];ng\y;

nk\pd;];
(M–SCHEME)

e. Iadhug;gd;> M.E., M.I.S.T.E.

Kjy;th;
= NuZfhk;ghs; ghypnlf;dpf; fy;Y}hp
Ngh@h; - 606 907.
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2 & 3 MARKS QUESTIONS AND ANSWERS

Unit – I

MANUFACTURING OF PLASTIC COMPONENTS

1. Define plastic.
Plastic (nefpop) vd;gJ
mouldfspy; thh;j;J jplg;
nghUl;fshf khw;wf; $ba tifapy; ,sfpa jd;ik
nfhz;l gytifahd nraw;if polymerfs; my;yJ
ghjp nraw;ifahd ,aw;if polymerfis cs;slf;fpa
nghUs; MFk;.
2. What is polymer?
polymer vd;gJ xNu khjphpahd gy %yf;$Wfs; ePz;l
rq;fpypj; njhlh; thpirapy; ,izf;fg;gl;l xU
Ntjpapay; fyit MFk;.
3. State the major classification of plastics.
a) Thermo plastics
b) Thermosetting plastics
4. Give the basic difference between thermoplastics and
thermosetting plastics.
 ntg;gg; gLj;Jk;NghJ kpUJthfp cUff;$ba>
jpUk;g jpUk;g mould nra;aty;y plasticfs;
thermoplastics vdg;gLk;. ,j;jifa plasticfis
gyKiw ntg;gg; gLj;Jtjhy; mtw;wpd; gz;Gfspy;
epue;jukhd khw;wk; vJTk; Vw;glhJ.
 Thermosetting plasticfs; ntg;gg; gLj;Jk;NghJ
kpUJthfp tpLk;. Mdhy; Fsph;tpf;Fk;NghJ>
epue;jukhf fbdkhfp tpLk;. jpUk;gTk; ,jid mould
nra;a KbahJ.
5. Give examples for thermoplastics.
1) Polyvinyl Chloride (PVC) 2) Polyethylene (PE)
3) Polystyrene (PS) 4) Polypropylene (PP)
5) Polycarbonate (PC) 6) Polyamide (PA)
7) Acrylic (PMMA) 8) Acetal (POM)
9) Polyester 10) Polyphenylene (PPO)
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6. Give examples for thermosetting plastics.

1) Polyurethanes 2) Vulcanized rubber 3) Bakelite
4) Duroplast 5) Urea-formaldehyde 6) Melamine resin
7) Epoxy resin 8) Polyimides
7. List out the types of plastics.
1) Engineering Plastics 2) Thermosets 3) Composites
4) Structural foam 5) Elastomers 6) Polymer alloys
7) Liquid crystal polymers
8. What do you mean by engineering plastics? Give examples.
 Engineering plasticfs; vd;git> ngUkstpy;
gad;gLj;jg;gLk; rhjhuz plasticfisf; fhl;bYk;
mjpf mechanical kw;Wk; thermal gz;Gfisf; nfhz;l
plasticfs; MFk;.
 Nylon, acetal, acrylonitrile butadiene styrene (ABS),
polycarbonate, modified polyphenylene oxide (PPO),
thermoplastic polyesters, polysulphone, polyphenylene
sulphide, etc.
9. What is thermoset? Give examples.
 Thermosetting plasticfs; thermosets vd miof;fg;gLfpd;wd.
 Examples : Phenolic moulding materials, granular
thermosetting materials based on urea, melamine,
unsaturated polyester (UP) kw;Wk; epoxide resinfs;.
10. List out the applications of structural foams.
 tpahghu cgfuzq;fs; kw;Wk; tPl;L cgNahfg;
nghUl;fSf;fhd Nkw;ghfq;fs;.
 Vehicle body panelfs; kw;Wk; furniturefs;.
 Wall panel, support brackets, Nghd;wtw;wpd;
xUq;fpize;j moulding.
11. What are elastomers? How they are manufactured?
 Thermoplastic rubber MdJ elastomer vd;W miof;fg;
gLfpwJ.
 Vulcanization Kiwapy; moulding nra;j gpd;G> cross-
linking %yk; Njitahd tbtpy; cUthf;fg;gLfpwJ.

