III SEMESTER
SUBJECT:MANUFACTURING PROCESS-I
Unit-I
Introduction to Machining Parameters
Q.1) Describe the tool geometry of a single point cutting tool with neat sketch.
Q.2) What do you mean by oblique and orthogonal cutting? How do they differ from each other.
Q.3) What do you understand cutting tool nomenclature? Sketch and label tool angles/tool nomenclatures.
Q.4) Describe in brief how you measure tool life. What is machinability and what is machinability index?
Q.5) Describe the different types of chip formation in metal cutting.
Q.6) Why coolants are used in machining process? State the desirable properties required in cutting fluids.
Q.7) State the different types of tool materials and explain how the appropriate tool material is selected.
Q.8) What are the purposes of cutting fluids? What are the types?
Q.9) What are the desirable characteristics of cutting tool materials? Describe them in brief?
Q.10) List various types of chip breakers. Why they are used?
Q.11) Why tools fail during cutting? Explain, giving reasons of tool wear.
Q.12) How do you define cutting speed and feed ? State various factors that may be considered to fix cutting speed and feed.
Q.13) Write short notes on
i) Tool signature ii) Chips with built up edge
Q.14) Explain different heat sources in metal cutting with neat sketch.
Q.15) Explain the factors affecting tool life of single point cutting tool.
Q.16) Differentiate between continuous and discontinuous chips.
Q.17) Find the angle at which the compound rest should be setup to turn taper on work piece having a length of 200 mm, larger diameter 45 mm and smaller diameter 30 mm.

Unit-II
Lathe Machine
Q.1) What is the main function of a lathe? List various types of lathes.
Q.2) How a Lathe is specified? Discuss.
Q.3) Explain with neat sketch the principal parts of lathe machine.
Q.4) Why chucks are used? List various types of chucks used in lathes.
Q.5) What is a mandrel? Why they are used in lathes? List different types of mandrels.
Q.6) What are the different machining operations performed on a lathe by holding the workpieces between centers or chucks?
Q.7) Distinguish rough and finish turning.
Q.8) Define taper. How is the amount of taper expressed? Name different methods of taper turning done on a centre lathe drawing simple sketches?
Q.9) Why turning is produced on a surface? How it is produced on a lathe.
Q.10) How turning tools are classified? List various turning tools.
Q.11) What are the influences of cutting tool angles on machining? Briefly state the effect of rake angle during cutting.
Q.12) Sketch a square thread cutting tool and label tool angles.
Q.13) Explain Tailstock with neat sketch.
Q.14) State the different methods of taper turning and explain Compound Rest method with neat sketch.
Q.15) Explain Lathe Accessories and Attachments with neat sketches.
Q.16) Write short notes on
i) Chucks ii) Lathe Carriage iii) Apron Mechanism in Lathe
Q.17) Why there is need for speed variation in lathe.
Q.18) Explain Thread cutting operation in Lathe machine.
Q.19) Explain all geared head stock with neat sketch.

Unit-III
Shaper, Planer, Slotter
Q.1) How the size of shaper is specified? Discuss.
Q.2) State the classification of shaper.
Q.3) Describe Whitworth quick return mechanism, used in shapers in brief.
Q.4) Explain in short with neat sketch the hydraulic mechanism in shaper machine.
Q.5) Explain with a neat sketch the crank and slotted lever mechanism in a shaper. Discuss the quick return motion of tool.
Q.6) Name different parts of a shaper. Describe them in brief pinpointing their functions.
Q.7) Define speed, feed and depth of cut in a shaper.
Q.8) How you can adjust the length of stroke in a shaper? Explain.
Q.9) Name and describe the various work holding devices in shapers.
Q.10) What types of operation can be performed in a shaper efficiently. Describe them in brief.
Q.11) Describe various types of slotters in brief. How a slotter is specified?
Q.12) Describe the main parts of a slotting machine.
Q.13) Describe various feed movement in a slotting machine?
Q.14) Describe in brief how you can machine circular surfaces in a slotting machine.
Q.15) What is the fundamental difference between a planner and a shaper?
Q.16) How the size of a planer is specified? Describe.
Q.17) What are the various feed mechanism in a shaper?
Q.18) What types of operations can be performed efficiently by a planer? List and explain.
Q.19) List various mechanism for table drive in shaper.
Q.20) Sketch various planer tool indicating applications.
Q.21) Differentiate between shaper and slotter.
Q.22) Write a short note on
i) Pit planner ii) Divided table planner
Q.23) Explain open and cross belt drive of planer.
Q.24) Explain slotted disc mechanism of slotter.
Q.25) Explain the tool head of shaper with neat sketch.

