Production Question Set 2 2 PDF

12/30/2011
Set-2
IES 2001
Thespindlespeedrangeinageneralpurposelathe
isdividedintostepswhichapproximatelyfollow
(a) Arithmeticprogression
Lathe (b) Geometricprogression
(c) Harmonicprogression
(d) Logarithmicprogression
Ans.(b)
BySKMondal
IES 1992 Example

Feedgearboxforascrewcuttinglatheisdesigned
How much machining time will be required to reduce
onthebasisof
(a) Geometricprogression the diameter of a cast iron rod from 120 mm to 116 mm
(b) Arithmeticprogression over a length of 100 mm by turning using a carbide
(c) Harmonicprogression
insert. Cutting velocity is 100 m/min and feed rate = 0.2
(d) None
mm/rev.
Ans.(a)
IES2010 IES 2003

In turning a solid round bar, if the travel The time taken to face a workpiece of 72 mm
of the cutting tool in the direction of diameter, if the spindle speed is 80 r.p.m. and cross
feed is 0.3 mm/rev, is
feed motion is 1000 mm, rotational
(a) 1.5 minutes (b) 3.0 minutes
p
speed of the workpiece
p is 5500 rpm,
p , and ( ) 5.4 minutes
(c) i t (d) 8.58 minutes
i t
rate of feed is 0.2 mm/revolution, then
the machining time will be Ans. (a)
(a) 10 seconds (b) 100 seconds
(c) 5 minutes (d) 10 minutes
Ans. (d)
Page 1 of 70
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Set-2
IAS 2002 IES 2004

A 150 mm long, 12 mm diameter 304 stainless steel A medium carbon steel workpiece is turned on a
rod is being reduced in diameter to 115 mm by lathe at 50 m/min. cutting speed 0.8 mm/rev feed
turning on a lathe. The spindle rotates at N = 400 and 1.5 mm depth of cut. What is the rate of metal
rpm and the tool is travelling at an axial speed of removal?
200 mm/min. The time taken for cutting is given by (a) 1000 mm3/min
(a) 30 s (b) 36 s (b) 60,000 mm3/min
(c) 1 minute (d) 45 s (c) 20,000 mm3/min
(d) Can not be calculated with the given data
Ans. (d)
Ans. (b)
IES 2006 Example

For taper turning on centre lathes, the method of Find the angle at which the compound rest should
swiveling the compound rest is preferred for: be set up to turn taper on the workpiece having a
(a) Long jobs with small taper angles length of 200 mm, larger diameter 45 mm and the
(b) Long jobs with steep taper angles smaller 30 mm.
(c) Short jobs with small taper angles
(d) Short jobs with steep taper angles
Ans. (d)
IES 1992 IAS 2002

Tail stock set over method of taper turning is The amount of offset of tail stock for turning taper
preferred for on full length of a job 300 mm long which is to have
(a) Internal tapers its two diameters at 50 mm and 38 mm ultimately is
(b) Small tapers (a) 6 mm (b) 12 mm
(c) Long slender tapers ( ) 25 mm
(c) (d) 44 mm
(d) Steep tapers
Ans. (a)
Ans. (c)
Page 2 of 70
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Set-2
IES 1998 IES2010

A 400 mm long shaft has a 100 mm tapered step at The effect of centering error
when the tool is set above the
the middle with 4 included angle. The tailstock
center line as shown in the figure
offset required to produce this taper on a lathe results effectively in
would be 1. Increase in rake angle.
(a) 400 sin 4
4 (b) 400 sin 22 2. Reduction
R d i in i rake
k angle.l
(c) 100 sin 4 (d) 100 sin 2 3. Increase in clearance angle.
Ans. (b) 4. Reduction in clearance angle.
Which of these statements is/are
correct?
(a) 1 only (b) 1 and 4 only
(c) 2 and 4 only (d) 1, 2, 3 and 4
Ans. (b)
GATE 2002 GATE 2008

A leadscrew with half nuts in a lathe, free to rotate The figure shows an incomplete schematic of a
conventional lathe to be used for cutting threads
in both directions has with different pitches. The speed gear box Uv, is
shown and the feed gear box Us, is to be placed. P, Q.
(a) Vthreads
R and S denote locations and have no other
(b) Whitworth threads significance. Changes in Uv, should NOT affect the
pitch of the thread being cut and changes in Us,
(c) Buttress threads should NOT affect the cutting speed.
(d) ACME threads Ans. (d)
Contd..
Ans.(c)
GATE2008Contd. GATE 2003
Qualityscrewthreadsareproducedby
(a) Threadmilling
(b) Threadchasing
(c) Threadcuttingwithsinglepointtool
(d) Threadcasting
ThecorrectconnectionsandthecorrectplacementofUsare
givenby Ans.(b)
(a) QandEareconnected. Us,isplacedbetweenPandQ.
(b) SandEareconnected.Us isplacedbetweenRandS.
(c) QandEareconnected.Us,isplacedbetweenQandE.
(d) SandEareconnected.Us,isplacedbetweenSandE.
Page 3 of 70
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Set-2
IES2010 IES2011
For producing both internal and external External threads can be produced by :
screw threads, the method used is 1. Rolling
(a) Thread chasing with multiplerib chasers 2. Grinding
((b)) Thread milling
g and multiplethread
p cutters 33. Milling
g
(c) Thread tapping with taps (a) 1 and 3 only
(d) Die threading with selfopening die heads (b) 1 and 2 only
(c) 2 and 3only
(d) 1, 2 and 3
Ans. (b) Ans. (d)
IES 2004 GATE1994

Match List I (Cutting tools) with List II (Features) To get good surface finish on a turned job,
and select the correct answer using the codes given one should use a sharp tool with a ..feed
below the Lists: and speed of rotation of the job.
List I List II Ans.(c) ((a)) Minimum, minimum
A.
A Turning
T i toolt l 1. Chisel
Chi l edge
d
B. Reamer 2. Flutes
(b) Minimum, maximum
C. Milling cutter 3. Axial relief (c) Maximum, maximum
4. Side relief (d) Maximum, minimum
Codes: A B C A B C
Ans.(b)
(a) 1 2 3 (b) 4 3 2
(c) 4 2 3 (d) 1 3 2
IES 1996 IES 2009

Inturningofslenderrods,itisnecessarytokeep Whatisthenumberofjawsinselfcentred chuck?
thetransverseforceminimummainlyto (a) Eight
(a) Improvethesurfacefinish (b) Six
(b) Increaseproductivity (c) Four
(c) Improvecuttingefficiency (d) Three
(d) Reducevibrationsandchatter.
Ans.(d)
Ans.(d)
Page 4 of 70
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Set-2
IES 1999 IES 2009

Which one of the following sets of forces are Whichoneofthefollowingmethodsshouldbeused
encountered by a lathe parting tool while groove forturninginternaltaperonly?
cutting? (a) Tailstockoffset
(a) Tangential, radial and axial (b) Taperattachment
(b) Tangential
T ti l and
d radial
di l (c) Formtool
(c) Tangential and axial (d) Compoundrest
(d) Radial and axial
Ans.(d)
Ans. (a)
IES 1998 IES 1993

A single start thread of pitch 2 mm is to be produced It is required to cut screw threads of 2 mm pitch on
on a lathe having a lead screw with a double start a lathe. The lead screw has a pitch of 6 mm. If the
thread of pitch 4 mm. The ratio of speeds between spindle speed is 60 rpm, then the speed of the lead
the spindle and lead screw for this operation is screw will be
(a) 1 : 2 (b) 2: 1 (a) 10 rpm (b) 20 rpm
(c) 1: 4 (d) 4: 1 (c) 120 rpm (d) 180 rpm
Ans. (d) Ans. (b)
IES 1992 IES 2006

Whichofthefollowingstatementisincorrectwith It is required to cut screw threads with double start
referenceoflathecuttingtools? and 2 mm pitch on a lathe having lead screw pitch
(a) Theflankofthetoolisthesurfacebelowand of 6 mm. What is the speed ratio between lathe
adjacenttothecuttingedges spindle and lead screw?
(b) Thenoseisthecorner,orchamferjoiningtheside
Th i th h f j i i th id (a) 1 : 3 (b) 3: 1
cuttingandtheendcuttingedges (c) 2 : 3 (d) 3: 2
(c) Theheelisthatpartofthewhichisshapedto
producethecuttingedgesandface Ans. (d)
(d) Thebaseisthatsurfaceoftheshankwhichagainst
thesupportandtakestangent
Ans.(c)
Page 5 of 70
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Set-2
IES 1997 IES 2009

Consider the following operations: A capstan lathe is used to massproduce, in batches
1. Under cutting 2. Plain turning of 200, a particular component. The direct material
3. Taper turning 4. Thread cutting cost is Rs 4 per piece, the direct labour cost is Rs 3
per piece and the overhead costs are 400% of the
The correct sequence of these operations in machining a labour costs. What is the production cost per piece?
product is
(a) Rs 19 (b) Rs 23
(a) 2, 3, 4, 1 (b) 3, 2, 4, 1
(c) Rs 16 (d) Rs 15
(c) 2, 3, 1, 4 (d) 3, 2, 1, 4
Ans. (a)
Ans. (c)
IES 2007 IES 1995

Assertion (A): In a multispindle automatic lathe, the Consider the following characteristics:
turret tool holder is indexed to engage the cutting tools 1. Multiple operations can be performed
one by one for successive machining operations. 2. Operator's fatigue is greatly reduced.
Reason (R): Turret is a multiple tool holder so that for 3. Ideally suited for batch production
successive machining g operation,
p , the tools need not be
4 A breakdown
4. break down in one machine does not affect the
changed.
flow of products.
(a) Both A and R are individually true and R is the correct
5. Can accommodate modifications in design of
explanation of A components, within certain limits.
(b) Both A and R are individually true but R is not the The characteristics which can be attributed to special
correct explanation of A purpose machines would include
(c) A is true but R is false (a) 1, 3 and 4 (b) 1, 2 and 4
(d) A is false but R is true Ans. (a) (c) 2, 3 and 5 (d) 1, 2 and 5 Ans. (c)
IES 1996 IES 2003

Assertion (A): Special purpose machine tools and Which one of the following mechanisms is
automatic machine tools are quite useful for job employed for indexing of turret in an automatic
shops lathe?
Reason (R): Special purpose machine tools can do (a) Whitworth (b) Rack and pinion
special types of machining work automatically ( ) Ratchet
(c) R t h t and
d pawll (d) Geneva
G wheel
h l
(a) Both A and R are individually true and R is the
correct explanation of A Ans. (c)
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true Ans. (d)
Page 6 of 70
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Set-2
IES 2009 IES 2001

For the manufacture of screw fasteners on a mass The indexing of the turret in a singlespindle
scale, which is the most suitable machine tool? automatic lathe is done using
(a) Capstan lathe (a) Geneva mechanism
(b) Singlespindle automatic lathe (b) Ratchet and Pawl mechanism
(c) CNC turning centre (lathe) (c) Rack and pinion mechanism
(d) CNC machining centre (d) Whitworth mechanism
Ans. (b) Ans. (b)
IES 1995 IES 1992

Assertion (A): In a Swiss type automatic lathe, the Maximum production of small and slender parts is
turret is given longitudinal feed for each tool in a done by
specific order with suitable indexing.
(a) Watch maker's lathe
Reason (R): A turret is a multiple tool holder to
facilitate machining with each tool by indexing (b) Sliding head stock automatic lathe
without the need to change the tools. (c) Multispindle automatic lathe
(a) Both A and R are individually true and R is the (d) Capstan lathe
correct explanation of A Ans. (c)
IES 2007 IAS 2007

Screw threads are produced on solid rods by using Which one of the following is the characteristic for
which of the following? capstan lathe?
(a) Dies (b) Punch (a) Rate of production is low
(c) Mandrel (d) Boring bar (b) Labour cost is high
(c) Used for handling jobs of varying shapes and sizes
Ans. (a) (d) Capstan head is mounted on a slide
Ans. (d)
Page 7 of 70
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Set-2
IAS 2002 IAS 1996

Consider the following statements related to Turret Apart from hexagonal turret, the elements (s) in a
lathe: turret lathe include (s)
1. Turret is mounted directly on the saddle. (a) Crossslide tool post
2. Turret is mounted on an auxiliary slide. (b) Crossslide tool post and rear tool post
3. Much heavier and larger jobs than Capstan lathe can (c) Crossslide tool post and tail stock
be produced. (d) Teal tool post and tail stock
Which of the above statements is/are correct?
(a) 1 and 3 (b) 2 and 3 Ans. (a)
(c) 1 only (d) 2 only
Ans. (a)
IAS 2004 IAS 2001

Swiss type screw machines have Consider the following operations and time
(a) Turrets (b) Radial slides required on a multi spindle automatic machine to
(c) Spindle carriers (d) Tool posts produce a particular job
1. Turning 1.2 minutes
Ans. (c) 2. Drilling
D illi 1.6
6 minutes
i t
3. Forming 0.2 minute
4. Parting 0.6 minute
The time required to make one piece (cycle time) will be
(a) 0.6 minutes (b) 1.6 minutes
(c) 3.6 minutes (d) 0.9 minute Ans. (b)
IAS 1995 IAS 1994

Assertion (A): In a multispindle automat, the turret A multispindle automat performs four operations
is indexed to engage each of the cutting tool with times 50, 60, 65 and 75 seconds at each of its
mounted on it. work centers. The cycle time (time required to
Reason(R): Turret is a multiple tool holder so that manufacture one work piece) in seconds will be
the machining can be continued with each tool
without the need to change the tool. (a) 50 + 60 + 65 + 75
(a) Both A and R are individually true and R is the (b) (50 + 60 + 65 + 75) /4
correct explanation of A (c) 75/4
(b) Both A and R are individually true but R is not the (d) 75
Ans. (d)
Page 8 of 70
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Set-2
IAS 1998 IAS 1998

Assertion (A): For thread cutting, the spindle speed Consider the following statements associated with
selected on a lathe, is very low. the lathe accessories:
Reason (R): The required feed rate is low in 1. Steady rest is used for supporting a long job in
threading operation. between head stock and tail stock.
(a)
( ) Both
B th A and d R are individually
i di id ll true
t and
d R is
i the
th 2. Mandrel
M d l is i usedd for
f turning
t i small ll cylindrical
li d i l job.
j b
correct explanation of A 3. Collects are used for turning discshaped job.
(b) Both A and R are individually true but R is not the Of these statements:
correct explanation of A (a) 1 and 2 are correct (b) 2 and 3 are correct
(c) A is true but R is false (c) 3 alone is correct (d) 1 alone is correct
(d) A is false but R is true Ans. (c) Ans. (d)
IES2011 IAS 2000

In Norton type feed gearbox for cutting Whitworth Consider the following features:
standard threads with a standard TPI Leadscrew, power 1. All spindles operate simultaneously,
flows from:
2. One piece is completed each time the tools are
(a) Spindle to Tumbler gear to Norton cone to Meander
withdrawn and the spindles are indexed
drive to Leadscrew
(b) Spindle to Norton cone to Tumbler geat to Meander 3. The tool slide indexes or revolves with the spindle
drive to Leadscrew carrier
(c) Spindle t o Tumbler gear to Meander drive to Norton Which of these features are characteristics of a multi
cone to Leadscrew spindle automatic machine used for bar work?
(d) Spindle to Norton cone to Meander drive to Tumbler (a) 1, 2 and 3 (b) 1 and 2
gear to Leadscrew Ans. (a) (c) 2 and 3 (d) 1 and 3 Ans. (a)
Page 9 of 70
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Set-2
Drilling IES 2004

