Production Technology - GATE 2020

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MECHANICAL
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Production Technology
Text Book : Theory with worked out Examples
and Practice Questions
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Production Technology
Solutions for Text Book Practice Questions
04. Ans: (a)

Chapter
Sol: Q = 1.6 10-3 m3/sec
1 Metal Casting
A = 800 mm2
Q=AV
01. Ans: (d) 1.6  10-3 = (800 10-6) V
VH
Sol: Permeability number = V = 2 m/sec = 2gh
PAT
2
For standard specimen H = D = 5.08 cm  2 
h =   = 0.203m
P = 5 gm/cm2, V=2000 cc, T= 2 min  2  9.81 
2000  5.08 = 203 mm
PN =  50.1 2

5   5.08  2
2
4 05. Ans: (c)

 2
Sol: Vol. of casting = D L
02. Ans: (c) 4
Sol: Net buoyancy force = Weight of core – 
=  150 2  200
weight of the liquid 4
which is displaced by core  3534291 mm3
= V.g (  – d ) ht = 200+ 50 = 250 mm
 2 AC = Amin = sprue base area
  d h  g    d 
4 400
=  200 mm2
 2
 0.12   0.18  9.81  11300  1600 
2

4 G.R.= 1:1.5:2
= 193.6N Volume of Casting
Pouring time =
A C.  Vmax
03. Ans: (a) 3534291

Volume 200  2  9810  250
Sol: Pouring time =
A C  Vmax 17671
=  8 Sec
2  10 6
2  9810  250

200  2  10000  175
= 5.34 sec
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2 GATE – Text Book Solutions
06. Ans: (c) 07. Ans: (c)

Sol: The dimension of pouring basin will not Sol: 1 1
hpb =50 mm
affect the pouring time 2 2
Let V = maximum velocity of molten metal
hs= 200 mm
in the gating system,
3
d = dmin = dia. Sprue bottom
h = height of sprue = 200 mm
volume. of casting A2 = 650 mm2
Pouring time = P. T 
A c  Vmax Q = flow rate = 6.5 105 mm3/s
353 g = 104 mm/sec2
 = 25
 2 6.5  105
d V V2 =  1000 mm 2 / Sec
4 650
35 3 = 2gh pb  2  10 4  h pb
V  2183.6 / d 2 …… (1)
 2
d  25
4 hpb = 50 mm = height of molten metal
To ensure the laminar flow in the gating in the pouring basin
system Re  2000 ht = total height of molten metal above
the bottom of the sprue
= 200 + 50mm
For limiting condition Re = 2000
 V d Vd Q  A2 V2  A3V3  A3 2  10 4  250
R e  2000  =
  = 6.5  105 mm 3 / s
Vd  A3 = 290.7 mm2
 2000 

2000 2000 0.9 1800
V   … (2) 08. Ans: (d)
d d d
Sol: dtop = 225 mm
ht = 250 + 100 = 350 mm
From (1) and (2)
Volume flow rate Q = 40×106 mm3/sec
2183.6 1800
 Vbottom = 2  g  ht = 2  9810  350
d2 d
2183.6 = 2620 mm/s
d  1.21mm
1800 Q = Atop×Vtop=Abottom×Vbottom
3 Production Technology
40  10 6 2
 M SP   D 6 
2 2
Abottom = =15267.17 mm2  SP   D
2620    = 
 Cub  M Cub   a 6  a
4  15267.17
dbottom = =139.42 mm
 2
 2R   2R 
2
=  =   1.54
 a   1.61R 
09. Ans: (b) 2
 SP  M SP 
Sol: A2V2 = A3V3  
 cyl  M cyl 

 2252  2  9810  100 2
4 D  2
 D Sp   2R 
2

= 6       = 1.306
  D   1.75 R 
  d 2b  2  9810  350  D   cyl 
4  6
 db = 164.5mm
So aspiration will not occur. 12. Ans: 1.205
Sol: Casting – 1 (circular)
Common Data for 10 & 11 Diameter = 20mm, length = 50mm
Casting -2 (elliptical)
10. Ans: (a) Major/Minor = 2, length = 50mm,
11. Ans: (b) C.S. area of the casting -1 = C.S area of the
Sol: 3 castings of spherical, cylindrical and casting -2
cubical  solidification time of casting  1 
Vsp = Vcube  solidification time of casting  2 
 
4 3 2
R  a 3 M   V  A c2 
3 =  c1  =  c1 
 M c2   Vc 2  A c1 
4
a =R 3  = 1.61 R
3   
Vc1 =  d 2  h =  20 2  50
Vcyl = VSp 4 4 
  = 15707.96 mm3
D H   R3
2
4 3 
Ac1 = 2   d 2  dh
  4
D 3   R 3 (D  H)
4 3  
1
  20 2  2    20  50
16 3  16  3
4 
D= 3 R    R  1.75R
3 3 = 3769 mm2
C.S area of cylinder = C.S area of ellipse 13. Ans: 50

    maj.axis  min .axis Sol: m = 2 kg, Q = 10 kW
 4  20  
2
4 Time taken for removing latent heat

  2  (min .axis) 2 = 20 – 10 = 10 sec
=
4 Latent heat
Time 
1 Q
 4 2 Latent heat = time  Q
Minor axis =   20 2 
4   2  = 10  10 = 100 kJ
Minor axis = 14.14mm 100
Latent heat/kg = = 50 kJ/kg
Major axis = 2  minor axis = 28.3mm 2
a 2  b2 14. Ans: (a)
Perimeter = 2
2 Sol: Circular disc casting Squared disc casting
28.3 C1 C2
where a = major axis /2  = 14.14 mm ;
2 d  20cm a  20cm
14.14 t  10cm ; t  10cm
b = minor axis /2  = 7.07 mm
2
 As 
Perimeter = 70.24 mm  
 V  C1
Surface area of ellipse Freezing ratio (F.R) = X1 =  1.4
 As 
= perimeter  length + 2 C.S. area  
 V R
= 70.2450 + 314  2  As 
 
= 4140 mm2 = AC2  As   V  C1
  
Volume of the ellipse  V R 1 .4
= C.S area  length  As   As 
3    
= 314  50 = 15708 mm = Vc2  V  C2  V  C2
X1    1.4
 solidifica tion time of casting  1   As   As 
   
 solidifica tion time of casting  2   V R  V  C1
 
2
1.4
M    As  A  
=  c1       s   0.4 
 M c2   V   V  C1 
 C2 
2 2
 V  Ac2  15707.96  4140  VR
=  c1    Volumetric ratio,(V.R) = Y1 =  0 .8
 Vc 2  A c1   15708  3769.9  VC
= 1.205  VR = 0.8 VC1
VR 0.8VC1 Common Data for Q.16 & Q. 17

Now Y2  
VC 2 VC2
16. Ans: (a) 17. Ans: (a)
  Sol: In centrifugal casting
0.8  20 2  10 
 4  = 0.628 Centrifugal force = FC = ma = m r 2
20  20  10
a = r2
D
15. Ans: (b) 75 g = (2 N)2
2
Sol: VC = 40 × 30 × 0.3 = 360 cc
VSc = shrinkage volume 4 2
75 ×9810 = N D  2
2
3
=  360  10.8 cc 75  9810
100 Constant = N 2 D   37273
2 2
 2
Volume of riser Vr = d h Constant = N 2 D  37273
4
 2 0.5  0.52
=  4  4  50.24 cc D= = 0.51 m = 510 mm
4 2
Vr ≥ 3 Vsc  Vr  3  10.8  32.4cc 37273 37273
N  = 8.55 RPS
Vr ≥ 3 VSc → Satisfied D 510
r C
18. Ans: 51.84 mm
where
2
r = time taken for riser material to solidify R  m R 
Sol:  
C  m C 
C = time taken for casting to solidify
Mr  Mc 80  120  20
mc 
280  120  120  20   80  20
V V
      mc = 7.05
 A s  r  A s  casting
d
V 360 mR   side riser given 
 6
As 240  30  30  0.3  0.3  40 
mR
  1.5
V d 4 mC
     = 0.666
 As r 6 6  d = 51.84 mm
360
=  0.147
2442
 r > C
Hence diameter of riser = 4 cm
20. Ans: 0.05 s

Sol: Momentum is considered as constant Chapter
Momentum of water = Momentum of liquid 2 Welding

metal
pressure  time pressure  time 01. Ans: (a)
 Sol: V0 = 80 V, IS = 800 A
density density
200  0.05 400  time Let for arc welding V = a+bL
 V0
1000 2000 For power source, Vp = V0– I
Is
 time  0.05 s
For stable V = Vp
V0
 a  b L  V0  I
Is
When L = 5, I = 500
80
 a + b × 5 = 80 –  500  30
800
a + 5b = 30
when L = 7, I = 460
80
a  b  7  80   460  34
800
By solving, b = 2, a = 20
 V = a + bL = 20 + 2L
02. Ans: 4860 W, 1.5 mm

Sol: For power source,
I
Vp = 36 –
60
Va = 2L + 27
At equilibrium conditions
Va = VP
I
27 + 2 L = 36 –
60
I
 36  27  2L  9  2L
60
I = 60 (9 – 2L) V0 40 4
 
If current is 360 Amps I s 50 5
360 = 60 (9 – 2L) 4
V0  140   250
360 5
9 – 2L = 6
60 = 140 + 200 = 340
2L = 9 – 6 = 3 V0 4 V  5 340  5
  Is  0   425 A
3 Is 5 4 4
L=  1 .5
2
If L = 1.5 mm, 04. Ans: 26.7 sec
V = 27 + 2 ×1.5 = 27+ 3 = 30 V Sol: Rated Power = Vr Ir = 50 ×103
I = 60 (9 – 2 ×1.5) = 360 A
50  10 3
P = 30 ×360 = 10800 W  Ir   2000 A
25
If L = 4 mm, V = 27 + 1.5 ×4 = 33 V Dr = 50% (rated duty cycle)
I = 60 (9 – 1.5 ×4) = 180 A
If Id = 1500 A (desired current)
P = 33 × 180 = 5940 W Desired duty cycle,
Change in power = 10800 – 5940 2
I 2r D r  2000 
= 4860 W Dd = 2
   0.5  0.89
Id  1500 
If the maximum current capacity is 360A,
the maximum arc length is 1.5mm Arc on time
Dd = = 0.8930
Total welding time
03. Ans: 425 = 26.7 sec
Sol: V = 100 + 40 L ,
L = 1 to 2 mm , I = 200 to 250 A 05. Ans: 27.78 mm/sec
L = 1, I = 250 Sol: Power = P = 4 + 0.8L – 0.1L2
V0 For optimum power
V = 100 + 401 = 140  V0   250
Is dP
 0  0.8 – 0.2L = 0
L = 2, I = 200 dL
V0 0.8
V = 100 + 40  2 = 180  V0   200 L  4 mm
Is 0 .2
P = 4 + 0.8L – 0.1 L2
V
 40  50  0 = 4 + 0.8 ×4 – 0.1 × 42 = 5.6 kW
Is
Energy losses = 20% ,  = 80%
Area of weld bead (WB)

