Unit 1

Q1. Derive relationship in angles specified in ASA and ORS nomenclature.

Q2. Write short notes on

(i) Oblique cutting

(ii) Measurement of chip tool interface temperature
(iii) Thermal aspects of metal cutting

Q3. Draw the geometry of a single point cutting tool and discuss effect of various angles on cutting.

Q4. What do you understand by orthogonal and oblique cutting? Explain in detail.

Q5. Define back rake angle, depth of cut and cutting speed, depth of cut and cutting speed. How do they
affect the cutting force on orthogonal cutting?

Q6. Name different parameters at the tool signature given below

15, 10, 5, 6, 8, 7, 1

Q7. In orthogonal cutting turning of 50 mm diameter mild steel bar on a lathe the following data are
obtained-

Rake angle=15°, chip thickness=0.3 mm, feed=0.2 mm/rev, cutting force=180 kg, feed force=60 kg

Calculate the shear plane angle, coefficient of friction, cutting power and the chip flow velocity.

Q8. Draw merchant’s circle, and establish the relationship between forces.

Q9. Classify types of chips, explain them in detail.

Q10. In a single point cutting tool used for turning, the geometry as per ASA is

Back rake= 8°, side rake= 4°, side cutting edge angle= 15°

Find the values of inclination angle and rake angle in ORS of tool nomenclature.
 Unit 2
Q1. What are the effects of the following variables on tool life?

(i) Cutting speed, feed and depth of cut

(ii) Tool material and tool geometry

Q2. A carbide cutting tool tested for 3 hours while machining M.S at 40 m/min. if a similar tool is used at
30% higher speed to machine M.S. calculate the value of cutting speed if the tool is to machine for 2
hours. Assume n=0.27 in tool life equation VTn=C.

Q3. Describe adhesion, diffusion, and electro chemical mechanism of tool wear.

Q4. Write short notes on

(i) Cutting fluids

(ii) Adhesion and fatigue wear

Q5. When machining steel with H.S.S tool, the following equation was found to fit the too life data fairly
well:

VT0.13 f0.77 d0.37=28.38, where V= cutting speed in m/min, T= tool life in min, F=feed in mm/rev, d= depth
of cut in mm. what is expected tool life at cutting speed=30 m/min. feed=0.30 mm/rev, depth of cut=2.5
mm. also calculate the effect of 20% increase in each of the above parameters.

(i) Made separately

(ii) Made in all of them simultaneously

Q6. Discuss the different mechanism of tool wear.

Q7. Differentiate between plain tungsten carbide and coated carbide tools.

Q8. What are the various relationships for determining tool life and what influences can be from each.

Q9. Define the term machinability. What are the various ways of evaluating machinability?

Q10. Write short note on

(i) Economics of machining

(ii) Cutting fluids
(iii) Cutting tool materials
 Unit 3
Q1. Differentiate between automatic and semi automatic lathe machine

Q2. Write short note on swiss type automatic machine.

Q3. Write short note on multiple automatic machine.

Q4. What do you understand by numeric controlled machine tools? What are their advantage and
disadvantage over conventional machine tools?

Q5. Write short notes on

(i) Honing
(ii) Lapping
(iii) Buffing
(iv) Burnishing

Q6. Differentiate between grinding and finishing processes.

Q7 write of short notes on

(i) Balancing of grinding wheel

(ii) Mounting of grinding wheel

Q8. Explain the selection criteria of grinding wheel.

Q9. Explain different types of abrasive materials used in grinding wheel.

Q10. Classify the grinding machines. Explain about bonding materials for grinding wheel?
 Unit 4
Q1. With the help of suitable sketch explain the principle of gear shaping.

Q2. Describe the bevel gear generating method.

Q3. Write short note on gear finishing methods.

Q4. With the help of suitable sketch explain the principle of gear hobbing. What are the advantage and
disadvantages?

Q5. How do you proceed to mill a gear by formed disc cutter? What are its advantages?

Q6. Briefly explain different materials used in gear manufacturing process.

Q7. Describe the base tangent method in detail.

Q8. Explain ear cutting by milling in detail.

Q9. Discuss the main differences between hobbing and milling process for the manufacture of gear.

Q10. Discuss the comparison between different manufacturing processes.

Unit5
Q1. Explain your understanding about human factors in machine equipment safety.

Q2. Write short note on human factor in machine equipment safety.

Q3. What do you mean by industrial safety? Explain its importance in current scenario.

Q4. Explain different methods to reduce noise.

Q5. Briefly explain the precautions to be taken by operators for safe working on different machine tools.

Q6. Explain about high velocity forming process. Discuss its advantages.

Q7. Explain about electro hydraulic forming process in detail. Discuss its advantages.

Q8. Explain about magnetic pulse forming process in detail. Discuss its advantages.

Q9. Classify the hydro forming processes. And explain them

Q10. Write short notes on

(i) Application of electro hydraulic forming

(ii) Explosive forming
(iii) Process variables in explosive forming
(iv) High velocity forming