Consider the following statements:
The helical flute in a twist drill provides the necessary
1. Clearance angle for the cutting edge
2. Rake angle for the cutting edge
3. Space for the chip to come out during drilling
4. Guidance for the drill to enter into the workpiece
Which of the statements given above are correct?
(a) 1 and 2 (b) 2 and 3
BySKMondal (c) 3 and 4 (d) 1 and 4 Ans. (b)
IES 2003 GATE 1996

The purpose of helical grooves in a twist drill is to The rake angle in a drill
1. Improve the stiffness (a) Increases from centre to periphery
2. Save a tool material (b) decreases from centre to periphery
3. Provide space for chip removal (c) Remains constant
4. Provide rake angle for the cutting edge (d) Is irrelevant to the drilling operation
Select the correct answer using the codes given below:
Codes: Ans. (a)
(a) 1 and 2 (b) 2 and 3
(c) 3 and 4 (d) 1 and 4 Ans. (c)
IES 1997 IES 1992

The rake angle in a twist drill A drill for drilling deep holes in aluminum should
(a) Varies from minimum near the dead centre to a have
maximum value at the periphery (a) High helix angle (b) Taper shank
(b) Is maximum at the dead centre and zero at the (c) Small point angle (d) No lip
periphery
i h
(c) Is constant at every point of the cutting edge Ans. (a)
(d) Is a function of the size of the chisel edge.
Ans. (a)
Page 10 of 70
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Set-2
GATE 1997 IES 1992

Helix angle of fast helix drill is normally Low helix angle drills are preferred for drilling
(a) 35o holes in
(b) 60o (a) Plastics (b) Copper
(c) 90o (c) Cast steel (d) Carbon steel
(d) 5o
Ans. (d)
Ans. (a)
Example GATE 2002

A hole with 40mm diameter and 50mm depth is to The time taken to drill a hole through a 25 mm thick
plate with the drill rotating at 300 r.p.m. and
be drilled in mild steel component. The cutting moving at a feed rate of 0.25 mm/revolution is
speed can be taken as 65 m/min and the feed rate as (a) 10 sec (b) 20 sec
( ) 60
(c) 6 sec (d) 100 sec
0.25 mm/rev. Calculate the machining time and the
material removal rate.
Ans. (b)
GATE 2004 IES 2002

Through holes of 10 mm diameter are to be drilled The arm of a radial drilling machine is being raised
in a steel plate of 20 mm thickness. Drill spindle at a speed of 3.9 m/min by single start square
speed is 300 rpm, feed 0.2 mm/ rev and drill point threads of 6 mm pitch and 30 mm diameter. The
angle is 120. Assuming drill over travel of 2 mm, the speed of the screw
time for producing a hole will be (a) Is 650 rpm
(a) 4 seconds (b) 25 seconds (b) Is 180 rpm
(c) 100 seconds (d) 110 seconds (c) Is 130 rpm
(d) Cannot be determined as the data is insufficient
Ans. (b) Ans. (a)
Page 11 of 70
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Set-2
IES 1994 IES 2009

The ratio between two consecutive spindle speeds What is the drilling time for producing a hole in an
for a sixspeed drilling machine using drills of MS sheet of 25 mm thickness using an HSS drill of
diameter 6.25 to 25 mm size and at a cutting velocity 20 mm diameter? The cutting speed and feed for
of 18 m/min is drill are 20 m/min and 0.25 mm/revolution
(a) 1.02
1 02 (b) 1.32
1 32 respectively, Neglect time taken for setting up,
(c) 1.62 (d) 1.82 approaching and travelling of tools.
(a) 0.314 min (b) 0.236 min
Ans. (b) (c) 0.438 min (d) 0.443 min
Ans. (a)
IES 2002 IAS 1999

A 31.8 mm H.S.S. drill is used to drill a hole in a cast To drill a 10 mm diameter hole through a 20 mm
iron block 100 mm thick at a cutting speed 20 thick M.S. plate with a drill bit running at 300 rpm
m/min and feed 0.3 mm/rev. If the over travel of and a feed of 0.25 mm per revolution, time taken
drill is 4 mm and approach 9 mm, the time required will be
to drill the hole is (a) 8 s (b) 16 s
(a) 1 min 40 s (b) 1 min 44 s (c) 24 s (d) 32 s
(c) 1 min 49 s (d) 1 min 53 s
Ans. (b)
Ans. (d)
IAS 1994 IES 1999

The time (in minutes) for drilling a hole is given by Match ListI (Drill bits) with ListII (Applications) and select the correct
answer using the codes given below the Lists:
Depth of the hole + h ListI ListII
t= A. Core drill 1. To enlarge a hole to a certain depth so as to
Feed RPM accommodate the bolt head of a screw
where 'h' is the B.. Reamer
ea e 2.. Tood
drill aandd eenlarge
a ge aan aalready
eady eexisting
st g hole
o e in a
(a) Length of the drill casting
C. Counter bore drill 3. To drill a hole before making internal
(b) Drill diameter thread
(c) Flute length of the drill D. Tap drill 4. To improve the surface finish and dimensional
accuracy of the already drilled hole
(d) Cone height of the drill.
Code:A B C D A B C D
(a) 1 3 2 4 (b) 2 3 1 4
Ans. (d) (c) 2 4 1 3 (d) 3 2 4 1
Ans. (c)
Page 12 of 70
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Set-2
IES 1999
Which one of the following processes results in the
best accuracy of the hole made?
(a) Drilling (b) Reaming
Reaming,Boring,Broaching (c) Broaching (d) Boring
Ans. (b)
BySKMondal
IES 1999 IES 1998

Consider the following statements regarding Match ListI with ListII and select the correct answer
reaming process: using the codes given below the lists:
1. Reaming generally produces a hole larger than its ListI ListII
own diameter A. Reaming 1. Smoothing and squaring surface
2. Generally
G ll rake
k angles
l are nott provided
id d on reamers. around the hole for proper seating
B. Counterboring 2.Sizing and finishing the hole
3. Even numbers of teeth are preferred in reamer
design. C. Countersinking 3. Enlarging the end of the hole
D. Spot facing 4. Making a conical enlargement at the
Which of these statements are correct?
end of the hole Ans. (d)
(a) 1 and 2 (b) 2 and 3 Code:A B C D A B C D
(c) 1 and 3 (d) 1, 2 and 3 Ans. (b) (a) 3 2 4 1 (b) 2 3 1 4
(c) 3 2 1 4 (d) 2 3 4 1
IES 1994 IES 1993

In reaming process A hole of 30 mm diameter is to be produced by reaming.
(a) Metal removal rate is high The minimum diameter permissible is 30.00 mm while
the maximum diameter permissible is 30.05 mm. In this
(b) High surface finish is obtained. regard, consider the following statements about the
(c) High form accuracy is obtained reamer size:
(d) High dimensional accuracy is obtained. 1. The minimum diameter of the reamer can be less than 30 mm.
2. The minimum diameter of the reamer cannot be less than 30 mm.
3. The maximum diameter of the reamer can be more than 30.05 mm.
Ans. (d) 4.The maximum diameter of the reamer must be less than 30.05 mm.
Of these statements Ans. (d)
(a) 1 and 4 are correct (b) 1 and 3 are correct
(c) 2 and 3 are correct (d) 2 and 4 are correct
Page 13 of 70
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Set-2
IES 1998 IAS 1999

A component requires a hole which must be within For reaming operation of blind hole, the type of
the two limits of 25.03 and 25.04 mm diameter. reamer required is
Which of the following statements about the (a) Straight flute reamer
reamer size are correct? (b) Right hand spiral fluted reamer
1.
1 Reamer size cannot be below 25.03
25 03 mm.
mm (c) Left hand spiral fluted reamer
2. Reamer size cannot be above 25.04 mm. (d) None of the above
3. Reamer size can be 25.04 mm.
4. Reamer size can be 25.03 mm. Ans. (b)
(a) 1 and 3 (b) 1 and 2 Ans. (b)
(c) 3 and 4 (d) 2 and 4
IAS 2003 IES 1992

Match List I (Operation) with List II (Application) and select Shell reamers are mounted on
the correct answer using the codes given below the lists:
ListI ListII Ans. (c)
(a) Tool holders (b) Amour plates
(Operation) (Application) (c) Arbor (d) Shanks
(A) Reaming 1. Used for enlarging the end of a hole to give it a
conical
i l shape
h for
f a short
h distance
di
Ans. (c)
(B) Boring 2. Used for enlarging only a limited portion of the
hole
(C) Counter boring 3. Used for finishing a hole
(D) Counter sinking 4. Used for enlarging a hole
Codes:A B C D A B C D
(a) 3 2 4 1 (b) 1 4 2 3
(c) 3 4 2 1 (d) 1 2 4 3
IES 1993 IES 1994

The main purpose of boring operation, as compared Enlarging an existing circular hole with a rotating
to drilling is to: single point tool is called
(a) Drill a hole (a) Boring (b) Drilling
(b) Finish the drilled hole (c) Reaming (d) Internal turning.
(c) Correct the hole
(d) Enlarge the existing hole Ans. (a)
Ans. (d)
Page 14 of 70
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Set-2
IES 1992 IES 2000

Which of the machine tools can be used for boring Which one of the following sets of tools or tools and
1. Lathe processes are normally employed for making large
2. Drilling machine diameter holes?
3. Vertical milling machine (a) Boring tool
4. Horizontal milling machine (b) BTA tools
t l (Boring
(B i and d trepanning
t i association)
i ti ) andd
gun drill
(a) 1, 2, 3 (b) 1, 3, 4
(c) Gun drill and boring tool
(c) 2 and 4 (d) 1, 2, 3, 4
(d) Boring tools and trepanning
Ans. (a)
Ans. (d)
IES 1996 IES 1995

Which of the following statements are correct? The effects of setting a boring tool above centre
1. A boring machine is suitable for a job shop. height leads to a/an.
2. A jig boring machine is designed specially for doing (a) Increase in the effective rake angle and a decrease in
more accurate work when compared to a vertical the effective clearance angle.
milling
illi machine.
hi (b) Increase
I i both
in b th effective
ff ti rakek anglel andd effective
ff ti
3. A vertical precision boring machine is suitable for clearance angle.
boring holes in cylinder blocks and liners. (c) Decrease in the effective rake angle and an increase
(a) 1, 2 and 3 (b) 1 and 2 in the effective clearance angle.
(c) 2 and 3 (d) 1 and 3 (d) Decrease in both effective rank angle and effective
Ans. (a) clearance angle. Ans. (c)
JWM2010 IES 2007

Considerthefollowingoperationsregardingboring Among the following machining processes, which
machines: can be used for machining flat surfaces?
1.Counterboring 1. Shaping 2. Milling 3. Broaching
2.Countersinking Select the correct answer using the code given below:
3.Trepanning (a) 1 and 2 only (b) 1 and 3 only
Whichoftheaboveoperationsis/arecorrect? (c) 2 and 3 only (d) 1, 2 and 3
(a)1,2and3 (b)1and2only
(c)2and3only (d)1only Ans. (d)
Ans.(a)
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Set-2
IES 1993 IES 1993,2001

Assertion (A): Soluble oils are employed with Assertion (A): No separate feed motion is required
broaching machine. during broaching.
Reason (R): Soluble oils have excellent cooling Reason (R): The broaching machines are generally
effect. hydraulically operated.
(a)
( ) Both
i di id ll true
t andd R is
i the
th (a)
( ) Both
i di id ll true
t and
d R is
i the
th
correct explanation of A correct explanation of A
(b) Both A and R are individually true but R is not the (b) Both A and R are individually true but R is not the
correct explanation of A correct explanation of A
(c) A is true but R is false (c) A is true but R is false
(d) A is false but R is true Ans. (a) (d) A is false but R is true Ans. (b)
IES 2001 IAS 2004

The screw and nut in a broaching machine are Which one of the following is true for the last few
changed from square thread to ACME thread. The teeth of a broach which are meant for fine
power requirement of the machine at the same finishing?
r.p.m. will (a) They have equal diameter
(a) Remain same (b) They
Th have
h i
increasing
i diameter
di t
(b) Decrease (c) They have decreasing diameter
(c) Increase (d) They have alternately increasing and decreasing
(d) Depend on the operator diameter.
Ans. (c) Ans. (a)
IES 2005 IES 2002

Match List I (Tool) with List II (Element of Tool) and Match List I with List II and select the correct answer:
select the correct answer using the code given below the List I (Machine tool) List II (Features)
Lists: Ans. (c)
List I List II A. Lathe 1. Push or pull tool
A Broach 1. Tang B. Drilling machine 2. Rachet and pawl
B. Reamer 2. Pilot mechanism
C. Drill 3. Front taper C. Shaper 3. Dividing head
D. Carbide insert face mill 4. Bond D. Broaching machine 4. Hollow tapered spindle
5. Sweeper tooth 5. Face plate Ans. (d)
Codes:A B C D A B C D Codes:A B C D A B C D
(a) 2 5 1 3 (b) 1 3 4 5 (a) 2 4 5 1 (b) 5 3 2 4
(c) 2 3 1 5 (d) 1 5 4 3 (c) 2 3 5 4 (d) 5 4 2 1
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Milling Example
AC50steelflatsurfaceofdimensions100mm 250
mmistobeproducedonahorizontalaxismilling
machine.AnHSSslabmillwitha100mmdiameter
and150mmwidthistobeusedforthepurpose.The
millingcutterhas8teeth.
Calculatethemachiningtimeassumingthatentire
stockcanberemovedinonedepthof2mm.
Given,
BySKMondal Feed,f=0.13mm/tooth,
Cuttingspeed,V=20m/min.
Ans.4.11min
GATE 1995 GATE 1993

ListI List II A milling cutter having 8 teeth is rotating at 150
(Manufacturing Processes) (Condition) rpm. If the feed per tooth is 0.1, the table speed in
(A) Finish turning 1. Backlash eliminator mm per minute is
(B) Forming 2. Zero rake (a) 120 (b) 187
(C) Thread cutting 3. Nose radius ( ) 125 (d) 70
(c)
(D) Down milling 4. Low speed
Codes:A B C D A B C D Ans. (a)
(a) 2 3 4 1 (b) 3 4 1 2
(c) 1 2 3 4 (d) 4 1 2 3
Ans. (a)
IES 2003 IES 2009

In milling machine, the cutting tool is held in The arbor of a milling machine is used to hold
position by which one of the following?
(a) Chuck (b) Spindle (a) Spindle (b) Overarm
(c) Arbor (d) Tool holder (c) Cutting tool (d) Mandrel
Ans. (c)
Ans. (c)
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IES 1994 IES 1992

Consider the following operations: A set of eight form relieved milling cutters for each
1. Cutting key ways on shafts module is provided to enable cutting of gears of
2. Cutting external screw threads. different
3. Cutting teeth of spur gears (a) Materials
4. Cutting external splines. (b) Types
T e.g. spur, helical,
h li l etc.
t
Those which can be performed with milling cutters (c) Number of teeth
would include (d) Width of gears
(a) 1 and 2 (b) 2,3 and 4
(c) 1 and 3 (d) 1,2,3 and 4 . Ans. (c)
Ans. (d)
IES 2007 GATE 1992

What is the process of removing metal by a milling In horizontal milling process. (up/down)
cutter which is rotated against the direction of milling provides better surface finish and..
travel of the work piece, called? (updown) milling provides longer tool life.
(a) Down milling (b) Up milling
(c)
( ) End
E d milling
illi (d) Face
F milling
illi
Ans. (b) Ans. down, down
IES 1997 IES 1995