Unit-IV
Milling Machine
Q.1) Classify milling machines and list them accordingly. How milling differs from turning in lathe?
Q.2) Give the classification of milling machine.
Q.3) Draw a neat sketch of plain milling cutter and state its angles.
Q.4) Compare between plain and universal milling machine.
Q.5) Differentiate between factory- production milling and tool room milling.
Q.6) Name and describe the principal parts of a milling machine.
Q.7) Describe various milling machine attachments in brief.
Q.8) Classify milling cutters .State material and features of each.
Q.9) What are the general characteristics of an end mill?
Q.10) What are the reasons that you cannot use end mill as a drill?
Q.11) What are the differences between single angle and double angle milling cutter?
Q.12) Describe various milling operations with neat sketches.
Q.13) What are the different methods of production of gears?
Q.14) What is indexing? How and why it is performed for gear manufacturing?
Q.15) What are the different methods of indexing?
Q.16) What is compound indexing? Write the procedure of determining the index circles.
Q.17) What is differential indexing?
Q.18) What is gear hobbing?
Q.19) What is gear shaping? Describe in brief.
Q.20) Calculate all machining particulars for cutting a spur gear of 4 module and 60 teeth with proper index plate hole circle and sector.
Q.21) Compare plain milling and universal milling.
Q.22) Write short notes on
i) Fly cutters ii) Column and Knee milling machine
Q.23) Differentiate between
i) Up milling and Down milling ii) Omniversal and Universal milling machine
Q.24) Explain the following Milling Operations with the help of suitable sketches
(i) Plain milling (ii) Straddle milling (iii) Gang milling (iv) Form milling

Unit-V
Grinding and Super Finishing Process
Q.1) Classify grinding operations in brief.
Q.2) Explain the principle of grinding.
Q.3) Give the classification of precision grinding.
Q.4) How will you classify the grinding machine explain.
Q.5) Explain with neat sketch the process of center less grinding.
Q6) Explain the mechanism of metal removal in grinding operation.
Q.7) Explain how the grinding wheels are specified.
Q.8) State abrasive materials used in grinding wheel. Which process parameters affect the surface finish in grinding operation.
Q.9) Write a short note on Facing and Truing of grinding wheel.
Q.10) Differentiate between wheel dressing and wheel truing in grinding wheel.
Q.11) Write short notes on
i) Cylindrical grinders ii) Center less grinders iii) Grinding wheel
iv) Internal grinders v) Surface grinders
Q.12) What are grit, grade and structure of abrasive particles used in grinding wheel.
Q.13) What is standard marking system of grinding wheel.
Q.14) What are various methods used for feeding the work piece in center less grinding.
Q.15) Differentiate between centre type and centre less grinding.
Q.16) What are the different types of bonds used in grinding wheel, explain .
Q.17) On a grinding wheel it is printed as under
WA46H8V15
Explain what does each letter and number indicates.
Q.18) Differentiate between surface grinder and tool and cutter grinder.
Q.19) What is Honing. Describe the process of honing with a neat sketch.
Q.20) What is Lapping and state necessity and applications of lapping.
Q21) Differentiate between super finishing and lapping.
Q.22) Explain Buffing process. State its advantages and applications.
Q.23) Write short notes on
i) Polishing ii) Burnishing iii) Metal Spraying iv) Electroplating

Unit-VI
Drilling, Reaming, Boring, Broaching
Q.1) Give the classification of drilling machine.
Q.2) How drilling machines are specified. State the different operations performed on drilling machine.
Q.3) How drills are classified. Draw a neat sketch of a twist drill and show all its elements.
Q.4) What is sensitive drilling machine explain with neat sketch.
Q.5) Explain with neat sketch the working of Radial drilling machine and give its advantages.
Q.6) Explain with neat sketch an upright drilling machine.
Q.7) Name the work holding devices used for drilling operations. Sketch the arrangement of clamping work piece by using ‘V’ block.
Q.8) State and explain the different operations performed on drilling machine.
Q.9) Differentiate between counter boring and counter sinking with neat sketch.
Q.10) Describe the following operations on drilling machine
i) Trepanning ii) Tapping iii) Spot Facing
Q.11) What do you understand by ‘Deep hole drilling’.
Q.12) Explain the terms cutting speed, feed and depth of cut related to drilling operations.
Q.13) Explain how drilling time is estimated.
Q.14) Explain any two work holding devices for drilling machine.
Q.15) Differentiate between
i) Drilling and Reaming ii) Gang drilling and Multiple spindle drilling machine
Q.16) Give the classification of boring machine.
Q.17) How horizontal boring machine is specified.
Q.18) What is the function of boring head.
Q.19) Sketch two operations each performed on vertical and horizontal boring machine.
Q.20) Describe Jig boring machine.
Q.21) State the methods of locating holes in jig boring machine.
Q.22) Sketch any two types of boring tools.
Q.23) Explain the types of boring and their mountings.
Q.24) Differentiate between boring and counter boring with neat sketch.
Q.25) What is broaching . Name the types of broaches.
Q.26)How broaching machines are classified.

Q.27) How are broaching machines specified. Explain the horizontal broaching machine with neat sketch.
Q.28) Sketch and explain the parts of pull type broach.
Q.29) Differentiate between pull broaching and push broaching.
Q.30) How broaching is advantageous over other machining methods.
Q.31) What is external broaching. Which machines are used for external broaching.
Q.32) What is reaming. Draw a sketch of reamer.
Q.33) What do you mean by reamer. Describe the various types of reamer with sketch.
Q.34) Describe various elements of reamer.