 1995
Page 63
The
off setting
a boring
tooll above
centre
Th effects
ff
i
b i
b
height leads to a/an.
(a) Increase in the effective rake angle and a decrease in
the effective clearance angle.
angle
(b) Increase in both effective rake angle and effective
clearance
l
angle.
l
(c) Decrease
ec ease in tthee eeffective
ect ve rake
a e aangle
g e aand
d aan increase
c ease
in the effective clearance angle.
(d) Decrease
D
i both
in
b th effective
ff ti rank
k angle
l and
d effective
ff ti
clearance angle.
C
IES 2007
JWM2010
Considerthefollowingoperationsregardingboring
machines:
1.Counterboring
2.Countersinking
C
i ki
3
3.Trepanning
p
g
Whichoftheaboveoperationsis/arecorrect?
( ) d
(a)1,2and3
(b) d l
(b)1and2only
(c)2and3only
(c)
a d 3 o y (d)
(d)1only
o y
A
IES 1993
Among
the
machining
processes, which
A
h following
f ll i
hi i
hi h
can be used for machining flat surfaces?
1. Shaping
2.
Milling
3.
Broaching
Select the correct answer using the code given below:
(a) 1 and 2 only
(b) 1 and 3 only
(c) 2 and 3 only
(d) 1, 2 and 3
Assertion
(A):
Soluble
A
i
(A)
S l bl oils
il are employed
l
d with
ih
broaching machine.
Reason (R): Soluble oils have excellent cooling
effect.
effect
correct explanation
l
off A
(b) Both
ot A aand
d v dua y ttrue
ue but R iss not
ot tthee
( ) A is
(c)
i true
t
b t R is
but
i false
f l
IES 1993,2001
Assertion
(A):
is
A
i
(A) No
N separate feed
f d motion
i
i required
i d
during broaching.
Reason (R): The broaching machines are generally
hydraulically operated.
operated
correct explanation
l
off A
(b) Both
ot A aand
d v dua y ttrue
ue but R iss not
ot tthee
( ) A is
(c)
i true
t
b t R is
but
i false
f l
IES 2001
IAS 2004
The
machine
are
Th screw and
d nut in
i a broaching
b
hi
hi
changed from square thread to ACME thread. The
power requirement of the machine at the same
r.p.m.
p
will
(a) Remain same
(b) Decrease
(c) Increase
c ease
(d) Depend on the operator
C
Which
is
few
Whi h one off the
h following
f ll i
i true for
f the
h last
l
f
teeth of a broach which are meant for fine
finishing?
(a) They have equal diameter
(b) They have increasing diameter
(c) They have decreasing diameter
(d) They have alternately increasing and decreasing
diameter.
A
IES 2005
IES 2002
Match
M t h List
Li t I (Tool)
(T l) with
ith List
Li t II (Element
(El
t off Tool)
T l) and
d
select the correct answer using the code given below the
Lists:
List I
List II
A Broach
B
h
1.
T
Tang
B. Reamer
2.
Pilot
C. Drill
3.
Front taper
D. Carbide insert face mill 4.
Bond
[C]
5.
Sweeper tooth
Codes:A
B
C
D
A
B
C
D
(a) 2
5
1
3
(b) 1
3
4
5
( ) 2
(c)
3
1
5
(d) 1
5
4
3
Match
the
M h List
Li I with
i h List
Li II and
d select
l
h correct answer:
List I (Machine tool)
List II (Features)
A. Lathe
1.
Push or pull tool
B Drilling machine
B.
2
2.
Rachet and pawl
mechanism
C Shaper
C.
Sh
3.
Di idi head
Dividing
h d
D. Broaching
g machine
4.
Hollow tapered
p
spindle
p
5.
Face plate [D]
Codes:A
B
C
D
A
B
C
D
(a) 2
4
5
1
(b) 5
3
2
4
(c) 2
3
5
4
(d) 5
4
2
1
Page 64
Milling
BySKMondal
IES 2007
IES 1997
Consider
C
id the
th following
f ll i statements:
t t
t
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 that of cutter
rotation.
Of these statements correct are:
(a) 1 and 3
(b) 1 and 4
(c) 2 and 3
(d) 2 and 4
A
What
Wh is
i the
h process off removing
i metall by
b a milling
illi
cutter which is rotated against the direction of
travel of the work piece, called?
(a) Down milling
(b) Up milling
(c) End milling
(d) Face milling
B
IES 1995,ISRO2010
IAS2009main
IAS2009 main
In
operation
two side
cutters are
I a milling
illi
i
id milling
illi
mounted with a desired distance between them so
that both sides of a work piece can be milled
simultaneously.
y This set up
p is called.
(a) Gang milling
(b) Straddle milling
( ) String
(c)
S
milling
ll
(d) Side
S d milling.
ll
Definethetermfeedinmilling.[2Marks]
IES2010
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.
operation
Reason (R): In climb or down milling operation, the
rotational motion of the cutter as well as the feed motion of
the workpiece are in the same direction, and the depth of
cut is maximum at the entry point as the cutter engages the
workpiece.
explanation of A
(b) Both
B th A and
i di id ll true
t
b t R is
but
i NOT the
th correctt
explanation of A
( ) A is true but
(c)
b R is false
f l
B
IAS2009Main
IAS2009 Main
With a sketch,
k t h explain
l i the
th principle
i i l off working
ki
and variations of bed
bedtype
type milling machine.
machine
[9 marks]
[9marks]
IES 2006
IES 2009
Gang
milling
G
illi is
i a
((a)) Milling
gp
process for g
generating
g hexagonal
g
surfaces
(b) Process of cutting gears
( ) Process
(c)
P
i which
in
hi h two or more cutters are used
d
simultaneously
(d) Milling operation combined with turning
C
For
which
gang
F machining,
hi i
hi h one off the
h following
f ll i
milling operations is employed?
(a) Threads
(b) Bores
(c) Grooves
(d) Steps on prismatic parts
D
Page 65
IES 2004,ISRO2011
One
brand
machine
has
two
O
b
d off milling
illi
hi
h the
h following
f ll i
index plates supplied along with the indexing head:
Plate 1: 15, 16, 17, 18, 19, 20 hole circles
Plate 2: 21, 23, 27, 29, 31, 33 hole circles
It is proposed to mill a spur gear of 28 teeth using simple
indexing method.
method Which one of the following combinations
of index plate and number of revolutions is correct?
( ) Plate 1: 1 revolution and 9 holes in 18 hole circles
(a)
((b)) Plate 2: 1 revolution and 9 holes in 21 hole circles
(c) Plate 2: 1 revolution and 9 holes In 33 hole circles
(d) Plate 1: 1 revolution
re olution and 9 holes In 15 hole circles B
IES 2000
One
off the
plates
off a milling
machine
O
h index
i d
l
illi
hi
dividing head has the following hole circles: 15; 16;
17; 18; 19; 20
A gear wheel of 34 teeth has to be milled by simple
indexing method. To machine each tooth, the index
crank has to be rotated through
(a) 17 holes in the 20hole circle
(b) 18 holes in the 20hole circle
( ) 1 revolution
(c)
l ti and
d 3 holes
h l in
i 17hole
h l circle
i l
(d) 1 revolution and 2 holes in 18hole circle C
A standard
head
d d dividing
di idi
h d is
i equipped
i
d with
i h the
h
following index plates
1. Plate with 12, 16, 17, 18, 19, 20 holes circles
2 Plate with 21,
2.
21 23,
23 27,
27 29,
29 31,
31 33 holes circles
3. Plate with 37, 39, 41,43,47,49 holes circles
For obtaining 24 divisions on a work piece by simple
indexing
(a) Hole plate 2 alone can be used
(b) Hole plates 1 and 2 can be used
(c) Hole plates 1 and 3 can be used
(d) Any of the three hole plates can be used D
GATE 1995
ListI
Li I
((Manufacturing
g Processes))
(A) Finish turning
1.
(B) Forming
F
i
2.
((C)) Thread cutting
g
33.
(D) Down milling
4.
Codes:A
d
B
C
D
(a) 2
3
4
1
(b)
(c) 1
2
3
4
(d)
List
Li II
((Condition))
Backlash eliminator
Z
Zero
rake
k
Nose radius
Low speed [A]
A
B
C
D
3
4
1
2
4
1
2
3
IES 2009
The
off a milling
machine
is
Th arbor
b
illi
hi
i used
d to hold
h ld
which one of the following?
(a) Spindle
(b) Overarm
(c) Cutting tool
(d) Mandrel
C
E
Example
l
IAS 1994
AC50steelflatsurfaceofdimensions100mm
AC
lfl f
fdi
i
250
mmistobeproducedonahorizontalaxismilling
machine.AnHSSslabmillwitha100mmdiameter
and150mmwidthistobeusedforthepurpose.The
5
p p
millingcutterhas8teeth.
Calculatethemachiningtimeassumingthatentire
stockcanberemovedinonedepthof2mm.
Given,
Feed f=0 13mm/tooth
Feed,f=0.13mm/tooth,
Cuttingspeed,V=20m/min.
GATE 1993
IES 2003
A milling
cutter having
8 teeth
at 150
illi
h i
h is
i rotating
i
rpm. If the feed per tooth is 0.1 mm, the table speed
in mm per minute is
(a) 120 (b) 187
(c) 125 (d) 70
In
machine,
the
tooll is
I milling
illi
hi
h cutting
i
i held
h ld in
i
position by
(a) Chuck
(b) Spindle
(c) Arbor
(d) Tool holder
C
IES 1994
Consider
C
id the
h following
f ll i operations:
i
g keyy ways
y on shafts
1. Cutting
2. Cutting external screw threads.
3. Cutting
C i teeth
h off spur gears
4. Cutting
4
g external splines.
p
Those which can be performed with milling cutters
would
ld include
i l d
(a) 1 and 2
(b) 2,3 and 4
(c) 1 and 3
(d) 1,2,3 and 4 D
Page 66
IES 1992
A set off eight
relieved
i h form
f
li
d milling
illi cutters for
f each
h
module is provided to enable cutting of gears of
different
(a) Materials
(b) Types e.g. spur, helical, etc.
(c) Number of teeth
(d) Width of gears
C
GATE 1992
IES 1995
In
process. (up/down)
I horizontal
h i
l milling
illi
( /d
)
milling provides better surface finish and..
(updown) milling provides longer tool life.
Assertion
(A):
or climb
is
A
i
(A) Up
U milling
illi
li b milling
illi
i
commonly used for machining castings and
forgings.
Reason (R): Up milling can be done on universal
milling machines.
( ) Both
(a)
h A and
d d ll true and
d R is the
h
D
Ans down,
Ans.
down down
IES 1993
Which
Whi h one off the
h following
f ll i statements is
i correct??
In upmilling
p
g operation,
p
, the undeformed chip
p thickness,,
a) Is zero at the start of the cut and increases to a
maximum value just before the tooth disengages the
workpiece.
b) Increases to the maximum value at the centre of the
ttravel
ave aand
d dec
decreases
eases to
towards
a ds tthee eend
d o
of toot
tooth
engagement.
c)) Has
H a maximum
i
value
l just
j t after
ft the
th cutt is
i started
t t d and
d
drops to zero at the end of the cut.
d) Remains unchanged.
A
IES 2002
Assertion
(A):
milling
machines
A
ti
(A) Virtually
Vi t ll all
ll modern
d
illi
hi
are capable of doing downmilling.
R
Reason
(R) In
(R):
I downmilling
d
illi
the
h cutter tends
d to push
h
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.
cut
explanation of A
correctt explanation
l
ti off A
C
Climb
while
Cli b milling
illi is
i chosen
h
hil machining
hi i because
b
((a)) The chip
p thickness increases g
graduallyy
(b) It enables the cutter to dig in and depth of cut
( ) The
(c)
Th specific
ifi power consumption
i is
i reduced
d d
((d)) Better surface finish can be obtained
D
IES 1999
IES 2002
A straight
cutter off 100 mm
i h teeth
h slab
l b milling
illi
diameter and 10 teeth rotating at 200 r.p.m. is used
to remove a layer of 3 mm thickness from a steel bar.
If the table feed is 4
400 mm/minute,
/
, the feed p
per
tooth in this operation will be
(a) 0.2
0 2 mm
(b) 0.4
0 4 mm
(c) 0.5 mm
(d) 0.6 mm
A side
cutter 125 mm diameter
has
id and
d face
f
di
h 10 teeth.
h
It operates at a cutting speed of 14 m/min with a
table traverse 100 mm/min. The feed per tooth of
the cutter is
(a) 10 mm
(b) 2.86 mm
( ) 0.286 mm (d) 0.8 mm
(c)
C
IES 2005
Page 67
IES 2004
The
speed
cutter while
Th cutting
i
d off a milling
illi
hil cutting
i
brass is:
(a) 45 to 60 m/min
(b) 30 to 40 m/min
(c) 25 to 35 m/min
(d) 15 to 20 m/min
A
GATE 2012(PI)CommonDataS1
Data for a plain milling operation are given below.
Length of workpiece
200 mm
Cutter diameter
100 mm
No. of teeth
4
Cutter speed
100 rpm
Feed
200 mm/min
Depth of cut
2 mm
Total clearance (entry and exit) 5 mm [C]
Mean undeformed chip thickness (in microns) is
(a) 142
(b) 100
(c) 71
(d) 50
GATE 2012(PI)CommonDataS2
IES 2004
Data for a plain milling operation are given below.