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12. What are LCPs? Give examples.

 Liquid Crystal Polymerfs; vd;git aromatic polyesterfis
mbg;gilahff; nfhz;lJ. cUfpa epiyapYk;
Kiwahd tbtikg;igg; ngw;wpUf;Fk;.
 PET co-polyester, co-polyamide and polyester-amide.
13. Define flammability (Critical Oxygen Index).
Plasticfspy; flammability gz;ghdJ Critical Oxygen
Index(COI) %yk; Fwpf;fg; gLfpwJ. ,e;j vz;zhdJ>
oxygen kw;Wk; nitrogen fye;j fyitia jP%l;Ltjw;F>
mf;fyitapy; ,Uf;f Ntz;ba Fiwe;jgl;r oxygend;
rjtPjj;ijf; Fwpf;Fk;.
14. What is extrusion? List the types of extruders.
 xU barrelf;Fs; nghUj;jg;gl;l screwd; cjtpahy;
plastic nghUl;fis cw;gj;jp nra;Ak; xU nghJthd
KiwNa extrusion MFk;.
 Types : (i) Single screw extruder (ii) Twin screw extruder
15. What are the different zones in extruder screw?
 Feed zone : PlasticI Kd;$l;bNa ntg;gg; gLj;JtJ.
 Compression zone : Plastic I ,Wf;FtJ.
 Metering zone : Plastic nrYj;jg;gLk; tPjj;ijf;
fl;Lg;gLj;JfpwJ.
16. List out the configurations in twin screw extruder.
a) Intermeshing counter-rotating
b) Intermeshing co-rotating
c) Non-intermeshing counter-rotating
d) Non-intermeshing co-rotating
17. Mention the different methods of extrusion.
 Sheet/film extrusion
 Blown film extrusion
 Over jacketing extrusion
 Tubing extrusion
 Coextrusion
 Extrusion coating
 Compound extrusions

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18. Mention the applications of injection moulding.

Electric drill casing, television housing, comb, syringe, paint
brush handle, helmet, gearwheel, typewriter, reflector,
telephone, brief case Nghd;wtw;iw cw;gj;jp nra;tjw;F
injection moulding gad;gLfpwJ.
19. State limitations of plunger type injection moulding.
 cUfpa plastic gpw nghUl;fSld; fye;jtpl
tha;g;Gs;sJ.
 Plastic cUz;ilapd; msitf; fl;Lg;gLj;JtJ fbdk;.
 nozzley; cs;s pressure MdJ xt;nthU cyclef;Fk;
khwpf; nfhz;Nl ,Uf;Fk;.
 Torpedo ,Ug;gjhy;> Fwpg;gplj;jf;f msT pressure
loss Vw;gLfpwJ.
20. How foam effect is achieved in plastics?
Moulding nra;tjw;F Kd;G> cUfpa epiyapy; cs;s
resin KOtJk; xU inert gasI Neubahf nrYj;jp foam
effect ngwg;gLfpwJ. ngUk;ghYk; iel;u[d; gas
,jw;fhfg; gad;gLj;jg; gLfpwJ.
21. List out the advantages of foam moulding.
 xU Fwpg;gpl;l vilf;F> jpl plasticfis tpl foam
plasticfspd; typik mjpfk;.
 mstpy; RUq;Fjy; kw;Wk; mikg;gpy; khWjy;
Nghd;w khw;wq;fs; ,tw;wpy; ,Uf;fhJ.
 ve;j xU RUf;fKk; ,y;yhky; mjpf jbkdhd
nghUl;fisAk; moulding nra;ayhk;.
 Fiwthd clamping force NghJkhdJ.
 Mouldd; tpiy FiwT.
22. What is sandwich moulding?
Sandwich moulding vd;gJ xU injection moulding MFk;.
,k;Kiwapy;> tpiy mjpfk; nfhz;l nray;ghl;Lj;jpwd;
nfhz;l nghUs; Nkw;Gwj;ij cUthf;Ftjw;Fk;>
tpiy Fiwthd my;yJ recycle plastic nghUs;
cl;Gwj;ij cUthf;Ftjw;Fk; gad;gLj;jg;gLfpwJ.
23. State the advantages of gas injection moulding.
 Moulding KOtJkhf xNu rPuhd pressure jf;if
itf;fg; gLfpwJ.