Consider the following statements: Assertion (A): Up milling or climb milling is
In Up milling process, commonly used for machining castings and
1. The cutter starts the cut from the machined surface and forgings.
proceeds upwards.
Reason (R): Up milling can be done on universal
2. The cutter starts the cut from the top p surface and
proceeds downwards. milling machines.
machines
3. The job is fed in a direction opposite to that of cutter (a) Both A and R are individually true and R is the
rotation. correct explanation of A
4. The job is fed in the same direction as that of cutter (b) Both A and R are individually true but R is not the
rotation. correct explanation of A
Of these statements correct are:
(a) 1 and 3 (b) 1 and 4
(c) 2 and 3 (d) 2 and 4 Ans. (a) (d) A is false but R is true Ans. (d)
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IES 2005 IES 1993

Which one of the following statements is correct? Climb milling is chosen while machining because
In upmilling operation, the undeformed chip thickness, (a) The chip thickness increases gradually
a) Is zero at the start of the cut and increases to a (b) It enables the cutter to dig in and depth of cut
maximum value just before the tooth disengages the (c) The specific power consumption is reduced
workpiece.
k i (d) Better surface finish can be obtained
b) Increases to the maximum value at the centre of the
travel and decreases towards the end of tooth
engagement. Ans. (d)
c) Has a maximum value just after the cut is started and
drops to zero at the end of the cut.
d) Remains unchanged. Ans. (a)
IES2010 IES 2002

Assertion (A): Climb or down milling operation ensures Assertion (A): Virtually all modern milling machines
smoother operation of the machine tool and longer tool life are capable of doing downmilling.
as compared to the conventional up milling operation. Reason (R): In downmilling the cutter tends to push
Reason (R): In climb or down milling operation, the the work along and lift it upward from the table. This
rotational motion of the cutter as well as the feed motion of action tends to eliminate any effect in looseness in the
the workpiece
work piece are in the same direction,
direction and the depth of feed screw and nut of the milling machine table and
cut is maximum at the entry point as the cutter engages the results in smooth cut.
workpiece. (a) Both A and R are individually true and R is the correct
(a) Both A and R are individually true and R is the correct explanation of A
explanation of A (b) Both A and R are individually true but R is not the
(b) Both A and R are individually true but R is NOT the correct correct explanation of A
explanation of A (c) A is true but R is false
(c) A is true but R is false (d) A is false but R is true Ans. (c)
(d) A is false but R is true Ans. (b)
IES 2004 IES 2006

The cutting speed of a milling cutter while cutting Gang milling is a
brass is: (a) Milling process for generating hexagonal surfaces
(a) 45 to 60 m/min (b) 30 to 40 m/min (b) Process of cutting gears
(c) 25 to 35 m/min (d) 15 to 20 m/min (c) Process in which two or more cutters are used
simultaneously
Ans. (a) (d) Milling operation combined with turning
Ans. (c)
Page 19 of 70
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IES 2009 IES 1995

For machining, which one of the following gang In a milling operation two side milling cutters are
milling operations is employed? mounted with a desired distance between them so
(a) Threads that both sides of a work piece can be milled
(b) Bores simultaneously. This set up is called.
(c) Grooves (a) Gang milling (b) Straddle milling
(d) Steps on prismatic parts (c) String milling (d) Side milling.
Ans. (d) Ans. (b)
IES 2004 IES 2000

One brand of milling machine has the following two One of the index plates of a milling machine
index plates supplied along with the indexing head: dividing head has the following hole circles: 15; 16;
Plate 1: 15, 16, 17, 18, 19, 20 hole circles 17; 18; 19; 20
Plate 2: 21, 23, 27, 29, 31, 33 hole circles A gear wheel of 34 teeth has to be milled by simple
It is proposed to mill a spur gear of 28 teeth using simple indexing method.
method To machine each tooth,tooth the index
indexing method. Which one of the following combinations crank has to be rotated through
of index plate and number of revolutions is correct? (a) 17 holes in the 20hole circle
(a) Plate 1: 1 revolution and 9 holes in 18 hole circles
(b) 18 holes in the 20hole circle
(b) Plate 2: 1 revolution and 9 holes in 21 hole circles
(c) 1 revolution and 3 holes in 17hole circle
(c) Plate 2: 1 revolution and 9 holes In 33 hole circles
(d) 1 revolution and 2 holes in 18hole circle
(d) Plate 1: 1 revolution and 9 holes In 15 hole circles
Ans. (c)
Ans. (b)
IES 1999 IES 2002

A straight teeth slab milling cutter of 100 mm A side and face cutter 125 mm diameter has 10 teeth.
diameter and 10 teeth rotating at 200 r.p.m. is used It operates at a cutting speed of 14 m/min with a
to remove a layer of 3 mm thickness from a steel bar. table traverse 100 mm/min. The feed per tooth of
If the table feed is 400 mm/minute, the feed per the cutter is
tooth in this operation will be (a) 10 mm (b) 2.86
2 86 mm
(a) 0.2 mm (b) 0.4 mm (c) 0.286 mm (d) 0.8 mm
(c) 0.5 mm (d) 0.6 mm
Ans. (c)
Ans. (a)
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IES 2004 IAS 2001

Match List I (Milling problem) with List II (Probable Which one of the following statements are correct in respect of
upmilling and downmilling?
causes) and select the correct answer using the codes
1. In upmilling the cutter rotates in a direction opposite to that of
given below the Lists: workpiece travel whereas in downmilling the cutter rotates in a
List I List II Ans. (b) direction similar to that of workpiece travel.
2. In downmilling chip will be thin at the beginning and increase to a
A. Chatter 1. Too high feed maximum at the end of the cut and reverse will be the case for a chip p
B. Poor surface finish 2. Lack of rigidity in machine formed
f d by
b upmilling.
ll
fixtures, bar or workpiece 3. Downmilling is desirable with milling cutters having a high radial
rake angle when compared to upmilling.
C. Loss of accuracy 3. High cutting load 4. Downmilling forces the workpiece against the milling table to
D. Cutter burrs 4. Radial relief too great exert more pressure while upmilling tends to lift the workpiece from the
table.
5. Not enough lubricant Select the correct answer using the codes given below:
Codes:A B C D A B C D Codes:
(a) 2 1 5 3 (b) 2 1 3 5 (a) 1, 2 and 3 (b) 1, 2 and 4
(c) 3 and 4 (d) 1, 3 and 4 Ans. (d)
(c) 4 5 2 3 (d) 4 2 3 5
IAS 1998 IAS 2001

Which of the following statements are true of face Which of the following mechanisms are suitable for
milling? indexing the table of rotary transfer line?
1. Face milling cutter is held on an arbor. 1. Rack and pinion 2. Ratchet and pawl
2. It has two rake angles axial rake and radial rake. 3. Lead screw 4. Geneva mechanism
3.
3 The maximum chip thickness equals the feed per
tooth. Select the correct answer by using the codes given below:
4. The chip thickness varies from a minimum at the Codes:
start of cut to a maximum at the end of cut. (a) 1, 2 and 3 (b) 2, 3 and 4
Select the correct answer using the codes given below: (c) 1, 3 and 4 (d) 1, 2 and 4 Ans. (d)
Codes :
(a) 1 and 2 (b) 2 and 3
(c) 2 and 4 (d) 3 and 4 Ans. (b)
IAS 2000 IAS 1994

Consider the following mechanisms: A standard dividing head is equipped with the
1. Geneva gearing following index plates
2. Rack and pinion 1. Plate with 12, 16, 17, 18, 19, 20 holes circles
3. Ratchet and pawl 2. Plate with 21, 23, 27, 29, 31, 33 holes circles
Which of these mechanisms are used to index the work 3. Plate with 37, 39, 41,43,47,49 holes circles
table on a transfer machine? For obtaining 24 divisions on a work piece by simple
(a) 1 and 2 (b) 2 and 3 indexing
(c) 1 and 3 (d) 1, 2 and 3 (a) Hole plate 2 alone can be used
Ans. (d) (b) Hole plates 1 and 2 can be used
(c) Hole plates 1 and 3 can be used Ans. (d)
(d) Any of the three hole plates can be used
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IAS 2003 IES1994

A milling cutter of 70 mm diameter with 12 teeth is Whichoneofthefollowingoperationsiscarriedout
attheminimumcuttingvelocityifthemachinesare
operating at a cutting speed of 22 m/min and a feed equallyrigidandthetoolworkmaterialsarethe
of 0.05 mm/tooth. The feed per minute is same?
(a) Turning
(a) 110 m/min (b) 35 mm/min (b) Grinding
(c) 6 mm/min (d) 60 mm/min (c) Boring
(d) Milling
Ans (d)
Ans(d)
IES2011 IES 2002

MatchListIwithListIIandselectthecorrectanswerusing
thecodegivenbelowthelists: Ans(b) Match List I with List II and select the correct
answer:
ListI ListII List I (Machine tools) List II (Machine tool parts)
A.Lathe 1.Flute A. Lathe 1. Lead strew
B.Shaper 2.Universalindexing B. Milling machine 2. Rocker arm
C. Shaper 3. Universal indexing
C.Drillingmachine 3.Leadscrew
D. Drilling machine 4. Flute Ans (d)
D.Millingmachine
Codes 4.Rockerarm Codes:A B C D A B C D
A B C D A B C D (a) 4 2 3 1 (b) 1 3 2 4
(a) 2 4 1 3 (b) 3 4 1 2 (c) 4 3 2 1 (d) 1 2 3 4
(c) 2 1 4 3 (d) 3 1 4 2
Ch7:Milling
QNo Option Q.No Option
1 B 7 D
2 B 8 D
3 D 9 A
4 A 10 D
5 C 11 C
6 D 12 D
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GATE 2005
A 600 mm x 30 mm flat surface of a plate is to be
finish machined on a shaper. The plate has been
fixed with the 600 mm side along the tool travel
direction. If the tool overtravel at each end of the
Shaper,Planner,Slotter plate is 20 mm, average cutting speed is 8 m/min,
feed rate is 0.3 mm/stroke and the ratio of return
time to cutting time of the tool is 1:2, the time
required for machining will be
(a) 8 minutes (b) 12 minutes
BySKMondal
(c) 16 minutes (d) 20 minutes
Ans. (b)
IES 2004 IES 2001

Consider the following alignment tests on machine In a shaper machine, the mechanism for tool feed is
tools (a) Geneva mechanism
1. Straightness 2. Flatness (b) Whitworth mechanism
3. Run out 4. Parallelism (c) Ratchet and Pawl mechanism
Which of the above alignment tests on machine tools are (d) Ward Leonard system
common to both lathe and shaper?
(a) 1 and 2 (b) 2 and 3 Ans. (c)
(c) 3 and 4 (d) 1 and 4
Ans. (d)
IES2010 IES 1997

Assertion (A): Longitudinal cutting motion of the Which of the following are the advantages of a
tool and crosswise feed motion of the job generates hydraulic shaper over a mechanically driven shaper?
flat surfaces in planning process. 1. More strokes per minute can be obtained at a given
Reason (R): Jobs used in planning machines are cutting speed.
generally long and heavy compared to shaping. 2. The
Th cutting
tti stroke
t k has
h a definite
d fi it stopping
t i point.
i t
(a) Both A and R are individually true and R is the 3. It is simpler in construction.
4. Cutting speed is constant throughout most of the
(b) Both A and R are individually true but R is NOT the cutting stroke.
(a) 1 and 2 (b) 1 and 4
(c) 2 and 4 (d) 1, 3 and 4 Ans. (b)
Page 23 of 70
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IES 1995 IES 1994

In a mechanical shaper, the length of stroke is Given that, average cutting speed = 9 m/min, the
increased by return time to cutting time ratio is = 1 : 2, the feed
(a) Increasing the centre distance of bull gear and crank rate = 0.3 mm/stroke, the clearance at each end of
pin cut = 25 mm and that the plate is fixed with 700 mm
(b) Decreasing
D i the
th centre
t distance
di t off bull
b ll gear and d side along the direction of tool travel, the time
crank pin required for finishing one flat surface of a plate of
size 700 x 30 mm in a shaper, will be
(c) Increasing the length of the ram
(a) 10 min (b) 12.5 min Ans. (b)
(d) Decreasing the length of the slot in the slotted lever
(c) 15 min (d) 20 min
Ans. (a)
IAS 1995 IAS 1994

Size of a shaper is given by Stroke of a shaping machine is 250 mm. It makes 30
(a) Stroke length (b) Motor power double strokes per minute. Overall average speed of
(c) Weight of the machine (d) Table size operation is
(a) 3.75 m/min (b) 5.0 m/min
( ) 7.5 m/min
(c) / i (d) 15 m/min
/ i
Ans. (a)
Ans. (d)
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IES 1999
Consider the following processes for the
GearManufacturing manufacture of gears:
1. Casting
2. Powder metallurgy
3. Machining from bar stock
4. Closed die forging
The correct sequence in increasing order of bending
strength of gear teeth is
BySKMondal (a) 1, 2, 3, 4 (b) 1, 2, 4, 3
(c) 2, 1, 4, 3 (d) 2, 1, 3, 4 Ans. (a)
IES 2006 IES 2005

Which of the following is/are used for cutting In helical milling, the ratio of the circumference of
internal gears? the gear blank to the lead of the helix determines
1. Gear hobber 2. Gear shaper the:
3. Rack cutter 4. Jig borer (a) Proper speed to use
Select the correct answer using the codes given below: (b) Proper
P f d and
feed d depth
d th off cutt required
i d
(a) Only 1 and 2 (b) Only 2 and 3 (c) Angle setting of the machine table
(c) Only 1 and 4 (d) Only 2 (d) Gear ratio for table screw and dividing head
Ans. (d) Ans. (c)
IES2010 IES 1996

Match List I with List II and select the correct answer using Gear cutting on a milling machine using an involute
the code given below the lists: Ans. (d)
profile cutter is a
List I List II
(a) Gear forming process
(Type of work) (Manufacturing)
A. High rate production of worm Gears and 1. Gear shaving (b) Gear generating process.
worm wheel (c) Gear shaping process
B. Generating internal gears and Cluster gears 2. Gear milling (d) Highly accurate gear producing process.
C. Finishing of gear tooth profiles 3. Gear hobbing
D. Repair and piece production of gears 4. Gear shaping
A B C D A B C D
Ans. (a)
(a) 2 1 4 3 (b) 3 1 4 2
(c) 2 4 1 3 (d) 3 4 1 2
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IES 2000 IES 2009

Which one of the following processes of gear Assertion (A): Gears produced by employing form
manufacture results in best accuracy of the involute cutting principle using gearmilling cutter on a milling
machine are not very accurate.
gear tooth profile?
Reason (R): Production of the correct gear tooth profile
(a) Milling employing formcutting principle would require a
(b) Hobbing
H bbi separate cutter for cutting different numbers of teeth
even for the same module and also errors are associated
(c) Rotary gear shaper with inaccurate operation of indexing mechanism.
(d) Rack type gear shaper (a) Both A and R are true and R is the correct explanation of
A
(b) Both A and R are true but R is NOT the correct
Ans. (b) explanation of A
(d) A is false but R is true Ans. (a)
IES 1996 IES 2009

Consider the following processes of gear By which one of the following machines the teeth of
manufacture: an internal spur gear can be cut accurately?
1. Milling with form cutter (a) Milling machine
2. Rack type gear shaper (gear planer) (b) Slotting machine
3. Rotary gear shaper (gear shaper) (c) Hobbing machine
4. Gear hobbing (d) Gearshaping machine
The correct sequence of these processes in increasing
order of accuracy of involute profile of the gear Ans. (d)
(a) 3, 2, 4, 1 (b) 2, 3, 4, 1
(c) 3, 2, 1, 4 (d) 2, 3, 1, 4 Ans. (d)
IES 2004 IES 1992

