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Q.1
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Chillsareusedinholeplatescanbeused
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achievedirectionalsolidification

reducepossibilityofblowholes

reducethefreezingtime

increasethesmoothnessofcastsurface
Solution
Achillisusedtopromotesolidificationinaspecificportionofcasting
mould.Itcanbestrategicallyplacedtohelpindirectional
solidification.

Correct

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Ingasweldingofmildsteelusinganoxyacetyleneflame,thetotal
amountofacetyleneconsumedwas10litre.Theoxygen
consumptionfromthecylinderis
5litre
10litre
15litre
20litre
Solution
Theneutralflameiscommonlyusedforweldingofmildsteel.In
neutralflame,theratioofoxygentoacetyleneisoneacetylene
mixtureisone.So,oxygenconsumption=10litre

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Time(Secs)

24

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Q.3
Finegrainsizeduringsolidificationofmetalisachievedby
Lowernucleationrate
Highernucleationratewithlowergrowthrate
Highernucleationratewithhighergrowthrate
Lowergrowthrate
Solution
Sol.(b)

InCorrect

YourAns

CorrectAns

Time(Secs)

49

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Temperingprocessisusedinsteelstoachieve
Lowerhardnessbytransformingaustenitetopearlite
Lowerhardnessbytransformingmartensitetopearlite
Highhardnessbytransformingaustenitetomartensite
Highhardnessbytransformingmartensitetopearlite
Solution
Sol.(b)

Correct

YourAns

CorrectAns

Time(Secs)

19

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Q.5
Cuttingforceisreducedifrakeangleispositivebecausepositive
rakeangle
Makesthetoolstronger
Increasesshearangle
Makesthecuttingedgesharper
Increasesthechipthickness
Solution
Sol.(c)

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Time(Secs)

25

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Inthefigureshownbelow.Theclearanceangle(indegree)is
______

Solution
Clearanceangle=90(60+20)

Correct

YourAns

10

CorrectAns

10

Time(Secs)

16

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Q.7
Asteelworkpieceisturnedonalatheat60m/mincuttingspeed,
0.8mm/revfeedand1.2mmdepthofcut.Themetalremovalrate
(inmm3/min)is______.
Solution
MRR=TdV
=0.81.260103
MRR=57600mm3/min

Correct

YourAns

57600

CorrectAns

57500|57700

Time(Secs)

44

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Flankwearmainlyoccurson
Relieffaceoftool
Rakeface
Noseoftool
Cuttingedge
Solution
Sol.(a)

InCorrect

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Time(Secs)

12

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Q.9
InTaylortoollifeequationVTn=C,n=0.5andC=300.The
percentageincreaseintoollifewhenthecuttingspeedisreduced
by50%is
400%
300%
200%
100%
Solution

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Time(Secs)

11

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Q.10

Solution
Tolerance=0.05(0.05)=0.1mm
Tolerance=1000microns

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100

Time(Secs)

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Q.11
Ashaperhavinglengthof200mmhas30numberofdouble
strokesperminutewithratioofcuttingtimetotimeofreturnequal
to3/2.Thecuttingspeedis_____m/min.
Solution

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9.9|10.1

Time(Secs)

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Dropforgingisusedtoproduce
smallcomponents
largecomponents
identicalcomponentsinlargenumber
mediumsizecomponents
Solution
Sol.(a)

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Q.13
Austeniteisthe
BCCformofiron
FCCformofiron
Pureironwithverylowcarbon
Intermetalliccompoundironcarbide
Solution
Sol.(b)

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Thecuttingvelocityinm/sec.,forturningaworkpieceordiameter
100mmatthespindlespeedof480RPMis
1.26
2.51
48
151
Solution

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Q.15
Maximumcarboncontentinsteelsisupto
0.2%
6.67%
2%
1.2%
Solution
Sol.(c)

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Dropforgingisusedtoproduce
smallcomponents
largecomponents
identicalcomponentsinlargenumbers
mediumsizecomponents
Solution
Dropingforgingisusedtoproducelargenumberofidentical
components.Inthisprocess,ashapeddieisused,withonehalf
beingattachedtothehammerandtheotherhalftotheaxvil.Itisa
massproductiontechnique.

