Production Question and Answer Set 1 - baixardoc

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Theory Theory of of MetalMetal CuttingCutting

By By SS KK MondalMondal

CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

Q. Q. WhWhy y eveven a en a batbattetery operry operatateded

ppeenncciil l sshhaarrppeenneer r ccaannnnoot t bbee

accepted as a machine tool?accepted as a machine tool?

yy ns.ns. n n sp sp te te o o aav nv ng g a a ot ot er er ma ma or or eaeatutureres s oo

machmachineine tooltools, s, thethe sharsharpenerpener isis of of lowlow valuevalue..


IESIES‐‐20012001For cutting of brass with singleFor cutting of brass with single‐‐point cutting toolpoint cutting toolonon aa lathe, tlathe, tool shool should haould haveve

(a) (a) NegNegativativee rakerake angleangle

(b) (b) PosPositivitivee rakerake angleangle

(c) (c) ZerZeroo rakerake angleangle

(d(d) ) ZeZeroro sideside relief relief angleangle

Ans. Ans. (c)(c)


IESIES‐‐19951995

SingleSingle pointpoint threadthread cuttingcutting tooltool shouldshould ideally ideally have:have:

a)a) ZeroZero rakerake

b)b) PositivePositive rakerake

c)c) NegativeNegative rakerake

d)d) NormalNormal rakerake

Ans. Ans. (a)(a)


GATEGATE‐‐1995;1995; 20082008CuttingCutting powerpower consumptionconsumption inin turningturning cancan bebe

significantly significantly reducedreduced by by

(a)(a) IncreasingIncreasing rakerake angleangle of of thethe tooltool

(b)(b) IncreasingIncreasing thethe cuttingcutting anglesangles of of thethe tooltool

(c)(c) Widening Widening thethe nosenose radiusradius of of thethe tooltool

(d)(d) IncreasingIncreasing thethe clearanceclearance angleangle

Ans. Ans. (a)(a)


IESIES‐‐19931993 Assertion Assertion (A): (A): For a For a negative rake negative rake tool, tool, the the specificspecificcutticutting ng prespressure is sure is smallesmaller r than for than for a a positpositive rakeive raketool undtool underer otherotherwisewise identiidenticalcal condiconditionstions..

Reason (R): The shear strain undergone by the chipReason (R): The shear strain undergone by the chip..

(a(a) ) BoBoth A th A anand d R R arare e inindidivividudualally truly true e anand d R R is theis thecorcorrecrectt explexplanatianationon of A of A

(b) (b) Both A and R Both A and R are indare individuividually trally true but R isue but R is notnot thethecorcorrecrectt explexplanatianationon of A of A

(c) (c) A is trA is true but R is ue but R is falsefalse

(d) (d) A is falsA is false but R is true but R is truee Ans. (d)Ans. (d)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

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IESIES – 2005 – 2005 Assertion Assertion (A): (A): Carbide Carbide tips tips are are generally generally givengivennegatnegativeive rakrakee angleangle..

Reason (R): Carbide tips are made from very hardReason (R): Carbide tips are made from very hardmaterials.materials.

a a oot t aan n aarre e n v n v uua a y y ttrruue e aan n s s t t eecorcorrectrect explexplanatianationon of A of A

(b) (b) Both A and R Both A and R are indare individuaividually true bully true but R ist R is notnot thethecorcorrectrect explexplanatianationon of A of A

(c) (c) A is trA is true but ue but R is falsR is falsee

(d) (d) A is false A is false but R is tbut R is truerue

Ans. (b) Ans. (b)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

IESIES – 2002 – 2002 Assertion Assertion (A): (A): Negative rake Negative rake is is usually usually provided provided ononcarbidcarbidee tipped tools.tipped tools.

RReeaassoon n ((RR)): : CCaarrbbiide de ttoooolls s aarre e wweeakaker er iinncompression.compression.

a a oot t aan n aarre e n v n v uua a y y ttrruue e aan n s s t t eecorcorrecrectt explaexplanationationn of A of A

(b) (b) Both A and R Both A and R are indare individuividually trally true but R isue but R is notnot thethecorcorrecrectt explaexplanationationn of A of A

(c) (c) A is trA is true but R is ue but R is falsefalse

(d) (d) A is falsA is false but R is truee but R is true

Ans. (c) Ans. (c)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

IESIES 20112011 Which Which one one of of the the following following statement statement is is NOT NOT correccorrectt with with referereference to nce to the the purposes and purposes and effects of effects of rake anglerake angleof aof a cuttcutting tooling tool??

(a) (a) TToo guideguide thethe chip chip flowflow diredirectioctionn

(b) To reduce the friction between the tool flanks and(b) To reduce the friction between the tool flanks andthe machined surfacethe machined surface

(c) T(c) Too add keenneadd keennessss oror sharpsharpness to theness to the cuttcutting edging edges.es.

