Question bank for Production Process II

Date: 30/3/2015
1. What are the standard angles of cutting tool? Describe them. What is the difference between
standard angles and working angles?
2. What do you understand by shear strain? Derive the expression for it.
3. Explain the mechanism of chip formation. Also prove that the specific cutting pressure in an ideal
1

orthogonal cutting is 2Sc cot

4. Show that Vopt = C

=2

+=

n
K1
n
n
}
{
1n
tcK 1+ K 2 }

Where,

5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

21.
22.

i. Where C = Taylor constant

ii. n = Taylor exponent
iii. K1 = operating constant
iv. tc = tool changing time for one edge
v. K2 = tool cost per edge
Explain the three techniques of tool temperature measurement
Describe any six factors effects on metal cutting characteristics
How do you define tool failure? Define tool failure by normal tool wear.
On what basis cutting fluid is selected? Also define effect of cutting fluid on tool life.
Why heat is generated during cutting metals.
Describe the construction and working principle of turning, drilling and milling dynamometer
with labeled diagram.
Write all the stages involved in general principle of measurement.
Design and sketch the round pull broach for producing a hole of 40H 7 and length of 30 mm on a
mild steel work piece.
Design a single point cutting tool for strength and rigidity.
Design a helical drill bit
Design circular and flat form tool by (graphical method)
Describe the change in effective grit geometry due to material loading at the grit tip.
Why does single layer grinding wheel show progressive rise of force during grinding of high
speed steel?
What is need and purposes of measurement of Cutting Forces?
How the cutting force in drilling and milling is estimated analytically.
A 125 mm long, 38 mm diameter bar is to be turned at a feed rate of 0.25 mm/rev. The operating
cost is Rs 10.0/min and tool cost is Rs 75/ edge the tool changing time is 4 min. A carbide tool is
used with two cutting fluids for which values of n and C in tool life is given as below. Find
cutting fluid to be used for machining cutting fluid A, n= 0.22 and C= 67, for cutting fluid B, n=
0.32, C= 67.
Determine the percentage change in cutting speed required to give 50 % reduction in tool life
equation as VT0.2 = C.
A 200 mm long and 60 mm diameter bar is to be turned on a lathe with feed rate of 0.15 mm/rev
the operating cost is Rs 0.50/ min while the tool cost is Rs 10 / edge. The tool changing time is

about 2min. Assume weight of work piece = 0.14 kg. The following work piece material may be
used
Material
A

Cost/kg
Rs 100/-

Tool life (min)

Cutting peed (m/min)
15
40
35
30
B
Rs 120/15
140
45
90
a) Calculate tool life value and optimum cutting speed for minimum cost criterion
b) Select which material should be selected or analyze for selection based on minimum cost
criterion
c) If production rate is the criteria what will be difference in total cost
23. In an orthogonal cutting set up, the depth of cut is 5 mm, feed 1 mm/rev, cutting speed 70 m/min
and chip thickness ratio 0.3. The shear stress of the material at zero compressive stress is 100
kg/cm2. The tool signature is 8-10-7-7-8-0-0.5. Assume the value of constant K in equation 2
1

+ =cot K . Calculate the resultant force, rate of material removal, shear strain and
specific cutting resistance.

A. Quiz Test:
Select the correct answer from the given four possible answers: 1. Machining is a
(a) shaping process
(b) removal process
(c) regenerative process
(d) joining process.
2. An object is machined to
(a) fulfill its functional requirement
(b) provide desirably good performance
(c) render longer service life
(d) all of the above.
3. Feed rate is expressed in turning operation by
(a) mm/revolution
(b) mm/stroke
(c) mm per min
(d) none of the above.
4. Rapid prototyping is a
(a) joining process
(b) removal process
(c) regenerative manufacturing process
(d) finishing process.
1. In high speed machining of steels the teeth of milling cutters may fail by
(a) mechanical breakage
(b) plastic deformation
(c) wear
(d) all of the above
2. Tool life in turning will decrease by maximum extent if we double the
(a) depth of cut
(b) feed
(c) cutting velocity
(d) tool rake angle
3. In cutting tools, crater wear develops at
(a) the rake surface
(b) the principal flank
(c) the auxiliary flank
(d) the tool nose
4. To prevent plastic deformation at the cutting edge, the tool material should possess
(a) high fracture toughness
(b) high hot hardness
(c) chemical stability
(d) adhesion resistance

Answers of the given questions.

A. 1. (b)
2. (d)
3. (a)
4. (c)
Q. 1 : (d)
Q. 2 : (c)
Q. 3 : (a)
Q. 4 : (b)

Quiz Test
Identify the correct answer from the given four options.
1. In high speed machining of steels the teeth of milling cutters may fail by
(a) mechanical breakage
(b) plastic deformation
(c) wear
(d) all of the above
2. Tool life in turning will decrease by maximum extent if we double the
(a) depth of cut
(b) feed
(c) cutting velocity
(d) tool rake angle
3. In cutting tools, crater wear develops at
(a) the rake surface
(b) the principal flank
(c) the auxiliary flank
(d) the tool nose
4. To prevent plastic deformation at the cutting edge, the tool material should possess
(a) high fracture toughness
(b) high hot hardness
(c) chemical stability
(d) adhesion resistance
Problems

Problem 1
During turning a metallic rod at a given condition, the tool life was found to increase from 25
min to 50 min. when VC was reduced from 100 m/min to 80 m/min. How much will be the
life of that tool if machined at 90 m/min ?
Problem 2
While drilling holes in steel plate by a 20 mm diameter HSS drill at a given feed, the tool life
decreased from 40 min. to 24 min. when speed was raised from 250 rpm to 320 rpm. At
what speed (rpm) the life of that drill under the same condition would be 30 min.?
Version 2 ME IIT, Kharagpur

Answers of the questions of Exercise 3.2

Quiz Test
Q. 1 : (d)
Q. 2 : (c)
Q. 3 : (a)
Q. 4 : (b)
Solution to Problem 1.
Ans. 34.6 min
Solution to Problem 2
Ans. 287 rpm.
Version