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UNIT I
MECHANICS OF METAL CUTTING
Mechanics of chip formation, single point cutting tool, forces in machining, Types of chip, cutting tools
– nomenclature, orthogonal metal cutting, thermal aspects, cutting tool materials, tool wear, tool life,
surface finish, cutting fluids and Machinability.
S.No.
Part – A ( 2 Marks )
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Write a short note on heat zone in cutting.
Mention any two modern tool materials.
Explain the condition that induces the formation of Built up
edge.
How tool life is estimated?
Classify the different types of chip breakers.
List the various metal removal processes.
Interpret the significance of negative rake angle.
Discuss how chip formation occurs in metal cutting.
Illustrate the various parts in single point cutting tool.
List the various angles in cutting tool.
What are the assumptions made in drawing Merchant’s circle?
Examine chip thickness ratio.
Classify the cutting fluids.
Draw the nomenclature of cutting tool geometry.
Point out the objectives and functions of cutting fluids.
Point out the various cutting tool materials.
Deduce the factors that contribute to poor surface finish in
cutting.
Summarize the four important characteristics of materials used
for cutting tools
Explain the advantage of high machinability
Summarize machinability index.
PART B (13 Marks)
(i) Explain various cutting tool materials.
(ii)List the properties of cutting tool materials.
In an orthogonal cutting operation on a work piece of width
2.5mm, the uncut chip thickness was 0.25mm and 25 degree. It
was observed that the chip thickness was 1.25mm.The cutting
force was measured to be 900N and the thrust force was found
to be 810 N.
(a) Find the shear angle.
(b) If the coefficient of friction between the chip and the tool, was
0.5, what is the machining constant Cm
(i).Describe the chip formation with neat sketches.
(ii).Explain about chips With Built up edge.
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(i). Mention the functions of Cutting Fluids.
(ii). Explain the uses of Cutting Fluids.
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Describe the mechanism of metal cutting and process involved in
detail
List the various tool materials used in industry. State the
optimum temperature of each of the tool materials.
A turning tool with side and end cutting edge of 20 degree and
30 degree respectively operates at a speed of 0.2 mm/rev.
Calculate the CLA of the surface produced if the tool force
radius is 3 mm.
(i).Examine the parameters that influence the life of tool and
discuss.
(ii).Illustrate the formulas involved in life of tool.
Explain merchant force circle assumptions, diagram and
characteristics.
(i).Differentiate between orthogonal cutting and oblique cutting
(ii).Discuss their merits and demerits
Explain the geometry of a single point cutting tool with suitable
sketches
Explain the basic actions, characteristics and properties of cutting
fluids
(i).Express the formulae in Orthogonal metal cutting.
(ii).Describe the expression for the shear angle in Orthogonal
metal cutting
Explain the standard angles of cutting. Illustrate with an example
PART C (15 Marks)
Give your understanding of the basic metal-cutting process,
what are the important physical and chemical Properties of a
cutting tool.
Maximum temperature in orthogonal cutting is located at about
the middle of the tool-chip interface - Evaluate
Why is it not always advisable to increase cutting speed in order
to increase production rate?
Describe in detail your thoughts regarding the technical and
economic factors involved in tool material selection
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UNIT 2 TURNING MACHINES
Centre lathe, constructional features, specification, operations – taper turning methods, thread cutting
methods, special attachments, machining time and power estimation. Capstan and turret lathes- tool layout
– automatic lathes: semiautomatic – single spindle: Swiss type, automatic screw type-Multispindle
S.NO.
PART – A (2 MARKS)
MARKS
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List out the factors to be considered while specifying a lathe.
Explain the meaning of “swing of the lathe".
Discuss the difference between feed rod and lead screw.
Define the term “Conicity”.
Illustrate the methods of taper turning on lathe.
Express the formula for calculating taper turning angle by
tailstock set over distance and compound rest method.
Calculate the angle at which the compound rest will be swiveled
when cutting a taper on a piece of work having the following
dimensions. OD = 60 mm; Length of the tapered portion 80 mm
and smallest diameter – 20mm.