Length of workpiece
200 mm
Cutter diameter
100 mm
No. of teeth
4
Cutter speed
100 rpm
Feed
200 mm/min
Depth of cut
2 mm
Total clearance (entry and exit) 5 mm
Machiningtimeforasinglepass(inseconds)is
(a)60 (b)66
(c)126
(d)150
[B]
Match
problem)
M t h List
Li t I (Milling
(Milli
bl ) with
ith List
Li t II (Probable
(P b bl
causes) and select the correct answer using the codes
given below the Lists:
List I
List II
A Chatter
A.
Ch
1.
T high
Too
hi h feed
f d
B. Poor surface finish 2.
Lack of rigidity in machine
fixtures, bar or workpiece
High
g cutting
g load
C. Loss of accuracyy 33.
D. Cutter burrs
4.
Radial relief too great
5
5.
Not enough lubricant [B]
Codes:A
B
C
D
A
B
C
D
(a) 2
1
5
3
(b) 2
1
3
5
(c) 4
5
2
3
(d) 4
2
3
5
IAS 1998
IAS 2001
Which
statements
off face
Whi h off the
th following
f ll i
t t
t are true
t
f
milling?
1. Face milling cutter is held on an arbor.
2. It has two rake angles
g
axial rake and radial rake.
3. The maximum chip thickness equals the feed per
tooth.
tooth
4. The chip thickness varies from a minimum at the
start
t t off cutt to
t a maximum
i
att the
th end
d off cut.
t
Codes :
(a) 1 and 2
(b) 2 and 3
(c) 2 and 4
(d) 3 and 4
[B]
IAS 2003
A milling
cutter off 70 mm diameter
with
illi
di
i h 12 teeth
h is
i
operating at a cutting speed of 22 m/min and a feed
of 0.05 mm/tooth. The feed per minute is
(a) 110 m/min (b) 35 mm/min
(c) 6 mm/min (d) 60 mm/min
[D]
Which
are suitable
Whi h off the
h following
f ll i mechanisms
h i
i bl for
f
indexing the table of rotary transfer line?
1. Rack and pinion
2.
Ratchet and pawl
3 Lead screw
3.
4
4.
Geneva mechanism
Select the correct answer by using the codes given below:
Codes:
( ) 1, 2 and
(a)
d 3 (b) 2, 3 and
d4
(c) 1, 3 and 4 (d) 1, 2 and 4 [D]
IES1994
Whichoneofthefollowingoperationsiscarriedout
Whi h
f h f ll i
i
i
i d
attheminimumcuttingvelocityifthemachinesare
equallyrigidandthetoolworkmaterialsarethe
same?
(a) Turning
(b) Grinding
G d
(c) Boring
o g
(d) Milling[D]
Page 68
IAS 2001
Which one of the following statements are correct in respect of
upmilling and downmilling?
1.
In upmilling
p
g the cutter rotates in a direction opposite
pp
to that of
workpiece
k
travell whereas
h
in downmilling
d
ll
the
h cutter rotates in a
direction similar to that of workpiece travel.
2
2.
In down
downmilling
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 for a chip
formed by upmilling.
3.
D
Downmilling
illi is
i desirable
d i bl with
ith milling
illi cutters
tt
h i a high
having
hi h radial
di l
rake angle when compared to upmilling.
4.
Downmilling
Dow
g forces
o ces tthee wo
workpiece
p ece aga
against
st tthee milling
g tab
tablee to
exert more pressure while upmilling tends to lift the workpiece from the
table.
Codes:
(a) 1, 2 and 3
(b)
1, 2 and 4
(c) 3 and 4
(d)
1, 3 and 4
[D]
IAS 2000
Consider
C
id the
h following
f ll i mechanisms:
h i
g
g
1. Geneva gearing
2. Rack and pinion
3. Ratchet
R h and
d pawll
Which of these mechanisms are used to index the work
table on a transfer machine?
( ) 1 and
(a)
d2
(b) 2 and
d3
(c) 1 and 3
(d) 1, 2 and 3 [D]
IES 2012
Statement
in
are induced
to
St t
t (I):
(I) Vibrations
Vib ti
i milling
illi
i d d due
d
t
interrupted cutting operation.
S
Statement
(II) Vib i
(II):Vibrations
can be
b suppressed
d to a large
l
extent
by using equal spacing of teeth along the periphery of the
cutters.
cutters
(a) Both Statement (I) and Statement (II) are individually
t
true
and
d Statement
St t
t (II) is
i the
th correctt explanation
l
ti
off
Statement (I)
(b) Both
B h Statement
S
(I) and
d Statement
S
(II) are individually
i di id ll
true but Statement (II) is not the correct explanation of
St t
Statement
t (I)
(c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement (II) is true [B]
IES 2011
IES2011
g
MatchListIwithListIIandselectthecorrectanswerusing
thecodegivenbelowthelists:
Li I
ListI
Li II
ListII
A Lathe
A.Lathe
1 Flute
1.Flute
B.Shaper
2.Universalindexing
C.Drillingmachine
3.Leadscrew
D.Millingmachine
Codes
4.Rockerarm[B]
A
(a) 2
(c) 2
B
4
1
C
1
4
D
3
3
(b)
(d)
A
3
3
B
4
1
C
1
4
D
2
2
IES 2002
Match
M h List
Li I with
i h List
Li
answer:
List I (Machine tools)
A Lathe
A.
B. Milling machine
C. Shaper
D Drilling
D.
D illi machine
hi
Codes:A B
C
D
(a) 4
2
3
1
( ) 4
(c)
3
2
1
IES 1999
Consider
the
following
processes for
the
C
id
h
f ll i
f
h
manufacture of gears:
1. Casting
2 Powder metallurgy
2.
3. Machining from bar stock
4. Closed die forging
Th correctt sequence in
The
i increasing
i
i
order
d off bending
b di
strength of gear teeth is
(a) 1, 2, 3, 4
(b) 1, 2, 4, 3
(c) 2,
2 1,
1 4,
4 3
(d) 2,
2 1,
1 3,
3 4
A
List II (Machine tool parts)

1
1.
Lead strew
2.
Rocker arm
3.
Universal indexing
4.
Fl t
Flute
[B]
A
B
C
D
(b) 1
3
2
4
(d) 1
2
3
4
GearManufacturing
g
BySKMondal
IES 2006
Which
is/are
used
cutting
Whi h off the
h following
f ll i
i /
d for
f
i
internal gears?
1. Gear hobber
2.
Gear shaper
3 Rack cutter
3.
4
4.
Jig borer
(a) Only 1 and 2
(b) Only 2 and 3
( ) Only
(c)
O l 1 and
d4
(d) Only
O l 2
D
IES 2005
In
the
off
I helical
h li l milling,
illi
h ratio
i off the
h circumference
i
f
the gear blank to the lead of the helix determines
the:
(a) Proper speed to use
(b) Proper feed and depth of cut required
(c) Angle setting of the machine table
(d) Gear ratio for table screw and dividing head
C
IES2010
Match List I with List II and select the correct answer using
the code given below the lists:
Li t I
List
Li t II
List
(Type of work)
(Manufacturing)
A. High rate production of worm Gears and 1. Gear shaving
worm wheel
[D]
B. Generating internal gears and Cluster gears 2. Gear milling
C Finishing of gear tooth profiles
C.
3 Gear hobbing
3.
D. Repair and piece production of gears
4. Gear shaping
A
B
C
D
A
B
C
D
(a)
2
1
4
3
(b)
3
1
4
2
(c)
2
4
1
3
(d)
3
4
1
2
II and
the
d select
l
h correct
IES 1996
Gear
cutting
G
i on a milling
illi machine
hi using
i an involute
i
l
profile cutter is a
(a) Gear forming process
(b) Gear generating process.
process
(c) Gear shaping process
(d) Highly accurate gear producing process.
IES 2000
Which
processes off gear
Whi h one off the
h following
f ll i
manufacture results in best accuracy of the involute
gear tooth profile?
(a) Milling
(b) Hobbing
(c) Rotary gear shaper
(d) Rack type gear shaper
[A]
D
Page 69
IES 2009
Assertion
(A):
produced
form
A
ti
(A) Gears
G
d
d by
b employing
l i
f
cutting principle using gearmilling cutter on a milling
machine are not very accurate.
accurate
Reason (R): Production of the correct gear tooth profile
employing formcutting
form cutting principle would require a
separate cutter for cutting different numbers of teeth
even for the same module and also errors are associated
with inaccurate operation of indexing mechanism.
(a) Both A and R are true and R is the correct explanation of
A
(b) Both
B th A and
d R are true
t
b t R is
but
i NOT the
th correctt
explanation of A
( ) A is
(c)
i true but
b R is
i false
f l
[A]
IES 1996
Consider
the
following
processes off gear
C
id
h
f ll i
manufacture:
1. Milling with form cutter
2 Rack type gear shaper (gear planer)
2.
3. Rotary gear shaper (gear shaper)
4. Gear hobbing
Th correctt sequence off these
The
th
processes in
i increasing
i
i
order of accuracy of involute profile of the gear
(a) 3, 2, 4, 1
(b) 2, 3, 4, 1
(c) 3,
3 2,
2 1,
1 4
(d) 2,
2 3,
3 1,
1 4
[A]
IES 2004
Gear
shaping
G
h i is
i a process off manufacturing
f
i gears.
gp
principles
p is employed
p y byy it?
Which one of the following
(a) Form cutting with cutter
(b) Generating
G
i tooth
h form
f
with
i h a reciprocating
i
i cutter
((c)) Generating
g tooth form byy a rotating
g cutter
(d) Generating form with a reciprocating and revolving
cutter
tt
IES 2009
By
the
B which
hi h one off the
h following
f ll i machines
hi
h teeth
h off
an internal spur gear can be cut accurately?
(a) Milling machine
(b) Slotting machine
(c) Hobbing machine
(d) Gearshaping machine
[D]
IES 1992
IES 2003
In
I gear hobbing
h bbi
((a)) Onlyy hob rotates
(b) Only gear blank rotates
( ) Both
(c)
B h hob
h b and
d gear blank
bl k rotate
((d)) Neither hob nor g
gear blank rotates
A spur gear off 40 teeth

h is
i machined
hi d in
i a gear
hobbing machine using a double start hob cutter.
The speed ratio between the hob and the blank is
(a) 1:20 (b) 1:40
(c) 40: 1 (d) 20: 1
IES 2008
Which
processes are used
gear
Whi h machining
hi i
d for
f
manufacture?
1. Form milling
2.
Broaching
3 Roll forming
3.
4
4.
Hobbing
(a) 1, 2 and 3
(b) 1, 3 and 4
( ) 1, 2 and
(c)
d4
(d) 2, 3 and
d4
C
IES 1999
A 60teeth
hobbed
6
h gear when
h
h bb d on a differential
diff
i l
hobber with a twostart hob, the index change gear
ratio is governed by which one of the following
kinematic balance equations?
q
(a) 1 revolution of gear blank = 1/60 of hob revolutions
(b) 1 revolution
l
off gear blank
bl k = 2/60
/ off hob
h b revolutions
l
(c) 1 revolution
evo ut o o
of hob
ob = 2/60
/60 o
of b
blank
a revolutions
evo ut o s
(d) 1 revolution of hob = 1/60 of blank revolutions
C
Page 70
IES 1997
Which
motions
are not needed
Whi h off the
h following
f ll i
i
d d for
f
spur gear cutting with a hob?
1. Rotary motion of hob
2 Linear axial reciprocator motion of hob
2.
3. Rotary motion of gear blank
4. Radial advancement of hob.
S l t the
Select
th correctt answer using
i the
th codes
d given
i
b l
below:
(a) 1, 2 and 3 (b) 1, 3 and 4
(c) 1, 2 and 4 (d) 2, 3 and 4
D
IES 2007
Which
Whi h off the
h following
f ll i methods
h d are gear generating
i
processes?
1. Gear shaping
2 Gear hobbing
2.
3. Gear milling
( ) 1, 2 and
(a)
d3
(b) 1 and
d 2 only
l
(c) 2 and 3 onlyy
(d) 1 and 3 onlyy
B
GATE 2007(PI)
( )
Which
Whi h one off the
th following
f ll i gear manufacturing
f t i
processes is NOT based on g
p
generation p
principle?
p
(a) Gear Hobbing
(b) Gear Shaping
(c) Gear Milling
(d) Gear Shaving
IES 2006
IES 1996
Which
cannot be
Whi h off the
h following
f ll i
b cut by
b hobbing
h bbi
process?
(a) Helical gears
(b) Bevel gears
(c) Worm gears
(d) Spur gears
For
the
off full
F
h manufacture
f
f ll depth
d
h spur gear by
b
hobbing process, the number of teeth to be cut = 30,
module = 3 mm and pressure angle = 20. The radial
depth
p of cut to be employed
p y should be equal
q
to
(a) 3.75 mm
(b) 4.50 mm
( ) 6.00 mm
(c)
(d) 6.75 mm
B
D
IES 1995
While
helical
Whil cutting
i
h li l gears on a nondifferential
diff
i l
gear hobber, the feed change gear ratio is
(a) Independent of index change gear ratio
(b) dependent on speed change gear ratio
(c) Interrelated to index change gear ratio
(d) Independent of speed and index change gear ratio.
Internal
I
l gear cutting
i operation
i can be
b performed
f
d by
b
((a)) Milling
g
(b) Shaping with rack cutter
( ) Shaping
(c)
Sh i with
i h pinion
i i cutter
((d)) Hobbing
g
IAS 1998
Assertion
(A):
A
i
(A) Internal
I
l gears are cut on a gear
shaper.
Reason (R): Hobbing is not suitable for cutting
internal gear.
gear
correct explanation
l
off A
(b) Both
ot A aand
d v dua y ttrue
ue but R iss not
ot tthee
( ) A is
(c)
i true
t
b t R is
but
i false
f l
[B]
IES 1993
IES 1992
Gear
burnishing
G
b
i hi process for
f
((a)) Removing
g residual stresses from teeth roots
(b) Surface finishing
( ) Undercut
(c)
U d
gears
((d)) Cycloidal
y
gears
g
IAS 2003
Which
is
off gear
Whi h one off the
h following
f ll i
i not a feature
f
hobbing process?
(a) High rate of production
(b) Generation of helical gears
(c) Very accurate tooth profile
(d) Generation of internal gears
B
D
C
Page 71
IAS 2001
Consider
motions
and
in
C
id the
h following
f ll i
i
d setting
i
i a
hobbing machine:
1. Hob rotation
2 Job rotation
2.
3. Axial reciprocating hob rotation
4. Tilting of hob to its helix angle
Whi h off these
Which
th
motions
ti
and
d setting
tti
i a hobbing
in
h bbi
machine are required to machine a spur gear?
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1,
1 2 and 4 (d) 1,
1 3 and 4
C
IES 1994
Consider
C
id the
h following
f ll i machine
hi tools:
l
g machine
1. Hobbing
2. Gear shaping machine
3. Broaching
B
hi machine.
hi
p g
gears can be cut in
The teeth of internal spur
(a) 1, 2 and 3 (b) 1 and 2
( ) 1and
(c)
d3
(d) 2 and
d3
Qualityscrewthreadsareproducedby
Q li
h d
d
db
((a)) Threadmilling
g
(b) Threadchasing
( ) Threadcuttingwithsinglepointtool
(c)
Th d
i i h i l i l
((d)) Threadcasting
g
B
IES2011
Externall threads
h d can be
b produced
d d by
b :
1. Rolling
g
2. Grinding
3 Milling
3.
(a) 1 and 3 only
(b) 1 and 2 only
(c) 2 and 3only
(d) 1, 2 and 3
D . Form g
grinding
g wheel p
produces veryy g
good q
qualityy
thread.
BySKMondal
IES2010
For
producing
both
F
d i
b th internal
i t
l and
d external
t
l
screw threads, the method used is
(a) Thread chasing with multiplerib chasers
(b) Thread milling and multiplethread cutters
(c) Thread tapping with taps
((d)) Die threading
g with selfopening
p
g die heads
Gear
lapping
G
l
i
((a)) An operation
p
after heat treatment
(b) An operation prior to heat treatment
( ) An
(c)
A independent
i d
d
operation
i for
f gear reconditioning
di i i
((d)) None of the above
GATE 2003
ScrewThread
Manufacturing
IES 1992
IES 2007
Screw
threads
S
h d are produced
d
d on solid
lid rods
d by
b using
i
which of the following?
(a) Dies
(b) Punch
(c) Mandrel (d) Boring bar
ISRO2011
Whi h fth f ll i
Whichofthefollowingscrewthreadisadaptedfor
th di d t df
powertransmissioninonedirection
(a)Acmethreads
( )
(b)Buttressthreads
( ) q
(c)Squarethreads
(d)Multiplethreads
Page 72
IES 2012
ISRO2010
I t
Internal
l and
d external
t
l threads
th d can be
b produced
d d
on tapered surfaces conveniently by
(a) Universal milling machine
(b) Plano
a o miller
e
The differential screw is used in a
Multistart threads are used to get
(a) Turnbuckle
(a) Smaller linear displacement
(b) Micrometer
(b) Larger linear displacement with assured self locking
(c) Vernier Caliper
(c) Larger linear displacement with no guarantee of self
locking
(d) Coupler
C
l
((c)) Planetaryy milling