(d) T(d) To provideo provide betterbetter thermal efficiencythermal efficiency..

Ans. (b) Ans. (b)


IASIAS – 1994 – 1994ConsiderConsider thethe followingfollowing characteristicscharacteristics

11. . TThhee cuttingcutting edgeedge isis normalnormal toto thethe cuttingcutting velocity velocity..

22. . TThhee cuttingcutting forcesforces occuroccur inin twotwo directionsdirections only.only.

33. . TThhee cuttingcutting edgeedge isis wider wider thanthan thethe depthdepth of of cut.cut.

TheThe characteristicscharacteristics applicableapplicable toto orthogonalorthogonal cuttingcutting would would includeinclude

(a(a) ) 11 andand 22 ((bb) ) 11 andand 33

(c(c) ) 22 andand 3 3 ((dd) 1) 1,, 22 andand 33

Ans. Ans. (d)(d)


IESIES‐‐20062006

Which Which of of thethe followingfollowing isis aa singlesingle pointpoint cuttingcuttingtool?tool?

(a) (a) HackHacksawsaw bladeblade

b b MiMillllinin cuttercutter

(c) (c) GrindiGrindingng wheel wheel

(d) (d) PartPartinging tooltool

Ans. Ans. (d)(d)


IESIES‐‐19951995The angle between the face and the flank of theThe angle between the face and the flank of thesinsinglegle poipointnt cutcuttintingg tootool isl is knoknownwn asas

a)a) RakeRake anglanglee

b)b) ClearanceClearance angleangle

c)c) LipLip anglanglee

d)d) PoinPointt anglanglee

Ans. (c) Ans. (c)



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IESIES‐‐20062006 Assertion Assertion (A): (A): For For drilling drilling cast cast iron, iron, the the tool tool isisprprovovidided ed wiwith th a a popoinint t ananglgle e smsmalaller ler ththan an ththatatrequirequired red forfor aa ductilductilee matermaterial.ial.

ReaReason son (R)(R): : SmaSmalleller r poipoint nt angangle le resresultults s in in lowlowererra ra ee anang eg e..

(a) (a) BotBoth h A A and R and R arare e indindiviividuadually true and R lly true and R is theis thecorcorrecrectt explexplanatianationon of A 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 thecorcorrecrectt explexplanatianationon of A 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(d) A is false but R is true Ans. (c)Ans. (c)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

IESIES‐‐20022002ConsiConsiderder thethe follofollowingwing statestatementsments::

The strength of a single point cutting tool dependsThe strength of a single point cutting tool dependsuponupon

1. Rak1. Rakee angleangle

2. Clearanc2. Clearancee angleangle

3. Lip 3. Lip angleangle

Which Which of theseof these statementsstatements areare correct?correct?

((aa) 1 ) 1 aannd d 3 3 ((bb) ) 2 2 aannd d 33

((cc) ) 1 1 aannd d 2 2 ((dd) ) 11, , 2 2 aannd d 33

Ans. (d) Ans. (d)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

IESIES‐‐20092009Consider the following statements with respectConsider the following statements with respecttoto thethe effeffectectss of of a a larlargege nosnosee radradiusius onon thethe tootool:l:

1. 1. ItIt detdeterierioraoratessurfatessurfacece finifinish.sh.

2. 2. ItIt incincreareasesses thethe pospossibsibiliilityty of of chachatttterer..

3. 3. ItIt improvesimproves tool life.tool life.

Which Which of theof the aboveabove statementsstatements is/areis/are correct?correct?

((aa) ) 2 2 oonnlly y ((bb) ) 3 3 oonnlly y

(c(c) ) 2 2 aand nd 3 3 oonlnly y ((d) d) 1, 1, 2 2 aand nd 33

Ans. (c) Ans. (c)


IESIES‐‐19951995ConConsidsider er the the folfollowlowing ing stastatemtementents s aboabout ut nosnoseeradiusradius

1. It impro1. It improvesves tool lifetool life

2. It2. It redureduces theces the cuttcutting forcing forcee

3. It improv3. It improveses thethe surfasurface finish.ce finish.

SeleSelectct thethe corcorrecrectt answanswerer using using thethe codecodess givgiven en belobelow:w:

((aa) ) 1 1 aannd d 2 2 ((bb) ) 2 2 aannd d 33

((cc) ) 1 1 aannd d 3 3 ((dd) ) 11, , 2 2 aannd d 33

Ans. (c) Ans. (c)


IESIES‐‐19941994Tool geometry of a single point cutting tool is specified by Tool geometry of a single point cutting tool is specified by thethe followfollowing elements:ing elements:

1. 1. BaBackrackrakeankeangglele

2. 2. SiSiderakderakee ananglglee

3. 3. EndcuttEndcutting ing edgedgee anganglele

4. 4. SidSidee cutcuttinting g edgedgee anganglele

5. 5. SidSidee rerelielief f anganglele

6. End relief angle6. End relief angle

7. 7. NoNosese raradidiusus

The The cocorrrrect ect sesequequencnce e of of thethese se totool ol eleelemements nts useused d foforrcorrecorrectlyctly specifying the tool geometry isspecifying the tool geometry is

(a(a) ) 1 ,1 ,2,2,3,3,66,5,5,4,4,7 ,7 (b(b) ) 11,2,2,6,6,5,5,3,3,4,4,7,7

((cc) 1) 1,,22,,55,,66,,33,,44,,7 7 ((dd) ) 11, , 22, , 66, , 33, , 55, , 44,,7 7 A A ns. (b)ns. (b)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

IESIES‐‐20092009

TheThe follofollowing wing tool tool signatsignatureure isis specifispecified ed forfor aa singlsinglee‐‐

pointpoint cuttcutting toing tool inol in AmeriAmericancan systsystem:em:

10, 12, 8, 6, 15, 20, 310, 12, 8, 6, 15, 20, 3

What What doesdoes thethe angle 12 represent?angle 12 represent?

(a) (a) SidSidee cutcuttintingg‐‐edgedgee angleangle

(b) Side(b) Side rarakeke anganglele

(c) (c) Back Back rakrakee anglanglee

(d) Side(d) Side cleaclearancrancee anglanglee

Ans. (b) Ans. (b)



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IESIES‐‐19931993In ASA System, if the tool nomenclature is 8In ASA System, if the tool nomenclature is 8 ‐‐66‐‐55‐‐55‐‐1010‐‐1515‐‐22‐‐mm, mm, thethenn thethe siderakesiderake anganglele wilwill bel be

((aa) ) 55° ° ((bb) ) 66° ° ((cc) ) 88° ° ((dd) ) 1100°°

Ans. (b) Ans. (b)


GATEGATE‐‐19951995

PlainPlain millingmilling of of mildmild steelsteel plateplate producesproduces

(a)(a) IrregularIrregular shapedshaped discontinuousdiscontinuous chipschips

(b)(b) RegularRegular shapedshaped discontinuousdiscontinuous chipchip

cc on on nuonuousus c c psps w w ouou uu upup e e gege

(d)(d) Joined Joined chipschips

Ans. Ans. (b)(b)


IESIES 20072007DuringDuring machining,machining, excessexcess metalmetal isis removedremoved inin thethe formformof of chipchip asas inin thethe casecase of of turningturning onon aa lathe.lathe. Which Which of of thethefollowingfollowing areare correct?correct?

ContinuousContinuous ribbonribbon likelike chipchip isis formedformed when when turningturning

11. . AAtt aa hi herhi her cuttincuttin s s eeeedd

22. . AAtt aa lowerlower cuttingcutting speedspeed

3. 3. A A brittlebrittle materialmaterial

4. 4. A A ductileductile materialmaterial

SelectSelect thethe correctcorrect answeranswer usingusing thethe codecode givengiven below:below:

((a) a) 11 andand 3 3 ((bb) ) 11 andand 44

(c) 2(c) 2 andand 3 3 ((dd) 2) 2 andand 44

Ans. Ans. (b)(b) CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

GATEGATE‐‐20022002 A A builtbuilt‐‐upup‐‐edgeedge isis formedformed while while machiningmachining

(a)(a) DuctileDuctile materialsmaterials atat highhigh speedspeed

(b)(b) DuctileDuctile materialsmaterials atat lowlow speedspeed

(c)(c) BrittleBrittle materialsmaterials atat highhigh speedspeed

(d)(d) BrittleBrittle materialsmaterials atat lowlow speedspeed

Ans. Ans. (b)(b)


IESIES‐‐19971997 Assertion (A) Assertion (A) : : For high For high speed speed turning turning of of cast cast iron pistons,iron pistons,

carbcarbideide tool bitsaretool bitsare proprovidevided withd with chipbreakerchipbreakers.s.Reason (R): High speed turning may produce long, ribbonReason (R): High speed turning may produce long, ribbontype continuous chips which must be broken into smalltype continuous chips which must be broken into smalllengths which otherwise would be difficult to handle andlengths which otherwise would be difficult to handle andmayprovemayprove hazahazardordous.us.a a BBoot t aan n R aR arre e iin in ivvi ui ua y a y t rt ruue ae an n R iR is t e s t e ccoorrrreecctt

explanaexplanationtion of A of A (b) (b) Both A and R arBoth A and R are indie individualvidually true bly true but R isut R is notnot the correctthe correctexplanaexplanationtion of A of A (c) (c) A iA is trus true but e but R is R is falsefalse(d) (d) A is A is false false but R but R is tis truerue

Ans. (d) Ans. (d)