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Q.17
A150mmlong,12mmdiameter304stainlesssteelrodisbeing
reducedindiameterto11.5mmbyturningonalathe.Thespindle
rotatesatN=400rpmandthetoolistravellingatanaxialspeedof
200mm/min.Thetimetakenforcuttiingisgivenby
30s
36s
1minute
45s
Solution

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Theamountofoffsetoftailstockforturningtaperonfulllengthofa
job300mmlongwhichistohaveitstwodiametersat50mmand
38mmultimatelyis
6mm
12mm
25mm
44mm
Solution

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Q.19
Amillingcutterof70mmdiameterwith12teethisoperatingata
cuttingspeedof22m/minandafeedof0.05mm/tooth.Thefeed
perminuteis
110mm/min
35mm/min
6mm/min
60mm/min
Solution

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Q.20
Blowholesinsandcastingarecausedby
poorcastingdesign
facultymouldflask
lowerstrengthofthesolidifiedmetal
highermoistureinthemouldingsand
Solution
Sol.(d)

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Q.21
Hottearissandcastingiscausedby
Pouringhotmetalintothemould
Nonuniformthicknessofwallsjoininginacasting
Poorrefractorypropertyofthemouldingsand.
Lowthermalconductivityofthemouldingsand.
Solution
Sol.(b)

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Inanorthogonalturningofmildsteel.Thecuttingvelocity,feedand
depthofcutwere120m/min,0.25mm/rev,and2mmrespectively.
Whenthecuttingforceof800Nwasapplied.Thespecificenergy
consumptionfortheturningoperation(inJ/mm3)is_____.
Solution

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CorrectAns

1.6

Time(Secs)

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Q.23
InASA,thetoolnomenclatureis88561023mm,thentheside
cuttingedgeangleforthetool(indegree)is_________.
Solution
Sol.[2]

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Amoltenliquidmetalhavingsphericalshapewith2mmradius
takes8secondstosolidify.Thesamemoltenmetaldropwith
doubletheradiuswilltake______secondstosolidify.
Solution

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32

Time(Secs)

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Q.25
Mainadvantageofusingshellmouldingis
Anycomplexshapecanbeobtained
Costofthepatternislow
Verythinsectionscanbereadilymade
Anysizeofcastingcanbeobtained.
Solution
Sol.(c)

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Arcblowinmanualmetalarcweldingiscausedby
TheuseofACweldingwithnonconsumableelectrodes
TheuseofDCweldingwithconsumableelectrodes
TheuseofACweldingwithconsumableelectrodes
noneoftheabove
Solution
Sol.(b)

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Q.27
Inawiredrawingoperation,diameterofsteelwireisreducedfrom
8mmto7mm.Themeanflowstressofmaterialis250MPa.The
idealforcerequiredfordrawing(inkN)is_____.
Solution

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2.55|2.59

Time(Secs)

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Q.28

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Ablankofwidth15mmwidthand25mmlengthiscutfroma2mm
thickstrip.,iftheultimateshearstrengthofmetalstripis300MPa.
Theblankingforcerequiredis_____kN.
Solution

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CorrectAns

48

Time(Secs)

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Q.29
Acupof120mmdiameterand50mmheightistobedrawnusing
ablank.Therequiredblankdiameterwillbe_____mm.
Solution

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195|197

Time(Secs)

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Nitridingprocessisusedtoincreasesurfacehardnessfor
Lowcarbonsteels
Alloysteels
Mediumcarbonsteels
Highcarbonsteels
Solution
Sol.(b)

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Q.31
Millerindicesforthehatchedplaneinthebelowunitcellwillbe

(100)
(110)
(111)
(101)
Solution

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Q.32
Duringanorthogonalcuttingwithrakeangleof12,thechip
thicknessratiowasfoundtobe0.4andwidthofcutanduncutchip
thicknesswere2mmand0.5mrespectively.Iftheyieldshear
stressofworkmaterialis250MPa,theshearforceontotalis
_____N.
Solution

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630|645

Time(Secs)

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Solution
Sol.(d)

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Aholeistobepunchedina15mmthickplatehavingultimate
shearstrengthof2.5N/mm2.Iftheallowablecrushingstressinthe
punchis6N/mm2,thediameterofthesmallestholewhichcanbe
punchedisequalto
15mm
20mm
25mm
30mm
Solution

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Q.35
Ametallicsheetisreducedfromaninitialthicknessof10mmtoa
finalthicknessof7mminasinglepassrollingwithrollersof
diameter300mm.Theangleofbit(indegrees)wouldbe_____.
Solution

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8.0|8.2

Time(Secs)

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Q.36
Thecastingshowninfigureistobemadeusingsteelwhichhasa
shrinkageallowanceof21mm/m.Assumingshrinkageallowance
only,thedimensionofthepatternwillbe.(Alldimensionsinmm).