Describe the term “Thread cutting”.
Explain how the number of teeth on various change gears be
calculated?
Generalize the formula to find the following parameters
(i) Machining time (ii) Total length of tool travel (iii)
Number of passes or cut.
Define automatic machine.
Examine the three stages of a tool-layout?
Compare the advantages of turret lathe over capstan lathe.
Recommend different drives used in copying lathes.
Explain the term "copy turning".
Differentiate automatic lathe and capstan lathe.
Support the sketch illustrating the principle of operation of Swiss
type automatic lathe.
Tabulate the difference between parallel action and progressive
action multi spindle automatic lathes.
Discover the four major parts of swiss type automatic lathes.
Discuss the purpose of providing lead cam in single spindle
automatic screw cutting machine.
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PART B (13 Marks)
(i) What are the different types of machining operations that can
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be performed on a lathe? Explain any four in
detail.
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(ii) A hollow work piece of 50 mm diameter and 200mm long is
to be turned over in 4 passes. If the approach length is 20mm over
travel 10mm, feed 0.8mm/rev and cutting speed 30m/min, Find
machining time.
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Explain the construction and working principle of a lathe with a
neat sketch.
(i) Describe the difference between a steady rest and follower
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rest. Give an application of each.
(ii) Summarize various types of chucks. Explain any twoF.or More Vis it : w6ww.LeBarTnE2ngineUernindge.rinstand
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(i) Explain taper turning operation in a lathe by taper turning
attachment method.
(ii) Point out why the boring operation on a lathe be a difficult
operation?
Describe the following methods of taper turning in lathe by
i. Swiveling the compound rest.
ii. Form tool method.
(i) Explain the thread cutting operation in a lathe with a neat
sketch. Also make a note on knurling, grooving and forming
operations in a lathe.
(ii) Illustrate the purpose of various attachments used on a centre
lathe.
(i) Calculate the gears for cutting metric threads of following
pitch. i) 4mm pitch, ii) 5.25 mm pitch. The lead screw of lathe
contains 6 TPI. The lathe is supplied with 20 to 120 teeth in step
of 5and an additional gear wheel of having 127 teeth.
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(ii) Calculate the time required for one complete cut on a piece of
work having 250 mm long and 40 mm diameter. The cutting
speed is 32 m/min and feed is 0.4 mm/rev.
Discuss about the Geneva mechanism of turret lathe with neat
sketch.
(i) Explain the classification of automatic lathes.
(ii) Describe the features of Swiss type automatic lathe and bar
type automatic lathe.
Discuss the features of Ram type and Saddle type turret with neat
Sketch.
(i) Explain the tooling layout for the producing of a Hexagonal
bolt in a Capstan lathe.
(ii) Discuss the tooling layout for production of a hexagonal nut
in Turret lathe.
(i) Classify transfer machines. Sketch and explain the working
of Swiss type automatic screw machine.
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(ii) What are the advantages of automatic machines?
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(i) Briefly explain the principle of working of sliding head type
single spindle automatic machine.
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(ii) Differentiate between parallel action and progressive action
multi spindle automatics.
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Describe the working principle of multi spindle automatics. Give
its advantages and applications.
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PART C (15 Marks)
A badly oxidized and uneven round bar is being turned on a
lathe. Would you recommend a small or in large depth of cut?
Explain.
Describe the problems, if any, that may be encountered in
clamping a work piece made of a soft metal in a three- jaw chuck.
We have seen that cutting speed, feed, and depth of cut are the
main parameters in a turning operation. In relative terms, at what
values should theses parameters be set for a (a) roughing
operation and (b) finishing operation?
Explain the economic justification for purchasing a turret lathe
instead of a conventional lathe.
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UNIT-III RECIPROCATING MACHINE TOOLS
Shaper - Types of operations. Drilling, reaming, boring, Tapping. Milling operations- types of milling
cutter. Gear cutting – forming and generation principle and construction of gear milling, hobbing and gear
shaping processes –finishing of gears.
S.No.
PART- A (2 MARKS)
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Mention the differences between shaper and planer.