g machine
((d)) lathe
IES 2012
(d) None of the above
IES 2012
GATE 2005
Which of the following screw threads is adopted for

power transmission in either
h direction
d
Sh
Shaper,Planner,Slotter
Pl
Sl
( ) ACME threads
(a)
h d
(b) Square
S
th d
threads
(c) Buttress threads
BySKMondal
(d) Multiple threads

B
IES 2004
Consider
tests on machine
C
id the
h following
f ll i alignment
li
hi
tools
1. Straightness
2.
Flatness
3 Run out
3.
4
4.
Parallelism
Which of the above alignment tests on machine tools are
common to both lathe and shaper?
(a) 1 and 2
(b) 2 and 3
(c) 3 and 4
(d) 1 and 4
D
IES 2001
In a shaper machine, the mechanism for tool feed is
(a) Geneva mechanism
(b) Whitworth mechanism
( ) Ratchet and Pawl mechanism
(c)
(d) Ward
W d Leonard
L
d system
C
Page 73
A 600
mm x 30 mm flat
off a plate
is
6
fl surface
f
l
i to be
b
finish machined on a shaper. The plate has been
fixed with the 600 mm side along the tool travel
direction. If the tool overtravel at each end of the
plate is 20 mm, average cutting speed is 8 m/min,
feed rate is 0.3
0 3 mm/stroke and the ratio of return
time to cutting time of the tool is 1:2, the time
required
i d for
f machining
hi i will
ill be
b
(a) 8 minutes (b) 12 minutes
(c) 16 minutes (d) 20 minutes
B
IES2010
Assertion (A): Longitudinal cutting motion of the
tool and crosswise feed motion of the job generates
fl surfaces
flat
f
i planning
in
l
i process.
) JJobs used in p
planning
g machines are
Reason ((R):
generally long and heavy compared to shaping.
( ) Both
(a)
B th A and
i di id ll true
t
and
d R is
i the
th
(b) Both A and R are individually true but R is NOT the
D
IES 1997
IES 1995
Which
are the
off a
Whi h off the
h following
f ll i
h advantages
d
hydraulic shaper over a mechanically driven shaper?
1. More strokes per minute can be obtained at a given
cutting speed.
speed
2. The cutting stroke has a definite stopping point.
3. It is simpler in construction.
4 Cutting speed is constant throughout most of the
4.
cutting stroke.
Select
l
the
h correct answer using the
h codes
d given below:
b l
(a) 1 and 2
(b) 1 and 4
(c) 2 and 4
(d) 1, 3 and 4
B
In
the
I a mechanical
h i l shaper,
h
h length
l
h off stroke
k is
i
increased by
(a) Increasing the centre distance of bull gear and crank
pin
(b) Decreasing the centre distance of bull gear and
crank
k pin
(c) Increasing
c eas g tthee length
e gt o
of tthee ram
a
(d) Decreasing the length of the slot in the slotted lever
A
ISRO2010
Size of a shaper is given by

(b)
Motor power
(c) Weight of the machine
(d)
Table size
Th cutting
The
tti
speed
d off the
th tool
t l in
i a mechanical
h i l
shaper is
(a) Maximum at the beginning of the cutting stroke
((b)) Maximum at the end of the cutting
g stroke
Given
that,
average cutting
speed
Gi
h
i
d = 9 m/min,
/ i the
h
return time to cutting time ratio is = 1 : 2, the feed
rate = 0.3 mm/stroke, the clearance at each end of
cut = 255 mm and that the p
plate is fixed with 7700 mm
side along the direction of tool travel, the time
required for finishing one flat surface of a plate of
size 700 x 30 mm in a shaper, will be
( ) 10 min
(a)
(b) 12.5 min
(c) 15 min
(d) 20 min
B
IAS 1995
(a) Stroke length
IES 1994,ISRO2008
IAS 1994
Stroke
S k off a shaping
h i machine
hi is
i 250 mm. It
I makes
k 30
double strokes per minute. Overall average speed of
operation is
(a) 3.75
3 75 m/min
(b) 5.0
5 0 m/min
(c) 7.5 m/min
(d) 15 m/min
D
((c)) Maximum at the middle of the cutting

g stroke
(d) Minimum at the middle of the cutting stroke
C
GATE 2012 (PI)

GATE2012(PI)
GATE2011(PI)
GATE 2011 (PI)
In a shaping process, the number of double strokes per
Grindingratioisdefinedas
minute is 30 and
d the
h quick
k return ratio is 0.6. Iff the
h
length of the stroke is 250 mm,
mm the average cutting
velocity in m/min is
((a)) 33.0
((b)) 4
4.55
((c)) 77.55
G d g&
s
g
Grinding&Finishing
((d)) 12.0
BySKMondal
volume of wheel wear