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 kpff; Fiwthd clamping force.
 nghUspd; Nkw;gug;gpy; ve;j ghjpg;Gk; Vw;glhJ.
 cw;gj;jp Neuk; FiwT.
24. Define calendering.
vjpnujpuhfr; RoYk; ,uz;L cylinderfSf;F ,ilapy;
plastic nghUis nrYj;jp> mjid mOj;jp film my;yJ
sheet tbtpy; cUthf;Fk; Kiw calendering MFk;.
25. What are the uses and advantages of rotational moulding?
Hollow plastic nghUl;fis cUthf;Ftjw;F rotational
moulding cjTfpwJ.
Advantages :
 Stress ,y;yhj moulding
 Mouldf;fhd nryT FiwT.
 cw;gj;jp Neuk; FiwT.
 Wall thicknessI vspjhf fl;Lg; gLj;jyhk;.

COMPOSITE MANUFACTURING

26. Define composite. What are the constituents in composite?

 ntt;NtW ,aw;gpay; kw;Wk; Ntjpapay; gz;Gfisf;
nfhz;l ,uz;L my;yJ mjw;F Nkw;gl;l
nghUl;fis xd;whf ,izj;J ngwg;gLk; nghUs;
composite vdg;gLk;.
 cl;nghUl;fs; : 1) Reinforcement (or) Fiber 2) Matrix
27. List out the characteristics of composite manufacturing.
 Matrix kw;Wk; fiberf;F ,ilNa ey;y gpizg;G
 Fiberfspd; rhpahd mLf;F Kiw
 mjpf mstpyhd fiberfs;
 Matrix nghUSf;Fs; fiberfs; rPuhd Kiwapy; gutp ,Uj;jy;
 ResinI Kiwahf curing nra;jy;:
 Fiwthd void kw;Wk; defect
 nghUspd; ,Wjp tbt msTfis rhpahf fl;Lg;gLj;Jjy;
28. What is reinforcement? Give examples.
 Compositey; cs;s reinforcement MdJ loadIj;
jhq;f;f $ba Kf;fpa cl;nghUs; MFk;. nghJthf
fiber MdJ reinforcement Mf gad;gLj;jg; gLfpwJ.
 Examples : Glass, carbon, Kevlar boron, ceramics
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29. What is matrix? Give examples.

 Composite nghUspy;cs;s cl;nghUshd matrix
MdJ> kw;nwhU cl;nghUshd fiberfis xd;Wld;
xd;W gpizj;J typikiaj; jUfpwJ.
 Examples : Thermoset plastic resins, thermoplastic resins,
ceramics and metals
30. List out the functions of matrix material.
 nrYj;jg;gLk; ve;j xU tpiriaAk; fiberfSf;F
flj;JfpwJ.
 Fiberfis epiyahf xNu ,lj;jpYk; jpirapYk;
,Uf;FkhW nra;fpJ.
 Compositef;F compression strength kw;Wk; shear strengthI
toq;FfpwJ.
 Rw;Wg;Gwj; jhf;Fjy;fspy; ,Ue;J fiberfis
fhg;ghw;WfpwJ.
31. What are the different types of glass fibers?
 E glass (E - electrical grade)
 S glass (S - strength)
 C glass (C - corrosion resistance)
32. Give the difference between graphite and carbon fibers.
 Graphene layerfs; Kg;ghpkhz Kiwapy; mLf;fg;
gl;bUe;jhy;> mg;nghUs; graphite MFk;.
 Graphene layerfs; ,Ughpkhz Kiwapy; mLf;fg;
gl;bUe;jhy;> mg;nghUs; carbon MFk;.
33. What is Kevlar? Mention its types.
 Kevlar vd;gJ aramid fiberfSf;fhd tpahghug; ngah;
MFk;. Aramid fiberfs; Fiwthd vil> mjpf strength
kw;wk; toughness nfhz;bUf;Fk;.
 Types : Kevlar-49(high stiffness) kw;Wk; Kevlar-29 (low stiffness)
34. State the applications of boron and ceramic fibers.
 thD}h;jpfspd; Nkw;gug;gpy; Vw;gLk; tphpry;fis
rhpnra; tjw;F boron fiberfs; gad;gLj;jg;gLk;.
 Gas turibe enginey; cs;s turbine bladefs; Nghd;W,
mjpf ntg;gepiyf;F cl;gLj;jg;gLk; ghfq;fis
jahhpg;gjpy; ceramics fiberfs; cjTfpd;wd.

