PSNA COLLEGE OF ENGINEERING AND TECHNOLOGY, DINDIGUL-22

DEPARTMENT OF MECHANICAL ENGINEERING (2008-09)

MANUFACTURING TECHNOLOGY-II
II YEAR / IV SEM ( A & B sections)

QUESTION BANK
UNIT-I

THEORY OF METAL CUTTING

PART A
01. Sketch the orthogonal cutting.
02. Define machinability.
03. What is meant by cutting tool signature?
04. Write Taylors tool life equation.
05. What are four important characteristics of materials used for cutting tools?
06. How do you define tool life?
07. What are the desirable properties of a cutting fluid? **
08. Name any two conditions for continuous chip formation while machining.
09. What are conditions that favor the formation of continuous chips with a Built up
edge?.
10. What are the important properties of cutting tool?
11. State true or false. Justify your answer. Diamond can be used for machining of
ferrous alloys.
12. Which coolants would you suggest for turning the following metals with HSS tool?
a. Aluminium, b. Copper.
13. Define the term tool life.
14. Name any two functions of cutting fluids.
15. What are the requirements for tool material?
16. What are the importances of chip breakers in machining process?
17. List the factors which affect the tool life.
18. Differentiate between orthogonal and oblique cutting processes.
19. A shaft of 25 mm diameter is turned at a cutting speed of 50m/mij .Find the rpm of
the shaft?
20. Define machinability and tool life.
21. Differentiate between orthogonal and oblique cutting.
22. Draw and explain the geometry of chip formation in orthogonal cutting.
PART B
1. i. What are the conditions that favour the formation of continuous and discontinue
chips?
(8)
ii. What are the functions of the rack angle and end relief angle in single point
cutting tool?
(8)
2. i. What is crater wear?
(4)

ii. During machining C20 steel with a carbide cutting tool having a tool geometry
given by 0-5-6-6-8-75-1 mm ORS ,the following forces have been recorded by
a two dimensional dynamometer.
Cutting force=1300 N; Feed force=800 N. Determine the following: Radial
component of the force, Frictional force, Normal force; Kinetic coefficient
of friction.
(12)
3. i. Discuss the various forces encounted in metal cutting.
(8)
ii. The following equation for tool life has been obtained for HSS tool.
VT0.13 f 0.6 d 0.3 =C
A 60 min. tool life was obtained using the following conditions:
V=40 m/min., f=0.25mm, d=2.0 mm. Calculate the effect on tool life, if the speed,
feed and depth of cut are together increased by 25% and also if they are increased
individually by 25%.
(8)
4. i. Explain continuous chip formation process. Discuss the conditions that favour
continuous chip formation.
(6)
ii. During machining C20 steel with a carbide cutting tool having a geometry
given by 0-5-6-6-8-75-1 mm ORS, the following forces have been recorded by
the two dimensional dynamometer: Fz =1300 N; Fx =800 N, Determine the
following
Radial component of force, Fy
1.
Frictional force P and Normal force N
2.
Kinetic Coefficient of friction
(10)
3.
5. i. Discuss the types of wear occurs in the cutting tool due to machinery.
(8)
ii. Discuss the functions of cutting fluids. List down the essential properties of
cutting fluids.
(8)
6. i. The following equation for the tool life is given for turning operation
VT 0.15 f 0.8 d 0.4 = C.
A 60 min tool life was obtained while cutting at V= 30 m/min, f= 0.4 mm/rev and
d= 2.4 mm. Determine the change in tool life if the cutting speed ,feed and depth
cut are increased by 15% individually and also taken together.
ii. Define the term machinability. Explain how it is influenced by work material
micro-structure.
(12)
ii Define the term machinability.
(4)
7. i. Explain Merchant force circle with suitable diagram.
(5)
ii. Discuss the various types of tool wear.
(5)
iii. Discuss the various types of chips produced during metal cutting.
(6)
8. i. Write short notes on the following tool materials.
HSS, Cemented carbides and Cubic boron nitrides
(12)
ii. A tool life of 80 min is obtained at a speed of 30 mpm and 8 minutes at 60 mpm.
Determine the following 1.Tool life equation 2. Cutter speed for 4 minutes tool
life.
(4)
9. i. Compare the Orthogonal and Oblique cutting.
(4)