volume of work material removed
volume of work material removed
(b)
volume of wheel wear
cutting speed
(c)
feed
l it di l feed
longitudinal
f d
(d)
transverse feed
( )
(a)
Page 74
GATE 1995
IES2009
IES 2009
Among
the
processes,
A
h conventional
i
l machining
hi i
maximum specific energy is consumed in
(a) Turning
(b) Drilling
(c) Planning (d) Grinding
D
GATE 1998
Ideal
roughness,
as measured
Id l surface
f
h
d by
b the
h
maximum height of unevenness, is best achieved
when, the material is removed by
(a) An end mill
(b) A grinding wheel
(c) A tool with zero nose radius
(d) A ball mill
[2MARKS]
GATE 1998
In
using
abrasive
material,
I machining
hi i
i
b i
i l increasing
i
i
abrasive grain size
(a) Increases the material removal rate
(b) Decreases the material removal rate
(c) First decreases and then increases the material
removal rate
(d) First increases and then decreases the material
removal rate
GATE 2000
Abrasive
wheel
Ab i material
i l used
d in
i grinding
i di
h l selected
l
d
for grinding ferrous alloys is
(a) Silicon carbide
(b) Diamond
(c) Aluminium oxide
(d) Boron carbide
C
GATE 2002
The
off a grinding
wheel
Th hardness
h d
i di
h l is
i determined
d
i d by
b
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 work
piece
B
GATE 2006
If each
tool,
h abrasive
b i grain
i is
i viewed
i
d as a cutting
i
l
then which of the following represents the cutting
parameters in common grinding operations?
(a) Large negative rake angle,
angle low shear angle and high
cutting speed
(b) Large positive rake
k angle,
l low
l
shear
h
angle
l and
d high
h h
cutting speed
(c) Large negative rake angle, high shear angle and low
cutting speed
(d) Zero rake angle, high shear angle and high cutting
speed
A
GATE 1997
List
Li I
( ) Grinding
(A)
g
(B) Honing
(C) Superfinishing
D) Burnishing
1.
2.
3.
4.
5.
6.
List
Li II
Surface for oil retention
Surface for max. load
capacity
Surface of limiting friction
Surface of matte finish
S f
Surface
f pressure sealing
for
li
Surface for interference fit.
A
Ans.
(A) 3, (B) 1, (C)2,
(C) (D)5
(D)
Page 75
IES 2005
Consider
the
statements in
C
id
h following
f ll i
i respect off
grinding?
1. The pitch of the grit cutting edges is larger than the
pitch of the milling cutter.
cutter
2. The cutting angles of the grits have a random
geometry.
3. The
e ssizee o
of tthee cchip
p cuts iss ve
veryy ssmall
a for
o g
grinding.
d g.
Which of the statements given above are correct?
( ) 1 and
(a)
d2
(b) 2 and
d3
(c) 1 and 3
(d) 1, 2 and 3
B
IES 2009
IES 1997
Which
Whi h one off the
h following
f ll i is
i NOT used
d as abrasive
b i
material in grinding wheels?
(a) Aluminium oxide
(b) Silicon carbide
(c) Cubic boron nitride
(d) Manganese oxide
Which
Whi h one off the
h following
f ll i materials
i l is
i used
d as the
h
bonding material for grinding wheels?
(a) Silicon carbide
(b) Sodium silicate
(c) Boron carbide
(d) Aluminum oxide
IES 1996
Grinding
G i di wheel
h l is
i said
id to be
b loaded
l d d when
h the
h
((a)) Metal p
particles g
get embedded in the wheel surface
blocking the interspaces between cutting grains.
(b) Bonding material comes on the surface and the
wheel becomes blunt.
(c) Work piece being ground comes to a stop in
cylindrical
cy
d ca g
grinding.
d g.
(d) Grinding wheel stops because of very large depth of
cutt
A
IES 2001
Specific
energy is
process
S
ifi cutting
i
i more in
i grinding
i di
compared to turning because
(a) Grinding (cutting) speed is higher
(b) The wheel has multiple cutting edges (grains)
(c) Plaguing force is significant due to small chip size
(d) Grinding wheel undergoes continuous wear
B
IES 1996
Specific
in
process
S
ifi energy requirements
i
i a grinding
i di
are more than those in turning for the same metal
removal rate because of the
(a) Specific pressures between wheel and work being
high.
(b) Size
S effect
ff
off the
h larger
l
contact areas between
b
wheel
h l
and work.
(c) High cutting velocities
(d) High
Hi h heat
h t produced
d d during
d i grinding
i di
IES 1994
The
force
to cutting
is
Th ratio
i off thrust
h
f
i force
f
i nearly
l 2.5
in
(a) Turning
(b) Broaching
(c) Grinding (d) Plain milling
C
IES 1992
Assertion
(A):
A
i
(A) Vitrified
Vi ifi d bond
b d is
i preferred
f
d for
f thin
hi
grinding wheels.
Reason (R): Vitrified bond is hard brittle.
correct
co
ect eexplanation
p a at o o
of A
(d) A is false
f l but
b R is true
A
IES 2000
Assertion
to
is
A
ti (A):
(A) The
Th ratio
ti off cutting
tti force
f
t thrust
th
t force
f
i
very high in grinding process as compared to other
machining processes.
processes
Reason (R): Random orientation and effective negative
rake angles of abrasive grains increase the cutting force
and adversely affect the cutting action and promote
rubbing action.
action
explanation of A
correctt explanation
l
ti off A
D
Page 76
IES 1995
Soft
S f materials
i l cannot be
b economically
i ll grind
i d due
d to
((a)) The high
g temperatures
p
involved
(b) Frequent wheel clogging
( ) Rapid
(c)
R id wheel
h l wear
((d)) Low work p
piece stiffness
B
IES2010
In
to
I relation
l ti
t the
th peripheral
i h l or surface
f
p
of the g
grinding
g wheel and that of the
speeds
workpiece in cylindrical grinding of alloy
steel workpieces,
workpieces the grinding wheel speed is
((a)) Less than the speed
p
of the workpiece
p
(b) Same as the speed of the workpiece
(c) Double the speed of the workpiece
(d) 65
6 to
t 75 times
ti
th speed
the
d off the
th workpiece.
k i
D
IES 2001,ISRO2009
The
Th marking
ki on a grinding
i di wheel
h l is
i '51
' A 36
6 L 5 V 93'.'
The code '36' represents the
(a) Structure
(b) Grade
(c) Grain size
(d) Manufacturer's number
C
IES 1993
Tool
T l life
lif in
i the
h case off a grinding
i di wheel
h l is
i the
h time
i
((a)) Between two successive regrinds
g
of the wheel
(b) Taken for the wheel to be balanced
( ) Taken
(c)
T k between
b
two successive
i wheel
h l dressings
d
i
((d)) Taken for a wear of 1mm on its diameter
C
IES 2009
Given
that
Gi
h the
h peripheral
i h l speed
d off the
h grinding
i di
wheel of 100 mm diameter for cylindrical grinding
of a steel work piece is 30 m/s, what will be the
estimated rotational speed
p
of the g
grinding
g wheel in
revolution per minute (r.p.m.)?
(a) 11460
(b) 5730
30
(c) 2865
(d) 95
B
IES 2002
Which
materials
Whi h off the
h following
f ll i
i l are used
d in
i
grinding wheel?
1. Aluminium oxide
2 Cubic boron nitride
2.
3. Silicon carbide
( ) 1, 2 and
(a)
d 3 (b) 1 and
d2
(c) 2 and 3
(d) 1 and 3
A
IES 2000
The
"S 14 K 14 S" on a grinding
Th sequence off markings
ki
i di
wheel represents respectively
(a) Bond type, structure, grade, grain size and abrasive
type
(b) Abrasive type, grain size, grade, structure and bond
type
(c) Bond
o d type, g
grade,
ade, st
structure,
uctu e, g
grain
a ssizee aand
d ab
abrasive
as ve
type
(d) Abrasive
Ab i type,
t
structure,
t t
grade,
d grain
i size
i and
d bond
b d
type
B
IES 2001
Assertion
(A):
for
A
i
(A) Hard
H d wheels
h l are chosen
h
f grinding
i di
hard metals.
Reason (R): In hard wheels only the abrasive grains
are retained for long time.
time
correct explanation
l
off A
(b) Both
ot A aand
d v dua y ttrue
ue but R iss not
ot tthee
( ) A is
(c)
i true
t
b t R is
but
i false
f l
D
Page 77
IES 1995
In
I the
h grinding
i di wheel
h l off A 60
6 G 7 B 23, B stands
d for
f
((a)) Resinoid bond
((b)) Rubber bond
(c) Shellac bond
(d) Silicate bond.
A
IES 1994
Consider
the
following
statements regarding
C
id
h
f ll i
di
grinding of high carbon steel:
1. Grinding at high speed results in the reduction of
chip thickness and cutting forces per grit.
grit
2. Aluminium oxide wheels are employed.
3. The grinding wheel has to be of open structure.
Of these statements
(a) 1, 2 and 3 are correct
(c) 1 and 3 are correct
B
IES 1999
Consider
C
id the
h following
f ll i reasons:
g wheel is soft
1. Grinding
2. RPM of grinding wheel is too low
3. Cut
C is
i very fine
fi
4. An improper
4
p p cutting
g fluid is used
A grinding wheel may become loaded due to reasons
stated
t t d att
(a) 1 and 4
(b) 1 and 3
(c) 2 and 4
(d) 2 and 3
C
IES 2001
Dry
fluid
D and
d compressed
d air
i is
i used
d as cutting
i
fl id for
f
machining
(a) Steel
(b) Aluminium
(c) Cast iron (d) Brass
C
IES 1996
A grinding
is
i di wheel
di
i rotating
i at
3000 rpm. The grinding speed is
IES 2007
Honing
gives
surface
finish
H i Process
P
i
f
fi i h off what
h order?
d ?
((a)) 10
m ((CLA))
((b)) 1.0
m ((CLA))
(c) 0.1 m (CLA)
(d) 0.01 m (CLA)
IES 1992
CLA value
l for
f Honing
H i process is
i
((a)) 6
((b)) 0.055 33.0
(c) 0.05 1.0 (d) 0.025 0.1
C
C
In
grinding,
the
centre will
I centreless
l
i di
h work
k piece
i
ill be
b
((a)) Above the line jjoining
g the two wheel centres
(b) Below the line joining the two wheel centres
( ) On
(c)
O the
h line
li joining
j i i the
h two wheel
h l centres
((d)) At the intersection of the line jjoining
g the wheel
centres with the work plate plane.
A
IES 2000
Consider
C
id the
h following
f ll i advantages:
d
p p
process
1. Rapid
2. Work with keyways can be ground
3. No
N work
k holding
h ldi device
d i is
i required.
i d
g
of centre less
Which of these are the advantages
grinding?
( ) 1, 2 and
(a)
d 3 (b) 1 and
d2
(c) 2 and 3
(d) 1 and 3
D
IES 1993
Page 78
IES 1993
Consider
C
id the
h following
f ll i parameters:
g wheel diameter.
1. Grinding
2. Regulating wheel diameter.
3. Speed
S
d off the
h grinding
i di wheel.
h l
4. Speed
4
p
of the regulating
g
g wheel.
5. Angle between the axes of grinding and regulating
wheels.
h l
Among
g these p
parameters, those which influence the
axial feed rate in centreless grinding would include
(a) 2,
2 4 and 5 (b) 1,
1 2 and 3
(c) 1, 4 and 5 (d) 3, 4 and 5
A
IES 2012
Statement(I):Honingisanabradingprocesstoremove
St t
t(I) H i i b di
t
stockfrommetallicsurfaces.
Statement(II):Honingiscommonlydoneoninternal
surfaces.
(a) Both Statement (I) and Statement (II) are
individuallyy true and Statement ((II)) is the correct
explanation of Statement (I)
(b) Both Statement (I) and Statement (II) are
individually true but Statement (II) is not the correct
explanation of Statement (I)
( ) Statement (I)
(d)
( ) is false but Statement (II)
( ) is true [B]
[ ]
IES 2001
Match
Tools)
M t h ListI
Li t I (Cutting
(C tti
T l ) with
ith ListII
Li t II (Applications)
(A li ti
)
and select the correct answer using the codes given
below the lists:
List I
List II
A Trepanning
A.
T
i tooll 1.
F surface
For
f
fi i hi by
finishing
b
honing
B. Side milling cutter 2.
For machining gears
33.
For cutting
g keyways
y y in shafts
C. Hob cutter
D. Abrasive sticks
4.
For drilling large diameter
[ ]
[B]
holes
Codes:A
B
C
D
A
B
C
D
(a) 1
3
2
4
(b) 4
3
2
1
(c) 1
2
3
4
(d) 4
2
3
1
IAS 2004
The
effect
refers
to the
in
Th size
i
ff
f
h increase
i
i specific
ifi
cutting energy at low values of under formed chip
thickness. It is due to which one of the following?
(a) Existence of ploughing force
(b) Work hardening
(c) High strain rate
(d) Presence of high friction at chiptool interface.
interface
A
IAS 2001
Consider the following statements:
The setup for internal centreless grinding consists of a
regulating wheel, a pressure roll and a support roll, between
which the tubular workpiece is supported with the grinding
wheel within the tube, wherein
1.The
Th grinding
i di
wheel,
h l workpiece
k i
and
d regulating
l i
wheel
h l centers
must lie on one line
2 The directions of rotation of workpiece and grinding wheel are
2.The
same
33.The directions of rotation of p
pressure roll,, support
pp
roll and
regulating wheel are same
4.The directions of rotation of grinding wheel and regulating
wheel
h l are same
( ) 1, 2 and
(a)
d3
(b)
1, 3 and
d4
(c) 2 and 3
(d)
3 and 4
A
IES 1992
A surface
finish
CLA values
f
fi i h off 0.025 0.1 micrometer
i
l
is to by produced. Which machining process would
you recommend?
(a) Grinding (b) Rough turning
(c) Lapping
(d) Honing
IES 1992
Buffing
B ffi wheels
h l are mode
d off
((a)) Softer metals
((b)) Cotton fabric
(c) Carbon
(d) Graphite
B
IAS 2000
Consider
statements in
C
id the
h following
f ll i
i respect off a
grinding wheel of specification, 51A 36L7R23,
using the standard alphanumeric codification:
1 Abrasive used in the wheel is aluminum oxide
1.
2. The grain size of abrasive is medium
3. The wheel grade is medium hard
4 It has an open structure
4.
5. It has resinoid as bonding agent
Which (If these statements are correct?
(a) 1,
1 2 and 3 (b) 1,
1 3 and 4
(c) 2, 3 and 5 (d) 1, 4 and 5
A
IAS 1999
Assertion
(A):
wheel
A
i
(A) The
Th grade
d off a grinding
i di
h l is
i a
measure of hardness of the abrasive used for the
wheel.
Reason (R): Grading is necessary for making right
selection of the wheel for a particular work.
( ) Both
(a)
h A and
d d ll true and
d R is the
h
D
IAS 1997
IAS 2007
Which
Whi h off the
h following
f ll i pairs
i are correctly
l matched?
h d?
1. Drill p
press :
Trepanning
p
g
2. Centreless grinding:
Through feeding
3. Capstan
C
l h
lathe:
R
Ram
type turret
g the codes g
given below:
Select the correct answer using
Codes:
( ) 1 and
(a)
d2
(b) 1, 2 and
d3
(c) 1 and 3
(d) 2 and 3
B
Match
M t h List
Li t I with
ith List
Li t II and
d select
l t the
th correctt answer
using the code given below the Lists:
Li I
List
Li II
List
(Machine Tool/ Cutting Tool)
(Part/ Characteristics)
A. Screw cutting lathe1.
Self locking taper
g dial
B. Drill
2.
Chasing
C. End mill
3.
Wiper insert
D Grinding wheel
D.
4
4.
Self releasing taper
5.
Balance weights
[B]
C d A
Code:A
B
C
D
A
B
C
D
(a) 4
5
3
1
(b) 2
1
4
5
(c) 4
1
3
5
(d) 2
5
4
1
Page 79
IAS 1999
IAS 2001
Which
processing
sequences
Whi h one off the
h following
f ll i
i
will give the best accuracy as well as surface finish?
(a) Drilling, reaming and grinding
(b) Drilling,
Drilling boring and grinding
(c) Drilling, reaming and lapping
(d) Drilling, reaming and electroplating
Which
grinding
wheels
Whi h one off the
h following
f ll i
i di
h l (with
( ih
Grade, Grit and Bond) is suitable for cutter
grinding?
(a) K 60 vitrified
(b) K 320 vitrified
(c) T 60 resinoid
(d) T 320 resinoid
NC,CNC&Robotics
BySKMondal
IAS 1996
Assertion
(A):
A
i
(A) The
Th temperature controll off an
electric iron is an example of servomechanism.
Reason (R): It is an automatic control system.
correct
co
ect eexplanation
p a at o o
of A
(d) A is false
f l but
b R is true
D
GATE 1994
CNC machines
are more accurate than
hi
h conventional
i
l
machines because they have a high resolution
encoder and digital readouts for positioning.
True or false?
Ans. True
IES 1995
Consider
the
following
characteristics
off
C
id
h
f ll i
h
i i
production jobs:
1. Processing of parts frequently in small lots
2 Need to accommodate design changes of products.
2.
products
3. Low rate of metal removal
4. Need for holding close tolerances
Th
The
characteristics
h
t i ti
which
hi h favour
f
th choice
the
h i
off
numerically controlled machines would include
(a) 1, 2 and 3
(b) 2, 3 and 4
(c) 1,
1 3 and 4 (d) 1,
1 2 and 4
D
IES 1999
Consider
the
following
statements
C
id
h
f ll i
numerically controlled machine tools:
1. They reduce nonproductive time
2 They reduce fixturing
2.
3. They reduce maintenance cost
( ) 1, 2 and
(a)
d 3 (b) 1 and
d2
(c) 2 and 3
(d) 1 and 3
B
IES 2009
In
machining
manuall part
I which
hi h off the
h following
f ll i
hi i
programming is done?
(a) CNC machining
(b) NC machining
(c) DNC machining
(d) FMS machining
B
GATE 1993
With
to NC machine,
which
Wi h reference
f
hi
hi h off the
h
following statement is wrong?
(a) Both closedloop and openloop control systems are
used
(b) Paper tapes, floppy tapes and cassettes are used for
data storage
(c) Digitizers
g t e s may
ay be used as interactive
te act ve input
put dev
devices
ces
(d) Post processor is an item of hardware
D
Page 80
regarding
di
IES 2007
What
Wh are the
h main
i components off an NC machine?
hi ?
1. Part program
p g
2. Machine Control Unit
3. Servo
S
motor
g the code g
given below:
Select the correct answer using
(a) 1, 2 and 3
(b) 1 and 2 only
( ) 2 and
(c)
d 3 only
l
(d) 1 and
d 3 only
l
A
IES 2009
JWM2010
Consider the following components regarding numerical
control system :
1. Programme of instructions
2 Machine control unit
2.
3. Processing equipment
Which of these are correct ?
(a) 1,
1 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only (d) 1 and 3 only
A
IES 1999
ConsiderthefollowingadvantagesofDNCsystems:
1.Timesharing
2.Greatercomputationalcapability
3 Remotecomputerlocation
3.Remotecomputerlocation
IES 2002Contd..FromS1
d
DNC system
t
3.
The
Th controller
t ll consists
i t off
softwired computer and
h d wired
hard
i d logic
l i Graphic
G hi
display of tool path is
also
l possible
ibl
D. Machining centre 4.
The instructions on tape is
prepared in binary
decimal form and operated
p
byy
a series of coded
[ ]
[C]
instructions
Codes:A
B
C
D
A
B
C
D
(a) 4
2
3
1
(b) 1
3
2
4
(c) 4
3
2
1
(d) 1
2
3
4
IES 2002S1
JWM2010
Consider
C
id the
h following
f ll i components:
p
1. A dedicated computer
2. Bulk memory
3. Telecommunication
Tl
i i lines
li
p
are required
q
for a DNC
Which of these components
system?
( ) 2 and
(a)
d3
(b) 1 and
d2
(c) 1, 2 and 3 (d) 1 and 3
C.
C
What
is
computers in
Wh
i the
h purpose off satellite
lli
i
Distributed Numerical Control machines?
(a) To act as standby systems
(b) To share the processing of largesize
large size NC programs
(c) To serve a group of NC machines
(d) To network with another DNC setup
Whichoftheaboveis/arecorrect?
( ) d l
(a)1and2only
(b) d l
(b)2and3only
(c)2only
y
(d)1,2and33
IAS2011main
IAS2011 main
Match
M t h List
Li t I with
ith List
Li t II and
d select
l t the
th correctt
answer:
List I
List II
((NC machine tool systems)
y
)
((Features))
A. NC system 1.
It has an integrated automatic tool
changing unit and a component
indexing device
B CNC system
B.
t
2.
A number
b off machine
hi
t l are
tools
controlled by a computer. No tape
reader,
d the
th partt program is
i
transmitted directly to the
machine
hi tool
t l from
f
th
the
computer memory
IAS2009main
IAS2009 main
E l i att least
Explain,
l t two,
t
characteristics
h
t i ti each
h off NC,
NC
CNC and DNC.
DNC
Wh t is
What
i the
th function
f
ti off stepper
t
motor?
t ?
[2 marks]
[2
[10 Marks]
[10Marks]
Page 81
GATE 2007
IAS2010Main
Illustratewiththehelpofneatsketchesthedifferences
betweenopenloopandclosedloopcontrolinNC
system.Whyisfeedbacknotpossibleinopenloop
controls stem?
controlsystem?
WhichtypeofmotorisNOTusedinaxisorspindle
Whi h
f
i NOT
di i i dl
drivesofCNCmachinetools?
(a) Inductionmotor
(b) DCservomotor
(c) Steppermotor
(d) Linearservomotor
A
IES 1994
Feed
in
machines
are provided
F d drives
d i
i CNC milling
illi
hi
id d
by
(a) Synchronous motors
(b) Induction motors
(c) Stepper motors
(d) Servomotors.
[22 Marks]
[22
IES 2002
GATE 1997
In
I a CNC machine
hi tool,
l encoder
d is
i used
d to sense and
d
control
(a) Table position
(b) Table velocity
(c) Spindle speed
(d) Coolant flow
B
In
the
I a point
i to point
i controll NC machine,
hi
h slides
lid
are positioned by an integrally mounted stepper
motor drive. If the specification of the motor is
1o/p
/pulse,, and the p
pitch of the lead screw is 33.6 mm,,
what is the expected positioning accuracy?
( a ) 1 m
(c ) 50 m
(b) 10 m
(d ) 100 m
GATE 2007(PI)
( )
In
feed
a stepper
motor
I a CNC machine
hi
f d drive,
di
t
t
o
with step
p angle
g of 1.8 drives a lead screw with
pitch of 2 mm. The Basic Length Unit (BLU) for
this drive is
((a)) 10 microns
((b)) 20 microns
(c) 40 microns
(d) 100 microns
A
GATE 2008(PI)
A stepper motor has 150 steps. The output shaft of the
motor is directly
d
l coupled
l d to a lead
l d screw off pitch
h 4 mm,
which drives a table.
table If the frequency of pulse supply to
the motor is 200 Hz, the speed of the table (in mm/min)
is
(a) 400
(b) 320
(c) 300
(d) 280
Example
IES2011Conventional
y A DC servomotor is coupled
l d directly
d
l to a leadscrew
l d
y The
is driven
by
h table
bl off a CNC machine
h
d
b a Lead
d screw which
h h
which drives the table of an NC machine tool. A