GATEGATE‐‐20012001

During orthogonal cutting of mild steel withDuring orthogonal cutting of mild steel witha 10° rake angle tool, the chip thickness ratioa 10° rake angle tool, the chip thickness ratio

was was obtained obtained as as 0.4. 0.4. The The shear shear angle angle (in(inde de reerees s evaevaluatluated ed frofromm thisthis datdata a isis

(a)(a) 6.536.53 (b)(b) 20.2220.22

(c)(c) 22.9422.94 (d)(d) 50.0050.00

Ans. Ans. (c)(c)



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GATEGATE 20112011 A A single single – – point point cutting cutting tool tool with with 12° 12° rake rake angle angle isisused to machine a steel work – piece. The depth of used to machine a steel work – piece. The depth of cucut, t, i.i.e. e. ununcucut t ththicicknknesess s is is 0.0.81 81 mmmm. . ThThe e chchipipthickness under orthogonal machining condition isthickness under orthogonal machining condition is. . ..

(a) 22°(a) 22°

(b) 26°(b) 26°

(c) 56°(c) 56°

(d) 76°(d) 76°

Ans. (b) Ans. (b)


IESIES‐‐19941994The The fofollllowowing ing parparamameteters ers detdetermermine ine thethemodelmodel of cof continuous ontinuous chipchip formatformation:ion:

1. 1. TTrurue e fefeeded

2. 2. CuCuttttin in veveloclocitit

3. 3. ChiChip p thithickncknessess

4. 4. RakRakee angangle le of tof thehe cutcuttinting tg tool.ool.

The parameters which govern the value of shearThe parameters which govern the value of shearangleangle woulwould included include

(a(a) 1,) 1,2 2 anand d 3 3 (b(b) ) 1,1,3 3 anand d 44

(c(c) 1) 1,2 ,2 anand d 4 4 (d(d) ) 2,2,3 3 anand d 44 Ans. (Ans. (bb))Co Co mpimpiledledBy:By: SS KK MondalMondal MadeMade Easy Easy

Minimum shear strain in orthogonal turningMinimum shear strain in orthogonal turning with with aa cutting toolcutting tool of zeroof zero rakerake angleangle isis

(a) 0.0(a) 0.0

b b 0.0.

GATEGATE ‐‐20092009

(c) 1.0(c) 1.0

(d) 2.0(d) 2.0

Ans. (d) Ans. (d)


In a machining operation chip thickness ratioIn a machining operation chip thickness ratiois 0.3 and the back rake angle of the tool is 10°.is 0.3 and the back rake angle of the tool is 10°.

What What isis thethe valuevalue of theof the shearshear strain?strain?

a a 00. . 1 1 b b 00..11

IESIES 20042004

((cc) ) 33..000 0 ((dd) ) 33..3344

Ans. (d) Ans. (d)


GATEGATE‐‐20072007In orthogonal turning of a low carbon steel barIn orthogonal turning of a low carbon steel barof of diadiametmeter er 150 150 mm mm witwith h uncuncoatoated ed carcarbidbideetool, the cutting velocity is 90 m/min. The feedtool, the cutting velocity is 90 m/min. The feedis 0.24 mm/rev and the depth of cut is 2 mm.is 0.24 mm/rev and the depth of cut is 2 mm.

. . ..orthogonal rake angle is zero and the principalorthogonal rake angle is zero and the principalcutcuttinting g edgedge e angangle is le is 90°90°, , the shear anglthe shear angle e isisdegdegreeree isis

((aa) ) 2200.5.56 6 ((bb) ) 2266..5566

((cc) ) 3300.5.56 6 ((dd) ) 3366..5566

Ans. (b) Ans. (b)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

GATEGATE‐‐20082008InIn aa singlesingle pointpoint turningturning tool,tool, thethe sideside rakerake angleangleandand orthogonalorthogonal rakerake angleangle areare equal.equal. isis thetheprincipalprincipal cuttingcutting edgeedge angleangle andand itsits rangerange isis

.. TheThe chipchip flowsflows inin thethe orthogonalorthogonal plane.plane.

φφ

0 0 9090o o ooφ φ ≤ ≤ ≤≤

(a) 0(a) 000 (b) 45(b) 4500

(c) 60(c) 6000 (d) 90(d) 9000

Ans. Ans. (d)(d)



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IESIES‐‐20042004ConsiderConsider thethe followingfollowing statementsstatements with with respectrespect totothethe relief relief angleangle of of cuttingcutting tool:tool:

1.1. ThisThis affectsaffects thethe directiondirection of of chipchip flowflow

2.2. ThisThis reducesreduces excessiveexcessive frictionfriction betweenbetween thethe tooltoolanan wor wor p ecep ece

3. 3. ThisThis affectsaffects tooltool lifelife

4.4. ThisThis allowsallows betterbetter accessaccess of of coolantcoolant toto thethe tooltool work work piecepiece interfaceinterface

Which Which of of thethe statementsstatements givengiven aboveabove areare correct?correct?

