Q.

1
(a) Hot hardness: ability to maintain hardness at elevated temperatures so that
machining is not affected at high cutting temperatures.
High fracture toughness: ability of the material to absorb energy without
failing. Cutting if often accompanied by impact forces especially if cutting is
interrupted, and cutting tool may fail very soon if it is not strong enough.
High wear resistance: for longer tool life
Good thermal conductivity: to reduce cutting temperatures near the tool edge
which is in contact with workpiece
Chemical stability or inertness: to avoid adverse reactions at high temp.
High stiffness: to maintain accuracy
Cost
(b) Taylors tool life relationships
Tool life is defined as the time interval for which tool works satisfactorily
between two successive grinding or resharpening of the tool.

[3]

[4]

Log-log plot of Cutting speed Vs Tool life.

With the slope (n) and intercept (C), Taylor
derived the simple equation as VTn = C
Where
v = cutting speed, m/min
T = tool life, min
n = Taylor's tool life exponent, mainly
depends on tool material
C = a constant, depends mostly on work and
tool material but also affected by feed,
depth of cut, cutting fluid etc.
(c)

Given: t1=0.25 mm
Ft=1130 N

t2=0.45 mm
Ff=295 N

w=2.5 mm
=10

V=2.5 m/sec

(i)

Chip thickness ratio = 0.556

(ii)

Shear plane angle = 31.2

(iii)

Shear force Fs = Ft cos Ff sin = 813.7 N

(iv)

Compressive force FN = Ff cos + Ft sin=837.7 N

(v)

Friction force: F = Ff cos + Ft sin = 486.74 N

(vi)

Normal force: N = Ft cos - Ff sin = 1061.6 N

(vii)

Coefficient of friction = 0.4585 (i.e. 24.63)

Q.2
(a) Types of tool wear and their causes:

[7]

[7]

Gradual Wear: Loss of tool material from its flanks and rake surface. Gradual
wear is inevitable, but can be slowed down so as to enhance the working life of
the tool.
Three main forms of gradual tool wear are:
1. Adhesion wear: Excessive cutting pressure results in the generation of high
friction between chip and tool face and hence extremely high localized
temperature. Fragments of the workpiece get welded to the tool surface at
high temperatures. Microscopically rough surface exists under the chip and
on the tool face leading to point contact at the chip-tool interface. Eventually,
the welded fragments of workpiece break off when the chip slides. During the
process, small portion of the tool material also gets removed.
2. Abrasion wear: A type of mechanical wear which occurs when hard
particles (harder than tool materials) on the bottom surface of the chips rub
against the tool surface and remove metal particles from the tool.
Reasons: The tool material is softened due to high temperature. Hard
particles on the underside of the chip may include fragments of hard tool
material, broken pieces of strain hardened built up edge, extremely hard
constituents (carbides, oxides and nitrides, etc,) present in the workpiece
material.
3. Diffusion wear: Diffusion of atoms takes place at elevated temperature from
the area of high concentration to low concentration. The rate of diffusion
increases exponentially with temperature. Diffusion of harder metal atoms
into softer matrix increases the hardness of the workpiece surface layer.
Similarly, diffusion of softer metal atoms into harder matrix softens the
surface layer of the tool. Wear of carbide tools by diffusion is well known
phenomenon.
(b)

Given:

Dia. of bar = 300 mm

N= 45 rpm

d= 2.5 mm

f= 0.3 mm/rev

Ft=1850 N

Ff=450 N

(i)

Cutting velocity V = 42.41 m/sec

(ii)

MRR = 424.115 mm3/sec

(iii)

Power consumed in cutting P = Cutting speed*Cutting force = 2307.64 W

(iv)

Specific power Ps = 3.083 Joule/mm3

[7]

---- OR ---(c)

Given: V T0.13 f0.77 d0.37 = C

T = 60 min, V= 30 m/min, f=0.3 mm/rev, d = 2.5 mm
(i)

C= 28.373

(ii)

20% increase in cutting speed (V=36 m/min): T = 14.76 min

(iii)

20% increase in feed rate (f = .36 mm/rev): T = 20.38 min

(iv)

20% increase in depth of cut (d=3 mm); T = 35.71 min

(v)

20% increase in all parameters: T = 2.98 min

[7]

Q.3
(a)

(b)

Classification of various NTMP processes

Energy
Source
Principle of
Metal
removal

Mechanical

Chemical

Erosion

Etching

Medium
used for
metal
removal
Processes

Abrasive
particles at
high
velocity
USM, AJM,
WJM,
AWJM

Electrolyte

CHM

[7]
Electrochemical
Ion
displaceme
nt (Anodic
dissolution)
High
density
current and
electrolyte
ECM, ECG

