Professional Documents
Culture Documents
REFERENCES:
1. Richerd R Kibbe, John E. Neely, Roland O. Merges and Warren J.White “Machine Tool
Practices”, Prentice Hall of India, 1998
2. HMT, "Production Technology", Tata McGraw Hill, 1998.
3. Geofrey Boothroyd, "Fundamentals of Metal Machining and Machine Tools", Mc Graw
Hill,1984
4. Roy. A.Lindberg, “Process and Materials of Manufacture,” Fourth Edition, PHI/Pearson
Education 2006.
COURSE OUTCOMES:
To understand the basic concepts of metal cutting, different types of machine tools,
CO 403.1 tool materials, single point cutting tool geometry and cutting fluids used in
manufacturing
To understand the working principle of types of turning machine and its operations
CO 403.2
along with power and machining time estimation.
To understand working principles and applications of shaping, drilling, boring,
CO 403.3
milling and gear generating machines.
To enrich the knowledge of abrasive process, types of grinding and broaching
CO 403.4
machines.
Ability to understand the evolution, types, features and gaining the CNC
CO 403.5
programming knowledge, and micro machining.
Attainment of POs and PSOs through COs (Legends : 1 – Low , 2 – Medium, 3 – High)
PSO 1
PSO 2
PSO 3
PO 10
PO 11
PO 12
PO 1
PO 2
PO 3
PO 4
PO 5
PO 6
PO 7
PO 8
PO 9
ME 6402
CO 403.1 3 2 - - - 1 - 1 1 1 2 2 2 3 3
CO 403.2 3 1 1 - 1 1 - 1 2 2 2 2 2 3 2
CO 403.3 3 1 1 - - 1 - 1 2 2 2 2 2 3 3
CO 403.4 3 2 1 - 1 1 - 1 2 2 2 2 2 3 3
CO 403.5 3 1 2 - 2 1 - 1 2 2 2 2 2 3 3
Course
S.No Knowledge level UNIT
Outcomes
1 R, An, U & E THEORY OF METAL CUTTING CO 403.1
2 R, U & E TURNING MACHINE CO 403.2
SHAPER, MILLING AND GEAR CUTTING
3 R,Ap,An,U& E CO 403.3
MACHINES
4 R, Ap, An,U & E ABRASIVE PROCESS AND BROACHING CO 403.4
5 R, Ap, An,U,E & C CNC MACHINING CO 403.5
PART – B
1. (i) A cutting tool made of HSS gave a tool life of 50min when operated at a speed of
200m/min. At what speed should the tool have to be operated in order to have a tool life of 2
hrs 15min. Assume n=0.185. (May/June 2015)
(ii). Differentiate Orthogonal cutting and Oblique cutting. (May 2011) (Nov 2013)
2. Draw the merchants circle and derive the relationship between various cutting forces.
Mention the assumptions made. (April/May 2010) (May/June 2015)
3. (i) Explain orthogonal metal removal process.
(ii) What are the important properties required for cutting tool material and explain the
different cutting tool materials in detail. (May11/May13/ Nov 13/ May14/Nov15/ May 16)
4. What is meant by tool wear? Explain the different types of tool wear and the parameters
influencing tool wear with examples. (April/May 2010) (Nov/Dec 2013) (Nov/Dec 2015)
5. Explain the conditions that promote the formation of the following chip with Sketches.
(i) Continuous chip without Built up edge (ii) Continuous chip with built up edge
(iii) Discontinuous chips (April/May 2010, 2011) (May/June 2015)
6. (i) During a tool cutting test on HSS tool material the following data were recorded. Tool
life Cutting speed: 40 min 25m/min,5 min 75m/min Calculate the values of n and C of
Taylor’s equation, (ii) The tool life equation for HSS tool is expressed by VT0.15 = C and the
tungsten carbide tool is expressed by VT0.25 = C. If at a speed of 30m/min the tool life is 120
min, compare the life of the two tools at a speed of 40m/min.
7. The following data from an orthogonal cutting test is available; Rake angle = 150 , Chip
thickness ratio = 0.383, Uncut chip thickness = 0.5mm, Width of cut = 3mm, Yield stress of
the material in shear = 28N/mm2, Average coefficient of friction on the tool face = 0.7
Determine the normal and tangential forces on the tool face.