(a) 1(a) 1 andand 2 2 ((bb) 2) 2 andand 33

(c(c) ) 22 andand 4 4 ((dd) 3) 3 andand 44 Ans. Ans. (b)(b)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

IESIES‐‐20062006ConsiderConsider thethe followingfollowing statements:statements:

1. 1. A A largelarge rakerake angleangle meansmeans lowerlower strengthstrength of of thethecuttingcutting edge.edge.

2. 2. CuCuttttiningg torquetorque decreasesdecreases with with rakerake angle.angle.

Which Which of of thethe statementsstatements givengiven aboveabove is/areis/are correct?correct?

(a) (a) OnlOnly y 1 1 ((bb) ) OOnnlly y 22

(c) (c) BotBothh 11 andand 2 2 ((dd) N) Neeiitthheerr 11 nornor 22

Ans. Ans. ((cc))


IESIES‐‐20042004Match.Match. ListList II with with ListList IIII andand selectselect thethe correctcorrect answeranswerusingusing thethe codescodes givengiven belowbelow thethe Lists:Lists:

ListList I I LLiisstt IIII

A. A. PlanPlan approachapproach aanngglle e 11. . TTooooll faceface

BB. . RaRakekeaanngglle e 22. . TTooooll flankflank

C. C. CleCleararancancee aanngglle e 33. . TTooooll faceface andand flankflank

DD. . WWedgedgee aanngglle e 44. . CCuuttttiinngg edgeedge

55. . TTooooll nosenose

A A BB C C DD A A B B C C DD

(a)(a) 11 44 22 55 (b)(b) 44 1 1 33 22(c)(c) 44 11 22 33 (d)(d) 11 44 33 55

Ans. Ans. (c)(c)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

IESIES‐‐20032003ThThe e ananglgle e of of ininclclininatatioion n of of ththe e rarake ke faface ce wiwiththrerespspecect t to to ththe e totool ol babase se memeasasurured ed in in a a plplananeeperpendicular to the base and parallel to the widthperpendicular to the base and parallel to the widthof theof the tootool isl is calcalledled

(b) Side(b) Side rarakeke anganglele

(c) (c) SideSide cuttcutting ing edgedgee angleangle

(d) End(d) End cutcuttintingg edgedgee anganglele

Ans. (b) Ans. (b)


IESIES‐‐20042004The rake angle of a cutting tool is 15°, shearThe rake angle of a cutting tool is 15°, shearangangle le 4545° ° and and cutcuttinting g vevelolocitcity y 35 35 m/m/mimin.n.

What What is is the the velocity velocity of of chip chip along along the the tooltoolface?face?

(a(a) ) 2828.5 .5 m/m/mimin n (b(b) ) 2727.3 .3 m/m/miminn

(c(c) ) 2525.3 .3 m/m/mimin n (d(d) ) 2323.5 .5 m/m/miminn

Ans. (a) Ans. (a)


[IES[IES‐‐2008]2008]ConsiderConsider thethe followingfollowing statements:statements:

InIn anan orthogonalorthogonal cuttingcutting thethe cuttingcutting ratioratio isis foundfound toto bebe00∙∙75.75. TheThe cuttingcutting speedspeed isis 6060 m/minm/min andand depthdepth of of cutcut 22∙∙44mm.mm. Which Which of of thethe followingfollowing areare correct?correct?

11. . CChhiipp velocity velocity will will bebe 4545 m/min.m/min.

22. . CChhiipp velocity velocity will will bebe 8080 m/min.m/min.

3. 3 . CChhiipp thicknessthickness will will bebe 11∙∙88 mm.mm.

4. 4. ChChipipthicknessthickness will will bebe 33∙∙22 mm.mm.

SelectSelect thethe correctcorrect answeranswer usingusing thethe codecode givengiven below:below:

(a(a) ) 11 andand 3 3 ((bb) ) 11 andand 44

(c(c) ) 22 andand 3 3 ((dd) 2) 2 andand 44

Ans. Ans. (b)(b)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy


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IESIES‐‐20012001If If α α is is the the rarake ke angangle ole of the f the cutcuttinting tog tool, ol, is is thetheshear angle and V is the cutting velocity, then theshear angle and V is the cutting velocity, then the

velocity velocity of of chip chip sliding sliding along along the the shear shear plane plane isisgiven by given by

φ φ

((aa) ) ((bb))

((cc) ) ((dd))

Ans. ( Ans. (aa))

coscos

ccooss( ( ))

V V α α

φ φ α α −− ( ( ))sinsin

coscos −−

V V φ φ

φ φ α α

coscos

ssiinn( ( ))−−

V V α α

φ φ α α

sinsin

ssiinn( ( ))