Thermo-electric
Fusion and
vaporizations

ElectronsHigh
voltage
discharge
EDM

Radiation

LBM, EBM

(i) Working principle of EDM: [3M]

[7]

(ii) Process parameters: [2M]

(iii) Advantages of EDM: [3M]
---- OR ---Q.3
(a)

(b)

(c)

State various thread manufacturing methods:

(i) Casting: Sand and die casting, Permanent mold, Plastic molding, Shell
molding, Lost wax
(ii) Thread cutting: (a) Single point tool: Lathe
(b) Multipoint tool: Milling, thread chasing, tapping,
threads using dies
(iii) Thread rolling: using flat dies and round dies
(iv) Thread grinding: Traverse grinding, Plunge grinding, Centreless grinding
Differentiate between gear forming and gear generating methods.
Gear Forming:
In all tooth-forming operations, the teeth on the gear are formed all at once
from a mold or die into which the tooth shapes have been machined.
The accuracy of the teeth is entirely dependent on the quality of the die or
mold and in general is much less than that can be obtained from roughing or
finishing methods.
Most of these methods have high tooling costs making them suitable only for
high production quantities.
Methods: Casting, powder metallurgy, Injection moulding, Extrusion, Cold
drawing, Stamping, Forging, Gera rolling
Gear generation:
accomplished by various cutting tools in different machine tools like lathes,
milling machines, drilling machines (with tapping attachment) etc.
Widely used for high accuracy and finish.
Employed for wide ranges of threads and volume of production; from piece to
mass production.
Methods:
Roughing: Gear hobbing, milling, shaping, broaching,
Finishing: grinding, shaving, burnishing, honing, lapping
Explain gear finishing processes.

[3]

[4]

[7]

Q.4
(a)

(b)

What are the advantages of using jigs and fixtures?

Increased Productivity:
Elimination of individual marking, positioning and frequent checking (reduce
job setting time a non machining time)
Reduction in operation time (increase in the speed, feed and depth of cut
because of high clamping rigidity). Heavy and complex shaped parts to be
machined are being held rigidly to the machine.
Possibility of machining two or more workpieces simultaneously.
Interchangeability
Jigs and fixtures facilitate repeatability in manufacture.
Ease of assembly - all components are interchangeable. No need for selective
assembly.
Skill Reduction
Simplified locating and clamping of the workpiece. Use of semi skilled labour
Tool guiding elements ensure correct positioning of the tools with respect to
the workpiece.
Cost Reduction
Higher production rate, reduction in scrap, ease of assembly, and savings in
labour.
Less QC efforts.
Explain in brief: Angle jig

An angle plate jig allows workpieces to be located and clamped for the
perpendicular surface to be machined.
Locators are also perpendicular to the surfaces to be machined.
Clearance problems: As the drill exits the product being drilled, it has little or no
space for the drill point to clear the product completely, produce a round hole all
the way through the part, and avoid drilling the part locator.
(c)
Basic design steps for cam for single spindle automat:
1. Obtain the main data about the cam and the drive unit of the machine tool
(max. radius of cam, base radius, height of the cam lever fulcrum, ratio of
lever system, etc..
2. Determine the cam radius for each operation from the final position of the
hexagonal turret or cross slide
3. Find the cam radii for the beginning of the working travel for each operation.
4. After knowing all the cam radii, obtain the cam profile by graphical method
drawing the cam to full size.
5. Precautions:
(a) Rapid approach and rapid return of the operative unit are idle motions and
should be performed in least time. The cam should rise and drop sharply
at these points.
(b) The working travel curve should provide the motion at a uniform rate i.e.
profile should be a smooth curve.
---- OR ----

[3]

[4]

[7]

Q.4
(a)

(b)

(c)

Explain in brief Hydraulic clamp.

Oils are incompressible. Hence, variation in load does not cause much speed
variation in hydraulic systems.
Operating pressure of a hydraulic system varies from 7 atm. to 250 atm. (high
pressure permits small compact cylinders to develop high force).
Hydraulic cylinders are slow in operation compared to pneumatic cylinders.
Generally, each fixture would have its own hydraulic reservoir and power
unit.
Hydraulic system is costly substantial investment in hydraulic power pack
and cylinders.