8. In an orthogonal cutting operation, the following data have been observed: Uncut chip
thickness = 0.127 mm Width of cut = 6.35mm, Cutting speed = 2m/s, Rake angle = 20 0
Cutting force = 567 N, Thrust force = 227 N, Chip thickness = 0.228mm. Determine shear
angle, friction angle, shear stress along the shear plane and the power for the cutting
operation. (Nov/Dec 2015)
9. During machining C20 steel with a carbide cutting tool having a tool geometry is given by
0-5-6-6-8-75-1mm ORS, the following forces have been recorded by a two dimensional
dynamometer Cutting force = 1300N, Feed force = 800N. Determine the following: Frictional
force, Normal force and kinetic coefficient of friction. (May/June 2016)
10. Explain the geometry of a single point tool with suitable sketches. (May/June 2009)
11. State the functions of cutting fluids and explain the types of cutting fluid in detail.
(Nov10/May13/Nov13/May14/Nov15/May16)
be swiveled horizontally and can be fed at angle to the milling m/c spindle. The universal
milling machine is provided with auxiliaries such as dividing head, vertical milling
attachment and rotary table etc. hence it is possible to make spiral, bevel gear, twist drills,
reamers etc on universal milling m/c.
19. List the various types of milling attachments.
Vertical milling attachment, Universal milling attachment, High speed milling attachment,
Rotary milling attachment, Slotting milling attachment, Rack milling attachment.
20. Classify milling cutters. (April/May 2016)
According to the shape of the tooth, milling cutters are classified as: Milled tooth cutters,
Form relieved cutters According to the type of operation: Plain milling cutters, side milling
cutters, end milling cutters, angle milling cutters, t- slot milling cutters, slitting saws, form
milling cutters, fly cutters, wood ruff key slot milling cutter. According to the way of
mounting on the machine: arbor cutters, shank cutters, face cutters.
21. Define Up milling and Down milling. (Apr/May 2011, Nov/Dec 2011, 2013,Nov / Dec
2015) (May/June 2016)
Up milling is a process in which milling cutter rotates opposite to the direction of feed of the
work piece. The chip thickness is minimum at the beginning and maximum at the end of the
cut. So the stress is minimum at the beginning of the cut. Down milling is a process in which
milling cutter rotates in the same direction of feed of the work piece. The chip thickness is
maximum at the beginning and minimum at the end of the cut. So the stress is maximum at
the beginning of the cut
22. List out the various milling operations. (May/June 2016)
Plain or slab milling, face milling, angular milling, straddle milling, gang milling, form
milling, end milling, T- slot milling, gear cutting.
23. Define straddle milling and gang milling. (April/May 2016)
Straddle milling operation is the production of two vertical flat surfaces on the both sides of
the job by using two side milling cutters which are separated by collars. Gang milling is the
production of many surfaces of a job simultaneously by feeding the table against a number of
required cutters.
24. What are the other forming methods for manufacturing gears?
a. Gear cutting by single point form tool, b. Gear cutting by shear speed shaping process, c.
Gear milling using formed end mild. d. Gear broaching, e. Template method.
25. List the gear generating process. (May/June 2013)
Gear shaping process, gear planning process, gear hobbing process.
26. List the various gears finishing process. (April/May 2016)
(a)Gear shaving, (b) gear burnishing, (c) Gear grinding, (d) Gear lapping
27. Give the functions of flutes on taps. (May/June 2014)
Flutes serve to provide clearance to the chips produced at the cutting edges. They also allow
the cutting fluid to reach the cutting edges.
28. List the materials used for broaching tool. (May/June 2014).
Tungsten-chromium-vanadium (18-4-1) steel, Carbide.
29. What do you meant by differential Indexing. (May/June 2015)
This method is used for divisions that could not be indexed by simple indexing.
The required divisions is obtained by combination of;
1. movement of the index crank is similar to simple indexing.
2. Simultaneous movement of the index plate when the crank is turned.
30. Why milling a versatile machining process. (May/June 2015)
Milling machine performs drilling, boring, thread and gear cutting and slotting operations,
which used to be performed by different machines that were designed to perform each
different work. So it milling machine is a versatile machining process.