digital encoder, which emits 500 pulses per
revolution, is mounted on the other end of the
leadscrew. If the leadscrew pitch is 5 mm and the
motor rotates at 600 rpm, calculate
(a) The linear velocity of the table
(b) The BLU of the NC system
(c) The frequency of pulses transmitted by the encoder.
Ans. 3 m/min,, 10 micron,, 55000 pp
pps
Page 82
is rotated by a DC servomotor. A digital encoder which emits

1000 pulses per second is mounted on the lead screw as a
feedback device. If the lead screw pitch is 6 mm and motor
rotates
t t att 500 rpm, find
fi d
1
1.
Basic length Units of the system
2.
Linear velocity of the table.
3.
Frequency of pulses generated by the feedback device.

Ans. 50 microns, 3 m/min, 1000 pps
[5 Marks]
GATE 2010(PI)
StatementforLinkedAnswersquestions:S1
For
the
F a 3 axes CNC table,
bl the
h slide
lid along
l
h vertical
i l axis
i
of the table is driven by a DC servo motor via a lead
screw nut mechanism. The lead screw has a pitch of 5
mm. This lead screw is fitted with a relative
(incremental) circular encoder. The basic length unit
(BLU) of the slide along the vertical axis of the table is
0.005 mm. When the table moves along the vertical axis
b 9 mm, the
by
th corresponding
di number
b off pulses
l
generated
t d
by the encoder is
(a) 1400
(b) 1800
(c) 4200
(d) 9000
B
In
CNC
I the
h feed
f d drive
d i off a PointtoPoint
P i
P i open loop
l
drive, a stepper motor rotating at 200 steps/rev drives a
table through a gear box and lead screwnut mechanism
(pitch = 4 mm,, number of starts = 1).
(p
)
Output rotational speed
The gear ratio = Input rotational speed is given by U = 14
The
h stepper motor (driven
(d
b voltage
by
l
pulses
l
f
from
a pulse
l
generator) executes 1 step/pulse of the pulse generator.
The frequency of the pulse train from the pulse
generator is f = 10,000 pulses per minute.
GATE 2008Q2 (StatementinS1)

(
)
The total angular movement (in degrees) of a leadscrew

with a pitch of 5.0 mm to drive the worktable by a
di
distance
off 200 mm in
i a NC machine
hi is
i
( ) 14400
(a)
(b) 28800
88
( ) 57600
(c)
6
(d) 72000
p
p NC system
y
pp g motor is
In openloop
the shaft of a stepping
connected directly to the lead screw xaxis of the
machine table. The pitch of the lead screw is 3.0 mm.
The number of step angles on the stepping motor is 200.
Determine how closely the position of the table can be
controlled assuming that there are no mechanical errors
controlled,
in the positioning system.
Also, what is the required frequency of the pulse train
and the corresponding rotational speed of the stepping
motor in order to drive the table at a travel rate of 100
mm/min?
[8 Marks]
[8
Ans. (a) It is correct ans.

Ans
ans Most books will give (c).
(c) For
same table speed, f must be half.
GATE 1992
The
the
Th Basic
B i Length
L
h Unit
U i (BLU),
(BLU) i.e.,
i
h table
bl
movement corresponding to 1 pulse of the pulse
generator, is
(a) 0.5
0 5 microns
(b) 5 microns
(c) 50 microns
(d) 500 microns
B
IAS 2010 Main

IAS2010Main
GATE 2009(PI)
A customer
insists
the
t
i i t on a modification
difi ti to
t change
h
th BLU
of the CNC drive to 10 microns without changing the
t bl speed.
table
d The
Th modification
difi ti can be
b accomplished
li h d by
b
GATE 2008Q1 (StatementinS1)

(
)
GATE 2006
In
I a pointtopoint
i
i type off NC system
((a)) Control of p
position and velocityy of the tool is
essential
(b) Control of only position of the tool is sufficient
(c) Control of only velocity of the tool is sufficient
(d) Neither position nor velocity need be controlled
GATE2005
NC contouring
i is
i an example
l off
((a)) Continuous p
path p
positioning
g
(b) Pointtopoint positioning
( ) Absolute
(c)
Ab l
positioning
ii i
((d)) Incremental p
positioning
g
WhichamongtheNCoperationsgivenbeloware
continuouspathoperations?
ArcWelding(AW)
Milling(M)
Drilling(D)
PunchingisSheetMetal(P)
LaserCuttingofSheetMetal(LC)SpotWelding(SW)
(a) AW,LCandM
( ) D,LC,PandSW
(c)
d
A
B
Page 83
(b)AW,D,LCandM
(d)
(d)D,LC,andSW
d
IES 2000
Assertion
(A):
machine
A
i
(A) The
Th axis
i off an NC drilling
d illi
hi
spindle is denoted as zaxis.
Reason (R): In NC machine tool, the axis
perpendicular to both x
x and y
yaxis
axis is designated as
zaxis
( ) Both
(a)
h A and
d d ll true and
d R is the
h
A
IES 1996
Assertion
(A):
A
i
(A) Numerically
N
i ll controlled
ll d machines
hi
having more than three axes do not exist.
Reason (R): There are only three Cartesian
coordinates namely x
xyz
y z.
correct explanation
l
off A
(b) Both
ot A aand
d v dua y ttrue
ue but R iss not
ot tthee
( ) A is
(c)
i true
t
b t R is
but
i false
f l
D
IES 2003Contd..FromS1
d
If incremental
system is
i
l coordinates
di
i used,
d the
h co
ordinates of each point A, B and C are
(a) A: X 5.0, Y 10.0
(b) A: X 5.0, Y 10.0
B: X 20.0,
20 0 Y5.0
Y5 0
B: X 25
25, Y 15.0
15 0
C: X 10.0, Y 10.0
C: X 35, Y 5.0
(c) A: X 10.0, Y 5.0
(d) A: X 10.0, Y 5.0
B X 15.0, Y 25.0
B:
B X 5.0, Y 20.0
B:
C: X 15.0, Y 35.0
C: X 10.0, Y 10.0
IES 2003S1
GATE2012
GATE 2012 SameQinGATE2012(PI)
Same Q in GATE 2012 (PI)
A CNC vertical milling machine has to cut a
straight slot of 10 mm width and 2 mm depth by a
cutter of 10 mm diameter between points (0,
(0 0)
and (100, 100) on the XY plane (dimensions in
mm).
) The
Th feed
f d rate used
d for
f milling
illi is
i 50 mm/min.
/ i
Milling time for the slot (in seconds) is
(a) 120
(b) 170
(c) 180
(d) 240
While
Whil part programming
i
in CNC machines, the
input
of
dimensional
information for the tool
path can be given in the
absolute
coordinate
system or in incremental
coordinate
di t system.
t
Th
The
above figure shows the
route to be
b followed
f ll
d by
b the
h
tool from O to C, i.e., O A
B C.
GATE 2007(PI)
( )
The
Th interpolator
i t
l t in
i a CNC machine
hi controls
t l
(a) Spindle Speed
(b) Coolant flow
(c) Feed rate
(d) Tool change
C
GATE 2004
During
D i the
h execution
i off a CNC part program block
bl k
N020 G02 X45.0
45 Y25.0
5 R5.0
5 the type
yp of tool motion will
be
(a) Circular Interpolation clockwise
(b) Circular Interpolation counter clockwise
(c) Linear Interpolation
(d) Rapid
R id feed
f d
A
GATE 2010
In
G02
I a CNC program block,
bl k N002
N
G G91
G X40
X Z40,
Z
G02 and G91 refer to
(a) Circular interpolation in counterclockwise direction
and incremental dimension
(b) Circular interpolation in counterclockwise direction
and
d absolute
b l
d
dimension
(c) C
Circular
cu a interpolation
te po at o in cclockwise
oc
se d
direction
ect o aand
d
incremental dimension
(d) Circular
Ci l interpolation
i t
l ti
i clockwise
in
l k i direction
di ti
and
d
absolute dimension
C
Page 84
IES 2009
Interpolation in the controller refers to control of
which
h h one off the
h following
f ll
in a CNC machine?
h
( ) Loading/unloading
(a)
L di / l di off jobs
j b on machine
hi
(b) Loading/unloading
L di / l di off tools
t l from
f
th tool
the
t l changer
h
(c) Axes of machine for contouring
(d) Coolant and miscellaneous functions on machine
C
GATE 2001
GATE 2005
In
operation,
the
I an NC machining
hi i
i
h tooll has
h to be
b
moved from point (5, 4) to point (7, 2) along a
circular path with centre at (5, 2). Before starting the
operation,
p
, the tool is at (5, 4)
4). The correct G and M
code for this motion is
(a) N010 G03 X7.0
X 0 Y2.0
Y2 0 I5.0
I 0 J2.0
J2 0
(b) N010 G02 X7.0 Y2.0 I5.0 J2.0
(c) N010 G01 X7.0 Y2.0 I5.0 J2.0
(d) N010
N
G X7.0
G00
X
Y
Y2.0
I
I5.0
J
J2.0
B
The
has
a
Th tooll off an NC machine
hi
h to move along
l
circular arc from (5, 5) to (10,10) while performing an
operation. The centre of the arc is at (10, 5). Which
one of the following
g NC tool p
path commands
performs the above mentioned operation?
(a) N010G02 X10 Y10 X5
X Y5
Y R5
R
(b) N010G03 X10 Y10 X5 Y5 R5
(c) N010G01 X5 Y5 X10 Y10 R5
(d) N010G02
N G X5
X Y5
Y X10
X Y10
Y R5
R
D
GATE 2009
IES 1993
A 'block'
in
program
'bl k' off information
i f
i
i N.C.
N C machine
hi
means
(a) One row on tape
(b) A word comprising several rows on tape
(c) One complete instruction
(d) One complete program for a job
c
IES 1995
Match List I with List II and select the correct answer
List I
List II
(A function connected
(Associated parameter)
with NC m/c tool)
A. Interpolation
1. Tape preparation
B Parity check
B.
2 Canned cycle
2.
C. Preparatory function
3. Drilling
D Point
D.
P i t to
t point
i t control
t l
4. Contouring
C t i
5. Turning
[A]
C d A
Code:A
B
C
D
A
B
C
D
(a) 4
1
2
3
(b) 4
1
2
5
( ) 5
(c)
1
3
2
(d) 1
4
3
2
IAS2011Main
In an NC drilling operation,
operation the tool tip is at location (
(
100, 0, 100). The datum (0, 0, 0) is left hand lower corner
on top surface
f
off the
h workpiece,
k i
which
hi h is
i rectangular
l
(300 mm x 300 mm x 1.5 mm thick). A thru' hole of 10
mm diameter is t o be drilled in the centre of the
workpiece. Using only rapid positioning and linear
interpolation functions, write the program blocks, in
absolute mode.
mode
Assume permitted cutting speed = 32 m/min and feed
rate = 150 mm/min.
[10Marks]
Page 85
GATE 2000
In
off an island
with
I finish
fi i h machining
hi i
i l d on a casting
i
ih
CNC milling machine, an end mill with 10 mm
diameter is employed. The corner points of the
island are represented
p
by
y ((0,, 0),
), ((0,, 330),
), (5
(50,, 330),
), and
(50, 0). By applying cutter radius right
compensation the trajectory of the cutter will be
compensation,
(a) (5, 0), (5, 35), (55, 35), (55, 5), (5, 5)
(b) (0, 5), (55, 5), (55, 35), (5, 35), (5, 5)
(c) (5,
(5 5),
5) (5,
(5 25),
25) (45,
(45 25),
25) (45,
(45 5),
5) (5,
(5 5)
(d) (5, 5), (45, 5), (45, 25), (5, 25), (5, 5)
B
IES 1996
In
for
I manuall programming
i and
d tape preparation
i
f a
NC drilling machine, the spindle speed was coded
as S 684 (using the magicthree code). The spindle
speed
p
in rpm
p will be
(a) 684
(b) 68.4
(c) 840
(d) 6840
A
IFS2011
IFS 2011
I NC machine,
In
hi
what
h t is
i the
th purpose off the
th parity
it
check ? What is the function of Data Processing
Unit (DPU) and Control Loop
p Unit (CLU) of MCU.
How is Feed Rate Number (FRN) expressed ? What
is indirect feedback ?
[10marks]
IES 1998
IES2008
Prepare part using APT language for milling the contour