1 l = 1 m =1000 mm;
= 2   AB  AC
2 t = 30 mm,
= 5 tan 30 × 5 = 14.43 d = 4 mm,
Lt = 450 mm;
5 tan 30
A B LS = 50 mm,
300
A1 = 4  30 = 120 mm2
0
60 5 1
A2 = A3 =  30 tan 30  30 = 259.8 mm2
2
C
Total volume of weld bead
Volume of W.B = 14.43 × 1000 = volume of weld bead + crowning
= 14433 mm3 = 1.1  volume of weld bead
Weight of W.B = 14433 × 10-6 × 8 = 1.1 (A1+2A2)1000 = 703560 mm3
= 115.5 g 
Volume /Electrode =  D2  Le
Heat required for melting of W.B 4
= 115.5 ×1400 = 161.66 kW  2
  4  (450  50) = 1600
161.66 4
Time for welding =  36 Sec
0.8  5.6 No of electrodes required
1000 Total volume of weld bead
Welding speed = 
36 volume / Electrode
 27.78 mm/sec 703560
  139.96  140
1600
Common data for 06, 07 & 08. x = 200mm (given)
1000
No of electrodes/pass = 5
06. Ans: (d) 07. Ans: (d) 200
140
No of passes =  28
08. Ans: (c) 5
Sol: Total Arc on time
(2) (1) (3)
1000
30mm
30o 30o =  28  280 minutes

100
280
Total weld time =  466.67 minutes
0.6
4mm
09. Ans: 0.64 mm & 2.1 mm 11. Ans: (b)

Sol: Given AC = 10 mm, Sol: Filling rate of weld bead = filled rate by
O1A = O1C = 7 mm, electrode
O2A = O2C = 20 mm 
Area of W.B × Speed = d2  f
O2 4
r=7 
D  1.2 2  4000
A B C
Area of W.B= 4  25.12 mm2
180
r=20 E
Common data for 12 & 13
O1
12. Ans: 2000 J
Sol: H.G = I2 R 
5
Height of Bead = BD = O1D – O1B = (10000)2×200×10-6×  2000 J
50
= O1D– O1 A2  AB 2 13. Ans: 1264 J
= 20 – 20 2  5 2 Sol: h = 2t – 2 × 0.1 t = 1.8 t
= 0.64 mm = 1.8 ×1.5 = 2.7 mm
D = 6 t  6 1.5 = 7.35 mm
Depth of Penetration = BE = O1E–O1B
=  O1 E    O2 A    AB 
2 2 0.1 t
h
= 7  7 2  52 = 2.10 mm
0.1 t
Common Data Q. No 10 and 11
10. Ans: (c)


Sol: I = 200, V = 25, speed = 18 cm /min Vol. of nugget = D2h
4
D = 1.2 mm, f = 4 m /min,  = 65%,

VIη = 7.352  2.7 = 114.5 mm2
Heat input = 4
speed
Heat required = Volume × ×heat required /g
25  200  0.65  60
 = 114.5  10 3  8  1380
18
= 1264 J
= 10.83 kJ / cm
14. Ans: 2.3 & 4.6 MJ 17. Ans: (b)

   Sol: Heat dissipated = 360 – 344 = 16 J
Sol: RC = 0.85  
 nr 
 = Resistivity of metal 18. (i) Ans: (a), (ii) Ans: (b)
V2
2 Sol: P = 2 kW = 2  103 Watt,
V
(Heat generation)1 = I2R =    R = V = 200 mm/min, L = 300 mm
R R
Heat required (HR) = 40 Kcal
0.85  2  10 5
R C1  = 1.082105 = 401034.2 Joule
25    0.02
300
0.85  2  10 5 Welding time =  1.5 min  1.5  60
R C2  = 5.41  106 200
50    0.02
= 90sec
52
(H.g)1 = = 2310546.04 Heat input = 2 10  90 Joule 3
1.082  10 5
HR 40  10 3  4.2
52 HI =   0.9333
(H.g)2 = = 4621072.08 HI 2  10 3  90
5.41 10 6
= 93.33%
15. Ans: (c)
19. Ans: (d)
Sol: Heat generated = Heat utilized
Sol: Heat supplied = Heat utilized
I2R = Vol. of nugget × × H. R/g
0.5 J = m (S.H. + L.H) = V (SH+LH)
I 2  200  10 6  0.1
= (a×h)  (Cp (Tm–Tr)+LH)

 0.005  1.5  10 3  8000  1400  103
2
= 0.05 × 10-6 × h × 2700 [896  (933 –
4
303) + 398 × 103]
I = 4060 A
 h = 0.00385 m = 3.85 mm
Common Data Q. 16 & Q. 17
16. Ans: (c) 20. Ans: (c)

Sol: I = 3000 A,  = 0.2, R = 200 Ω Sol: Volume to be melted = (110 2  100 2 )  2
4
Volume of nugget = 20 mm3
2  3298.66 mm3
Heat generation = I R
Total heat required
= 30002 ×200×10-6 ×0.2 = 360 J
= 3298.66 × 10-9 × 64.4 ×106

Heat required = V c p Tm  Tr   LH  = 212.4 Joules
-9 3
= 800020×10 ×500(1520 –20)+1400×10 V V 2 30 2
= 344 J P = VI = V     21.43
R R 42
Total heat required = heat to be generated 23. Ans: 61.53 %

212.4 = Pt Heat required
Sol: Thermal efficiency =  100
212.4 Heat supplied
t=  10 sec
21.43 Heat required = 10 × 80 = 800 J
800
thermal =  100 = 61.53 %
21. Ans: (a) 1300
Sol: Frictional force F = Pressure × Area ×
24. Ans: 464.758 A

= 200   10 2  0.5  7854 Sol: Dd = 100% = 1, Ir = 600A, Dr = 0.6
4
D d I 2r
3 
Torque = F   Radius D r I d2
4
3 1 600 2
Torque = 7854   5  10 3  29.45  2  I d2  600 2  0.6
4 0.6 Id
2NT  Id = 464.758A
Power, P =
60000
2  4000  29.45 25. Ans: 17
 = 12.33 kW Sol: Number of electrodes
60000
Total volume of metal deposited

22. Ans: 0.065 sec Volume deposited from one electrode
Sol: Given: Total Volume of metal deposited

 2
Volume = 80 mm3,
4
3   450  50
Current (I) = 10000 A,
E = 10 J/mm3, 17mm
19mm
2mm 30o 30o
Qlost = Heat lost = 500 J,
R = 0.0002 ohms 2
x
Total energy supplied during process tan 30  o
17 mm
= [(80 × 10) + 500] J x = 9.814 mm
Qtotal = 1300J = i2Rt
1 
1300 = (104)2 × 0.0002 × t Area    9.814  17  2  2  19  1.1  1.15
2 
 t = 0.065 seconds
Volume  204.85mm 2  1.1  1.15  180
= 46645.30767mm3
 Number of electrodes = 17
cosCS = 1  Cs = 0
Chapter  = 90 – CS = 90
3 Metal Cutting
 tan  b   sin  cos    tan i 
 tan     cos  sin    tan  
 s   
Common Data for Q. 01 & 02
tanb = sin tani+costan
tanb = sin90 tani + 0
01. Ans: (a)
 b = i = 10
02. Ans: (d)

Common Data for Q.04, 05 & 06
Sol:
Vf Vs 04. Ans: (c) 05. Ans: (b)

06. Ans: (d)
90 
Sol: d = t1 = 2 mm, w = b = 15 mm
Vc
VC  0.5m / s, =0
Vc = 40 m/min; Vf = 20 m/min FC  1200, FT  800,   300

Vf 800
 = 10o; r  0 .5     tan 1  33.690
Vc 1200
 r cos     tan   tan 33.69  0.67
  tan 1  
 1  r sin   60
Power = P = FC  VC  1200 
 0.5 cos10  60
 tan 1    28.33
o
 1  0.5 sin 10  = 1200 W

Vf Length of shear plane = LS
Vs   cos 
sin  t1 2
=   4mm
sin  sin 30
20
  cos10 = 41.5 m/min
sin 28.33
07. Ans: (a)
03. Ans: 10 Sol: For theoretically minimum possible shear
Sol: f = 0.25 mm/rev, strain to occur
t1 = 0.25, i = 10,  = ? 2    90
t1 = f cosCS 90   90  6
   48 o
0.25 = 0.25 cosCS 2 2
Common Data for Q. 08 & 09 t1 L 2 60 60

r     0.59
08. Ans: (c) t 2 L1 D 0   32
t1 t 0.1
r  t2  1   0.169
09. Ans: (c) t2 r 0.59
Sol:  = 6 , VC  1 m / s  0.59 cos 35 
  tan 1   = 36.150
b = w = 3, d = t1 = 1 mm  1  0.59 sin 35 
t2 = 1.5 mm; use 2      90 o FT 80
tan      
t1 1 2 FC 200
r    0.67
t2 1.5 3
 80 
    tan 1  
 0.67 cos 6   200 
  tan 1    35.62 0
 1  0.67 sin 6   35  21.8  56.8o
For minimum energy condition use   tan   tan 56.8  1.52
2 +   = 90 (In general  < 1)
  90    2  90  6  2  35.62 Hence by applying classical friction
= 24.76 theorem
  tan   tan 24.76  0.461 1  1 
ln  ln 
Vf  rv c  0.67 1  60  r  0.59 
 
  
 40.2 m / min   35 
2 2 180
Area of shear plane = As = Ls × b 0.5276
  0.55
t1  b 1 3 1.04
= =  5.2 mm 2
sin  sin 35.62 Vf
 r  V f  rVc = 0.59 ×10 = 5.9 m/min
VC
Common Data for Q. 10 & 11 Vf 5.9
Vs  cos    cos 35
sin  sin 36.15
10. Ans: (d)  8.42 m / min
11. Ans: (d)