Gear shaping is a process of manufacturing gears. In gear hobbing
Which one of the following principles is employed by it? (a) Only hob rotates
(a) Form cutting with cutter (b) Only gear blank rotates
(b) Generating tooth form with a reciprocating cutter (c) Both hob and gear blank rotate
(c) Generating tooth form by a rotating cutter (d) Neither hob nor gear blank rotates
(d) Generating form with a reciprocating and revolving
cutter Ans. (c)
Ans. (d)
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IES 2003 IES 2008

A spur gear of 40 teeth is machined in a gear Which machining processes are used for gear
hobbing machine using a double start hob cutter. manufacture?
The speed ratio between the hob and the blank is 1. Form milling 2. Broaching
(a) 1:20 (b) 1:40 3. Roll forming 4. Hobbing
(c)
( ) 40: 1 (d) 20: 1 Select the correct answer using the code given below:
(a) 1, 2 and 3 (b) 1, 3 and 4
Ans. (d) (c) 1, 2 and 4 (d) 2, 3 and 4
Ans. (c)
IES 1999 IES 1997

A 60teeth gear when hobbed on a differential Which of the following motions are needed for spur
hobber with a twostart hob, the index change gear gear cutting with a hob?
ratio is governed by which one of the following 1. Rotary motion of hob
kinematic balance equations? 2. Linear axial reciprocator motion of hob
(a) 1 revolution of gear blank = 1/60 of hob revolutions 3. Rotary motion of gear blank
(b) 1 revolution of gear blank = 2/60 of hob revolutions 4. Radial advancement of hob.
(c) 1 revolution of hob = 2/60 of blank revolutions Select the correct answer using the codes given below:
(d) 1 revolution of hob = 1/60 of blank revolutions (a) 1, 2 and 3 (b) 1, 3 and 4
(c) 1, 2 and 4 (d) 2, 3 and 4
Ans. (c) Ans. (a)
IES 2007 IES 1993

Which of the following methods are gear generating Internal gear cutting operation can be performed by
processes? (a) Milling
1. Gear shaping (b) Shaping with rack cutter
2. Gear hobbing (c) Shaping with pinion cutter
3. Gear milling (d) Hobbing
Select the correct answer using the code given below:
(a) 1, 2 and 3 (b) 1 and 2 only Ans. (c)
(c) 2 and 3 only (d) 1 and 3 only
Ans. (b)
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IAS 1998 IES 2006

Assertion (A): Internal gears are cut on a gear Which of the following cannot be cut by hobbing
shaper. process?
Reason (R): Hobbing is not suitable for cutting (a) Helical gears (b) Bevel gears
internal gear. (c) Worm gears (d) Spur gears
(a)
( ) Both
i di id ll true
t and
d R is
i the
th
correct explanation of A Ans. (b)
(d) A is false but R is true
Ans. (b)
IES 1996 IES 1995

For the manufacture of full depth spur gear by While cutting helical gears on a nondifferential
hobbing process, the number of teeth to be cut = 30, gear hobber, the feed change gear ratio is
module = 3 mm and pressure angle = 20. The radial (a) Independent of index change gear ratio
depth of cut to be employed should be equal to (b) dependent on speed change gear ratio
(a) 3.75
3 75 mm (b) 4.50
4 50 mm (c) Interrelated to index change gear ratio
(c) 6.00 mm (d) 6.75 mm (d) Independent of speed and index change gear ratio
Ans. (d) Ans. (c)
IES 1992 IAS 2003

Gear burnishing process for Which one of the following is not a feature of gear
(a) Removing residual stresses from teeth roots hobbing process?
(b) Surface finishing (a) High rate of production
(c) Undercut gears (b) Generation of helical gears
(d) Cycloidal gears (c) Very accurate tooth profile
(d) Generation of internal gears
Ans. (b)
Ans. (d)
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IAS 2001 IES 1994

Consider the following motions and setting in a Consider the following machine tools:
hobbing machine: 1. Hobbing machine
1. Hob rotation 2. Gear shaping machine
2. Job rotation 3. Broaching machine.
3. Axial reciprocating hob rotation The teeth of internal spur gears can be cut in
4. Tilting of hob to its helix angle (a) 1, 2 and 3 (b) 1 and 2
Which of these motions and setting in a hobbing (c) 1 and 3 (d) 2 and 3
machine are required to machine a spur gear?
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1, 2 and 4 (d) 1, 3 and 4 Ans. (c)
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GATE 1995
Among the conventional machining processes,
maximum specific energy is consumed in
(a) Turning (b) Drilling
(c) Planning (d) Grinding
Grinding&Finishing
Ans. (d)
BySKMondal
GATE 1998 GATE 1998

Ideal surface roughness, as measured by the In machining using abrasive material, increasing
maximum height of unevenness, is best achieved abrasive grain size
when, the material is removed by (a) Increases the material removal rate
(a) An end mill (b) Decreases the material removal rate
(b) A grinding
i di wheel
h l (c) First decreases and then increases the material
(c) A tool with zero nose radius removal rate
(d) A ball mill (d) First increases and then decreases the material
removal rate
Ans. (b)
Ans. (d)
GATE 2000 GATE 2002

Abrasive material used in grinding wheel selected The hardness of a grinding wheel is determined by
for grinding ferrous alloys is the
(a) Silicon carbide (b) Diamond (a) Hardness of abrasive grains
(c) Aluminium oxide (d) Boron carbide (b) Ability of the bond to retain abrasives
(c) Hardness of the bond
Ans. (c) (d) Ability of the grinding wheel to penetrate the work
piece
Ans. (b)
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GATE 2004 GATE 2006

Typical machining operations are to be performed on hard If each abrasive grain is viewed as a cutting tool,
tomachine materials by using the processes listed below.
Choose the best set of OperationProcess combinations then which of the following represents the cutting
Operation Process parameters in common grinding operations?
P. Debarring (internal surface) 1. Plasma Arc Machining (a) Large negative rake angle, low shear angle and high
Q.
Q Die sinking 2.
2 Abrasive Flow Machining cutting speed
R. Fine hole drilling in thin sheets 3. Electric Discharge (b) Large positive rake angle, low shear angle and high
Machining
cutting speed
S. Tool sharpening 4. Ultrasonic Machining
5. Laser beam Machining (c) Large negative rake angle, high shear angle and low
Ans. (d) 6. Electrochemical Grinding cutting speed
(a) P1 Q5 R3 S4 (b) P1 Q4 R1 S2 (d) Zero rake angle, high shear angle and high cutting
(c) P5 Q1 R2 S6 (d) P2 Q3 R5 S6 speed Ans. (a)
GATE 1997 IES 2005

List I List II Consider the following statements in respect of
(A) Grinding 1. Surface for oil retention grinding?
(B) Honing 2. Surface for max. load 1. The pitch of the grit cutting edges is larger than the
capacity pitch of the milling cutter.
(C) Superfinishing 3. Surface of limiting friction 2. The
Th cutting
tti angles
l off the
th gritsit have
h a random
d
D) Burnishing 4. Surface of matte finish geometry.
3. The size of the chip cuts is very small for grinding.
5. Surface for pressure sealing
6. Surface for interference fit. Which of the statements given above are correct?
(a) 1 and 2 (b) 2 and 3
Ans. (A) 3, (B) 1, (C)2, (D)5 (c) 1 and 3 (d) 1, 2 and 3 Ans. (d)
IES 2009 IES 1997

Which one of the following is NOT used as abrasive Which one of the following materials is used as the
material in grinding wheels? bonding material for grinding wheels?
(a) Aluminium oxide (a) Silicon carbide
(b) Silicon carbide (b) Sodium silicate
(c) Cubic boron nitride (c) Boron carbide
(d) Manganese oxide (d) Aluminum oxide
Ans. (d) Ans. (b)
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IES 1996 IES 2001

Grinding wheel is said to be loaded when the Specific cutting energy is more in grinding process
(a) Metal particles get embedded in the wheel surface compared to turning because
blocking the interspaces between cutting grains. (a) Grinding (cutting) speed is higher
(b) Bonding material comes on the surface and the (b) The wheel has multiple cutting edges (grains)
wheel
h l becomes
b blunt.
bl t (c) Plaguing force is significant due to small chip size
(c) Work piece being ground comes to a stop in (d) Grinding wheel undergoes continuous wear
cylindrical grinding.
(d) Grinding wheel stops because of very large depth of Ans. (b)
cut
Ans. (a)
IES 1996 IES 1994

Specific energy requirements in a grinding process The ratio of thrust force to cutting force is nearly 2.5
are more than those in turning for the same metal in
removal rate because of the (a) Turning (b) Broaching
(a) Specific pressures between wheel and work being (c) Grinding (d) Plain milling
high.
high
(b) Size effect of the larger contact areas between wheel Ans. (c)
and work.
(c) High cutting velocities
(d) High heat produced during grinding.
Ans. (d)
IES 1992 IES 2000

Assertion (A): Vitrified bond is preferred for thin Assertion (A): The ratio of cutting force to thrust force is
grinding wheels. very high in grinding process as compared to other
machining processes.
Reason (R): Vitrified bond is hard brittle. Reason (R): Random orientation and effective negative
(a) Both A and R are individually true and R is the rake angles of abrasive grains increase the cutting force
correctt explanation
l ti off A and adversely affect the cutting action and promote
rubbing action.
(a) Both A and R are individually true and R is the correct
correct explanation of A explanation of A
(c) A is true but R is false (b) Both A and R are individually true but R is not the
(d) A is false but R is true correct explanation of A
Ans. (a)
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IES 1995 IES2010

Soft materials cannot be economically grind due to In relation to the peripheral or surface
(a) The high temperatures involved speeds of the grinding wheel and that of the
(b) Frequent wheel clogging workpiece in cylindrical grinding of alloy
(c) Rapid wheel wear steel workpieces, the grinding wheel speed is
(d) Low work piece stiffness (a) Less than the speed of the workpiece
(b) Same as the speed of the workpiece
Ans. (b) (c) Double the speed of the workpiece
(d) 65 to 75 times the speed of the workpiece.
Ans. (d)
IES 2009 IES 2002

Given that the peripheral speed of the grinding Which of the following materials are used in
wheel of 100 mm diameter for cylindrical grinding grinding wheel?
of a steel work piece is 30 m/s, what will be the 1. Aluminium oxide
estimated rotational speed of the grinding wheel in 2. Cubic boron nitride
revolution per minute (r.p.m.)?
3. Silicon carbide
(a) 11460 (b) 5730
(c) 2865 (d) 95
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
Ans. (b)
Ans. (a)
IES 2001 IES 2000

The marking on a grinding wheel is '51 A 36 L 5 V 93'. The sequence of markings "S 14 K 14 S" on a grinding
The code '36' represents the wheel represents respectively
(a) Structure (a) Bond type, structure, grade, grain size and abrasive
(b) Grade type
(c) Grain size (b) Abrasive
Ab i type,
t grain
i size,
i grade,
d structure
t t and
d bond
b d
(d) Manufacturer's number type
(c) Bond type, grade, structure, grain size and abrasive
type
Ans. (c)
(d) Abrasive type, structure, grade, grain size and bond
type
Ans. (b)
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IES 1995 IES 1993

In the grinding wheel of A 60 G 7 B 23, B stands for Tool life in the case of a grinding wheel is the time
(a) Resinoid bond (b) Rubber bond (a) Between two successive regrinds of the wheel
(c) Shellac bond (d) Silicate bond (b) Taken for the wheel to be balanced
(c) Taken between two successive wheel dressings
Ans. (a) (d) Taken for a wear of 1mm on its diameter
Ans. (c)
IES 2001 IES 1994

Assertion (A): Hard wheels are chosen for grinding Consider the following statements regarding
hard metals. grinding of high carbon steel:
Reason (R): In hard wheels only the abrasive grains 1. Grinding at high speed results in the reduction of
are retained for long time. chip thickness and cutting forces per grit.
(a)
( ) Both
i di id ll true
t and
d R is
i the
th 2. Aluminium
Al i i oxide
id wheels
h l are employed.
l d
correct explanation of A 3. The grinding wheel has to be of open structure.
(b) Both A and R are individually true but R is not the Of these statements
correct explanation of A (a) 1, 2 and 3 are correct (b) 1 and 2 are correct
(c) A is true but R is false (c) 1 and 3 are correct (d) 2 and 3 are correct
(d) A is false but R is true Ans. (b)
Ans. (d)
IES 1999 IES 1993

Consider the following reasons: In centre less grinding, the work piece centre will be
1. Grinding wheel is soft (a) Above the line joining the two wheel centres
2. RPM of grinding wheel is too low (b) Below the line joining the two wheel centres
3. Cut is very fine (c) On the line joining the two wheel centres
4. An improper cutting fluid is used (d) At the intersection of the line joining the wheel
A grinding wheel may become loaded due to reasons centres with the work plate plane.
stated at
(a) 1 and 4 (b) 1 and 3 Ans. (a)
(c) 2 and 4 (d) 2 and 3
Ans. (c)
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IES 2000 IES 1996

Consider the following advantages: A grinding wheel of 150 mm diameter is rotating at
1. Rapid process 3000 rpm. The grinding speed is
2. Work with keyways can be ground
3. No work holding device is required.
Which of these are the advantages of centre less
grinding?
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3 Ans. (a)
Ans. (d)
IES 1993 IES 2007

Consider the following parameters: Honing Process gives surface finish of what order?
1. Grinding wheel diameter. (a) 10 m (CLA) (b) 1.0 m (CLA)
2. Regulating wheel diameter. (c) 0.1 m (CLA) (d) 0.01 m (CLA)
3. Speed of the grinding wheel.
4. Speed of the regulating wheel. Ans. (c)
5. Angle between the axes of grinding and regulating
wheels.
Among these parameters, those which influence the
axial feed rate in centreless grinding would include
(a) 2, 4 and 5 (b) 1, 2 and 3
(c) 1, 4 and 5 (d) 3, 4 and 5 Ans. (a)
IES 1992 IES 2001

CLA value for Honing process is Match ListI (Cutting Tools) with ListII (Applications)
and select the correct answer using the codes given
(a) 6 (b) 0.05 3.0 below the lists:
(c) 0.05 1.0 (d) 0.025 0.1 List I List II
A. Trepanning tool 1. For surface finishing by
h i
honing
Ans. (c)
B. Side milling cutter 2. For machining gears
C. Hob cutter 3. For cutting keyways in shafts
D. Abrasive sticks 4. For drilling large diameter
holes Ans. (b)
(a) 1 3 2 4 (b) 4 3 2 1
(c) 1 2 3 4 (d) 4 2 3 1
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IES 1992 IES 1992

A surface finish of 0.025 0.1 micrometer CLA values Buffing wheels are mode of
is to be produced. Which machining process would (a) Softer metals (b) Cotton fabric
you recommend? (c) Carbon (d) Graphite
(a) Grinding (b) Rough turning
(c)
( ) Lapping
L i (d) Honing
H i Ans. (b)
Ans. (c)
IAS 2004 IAS 2000