shown in Fig. in a single pass. D
[20Marks]
20
L2
L3
135
20
C1
110
120
E
R40
L1
20
20
100
P1
IES2006
R20
40
C2
L5
80
L4
P2
Prepare part program to machine the contour shown in

the figure using APT on CNC milling machine.
[15Marks]
5
R30
R30
Q
40
30
110
+ 40
Which
following
are the
rules
off
Whi h off the
h
f ll i
h
l
programming NC machine tools in APT language?
1. Only capital letters are used
2 A period is placed at the end of each statement
2.
3. Insertion of space does not affect the APT word
( ) 1 and
(a)
d2
(b) 2 and
d3
(c) 1 and 3
(d) 1 alone
D
IES2007
Name the four types of statements in a complete APT

part program. Prepare part program for geometry
description
p
of the contour shown in the figure
g
below:
Y
[15Marks]
P
Material : M S.
8 mm
HomeWork
IES2011Conventional
Write a complete part program in APT for machining

the product which is given in the diagram. Thickness of
th workpiece
the
k i
i 6 mm. All dimensions
is
di
i
are in
i mm.
[15]
State the method of defining line segment of

cutter
tt motion
ti using
i APT program format.
f
t
[5 Marks]
100 mm
80
50
60
200 mm
Material: MS
Thickness: 8.0 mm
IES 1997
Which
are valid
Whi h off the
h following
f ll i
lid statements for
f
point to point motion of the tool in APT language?
1. GO/TO/............
2 GO DLTA/............
2.
DLTA/
3. GO/TO, .
( ) 1 and
(a)
d2
(b) 2 and
d3
(c) 1 and 3
(d) 1, 2 and 3
C
GATE 2008 (PI)

GATE2008(PI)
IES 1995
In
the
in
I APT language,
l
h cutter motion
i
i incremental
i
l
coordinate mode is addressed as
(a) GO/TO/.....
(b) GO/TO.....
GO/TO
(c) GO DLTA/....
(d) GO FWD/...
C
Suppose point P1 in APT programming is coded by statement

P1 = POINT/XSMALL, INTOF, LN1, CR1
The
h coded
d d geometric situation without
h
causing error is
B
Page 86
IES 2012
IES2011
Theconfigurationofarobotusingatelescopingarmthat
Th
fi
i f b i l
i
h
canberaisedorloweredonahorizontalpivotmounted
onarotatingbaseiscalled
(a)Polar
(b)Cylindrical
(c)Cartesiancoordinate
(d)Jointedarm
Trajectoryofarobotmean:
(a)Pathtracedbytheendeffectors
(b)
(b)KinematicsofRobot
f b
( )R b tj i t
(c)Robotjoints
(d)Robotprogramming
B
A
IES 2006
IES 2000
Which
is
Whi h one off the
h following
f ll i
i the
h third
hi d basic
b i
component of robots besides power supply and
control (memory) console?
(a) Software
(b) Coaxial cable
(c) Mechanical unit arm (d) Microcomputer
C
Consider
C
id the
h following
f ll i characteristics
h
i i off a robot:
b
1. The tip of the robot arm moves from one point to
another with its inbetween path not being defined.
2. It can be used for drilling holes at difference points in a
workpiece.
3. It can be used for V butt joint welding between two
points.
4. The memory capacity required for its control unit is low.
Which of these are the characteristics associated with a point
p
to point robot?
(a) 1 and 2
(b) 1,
1 3 and 4
(c) 1, 2 and 4
(d) 2, 3 and 4
C
IES 2006
Which
best
describes
Whi h item
i
b
d
ib a CAM technology?
h l
?
((a)) Geometric modeling
g ((b)) Documentation
(c) Drafting
(d) Numerical control
IES 2012
ISRO2011
Programmableautomationissuitablefor
I CAM,
In
CAM " Part
P programming"
i " refers
f to
(a)Lowproductionvolumeandlargevarietiesofparts
(a) Generation of cutter location data
(b)Lowproductionvolumeandsmallvarietiesofparts
(b) Online Inspection
( )
(c)Highproductionvolumeandsmallvarietiesofparts
IES 1996
Whichofthefollowingpairsarecorrectlymatched?
Whi h f h f ll i i
l
h d?
1. CNCmachinePostprocessor
p
2. Machiningcentre.Toolmagazine
3. DNC.FMS
DNC
FMS
((a)) 1,2and3
,
3 ((b)) 1and2
(c) 1and3
(d)2and3
(d)Hi h d i l
(d)Highproductionvolumeandlargevarietiesofparts
dl
i i f
(c) Machine Selection

(d) Tool Selection
IES2010
Consider the following statements:
Good dynamic performance is usually difficult to achieve
i robots
in
b
which
hi h contain
i a rotary base
b
b
because
1. Position, speed and acceleration of the other joints cause
variations in the reflected torque and moment of inertia.
2. The moment of inertia reflected at the base depends
p
upon
p the
weight of the object being carried.
3 The moment of inertia reflected at the base also depends upon
3.
the distance between the base axis and the manipulated object.
Which of the above statements is/are correct?
(a) 1, 2 and 3
(b) 2 and 3 only
(c) 1 only
(d) 1 and 3 only
B
A
A
Page 87
IES 2006
Flexible manufacturing allows for:
(a) Tool design and production
(b) Automated design
( ) Quick and inexpensive product change
(c)
(d) Quality
Q li controll
IES 2004
Consider
C
id the
h following
f ll i characteristics:
h
i i
g machine tool
1. Single
2. Manual materials handling system
3. Computer
C
controll
4. Random sequencing
4
q
g of p
parts to machines
Which of the above characteristics are associated with
fl ibl manufacturing
flexible
f t i system?
t ?
(a) 1, 2 and 3 (b) 1 and 2
(c) 3 and 4
(d) 2, 3 and 4
A
IES 2012
Whichofthefollowingprocesseshasveryhighmaterial
NTMM
removalrateefficiency?
l
ff
( )El
(a)Electronbeammachining
b
hi i
(b)El t h i l
(b)Electrochemicalmachining
hi i
(c)Electrodischargemachining
(d)Plasmaarcmachining
BySKMondal
IES 2007
Consider
C
id the
h following
f ll i statements in
i relation
l i to the
h
unconventional machining processes:
1. Different forms of energy directly applied to the
piece to have shape transformation or material removal
from work surface.
2. Relative
l
motion between
b
the
h work
k and
d the
h tooll is
essential.
3. Cutting tool is not in physical contact with work
piece.
piece
(a) 1 and 2 only
(b) 1, 2 and 3 only
(c) 2 and 3 only
(d) 1 and 3 only
D
IES 2012
Rankorderclusteringasappliedtomanufacturing
R k d l
i
li d
f
i
automationis
(a)Atechniqueofidentifyingprocesssequencein
productionofacomponent
(b)Ajustintime(JIT)method
(c)Anapproachofgroupingthemachinesintocellsin
a
anFMSsystem
S syste
(d)Atooltogeneratebillofmaterials
C
GATE 2006
Arrange
the
order
A
th processes in
i the
th increasing
i
i
d off
their maximum material removal rate.
Electrochemical Machining (ECM)
Ultrasonic Machining
g ((USM))
Electron Beam Machining (EBM)
Laser Beam Machining (LBM) and
Electric Discharge Machining (EDM)
(a) USM, LBM, EBM, EDM, ECM
(b) EBM,
EBM LBM,
LBM USM,
USM ECM,
ECM EDM
(c) LBM, EBM, USM, ECM, EDM
(d) LBM,
LBM EBM,
EBM USM,
USM EDM,
EDM ECM
[D]
IES 2009
IAS 2002
Which
Whi h one off the
h following
f ll i statements is
i correct in
i
respect of unconventional machining processes?
(a) The cutting tool is in direct contact with the job
(b) The tool material needs to be harder than the job
material
(c) The tool is never in contact with the job
(d) There has to be a relative motion between the tool
and the job
C
Match
M t h List
Li t I (Processes)
(P
) with
ith List
Li t II (Tolerances
(T l
obtained) and select the correct answer using the codes
List I
List II
(P
(Processes)
)
(T l
(Tolerances
obtained)
b i d)
A. Plasma Arc machining 1.
75 microns
B. Laser Beam machining 2.
25 microns
C. Abrasive Jet machining 3.
50 microns
D. Ultrasonic machining
4.
125 microns [C]
Codes:A
B
C
D
A
B
C
D
(a) 4
1
3
2
(b) 3
2
4
1
( ) 4
(c)
2
3
1
(d) 3
1
4
2
Page 88
ISRO2009
The machining process in which the work picce is
dissolved into an electrolyte solution is called
(a) Electrochemical machining
(b) Ultrasonic machining
(c) Electrodischarge machining
PSU
PSU
ECMcannotbeundertakenfor
(a)steel
(b)Nickelbasedsuperalloy
(c)Al2O3
(d)Titaniumalloy
Commercial ECM is carried out at a combination

of
( ) low
(a)
l voltage
l
hi h current
high
((b)) low current low voltage
g
(c) high current high voltage
(d) low
l current low
l voltage
l
A
(d) Laser machining

A
IAS2011Main
IAS2011 Main
What is the principle of electro
electrochemical
chemical
machining (ECM)?
Wh are the
What
h advantages
d
and
d disadvantages
di d
off
ECM over conventional drilling?
Comment on the surface finish and the accuracy of
the ECM.
ECM
[20Marks]
Example
l
UsingECMremove5cm
U i ECM
3/minfromanironworkpiece,
/ i f
i
k i
whatcurrentisrequired?
Atomicweightofiron56,density7.8g/cm3 valency,2
GATE2008(PI)
In an electro chemical machining (ECM) operation, a
square hole of dimensions 5 mm x 5 mm is drilled in a
block of copper. The current used is 5000 A. Atomic
weight of cupper is 63 and valency of dissolution is 1.
Faradayss constant is 96500 coulomb.
Faraday
coulomb The material
removal rate (in g/s) is
(a) 0.326
(b) 3.260
(c) 3.15 x 103
(d) 3.15 x 105
GATE 2011(PI)
( )
While
iron
(atomic
Whil removing
i material
i l from
f
i
(
i weight
i h = 56,
6
valency = 2 and density = 7.8 g/cc) by electrochemical
machining, a metal removal rate of 2 cc/min is desired.
The current ((in A)) required
q
for achieving
g this material
removal rate is
(a) 896.07
896 0
(b) 14.93
14 93
(c) 448.03
(d) 53764.29
A
Example
l
Calculate
the
C l l
h material
i l removall rate and
d the
h
electrode feed rate in the electrochemical
machining of an iron surface that is 25 mm 25 mm
in crosssection using
g NaCl in water as electrolyte.
y
The gap between the tool and the workpiece is 0.25
mm The supply voltage is 12 V DC.
mm.
DC The specific
resistance of the electrolyte is 3 c m
For iron, Valency,
l
Z=2
Atomic weight, A = 55.85
Density, = 7860 kg / m3
3.53 mm/min
Page 89
Example(GATE2009)
l (
)
Electrochemicalmachiningisperformedtoremove
El
h i l
hi i i f
d
materialfromanironsurfaceof20mmx20mmunder
thefollowingconditions:
Interelectrodegap
=
0 2mm
0.2mm
SupplyVoltage(DC) =
12V
Specificresistanceofelectrolyte
=2cm
AtomicweightofIron =
55 85
55.85
ValencyofIron =
2
Faraday'sconstant
=
96540Coulombs
Thematerialremovalrate(ing/s)is[0 347]
Thematerialremovalrate(ing/s)is[0.347]
Example
l
GATE 2008
Composition of a Nickel superalloy

super alloy is as follows:
Ni = 70.0%, Cr = 20.0%, Fe = 5.0% and rest Titanium
Calculate rate of dissolution if the area of the tool is 1500
mm2 and a current of 1000 A is being passed through the
cell. Assume dissolution to take place at lowest valancy
off the
th elements.
l
t
Example
l
A researcher conducts electrochemical machining

3) of
(
(ECM)
) on a binary
b
alloy
ll (density
(d
6000 kg/m
k
f iron
(atomic weight 56,