V V α α

φ φ α α −−


IESIES‐‐20032003 An An orthogonal orthogonal cutting cutting operation operation is is beingbeingcarried out under the following conditions:carried out under the following conditions:cutting speed = 2 m/s, depth of cut = 0.5 mm,cutting speed = 2 m/s, depth of cut = 0.5 mm,chchip ip ththicicknknesess s = = 0.0.6 6 mmmm. . ThThen en ththe e chchipip

velocity is velocity is

(a(a) ) 2.2.0 0 m/m/s s (b(b) ) 2.2.4 4 m/m/ss

(c(c) ) 1.1.0 0 m/m/s s (d(d) ) 1.1.66 66 m/m/ss

Ans. (d) Ans. (d)


IASIAS‐‐19971997ConsiderConsider thethe followingfollowing machiningmachining conditions:conditions: BUEBUE will willformform inin

(a) (a) DuctDuctileile mamateteririalal. . (b(b) ) HiHighgh cuttingcutting speed.speed.

(c) (c) SmSmallall rakerake angle.angle. (d(d) ) SSmmalalll uncutuncut chipchip thickness.thickness.

Ans. Ans. (a)(a)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

IASIAS‐‐20032003InIn orthogonalorthogonal cutting,cutting, shearshear angleangle isis thethe angleangle betweenbetween

(a) (a) ShShearear planeplane andand thethe cuttingcutting velocity velocity

(b) (b) SheaShearr planeplane andand thethe rakerake planeplane

(c) (c) ShShearear planeplane andand thethe vertical vertical directiondirection

earear p anep ane anan t t ee rect onrect on oo e ongat one ongat on oo crysta scrysta s nnthethe chipchip

Ans. Ans. (a)(a)CompiledCompiled By:By: SS KK MondalMondal MadeMade Easy Easy

IASIAS‐‐20022002

Ans. Ans. (a)(a)


IASIAS‐‐20002000

Ans. Ans. (d)(d)



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IASIAS‐‐19981998The cutting velocity in m/sec, for turning a work pieceThe cutting velocity in m/sec, for turning a work pieceof diaof diametmeterer 100 mm100 mm atat thethe spispindlndlee spespeeded of 480 RPM isof 480 RPM is

((aa) 1) 1.2.26 6 ((bb) ) 22..5511

((cc) ) 448 8 ((dd) ) 115511

Ans. (b) Ans. (b)


IASIAS‐‐19951995In an orthogonal cutting, the depth of cut is halved andIn an orthogonal cutting, the depth of cut is halved andthe feed rate is double. If the chip thickness ratio isthe feed rate is double. If the chip thickness ratio isunaffunaffected with ected with the the changchanged ed cuttcutting ing condconditioitions, ns, thetheactualchipactualchip thickthicknessness will will bebe

aa) ) DDoouubblleed d bb) h) haallvveedd

(c(c) ) QuQuadadrurupplled ed ((d) d) UUncnchhananggeed.d.

Ans. ( Ans. (bb))




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FForce & orce & PPower in Metower in Met a l Ca l Cut tu t t inging

By By SS KK MondalMondalCompiledCompiled by:by: SS KK MondalMondal MadeMade Easy Easy

ESEESE‐‐20032003‐‐ ConventionalConventionalDuring turning a carbon steel rod of 160 mm diameter by aDuring turning a carbon steel rod of 160 mm diameter by acarbide tool of geometry; 0, 0, 10, 8, 15, 75, 0 (mm) at speed of carbide tool of geometry; 0, 0, 10, 8, 15, 75, 0 (mm) at speed of 400 rpm, feed of 0.32 mm/rev and 4.0 mm depth of cut, the400 rpm, feed of 0.32 mm/rev and 4.0 mm depth of cut, thefollowing observation were made.following observation were made.

TangTangential componentential component of theof the cutting forccutting force, Pe, Pzz = 1200 N= 1200 N

,, xx

ChipChip thicknthickness (afteress (after cut),cut),

FortheForthe abovabove machie machining cning conditionditionon deterdetermine thevaluesmine thevalues of of

(i) (i) FriFriction foction force, F and normrce, F and normal forcal force, N acting at the chip te, N acting at the chip tooloolinterface.interface.

(ii(ii) ) YiYield eld sheshears strenars strength of gth of the work the work mamaterteriaial l undunder er thithissmachining condition.machining condition.

(iii) (iii) Cutting poCutting powerwer consumption iconsumption in kWn kW..