ii. During the machining C25 Steel with 0-10-6-7-8-90-1 mm ORS shaped triple
carbide cutting tool, the following observations have been made; Feed =0.18
mm/rev. Depth of cut-2 mm, cutting speed 150m/ min, Fz =1600 N; Fx=800 N,
chip thickness -0.4 mm. Determine the following
1.Chip reduction coefficient
2. Shear force and normal force and shear plane.
3. Kinetic coefficient of friction.
(12)
10. i. List out various types of chips produced in metal cutting operations and state the
factors responsible foe their formation.
(6)
ii. An orthogonal machining operation is being carried out using C60 as the workpiece
material, width of cut =5 mm, feed= 0.2 mm/rev. The force in the direction of the
cutting speed and perpendicular to it were found to be 630 N and 900 N. The
thickness of the chip was 0.28 mm. The rake angle of the tool 10 o , cutting speed
=250 m/ min. Calculate: a. Coefficient of friction b. Friction force. c. Mean shear
strength, d. Work done in shear, e. Work done in overcoming friction.
(10)
11.i. List out various mechanisms of tool wear and describe any four mechanisms. (10)
ii. The Taylors tool life equation for machining C-40 steel with a 18:4:1 HSS cutting
tool a speed of 0.2 mm/min and a depth of cit of 2 mm is given by VT n = C, where n
& c are constant s. The following V&T observations have been noted
V 1 m/min 25 35
T1 min
90 20
-Calculate n &c
-Hence recommend the cutting speed for a desired tool life of 60 min.
(6)
12.i. Describe Merchants circle with suitable illustrations.
(10)
ii. Briefly discuss the different types of chips formed in metal cutting.
(6)
13.i. A tool life of 110 minutes is obtained at 25 mpm and 10 minutes at 65 mpm. What
is the tool life equation? Determine the cutting speed for tool life of 1 minute
and 200 minutes.
(8)
ii. Enumerate and briefly explain the characteristics required for tool materials,
(8)
14. i. Explain the types of chip produced in cutting processes.
(6)
ii. Explain the different types of forces acting on a cutting process.
(4)
iii. During the orthogonal cutting process, a chip length of 75 mm was obtained with
an uncut chip
length of 195 mm and the rake angle used was 20o with depth of
cut 0.45 mm. Calculate the shear plane angle and chip thickness.
(6)
15. i. Explain the chip formation process in metal cutting. What are the conditions that
favour the formation of continuous chips?
(8)
ii. In Orthogonal cutting of a material the feed force is 800 N and cutting force is
1500 N. Calculate the following : Normal and shear forces and coefficient of
friction of the chip on the tool face. Take Chip thickness ratio as 0.3 and rake angle
as 8o.
(8)
16. i. Write short notes on High Speed Steel (HSS) and Cubic Boron Nitride (CBN) (12)
ii. The tool life of a HSS tool at 18m/min is 3 hours. Calculate the tool life when the
tool operates at 24 /min. Take n=0.125 in the Taylors Equation VTn =C. (4)
17.i. Explain the mechanics of cutting & chip formation in theory of metal cutting. (10)
18.i. Explain the various friction and heat sources in metal cutting.
(6)

UNIT II

CENTRE LATHE AND SPECIAL PURPOSE LATHES

PART A
CENTRE LATHE:

1. What is swing diameter over bed?

2. Write down any four lathe accessories. ***
3. Write the specifications of a typical lathe. ****
4. What are the applications of offset cutter holder?
5. Mention any two functions of tailstock in a lathe.
6. What are the major specifications of a center lathe?
7. Sketch a tool post used in a lathe?
8. List the various types of lathe.
9. Determine the angle at which the compound rest will be swiveled when cutting a taper
on a piece of work having the following dimensions. a. outside diameter-60 mm,
b. length of the tapered portion 80 mm and c. smallest diameter-20 mm.
SPECIAL PURPOSE LATHES:

10. Mention any four components manufactured in automatic lathe **

11. What is the function of a cylindrical cam in automatic lathe?
12. Give any four differences between automatic and semi automatic lathe.
13. Define an automatic machine.
14. Differentiate between automatic and semi-automatic lathes.
15. What are the advantages of automatic lathes?
17. What are the types of multi spindle automatics?
18. How do you classify the automats based on their cycle control?
19. What are programmed automatic lathes?
20. What is meant by tooling?
21. What is an automat?
22. List down any four difference between capstan and turret lathe.
23. Differentiate between a capstan, a turret and an engine lathe.
24. Write short notes on Automats.
PART B
CENTRE LATHE:

1. Explain the following methods of taper turning in a lathe.

i.By swiveling the compound rest
ii.By taper turning attachment.
2. i. Explain with the neat diagram, the operation of thread cutting in a lathe.
ii. Briefly explain the different types of chucks used in lathe.
3. i Explain the taper turning operation in a lathe by taper turning attachment .Discuss its
advantages.
4. i. How do you specify a lathe? Explain with suitable diagram.
ii.Explain the working principle of apron mechanism with neat sketch.
5. i. Explain the taper turning by setting over the tailstock.
ii. Explain the thread cutting operation in lathe.
6. i. Describe the function and operation of a draw-in collet chuck.
ii. List the various operations performed in lathe and explain the half nut mechanism
7. i. Explain the apron mechanism of a lathe.
4

ii. Explain any one method of turning taper in a lathe.

8. .i A lathe has four steps, the diameter of each being 90 mm,130 mm,170 mm, and
210mm.The counter shaft pulley revolves at 100 rpm.The gears A,B,C and D have
16,48,16,48 teeth respectively. Find the various speeds for the spindle.
9. .i. Explain the different mechanisms that are commonly used in all geared headstock..
SPECIAL PURPOSE LATHES:

10. Explain the tooling layout for the production of a Hexagonal bolt in a capstan lathe.
11. i. Differenciate between a capstan lathe and turret a lathe. (3)
ii. Explain with the neat diagram the working principle of bar feeding mechanism used
in a capstan lathe.
12. i. Describe a typical spindle automatic chucking machine.
ii. Describe a single spindle automatic bar machine.
13. i. Describe a Swiss type automatic.
ii.Differenciate between parallel action and progressive action multi spindle automatics,
14. i. With a neat sketch, explain the bar-feed mechanism of automatic serene machines.
ii.What are the advantages of automatic machines?
15. Discuss the tooling layout for the production of a Hexagonal bolt in a Turret lathe.
16. i. Draw and explain the gearing diagram of Swiss type automatic.
ii. What are the relative advantages and disadvantages of single and mutispindle
automotives?
17. Explain the turret indexing mechanism with neat sketch.
18.i. Explain the working of an automatic cutting off machine, giving the operations
performed in that machine.
ii. With simple sketch, explain any two types of rotary feeders.
19. i. Describe the principle parts of a capstan lathe.
ii. What are the salient features of capstan lathe?
20 i. Discuss the types of automats giving their relative advantages.
ii. Explain the neat diagram the bar feed mechanism for automations.
21. i. Discuss any eight operations performed in a lathe.
ii. Describe with the neat sketch of the automatic feed mechanism used in lathes.
22. Briefly explain the operation of a Turret lathe with suitable sketches.
ii. A taper of length 80 mm has a taper length of 49 mm. the larger diameter of the
taper is 83 mm and the smaller diameter is 73 mm. Determine
-Taper in mm/metre and in degrees.- The angle to which the compound rest should
be set up. -The tailstock setting over.
23. i. Differenciate between single and multispindle automats.
ii. Describe the working principle of Swiss type automats, with suitable sketches.
24. i. What are the various methods of bar stock feeding? Explain any two methods.
ii.Explain with neat sketch the working of a copy turning lathe.
25. i.What are the advantages of automats as compared to engine lathes?
ii. Explain the mechanisms used for headstock driving arrangement in a lathe.
26. i.Explain the difference between turret and engine lathe.
ii. State and explain any four types of work holding devices for rotating work pieces.
27. i. Explain the structure of cam controlled automats.
ii. Describe the working principle of Swiss type automats with suitable sketches.
28 .i. Explain the working of copy turning lathe with neat sketch.