12. Ans: 56.23
Sol: D 0  32 mm,  = 35, K1 = 0.1 mm,
Sol:  = 10, t1 = 0.125,
FC = 200 N, VC = 10 m/min, Fc = 517 N; FT = 217 N
L2 = 60 mm, FT = 80 N
t2 = 0.43; Cm = 2 +  – 
t 1 0.125 14. Ans: (d)

r   0.29
t2 0.43 Sol:  = 30, FT = 800 N, Fc = 1200 N
 r cos   FC
  tan 1   Fs = cos     
 1  r sin   cos   
 0.29 cos10  FT
 tan 1   = 16.73 tan (  ) =
 1  0.29 sin 10  FC
F   800  
    tan 1  T     = tan 1   = 33.69
 FC   1200 
 217  1200
 10o  tan 1   = 32.77 Fs =  cos(30  33.69)  639.23N
cos 33.69
 517 
Cm = 2  16.73 + 32.77 – 10 = 56.23
Common Data for Q. 15 & 16
15. Ans: (a)
13. Ans: 272 N & 436 W
16. Ans: (b)
Sol: S0 = 0.12 mm = t1,
Sol: D = 100 mm, f = 0.25 mm/sec,
t = 2.0 mm, a 2  t 2  0.22
d = 4 mm
Major cutting for, b = pz = Fc
V = 90 m/min
 S0 .t.S  sec   tan   1
FC
FC = 1500 N FT F
S0 = 0.12,  S  400 FC = N = 1500 N
t = 2 – 0, FT = F
t2 a2 0.22
    1.83
t1 S0 0.12 Common Data for Q. 17 & 18
=0
Pz = 0.12×2.0×400(1.83sec0–Tan0+1) 17. Ans: (b) & 18. Ans: (b)
= 272 N Sol: VT a f b d c  K
Vf a = 0, 3 b = 0, 3, c = 0, 15
Power = p = FC  VC  p Z 
r f1
f2  , d 2  2d
52.6 2
 p Z  Vf    271 1.83
60 T1  T2  60
= 436 W V1T1a f1b d1c  V2T2a f 2b d 2c
V2  f1 
b
 d1 
c
20. Ans: (b)
   
V1  f 2   d2 
Sol: Let Q = no. of parts produced
0.15 T.C on E.L = T. C on T.L
1
=2   0.3
 1.11 30 60
2  Q  80  500   Q  160
V2 1.11 V1 60 60
40Q  500  16Q
V V
% change in speed = 2 1  11% 40 Q  16Q  24Q  500
V1
Productivity is proportional to MRR 500
 Q=  20.83  21
% change in productivity 24
MRR 2  MRR 1
= 21. Ans: (a)
MRR 1
Sol: n = 0.12, C = 130
f d V f d V
= 2 2 2 1 1 1 = 11 % C1 = 1.1 × 130 = 143,
f 1d 1 V1
V = V1 = 90 m/min
19. Ans: 49.2 % 1
Sol: T0 , V0 = original tool life and velocity  130  0.12
VT n  C  T     21.4 min
If V1  1.2V0 T1  0.5 T0  90 
1
V2  0.9V0 , T2  ? 1n  143  0.12
V T C T 
1

1 1
 47.4 min
 90 
V T  V0 T
1 1
n n
0
Increased tool life = 47.4 min
n
 T1  V Increase in tool life = 47.4 – 21.4 = 26 min
   0
 T0  V1
V 
ln  0  ln  1  22. Ans: (a)
V 1 .2 
n  1   0.263 Sol: Tool life = T1 
500
 50,
 T1  ln (0.5) 10
ln  
 T0  122
T2   12.2,
V0 T0  V2 T2n
n
10
1 1 V1  50rpm , V2  80 rpm
V  n
 V  0.263
T2  T0  0   T0  0  = 1.4927T0 The feed and depth of are same in both
 V2   0.9V0 
cases
% change in tool life
V1T1n  V2 T2n
T2  T0 1.4927T0  T0
=   0.4927
T0 T0
V2 80 dTC 
ln ln For min TC, 0
V1 50  0.47  0.333 dV
n  
T 50 1.41 1 
ln 1 ln  2  1 
T2 12.2 270C V n 
   1
 18C n  0

V T  V3 T
1 1
n n
3
V2 1
C n
1 1
V  n
 50  0.333
 1


2 
 1 
 T3  T1  1   50   29 270C V  0.25 
  1
 V3   60   0.25   18C
1
V2
C n
23. Ans: 30.8 m/min

270  3 18
Sol: TC = 3min, Tg = 3 min, 4
 V2  2
150 V
Lm = Rs. 0.5/min
18  150 4
Depreciation of tool regrind = Rs 0.5 V4 
270  3
C = 60, n = 0.2
 V = 57.91 m/min
Cg = 3  3  0.5 + 0.5 = 3.5
n
 n Lm  25. Ans: 2.5 & 23
VOpt = C  . 
1  n C g  Sol:  =10
0.2 t1= f.sin = 0.15 sin75 = 0.144
 0.2 0.5 
 60 .  = 30.8 m/min
1  0.2 3.5  t1
t2 = 0.36, r   0.402
t2
24. Ans: 57.91 chip reduction coefficient = t2/t1
18C 270C 1
Sol: C m  , Ct  , VT 0.5  150   K  2.5
V TV r
TC = k + Cm + Ct  r cos  
  tan 1  
k
18C 270C
  1  r sin  
V TV
 0.402 cos10 
18C 270C  tan 1   = 23.18o
k  1  1  0 . 402 sin 10 
V
 C n
V 
V
1 
 1 
n 
18C 270C V
k  1
V
Cn
27. Ans: 0.944

Chapter
Sol: T = 60 min Machining
4
67
VA   42.70 m / min
600.11 01. Ans: (i) 20 min, (ii) 50 min
77 L 576
VB =  45.22 m / min Sol: Time / cut =   20 min
600.13 fN 0.2  144
Under similar conditions with same tool life DN  100 144
V   45.2 m / min
cutting velocity on material B is greater 1000 1000
1
than the material A. Hence the  75 

0.75
VT 0.75  75  T   
machinability of material ‘B’ is higher than V
the material ‘A’.  75 
1.333
=   1.96 min
VA 42.7  45.2 
  0.944
VB 45.22 20
No. of tool changes =  1  9.2  10
1.96
28. Ans: 12 (Because 1 tool is already mounted on W.P)
Sol: Given, t1 = 0.2 mm, Total change time / piece = 20 + 10 × 3
w = 2.5 mm, = 50 min
Fc = 1177 N,
02. Ans: (a)
Ft = 560 N
Sol: For producing RH threads the direction of
As the cutting is approximated to be
rotation of job and lead screw must be in the
orthogonal. same direction, for this if the designed gear
tani = cos tan b – sin  tan s train is simple gear train use 1, 3, 5 odd
tan 0 = cos tanb – sin tan s number idle gear to get same direction of
= cos30 tan7 – sin30 tan s rotation, if the designed gear train is
 s = 12 compound gear train use 0, 2, 4,.. even
number of idle gears to get same direction.
In the given problem the designed gear train
is a compound gear train, to change the
hand of the thread it requires to change the
direction of rotation of job and lead screw
for this use 1, 3, 5… odd number of idle
gears.
03. Ans: (b) 07. Ans: (b)

N follower Sol: No. of D.S/min = 10
Sol: Train value = Gear ratio =
N Driver B = 300 min, f = 0.3 mm /stroke
pitch of job threads B 1
= Time/cut = 
pitch of lead screw threads f No. of D.S
3.175  40 127 300 1
   not possible =    100 min
6  40 240 0.3 10
127 1  20
= 
40 6  20 08. Ans: (b)
127 20 Sol: L = 2m
   possible
40 120 = 50 + 900 + 50 + 50 + 900 + 50
B = 300 + 5 + 5 = 310
04. Ans: (c) f = 1 mm/stroke, VC = 1 m /sec,
Sol: 1. Plane turning 2. Taper turning 1
3. under cutting 4. Thread cutting M=
2
B 1
05. Ans: (d) Time per two pieces =  1  M 
f V
N follower
Sol: Gear Ratio = Train value = 310 2000
N driver =  1  0.5 = 930 sec
1 1000
Tdriver P
=  driver 930
Tfollower Pfollower Time/piece =  465 sec
2
P job Pspindle N L.S
G.R =  
PL.S PLs.S N Spindle 09. Ans: (d)
P = pitch Sol: Shaping operation
N Spindle PL.S 6 3 M = 0.6 , L = 500 mm
 = =
N L.S PSpindle / job 2 2 2 Double stroke / time = 15
N = time / D.S = 1/15
06. Ans: (d) L
Sol: With this any change in UV will also Average speed, V = 1  M 
V
changes the speed of lead screw, the pitch 500
of the threads produced depends on the
 1  0.6 =12000 mm / min
1
 
speed of work and speed of lead screw. Us  15 
will not affect the speed of the work = 12 m / min
10. Ans: (c) 12.

Sol: Total depth to be removed = 30 – 27 Sol: D = 15 mm, Vc = 20 m/min,
= 3 mm 1000 V 1000  20
N = = 425 rpm
2  D  15
Given, m = = 0.67
3 N = 425rpm
feed = 0.5, f = 0.2 mm /rev
depth = 2 T = 100 min, l  45 mm
V = 60 m/min Time for idle time = 20s
Approach  50 m  Tool change time = 300 s
 length wise
Over time  50 min  L   0.5D
Time/hole = 
Approach  5 m  fN fN
 width wise
Over time  5 m  15
45 
L 2  0.617 min
Time/cut = 1  M   B 
0.2  425
V f
l = 800, = Tm = machining time
L = 800 + 50 + 50 = 900 i) No. of holes produced / drill
B = 400 + 5 + 5 = 410 100
=  162
900  2  410 0.617
Time / cut = 1    ii) Total time/hole
60000  3  0.5
= 20.5 min = Tm + idle time + Tool change time
3 20 300
No. of cuts =  1.5  2cuts = 0.617  
2 60 162  60
Total time = 20.5×2 = 41 mins = 0.9812 min = 58.87 = 59 sec
11. Ans: (b) 13. Ans: (b)
Sol: Time per hole = L/f.N

14. Ans: (b)
= 25/(0.25 300)
Sol: Given n = 6, Dmax = 25 mm
= 1/3 min = 20sec.
Dmin = 6.25 mm
Because dia of drill bit was not given, hence
V = 18 m/min
AP1 is zero.
N max
r= n 1
N min
1000V 1000  18 L
Nmax =  Time/cut =
D min   6.25 f t NZ
1000V 1000  18 230
Nmin =    1.2 min
D max   25 0.1 159 12
N max 25
r= 6 1 = 5
ii) If offset = 5mm with asymmetrical milling
N min 6.25
= 1.3195 = 1.32 AP1 =
1
2

D  D 2  w i2 
Where, wi = w+ 2(Of)
15. Ans: (d)
= 80 + 2 × 5 = 90
Sol: Hobbing process
No. of teeth = 30 (Not required) AP1 =
1
2

100  100 2  90 2 
Module = 3 mm
= 28.2 mm
Pressure angle = 200 (Not required)
L = 200 + 28.2 + 5 + 5 = 238.2
Radial depth= Addendum+1m+1.25m
L
= 2.25 module = 2.25  3 Time/cut =
f t Nz
Radial depth = 6.75 mm
238.2
  1.25 min
0.1 12 159
16.
Sol: Part size = 200 × 80 × 60 mm
17. Ans: (b)
D = 100 mm, Z = 12,
40
V = 50 m/min, Sol: Crank rotation =
No. of teeths
1000 V 000  50
N=   159 rpm 40
D 100 =
28
f t  0.1 mm , AP = OR = 5 mm  12  3
= 1  = 1
i) With symmetrical milling  28  7
AP1   1
2
D  D2  w 2  9
= 1 
 21 
= 100 
1
2
100 2  80 2   20 mm 1 complete revolution and 9 holes in 21 hole
circle.
L = l  AP1  AP  OR
= 200 + 20 + 5 + 5 = 230
18. Ans: (d)