PART – B
1. With a neat sketch explain the components and working principle of a shaper. (Nov/Dec
2010)
2. Explain the following mechanism of shaper. (i). Hydraulic Drive, (ii). Crank and slotted
link mechanism, (iii). Whitworth mechanism (Nov/Dec 2009, 2010, 201, 2012) (Apr/May
2011) (May/June 2014) (Nov/Dec 2015)
3. Describe the various operations performed on a shaper. (May/June 2015)
4. (i). Explain the working principle of radial drilling machine (Nov/Dec 2010, 2011, 2012)
(ii). Explain the working principle of Jig boring machine (Nov/Dec 2011)
5. (i). With a neat sketch explain the vertical boring machine (May/June 2013)
(ii). Describe the various operations done on drilling machine with suitable
sketch.(May/June 2012) (May/June 2016)
6. (i). Draw and explain the twist drill nomenclature. (May/June 2009,Nov/Dec2012,
Nov/Dec 2015)
(ii). Write short notes on reaming operation. (May/June 2014)
7. Explain the different type of milling cutters in detail. And milling operation (May/June
2009) (Nov/Dec 2015) (May/June 2016)(Apr/May 2010) (May/June 2013)
8. Sketch and explain the types of Column and knee type milling machines. (Nov/Dec 2010)
(May/June 2013) (Nov/Dec 2013)
9. (i). Draw the nomenclature of plain milling cutter.
(ii). Explain the Universal dividing head. (May/June 2014)
10. Discuss the various gear finishing methods. (May/June 2014) (May/June 2016)
11. Describe the following process in detail: (i). Gear shaping, (ii). Gear planning, (iii).
Gear hobbing (Apr/May 2010, 2011) (Nov/Dec 2010, 2011) (May/June 2013, 2015)
(May/June 2015) (May/June 2016)
12. (i). Write briefly about tool and cutter grinder. (Nov/Dec 2013).
(ii). State the difference between shaper and planner. (Nov/Dec 2013).
21. Define the term Grade used in grinding wheel. (Apr/May 2011)
Grade or hardness indicates the strength, with which the bonding material holds the abrasive
grains in the grinding wheel.
22. What is broaching? (Nov/Dec 2010, 2012) (Nov/Dec 2015)
Broaching is a process of machining a surface with a special multipoint cutting tool called
“broach” which has successively higher cutting edges in a fixed path.
23. Write the specification of broaching machine. (May/June 2009)
1. Maximum length of the stroke in mm, 2. Maximum force developed by the slide in tones.
24. What are the advantages and limitations of broaching? (May/June 2012)
Advantages:- 1.roughing , semi – finishing cuts are completed in one pass of the broach 2.
Broaching can be used for either external or internal surface finish. Limitations: - 1. high
initial cost of the broach tools compared to other tools. 2. Job work or batch work is not
available due to the high tool cost.
25. What are the types of broaching machine? (May/June 2015)
a. According to the nature and direction of primary cutting motion. horizontal, vertical and
continuous
b. According to the purpose:- internal & external surface. c. According to method of
operation: -pull or push d. According to the construction of the broach tool: - solid, inserted
tooth, progressive cut, built-up etc. e. According to the function:- key way, burnishing
,splines, round hole etc. f. According to the number of main slides or stations:- single
,multiple or double.g. According to the motion of the broach tool relative to the work:-
straight line motion or stationary broach tool.
26. What are the application of Broaching machine? (Apr/May 2011)
Used for machining through holes of any cross section shape, straight and helical slots,
External surface of various shape, external and internal toothed gears.
27. What is a tool post grinder? (May/June 2014).
Tool post grinder is used for miscellaneous and small grinding work on a lathe.
28. Name the process parameters involved in the lapping process. (Nov/Dec 2013)
Speed, Pressure, Allowances, Lap naterials, Lapping Abrasive.
29. How does loading differs from glazing in grinding process. (May/June 2015)
When the surface of a grinding wheel develops a smooth and shining appearance, it is said to
be glazed. This indicate the abrasive particles on the wheel face are not sharp. These are
worked down to bond level. When soft materials like al, copper, lead etc are ground the metal
particles get clogged the abrasive particles. This condition is called as loading.
30. Give the specification of a grinding wheel. (May/June 2016)
1) The type of grit material 2) The grit size 3) The bond strength of the wheel, commonly
known as wheel hardness 4) The structure of the wheel denoting the porosity i.e. the amount
of inter grit spacing 5) The type of bond material 6) other than these parameters, the wheel
manufacturer may add their own identification code prefixing or suffixing (or both) the
standard code
31. Why Gear finishing is required? (May/June 2016)
Surface of gear teeth produced by any of the generating process is not accurate and of good
quality (smooth). Dimensional inaccuracies and rough surface generated so become the
source of lot of noise, excessive wear, play and backlash between the pair of gears in mesh.