56 valency 2) and metal P (atomic
weight 24, valency 4). Faraday
Faraday'ss constant = 96500
coulomb/mole. Volumetric material removal rate of
the alloy is 50 mm3/s at a current of 2000 A. The
percentage of the metal P in the alloy is closest to
(a) 40
1.41 mm/min
Example
l
(b) 25
(c) 15
(d) 79 [B]
GATE 2007(PI)
( )
Which
process conditions
Whi h one off the
th following
f ll i
diti
g
MRR in ECM p
process?
leads to higher
(a) higher current, larger atomic weight
(b) higher valency, lower current
(c) lower atomic weight,
weight lower valency
((d)) higher
g
valency,
y, lower atomic weight
g
In
an equilibrium
gap off 2
I ECM operation
i off pure iron
i
ilib i
mm is to be kept. Determine supply voltage, if the total
overvoltage is 2.5 V. The resistivity of the electrolyte is 50
mm and the set feed rate is 0.255 mm/min.
/
13.73
3.73 Volt
ot
In an EDM process using RC relaxation circuit, a 12 mm
diameter through
g hole is made in a steel p
plate of 550 mm
thickness using a graphite tool and kerosene as
dielectric Assume discharge time to be negligible.
dielectric.
negligible
Machining is carried out under the following conditions:
R i
Resistance
40
Capacitance
p
20
F
Supply voltage
220 V
Discharge
h
voltage
l
110 V
Averagepowerinput(inkW)is
(a)0.373
(b)0.137
(c)0.218 (d)0.500C
The
surface
that
Th electrochemical
l
h i l machining
hi i off an iron
i
f
h is
i
25 mm 25 mm in crosssection using NaCl in water as
electrolyte. The gap between the tool and the workpiece
is 0.255 mm. The supply
pp y voltage
g is 12 V DC. The specific
p
resistance of the electrolyte is 3 cm.
Estimate the electrolyte
electrol te flow
flo rate.
rate Specific heat of the
electrolyte is given as 0.997 cal/gC. The ambient
temperature is 35C and
d the
h electrolyte
l
l
b l
boiling
temperature,
p
is 95C.
Density, = 7860 kg/m3
In an EDM process using RC relaxation circuit, a 12 mm
diameter through
g hole is made in a steel p
plate of 550 mm
thickness using a graphite tool and kerosene as
dielectric Assume discharge time to be negligible.
dielectric.
negligible
Machining is carried out under the following conditions:
R i
Resistance
40
Capacitance
p
20
F
Supply voltage
220 V
Discharge
h
voltage
l
110 V
The time for one cycle, in milliseconds, is
(a) 0.55 (b) 0.32
(c) 0.89
(d) 0.24 A
IES 2000
Consider
C
id the
th following
f ll i statements:
t t
t
In electrochemical grinding,
1. A rubber bonded alumina grinding wheel acts as the
p
as the anode.
cathode and the workplace
2. A copper bonded alumina grinding wheel acts as the
cathode and the work piece as the anode.
anode
3. Metal removal takes place due to the pressure
applied
li d by
b the
th grinding
i di wheel.
h l
4. Metal removal takes place due to electrolysis.
(a) 1 and 3
(b) 2 and 4
(c) 2 and 3
(d) 1 and3
[B]
Page 90
GATE 2001
In
I ECM,
ECM the
h material
i l removall is
i due
d to
((a)) Corrosion
(b) Erosion
( ) Fusion
(c)
F i
((d)) Ion displacement
p
[D]
GATE 1997
GATE 1992
GATE 1997
Selection
for
S l i electrolyte
l
l
f ECM is
i as follows:
f ll
((a)) Nonpassivating
p
g electrolyte
y for stock removal and
passivating electrolyte for finish control
(b) Passivating electrolyte for stock removal and non
non
passivating electrolyte for finish control
(c) Selection of electrolyte is dependent on current
de s ty
density
(d) Electrolyte selection is based on tool work
electrodes
l t d
The two main criteria for selecting the electrolyte in
Inter electrode gap in ECG is controlled by
El t
Electrochemical
h i l Machining
M hi i
(ECM) is
i that
th t the
th
(a) Controlling the pressure of electrolyte flow
[D]
Ans. (a, d)
electrolyte should
(b) Controlling the applied static load
((a)) Be chemicallyy stable

(b) Not allow dissolution of cathode material
(c) Not allow dissolution of anode material
(d) Have high electrical conductivity
IES 2002
IES 1997
Assertion
(A):
off the
A
i
(A) In
I ECM,
ECM the
h shape
h
h cavity
i is
i the
h
mirror image of the tool, but unlike EDM, the tool
wear in ECM is less.
Reason (R): The tool in ECM is a cathode.
cathode
correct explanation
l
off A
(b) Both
ot A aand
d v dua y ttrue
ue but R iss not
ot tthee
( ) A is
(c)
i true
t
b t R is
but
i false
f l
D
IES2009Conventional
IES 2009 Conventional
What is the principle of metal removal in EDM
process?
ii Describe
ii.
D
ib the
h process with
i h the
h help
h l off sketch.
k h
iii. List advantages
g and limitations of the system.
y
i.
[15marks]
(d) Controlling
C
lli the
h texture off the
h work
k piece
i
C
IES2011Conventional
Which one of the following processes does not
Discuss the effects of insufficient dielectric and
cause tooll wear?
electrolyte
l
l
circulation
l
in the
h interelectrode
l
d gap on the
h
( ) Ultrasonic
(a)
Ul
i machining
hi i
Electric Discharge machining and Electro Chemical
(b) Electrochemical
El t h i l machining
hi i
Machining process respectively.
[5 Marks]
(c) Electric discharge machining

(d) Anode mechanical machining
B
GATE 1994
Electric
machining
is
El
i discharge
di h
hi i
i more efficient
ffi i
process than Electrochemical machining for
producing large noncircular holes.
The above statement is
(a) True
(b) False
(c) Cant say
(d) Insufficient data
A
( ) Controlling the size of diamond particle in the wheel

(c)
Page 91
IES 2012
Statement
(I):
Discharge
Machining
(EDM)
S
(I) In
I Electro
El
Di h
M hi i
process, tool is made cathode and work piece anode
Statement (II): In this process if both electrodes are made of
same material,, g
greatest erosion takes p
place upon
p anode
(a) Both Statement (I) and Statement (II) are individually
true and Statement (II) is the correct explanation of
Statement (I)
(b) Both
B th Statement
St t
t (I) and
d Statement
St t
t (II) are individually
i di id ll
true but Statement (II) is not the correct explanation of
S
Statement
(I)
(d) Statement (I) is false but Statement (II) is true [A]
GATE 2004
GATE 2003
The
off material
Th mechanism
h i
i l removall in
i EDM
process is
(a) Melting and Evaporation
(b) Melting and Corrosion
(c) Erosion and Cavitation
(d) Cavitation and Evaporation
As
A tooll and
d work
k are not in
i contact in
i EDM process
((a)) No relative motion occurs between them
(b) No wear of tool occurs
( ) No
(c)
N power is
i consumed
d during
d i metall cutting
i
((d)) No force between tool and work occurs
wear in electrical discharge machining (EDM) would

be less if the tool material has
(a) high thermal conductivity and high specific heat
(b) high thermal conductivity and low specific heat
GATE 2007
In
discharge
machining
(EDM),
I electro
l
di h
hi i
(EDM) if the
h
thermal conductivity of tool is high and the specific
heat of work piece is low, then the tool wear rate
and material removal rate are expected
p
to be
respectively
(a) High and high
(b) Low
Lo and low
lo
(c) High and low
(d) Low and high
(c) low thermal conductivity and low specific heat

(d) low thermal conductivity and high specific heat
In
Machining
(EDM),
I ElectroDischarge
El
Di h
M hi i
(EDM) the
h tooll is
i
made of
(a) Copper
(b) High Speed Steel
(c) Cast Iron
(d) Plain Carbon Steel
A
GATE2010(PI)
Keeping all other parameters unchanged, the tool
GATE 1999
GATE 2005
A zigzag
cavity
i
i in
i a block
bl k off
high strength alloy is to be
finish machined. This can be
carried out by
y using
g
(a) Electricdischargemachining
(b) Electrochemicalmachining
l
h
l
h
(c) Laserbeammachining
ase bea
ac
g
(d) Abrasiveflowmachining
D
A
IES 2005
Which
is/are
used
wearing
Whi h off the
h following
f ll i
i /
d as low
l
i
tool material(s) in electric discharge machining?
(a) Copper and brass
(b) Aluminium and graphite
(c) Silver tungsten and copper tungsten
(d) Cast iron
GATE 2000
Deep
hole
say 0.2 mm is
D
h l drilling
d illi off small
ll diameter,
di
i
done with EDM by selecting the tool material as
(a) Copper wire
(b) Tungsten wire
(c) Brass wire
(d) Tungsten carbide
GATE 2009(PI)
A titanium sheet of 5.0 mm thickness is cut by wire
cut EDM process using a wire of 1.0 mm diameter.
A uniform spark gap of 0.5 mm on both sides of the
wire
ire is maintained during cutting operation.
operation If the
feed rate of the wire into the sheet is 20 mm/min,

mm/min
the material removal rate (in mm3/min) will be
(a) 150
Page 92
(b) 200
(c) 300
(d) 400
[B]
GATE 1994
GATE2010(PI)
Ultrasonic
is
the
process for
Ul
i machining
hi i
i about
b
h best
b
f
making holes in glass which are comparable in size
with the thickness of the sheet.
The above statement is
(a) True
(b) False
(c) Cant say
(d) Insufficient data
Ultrasonic machines, used in material removal processes,

require ultrasonic transducers. The transducers works on
different working principles.
principles One of the working principles
of such ultrasonic transducers is based on
(a) eddy current effect
(b) Seebeck effect
(c) piezoresistive effect
(d) piezoelectric effect
IES2011
USM has good machining performance for :
(a) Al
(b) Steel
(c) Super alloys
(d) Refractory material
D
[D]
GATE 1993
GATE 1992
In
Ultrasonic
(USM) the
I
Ul
i Machining
M hi i
h material
i l
removal rate would
(a) Increase
(b) Decrease
(c) Increase and then decrease
(d) decrease and then increase
with
ith increasing
i
i
mean grain
i diameter
di
t off the
th abrasive
b i
material.
In ultrasonic machining process, the material

removall rate will
ll be
b higher
h h for
f materials
l with
h
( ) Higher
(a)
Hi h toughness
h
(b)
Hi h ductility
Higher
d ili
( ) Lower
(c)
L
t
toughness
h
(d)
Hi h fracture
Higher
f t
strain
t i
IES 2009
By
processes the
B which
hi h one off the
h following
f ll i
h
metering holes in injector nozzles of diesel engines
can be suitably made?
(a) Ultrasonic machining
(b) Abrasive jet machining
(c) Electron beam machining
(d) Chemical machining
B
IES 2006
IAS 1996
During ultrasonic machining, the metal removal is
During ultrasonic machining, the metal removal is
achieved
h
d by
b
affected
ff
d by
b the
h
( ) High
(a)
Hi h frequency
f
eddy
dd currents
( ) Hammering
(a)
H
i action
i off abrasive
b i particles
i l
(b) high
hi h frequency
f
sound
d waves
(b) Rubbing
R bbi action
ti between
b t
t l and
tool
d workpiece
k i
(c) Hammering action of abrasive particles
(c) High frequency sound waves
(d) Rubbing action between tool and workpiece
(d) High frequency eddy currents
IFS2011
Writetheadvantages limitationsandapplicationsof
Writetheadvantages,limitationsandapplicationsof
electronbeammachining.Whatisthesafetyproblem
g
yp
connectedwithEBM?
Page 93
[5Marks]
GATE2012
GATE 2012 SameQinGATE2012(PI)
Same Q in GATE 2012 (PI)
In abrasive jet machining, as the distance between
the nozzle tip and the work surface increases, the
material removal rate
(a) increases continuously.
(b) decreases continuously.
(c) decreases,
decreases becomes stable and then increases.
increases
(d) increases, becomes stable and then decreases
D
GATE 1992
Match
components with
M h the
h following
f ll i
i h the
h appropriate
i
machining processes:
Component
Process
(A) Square hole in a high strength alloy
(1)
Milling
(B) Square hole in a ceramic component
(2)
Drilling
(C) Blind holes in a die
(3)
ECM
(D) Turbine blade profile on high strength alloy(4) Jig boring
(5)
EDM
[B]
(6)
USM
Codes:A
B
C
D
A
B
C
D
(a) 4
1
2
3
(b)
5
6
1
3
(c) 4
2
1
3
(d)
3
1
2
4
GATE 1998
List
Li I
((A)) ECM
(B) EDM
(C) USM
((D)) LBM
Codes:A
(a) 4
( ) 4
(c)
B
1
2
()
(1)
(2)
( )
(3)
(4)
(5)
( )
(6)
C
2
1
List
Li II
Plastic shear
Erosion/Brittle fracture
C
Corrosive
i reaction
i
Melting
g and vaporization
p
Ion displacement
[B]
Plastic
l
shear
h
and
d ion displacement
d l
D
A
B
C
D
3
(b) 5
4
2
4
3
( ) 3
(d)
1
2
4
IAS2011Main
IAS2011 Main
IFS2011
St t th
Statethemechanismofcuttingbyabrasivejet.
h i f tti b b i j t
Whatarethedisadvantagesofabrasivejetmachining?
Whataretheadvantagesanddisadvantagesof
Writesomeofitsapplications.
pp
[5Marks]
AJM?Mentiontwoapplications.
[
[10Marks]
]
GATE 2011
GATE2011
g non traditional machining

g
Match the following
processes with the corresponding material removal
mechanism:
Machiningprocess
Mechanismofmaterialremoval
g
P.Chemicalmachining
1.Erosion
Q.Electro chemical
machining
R.Electro discharge
machining
S.Ultrasonicmachining
2.Corrosivereaction
3.Iondisplacement
4.Fusionandvaporization
(a)P 2,Q 3,R 4,S 1(b)P 2,Q 4,R 3,S 1

(c)P 3,Q 2,R 4,S 1(d)P 2,Q 3,R 1,S 4[A]
GATE 2007
Matchthemostsuitablemanufacturingprocessesfor
M t hth
t it bl
f t i
f
thefollowingparts.
Parts
ManufacturingProcesses
P. Computerchip
p
p 1.
g
Q. Metalformingdiesandmoulds
2
2.
UltrasonicMachining
R. Turbineblade
3.
Electrodischarge
Machining[A]
h
[ ]
S. Glass
4.
4
PhotochemicalMachining
g
Codes:P Q
R
S
P
Q
R
S
(a) 4
3
1
2
(b) 4
3
2
1
(c) 3
1
4
2
(d) 1
2
4
3
IES 2008
IES 1998,ISRO2009
Match
the
M h ListI
Li I with
i h ListII
Li II and
d select
l
h correct answer
using the code given below the lists:
ListI
ListII
(Unconventional machining process) (Basic process)
A. Electro polishing
1.
Thermal
B Electrochemical
B.
El
h i l machining
hi i
2.
M h i l
Mechanical
C. Abrasive jjet machining
g
33.
Electrochemical
D. Electrical discharge machining 4.
Chemical
[A]
Code:A
B
C
D
A
B
C
D
(a) 4
3
2
1
(b) 2
1
4
3
(c) 4
1
2
3
(d) 2
3
4
1
Page 94
Match
process)) with
M h ListI
Li I (Machining
(M hi i
i h ListII
Li II
(Associated medium) and select the correct answer
ListII
List
ListII
List
II
A. Ultrasonic machining 1.
Kerosene
B. EDM
2.
Abrasive slurry
C ECM
C.
3
3.
Vacuum
D. EBM
4.
Salt solution
[B]
Code:A
B
C
D
A
B
C
D
(a) 2
3
4
1
(b) 2
1
4
3
(c) 4
1
2
3
(d) 4
3
2
1
IES 2005
IES 2003
Match List I (Machining Process) with List II