[3]

Explain in brief Indexing jig by taking suitable example

Used to drill holes in a pattern.
Location of the subsequent holes
achieved through the earlier
drilled hole.
An indexing arrangement
provided in the jig with required
accuracy.
Fig. shows a part located from the
central hole and then indexed
about the axis by means of a
plunger to drill four holes around
the cylindrical surface.

[4]

Capstan lathe
1. A light duty machine.
2. Turret head is mounted on the ram
and the ram is mounted on the
saddle.
3. Saddle will not be moved during
machining.
4. Longitudinal movement of turret
is less (smaller stroke) since turret
mounted on ram.
5. Short work pieces only can be
machined.
6. It is easy to move the turret head
as it slides over the ram.
7. The turret head cannot be moved
crosswise.
8. As the construction of capstan
lathe is not rigid, heavy cut cannot
be given.
9. It is used for machining work
pieces up to 60 mm diameter.
10. Collet is used to hold the work
piece and automatic bar feeding.

1.
2.

3.
4.

5.
6.
7.
8.

Turret lathe
A heavy duty machine.
Turret head is directly mounted on
the saddle and the saddle slides
over the bed ways.
Saddle is moved along with the
turret head during machining.
Longitudinal movement of turret
is more (longer stroke) because
turret is mounted on saddle.
Long work pieces can be
machined.
It is difficult to move the turret
head along with saddle.
The turret head can be moved
crosswise in some turret lathes.
As the construction of turret lathe
is rigid, heavy cut can be given.

9. It is used for machining work

pieces up to 200 mm diameter.
10. Jaw chuck is used to hold the
work piece.

[7]

Q.5
(a)

How cutting force is calculated for press work?

[3]
[4]

What are the various methods for reducing force requirements?

Applying a shear to the face of the tool is one of the methods used to reduce
the necessary cutting pressure. The punch is simply ground under an angle,
which would allow for its longest portion to begin cutting first, with the rest
of the tool to follow. Such an arrangement is unfortunately very crude, since
the shearing process is not centralized around the tool axis, but rather side
shifting away from the center of the tool.
A better approach is to shear the punch (or die) toward the center from all the
sides. The inclination of surface, being center-oriented, will produce a
centered-cutting process, with cutting forces more evenly spaced around the
punch.
Either the punch or the die can have its cutting surfaces sloped, the amount of
shear to be equal to the material thickness, with some thin materials using
1.5t.
Since the cut-out part or slug will always somewhat resemble the shape of the
punch, it is advisable to apply the shear to that part of the tooling, which will
constitute the scrap. This way the punch will be sheared if piercing, and the
die will be sheared when used for blanking.

(b)

Explain in brief two pass layout in press work by taking suitable example.

Double pass layout may be economical. But problems are:

After the strip is run through the blanking station for first pass, it is reversed
and then run through the die a second time.
While running the strip for the first row, it becomes curved and distorted, and
may cause it to stick while running for the second time.
---- OR ----

[7]

Q.5
(a)

(b)

Explain various methods of mounting of punches.

1.
Punch can be fastened by forcing it to punch
plate; top end of the punch is flattened to fit in
the countersunk recess.
2.

Punch can be clamped to the punch plate by a

set screw. The correct position of the punch is
located by cutting a slot into the punch plate

3.

Shank of the punch is forced into the punch

plate top end of the punch is made flat to fit into
the countersunk recess

4.

Punch can be tightly secured to the punch plate

with the help of grubs screws

5.

Set screws are used to fastened the punch to the

punch plate

6.

Fastening of punch with the help of a set screw

and it is located during fastening with the help
of two dowel pins

7.

Flange end of the punch is secured to the punch

plate by set screws from the punch end

Explain various machine tool structures, based on rigidity.

1. Influence of shape of section : Rectangular, Box, Circular, I section
2. Stiffener Arrangement-Box Section
Ribs that are square/parallel to the sectional walls
(1, 2 and 3 in fig) increase the bending stiffness
up to 17% and double the torsional stiffness.
The diagonal arrangement of stiffeners (4 and 5
in fig.) is superior and produces higher stiffness
not only against bending (78% increase) but also
against torsion (up to 3.7 times).
3. Stiffener Arrangement-Open Section
Stiffness of open structures, such as lathe beds, also
depends upon the arrangement of stiffeners.
Diagonal ribs are better than parallel or square ribs.
Only arrangements 4 and 5 are effective in terms of
stiffness-to-weight ratio of the structure.
Arrangement 4: two parallel shears connected by
diagonal ribs. This is known as the warren beam,
and is commonly used in machine tool beds.

[7]

[7]