The size effect refers to the increase in specific Consider the following statements in respect of a
cutting energy at low values of undeformed chip grinding wheel of specification, 51A 36L7R23,
thickness. It is due to which one of the following? using the standard alphanumeric codification:
(a) Existence of ploughing force 1. Abrasive used in the wheel is aluminum oxide
(b) Work
W k hardening
h d i 2. The
Th graini size
i off abrasive
b i is i medium
di
(c) High strain rate 3. The wheel grade is medium hard
(d) Presence of high friction at chiptool interface. 4. It has an open structure
Ans. (a) 5. It has resinoid as bonding agent
Which (If these statements are correct?
(a) 1, 2 and 3 (b) 1, 3 and 4
(c) 2, 3 and 5 (d) 1, 4 and 5 Ans. (a)
IAS 1999 IAS 2001

Assertion (A): The grade of a grinding wheel is a Consider the following statements:
The setup for internal centreless grinding consists of a
measure of hardness of the abrasive used for the regulating wheel, a pressure roll and a support roll, between
wheel. which the tubular workpiece is supported with the grinding
wheel within the tube, wherein
Reason (R): Grading is necessary for making right 1.The grinding wheel, workpiece and regulating wheel centers
selection of the wheel for a particular work.
work must lie on one line
(a) Both A and R are individually true and R is the 2.The directions of rotation of workpiece and grinding wheel are
same
correct explanation of A 3.The directions of rotation of pressure roll, support roll and
(b) Both A and R are individually true but R is not the regulating wheel are same
4.The directions of rotation of grinding wheel and regulating
correct explanation of A wheel are same
(c) A is true but R is false Which of these statements are correct?
(a) 1, 2 and 3 (b) 1, 3 and 4
(d) A is false but R is true Ans. (d) (c) 2 and 3 (d) 3 and 4 Ans. (a)
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IAS 1997 IAS 2007

Which of the following pairs are correctly matched? Match List I with List II and select the correct answer
using the code given below the Lists:
1. Drill press : Trepanning
List I List II
2. Centreless grinding: Through feeding (Machine Tool/ Cutting Tool) (Part/ Characteristics)
3. Capstan lathe: Ram type turret A. Screw cuttingg lathe1. Self lockingg taper
p
Select the correct answer using the codes given below: B. Drill 2. Chasing dial
Codes: C. End mill 3. Wiper insert
(a) 1 and 2 (b) 1, 2 and 3 D. Grinding wheel 4. Self releasing taper
5. Balance weights Ans. (b)
(c) 1 and 3 (d) 2 and 3
Ans. (b) (a) 4 5 3 1 (b) 2 1 4 5
(c) 4 1 3 5 (d) 2 5 4 1
IAS 1999 IAS 2001

Which one of the following processing sequences Which one of the following grinding wheels (with
will give the best accuracy as well as surface finish? Grade, Grit and Bond) is suitable for cutter
(a) Drilling, reaming and grinding grinding?
(b) Drilling, boring and grinding (a) K 60 vitrified (b) K 320 vitrified
(c) Drilling, reaming and lapping ( ) T 60
(c) 6 resinoid
i id (d) T 320 resinoid
i id
(d) Drilling, reaming and electroplating
Ans.(a)
Ans. (c)
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GATE 2006
Arrange the processes in the increasing order of
their maximum material removal rate.
Electrochemical Machining (ECM)
NTMM Ultrasonic Machining (USM)

Electron Beam Machining (EBM)
Laser Beam Machining (LBM) and
Electric Discharge Machining (EDM)
(a) USM, LBM, EBM, EDM, ECM
(b) EBM, LBM, USM, ECM, EDM
(c) LBM, EBM, USM, ECM, EDM
BySKMondal (d) LBM, EBM, USM, EDM, ECM Ans. (d)
IES 2007 IES 2009

Consider the following statements in relation to the Which one of the following statements is correct in
unconventional machining processes: respect of unconventional machining processes?
1. Different forms of energy directly applied to the (a) The cutting tool is in direct contact with the job
piece to have shape transformation or material removal (b) The tool material needs to be harder than the job
from work surface.
surface material
t i l
2. Relative motion between the work and the tool is (c) The tool is never in contact with the job
essential. (d) There has to be a relative motion between the tool
3. Cutting tool is not in physical contact with work and the job
piece.
(a) 1 and 2 only (b) 1, 2 and 3 only Ans. (c)
(c) 2 and 3 only (d) 1 and 3 only Ans. (d)
IAS 2002 PSU

Match List I (Processes) with List II (Tolerances
obtained) and select the correct answer using the codes ECMcannotbeundertakenfor
given below the Lists: (a)steel
List I List II (b)Nickelbasedsuperalloy
(Processes) (Tolerances obtained)
(c)Al2O3
A. Plasma Arc machining 1. 75 microns
(d)Titaniumalloy
B. Laser Beam machining 2. 25 microns
C. Abrasive Jet machining 3. 50 microns
D. Ultrasonic machining 4. 125 microns Ans. (c) y Ans.(c)
(a) 4 1 3 2 (b) 3 2 4 1
(c) 4 2 3 1 (d) 3 1 4 2
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Example
PSU UsingECMremove5cm3/minfromanironworkpiece,
Commercial ECM is carried out at a combination whatcurrentisrequired?
of Atomicweightofiron56,density7.8g/cm3 valency,2
(a) low voltage high current
(b) low current low voltage
(c) high current high voltage
(d) low current low voltage
Ans. (a)
Example Example(GATE2009)
Calculate the material removal rate and the Electrochemicalmachiningisperformedtoremove
electrode feed rate in the electrochemical materialfromanironsurfaceof20mmx20mmunder
machining of an iron surface that is 25 mm 25 mm thefollowingconditions:
in crosssection using NaCl in water as electrolyte. Interelectrodegap = 0.2mm
The gap between the tool and the workpiece is 0.25 S
SupplyVoltage(DC)
l V lt (DC) = 12V
V
mm. The supply voltage is 12 V DC. The specific
Specificresistanceofelectrolyte
=2cm
resistance of the electrolyte is 3 c m
For iron, Valency, Z = 2 AtomicweightofIron = 55.85
Atomic weight, A = 55.85 Valency ofIron = 2
Density, = 7860 kg / m3 Faraday'sconstant = 96540Coulombs
Thematerialremovalrate(ing/s)is
Example Example
Composition of a Nickel superalloy is as follows: The electrochemical machining of an iron surface that is
Ni = 70.0%, Cr = 20.0%, Fe = 5.0% and rest Titanium 25 mm 25 mm in crosssection using NaCl in water as
Calculate rate of dissolution if the area of the tool is 1500 electrolyte. The gap between the tool and the workpiece
mm2 and a current of 1000 A is being passed through the is 0.25 mm. The supply voltage is 12 V DC. The specific
cell.
cell Assume dissolution to take place at lowest valancy resistance of the electrolyte is 3 cm.
of the elements. Estimate the electrolyte flow rate. Specific heat of the
electrolyte is given as 0.997 cal/gC. The ambient
temperature is 35C and the electrolyte boiling
temperature, is 95C.
Density, = 7860 kg/m3
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Example IES 2000

In ECM operation of pure iron an equilibrium gap of 2 Consider the following statements:
mm is to be kept. Determine supply voltage, if the total In electrochemical grinding,
overvoltage is 2.5 V. The resistivity of the electrolyte is 50 1. A rubber bonded alumina grinding wheel acts as the
mm and the set feed rate is 0.25 mm/min. cathode and the workplace as the anode.
2.
2 A copper bonded alumina grinding wheel acts as the
cathode and the work piece as the anode.
3. Metal removal takes place due to the pressure
applied by the grinding wheel.
4. Metal removal takes place due to electrolysis.
(a) 1 and 3 (b) 2 and 4
(c) 2 and 3 (d) 1 and 3 Ans. (b)
GATE 2008 GATE 2001

A researcher conducts electrochemical machining In ECM, the material removal is due to
(a) Corrosion
(ECM) on a binary alloy (density 6000 kg/m3) of iron
(b) Erosion
(atomic weight 56, valency 2) and metal P (atomic (c) Fusion
weight 24, valency 4). Faraday's constant = 96500 (d) Ion displacement
coulomb/mole. Volumetric material removal rate of
Ans. (d)
the alloy is 50 mm3/s at a current of 2000 A. The
percentage of the metal P in the alloy is closest to
(a) 40 (b) 25 (c) 15 (d) 79 Ans. (b)
GATE 1997 GATE 1992

Selection electrolyte for ECM is as follows: The two main criteria for selecting the electrolyte in
(a) Nonpassivating electrolyte for stock removal and Electrochemical Machining (ECM) is that the
passivating electrolyte for finish control electrolyte should
(b) Passivating electrolyte for stock removal and non (a) Be chemically stable
passivating
i ti electrolyte
l t l t forf finish
fi i h control
t l (b) Not
N t allow
ll dissolution
di l ti off cathode
th d material
t i l
(c) Selection of electrolyte is dependent on current (c) Not allow dissolution of anode material
density (d) Have high electrical conductivity
(d) Electrolyte selection is based on tool work
electrodes Ans. (a, d)
Ans. (d)
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GATE 1997 IES 2002

Inter electrode gap in ECG is controlled by Assertion (A): In ECM, the shape of the cavity is the
(a) Controlling the pressure of electrolyte flow mirror image of the tool, but unlike EDM, the tool
(b) Controlling the applied static load wear in ECM is less.
(c) Controlling the size of diamond particle in the wheel Reason (R): The tool in ECM is a cathode.
(d) Controlling the texture of the work piece (a)
( ) Both
i di id ll true
t and
d R is
i the
th
Ans. (c) correct explanation of A
IES 1997 IES2011Conventional

Which one of the following processes does not Discuss the effects of insufficient dielectric and
cause tool wear?
(a) Ultrasonic machining electrolyte circulation in the interelectrode gap on the
(b) Electrochemical machining Electric Discharge machining and Electro Chemical
(c) Electric discharge machining Machining process respectively. [5 Marks]
(d) Anode mechanical machining
Ans. (b)
GATE 1994
IES2009Conventional Electric discharge machining is more efficient
i. What is the principle of metal removal in EDM process than Electrochemical machining for
process? producing large noncircular holes.
ii. Describe the process with the help of sketch. The above statement is
iii. List advantages and limitations of the system. ( ) True
(a) T
[15marks] (b) False
(c) Cant say
(d) Insufficient data
Ans. (a)
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GATE 2004 GATE 2003

The mechanism of material removal in EDM As tool and work are not in contact in EDM process
process is (a) No relative motion occurs between them
(a) Melting and Evaporation (b) No wear of tool occurs
(b) Melting and Corrosion (c) No power is consumed during metal cutting
(c) Erosion and Cavitation (d) No force between tool and work occurs
(d) Cavitation and Evaporation
Ans. (d)
Ans. (a)
GATE 1999 GATE 2007

In ElectroDischarge Machining (EDM), the tool is In electro discharge machining (EDM), if the
made of thermal conductivity of tool is high and the specific
(a) Copper (b) High Speed Steel heat of work piece is low, then the tool wear rate
(c) Cast Iron (d) Plain Carbon Steel and material removal rate are expected to be
respectively
(a) High and high (b) Low and low
Ans. (a)
(c) High and low (d) Low and high
Ans. (d)
GATE 2005 IES 2005

A zigzag cavity in a block of Which of the following is/are used as low wearing
high strength alloy is to be tool material(s) in electric discharge machining?
finish machined. This can be (a) Copper and brass
carried out by using (b) Aluminium and graphite
(a) Electricdischargemachining (c) Silver tungsten and copper tungsten
(b) Electrochemicalmachining (d) Cast iron
(c) Laserbeammachining
(d) Abrasiveflowmachining Ans. (c)
Ans.(a)
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GATE 2000 GATE 1994

Deep hole drilling of small diameter, say 0.2 mm is Ultrasonic machining is about the best process for
done with EDM by selecting the tool material as making holes in glass which are comparable in size
(a) Copper wire (b) Tungsten wire with the thickness of the sheet.
(c) Brass wire (d) Tungsten carbide The above statement is
(a)
( ) True
T
Ans. (b) (b) False
(c) Cant say
(d) Insufficient data
Ans. (a)
IES2011 GATE 1993

USM has good machining performance for : In ultrasonic machining process, the material
(a) Al removal rate will be higher for materials with
(b) Steel (a) Higher toughness (b) Higher ductility
((c)) Super
p alloys
y (c) Lower toughness (d) Higher fracture strain
(d) Refractory material
Ans. (c)
Ans. (d)
GATE 1992 IES 2009

In Ultrasonic Machining (USM) the material By which one of the following processes the
removal rate would metering holes in injector nozzles of diesel engines
(a) Increase can be suitably made?
(b) Decrease (a) Ultrasonic machining
(c) Increase and then decrease (b) Abrasive
Ab i jet j t machining
hi i
(d) decrease and then increase (c) Electron beam machining
with increasing mean grain diameter of the abrasive (d) Chemical machining
material.
Ans. (b)
Ans. (c)
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IES 2006 IAS 1996

During ultrasonic machining, the metal removal is During ultrasonic machining, the metal removal is
achieved by affected by the
(a) High frequency eddy currents (a) Hammering action of abrasive particles
(b) high frequency sound waves (b) Rubbing action between tool and workpiece
(c) Hammering action of abrasive particles (c) High frequency sound waves
(d) Rubbing action between tool and workpiece (d) High frequency eddy currents
Ans. (c) Ans. (c)
GATE 1992 GATE2011

Match the following non traditional machining
Match the following components with the appropriate processes with the corresponding material removal
machining processes: mechanism:
Component Process Machiningprocess Mechanismofmaterialremoval
(A) Square hole in a high strength alloy (1) Milling P.Chemicalmachining 1.Erosion
((B)) Square
q hole in a ceramic component
p ((2)) Drilling
g Q.Electro
Q Electro chemical 2 Corrosivereaction
2.Corrosivereaction
(C) Blind holes in a die (3) ECM machining
(D) Turbine blade profile on high strength alloy(4) Jig boring R.Electro discharge 3.Iondisplacement
Ans. (b) (5) EDM machining
(6) USM S.Ultrasonicmachining 4.Fusionandvaporization
(a) 4 1 2 3 (b) 5 6 1 3 (a)P 2,Q 3,R 4,S 1(b)P 2,Q 4,R 3,S 1
(c)P 3,Q 2,R 4,S 1(d)P 2,Q 3,R 1,S 4
(c) 4 2 1 3 (d) 3 1 2 4
Ans.(a)
GATE 2007 GATE 1998

Matchthemostsuitablemanufacturingprocessesforthe List I List II
followingparts.
(A) ECM (1) Plastic shear
Parts ManufacturingProcesses
P. Computerchip 1. ElectrochemicalMachining (B) EDM (2) Erosion/Brittle fracture
Q. Metalformingdiesandmoulds
g (C) USM (3) Corrosive reaction
2. UltrasonicMachining (D) LBM (4) Melting and vaporization
R. Turbineblade 3. Electrodischarge (5) Ion displacement Ans. (b)
Machining Ans.(a)
(6) Plastic shear and ion displacement
S. Glass 4. PhotochemicalMachining
Codes:P Q R S P Q R S Codes:A B C D A B C D
(a) 4 3 1 2 (b) 4 3 2 1 (a) 4 1 2 3 (b) 5 4 2 4
(c) 3 1 4 2 (d) 1 2 4 3 (c) 4 2 1 3 (d) 3 1 2 4
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IES 2008 IES 1998

Match ListI with ListII and select the correct answer Match ListI (Machining process) with ListII
using the code given below the lists: (Associated medium) and select the correct answer
ListI ListII Ans. (a) using the codes given below the lists:
(Unconventional machining process) (Basic process) ListI ListII Ans. (b)
A.
A Electro polishing 1.
1 Thermal A.
A Ultrasonic
Ult i machining
hi i 1. Kerosene
K
B. Electrochemical machining 2. Mechanical B. EDM 2. Abrasive slurry
C. Abrasive jet machining 3. Electrochemical C. ECM 3. Vacuum
D. Electrical discharge machining 4. Chemical
D. EBM 4. Salt solution
(a) 4 3 2 1 (b) 2 1 4 3
(a) 2 3 4 1 (b) 2 1 4 3
(c) 4 1 2 3 (d) 2 3 4 1
(c) 4 1 2 3 (d) 4 3 2 1
IES 2005 IES 2003