UNIT III

SHAPING, MILLING AND DRILLING PROCESS

PART - A
SHAPER & PLANER

Shaper:
1. What is meant by a vertical shaper?
2. What is pit planer?
3. How do you specify shaper?
4. What is draw cut shaper?
5. What is quick return motion mechanism? What is its advantage?
Planer:
6. How the shape of a planer is specified?
7. What is the function of the clapper block in a planner?
DRILLING

8. Write down any four operations that can be performed in a drilling machine.
9. What are the functions of flutes in a twist drill tool?
10. What is the function of Reamer? What is the function of a tap?
11. Explain the force system in a drilling process
12. Calculate the tap drill size to cut an internal thread for bolt of outside diameter10
mm, pitch 1.5 mm and depth of the thread 0.61 pitch.
MILLING

13. What is meant by differential indexing? **

14. Write the names of the work holding devices in a milling machine.
15. What is Gang milling operation?
16. What is shell end mill?
17. What is thread milling?
PART -B
SHAPER & PLANER

1. ( i) With a neat sketch, Explain the working of the crank and slotted link quick
return mechanism used in shaper.
*** (12)
(ii) Write any four differences between shaper and planer.
** (4)
2. ( i) Explain the crank and slotted link mechanism used in a shaper with a neat
sketch.
(10)
(ii) Explain the various operations performed in a planer.
(6)
3. Draw the sketch of crank shaper, mark the important parts and explain their
functions. Explain how quick return mechanism works.
(16)
04. ( i) What is clapper box mechanism in shaper? Explain.
(8)
(ii) What is fast and loose pulley arrangement in planer?
(8)
5. Name and describe the various work holding devices of shaper, Which way a
shaper tool differs from lathe tool?
(16)

DRILLING

1.

( i) Explain the twist drill nomenclature and define various elements of twist
drill.
** (12)
(ii) Determine the speed of a 20 mm drill for cutting steel at 25 m per min
surface speed.
(4)
02. ( i) With a neat sketch, Explain the any four operations that can be performed by
a drilling machine.
*** (12)
(ii) Write any four differences between shaper and planer.
** (4)
MILLING

01. ( i) With a neat sketch, indicate the various parts of arbor assembly.
(8)
(ii) Explain the thread milling operation.
(8)
6. With a neat sketch, explain the principal parts and angles of a plain milling cutter.
Explain them.
(16)
7. ( i) Explain the cam milling operation.
(10)
(ii) Explain the gear cutting by formed tool.
(6)
04. ( i) Explain with neat sketch differential indexing method.
(8)
(ii) Describe the horizontal knee type milling machine, with suitable sketch. (8)
05. ( i) Describe the column and knee type milling machine, with neat sketch.
(11)
(ii) Describe the method of direct indexing.
(5)
8. Explain the following milling operations with sketches:
** (4+4+4+4)
( i) Straddle milling, (ii) Gang milling, (iii) Form milling, (iv) End milling.
9. What is indexing in milling operations? Explain simple and compound
indexing.
(16)

UNIT IV

ABRASIVE CUTTING BROACHING AND GEAR MANUFACTURING

PART A
GRINDING AND POLISHING:

01. What is the purpose of dressing and tuning of grinding wheel? **

02. What is meant by buffing?
03. State true or false. Justify your answer. Diamond can be used for machining of
ferrous alloys.
04. What is honing?
05. What is the significance of grit in a grinding wheel?
06. What is glazing? How will you rectify this?
07. How do you select grinding wheel for vertical surface grinder.
BROACHING, GEAR MANUFACTURING:

08. Write down the rule for gear ratio in differential indexing?
09. Calculate the blank diameter and tooth depth for cutting spur gear of 3 module and
54 teeth.
10. What is meant by differential indexing?
11. What are the combinations of two movements takes place in differential indexing?
12. Name any four gear finishing methods. **
13. What is gear hobbing?
14. Differentiate between the gear shaping and gear hobbing.
15. Narrate the types of gear cutter.
PART B
GRINDING AND POLISHING:

01. ( i) Explain the external cylindrical grinding process & surface grinding process** (8)
(ii) Explain the Vitrified and Resinoid bonding process.
** (8)
02. ( i) Explain the working principle of centreless grinding.
(6)
nd
(ii) Draw and explain twist drill nomenclature. [2 unit]
**(10)
03. ( i) Explain the principle of working of centreless grinding machine.
*** (8)
(ii) What are Through feed, In feed, and End feed in centreless grinding
operations.
** (8)
04. ( i) Describe the types of surface grinding process.
(ii) Sketch the typical broach and indicate important elements.
05. ( i) Write note on the various types of broaching process.
( ii) Give a note on mounting on grinding wheels.
(iii) List the types of grinding machines.

(10)
(6)
(8)
(4)
(4)

06. ( i) Explain the factors considered in selecting a grinding wheel and also explain the
standard specification system used for grinding wheels.
(12)

( ii) Distinguish between lapping and honing.

07. ( i) With neat sketch, explain the nomenclature of Broaching tool.
( ii) Explain the construction and working of surface grinder.

( 4)
(8)
(8)

BROACHING, GEAR MANUFACTURING:

08. Describe briefly the production of helical gears by milling.

09. ( i) Explain the working principle of gear hobbing operations.
( ii) Enumerate the generation of straight bevel gears with sketches.
10. With neat sketch, explain the working of gear hobbing machine.

(16)
(8)
(8)
*** (16)

11. ( i) Differentiating between gear forming and gear generating.

(ii) Explain the process of gear shaping.

(6)
(10)

12. ( i) Describe the working mechanism of a universal dividing head, with neat
diagram.
(ii) Give the advantages and limitation of gear hobbing.

(10)
(6)

13. (i) What are the different methods of production of gears by machining operations.(6)
(ii) Explain the working mechanism of a universal dividing head.
** (10)
14. ( i) Calculate the machining particulars for cutting a spur gear of 3 module and 54
teeth with proper index plate hole circle and sector.
(5)
(ii) Explain with neat sketches the working principle of bevel gear generator.
(11)
15. Explain the principle of operation of gear hobbing operation. What are the advantages
of gear hobbing?
(16)
16. Explain the following gear cutting methods.
( i) Gear cutting by formed tool.
( ii) Gear hobbing.
(iii) Broaching.
17. ( i) Explain the working principle of gear shaper.
(ii) Differentiate between the gear generation and forming.
18. Write short note on:
( i) Broaching method to generate internal teeth.
( ii) Gear cutting by template.
19. Explain the limitations of gear shaping and gear hobbing.

(4)
(8)
(4)
(12)
(4)
(8)
(8)
(16)

UNIT V
PART A

CNC MACHINE TOOLS AND PART PROGRAMMING

CNC MACHINE TOOLS:

01. Make neat sketches of a typical turning centre, horizontal machining centre and
indicate primary x, y, z axes of motion.
PART PROGRAMMING:

02. State the ground rule to be followed while formulating APT geometry statement.
PART B
CNC MACHINE TOOLS:

01. Explain the distinct features of CNC machines? (16)

02. What are the advantages and disadvantages of CNC machine over conventional
machines? (16)
PART PROGRAMMING:

01. ( i) Explain the different statements used in APT programme.

(ii) What is your opinion about future of numerical control?
02. The component shown in Fig (Q 15a) is to be machined from a low carbon steel plate
which is approximately 2 mm oversize on the profile and has been previously
machined to produce the two locating dowel holes, and the clamping hole. It is
held in a fixture which locates and clamps the component write a part program
using absolute units to
(i). Mill the profile using a 16 mm diameter Mill. (ii). Mill the 10 mm slot.
Note: - The Z0 datum is on the face of the component.
- Cutter diameter compensation may be used if desired.
- Safe clearance plane is 15 mm above the surface.
03. ( i)Explain various steps in Computer Assisted Part Programming.
(6)
(ii) Write complete part program to machine the component shown in Fig.(Q15 b ii) (10)

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