Sol: d = 70 mm , Z = 12 teeth
V = 22 m/min
O1 O2
ft = 0.05 mm/tooth
1000 V A
fm = ftZN, N  d
d
B
1000  22 t
fm = 0.05  12  = 60 mm/min AP1
3.14  70
19. Ans: (b)

l
10 1 4
Sol: Crank rotation = 1  1   360
30 3 3 1000V 1000  120
N=  = 254.64 rpm
= 480 D   150
CR 480 Approach = AP1 + O1O2 = d D  d 
Job rotation = = = 12
40 40
= 0.5150  0.5 = 8.645 mm
Total time/machining
20. Ans: (b)
Sol: Given,
= No. of cutsTime/cut
Dtool = 15 cm = 150 mm Total depth 2

No. cuts =  =4
Feed = 0.08 mm/rev depth per cut 0.5
Depthmax = 0.5 mm = d L   AP
Time/cut = =
Length of workpiece, l = 200 mm fN fN
Cutting Velocity, V = 120 m/min 200  8.645
= = 10.227 min
Total depth to be cut = 2 mm 0.08  255
Total time = 10.227  4 = 40.91
= 41 min
21. Ans: 8.05 min

Sol: Broaching machine
P = 1.5 kW
d1 = 20 mm enlarged to df = 26 mm
t = 25 mm
p = 10 mm/tooth d r  d total   d f  d s 
h = 0.075 mm/tooth
= 4.5 – 0.1 = 4.4
V = 0.5 m/min
d r 4.4
Equation for time for broaching operation nr    44 teeth
h r 0.1
Length of tool travel
= Cutting length = effective length = Le
Linear velocity of tool
= L r  LS  L f
Length of tool travel = L
= 44 × 22 + 8 × 20 + 4 × 20
= t + Le + AP + OR
= 1208mm
As (AP + OR) is not given so take it zero
Le = effective length or cutting length 23. Ans: (b)
26  20 Sol: Out of all conventional method grinding is
Depth of cut d = =3
2 one which required largest specific cutting
n = no. of teeth = d/h = 3 / 0.075 = 40 energy.
Le = np = 40  10 = 400mm 1) Because of random orientation of
Le = 400 mm abrasive particles, rubbing energy losses
t  Le will be very high
Time for broaching =
V 2) Lower penetration of abrasive particle
25  400 3) Size effect of the larger contact areas
= = 8.05 min
0.5  100
between wheel and work.
Time for broaching = 8.05 min
24. Ans: (a)
22. Ans: (c) Sol: Common alignment test for shaper and lathe
Sol: are (1) Straightness (2) Flatness.
4.5 mm
Runout is used in lathe.
Parallelism used in shaper.
25. Ans: (a)

Sol: The curvature given is the concave
d total  4.5 mm curvature hence it increases the stress
concentration factor therefore it is used for
df  0
supply of lubricating oil to bearing
d S  n s  h s  0.0125  8  0.1
mounting
26. Ans: 18
Chapter
Sol: The output per annum = 800  52 Metal Forming Process
= 41600 units.
5
The rejection rate is 20%.
 The quantity to be produced (including 01. Ans: (a)
Re quiredoutput Sol:  y  1400 0.33
rejection) =
(1  rejection rate) 1
At maximum load, true strain 
41600 3
 = 52,000 units
(1  0.2) 0.33
1
 y  1400   971 MPa
Total time required for turning 3
= 52,000  40/60
= 34666.6 hours 02. Ans: (b)
Production time required with 80 per cent Sol: A0p = C.S area of P originally
efficiency = 34666.6 /0.8 = 43333.3 hours A1p = C.S area of P after 1st reduction
Time available per lathe per annum = 0.7 A0p
= 48  52 = 2496 hrs A2p = 0.8 × 0.7 × A0p = 0.56 A0p
 Number of lathes required  Aop 
 p  True strain in " P"  ln 
Time required (hrs) A 
=  2p 
Time available hrs 
 Aop 
43333.33  ln  = 0.58
= = 17.36 = 18  0.56 A 
2496  op 
 No. of lathes required = 18 A0Q = C.S area of Q originally
A1Q = C.S area of Q after 1st reduction
= 0.5 A0Q
 A0Q 
Q  ln   ln 1  = 0.693
A   0.5 
 1Q 
03. Ans: (a)

Sol: do = 25, di = 5mm
 y  315  0.54
A d 
2
06. Ans: (a)
  n o   n  o  Sol: Ho = 20 mm,
A1  di 
2
b = 100 mm
 25 
  n    3.22 H1=18 mm,
 5 
R = 250 mm,
 y  315 (3.22) 0.54  592 MPa. N  10 rpm,  y  300 MPa
04. Ans: 1.98 MN H  20  18  2mm

Sol: Given: H0 = 4.5 mm H
 = 0.089
H1 = 2.5 mm R
H = 2 L  length of deformation zone  RH
Droll = 350, Rroller = 175 mm
 250  2  22.36 mm
Strip wide = 450 mm = b
20  18
Average coefficient of friction = 0.1 H  19
2
y = 180 MPa
2  L 
RSF = Pavg  projected area Favg  R.S.F   y b  L 1  
3  4H 
2  L  2  0.089  22.36 
=   y 1  bL   300  100  22.36 1 
3  4H  4  19 
3 
L= RH = 175  2 = 18.7 = 795 kN.
H 0  H1 4.5  2.5
4=  = 3.5
2 2 T  Favg  a ,
2  0.1  18.7  Where
  1801    450  18.7
3  4  3.5  a = moment arm   L
RSF = 1982.64 kN = 1.98 MN  0.3L to 0.4  L
05. Ans: (a) T  Favg  0.4L  795  10 3  0.4  22.36
Sol: Ho = 4, H1 = 3mm, R = 150mm, = 7110 kN-mm
N = 100 rpm.
= 7.11 kN-m
Velocity of strip at neutral point
2 NT 2  10  7.110
= Surface Velocity of rollers Pav  
60 60
DN   300  100
   7.44 kW / roller
1000  60 1000  60
Total Power = 7.44 × 2 = 14.88 kW
= 1.57 m/sec
07. Ans: (d) 10. Ans: (b)

Sol: Ho = 16 mm, Sol: do = 15 mm,
H1 = 10 mm, df = 0.1 mm
R = 200 mm dia reduced in the draw
%Reduction=
H dia before draw
Angle of Bite    tan 1
R d 0  d1
  Ist draw
16  10 do
 tan 1  9 .9
200 d1  d 2
  2nd draw
d1
08. Ans: (a) a) 3 stages with 80% reduction at each stage
Sol: Given rolling process d o  d1
0 .8 
Initial thickness H0 = 30 mm do
Final thickness = H1 = 14 mm d1  0.2 d o  3mm
Droller = 680 = R = 340 mm d2 = 0.2. d1 = 0.6mm
y = 200 MPa d3 = 0.2 .d2 = 0.12mm (Error is 20%)
Thickness at neutral Hn = 17.2
b) 4 stages with 80% reduction in 1st 3 stages
V1 H
Forward slip = 1= n 1 followed by 20% in 4th stage
Vn H1
d1 = 0.2. d0 = 3
17.2 d2 = 0.2. d1 = 0.6
=  1 = 0.2285 = 23%
14
d3 = 0.2. d2 = 0.12
V H
Backward slip = 1  0  1  n d4 = 0.8. d3 = 0.096 (Error is 4%)
Vn H0
17.2 c) 5 stages, with 80, 80, 40, 40, 20 etc
 1 = 42.6%  43%
30 d1 = 0.2. d0 = 3
d2 = 0.2. d1 = 0.6
09. Ans: (b) d3 = 0.6. d2 = 0.36
Sol: Roll separation distance d4 = 0.6. d3 = 0.0216
= 2  R + H1 = 2  300 + 25 d5 = 0.8. d4 = 0.1728 (Error is 72%)
= 625 mm
From the given multiple choice B, the final
diameter of wire close to 0.1 mm.
11. Ans: (a) Common data for Q 12, 13 & 14

Sol: Given wire drawing process
d0 = 6 m, d1 = 5.2 mm 12. Ans: (b) , 13. Ans: (c), 14. Ans: (a)
Die angle = 180, diameter land = 4 mm Sol: Initial inside diameter of tube
Coefficient of friction = 0.15 d0 = 52 mm, H0 = 2.6
Yield dress = 260 MPa H1 = 1.8, D1 = 50 mm
 2  2d = 24=12, =0.12
A0 = 6 = 136 = 21.237
4 4
 2  2.6mm
A1 = 5.2 = = 21.237
4 4
1.8 mm
Drawing stress = 2
52mm
 1  B   A 1 
B
 50 mm
= y   1   
 B   A 0  

B = cot
1 1
= Die angle =  18 =90
2 2
=9 1   2
For stationary mandrel B =
Tan
B = 0.15  cot90 = 0.947
0.12  0.12
2 = 126.958MPa B= =1.29
Tan (12)
0 0.947 
 1  0.947   21.27 
= 260   1    
1  B    H1  
B

 0.947   28.270   2   y  1    
  B    H 0  
= 260(2.056)(0.2375)
1  1.29    1.8  
1.19
2 L
2 / y   1    
Total drawing stress 2 = y + (2y) e  1.129    2.6  
R1
(By considering friction)

2/y = 0.64
20.154
= 260 + (130260) e 2.6
total = 260  81.94 = 178.05 MPa 13. Movable mandrel

B = cot = (0.12)cot(12) = 0.564
Total drawing load = tA1
1  0.564    1.8  
0.564
= 178.05  21.237 2 / y   1      0.519

 0.564    2.6  
= 3.781 kN
14. Floating mandrel

d2 = d1 2 B 1
B=0 1 B
2 h  1
 n  0   1  2B
y C=   = 0.756
 h1  1 B 
 2.6 
= n  = 0.367
 1.8  Dia of wire in 2nd stage = 3.424 mm
d1 = d0  c
Common data for Q 15. & 16. d2 = d1 c = 4.530.756
= 3.424 > 1.34
15. Ans: 6 & 16. Ans: 3.4 d3 = d2  c
Sol: d0 = 6 mm, df = 1.34 mm
= 3.424 0.756
Given ideal condition
= 2.589>1.34
 = 0.2  = 60
d4 = d3c = 1.957>1.34
f = 60 MPa
d5 = d4  c = 1.4797 > df
Maximum reduction condition
d6 = d5c = 1.1186 < df
 1  B   d1  
2B
2  Hence No. of stages = 6
=11=   1
y  B   d 0  
B = cot; B = 1.9 Common data for Q 17, 18