Match List I (Machining Process) with List II Match List I (Materials) with List II (Machining) and
(Application) and select the correct answer using the select the correct answer using the codes given below
code given below the Lists: the Lists: Ans. (d)
List I List II List I List II
A. EDM 1. Holes & cavities in hard & brittle materials
(Materials) (Machining)
B.
B LBM 2. 2 Micro
Microdrilling
drilling & micro
microwelding
welding of
materials A. Machining of conducting materials 1. ECM
C. USM 3. Shaping of hard metals or reshaping of B. Ruby rod 2. EDM
cemented carbide tools C. Electrolyte 3. USM
D. ECM 4. Shaping of cemented carbide dies and D. Abrasive slurry 4. LBM
punches Ans. (c)
(a) 4 1 2 3 (b) 3 2 1 4 (a) 4 2 1 3 (b) 4 2 3 1
(c) 4 2 1 3 (d) 3 1 2 4 (c) 2 4 3 1 (d) 2 4 1 3
IES 2003 IAS 2002

Assertion (A): Water jet machining uses high Which one of the following pairs is NOT correctly
pressure and high velocity water stream which acts matched?
like a saw and cuts a narrow groove in the material.
(Unconventional (Application)
Reason (R): The force required for cutting is
generated from sudden change in the momentum machining method)
of the water stream. (a) Electric discharge : Machining of electrically
(a) Both A and R are individually true and R is the conductive materials
correct explanation of A (b) Laser beam : Micromachining
(b) Both A and R are individually true but R is not the (c) Plasma arc : Faster cutting of hard materials
(d) Electron beam : Faster metal removal rate
Ans. (d)
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IAS 1999 IES 2004

Match List I (Unconventional machining process) with Match List I (Machining processes) with List II
List II (Typical application) and select the correct (Operating media) and select the correct answer using
answer using the codes given below the lists: the codes given below the Lists:
List I List II Ans. (d) List I List II
A. Abrasive jet machining 1. Dielectric
A.
A Electro discharge machining 1.
1 Drilling micro holes in
very hard metals B. Electron beam machining 2. Electrolyte
C. Electrochemical machining 3. Abrasive slurry
B. Electro chemical machining 2. Drilling holes in glass
D. Electrodischarge machining 4. Vacuum
C. Ultrasonic machining 3. Die sinking
5. Air Ans. (a)
D. Laser beam machining 4. Machining contours Codes:A B C D A B C D
Codes:A B C D A B C D (a) 5 4 2 1 (b) 4 5 2 1
(a) 4 2 3 1 (b) 3 4 1 2 (c) 4 2 3 5 (d) 2 5 3 4
(c) 4 3 2 1 (d) 3 4 2 1
IES 1999 GATE 2004

Match ListI with ListII and select the correct answer Typical machining operations are to be performed on hard
using the codes given below the Lists: tomachine materials by using the processes listed below.
Choose the best set of OperationProcess combinations
ListI ListII
Operation Process
A. Die sinking 1. Abrasive jet machining
P. Debarring (internal surface) 1. Plasma Arc Machining
B. Debarring g 2. Laser beam machining g
Q Die sinking
Q. 2
2. Abrasive Flow Machining
C. Fine hole drilling (thin materials) 3. EDM R. Fine hole drilling in thin sheets 3. Electric Discharge
D. Cutting/sharpening hard materials Machining
4. Ultrasonic machining S. Tool sharpening 4. Ultrasonic Machining
Ans. (c) 5. Electrochemical grinding 5. Laser beam Machining
Code:A B C D A B C D 6. Electrochemical Grinding
(a) 3 5 4 1 (b) 2 4 1 3 (a) P1 Q5 R3 S4 (b) P1 Q4 R1 S2
(c) 3 1 2 5 (d) 4 5 1 3 (c) P5 Q1 R2 S6 (d) P2 Q3 R5 S6
Ans. (d)
Ch10:NonConventionalMachiningOperation
Q.No Option Q.No Option
1 D 8 D
2 B 9 A
3 B 10 B
4 D 11 D
5 D 12 A
6 B 13 A
7 A 14 B
Page 46 of 70
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NC,CNC&Robotics IAS 1996

Assertion (A): The temperature control of an
electric iron is an example of servomechanism.
Reason (R): It is an automatic control system.
(a) Both A and R are individually true and R is the
correctt explanation
l ti off A
(d) A is false but R is true
BySKMondal Ans. (d)
GATE 1994 IES 1999

CNC machines are more accurate than conventional Consider the following statements regarding
machines because they have a high resolution numerically controlled machine tools:
encoder and digital readouts for positioning. 1. They reduce nonproductive time
2. They reduce fixturing
True
T or false?
f l ? 3. They reduce maintenance cost
Ans. True (a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
Ans. (b)
IES 1995 IES 2009

Consider the following characteristics of In which of the following machining manual part
production jobs: programming is done?
1. Processing of parts frequently in small lots (a) CNC machining (b) NC machining
2. Need to accommodate design changes of products. (c) DNC machining (d) FMS machining
3. Low rate of metal removal
4. Need for holding close tolerances Ans. (b)
The characteristics which favour the choice of
numerically controlled machines would include
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1, 3 and 4 (d) 1, 2 and 4 Ans. (d)
Page 47 of 70
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Set-2
GATE 1993 IES 2007

With reference to NC machine, which of the What are the main components of an NC machine?
following statement is wrong? 1. Part program
(a) Both closedloop and openloop control systems are 2. Machine Control Unit
used 3. Servo motor
(b) Paper
P tapes,
t floppy
fl tapes
t and
d cassettes
tt are used d for
f Select the correct answer using the code given below:
data storage
(a) 1, 2 and 3 (b) 1 and 2 only
(c) Digitizers may be used as interactive input devices
(c) 2 and 3 only (d) 1 and 3 only
(d) Post processor is an item of hardware
Ans. (a)
Ans. (c)
JWM2010 IES 2009

Consider the following components regarding numerical What is the purpose of satellite computers in
control system : Distributed Numerical Control machines?
1. Programme of instructions (a) To act as standby systems
2. Machine control unit (b) To share the processing of largesize NC programs
3. Processing
P i equipment
i (c) To serve a group of NC machines
Which of these are correct ? (d) To network with another DNC setup
(a) 1, 2 and 3 (b) 1 and 2 only
(c) 2 and 3 only (d) 1 and 3 only Ans. (c)
Ans. (a)
IES 1999 JWM2010

Consider the following components: ConsiderthefollowingadvantagesofDNCsystems:
1. A dedicated computer 1.Timesharing
2. Bulk memory 2.Greatercomputationalcapability
3. Telecommunication lines 3.Remotecomputerlocation
Which of these components are required for a DNC
system? Whichoftheaboveis/arecorrect?
(a) 2 and 3 (b) 1 and 2 (a)1and2only (b)2and3only
(c) 1, 2 and 3 (d) 1 and 3 (c)2only (d)1,2and3
Ans. (c) And.(d)
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Set-2
IES 2002S1 IES 2002Contd..FromS1

Match List I with List II and select the correct C. DNC system 3. The controller consists of
answer: softwired computer and
List I List II hard wired logic Graphic
display of tool path is
(NC machine tool systems) (Features)
also possible
A.
A NC system 1.
1 It has an integrated automatic tool
D. Machining centre 4. The instructions on tape is
changing unit and a component
prepared in binary
indexing device
decimal form and operated by
B. CNC system 2. A number of machine tools are a series of coded
controlled by a computer. No tape instructions Ans. (c)
reader, the part program is
transmitted directly to the Codes:A B C D A B C D
machine tool from the (a) 4 2 3 1 (b) 1 3 2 4
computer memory (c) 4 3 2 1 (d) 1 2 3 4
GATE 2007 IES 1994

WhichtypeofmotorisNOTusedinaxisorspindle Feed drives in CNC milling machines are provided
drivesofCNCmachinetools? by
(a) Inductionmotor (b) DCservomotor (a) Synchronous motors
(c) Steppermotor (d) Linearservomotor (b) Induction motors
(c) Stepper motors
Ans.(a) (d) Servomotors.
Ans. (d)
IES 2002 Example

In a CNC machine tool, encoder is used to sense and y A DC servomotor is coupled directly to a leadscrew
control which drives the table of an NC machine tool. A
(a) Table position digital encoder, which emits 500 pulses per
(b) Table velocity revolution, is mounted on the other end of the
leadscrew If the leadscrew pitch is 5 mm and the
leadscrew.
(c) Spindle speed
motor rotates at 600 rpm, calculate
(d) Coolant flow
(a) The linear velocity of the table
(b) The BLU of the NC system
Ans. (b)
(c) The frequency of pulses transmitted by the encoder.
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IES2011Conventional StatementforLinkedAnswersquestions:S1
y The table of a CNC machine is driven by a Lead screw which In the feed drive of a PointtoPoint open loop CNC
is rotated by a DC servomotor. A digital encoder which emits drive, a stepper motor rotating at 200 steps/rev drives a
table through a gear box and lead screwnut mechanism
1000 pulses per second is mounted on the lead screw as a (pitch = 4 mm, number of starts = 1).
Output rotational speed
feedback device. If the lead screw p
pitch is 6 mm and motor The gear ratio = Input rotational speed is given by U = 14
rotates at 500 rpm, find The stepper motor (driven by voltage pulses from a pulse
1. Basic length Units of the system generator) executes 1 step/pulse of the pulse generator.
The frequency of the pulse train from the pulse
2. Linear velocity of the table. generator is f = 10,000 pulses per minute.
3. Frequency of pulses generated by the feedback device.
[5 Marks]
GATE 2008Q1 (StatementinS1) GATE 2008Q2 (StatementinS1)

The Basic Length Unit (BLU), i.e., the table A customer insists on a modification to change the BLU
movement corresponding to 1 pulse of the pulse of the CNC drive to 10 microns without changing the
generator, is table speed. The modification can be accomplished by
(a) 0.5 microns (b) 5 microns
(c)
( ) 50 microns
i (d) 500 microns
i
Ans. (b)
Ans. (a)
GATE 1997 GATE 1992

In a point to point control NC machine, the slides In a pointtopoint type of NC system
are positioned by an integrally mounted stepper (a) Control of position and velocity of the tool is
motor drive. If the specification of the motor is essential
1o/pulse, and the pitch of the lead screw is 3.6 mm, (b) Control of only position of the tool is sufficient
what is the expected positioning accuracy?
(c) Control of only velocity of the tool is sufficient
( a ) 1 m (b) 10 m
(d) Neither position nor velocity need be controlled
(c ) 50 m (d ) 100 m
Ans. (b)
Ans. (b)
Page 50 of 70
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GATE 2006 GATE2005

NC contouring is an example of
WhichamongtheNCoperationsgivenbeloware
(a) Continuous path positioning continuouspathoperations?
(b) Pointtopoint positioning ArcWelding(AW) Milling(M)
(c) Absolute positioning Drilling(D) PunchingisSheetMetal(P)
L
LaserCuttingofSheetMetal(LC)SpotWelding(SW)
C i fSh M l(LC)S W ldi (SW)
(d) Incremental positioning
(a) AW,LCandM (b)AW,D,LCandM
(c) D,LC,PandSW (d)D,LC,andSW
Ans. (a)
Ans.(a)
IES 2000 IES 1996

Assertion (A): The axis of an NC drilling machine Assertion (A): Numerically controlled machines
spindle is denoted as zaxis. having more than three axes do not exist.
Reason (R): In NC machine tool, the axis Reason (R): There are only three Cartesian
perpendicular to both x and yaxis is designated as coordinates namely xyz.
zaxis
z axis ( ) Both
(a) B th A and d R are individually
i di id ll true
t and
d R is
i the
th
(a) Both A and R are individually true and R is the correct explanation of A
correct explanation of A (b) Both A and R are individually true but R is not the
(b) Both A and R are individually true but R is not the correct explanation of A
correct explanation of A (c) A is true but R is false
(c) A is true but R is false (d) A is false but R is true Ans. (d)
IES 2003S1 IES 2003Contd..FromS1

While part programming If incremental coordinates system is used, the co
in CNC machines, the ordinates of each point A, B and C are
input of dimensional (a) A: X 5.0, Y 10.0 (b) A: X 5.0, Y 10.0
information for the tool B: X 20.0, Y5.0 B: X 25, Y 15.0
path can be given in the
absolute coordinate C: X 10.0, Y 10.0 C: X 35, Y 5.0
system or in incremental (c) A: X 10.0, Y 5.0 (d) A: X 10.0, Y 5.0
coordinate system. The B: X 15.0, Y 25.0 B: X 5.0, Y 20.0
above figure shows the C: X 15.0, Y 35.0 C: X 10.0, Y 10.0
route to be followed by the
tool from O to C, i.e., O A
B C. Ans. (a)
Page 51 of 70
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Set-2
GATE 2004 GATE 2010

During the execution of a CNC part program block In a CNC program block, N002 G02 G91 X40 Z40,
N020 G02 X45.0 Y25.0 R5.0 the type of tool motion will G02 and G91 refer to
be (a) Circular interpolation in counterclockwise direction
(a) Circular Interpolation clockwise and incremental dimension
(b) Circular Interpolation counter clockwise (b) Circular
Ci l interpolation
i t l ti ini counterclockwise
t l k i direction
di ti
(c) Linear Interpolation and absolute dimension
(d) Rapid feed (c) Circular interpolation in clockwise direction and
incremental dimension
(d) Circular interpolation in clockwise direction and
Ans. (a) absolute dimension
IES 2009 GATE 2001

Interpolation in the controller refers to control of In an NC machining operation, the tool has to be
which one of the following in a CNC machine? moved from point (5, 4) to point (7, 2) along a
(a) Loading/unloading of jobs on machine circular path with centre at (5, 2). Before starting the
(b) Loading/unloading of tools from the tool changer operation, the tool is at (5, 4). The correct G and M
code for this motion is
(c) Axes of machine for contouring
(a) N010 G03 X7.0 Y2.0 I5.0 J2.0
(d) Coolant and miscellaneous functions on machine
(b) N010 G02 X7.0 Y2.0 I5.0 J2.0
(c) N010 G01 X7.0 Y2.0 I5.0 J2.0
Ans. (c)
(d) N010 G00 X7.0 Y2.0 I5.0 J2.0
Ans. (b)
GATE 2005 GATE 2000

The tool of an NC machine has to move along a In finish machining of an island on a casting with
circular arc from (5, 5) to (10,10) while performing an CNC milling machine, an end mill with 10 mm
operation. The centre of the arc is at (10, 5). Which diameter is employed. The corner points of the
one of the following NC tool path commands island are represented by (0, 0), (0, 30), (50, 30), and
performs the above mentioned operation? (50, 0). By applying cutter radius right
(a) N010G02 X10 Y10 X5 Y5 R5 compensation, the trajectory of the cutter will be
(b) N010G03 X10 Y10 X5 Y5 R5 (a) (5, 0), (5, 35), (55, 35), (55, 5), (5, 5)
(c) N010G01 X5 Y5 X10 Y10 R5 (b) (0, 5), (55, 5), (55, 35), (5, 35), (5, 5)
(d) N010G02 X5 Y5 X10 Y10 R5 (c) (5, 5), (5, 25), (45, 25), (45, 5), (5, 5)
Ans. (d) (d) (5, 5), (45, 5), (45, 25), (5, 25), (5, 5)
Ans. (b)
Page 52 of 70
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GATE 2009 IES 1993