Solution

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Asprueistobedesignedforacastingtofeedthemoltenmetalat
arateof10kg/sec.Thedensityofliquidmetalis8000kg/m3and
theheightofpouringbasinandheightofsprueare6cmand9cm
respectively.Assumingspruetobeconicalshape,thediameterof
sprueattopendi.e.largerdiameterwillbe_____cm.
Solution

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3.7|3.9

Time(Secs)

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Q.38
Asprueistobedesignedforacastingtofeedthemoltenmetalat
arateof10kg/sec.Thedensityofliquidmetalis8000kg/m3and
theheightofpouringbasinandheightofsprueare6cmand9cm
respectively.Assumingspruetobeconicalshape.Thediameterof
sprueatlowerendwillbe_____cm.
Solution

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2.95|3.15

Time(Secs)

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Q.39
Astripofmetalofdimension40mm25mm100mmisreduced
to10mm100mm100mmbetweentwoflatdiesinaforging
process.Ifthecoefficientoffrictionis0.25,thelengthfromthe
centreofstripalonglengthuptowhichstrickingexistis
43mm
38.2mm
36.1mm
35.7mm
Solution

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Q.40
Averagenumberofatomsandcoordinationnumberforacrystal
havingHCPstructurearerespectively
4and12
6and6
6and12
6and9
Solution
Sol.(c)

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Q.41
Duringanorthogonalturningprocesswithatooldesignatedas:7
?668201mm,thetangentialandthrustcuttingforce
were1200Nand500Nrespectively.Thesiderakeangel(in
degrees)is_____.
Solution

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18.4|18.9

Time(Secs)

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Duringanorthogonalturningprocesswithatooldesignatedas:7
?668201mm,thetangentialandthrustcuttingforce
were1200Nand500Nrespectively.Thecoefficientoffrictionat
therakefaceis_____
Solution

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0.89|0.93

Time(Secs)

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Solution
Sol.(a)

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AssumingastraightlineVIcharacteristicsforadcweldings
generator,shortcircuitcurrentas400Aandopencircuitvoltage
as100V,whichoneofthefollowingisthecorrectvoltageand
currentsettingformaximumarcpower?
400Aand100V
200Aand100V
400Aand50V
200Aand50V
Solution

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Inanorthogonalcutting,rakeangleofthetoolis20andfriction
angleis25.5.UsingMerchantsshearanglerelationship,the
valueofshearanglewillbe
39.5
42.25
47.75
50.5
Solution

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Solution
Sol.(c)

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Q.47
Whichofthefollowingisclearancefit

Solution
Sol.(c)

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Q.48
Whichoneofthefollowingprocessingsequenceswillgivethebest
accuracyaswellassurfacefinish?
Drilling,reamingandgrinding
Drilling,boringandgrinding
Drilling,reamingandlapping
Drilling,reamingandelectroplating
Solution
Drilling,reamingandgrindingaremachiningprocessesusedfor
givingfinalshapetothecomponent,whereaslappingand
electroplatingaresurfacefinishingprocessesusedtoprovideda
goodsurfacefinishtothemachinecomponent.
Reamingisasizingoperationthatremovesasmallamountofmetal
fromaholealreadydrilled.

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MatchListI(Unconventionalmachiningprocess)withListII
(Typicalapplication)andselectthecorrectanswer:

Solution
EDMisusedforshappingalloyingsteelandtungstencarbidedies,
usedformoudling,forgin,extension,wiredrawingorsuitablemould
cavities,presstoolsandtogivenanyintricateshapeorprofile.
ECMisusedformachinarydifficulttomachinematerialsand
complexshapedparts.Lasercanmakeholesinawidevarietyof
materialssuchasplastics,ceramicsandmanymetalsandalloys.
USMcanbeusedfordrillingcircularornoncircularholesinvery
hardmaterials.