These all result in loss of power to be transmitted and incorrect velocity ratios. This can be
summarized as inefficient power transmission. In order to over come these problems some
finishing operations are recommended for the produced gears.
PART - B
1. Explain the types of rough grinding machines with neat sketch.(Apr/May 2010) (Nov/Dec
2015)
2. With neat sketch explain the working principle of cylindrical grinding machine. (Nov/Dec
2011), (Nov/Dec 2012)
St.Joseph’s College of Engineering 13
St.Joseph’s Institute of Technology
ME 6402- Manufacturing Technology-II Mechanical Engineering 2016-2017
3. Describe the centre less grinding machine and three methods of cylindrical center less
grinding in detail (May/June 2009, 2011, 2013) (Nov/Dec 2009), Nov/Dec 2010) (Nov/Dec
2015) (May/June 2016)
4. Discuss the construction and working of surface grinding machine.
5. (i). Explain the types of internal grinders. (Nov/Dec 2012)
(ii). Discuss Gear teeth grinding, Thread grinding, Cam grinding.
6. (i). Describe the type of abrasive materials used in grinding wheel. (May/June 2009, 2011,
2014) (Nov/Dec 2009) (May/June 2016)
(ii). Explain the types of bonds related to grinding wheel. (May/June 2016)
7. (i). What are the factors to be considered for the selection of grinding wheel? (May/June
2012) (May/June 2015) (Nov/Dec 2015)
(ii). Give the specification of a grinding wheel.
8. Explain the following: (i). lapping, (ii). Honing, (iii). Super finishing (May/June 2012)
(Nov/Dec 2012) (May/June 2014) (Nov/Dec 2013) (Nov/Dec 2015)
9. (i). Explain the types of Horizontal broaching machines. (Nov/Dec 2013) (May/June 2016)
(ii). Explain the types of vertical broaching machines. (Nov/Dec 2013) (May/June 2015)
10. (i). With a neat sketch explain the Continuous broaching machine.
(ii). Draw and explain the broaching tool nomenclature. (Nov/Dec 2009)
27. State the difference between CNC and DNC. (Nov/Dec 2013) (May/June 2015)
CNC system can do operations on only one machine at a time. But DNC involves that at a
time a large central computer directs the operations of separate NC machine.
28. What is Adaptive control. (May/June 2015)
Adaptive control is the control of the cutting process by on-line calculation and setting of the
optimal parameters subject to machining constraints.
29. Define “Micromachining” (May/June 2016)
The removing (as in drilling, planing, or shaping) of small amounts of material (such as
metal) by action other than that of a sharp-edged tool.
30. State the functions of the following codes. (May/June 2016)
G00- Rapid linear motion; G03-circular motion counter clockwise; M06-Automatic Tool
change; M03-Spindle on Clockwise
PART – B
1. (i). Compare NC, CNC with conventional system. (May/June 2014) (May/June 2015)
(ii). What are the advantages and limitations of NC system?
2. Explain the different drive systems used in CNC machines. and constructional features of
CNC machine. (Nov/Dec 2015) (May/June 2016).
3. Explain the working principle of a Machining center. (May/June 2013) (Nov/Dec 2013)
4. Describe the working principle of turning center.
5. What are the types of control used in NC machines? (May/June 2015) (Nov/Dec 2015)
6. What are G&M codes used in CNC machine Explain? (May/June 2009)
7. Difference b/w Point to Point & Continuous path type NC m/c tools.(June,Dec15, May 16)
8. (i). Explain the types of coordinate
(ii). Explain about open loop and closed loop system for machine control. (Nov/Dec 2013)
9. (i). Write about part programming. (May/June 2014) (May/June 2013) (May/June 2015)
(ii). Discuss the APT Statements.
10. Explain Ball screw, linear screw with neat sketch used in CNC machines? (Nov/Dec
2011)
11. Write the difference between manual part programming and computer assisted part
programming?
12. (i). Explain the different slide ways used in CNC machine. (May/June 2013)
(ii). Explain the different types of interpolation. (May/June 2013)