2B
B d 
 1   1  17. Ans: (c) & 18. Ans: (b)
1 B  d0 
Sol: 400
2B
 d1  B y
  1
 d0  1 B
1 200
=
1 B
d1 2 B 1 0.2 0.4
 
d0 1 B
1 do = 12.214, Lo = 100m
 1 
  6
1  21.9
d1 = d 0  2 B   df = 10mm, Lf =?
 1 B   1  1.9 
 y before  200 MPa ,
d1 = 4.53 ……… (1) stage
 y after  400 MPa
Ao Lo = Af Lf 22. Ans: 1
A d 
2
Sol: Let, d1 = d2 = d
L f  L o  o  L o  o 
h1 = height of first cylinder
Af  df 
2
h2 = height of second cylinder
 12.214 
 100     150m Assume h1 < h2
 10 
Let % reduction in height = 10%
True strain in the drawing process
2
A d  Ist cylinder
    n o   n  o   0.4
A1  d1  h0  hf
 0.1
From the graph  y at   0.2 , h0
 y  300 MPa h0 – hf = 0.1 h0

hf = h0 – 0.1 h0 = 0.9 h0
19. Ans: (b)

A0h0 = Af hf
d02h0 = df2 hf
20. Ans: (c)
h0 h0
Sol: (Extrusion force)min =  y  A 0 df  d0  d0
hf 0 .9 h 0

 10  10 2 = 78539.8N = 1.054 d0 = 1.054 (d0)1
4
(E.F) min 78539.8
Extrusion force   IInd cylinder
 ext 0.4
A0h0 = Afhf
= 196346.5 N
d02h0 = df2 hf
= 196 Tons
h0
df  d0
hf
21. Ans: (b)
Sol: Extrusion constant = K = 250 h0
 d0 = 1.054 (d0)2
do = 100 mm, df = 50 mm 0 .9 h 0
Ao d 0 1 1.054d 0 1
Extrusion Force = A o K ln Ratio   1
Af d 0 2 1.054d 0 2
2
  100 
 100 2  250 ln  = 2.72 MN.
4  50 
Common data for Q 23 & 24 27. Ans: 7.26

Sol:
23. Ans: 7068 J & 24. Ans: 0.354 m 0.3= 1.328
O
Sol: do = 100 mm, ho = 50 mm, 
A
h f  40 mm ,  y  80 MPa B C
H0 H1
ho 50
df  do  100  111.8mm
hf 40
Fi min  A 0   y
O
 Ho = 10 mm,
  1002  80  628.318 kN
4 H1 = 7 mm, 500 0.3
 1000
Ff min  A f   y  (111.8) 2  80 R= = 500 mm
B D
4 2
 785.350 kN C
1 H
Angle of bite () = tan
F  Ff min R
Fmin  i min  706.834 kN
2
10  7
W.D  Fmin  (h o  h f )  7068J = tan 1 = 4.429
500
 2 W  H OD
1.328 
7068 OB
H  0.354 m
2  10  103 OD = 500cos1.328 = 499.865
DC = 500 – OD = 0.1343 mm
25. Ans: (b) Thickness of neutral point = At point B
= 7 + 2  0.1343 = 7.2686 mm
26. Ans: 58%
Sol: Area after 1st pass = A1 = (1 – 0.4)A0
= 0.6 A0
29. Ans: 7.687 MPa, 19.7 %
nd
Area after 2 pass = A2 = (1 – 0.3)A1
Sol: d0 = 6.25 mm; d1 = 5.60 mm;
= 0.7  0.6  A0 = 0.42 A0
 = 0; y = 35 N/mm2
Overall % reduction = (1 – 0.42)  100
B = cot = 0
= 58 %
 1  B   A1   0
B
2   y   1 
 B   A 0   0
By applying L – Hospital rule 31. Ans: 20.52 kW

A  Sol: d0 = 10 mm;
 2   y n  0 
 A1  A 0  A1 A
0 .3   1 1
A0 A0
d 
  y  2n  0 
 d1  d 12
0.3  1 
d 02
= 7.687 MPa
d1 = 8.36 mm
A 0  A1 d 02  d12
% reduction in area =  B = cot = 0.1cot(6o) = .951
A0 d 02
= 19.71%  1  B   A 1 
B

2  y   1   
 B   A 0  

30. Ans: 29.85 tons
Sol: Initial size = 2525150mm
 1  0.951 
 240  1  0.7 
0.951

 0.951 
Final size = 6.25100150mm = 141.687 MPa
 = 0.25;  2
y = 0.7kg/mm 2 Drawing load =  2  A 1  141 
4
d 1 
As given piece is pressed; height is reduced 
Fd  141.687 d12
h0 = 25; 4

hf = 6.25 = 141 
4
 
8.36 2 = 7777.364 = 7.8 kN
A0 = 25150;
Af = 100150 Fd  v
P (motor) =
motor
 2hrf 
Forging force =  y A f 1   7.8  2.5
 3h f  P
0.95
(Ac)circular = (Ac)non – circular
 P = 20.52 kW
rf2  100  150
rf = 69.098mm
Forging force
 2  0.25  69.098 
= 0.7  15  10 3 1  
 3  6.25
= 29847.44kg = 292.80kN
05. Ans: (b)

Fp max .Kt
Chapter Sol: Fp 
Sheet Metal Operations Kt  I
6
40  0.6  1.25
  17.14 kN
0.6  1.25  1
Common data for Q. 1 to 5 Fb max kt
Fb 
kt  I
01. Ans: (b) 80  0.6  1.25
  34.28 kN
0.6  1.25
Sol: For punching operation
F  FP  Fb  51.42 kN
Punch size = Hole size = 12.7
Die size = punch size + clearance
Common data for Q. 06, 07 & 08
= 12.7 + 2  0.04 = 12.78
06. Ans: 83.6 N
Sol:
02. Ans: (a) 100
Sol: Die size = Blank size = 25.4mm
30
Punch size = Die size  2(radial clearance) 50mm
= 25.4  2(0.04) 450 20

Punch size = 25.32 mm
80mm 20
P  100  30  20 2  80  50  288.28
03. Ans: (b)
Fmax  Pt u  288.28  2  145  83.6 kN
Sol: Fmax = Fp max + Fb max
=   12.7  1.25  800    25.4  1.25  800
07. Ans: 66.88 J
= 40 +80 = 120 kN
Sol: Work done in blanking open
= Fmax.K.t
04. Ans: (c) = 83.61030.42103
Sol: Force required is Max [Fpunch, Fblank] = 66.88 J
 force required is Max [40, 80]
 force required = 80 kN 08. Ans: 1.98 mm
Sol: I = ?
F = 24 kN
Fmax = 83.6 kN 12. Ans: (d)

F(Kt + I) = Fmax  Kt Sol: d = 25 mm, t = 2.5 mm → piercing
Fmax  Kt  u  350 MPa
I= Kt
F Diameter clearance  C
 83.6  0.4  2   0.0064 K t
=  0.4  2  = 1.98 mm
 24 
 0.0064  2.5 350 = 0.3 mm
In piercing
09. Ans: (a)
P.S = H.S = 25 mm.
5
Sol: Fmax  5  dt  u  dt u  D.S = P.S + C = 25 + 0.3 = 25.3

Fmax    1.5d  0.4t   u Fmax  dt  u    25  2.5  350
= 68.72 kN.
   1.5  0.4  dt u
2
   1.5  0.4   3 KN 13. Ans: (a)

Sol: Die size = Blank size = 25 – 0.05
= 24.95
Common Solution for Q. 10 & 11
Punch size = Die size – clearance
= 24.95 – 2  0.06
10. Ans: (a)
= 24.83
11. Ans: (b)
Sol: t = 5 mm, L = 200 mm, τu = 100 MPa,
Common data for Q. 14 & 15
K = 0.2
W.D = Fmax Kt = L × t × τu × K.t
14. Ans: (b)
= 200 × 5 × 100 ×0.2 × 5
Dia.before
100  10 3 Sol: Draw Ratio =
  100 N  m (or ) J only Dia.after
1000
13.22
Shear provided over a length of  d1 = = 7.34 > 5cm
1.8
20
200 mm   200 = 10 mm 7.34
400  d2 = = 4.08< 5 cm
1.8
Fmax Kt = F (Kt + I)
n=2
100  10 3  0.2  5
F  9.09  10 kN
0.2  5  10
15. Ans: (a) Common data for 18 & 19

Sol: D  d 12  4d 1 h 1 18. Ans: 6
Sol: D  d 2  4dh  30 2  4  30  150
4d 1 h 1  D 2  d 12
 137.47
D 2  d 12 13.22 2  7.34 2
h1   = 4.11 mm d 1  D  0.6  137.47  0.6  82.48  30
4  d1 4  7.34
d 2  82.48  0.8  65.984  30
P1  Dt y
d 3  65.984  0.8  52.7  30
=   132.22  1.5  315
d 4  52.7  0.8  42.2  30
 196238 N = 196.238 kN
d 5  42.2  0.8  33.7  30
E = P1h1 = 196.2384.1110–3
d 6  33.7  0.8  27  30
= 806.6 kJ
n=6
16. Ans: (b)

19. Ans: 52.7 mm
D  d1 Sol: d3 = 52.7 mm
Sol: DRR 1  0.4 
D
d 1  D1  0.4   30.2  0.6  18.12 20. Ans: 144.42
d 2  d 1 1  0.25  18.120.75  13.59 d 100
Sol:   16.66  15 to 20
r 6
d 3  d 2 1  0.25  13.590.75  10.19
r
d3 < 12  n = 3 D  d 2  4dh 
2
6
17. Ans: (b)  100 2  4  100  25 
2
Sol: P1  Dt y    30.2  2  35  6641.3 = 138.42 +23
P1 D total  D  2  3  144.42 mm
 21 
 2
4

d 1  d 1  2 t 
2

21. Ans: (d)
6,641.3


4

18.12 2  18.12  2  2
2
 22. Ans: (c)
= 65.5 MPa Sol: Number of earing defects produced =2n
Where n is an integer
So possible option is 64.
23. Ans: 467 mm 26. Ans: 7.536 kN

 Sol: Punching a 10 mm circular hole from 1 mm
Sol: B1  15  0.5  2  180 
180 thickness sheet:
= 50.265 mm Punch size = Blank size = 10 mm
 Die size = Punch size + 2 C
B 2  6  0.5  2  90  = 10.99 mm
180 C = Clearance = 0.0032 t 
L 0  98  204  92  B1  2B 2
t = thickness = 1 mm
= 466.245 mm where,  = 240 N/mm2
C = 0.0032×1× 240
2mm
15 = 0.0495 mm = 0.05 mm
92
Die size = 10 + 2 × 0.05 = 10.1 mm
98 100 Force required = s × d × t
6 mm = 240 ×  × 10 × 1
8m
= 7.536 kN
8 204 8
220m
24. Ans: (b)
25. Ans: 3
Sol: D  d 2  4dh
 50 2  4  50  100  150mm
D  d1
0 .4 
D
0.4150 = 150 – d1
d1 = 90mm > 50
d2 = d1(1–0.4) = 54 > 50
d3 = 32.4 < 50
n=3
04. Ans: (c)