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Anglebetweendirectionshavingmillerindices[100]and[110]is
0
30
45
90
Solution

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Inanorthogonalmetalcuttingprocess.Thechipthicknessratio
wasfoundtobe0.35,therakeanglewas10andthechipflow
velocityas2.5m/s.Ifthemeanthicknessofprimaryshearzoneis
20microns,theshearstrainrate(ins1)is_____104.
Solution

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35.0|36.5

Time(Secs)

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Thetimerequiredtoturnamildsteelrodfrom5cmdiameterto4.9
cmalengthof10cmifthecuttingspeedis30m/minandfeedis
0.25mm/revolutionis
1.04min
1.96min
2.00min
2.09min
Solution

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Q.53
Ahollowcastinghastobeproducedbyacylindricalcoreof120
mmdiameterand180mmheight.Thedensityofliquidmetalis
11300kg/m3andthedensityofcorematerialis1300kg/m3.The
upwardliftingforceonthecorewillbe_____N.
Solution

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CorrectAns

198|201

Time(Secs)

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Q.54

Solution
Sol.(a)

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Twosteelsheetsof1mmthicknessareresistanceweldedinalap
jointwithacurrentof800amp.for0.2seconds.Theeffective
resistanceofthejointis120microohm.Thejointcanbe
consideredascylinderofdiameter10mmand1.5mmheight.The
heatrequiredtomeltsteelis0.1J/mm3.
Heatlosttosurroundingis_____Joules.

Solution

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3.5|3.7

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Q.56
Asincebarhasalengthof250mm.Eachrollerhasadiameterof
25mm.Duringtaperanglemeasurementofacomponent,the
heightfromthesurfaceplatetothecentreofrollerwasmeasured
as100mm.Thetaperangle(indegrees)is_____
Solution

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20.0|21.0

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Q.57
ThearclengthvoltagecharacteristicofaD.C.arcisgivenbythe
equation,V=24+4L,whereVisarcvoltageinvoltsandLisarc
lengthinmm.Thestaticvoltamperecharacteristicofthepower
sourceisapproximatedbyastraightlinewithanoloadvoltageof
90voltsandshortcircuitcurrentof600Amp.Theoptimumarc
lengthformaximumpoweris
1.31mm
2.62mm
5.25mm
6.00mm
Solution

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Q.58

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130.07mm
130.11mm
12.990.11mm
12.990.07mm
Solution
Sol.(c)

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Q.59
4.5mmthicksheetisrolledwith250mmdiameterrollstoreduce
thicknesswithoutanychangeitswidth.Thefrictioncoefficientat
theworkrollinterfaceis0.1.Theminimumpossiblethicknessof
sheetthatcanbeproducedinasinglepassis_____mm.
Solution

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3.20|3.30

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Q.60

Solution

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Q.61
Agatingratioof1:3:4isusedtodesignagatingsystem.Ifthe
sprueareais3mm2,thenthegateareawillbe_____mm2.
Solution

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12

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Q.62

Solution

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3.8|3.9

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Q.63

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Inablankingoperationtoproducesteelwasher,themaximum
punchloadusedis
2105N.Theplatethicknessis4mmandpercentagepenetration
is25.Theworkdoneduringthisshearingoperationis
200J
400J
600J
800J
Solution

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Q.64
Aholeof40mmdiameterand50mmdepthistobedrilledinmild
steelcomponent.Thecuttingspeedcanbetakenas65m/minand
thefeedrateas0.25mm/rev.Assuminglipangleofdrillis118.
Themachiningtime___minutes.
Solution

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0.5

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Q.65
InIndustrialengineering,thestandardtimeisequalto

Normaltime+Allowances
ObservedTime+Allowances

ObservedtimeRatingfactor
NormaltimeRatingfactor
Solution
Normaltime=observedtimeRatingfactor
Standardtime=Normaltime+Allowances

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Q.66
ASIMOchartshouldbeusedwith
processcharts
flowdiagrams
manmachineoperationcharts
therbligs
Solution
Sol.(d)

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