A 'block' of information in N.C. machine program
means
(a) One row on tape
(b) A word comprising several rows on tape
(c) One complete instruction
(d) One complete program for a job
y Ans. (c) Ans. (c)
IES 1996 IES 1995

In manual programming and tape preparation for a Match List I with List II and select the correct answer
using the codes given below the lists:
NC drilling machine, the spindle speed was coded
List I List II
as S 684 (using the magicthree code). The spindle (A function connected (Associated parameter)
speed in rpm will be with NC m/c tool)
(a) 684 A Interpolation
A. 1 Tape preparation
1.
(b) 68.4 B. Parity check 2. Canned cycle
C. Preparatory function 3. Drilling
(c) 840
D. Point to point control 4. Contouring
(d) 6840 5. Turning
(a) 4 1 2 3 (b) 4 1 2 5
Ans. (a)
(c) 5 1 3 2 (d) 1 4 3 2
Ans. (a)
IES 1998 IES2008

Name the four types of statements in a complete APT
Which of the following are the rules of part program. Prepare part program for geometry
programming NC machine tools in APT language? description of the contour shown in the figure below:
Y
1. Only capital letters are used [15Marks]
30 40
2. A period is placed at the end of each statement 20
3. Insertion of space does not affect the APT word L2

L3 20
C1
R
Select the correct answer using the codes given below: 135
(a) 1 and 2 (b) 2 and 3 L4

80
(c) 1 and 3 (d) 1 alone L1
C2
Ans. (d) L5
20
R P1
P2 20
X
Page 53 of 70
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Set-2
IES2007
Prepare part using APT language for milling the contour
IES2006
Prepare part program to machine the contour shown in
shown in Fig. in a single pass. D [20Marks] the figure using APT on CNC milling machine.
C 110
R30
[15Marks]
B
R30
Q
R20

110
120
100 mm
80
E
+
+
R40
40
A F
100 + 40 P
+
Material : M S. 60 50
200 mm
8 mm
Material: MS Thickness: 8.0 mm
IES2011Conventional IES 1997

State the method of defining line segment of Which of the following are valid statements for
point to point motion of the tool in APT language?
cutter motion using APT program format.
1. GO/TO/............
[5 Marks] 2. GO DLTA/............
3. GO/TO, .
(a) 1 and 2 (b) 2 and 3
(c) 1 and 3 (d) 1, 2 and 3
Ans. (c)
IES 1995 IES2011

In APT language, the cutter motion in incremental Trajectoryofarobotmean:
coordinate mode is addressed as (a)Pathtracedbytheendeffectors
(a) GO/TO/..... (b)KinematicsofRobot
(b) GO/TO..... ( )
(c)Robotjoints
j
(c) GO DLTA/.... (d)Robotprogramming
(d) GO FWD/... Ans.(a)
Ans. (c)
Page 54 of 70
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Set-2
IES2010 IES 2006

Consider the following statements: Which one of the following is the third basic
Good dynamic performance is usually difficult to achieve component of robots besides power supply and
in robots which contain a rotary base because control (memory) console?
1. Position, speed and acceleration of the other joints cause
(a) Software (b) Coaxial cable
variations in the reflected torque and moment of inertia.
2. The moment of inertia reflected at the base depends upon the (c)
( ) Mechanical
M h i l unit
it arm (d) Microcomputer
Mi t
weight of the object being carried.
3. The moment of inertia reflected at the base also depends upon Ans. (c)
the distance between the base axis and the manipulated object.
Which of the above statements is/are correct?
(a) 1, 2 and 3 (b) 2 and 3 only
(c) 1 only (d) 1 and 3 only Ans. (b)
IES 2000 IES 2006

Consider the following characteristics of a robot: Which item best describes a CAM technology?
1. The tip of the robot arm moves from one point to (a) Geometric modeling (b) Documentation
another with its inbetween path not being defined.
(c) Drafting (d) Numerical control
2. It can be used for drilling holes at difference points in a
workpiece.
workpiece
3. It can be used for V butt joint welding between two
Ans. (d)
points.
4. The memory capacity required for its control unit is low.
Which of these are the characteristics associated with a point
to point robot?
(a) 1 and 2 (b) 1, 3 and 4
(c) 1, 2 and 4 (d) 2, 3 and 4 Ans. (c)
IES 1996 IES 2006

Whichofthefollowingpairsarecorrectlymatched? Flexible manufacturing allows for:
1. CNCmachinePostprocessor (a) Tool design and production
2. Machiningcentre.Toolmagazine (b) Automated design
3. DNC.FMS (c) Quick and inexpensive product change
(a) 1,2and3 (b) 1and2 (d) Quality control
(c) 1and3 (d)2and3
Ans. (c)
Ans.(a)
Page 55 of 70
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Set-2
IES 2004
Consider the following characteristics:
1. Single machine tool
2. Manual materials handling system
3. Computer control
4. Random sequencing of parts to machines
Which of the above characteristics are associated with
flexible manufacturing system?
(a) 1, 2 and 3 (b) 1 and 2
(c) 3 and 4 (d) 2, 3 and 4
Ans. (a)
Page 56 of 70
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Set-2
GATE 2001
Allowance in limits and fits refers to
(a) Maximum clearance between shaft and hole
(b) Minimum clearance between shaft and hole
(c) Difference between maximum and minimum size of
Limit,Tolerance&Fits
Limit Tolerance&Fits hole
(d) Difference between maximum and minimum size of
shaft
Ans. (b)
BySKMondal
GATE 1998 GATE 2010

In the specification of dimensions and fits,
0.009
(a) Allowance is equal to bilateral tolerance A shaft has a dimension,350.025
(b) Allowance is equal to unilateral tolerance The respective values of fundamental deviation and
(c) Allowance is independent of tolerance tolerance are
(d) Allowance is equal to the difference between (a) 0.025, 0.008 (b) 0.025,0.016
maximum and minimum dimension specified by the (c) 0.009, 0.008 (d) 0.009,0.016
tolerance.
Ans. (c)
Ans.(d)
GATE 1992 GATE 2004

TwoshaftsAandBhavetheirdiametersspecifiedas In an interchangeable assembly, shafts of size
+0.040 +0.020
100 0.1mmand0.1 0.0001mmrespectively. 0.0100
25.000 mm mate with holes of size 25.0000.000 mm.
Whichofthefollowingstatementsis/aretrue? The maximum possible clearance in the assembly
(a) ToleranceinthedimensionisgreaterinshaftA will be
(b) Therelativeerrorinthedimensionisgreaterinshaft ( ) 10 microns
(a) i
A (b) 20 microns
(c) ToleranceinthedimensionisgreaterinshaftB (c) 30 microns
(d) Therelativeerrorinthedimensionissameforshaft (d) 60 microns
AandshaftB Ans. (c)
Ans.(a)
Page 57 of 70
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Set-2
GATE 2007 0 .0 5 0
IES 2005
A hole is specified as 4 0 mm. The mating
0 .0 0 0 The tolerance specified by the designer for the
shaft has a clearance fit with minimum clearance of diameter of a shaft is 20.00 0.025 mm. The shafts
0.01 mm. The tolerance on the shaft is 0.04 mm. The produced by three different machines A, B and C
maximum clearance in mm between the hole and have mean diameters of 1999 mm, 2000 mm and
20.01 mm respectively, with same standard
the shaft is deviation.
d i ti What
Wh t will
ill be
b the
th percentage
t rejection
j ti for
f
(a) 0.04 the shafts produced by machines A, B and C?
(b) 0.05 (a) Same for the machines A, Band C since the standard
(c) 0.10 deviation is same for the three machines
(d) 0.11 (b) Least for machine A
(c) Least for machine B
Ans. (c)
(d) Least for machine C Ans. (c)
IES2011 GATE 2005

Interference fit joints are provided for: In order to have interference fit, it is essential that
(a) Assembling bush bearing in housing the lower limit of the shaft should be
(b) Mounting heavy duty gears on shafts (a) Greater than the upper limit of the hole
((c)) Mounting
gp pulleyy on shafts (b) Lesser than the upper limit of the hole
(d) Assembly of flywheels on shafts (c) Greater than the lower limit of the hole
Ans. (a) (d) Lesser than the lower limit of the hole
Ans. (a)
GATE2011 IES 2007

+0.015
A hole is of dimension 9 +0
mm. The
+0.010
p
corresponding g shaft is of dimension 9 +0.001 mm.
The resulting assembly has
(a) loose running fit
(b) close running fit
(c) transition fit
(d) interference fit Ans.(a)
Ans. (c)
Page 58 of 70
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Set-2
IES 2006 IES 2009

Which of the following is an interference fit? Consider the following joints:
(a) Push fit 1. Railway carriage wheel and axle
(b) Running fit 2. IC engine cylinder and liner
(c) Sliding fit Which of the above joints is/are the result(s) of
(d) Shrink fit interference fit?
Ans. (d) (a) 1 only
(b) 2 only
(c) Neither 1 nor 2
(d) Both 1 and 2
Ans. (d)
IES 2008 IES 2004

Consider the following statements: Consider the following fits:
1. The amount of interference needed to create a tight 1. I.C. engine cylinder and piston
joint varies with diameter of the shaft. 2. Ball bearing outer race and housing
2. An interference fit creates no stress state in the 3. Ball bearing inner race and shaft
shaft.
h ft Which of the above fits are based on the interference
3. The stress state in the hub is similar to a thick system?
walled cylinder with internal pressure. (a) 1 and 2
Which of the statements given above are correct? (b) 2 and 3
(a) 1, 2 and 3 (b) 1 and 2 only (c) 1 and 3
(c) 2 and 3 only (d) 1 and 3 only (d) 1, 2 and 3 Ans. (b)
Ans. (d)
IES 2003 IES 2005

Match ListI (Phenomenon) with ListII (Significant Assertion (A): Hole basis system is generally
Parameters/Phenomenon) and select the correct
answer using the codes given below the Lists: preferred to shaft basis system in tolerance design
ListI ListII for getting the required fits.
(Phenomenon) (Significant Reason (R): Hole has to be given a larger tolerance
/
Parameters/Phenomenon) ) band than the mating shaft.shaft
A. Interference fit 1. Viscosity index
B. Cyclic loading 2. Interference (a) Both A and R are individually true and R is the
C. Gear meshing 3. Notch sensitivity correct explanation of A
D. Lubricating of bearings 4. Induced compressive (b) Both A and R are individually true but R is not the
stress [ Ans. (b)] correct explanation of A
(a) 3 4 1 2 (b) 4 3 2 1 (c) A is true but R is false
(c) 3 4 2 1 (d) 4 3 1 2 (d) A is false but R is true [Ans. (c)]
Page 59 of 70
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Set-2
IES2006Conventional IES 2008

Find the limit sizes, tolerances and allowances for a Consider the following statements:
100 mm diameter shaft and hole pair designated by A nomenclature 50 H8/p8 denotes that
F8h10. Also specify the type of fit that the above pair 1. Hole diameter is 50 mm.
belongs to. Given: 100 mm diameter lies in the
diameter step range of 80 120 mm. The fundamental
80120 2. It is a shaft base system.
deviation for shaft designation f is 5.5 D0.41 3. 8 indicates fundamental deviation.
Which of the statements given above is/are correct?
The values of standard tolerances for grades of IT 8 (a) 1, 2 and 3
and IT 10 are 25i and 64i respectively. (b) 1 and 2 only
Also, indicate the limits and tolerance on a diagram. (c) 1 and 3 only
[15Marks] (d) 3 only [Ans. (None)]
IES 2002 GATE 2009

In the tolerance specification 25 D 6, the letter D What are the upper and lower limits of the shaft
represents represented by 60 f8?
Use the following data:
(a) Grade of tolerance
Diameter 60 lies in the diameter step of 5080 mm.
(b) Upper deviation Fundamental tolerance unit,
(c) Lower deviation i, in m= 0.45 D1/3 + 0.001D, where D is the
(d) Type of fit [Ans. (c)] representative size in mm; [Ans. (a)]
Tolerance value for lT8 = 25i.
Fundamental deviation for 'f shaft = 5.5D0.41
(a) Lower limit = 59.924 mm, Upper Limit = 59.970 mm
(b) Lower limit = 59.954 mm, Upper Limit = 60.000 mm
(c) Lower limit = 59.970 mm, Upper Limit = 60.016 mm
(d) Lower limit = 60.000 mm, Upper Limit = 60.046 mm
GATE 2000 GATE 1996

A fit is specified as 25H8/e8. The tolerance value for The fit on a holeshaft system is specified as H7
a nominal diameter of 25 mm in IT8 is 33 microns s6.The type of fit is
and fundamental deviation for the shaft is 40 (a) Clearance fit
microns. The maximum clearance of the fit in (b) Running fit (sliding fit)
microns is
(c) Push fit (transition fit)
(a) 7
(d) Force fit (interference fit)
(b) 7
[Ans. (d)]
(c) 73
(d) 106
[Ans. (d)]
Page 60 of 70
4
9/30/2011
Set-2
GATE 2003 GATE 2003

The dimensional limits on a shaft of 25h7 are
(a) 25.000, 25.021 mm
(b) 25.000, 24.979 mm
(c) 25.000, 25.007 mm
(d) 25.000, 24.993 mm
[Ans. (b)]
[Ans.(b)]
GATE 1997 IES 2000

Three blocks B1 , B2 and B3 are Which one of the following tolerances set on inner
to be inserted in a channel of diameter and outer diameter respectively of headed
width S maintaining a
minimum gap of width T = jig bush for press fit is correct?
0.125 mm, as shown in Figure. (a) G7 h 6 (b) F7 n6
For P = 18.
18 75 0.08;
0 08; ( ) H 7h
(c) h6 (d) F7j6
F j6
Q = 25.00 0.12; [Ans. (b)]
R = 28.125 0.1 and
S = 72.35 + X, (where all
dimensions are in mm), the
tolerance X is
(a) +0.38 (b) 0.38 (c)+0.05 (d)0.05
[Ans.(d)]
GATE 2004 GATE 1995

GO and NOGO plug gages are to be designed for a Checking the diameter of a hole using GONOGO
0.05
hole 200.01 mm. Gage tolerances can be taken as 10% gauges is an, example of inspection by
of the hole tolerance. Following ISO system of gage ..(variables/attributes)
design, sizes of GO and NOGO gage will be The above statement is
respectively ( ) Variables
(a) V i bl
(a) 20.010 mm and 20.050 mm (b) Attributes
(b) 20.014 mm and 20.046 mm (c) Cant say
(c) 20.006 mm and 20.054 mm (d) Insufficient data [Ans. (b)]
(d) 20.014 mm and 20.054 mm [Ans. (b)]
Page 61 of 70
5
9/30/2011
Set-2
GATE 2006
A ring gauge is used to measure
(a) Outside diameter but not roundness
(b) Roundness but not outside diameter
(c) Both outside diameter and roundness
(d) Only external threads
[Ans. (c)]
Page 62 of 70
6
9/30/2011
Set-2
GATE 2008 S1
A displacement sensor (a dial indicator) measures the
lateral displacement of a mandrel mounted on the taper
hole inside a drill spindle. The mandrel axis is an
extension of the drill spindle taper hole axis and the
MeasurementofLines&Surfaces protruding portion of the mandrel surface is perfectly
cylindrical. Measurements are taken with the sensor
placed at two positions P and Q as shown in the figure.
The readings are recorded as Rx = maximum deflection
minus minimum deflection, corresponding to sensor
position at X, over one rotation.
BySKMondal
GATE 2008contdfromS1 IES 2006