= 8= 82727 ==

==22

0.8mm.0.8mm.α α

CompiledCompiled by:by: SS KK MondalMondal MadeMade Easy Easy

GATEGATE – 1995 – 1995 ‐‐ConventionalConventional While turning a C While turning a C‐‐15 steel rod of 160 mm diame15 steel rod of 160 mm diameterter atat 315 315 rpm, rpm, 2.5 2.5 mm mm depth depth of of cut cut and and feed feed of of 0.160.16mm/rev by a tool of geometry 0mm/rev by a tool of geometry 000, , 101000, , 8800, , 9900,15,1500, , 757500,,0(mm)0(mm), the, the follofollowing observwing observationswereationswere made.made.

TTangeangentialntial compcomponentonent of theof the cuttcutting foring forcece = 500 N= 500 N

Axial component Axial component of theof the cutting forcecutting force = 200 N= 200 N

ChiChipp thithickncknessess = 0.48 mm= 0.48 mm

Draw schematically the Merchant’s circle diagramDraw schematically the Merchant’s circle diagramfortheforthe cutcuttinting g forforce ince in thethe prepresensentt cascase.e.

Ans. F = 2 Ans. F = 2 99 11 , , NN = = 445757.6.67 7 NN, , FFnn = 3= 3 55 55.78 N, F.78 N, Fss = 40= 40 88.31 N.31 N

FricFrictiontion angle = 32angle = 32.49.49ooCompiledCompiled by:by: SS KK MondalMondal MadeMade Easy Easy

ESEESE ‐‐20002000 (Conventional)(Conventional)The following data from the orthogonal cutting testThe following data from the orthogonal cutting testis available. Rake angle = 10is available. Rake angle = 1000, chip thickness ratio =, chip thickness ratio =0.35, uncut chip thickness = 0.51, width of cut = 30.35, uncut chip thickness = 0.51, width of cut = 3mm, yield stresmm, yield stress s of of wowork materrk material = ial = 285 N/mm285 N/mm22,,meamean n frifrictiction on coco‐‐efefficficieient nt on on totool ol foforcrce e = = 0.6 0.6 ,,DetermineDetermine

(i) (i) CuCutttting ing forforce ce (F(Fcc))

(ii(ii) ) RadRadial ial forforce ce (F(Ftt))

(iii) (iii) NormNormal foral force ce (N) o(N) on toon tool andl and

(iv(iv) ) SheShearar forforcece on on the the totool ol (F(Fss ).).

Ans. F Ans. Fcc = 1597 N; F= 1597 N; Ftt = 678 N; F= 678 N; Fss = 1265 N; F = 944.95 N, N == 1265 N; F = 944.95 N, N =1453.8 N1453.8 N


ESEESE‐‐20052005 ConventionalConventional

MiMild ld ststeel eel is is bebeing ing macmachihined ned at at a a cutcuttintinggspeed of 200 m/min with a tool rake angle of speed of 200 m/min with a tool rake angle of 10. The width of 10. The width of cut and uncut thickness are 2cut and uncut thickness are 2mm and 0.2 mm res mm and 0.2 mm res ecectitivevel . l . If the avIf the averera a ee

value value of of coco‐‐efficient of friction between theefficient of friction between thetool and the chip is 0.5 and the sheartool and the chip is 0.5 and the shear stress of stress of thethe work matwork material is 400 N/mmerial is 400 N/mm22,,

DetermDetermine (ine (i) shi) shearear anglanglee and and [Ans[Ans. 36.. 36.77oo

(i(ii)Cuti)Cuttinting g anand d thrthrusust t cocompomponennent t of of thethemachinmachinee on forceon force. [Ans. F. [Ans. Fcc = 420 N, F= 420 N, Ftt = 125 N ]= 125 N ]


IASIAS‐‐20032003 MainMain ExaminationExaminationDuring turning process with 7During turning process with 7 ‐ ‐ ‐‐ 6 – 6 – 8 – 30 6 – 6 – 8 – 30 – 1 (mm)– 1 (mm)

ASA tool the ASA tool the undeformed chip thickness of undeformed chip thickness of 2.0 mm 2.0 mm andand width of cut of width of cut of 2.5 mm were used. The side rake angle of 2.5 mm were used. The side rake angle of the tool was a chosen that the machining operationthe tool was a chosen that the machining operation

..tangential cutting force and thrust force were 1177 N andtangential cutting force and thrust force were 1177 N and560 N respectively. Calculate:560 N respectively. Calculate:[30 marks][30 marks]

(i) (i) ThesideTheside rarakeke angangle le [A[Ansns. 1. 122oo ]]

(ii(ii) ) CoCo‐‐efficientefficient of frictionof friction at theat the rake rake face face [Ans. 0.8[Ans. 0.82]2]

(iii) The(iii) The dynadynamicmic sheashearr strestrengthngth of theof the wowork matrk materiaeriall

[Ans. 74.43 Mpa][Ans. 74.43 Mpa]CompiledCompiled by:by: SS KK MondalMondal MadeMade Easy Easy


7/13/20117/13/2011

22

GATEGATE‐‐20062006 CommonCommon DataData Questions(1)Questions(1)

InIn anan orthogonalorthogonal machiningmachining operation:operation:

UncutUncut thicknessthickness == 0.50.5 mmmm

CuttingCutting speedspeed == 2020 m/minm/min RakeRake angleangle == 15°15°

Width Width of of cutcut == mmmm ChiChi thicknessthickness == 0.0. mmmm

ThrustThrust forceforce == 200200 NN CuttingCutting forceforce == 12001200 NN

Assume Assume Merchant'sMerchant's theory.theory.