(Application) and select the correct answer using the
code given below the Lists:
List I
List II
A EDM 1.
A.
1
Holes & cavities in hard & brittle materials
B. LBM 2.
Microdrilling & microwelding of
materials
C. USM 3.
Shaping of hard metals or reshaping of
cemented carbide tools
D. ECM 4.
Shaping of cemented carbide dies and
punches
[C]
Codes:A
B
C
D
A
B
C
D
(a) 4
1
2
3
(b) 3
2
1
4
(c) 4
2
1
3
(d) 3
1
2
4
Match
M t h List
Li t I (Materials)
(M t i l ) with
ith List
Li t II (Machining)
(M hi i ) and
d
select the correct answer using the codes given below
the Lists:
List I
List II
(M
(Materials)
i l )
(M hi i )
(Machining)
A. Machining of conducting materials
1.
ECM
B. Ruby rod
2.
EDM
C. Electrolyte
3.
USM
D. Abrasive slurry
[D]
4.
LBM
Codes:A
B
C
D
A
B
C
D
(a) 4
2
1
3
(b) 4
2
3
1
( ) 2
(c)
4
3
1
(d) 2
4
1
3
IAS 2002
IAS 1999
IES 2004
Match
process)) with
M h List
Li I (Unconventional
(U
i
l machining
hi i
ih
List II (Typical application) and select the correct
answer using the
h codes
d given below
b l
the
h lists:
l
List I
List II
A. Electro discharge machining 1. Drilling micro holes in
very hard metals
B. Electro chemical machining 2. Drilling holes in glass
C. Ultrasonic machining
3.
Die sinking
[ ]
[D]
D. Laser beam machining
g 4
4.
Machining
g contours
Codes:A
B
C
D
A
B
C
D
(a) 4
2
3
1
(b) 3
4
1
2
(c) 4
3
2
1
(d) 3
4
2
1
Match
processes)) with
M t h List
Li t I (Machining
(M hi i
ith List
Li t II
(Operating media) and select the correct answer using
the codes given below the Lists:
List I
List II
A Abrasive
A.
Ab i jet
j machining
hi i
1.
Di l
Dielectric
i
B. Electron beam machining
2.
Electrolyte
C. Electrochemical machining
3.
Abrasive slurry
D. Electro
Electrodischarge
discharge machining 4.
Vacuum
5.
Air
[A]
Codes:A
B
C
D
A
B
C
D
(a) 5
4
2
1
(b) 4
5
2
1
( ) 4
(c)
2
3
5
(d) 2
5
3
4
Which
pairs
Whi h one off the
h following
f ll i
i is
i NOT correctly
l
matched?
(Unconventional
(Application)
machining method)
(a) Electric discharge : Machining of electrically
conductive materials
(b) Laser beam
: Micromachining
(c) Plasma arc
: Faster cutting of hard materials
(d) Electron beam : Faster metal removal rate
[D]
IES 1999
Match
M t h ListI
Li t I with
ith ListII
Li t II and
d select
l t the
th correctt answer
using the codes given below the Lists:
Li I
ListI
Li II
ListII
A. Die sinking
1. Abrasive jet machining
B. Debarring
2. Laser beam machining
g ((thin materials)) 33. EDM
C. Fine hole drilling
D. Cutting/sharpening hard materials
[C]
4 Ultrasonic machining
4.
5. Electrochemical grinding
C d A
Code:A
B
C
D
A
B
C
D
(a) 3
5
4
1
(b) 2
4
1
3
(c) 3
1
2
5
(d) 4
5
1
3
IES 2003
Assertion
(A):
jet
uses high
A
ti
(A) Water
W t
j t machining
hi i
hi h
pressure and high velocity water stream which acts
lik a saw and
like
d cuts
t a narrow groove in
i the
th material.
t i l
Reason (R): The force required for cutting is
generated from sudden change in the momentum
of the water stream.
correct
co
ect eexplanation
p a at o o
of A
(d)
[ ]
[A]
GATE 2004
Typical
operations
are to
T i l machining
hi i
ti
t be
b performed
f
d on hard
h d
tomachine materials by using the processes listed below.
Choose the best set of Operation
OperationProcess
Process combinations
Operation
Process
P
P.
Debarring (internal surface) 1.
1
Plasma Arc Machining
Q. Die sinking
2.
Abrasive Flow Machining
R Fine hole drilling in thin sheets 3.
R.
3 Electric Discharge
Machining
S
S.
Tool sharpening
4
4.
Ultrasonic Machining
5.
Laser beam Machining
6
6.
Electrochemical Grinding
(a) P1 Q5 R3 S4
(b)
P1 Q4 R1 S2
( ) P5
(c)
P Q1
Q R2
R S6
S6
(d)
P Q3
P2
Q R5
R S6
S6
[D]
Page 95
JigsandFixtures
BySKMondal
IES 2007
According
to the
in
A
di
h principle
i i l off location
l
i
i jigs
ji and
d
fixtures, how many degrees of freedom are to be
eliminated to have a body fixed in space?
(a) 3
(b) 4
(c) 5
(d) 6
GATE 2005
GATE 2001
When
a
Wh 321 principle
i i l is
i used
d to support and
d locate
l
three dimensional workpiece during machining,
the number of degrees of freedom that are
restricted is
(a) 7
(b) 8
(c) 9
(d) 10
321 method
in
would
h d off location
l
i
i a jig
ji or fixture
fi
ld
collectively restrict the workpiece in n degrees of
freedom, where the value of n is
(a) 6
(b) 8
(c) 9
(d) 12
C
IES2011
Inthe321principleoffixture3referstonumberof
:
(a)Setupspossible
(b)Cl
(b)Clampsrequired
i d
( )
(c)Positionsonprimaryface
p
y
(d)Locatingpositions
Ans.(d)Locationsonprimaryfacenotpositionson
s. (d) oca o s o p
a y ace o pos o s o
theprimaryface.
IES 1998,1999
Diamond
because
Di
d pin
i location
l
i is
i used
d in
i a fixture
fi
b
((a)) It does not wear out
(b) It takes care of any variation in centre distance
between two holes
(c) It is easy to clamp the part on diamond pins
(d) It is easy to manufacture
B
IES 1999
Assertion
(A):
are used
A
i
(A) Spherical
S h i l washers
h
d to locate
l
the job in the fixtures.
Reason (R): 321 principle should be adopted to
locate the job.
job
correct explanation
l
off A
(b) Both
ot A aand
d v dua y ttrue
ue but R iss not
ot tthee
( ) A is
(c)
i true
t
b t R is
but
i false
f l
(d) A is false but R is true D
IFS2011
What are the functions of jig ? Draw a jig to machine
four holes in a p
plate. What are two reasons for not
having drill bushings actually touching the workpiece
? What is a duplex fixture ?
[10marks]
IES 2009
A lever
having
two
precisely
one
l
h i
t
i l drilled
d ill d holes,
h l
smaller than the other, has to be located in a fixture
using
i
h d
hardened
d and
d ground
d plugs
l
f
for
f th
further
machining in relation to the holes. Select the
correctt method
th d off locating
l
ti the
th lever
l
f
from
th given
the
i
alternatives.
(a) Using two hardened and ground plugs, the smaller
one having flats machined on each side
(b) Using two hardened and ground plugs
(c) Using one hardened and ground plug and one V
block
(d) Using
U i two
t Vblocks
V bl k
A
Page 96
IES 1995
If the diameter of the hole is subject to considerable
variation, then
h for
f locating
l
in jigs and
d fixtures,
f
the
h
pressure type of locator used is
(a) Conical locator
(b) Cylindrical locator
(c) Diamond pin locator
((d)) Vee locator
IES 2005
With the help of a neat sketch,

sketch explain the working of
the diamond p
pin locator.
[5marks]
IES 1995
Match List I with List Ii and select the correct answer using the
codes given below the lists:
List I (Task)
List II (Recommendation)
A. Three components in a straight
1.
Clamp with a
floating pad.
line should worked in one loading
B.
Unloading
g of clamp
p element from jjig
g is essential
2.
Quick action nut
C. Clamping of rough surfaces
3.
Cam clamp
D. Need
d for
f heavy
h
clamping
l
f
force
4.
Equalising
l
clamp
l
5.
Strap clamp [D]
Code: A
B
C
D
A
B
C
D
(a) 5
2
3
4
(b)
4
2
1
5
(c) 1
4
2
3
(d)
4
1
5
3
Match List I (Components used in jigs and fixtures) with List II

(Their functions) and select the correct answer using the codes
List I
List II
A. JJack p
pin
1.
To g
guide the drill bit during
g machining
g
B. Vlocator
2.
For easy removal of the work piece from the
jjig or fixture after the machining operation
is over
C. Bushes
3.
To locate the circular or
semicircular objects in a jig or fixture
D. Ejectors
4.
To locate work piece whose dimensions are
subject to variations
[B]
Code: A
B
C
D
A
B
C
D
(a) 3
4
1
2
(b)
4
3
1
2
(c) 3
4
2
1
(d)
4
3
2
1
IES 2005
Which
is
Whi h one off the
h following
f ll i
i the
h most significant
i ifi
property to be considered in the selection of
material for the manufacture of locating pins and
drill jjig
g buses used in jjigs
g and fixtures?
(a) Wearresistance
(b) Elasticity
( ) Shearstrength
(c)
Sh
h
(d) Tensilestrength
l
h
A
IES 1996
Consider
C
id the
h following
f ll i statements:
g block in a milling
g fixture
The cutter setting
1. Sets the cutting tool with respect of two of its surfaces.
2. Limits
Li i the
h totall travell required
i d by
b the
h cutter during
d i
machining.
3. Takes location from the location scheme of the
component.
component
(a) 1,2 and 3 are correct
(c) 2 and 3 are correct
D
IES 2000
IES2011
Match
M t h List
Li t I (An
(A Element
El
t off Jigs
Ji and
d Fixtures)
Fi t
) with
ith List
Li t
II (Associating System) and select the correct answer
using the code given below the Lists:
List I
List II
A Bush
B h
1.
Milli fixture
Milling
fi
B. Setting block
2.
Turning fixture
C. Diamond pin
3.
Radial location
D. V
Vblock
block
4.
Cylindrical location
5.
Drill jigs
[C]
Codes:A
B
C
D
A
B
C
D
(a) 5
4
3
1
(b) 3
1
2
4
( ) 5
(c)
1
3
4
(d) 3
4
2
1
IES 1993
The
position
off the
fixture
in
Th floating
fl
i
ii
h holding
h ldi
fi
i a
rotary transfer device is used to
(a) Improve the accuracy of location
(b) Reduce the tendency to over index
(c) Reduce the cycle time
(d) Improve upon the acceleration and deceleration
characteristics
D
Page 97
IES 1996
Assertion
with
A
i (A):
(A) A workpiece
k i
i h rough
h unmachined
hi d
surface can be located in a jig or fixture on three
supporting points.
Reason (R): Indexing is made accurate by
supporting on three points.
( ) Both
(a)
h A and
d d ll true and
d R is the
h
C
GATE 2009(PI)
( )
Match the following:
Device
P. Jig
Function
1. Helps to place the workpiece in the same
position cycle
p
y after cycle
y
Q. Fixture 2. Holds the workpiece only
R. Clamp
R
Cl
3. Holds
H ld and
d positions
ii
the
h workpiece
k i
S. Locator 4
4. Holds and p
positions the workpiece
p
and
guides the cutting tool during a machining
operation
(a) P1, Q3, R1, S2
(c) P1, Q4, R3, S2
(b) P1, Q2, R3, S4

(d) P4, Q3, R2, S1

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NeedforUnconventionalProcesses

y New materials having high strength and hardness, such as

nimonic alloys and alloys with alloying elements such as

tungsten, molybdenum, and columbium are difficult to

increase in the work material hardness.

workpiece to have shape transformation or material

For-2013 (IES, GATE & PSUs)

electrochemical processes for the material removal.

achieve sufficient accuracy.

y The NTMM which have not been proved commercially

economical are: USM, AJM,

taking the electrodes shape.

electrolyte is fed through the tool.

Fig- Electrochemical Machining process

1. Micromachining and Drilling : LBM and EBM

y The limitation of electrical machining methods is that

consumption of electrical energy is very large.

y Expensive set up, low MRR and skilled labour required.

from the anode, which will have to be filtered before it is

small value 0.1 to 0.25 mm. A servo drive is provided on

High corrosion resistance

y Tool materials: Copper,

Steel, Cupro nickel, etc.

of their hardness, strength or even thermal properties.

generated to the heat absorbed by the electrolyte.

y If the total over voltage at the anode and the cathode is

V and the applied voltage is V, the current I is given

ffeed to the tool

y The process is used for shaping and sharpening

diamond grit grinding wheel.

carbide cutting tools, which cause high wear rates on

electrode, and the work to melt. But the electrode

causing sudden expansion.

molten particles loose, and the remaining molten metal

evaporation aided by cavitation.

For-2013 (IES, GATE & PSUs)

from 0.1 s to 8 ms.

cycles may be required for completion of the part.

y Surface finish obtained 0.25 m

the electrode at each spark. Tool wear is given in terms of

Volume of metal removed work

y Wear ratio for brass electrode is 1: 1.

metallic electrodes, it is about 3: 1 or 4: 1.

the wear ratio mayy range

electrode, particles will push out, and mainly collect at

Fig-Relaxation circuit used for generating the pulses in EDM process

by EDM. Thus non metallic, such as plastics, ceramics

y EDM is particularly useful when dealing with internal

y The method is also employed for blanking parts from sheets,

y Wire EDM is a special form of EDM wherein the

cutting off rods of materials,

work best with external cuts.

sharpening of tools, cutters and broaches.

diameter and as deep as 20mm diameters can be drilled

with virtually no bending or drifting of hole.

y The electrode wire is typically

fabricated (the use of punch as a tool to machine its own

EDM is particularly useful for machining of small holes,

mm diameter, which is wire electrode wound between

mating die is commonly employed in EDM method).

orifices or slots in dieselfuel injection nozzles, or in aircraft

the two spools.

engines, air brake valves and so on.