Sol: D
Chapter
7 Metrology
t
7.1 Limits, Fits & tolerances t = 0.01 to 0.015mm
When, t = 0.01 mm
01. Ans: (a) D = 30.01 + 20.01 = 30.03 mm
Sol: For Clearance fit = 30.05 + 2 0.01 = 30.07 mm
L- hole > H- shaft When, t = 0.015 mm
D = 30.01 + 20.015 = 30.04 mm
02. Ans: (c) = 30.05 + 2 0.015 = 30.08 mm
0.050
0.000 0.08
Sol: Hole = 40 mm , D  30 0.03 mm
Min. clearance = 0.01 mm,
Tolerance on shaft = 0.04 mm , 05. Ans: (d)
Max. clearance of shaft = ? 0.01
0.01 = L.hole – H.shaft Sol: A = 25.2 0.02

0.01 = 40.000 – H.shaft B = 30.4  0.01
 H.shaft = 40.000 – 0.01 = 39.99mm C = 32.7  0.02
H.shaft – L.shaft = 0.04 Tmax = Lmax  Amin  Bmin – Cmin
L.shaft = 39.99 – 0.04 = 39.95 = (118 + 0.08)  (25.2  0.02)  (30.4
Max. clearance = H.hole – L.shaft  0.01) – (32.7 – 0.02)
= 40.05 – 39.95 = 0.10 mm = 29.83 = 300.17
Tmin = Lmin  Amax  Bmax  Cmax
03. Ans: (d) = (118  0.09)  (25.2 + 0.01)  (30.4
Sol: Xmax = 50.02 – (37.985 + 9.99) = 2.045 + 0.01) (32.7+ 0.02)
Xmin = 49.98 – (38.015 + 10.01) = 1.955 = 29.57
X = Xmax  Xmin= 0.09
Tmin = 30 0.43
Dimension X = 2 ± 0.045 0.17
 T = 30 0.43
06. Anc: (c)

07. (i) Ans: (d)  0.09 = 65 – (H.L)shaft

Sol: Let the vertical distance between the holes  (H.L)shaft = 65  0.09= 64.91 mm
is ‘y’ Tolerance = (HL)shaft  (LL)shaft
2450.05  0.05 = 64.91 – (LL)shaft
 (LL)shaft = 64.86 mm
x
0.09
 0.14
25 Shaft = piston = 65
y 2500.2
30
0.2 (ii) Ans: (a)

60  0.0 (L.L)hole = 65 mm
(Tolerance)hole = (HL)hole  (LL)hole
y  0.05 = (HL)hole – 65
sin30 = y = 245sin30
245  (HL)hole = 65.05 mm
ymax = 245maxsin30max 0.05
0.00
= (245 + 0.05)sin(30 +15/60) = 123.45 Hole = Bore = 65
ymin = (245 0.05)sin(30015/60) = 121.55
(iii) Ans: (b)
(ii) Ans: (c) Max Clearance = 65.05 – 64.86
xmax = 250max– (60min+(30/2)min+ymin+(25/2)min) = 0.19 mm
= (250 + 0.2) (60 +15+121.55+12.5)
= 41.15mm 09.
xmin = 250min –(60max+(30/2)max + ymax + (25/2)max) Sol: Amax = 15max + 30max
= (2500.2)  (60.2 + 30.025/2 + 123.45 + = 15.06 + 30.1 = 45.16
25.025/2) Amin = 15min + 30min = 44.84
= 38.625 mm A = 45 ± 0.16. = A ± ∆A
Tolerance on X = Xmax – Xmin = 2.525 mm Bmax = Amax – 20min
= 45.16 – 19.93 = 25.23 mm
08. Bmin = Amin – 20max
Sol: L Hole = BS = 65mm = 44.84 – 20.07 = 24.77 mm
H Hole = BS + Tolerance = 65.05mm  B ± ∆ B = 25 ± 0.23.
(i) Ans: (c)
Allowance = (L.L)hole  (H.L)Shaft
10. = 99.725 mm
Sol: Let 0.075
 C  100 0.275
C = center distance between holes
Cmax = max. Outer distance of pins – 11.
sum of min rod holes. Sol: For the given conditions
C =100±0.1 14.875 9.875
X  100.1  
2 2
14.9  0.025 9.9  0.025
= 112.475 mm
 15.05 10.05 
C  X  
 2 2 
15  0.05 10  0.05 C = 99.925 mm
x
Because C is lying in between the limits, the
 9 .9   14.9  assembly is possible.
Xmax = 100 max    
 2  max  2  max
9.925 14.925 12. Ans: (b)
 100.1  
2 2 Sol: Fundamental deviation of hole ‘h’ is zero.
= 112.525 mm
13.
 9 .9   14.9 
Xmin = 100 min     0.03
 2  min  2  min Sol: Hole = 20 0.00

9.875 14.875 Min. interference = 0.03mm,
 99.9  
2 2 Max. interference = 0.08 mm
= 112.275 mm 0.03 = L.shaft – H.hole
 15  L.shaft = 0.03 + 20.03 = 20.06 mm

 10  
C max  X max        0.08 = H.shaft – L.hole
 2  min  2  min 
H.shaft = 0.08 + 20.00 = 20.08mm
 14.95 9.95 
 112.525     0.08
 2 2  shaft  20  0.06
= 100.075 mm
14.
 15   10  
C min  X min        Sol:
 2  max  2  max 
H. Limit H 0.021
 15.05 10.05  B.S
 112.525     L. Limit
 2 2 
Max clearance = different between

B.S
F.D=0.02mm minimum material limits
f
= H.hole – L.shaft
H. Limit Tol = 0.033mm
= (25.021)  (24.947)
L. Limit = 0.074 mm
D  18  30  23.24mm (iv) Ans: (a)
i  0.453 D  0.0010  1.3m Size of the GO plug gauge = max. material

limit of hole = L.hole = 25 mm
FD of hole H = 0
FD Shaft = 5.5(23.24)0.41 = 20m
(v) Ans: (b)
Hole tolerance, IT7 =16i = 20.8m
Size of the NOGO plug gauge = min.
= 21m = 0.021 mm
material limit of hole = H.hole = 25.021 mm
Shaft tolerance, IT 8 = 25i
= 32.5m = 33m
(vi) Ans: (c)
= 0.033mm Size of the GO ring gauge = max. material
L - hole = basic size =25 mm limit of shaft = H.shaft = 24.98 mm
H - hole = 25 + 0.021 = 25.021 mm
H - shaft = 25 – 0.02 = 24.98 mm (vii) Ans: (d)
L - shaft = 24.98 – .033 = 24.947 mm Size of the NOGO ring gauge = min.
material limit of shaft = L.shaft = 24.947
(i) Ans: (a)
mm
L- hole > H- shaft  Clearance fit
(viii) Ans: (a)
(ii) Ans: (b)
Allowance = difference between max.
15. Ans: (c)
material limits = L.hole – H.shaft
Sol: D  18  30  23.2
= 25.00 – 24.98 = 0.02 mm
i  0.45 3 D  0.001 D  1.3
(iii) Ans: (b) IT8 = 26i = 26 × 1.3 = 33.8
0.02
0.021
= 34 m = 0.034 mm
Shaft  250.053 , Hole = 250.00
0.034
Hole size  25H 8  25  0.000
16. Ans: (a)

Sol: D  50  80  63.24 mm p
H. Limit 0.042
i = 1.86 microns = 1.9 microns
0.026
IT8 = 25i = 47.5 microns B.S =50
L. Limit
Tolerance = 0.0475 mm
F.D = –5.5 D0.41 = – 5.5 × 63.240.41
0.042
= 30 Microns = 0.03 mm Shaft  50 0.026
H. shaft = 60 – F.D = 60 – 0.03 = 59.97 mm L.hole = B.S = 50
L. shaft = H. shaft – Tolerance H.hole – L.hole = Tolerance = 0.025 mm
= 59.97 – 0.047 = 59.923 mm. H.hole = L.hole + Tolerance = 50.025 mm
Max. interference = difference between
17. Ans: (d)
max. material limits = H.shaft – L.hole
Sol: Case (i) 25H7
= 50.042 – 50.00 = 0.042 mm
L.L = 25.00
Min. interference = difference between min.
U.L = 25.021
material limits = L.shaft - H.hole
Case (2) 25 H8
= 50.026 – 50.025 = 0.001 mm
UL = 25.033
Case (3) 25H6, UL - ?
19. Ans: (c)
(UL)H8 (UL)H7 = (UL)H7  (UL)H6
25.03325.021 = 25.021  (25 + x)
20. Ans: (b)
x = 0.009
Sol: To calculate exactly the data was not given
 (UL)H6 = 25.009 in the problem. But for shaft “h”,
H – Shaft = 25.000
18. (i) Ans: (a) , (ii) Ans: (a),
L – Shaft = less than 25.
(iii) Ans: (a), (iv) Ans: (c)
And h7 → 7 indicates IT 7 not 7 microns.
Sol:
21. Ans: (a)
H 0.025
H. Limit Sol: GO size = max. material limit of hole
50
L. Limit = 20.01 mm
NOGO size = min. material limit of hole
0.025 = 20.05 mm
Hole  50 0.000
22. Ans: (d) h 29.19

Sin     82332
Sol: To produce an interference fit, L-shaft must L 200
be greater than H-hole. For this with 03. Ans: (d)
multiple choice D it is possible because
For D: L-shaft = 20 – 0.02 = 19.98 mm, 04. (i) Ans: (c)
H-shaft = 20 + 0.02 = 20.02 mm h
Sol: sin  =
L-hole = 20 – 0.035 = 19.965mm, L
H-hole = 20 – 0.03 = 19.97mm, h = sin30o  125=62.5 mm
Hence, L-shaft (19.98) > H-hole (19.97)
(ii)
(A) Ans: (a)
7.2 Angular Measurements
 0 0.005 
d  tan 30  = 4.76
01. Ans: (a)  62.5 125 
Sol: (B) Ans: (a)
Sine bar
Slip gauges d 2  d1 0.002

dh  r2  r1    0.001
2 2
Given sine bar length = 200 = l  0.001 0 
d  tan 30  = 2
Angle =3256 = 32.085  62.5 125 
Slip gauge height = h say (C) Ans: (b)
h dh = 0.002
sin  
  0.002 0 
d  tan 30   = 4

sin 32.085 0   h
200
 62.5 125 
(D) Ans: (d)
 h = 106.235 dh =  0.005
  0.005 0 
d  tan 30   = 10
02. Ans: i-(b), ii-(a)  62.5 125 
Sol: l = 50 , L = 500
50  0.08 05. Ans: 0.048 mm/m
0.08 Sol: Gradient of spirit level
200  200   0.32
50 = Sensitivity specified in mm/m
h = h + 0.32 = 28.87 + 0.32 = 29.19 10 
   1000 = 0.04845 mm/m.
3600 180
06. Ans: (d) 7.3 Taper Measurement
01. Ans: 19.2