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35. What are the different forms of reinforcement or fibers.

Fibers, Filament, Strand, Tow, Yarn, Roving, Tape, Woven
fabric, Braid kw;Wk; Mat.
36. What is (i) Tow and (ii)Yarn.
 Tow: xU Fwpg;gpl;l vz;zpf;ifapy; njhlh;
filamentfisf; nfhz;l KWf;fg;glhj xU njhFg;G.
 gy njhlh;r;rpahd fiberfisf; nfhz;L KWf;fg;gl;l
xU njhFg;G. ,J twisted tow vdTk; miof;fg;gLk;.
nghJthf weaving nra;tjw;F ,it gad;gLk;.
37. What is (i) Rovings and (ii) mat.
 Roving: gy yarnfs; my;yJ towfs; ,izahf
mLf;fg;gl;l KWf;fg;glhj xU njhFg;G.
 Mat: Jz;Lfshf eWf;fg;gl;l fiberfs; my;yJ
Row;wg;gl;l njhlh;r;rpahd fiberfis rPuw;w Kiwapy;
mLf;fp xU binder %yk; jsh;thf gpizj;J
ngwg;gLk; jhs; tbt nghUs;.
38. Define (i) shelf life and (ii) pot life.
 gad;gLj;jf; $ba tifapy; xU resinI Nrkpj;J
itf;ff; $ba mjpfgl;r fhy msT mjd; shelf life
my;yJ storage life vdg;gLk;.
 Poty; cs;s resin MdJ nfl;Lg; Nghfhky;
gad;gLj;jf; $ba epiyapy; njhlh;e;J ,Uf;Fk;
fhy msT pot life vdg;gLk;.
39. Mention some important thermosetting resins.
1) Polyester Resins 2) Vinyl Ester Resin
3) Phenolic Resin 4) Epoxy resin
5) Polyimides 6) Polybenzimidazoles (PBI)
7) Bismaleimides (BMI)
40. State the commonly used thermoplastic resin.
1) Semicrystalline Thermoplastics
2) Amorphous Thermoplastics
3) Polyether Ether Ketone (PEEK)
41. Mention the applications of metal matrix.
Piston ring insert, piston, connecting rod, impeller, brake
caliper, viliaj; jhq;Fk; rhjqdq;fs;> kw;Wk; tennis
kl;ilfs; Mfpatw;wpd; jahhpg;gpy; metal matrix composite
gad;gLfpwJ.
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42. What are the stages in curing resin?
 A stage: ,e;epiyapy;> curing nra;a Njitg;gLk;
nghUl;fs; resin cld; fyf;fg;gLk;. Mdhy;
Ntjptpid njhlq;fhJ.
 B stage: ,e;epiyapy;> curing nra;a Njitg;gLk;
nghUl;fs; resin cld; fyf;fg;gLk;. Ntjptpid
njhlq;fg;gLk;.
 C stage: Resin KOtJkhf curing nra;a;gl;L ,Uf;Fk;.
43. What is prepreg?
Pre-impregnated (Kd; $l;bNa nrwpT+l;lg;gl;lJ)
vd;gjd; RUf;fNk prepreg. gFjp msT curing
nra;ag;gl;l resinI fiberfSld; ,izg;gJ prepregging
MFk;. Fiber kw;Wk; viscous resin ,izg;ghdJ prepreg
vdg;gLk;.
44. What is sizing and finish in glass fiber manufacturing?
 Sizing vd;gJ fiberfSf;F ,ilNaahd cuha;tpidf;
Fiwj;J> mit cilahky; jLg;gjw;fhf
gad;gLj;jg;gLk; chemical MFk;.
 Finish vd;gJ fiberd; Nkw;gug;ig ghJfhg;gjw;Fk;
composite cUthf;fj;jpd; NghJ resin cld; ey;y
gpizg;ig Vw;gLj;Jtjw;fhfTk; gad;gLj;jg;gLk;
chemical MFk;.
45. What is the use release agent in composite manufacturing?
Composite cw;gj;jpapd; NghJ gad;gLj;jg;gLk; resinfs;
mjpf xl;Lk; jd;ik nfhz;bUg;gjhy;> nghUshdJ
mouldy; xl;bf;nfhs;s tha;g;G cs;sJ. vdNt
nghUis vspjhf gphpj;njLg;gjw;F> wax my;yJ poly
vinyl alcohol Nghd;w release agent MdJ mould gug;gpd;
kPJ jltg;gl Ntz;Lk;.
46. What are the applications of hand laminating process?
Hand laminating my;yJ wet lay-up nray;KiwahdJ>
glFfs;> wind-turbine bladefs;> architectural mouldingfs;
kw;Wk; chemical njhopw;rhiyfSf;Fj; Njitahd
JUg;gpbf;fhj ghfq;fs; Mfpatw;iw Fiwe;j nrytpy;
cUthf;fg; gad;gLfpwJ.

