Anna University Exam Paper Theory of

Metal Cutting
PRODUCTION ENGINEERING
TIME 3 HRS MAX : 100 Marks
PART A (10 x 2 = 20 Marks)
ANSWER ALL QUESTIONS
1.List out the types of chips?
2.What is the function of chip breakers?

3.What is Built-Up-Edge?

4.Write the expression for shear angle with respect to

and rake angle and chip thickness coefficient?

5.Sketch the forces during turning.

6.What are the requirements of a dynamometer for measuring

forces in cutting?

7.What are the sources of heat generation in machining?

8.State the important functions of cutting fluids.

9.Define machinability.

10.What is crater wear?

PART B (5 x 16 = 80 Marks)

11. During the machining of mild steel with 0 10 8 8 90 2 mm

o o o o o

ORS shaped carbide tool, the following observations were made.

Depth of cut = 2.0 mm; feed = 0.2 mm / rev; cutting speed = 150m / min;

chip thickness = 0.4 mm; tangential force = 320 N; axial force = 170 N.
Calculate

(i) Shear force and normal force on shear plane (5)

(ii) Friction force and normal force on rake face (5)

(iii) Kinetic coefficient of friction and (3)

(iv) Specific energy in cutting (3)

12. a) (i) Sketch the nomenclature of tool in American System. (8)

(ii) Sketch the plain milling cutter and label its nomenclature. (8)

( OR )

b) Calculate : (i) orthogonal rake, (ii) inclination angle and

(iii) normal rake of a cutting tool having side rake (-10 ),

o

back rake (-5 ) and side cutting edge angle of 30 . Sketch

o o

the above geometries for the tool. (16)

13.a) (i) Define gauge factor and list out various types of strain gauges. (4)

(ii) Explain the strain gauge type dynamometer for turning. (12)

( OR )

b) (i) Discuss the chip production in upmilling and down milling. (8)

(ii) How are three forces measured in milling? (8)

14.a) (i) Discuss the heat generation in turning

(ii) How the temperature in machining affects the tool life?

OR

b) (i) Explain the action of cutting fluids

(ii) Enumerate the types of cutting fluids and mention the

composition and applications any three types

 15. 15. a) (i) Explain the mechanisms of tool wear.

(ii) Discuss the factors which influence machinability

15.b) (i) Discuss any three important tool materials with respect to

composition and applications

(ii) Derive the Expression for Tool life for maximum production rate.
Unit I
1. a) What are the objectives of machine tool- Explain the various elements
What are the principle angles of single point cutting tool and explai
ii. Clearance angle
2. a) What are the characteristics of cutting tool materials-
List out the different types of cutting tool materials.
b) A high speed steel tool is used for machining a work piece of mild steel.
Unit II
3. a) Describe the taper turning attachment on a lathe.
What are its merits and demerits over other methods of taper turning-
b) What are the attachments used on a center lathe
what purpose do they serve- 7M
4. a) Explain with a neat sketch the working principle of a lathe- 10M
b) Explain the classification of lathes- 5M
Unit III
5. a) Draw a neat sketch and explain the principal parts of a shaper.
b) Explain with the help of a neat sketch the angular cutting operation
6. a) Find the gear combination and indexing movement necessar
b) Draw a neat sketch of a plain milling cutter and explain it in detail-
Unit IV
7. a) What is drilling- What is the tool used for drilling-
Brief out the reason for the modern drilling machine.
b) Illustrate the salient design features of vertical precision
8. a) List out the advantages & disadvantages for vitrified and silicate
b) What is the cutting tool used for performing the grinding operation-
On what factors the cutting tool selection is made in the case of grinding-
Unit V
9. a) Classify Jigs and Fixtures. 5M
b) Compare grinding, lapping and honing process. 10M
10. Draw a neat sketch and explain any three types of locating devices.