What are the differences between drilling and reaming?
Briefly describe the importance of quill mechanism.
List the types of sawing machines.
Define the cutting speed, feed and machining time for
drilling.
What is broaching?
What is the difference between up milling and down
milling?
List four applications of broaching machines
How do you classify milling cutters?
What do you know about straight fluted drill and fluted
drill?
What is meant by up milling and down milling?
State the differences between a vertical shaper and slotters.
Write the differences between drilling and tapping.
What is a shell mill?
Mention the operations performed by a planner.
Why is sawing a commonly used process.
List out the various elements of a plain milling cutter with
a with neat sketch.
Give the two principal methods of gear manufacturing.
List out the gear finishing processes.
Explain gear hobbing.
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PART B (13 Marks)
Explain various milling cutters with neat sketches?
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Discuss various hole making processes.
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With a neat sketch explain the column and knee type
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milling.
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Explain hacksaw and band saw with neat sketches.
3w.Le aArnpEpnlgyiinnegering.in
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Discuss boring and reaming operation with neat sketches.
Discuss the principle of operation of boring operation with
a neat sketch.
Describe the working of a crank and slotted link
mechanism.
Sketch and explain the hydraulic drive of a horizontal
shaper.
What are the operations performed on a drilling machine?
Sketch a twist drill and explain.
Explain different types of milling cutters.
With the help of a neat sketch, discuss the Tapping and
gear hobbing operation.
Sketch the Quill mechanism .write its main parts and their
function.
(i).How will you cut the following types of surfaces on
milling machines? (a)Flat surfaces (b)Slots and splines
(ii).Make a note on different types of work holding devices
used in a slotting machine.
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PART C (15 Marks)
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(i).Explain the different types of table drive and feed mechanisms in
a planning machine
(ii).State the advantages of Ward- Leonard drive.
(i).Explain with a sketch “Fast and loose pulleys” quick return
mechanism of a planer table.
(ii).Write short notes on expanding hand reamers and adjustable
machine reamers.
(i).Sketch and explain the main parts of a band saw.
(ii).Explain different types of drilling machines with their special
features.
List the difference between shaper and planner.
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UNIT-III
RECIPROCATING MACHINE TOOLS
Abrasive processes: grinding wheel – specifications and selection, types of grinding process– cylindrical
grinding, surface grinding, centre less grinding and internal grinding- Typical applications –concepts of
surface integrity, broaching machines: broach construction – push, pull, surface and continuous broaching
machines
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How does loading differ from glazing in grinding process?
List out the factors involved in the selection of a grinding
wheel.
Why most abrasives are now made synthetically?
Narrate the working principle of abrasive jet machining.
What is an abrasive? What are super abrasives?
Define hardness of the grinding wheel.
Define lapping.
How will you express “grade” and “structure” of a grinding
wheel?
Discuss the parameters that would affect the MRR in abrasive
jet machining.
Give four important factors that influence the selection of
grinding wheel.
Discuss the need of truing and dressing operations in a
Point out the abrasives used in manufacture of grinding wheels.
Classify the types of external grinders.
Discuss the operations done in centre less grinders.
Explain the work holding and supporting devices used in
grinders.
Explain why the centre less grinders are called as specialized
machines for Cylindrical parts?
Classify the different types of fine finishing process.
Discuss surface integrity.
What is the principle of a broaching process?
What are the principal types of broaching machines?
LEVEL
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PART B (13 Marks)
(i) Explain the working mechanism of cylindrical and
surface grinding.
(ii) Discuss the various bonding materials used for making
grinding wheels.
(i) What are the consequences of allowing the temperature
to rise during grinding?
(ii) The performance of a grinding wheel depends upon the
type of abrasive, grain size, grade, structure and
bonding material. Discuss the effect of each.
(i) What do you understand by grinding as an abrasive
process? Explain with a neat sketch.
(ii) What precaution should you take when grinding high
precision?
(i) What is Surface grinding? What are the different types
of surface grinding machines?
(ii) Explain why there are so many different types and sizes
of grinding wheels?