TheThe coefficientcoefficient of of frictionfriction atat thethe tooltool‐‐chipchip interfaceinterface isis(a)(a) 0.230.23 (b)(b) 0.460.46

(c)(c) 0.850.85 (d)(d) 0.950.95

Ans. Ans. (b)(b)CompiledCompiled by:by: SS KK MondalMondal MadeMade Easy Easy








TheThe percentagepercentageof of totaltotal energy energy dissipateddissipated duedue totofrictionfriction atat thethe tooltool‐‐chipchip interfaceinterface isis

(a)(a) 30%30% (b)(b) 42%42%

(c)(c) 58%58% (d)(d) 70%70% Ans.Ans. (a)(a)CompiledCompiled by:by: SS KK MondalMondal MadeMade Easy Easy








TheThe values values of of shearshear angleangle andand shearshear strain,strain,respectively,respectively, areare

(a)(a) 30.30.3°3° andand 1.981.98 (b)(b) 30.30.3°3° andand 4.234.23

(c)(c) 40.2° and40.2° and 2.972.97 (d)(d) 40.2° and40.2° and 1.651.65 Ans. Ans. (d)(d)CompiledCompiled by:by: SS KK MondalMondal MadeMade Easy Easy


A A cylinder cylinder is is turned turned on on a a lathe lathe with with orthogonaorthogonallmachmachining princining principle. Spindliple. Spindle rotate rotates at 200 es at 200 rpm. rpm. TheTheaxial feed rate is 0.25 mm per revolution. Depth of cut isaxial feed rate is 0.25 mm per revolution. Depth of cut is0.4 mm. The rake ang0.4 mm. The rake angle is 10°. le is 10°. In the analysis it is In the analysis it is foundfoundt t aatt t t ee s s eaearr anang g e e s s 227.7.7755

TheThe thicknessthickness of of thethe producedproduced chipchip isis

(a)(a) 0.5110.511 mmmm (b)(b) 0.5280.528 mmmm

(c)(c) 0.8180.818 mmm m ((dd)) 0.8460.846 mmmm

Ans. Ans. (a)(a)



A A cylinder cylinder is is turned turned on on a a lathe lathe with with orthogonaorthogonallmachmachining princining principle. Spindliple. Spindle rotate rotates at 200 es at 200 rpm. rpm. TheTheaxial feed rate is 0.25 mm per revolution. Depth of cut isaxial feed rate is 0.25 mm per revolution. Depth of cut is0.4 mm. The rake ang0.4 mm. The rake angle is 10°. le is 10°. In the analyIn the analysis it is foundsis it is foundt att es earang e s 27.75t att es earang e s 27.75

InIn thethe aboveabove problem,problem, thethe coefficientcoefficient of of frictionfriction atatthethe chipchip tooltool interfaceinterfaceobtainedobtained usingusing EarnestEarnest andandMerchantMerchant theory theory isis

(a)(a) 0.180.18 (b)(b) 0.360.36

(c)(c) 0.710.71 (d)(d) 0.9080.908

Ans. Ans. (d)(d)CompiledCompiled by:by: SS KK MondalMondal MadeMade Easy Easy

GATEGATE‐‐20082008 CommonCommon DataData QuestionQuestion (1)(1)

Orthogonal turning is performed on a cylindrical workOrthogonal turning is performed on a cylindrical workpiecpiece with e with shear streshear strength of ngth of 250 MPa. 250 MPa. The followiThe followingngconditions are used: cutting velocity is 180 m/min. feedconditions are used: cutting velocity is 180 m/min. feedis 0.20 mm/rev. depth of cut is 3 mm. chip thicknessis 0.20 mm/rev. depth of cut is 3 mm. chip thicknessrraat t o = o = 00..55. . e oe orrt ot oggoonna a rra e aa e anng g e e s 7 s 7 . . ppp p y y Merchant'Merchant'ss theory theory forfor analysis.analysis.

TheThe shearshear planeplane angleangle (in(in degree)degree) andand thethe shearshearforceforce respectively respectively areare

(a)(a) 52:52: 320320 N N ((bb)) 52:52: 400N400N

(c)(c) 28:28: 400N400N (d)(d) 28:320N28:320N

Ans. Ans. (d)(d)CompiledCompiled by:by: SS KK MondalMondal MadeMade Easy Easy


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