07.
Sol:
Sol: (i) Ans: (b) 2.5 30
h2  h1 O2
sin =
w 50
/2
h2  h1 = 100sin30 = 50
h2 = h1 + 50 = 75 15
O1
(ii) Ans: (d)

h  25
sin(30)  h1 h2 d 2  d1
100.005 sin  / 2 
2h1  h 2   d 2  d1 
 h = 75.0025 mm
30  15
 h2 = 75.0025 + 0.005 = 75.0075 mm sin  / 2  
252.5  30  15
15
08. Ans: (a)  = 1/6
105  15
Sol: L = 250 mm, d = 20 mm
  = 19.2
h = 100 – (d/2) = 100 – 10 = 90 mm
90 02. Ans: 60
sin  
250 5
Sol: tan  / 2 
  = 21.2 deg 8.66
  = 60
09. Ans: 11.556 mm
Sol:  = 2732
o O2
 32  105=5
= 27   
o O1
 60  125
= 27.533 h
h 
sin =
25 36.345=31.34
h = 11.556 mm 36.34
40
50
03. Ans: 112.41 mm 05. Ans: 78.074 mm

Sol: Sol:
70 mm 30 mm
h2
h1 h1+r1=O2A+r2+h2
O2
D B A
O1 12.5mm 12.5mm
C
d1 = 100 m A C
M 


Diameter = O1C+O1A+O2D
d1 d2 O
  O1O 2 2  O 2 A 2 
X
2 2
O1O 2  r1  r2 =75
 +  = 4550 + 2910 = 75
O2A = h1 + r1 – r2 – h2

= 70 + 50  30  25 = 65  37.5 
2
D  50  75 2  65 2  25 75
   = 37.5 –  = 37.5 – 2910
2
= 112.4165 mm
= 820
le OBC
04. Ans: 43.33 mm
BC
Sol: sin 37.5 =
OB
BC 12.5
 OB    20.533
d = 25 O2 sin 37.5 sin 37.5
le OAB
42
35 OA
cos 820 =
O1 A OB
 OA = OB cos 820 = 20.316 mm
X = M – (OA + R)
O1A = 25  17  18.33
2 2
= 110.89 – (20.316 + 12.5)
D = r + O1A + r = 78.074 mm
= 25 + 18.33 = 43.33 mm
06. Ans: 1.1   3 

 Tan 1  = 6
Sol: d2 – d1 = 10 ; h2 – h1 = 12.138 2  28.54 
 d 2  d1 
sin    Taper angle    6 0
 2  2  (h 2  h 1 )  d 2  d1  2
 = 88.9 Included angle = 120
Error = 90 – 88.9 = 1.1
09. Ans: (c)
07. Ans: 38.94 10
Sol: tan     = tan-1(1/3)    18.434
Sol: 30
10mm 10mm
Z=40
h D
2
 D 30mm
2 2

10mm
Z=10
D
  2 D
Sin    
2 h D 2h  D Z=0
2 10 – (10/3)
 D
Sin 
2 2h  D Distance at Z = 0,
If D = 0, h = 0
 10 
D = 1, h = 1 D 0  210  10 tan 30  210  
 3
  1 1 = 6.67  2 = 13.33 mm
Sin    
 2  2 1  1 3
  1sec
 2   19.47   = 38.94 
  1
08. Ans: (d) With probe diameter compensation

 3 Dactual  13.334  2  r sec 
Sol: Tan   
 2  28.54
= 13.334 + 2 ×(1 sec 18.435)
= 15.442 mm.
 3
3
2
10. Ans: (d)
15.54 + 8 + 5 = 28.54
7.4 Screw Thread Measurements 1  71  0.11667 2.04103

2 = 91 = 0.15 2.618103
01. Ans: (d)
P = 0.004
Sol: Major diameter = s + (R2 R1)
De = 30.6651
= 35.5 + (11.8708 9.3768)  = 60 (metric thread)
= 37.994 mm Virtual correction
VC = (0.004  cos30) + (0.0131 
02. Ans: (a)
3.5(0.11667 + 0.15) )
Sol: Minor diameter
VC = 0.01569
= 30.5 + (15.3768  13.5218)
VED = De + VC
= 32.355 mm
= 30.6651 + 0.01569 = 30.6807
Correct answer is (a)
05. Ans: (a)

03. Ans: (a)
p 
Sol: best wire diameter, d =   sec  06. Ans: (d)
2 2
 R 2  R1
 3.5   60  Sol: Sin   
=  sec  = 2  2  M 2  M1  R 2  R 1 
 2   2 
1.4434  0.8660
M = 30.5 + (12.2428  13.3768) =
22.06  20.32  1.4434  0.8660
= 29.366 mm
 = 59.5566 = 593323
 p 
De = M  d  tan 
 2 2
07. Ans: 16.433 mm
 3.5 
= M  2   tan 30   p 
 2  Sol: De = M   d  tan 
 2 2
= 29.366 – 3.010366 = 26.355 mm
2
M = 14.701 + (1.155+ tan30) =16.433
2
04. Ans: (a)
Sol: VED = De  VC
08. Ans: (d)

VC  P cos  0.0131P 1   2  Sol: Lead = pitch  no of starts
2
lead 3
P = pitch error Pitch = = =1.5
no of starts 2
1, 2  flank angle errors in deg
09. Ans: (d) 7.5 Surface Finish Measurement

Sol: Rollers will not used to measure pitch
diameter. 01.
p  (i) Ans: (c)
Best size diameter d =   sec 
2 2 Sol: Rt = max. peak – min.valley
 2   60  = 4 2  18 = 24
=   sec 
2  2 
(ii) Ans: (c)
= 1.1547 = 1.155
Sol: CLA(Ra) = (h1+h2+h3+……+h10)/n
10. Ans: (d) 300

= = 30
10

Sol: V.C =  P.cos    0.0131 P(1+ 2) (iii) Ans: (b)
2
Sol: Peaks 35 40 35 42 35
= 0.2 cos30 = 0.346
Valley 25 22 18 25 23
peaks  valleys
Common data Q 11 & 12 Rz =
no of peaks
(35  40  35  42  35)  (25  22  18  25  23)
11. Ans: (a)  =15
5
p 
Sol: Best size diameter, d =   sec 
2 2 (iv) Ans: (b)
 2   60  h 12  h 22  h 32  ........  h 2n
=   sec  =1.155 mm Sol: RMS = = 33
2  2  n
(or) RMS = 1.1  R a=1.1  30=33
12. Ans: (a)
 p  (v) Ans: (c)
Sol: Deff = M –  d  tan 
 2 2 Sol: If Ra value from 18.75 to 37.5 international
= 16.455 – 1.155.tan30 = 14.7226 mm grade of roughness is given by N11.
13. Ans: 1.732 mm 02. Ans: (c)

Sol: The best wire size = (p/2) sec(/2)
Sol: Ra =
A  1

1000
= (3/2) sec(60/2) w HM VM
= 1.732 mm 480  480 1 1000
=   = 0.8
0.8 100 15000
03. Ans: (d)

0.05
Sol: Rt = =50  m Chapter
tan 45 Advanced Machining Methods
8 Numerical Control (NC) Machines
04. Ans: (c)

Sol: 01. Ans: (a)
Sol: Pitch of lead screw = 5mm
1 rev = 5mm
50 40
Am = 0.105
1mm = 1/5 rev
200mm = 1/5  200 = 40rev
10
= 40 360 = 14400 deg.
2.5
Am act = 0.105  0.01 2.5 = 0.08 02. Ans: (b)

A m act Sol: Pitch of lead screw = 5mm,
K=
(10 3  2.5)  0.04 BLU = 0.005mm
 Distance travelled /pulse
0.082 1
  = 0.8
 3
2.5  10  0.04 1000  Length of travel = 9mm
No.of pulses = L/BLU = 9 / 0.005
= 1800 pulse.
05. Ans: (c)
03. Ans: (b)

06. Ans: (c)
Sol: For 1 rev of motor 360 are required
 360 pulses are required
07. Ans: (a)
When motor is rotated by 1 rev
 lead screw will rotate by 1 rev
08. Ans: 2
When Lead screw is rotated by 1 rev 3.6
h 16  4  16  0 64
Sol: R a     2 m mm distance is travelled by axis
n 32 32
In total
For 360 pulses  360 deg of motor
 1 rev of motor
1 rev of lead screw
 3.6 mm of linear movement of axis
360 pulses = 3.6mm 07. Ans: (c)

1 pulse = 3.6/360 = 0.01mm = 10 microns Sol:
CNC drill table
X axis
pulses
04. Ans: (b)
Sol: 10V = 100 rpm Pulse Stepper
generator Driver
motor
= 100  5 = 500 mm/min
That is for 500mm/min = 10V
1mm /min = 10/500
3000mm/min = 10  3000 / 500=60 V BLU = the distance traveled by the table for
one pulse of electrical energy input to the
Common Data 05 & 06 motor.
05. Ans: (b) & 06. Ans: (a) Hence 200 pulse = 1 revolution of motor
Sol: A, Stepper motor  200 steps / rev = 1 revolution of lead screw = 4mm
That is 1 pulse = 4/200 = 1/50 = 0.02mm,
 200 pulses /rev
hence BLU does not depends on the
Pitch = 4 mm, no. of starts = 1,
frequency of pulse generator
Gear ratio = N0/Ni= 1/4 = U
 When frequency of pulse generator is
F = 10000 pulses per min
doubled, feed rate of table or tool will
200 pulses  1 rev of motor
double but BLU remains same.
 1/4 rev of lead screw
= 1/4  4  1 mm linear distance.
08. Ans: 20
= 1mm linear distance
Sol: p = 5 mm
1 pulse = 1/200 = 0.005mm
1000 pulses  1 rev of motor
= 5 microns = 1 BLU
 1 rev of lead screw
Feed = BLU  pulse /min
Velocity of table = 6 m/min
= 0.005  10000 = 50mm/min
= 6000 mm/min
For changing BLU = 10 microns
= 100 mm/sec
= 0.01mm
1000 pulses  1 rev of lead screw  5 mm
 Gear ratio has to be reduced to 1/2
5
Feed = BLU  pulse /min 1 pulse   0.005 mm
1000
 Pulses per min = feed / BLU BLU = 0.005 mm
= 50/0.01 = 5000 Table speed = BLU × Rate of Pulses
100 13. Ans: (d)