If Rp= RQ>0, which one of the The M and Esystem in metrology are related to
following would be consistent with the
observation? measurement of:
(A) The drill spindle rotational axis is (a) Screw threads (b) Flatness
coincident with the drill spindle taper
hole axis (c) Angularity (d) Surface finish
(B) The drill spindle rotational axis [Ans. (d)]
intersects the drill spindle taper hole
axis at point P
(C) The drill spindle rotational axis is
parallel to the drill spindle taper hole
axis
(D) The drill spindle rotational axis
intersects the drill spindle taper hole
axis at point Q [Ans. (c)]
IES 2007 IES 2008

What is the dominant direction of the tool marks or What term is used to designate the direction of the
scratches in a surface texture having a directional predominant surface pattern produced by
quality, called? machining operation?
(a) Primary texture (b) Secondary texture (a) Roughness (b) Lay
(c)
( ) Lay
L (d) Flaw
Fl ( ) Waviness
(c) W i (d) Cut
C t off
ff
[Ans. (c)] [Ans. (b)]
Page 63 of 70
1
9/30/2011
Set-2
IES2010 IES 2008

Match List I with List II and select the correct answer
using the code given below the lists:
List I List II
(Symbols for direction of lay) (Surface texture)
[Ans.(b)]
[Ans.(b)]
A B C D A B C D
(a) 4 2 1 3 (b) 3 2 1 4
(c) 4 1 2 3 (d) 3 1 2 4
GATE 1997 GATE 2003

List I List II Two slip gauges of 10 mm width measuring 1.000 mm
(A) Surface profilometer 1. Calibration and 1.002 mm are kept side by side in contact with each
(B) Light Section Microscope 2. Form tester other lengthwise. An optical flat is kept resting on the
(C) Microkater 3. Film thickness slip gauges as shown in the figure. Monochromatic light
measurement of wavelength 0.0058928 mm is used in the inspection.
(D) Interferometer 4. Centre line average The total number of straight fringes that can be observed
5. Comparator [Ans. (b)] on both slip gauges is
6. Surface lay measurement (a)2 (b)6
Codes:A B C D A B C D (c)8 (d)13
(a) 4 1 2 3 (b) 4 3 5 1
(c) 4 2 1 3 (d) 3 1 2 4 [Ans.(a)]
Page 64 of 70
2
9/30/2011
Set-2
GATE 1998
Auto collimator is used to check
(a) Roughness
(b) Flatness
(c) Angle
MiscellaneousofMetrology (d) Automobile balance.
[Ans. (c)]
BySKMondal
IES 1998 GATE 1992

Match ListI with ListII and select the correct answer using the Match the instruments with the physical quantities they
codes given below the lists:
measure:
ListI ListII
(Measuring Device) (Parameter Measured) Instrument Measurement
A. Diffraction grating 1. Small angular deviations on long (A) Pilottube (1) R.P.M. of a shaft
flat surfaces
B.
B Optical flat 2.
2 Online measurement of moving
(B) McLeod Gauge
g (2) Displacement
p
parts (C) Planimeter (3) Flow velocity
C. Auto collimators 3. Measurement of gear pitch (D) LVDT (4) Vacuum
D. Laser scan micrometer 4. Surface texture using interferometer
5. Measurement of very small (5) Surface finish
displacements (6) Area [Ans. (b)]
Code: A B C D A B C D
(a) 5 4 2 1 (b) 3 5 1 2
(c) 3 5 4 1 (d) 5 4 1 2 (a) 4 1 2 3 (b) 3 4 6 2
(c) 4 2 1 3 (d) 3 1 2 4
[Ans.(d)]
GATE 2004 GATE 1995

Match the following List I List II
Feature to be inspected Instrument (Measuring instruments) (Application)
P Pitch and Angle errors of screw thread 1. Auto Collimator (A) Talysurf 1. Tslots
Q Flatness error of a surface plate 2. Optical Interferometer (B) Telescopic gauge 2. Flatness
R Alignment
Ali error off a machine
hi slide
lid way 3. Dividing
Di idi Head
H d
(C) Transfer callipers 3. Internal diameter
and Dial Gauge
(D) Autocollimator 4. Roughness
S Profile of a cam 4. Spirit Level
5. Sine bar [Ans. (b)] Codes:A B C D A B C D
6. Tool maker's Microscope (a) 4 1 2 3 (b) 4 3 1 2
(a) P6 Q2 R4 S6 (b) P5 Q2 R1 S6 (c) 4 2 1 3 (d) 3 1 2 4
(c) P6 Q4 R1 S3 (d) P1 Q4 R4 S2 [Ans. (b)]
Page 65 of 70
1
9/30/2011
Set-2
GATE 2010 IAS 2001

A taper hole is inspected using a CMM, with a probe For transporting materials over long distances with
of 2 mm diameter. At a height, Z = 10 mm from the greater speed, which one of the following devices is
bottom, 5 points are touched and a diameter of most suitable?
circle (not compensated for probe size) is obtained (a) Motor vehicle
as 20 mm. Similarly, a 40 mm diameter is obtained (b) Industrial
I d t i l vehicle
hi l
at a height Z = 40 mm. the smaller diameter (in mm)
of hole at Z = 0 is (c) Belt conveyor
(a) 13.334 (d) Roller conveyor
(b) 15.334 [Ans. (b)]
(c) 15.442
(d) 15.542
[Ans.(a)]
IAS 1995 IAS 1994

For moving materials is varying paths, the material Consider the following situations
handling equipments that is not suitable is 1. Loads are uniform
(a) Crane 2. Materials move relatively continuously
(b) Conveyor 3. Movement rate is variable
(c) Truck 4. Routes do not vary
(d) Hand trolley For material transportation, conveyors are used when
the prevailing conditions include
[Ans. (b)] (a) 1, 3, and 4 (b) 1, 2, and 3
(c) 1, 2, and 4 (d) 2, 3 and 4
[Ans. (c)]
IES 2001 IAS 1998

During manufacture of cement, the handling of Match ListI (Material handling equipments) with List
II (Application in a foundry) and select the correct
limestone is done by answer using the codes given below the lists:
(a) Belt conveyor List I ListII
(b) Bucket conveyor A. Belt conveyor 1. To move the compacted mould
boxes
(c) Overhead crane B. Monorail conveyor 2. To move the prepared
(d) Forklift crane moulding sand
C. Apron conveyor 3. To move the rough casting to
[Ans. (b)] the fettling station
D. Roller conveyor 4. To transfer he molten metal
ladle [Ans. (d)]
(a) 1 2 3 4 (b) 2 1 3 4
(c) 2 4 1 3 (d) 2 4 3 1
Page 66 of 70
2
9/30/2011
Set-2
IAS 1997 IES 1994

Elevators are used for moving materials Killed steels
(a) Along fixed and horizontal paths (a) Have minimum impurity level
(b) In a vertical direction along a fixed path (b) Have almost zero percentage of phosphorus and
(c) Along a horizontal path to any distance sulphur
(d) In both the planes (c) Are produced by LD process
(d) Are free from oxygen
[Ans. (b)] [Ans. (d)]
IES 1992 IES 1999

Dye penetration method is generally used to locate Transfer machines can be defined as
(a) Core defects (a) Material processing machines
(b) Surface defects (b) Material handling machines
(c) Superficial defects (c) Material processing and material handling machines
(d) Temporary defects (d) Component feeders for automatic assembly
[Ans. (b)] [Ans. (c)]
Ch13:Metrology
IES 2000 Q.No Option Q.No Option
AscrewthreadspecifiedbyM20x2.5CasperBIS 1 C 10 D
threadsystemmeans
2 C 11 D
(a) Metricthreadof20mmnominaldiameterand2.5
mmpitchhavingcoarsetolerance 3 A 12 B
(b) Metricthreadof20mmrootdiameterand2.5mm
M t i th d f tdi t d 4 C 13 B
pitchhavingcoarsetolerance 5 C 14 D
(c) Metricthreadoffineclasshaving20mmroot 6 B 15 B
diameterand2.5mmpitch
7 C 16 C
(d) Metricthreadof20mmshankdiameterand2.5mm
threaddepthwithcoarsetolerance [Ans.(c)] 8 B 17 B
9 B
Page 67 of 70
3
9/30/2011
Set-2
GATE 1999
Choosethecorrectstatement:
(a) Afixtureisusedtoguidethetoolaswellastolocate
andclamptheworkpiece
JigsandFixtures (b) AJigisusedtoguidethetoolaswellastolocateand

clamptheworkpiece
l th k i
(c) JigsarcusedonCNCmachinestolocateandclamp
theworkpieceandalsotoguidethetool
(d) Noarrangementtoguidethetoolisprovidedinajig.
[Ans.(b)]
BySKMondal
IES 2007 GATE 2005

According to the principle of location in jigs and When 321 principle is used to support and locate a
fixtures, how many degrees of freedom are to be three dimensional workpiece during machining,
eliminated to have a body fixed in space? the number of degrees of freedom that are
(a) 3 restricted is
(b) 4 (a) 7
(c) 5 (b) 8
(d) 6 (c) 9
[Ans. (d)] (d) 10
[Ans. (c)]
GATE 2001 IES2011

321 method of location in a jig or fixture would Inthe321principleoffixture3referstonumberof
collectively restrict the workpiece in n degrees of :
freedom, where the value of n is (a)Setupspossible
(a) 6 (b)Clampsrequired
(b) 8 (c)Positionsonprimaryface
(c) 9 (d)Locatingpositions
(d) 12 [Ans.(d)]
[Ans. (c)]
Page 68 of 70
1
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Set-2
IES 1998,1999 IES 2009

Diamond pin location is used in a fixture because A lever having two precisely drilled holes, one
(a) It does not wear out smaller than the other, has to be located in a fixture
using hardened and ground plugs for further
(b) It takes care of any variation in centre distance machining in relation to the holes. Select the
between two holes correct method of locating the lever from the given
(c) It is easy to clamp the part on diamond pins alternatives.
lt ti
(d) It is easy to manufacture (a) Using two hardened and ground plugs, the smaller
one having flats machined on each side
[Ans. (b)]
(b) Using two hardened and ground plugs
(c) Using one hardened and ground plug and one V
block
(d) Using two Vblocks [Ans. (a)]
IES 1995 IES 2005

Match List I (An Element of Jigs and Fixtures) with List
If the diameter of the hole is subject to considerable II (Associating System) and select the correct answer
variation, then for locating in jigs and fixtures, the using the code given below the Lists:
List I List II
pressure type of locator used is A Bush 1. Milling fixture
B. Setting block 2. Turning fixture
(a) Conical locator
C. Diamond pin 3. Radial location
(b) Cylindrical locator D. Vblock 4. Cylindrical location
5. Drill jigs [Ans. (c)]
(c) Diamond pin locator Codes:A B C D A B C D
(a) 5 4 3 1 (b) 3 1 2 4
(d) Vee locator [Ans. (a)]
(c) 5 1 3 4 (d) 3 4 2 1
IES 2000 IES 1995

Match List I (Components used in jigs and fixtures) with List II Match List I with List Ii and select the correct answer using the
(Their functions) and select the correct answer using the codes codes given below the lists:
given below the Lists: List I (Task) List II (Recommendation)
List I List II A. Three components in a straight 1. Clamp with a
floating pad.
A. Jack pin 1. To guide the drill bit during machining
line should worked in one loading
B. Vlocator 2. For easyy removal of the work p piece from the
jig or fixture after the machining operation B. Unloading of clamp element from jig is essential
is over 2. Quick action nut
C. Bushes 3. To locate the circular or C. Clamping of rough surfaces 3. Cam clamp
semicircular objects in a jig or fixture D. Need for heavy clamping force 4. Equalising clamp
D. Ejectors 4. To locate work piece whose dimensions are 5. Strap clamp
Code: A B C D A B C D
subject to variations [Ans. (b)] (a) 5 2 3 4 (b) 4 2 1 5
Code: A B C D A B C D (c) 1 4 2 3 (d) 4 1 5 3
(a) 3 4 1 2 (b) 4 3 1 2 [Ans. (d)]
(c) 3 4 2 1 (d) 4 3 2 1
Page 69 of 70
2
9/30/2011
Set-2
IES 2005 IES 1996

Which one of the following is the most significant Assertion (A): A workpiece with rough unmachined
property to be considered in the selection of surface can be located in a jig or fixture on three
material for the manufacture of locating pins and supporting points.
drill jig buses used in jigs and fixtures? Reason (R): Indexing is made accurate by
(a) Wearresistance (b) Elasticity supporting on three points.
points
(c) Shearstrength (d) Tensilestrength (a) Both A and R are individually true and R is the
[Ans.(a)] correct explanation of A
(d) A is false but R is true [Ans. (c)]
IES 1996 IES 1993

Consider the following statements: The floating position of the holding fixture in a
The cutter setting block in a milling fixture rotary transfer device is used to
1. Sets the cutting tool with respect of two of its surfaces. (a) Improve the accuracy of location
2. Limits the total travel required by the cutter during (b) Reduce the tendency to over index
machining. (c) Reduce the cycle time
3. Takes location from the location scheme of the (d) Improve upon the acceleration and deceleration
component. characteristics
(a) 1,2 and 3 are correct (b) 1 and 2 are correct [Ans. (d)]
(c) 2 and 3 are correct (d) 1 and 3 are correct
[Ans. (d)]
JigsandFixtures
Q. No Option Q. No Option
1 C 6 C
2 D 7 D
3 B 8 D
4 B 9 C
5 C
Page 70 of 70
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IES 1992 Example

IES2010 IES 2003

IAS 2002 IES 2004

IES 2006 Example

IES 1992 IAS 2002

IES 1998 IES2010

GATE 2002 GATE 2008

IES 2004 GATE1994

IES 1996 IES 2009

IES 1999 IES 2009

IES 1998 IES 1993

Ans. (d) Ans. (b)

IES 1992 IES 2006

IES 1997 IES 2009

IES 2007 IES 1995

IES 1996 IES 2003

IES 2009 IES 2001

Ans. (b) Ans. (b)

IES 1995 IES 1992

IES 2007 IAS 2007

IAS 2002 IAS 1996

IAS 2004 IAS 2001

IAS 1995 IAS 1994

IAS 1998 IAS 1998

IES2011 IAS 2000

Drilling IES 2004

IES 2003 GATE 1996

IES 1997 IES 1992

GATE 1997 IES 1992

Example GATE 2002

GATE 2004 IES 2002

IES 1994 IES 2009

IES 2002 IAS 1999

IAS 1994 IES 1999

IES 1999 IES 1998

IES 1994 IES 1993

IES 1998 IAS 1999

IAS 2003 IES 1992

IES 1993 IES 1994

IES 1992 IES 2000

IES 1996 IES 1995

JWM2010 IES 2007

IES 1993 IES 1993,2001

IES 2001 IAS 2004

Ans. (c) Ans. (a)

IES 2005 IES 2002

GATE 1995 GATE 1993

IES 2003 IES 2009

IES 1994 IES 1992

IES 2007 GATE 1992

Ans. (b) Ans. down, down

IES 1997 IES 1995

IES 2005 IES 1993

IES2010 IES 2002

IES 2004 IES 2006

IES 2009 IES 1995

Ans. (d) Ans. (b)

IES 2004 IES 2000

IES 1999 IES 2002

IES 2004 IAS 2001

IAS 1998 IAS 2001

IAS 2000 IAS 1994