Explain the working principle and various methods of
centre less grinding with a neat sketch.
(i) Sketch and explain the three methods of external
cylindrical centre less grinding.
(ii) Why speed is so much higher in grinding than in
cutting?
(i) Explain dressing and truing of grinding wheel.
(ii)What factors could contribute to chatter in grinding?
(i) Explain the factors to be considered to select a grinding
wheel and recommended parameter.
(ii)What are the effects of wear flat on the grinding
process?
(i) How do you classify cylindrical grinders?
(ii) What is the difference between “Plain and universal
“cylindrical grinder?
(i) Briefly discuss about the different types of abrasives
used in a grinding wheel.
(ii) Discuss with neat sketch vertical broaching machines.
(i) Describe the factors that contribute to broaching force
and explain why.
(ii) Describe the conditions under which broaching would
be the preferred method of machining.
(i) Describe the concept of surface integrity.
(ii) Explain the generalized classification of broaching
machines.
Explain Surface and continuous broaching. Give the
advantages and disadvantages of surface and continuous
broaching
Explain the construction of a Push type and pull type
broaching machine.
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Part C (15 Marks)
Describe as many parameters as you can that could affect the
final surface finish in grinding
Jeweler applications required the grinding of diamonds into
desired shapes, How is this done, since diamond is the hardest
material known?
Would you encounter any difficulty in manufacturing
thermoplastics and thermo sets? If so, what precautions
would you take ?
Would you recommend broaching a keyway on gear
blank before or after machining the teeth ,Why?
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UNIT-IV CNC MACHINES AND UNIT V PROGRAMMNG OF CNC MACHINES
Numerical Control (NC) machine tools – CNC types, constructional details, special features,
machining centre, part programming fundamentals CNC – manual part programming –micromachining
– wafer machining
Sl.N
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PART A (2 Marks)
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List the differences between NC and CNC.
Define linear bearings.
Mention the type of ball screws.
Define feed drives.
Discuss the types of motion control system used in NC machines
Express the meaning of APT language.
Discuss closed loop NC system with open loop system.
Give the uses of preparatory function. How is it important in
CNC programming?
Illustrate the limitations of CNC machine tools.
Examine - canned cycle.
Define NC.
Explain the major elements of NC machines.
Compare the different NC machines
Compare incremental and absolute system
Explain the role of computer for NC machine tool.
Explain point –to – point (PTP) system.
Assess G-Codes and M-Codes.
Summarize the commonly uses of coordinate Systems.
Assess the types of statements in APT language.
Evaluate the process involved in wafer forming.
PART B (13 Marks)
(i) Narrate the design considerations of CNC machines.
Discuss about slide ways used in CNC machine tools.
(ii) Describe the spindle drives used in CNC machine tools
List the difference between manual and computer assisted part
programming
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Explain the following in CNC machining. (i)Linear
Interpolation (ii)Circular Interpolation
(iii) Cubic interpolation
Describe the spindle and feed drives. State the requirement of
the drives of CNC machine tools
Explain the various elements of NC machine with closed loop
control system.
(i) Explain the main difference between point to point and
continuous path of numerically controlled machine too
(ii) List any five motions and control statements of computer
assisted NC programming and explain.
Write the steps involved in APT language
Explain the various elements of NC machine with closed loop
control system
List any five motions and control statements of computer
assisted NC programming and explain
Describe the spindle and feed drives. State the requirement of
the drives of CNC machine tools
Write the part program for the part shown below
Write the part program for drilling holes in the part shown
below. The plate thickness is 20mm
How is manual programming of a NC m a c h i n e done.
Discuss the advantages of computer numerical control system
PART C (15 Marks)
(i).Describe in brief the basic components of a tape operated NC
machine tool
(ii).State a few typical applications where the use of numerical
control would be justified
(i).Write short notes on APT language
(b).Under what conditions of production the numerically
controlled machine tools are employed
(i).Define CNC and DNC. With a help of a diagram explain the
working of NC machine tool
(ii).Discuss the important design features of CNC machine tools
Describe in brief the basic components of a tape operated NC
machine tool
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