Rate of pulses =
0.005 Sol: Appropriate answer but the correct answer
= 20000 pulses/sec is
= 20000 Hz = 20 kHz N05 X5 Y5
N10 G02 X10 Y10 R5
09. Ans: (c) Because in CNC part program we are not
Sol: suppose to indicate information about one
75 axis more than once in one block.
centre
55 14. Ans: 60
(50,55)
Sol: In the combined movement, the tool is
moving for 50mm with a speed of
50 70
100mm/min. whereas in the same time tool
is traveling x-axis by only 30mm.
10. Ans: (b) Hence,
For 50mm 100mm/min
11. Ans: (a) 100
For 30mm   30  60mm / min
Sol: G02 – circular interpolation clockwise 50
G03 – circular interpolation counter clockwise
15. Ans: (a)
Sol: Because diameter of milling cutter is 16mm,
12. Ans: (c)
the radius is 8mm. the dotted line indicates
Sol: Because the tool has to travel from P1 to P2
cutter center position, which is shifted by 8
in clock wise.
mm all around the rectangular slot
Y P2 = (10, 15) (–8,58) (108,58)
  Center (15, 15) S R
(0,50) (100,50)
 (0,0) (100,0)
P1 = (15, 10) P Q
(–8,–8) (108,–8)
X
If the given shape is rectangular hole, then
the answer is
(8,8), (92,8), (92,42), (8,42), (8,8)
16. Ans: (a) 18. Ans: (b)

Sol:
Y Q (4,5)
19. Ans: (b)
Sol: Given coordinates (0,0) to (100, 100)
36.9
33.7 R
P D
3.2
(1,3)
milling
C slot (100, 100)
O
X
PQ  2 2  32 = 3.6055 = PC L
100
PD = PC  cos 3.2 = 3.6 10
x co-ordinate of point C = 1 + 3.6 = 4.6
DC = 3.6 sin 3.2 = 0.2 (0, 0)
y co-ordinate of point C = 3.0 – 0.2 = 2.8 100
17. Ans: (a) Depth, d = 2 mm,

Sol: “P” after translation = (1+2, 3+3, –5 –4) Diameter, D = 10 mm
= (3, 6, –9) L = actual distance travel by tool
Rotation about z- axis means L  100 2  100 2 = 141.42 mm
 x  cos   sin  0 0 x  disatnce
 y Time 
 y   sin  cos 
  0 0   speed
 z  0 0 1 0 z  141.42
        60
1  0 0 0 1 1  50 m / min
0  1 0 0 3 = 169.70  170 sec
1 0 0 0 6
  
0 0 1 0   9 20. Ans: 54.166 mm/sec, 10 micron
   
0 0 0 1 1 Sol: f = 500 pulse/rev
0  6  0  0    6  p = 5 mm,
3  0  0  0   3 
   N = 650 rpm

0  0  9  0    9  650  5
    (i) v = Np =
 0  0  0  1  1  60
Final point = [–6, 3, –9] v = 54.166 mm/sec
Now, 1 min = 650 rev

650 Chapter
1 sec = rev NTM, Jigs and Fixtures
60 9
650
 f  500 
60 01. Ans (c) 02. Ans: (d)
f = 5416.66 pulse/sec
03. Ans: (c)
And, v = B.L.U. f
Sol: In EDM the mechanism of MR is due to
= 54.166  BLU  5416.66 melting and vaporization associated with
B.L.U. = 0.01 mm cavitation and also erosion & cavitation or
B.L.U. = 10 microns spark erosion and cavitation
21. Ans: 287 04. Ans: (d)

Sol:  = 0.9 Sol: The high thermal conductivity of the tool
0.9 = 1 pulse material will have high electrical
360 conductivity hence the heat generated with
360  pulse  400 pulses
0.9 in the tool is low and what ever heat
 1 revolution = 4 mm pitch = 400 pulses generated it will be distributed easily
  2.87 mm = 287 pulses therefore tool melting rate reduces and tool
wear reduces. Where as due to specific heat
22. Ans: 100 pulse, 60 mm/min of work material, the rise in temp of W.P is
Sol: Pulse rate = N  pulse/rev faster and more amount of MR is possible.
400
 15   100 pulse / sec 05. Ans: (b)
60
Sol: Given w = 1 + (2 0.5) = 2
Feed rate = 15 rpm  4 mm/rev
t =5, f = 20 mm/rev
= 60 mm/min
MRR = wtf = 2.5.20 = 200 mm/min
06. Ans: (a)

Sol: As the thermal conductivity of tool material
is high the heat dissipation from the tool is
taking place and if the specific heat is high,
it needs large amount of heat for raising the
temps of tool material up to MP.
07. (i) Ans: (a) , (ii) Ans: (c) 10. Ans: (a)
Sol: D = 12mm, t = 50mm, R = 40 , Sol: In ECM
C = 20 F, Vs = 220V, Vd = 110V MRR  gram atomic weight of material
 Vs   Current density
Cycle time = R.C ln    tc 1
 Vs  Vd  
dis tan ce between tool and work
 220 
= 40 2010–6 × ln    Thermal conduction of electrolyte.
 110 
 554  10 6 sec  0.55 milli sec 11. Ans: (b)
Average power input = W Sol: I = 5000 A
 E   0.5  CVd 2  A = 63, Z = 1, F = 96500
=   AI 5000  63
 t c   tc  MRR  
ZF 1  96500
= 218 W = 0.218 kW  3.264 g / sec .
08. Ans: (b)

12. Ans: (a)
Sol: For Rough machining i.e. stock removal the
Sol: A = 55.85, Z = 2, F = 96540
electrolyte should have high electrical
Specific resistance = 2Ω-cm
conductivity, called passivity electrolyte,
Voltage = 12V
where as for finish machining the
Inter electrode gap = 0.2 mm
electrolyte should have low electrical
Resistance
conductivity called non–passivity
Sp. Resis tance  Inter electrode gap
electrolyte will be used. R
Suface area
2  10  0.2
09. Ans: (b)   0.01
20  20
Sol: In ECM
V 12
MRR  gram atomic weight of material I   1200A
R 0.01
MRR  Current density AI 55.85  1200
MRR  
1 ZF 2  96540
MRR 
dis tan ce between tool and work  0.3471 g / sec
MRR  Thermal conduction of electrolyte.
13. Ans: 51.542 18. Ans: (d)

1 Sol: Relative motion between tool and work
 0.009
L 50  0.009
Sol: R   0.02  piece is not necessary.
Area Area Area
V 12  1.5  Area 19. Ans: (c)
I   23.333  Area
R 50  0.009
Sol:
L = 3 + 6 = 9 m = 0.009
AI 55.85  23.333  Area A
MRR   B
ZF 7860  10 6  2  96500
= 0.98189  Area
MRR If D = Dmin = 59.9
 0.8590 mm / sec
Area X1 = distance between center of shaft and
 0.8590  60 mm / min 59.9
= 51.542 mm/min corner of V – block  2  34.583
sin 60
14. Ans: 680 60.1
X 2  2  34.698
15. Ans: (c) sin 60
Sol: EDM, ECM and AJM are used for Error in depth = 2(X2 – X1) = 0.223 mm
producing straight holes only but in LBM
by maneuvering or bending laser gun 20.
slightly it is possible perform the Zig – Zag Sol: Resolving the force “F” into Horizontal
hole. F sin   100 ………. (1)
F cos   100  100  200 …… (2)
16. Ans: (b) (Both are Correct)
(1) 100
Sol: In EBM Vacuum is provided to avoid the  tan  
(2) 200
dispersion of electrons after the magnetic
1
lense, but this vacuum is giving an addition   tan 1    26.565
2
function of providing efficient shield to the
100
weld bead. F  223.6 kg
Sin 
17. Ans: (d) Taking the moments about vertical axis

Sol: Out of all the NTM’s ECM will give large xF cos   100  30  100  30  100  20
MRR and EBM will give very small MRR.  x = 10 mm
21. (i) Ans: (d), (ii) Ans: 10.6 mm Positional error = 30.025 – 30 = 0.025 mm
Sol:
P
(b) Fixed V – block and movable rectangular
block
O1 O2
A
X1 X2
Clamping
Q 30 30.025
O1
O2
4 3
30
A x1   34.64
Sin 60
O1 O 2  4 2  3 2 = 5 30.025
x2   34.66
Sin 60
O1O 2  5  x 2  x 2
(c) Positional error = x2 – x1 = 0.0298 mm
x = 3.5
The positional error is mainly depends on
Block of uniform thickness is preferable
the fixed element. So when fixed V – block
because of balanced condition.
and marble V – block is used, the positional
error is remains same as (b).
22.
Out of the 3 cases, case (a) is giving lower
Sol:
positional error, hence preferable.
(a) Fixed rectangular block and movable V –
clamp.
O1 O2 Clamping
· ·
30
30.025

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04. Ans: (a)

4 05. Ans: (c)

06. Ans: (c) 07. Ans: (c)

C.S area of cylinder = C.S area of ellipse 13. Ans: 50

4 Time taken for removing latent heat

VR 0.8VC1 Common Data for Q.16 & Q. 17

20. Ans: 0.05 s

Momentum of water = Momentum of liquid 2 Welding

02. Ans: 4860 W, 1.5 mm

Area of weld bead (WB)

30o 30o =  28  280 minutes

09. Ans: 0.64 mm & 2.1 mm 11. Ans: (b)

10. Ans: (c)

14. Ans: 2.3 & 4.6 MJ 17. Ans: (b)

Total heat required = heat to be generated 23. Ans: 61.53 %

02. Ans: (d)

Vf Vs 04. Ans: (c) 05. Ans: (b)

Vc = 40 m/min; Vf = 20 m/min FC  1200, FT  800,   300

 1  0.5 sin 10  = 1200 W

Common Data for Q. 08 & 09 t1 L 2 60 60

11. Ans: (d)

t 1 0.125 14. Ans: (d)

23. Ans: 30.8 m/min

27. Ans: 0.944

than the material A. Hence the  75 

03. Ans: (b) 07. Ans: (b)

10. Ans: (c) 12.

Total time = 20.5×2 = 41 mins = 0.9812 min = 58.87 = 59 sec

11. Ans: (b) 13. Ans: (b)

Sol: Time per hole = L/f.N

18. Ans: (d)

19. Ans: (b)

Dtool = 15 cm = 150 mm Total depth 2

21. Ans: 8.05 min

25. Ans: (a)

03. Ans: (a)

04. Ans: 1.98 MN H  20  18  2mm

07. Ans: (d) 10. Ans: (b)

11. Ans: (a) Common data for Q 12, 13 & 14

(By considering friction)

total = 260  81.94 = 178.05 MPa 13. Movable mandrel

= 178.05  21.237 2 / y   1      0.519

14. Floating mandrel

B = cot; B = 1.9 Common data for Q 17, 18

 y  300 MPa h0 – hf = 0.1 h0

19. Ans: (b)

Common data for Q 23 & 24 27. Ans: 7.26

By applying L – Hospital rule 31. Ans: 20.52 kW

05. Ans: (b)

= 25.4  2(0.04) 450 20

Fmax = 83.6 kN 12. Ans: (d)

15. Ans: (a) Common data for 18 & 19

16. Ans: (b)

23. Ans: 467 mm 26. Ans: 7.536 kN

24. Ans: (b)

04. Ans: (c)

0.01 = L.hole – H.shaft Sol: A = 25.2 0.02

06. Anc: (c)

07. (i) Ans: (d)  0.09 = 65 – (H.L)shaft

0.2 (ii) Ans: (a)

 2  min  2  min Sol: Hole = 20 0.00