BIRLA VISHVAKARMA MAHAVIDYALAYA

(Engineering College)

MID SEM REMEDIAL EXAM

181903: PRODUCTION TECHNOLOGY
Date: 18/04/2015

Time: 8.30 am to 9.45 am

Note: Assume data, if necessary and not given.

Q.1
(a)

(i)

State the conditions of Continuous chip formation, and evaluate it in terms

of machining

[3]

(ii) Differentiate between positive rake and negative rake in single point
cutting tools. State the relative advantages and disadvantages of each of
them.
---- OR ---(i) State the causes of built-up edge and its effects on (i) tool life and (ii) the
finish of the surface being machined.

[3]

(ii) From the geometry of chip formation for a continuous type chip without
built-up edge, show that the shear plane angle is given by
r cos
tan c
where rc is the chip thickness ratio.
1 rc sin
State the assumptions made.

[3]

(b)

During orthogonal turning of a ductile alloy bar by a tool of side rake angle 15,
depth of cut 4.0 mm, feed 0.25 mm/rev, it was found that cutting force is 800 N
and feed force is 500 N. If chip thickness ratio is 0.4, evaluate using Merchant
Circle Diagram (Graphical method):
i. Magnitude of the resultant force
ii. the shear plane angle
iii. the frictional force
iv. the friction angle

[5]

(c)

C-40 steel is turned with a HSS tool of side rake angle of 8 at a cutting speed of
0.6 m/sec. The depth of cut (chip width) is 1.5 mm whereas the uncut chip
thickness is 0.3 mm. One meter long chip weighs 5.7 g. Assume that the width
of the chip remains unchanged and the metal density is 7.9 g/cm3. Calculate
i. Chip thickness ratio and shear angle.
ii. MRR and power requirement.

[4]

(i) Analyze the location system provided by (a) machine vise and (b) three jaw
collet. Evaluate the Degrees of freedom arrested in each case.

[4]

(ii) State the advantages of using jigs and fixtures.

[2]

---- OR ---(i) Analyze the location system provided by (a) three jaw chuck and (b) lathe
tool holder. Evaluate the Degrees of freedom arrested in each case.

[4]

(ii) What are various locating elements used in jigs and fixtures?

[2]

[3]

Q.2
(a)

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(b)

It is required to reduce 50 mm dia MS bar to 40 mm dia for 150 mm of length by

means of single operation on a lathe. The conditions are as follows.
Operators hourly rate = Rs. 60
Machine hourly rate = Rs. 240
Time to remove, replace and reset the tool = 0.1 10 min
Cost of regrinding the tool = Rs. 20
Initial cost of tool = Rs. 200
No. of possible regrinds of the tool = 10
No. of parts to be turned = 12000
Feed rate f = 0.2 mm/rev
Taylors Tool life equation VT 0.2 = 300
Evaluate the economic spindle speed for the lathe for minimum cost.

[5]

(c)

The life of two tools, A and B, are governed by the equations VT 0.125 2.5 and
VT 0.25 7 respectively in certain machining operation where V is the cutting
speed in m/sec and T is tool life in seconds.
(i) Find out the speed at which both the tools will have the same life. Also
calculate the corresponding tool life.
(ii) If you have to machine at a cutting speed of 1 m/sec, then which one of
these tools will you choose in order to have less frequent tool changes?

[4]

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