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47. List out the steps in autoclave processing.
1) Prepreg cUthf;Fjy;
2) Mould cUthf;Fjy;
3) Mouldd; kPJ prepregfis mLf;fp ghfj;ij
cUthf;Fjy;
4) Vacuum bag cUthf;Fjy;
5) Autoclavef;Fs; ghfj;ij curing nra;jy;

48. What is bleeder, barrier and breather?

 mLf;fpypUe;J tope;J nry;Yk; kpFjpahd resinI
cwpQ;Rtjw;fhf> release filmI mLj;J xU bleeder
material itf;fg;gLk;.
 Bleederf;Fs; nry;Yk; resinI fl;Lg;gLj;Jtjw;F
barrier film itf;fg;gLk;.
 Curing eilngWk; NghJ cUthFk; mjpfg;gbahd
fhw;W kw;Wk; Mtpg;nghUl;fis vspjhf
ntspNaw;Wtjw;F> bleederf;F ntspg;gf;fkhf
breather material itf;fg;gLk;.
49. What is autoclave? Mention its uses.
 Autoclave vd;gJ cl;Gwk; ntg;gg;
gLj;Jk;
trjpAld; $ba xU cah; mOj;j fyd; MFk;.
 fl;Lg;gLj;jg;gl;l ntg;gepiy kw;Wk; mOj;j #oypy;
composite ghfq;fis curing nra;tjw;F ,J
gad;gLfpwJ.
50. State the limitations of autoclave processing.
1) cgfuzq;fSf;fhd Muk;g nryT mjpfk;.
2) ,af;Fjy; kw;Wk; guhkhpg;G nryT mjpfk;.
3) nghpa msT rhjdq;fs; Njit.
4) cw;gj;jp Neuk; mjpfk;.
5) mstpy; rpwpa nghUl;fis cw;gj;jp nra;a Vw;wjy;y.
51. What is filament winding? State the different types of winding.
 Filament winding vd;gJ> Rod;W nfhz;bUf;Fk; xU
mandreld; kPJ> rovings tbtpy; cs;s njhlh;r;jpahd
fiberfis ,Wf;fkhf Rw;wp> Njitahd ghfq;fis
cUthf;Fk; vspa nray;Kiw MFk;.
 Winding Kiwfs; : polar, helical, layer, hoop, longitudinal,
kw;Wk; combination winding

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52. State the types of mandrels used in filament winding.
Mandrelfspd; tiffs; : Extractable, collapsible, breakable
kw;Wk; dissolvable mandrelfs;.
53. Mention the applications of filament winding.
Pressure vessels, rocket motor casing, chemical storage
tanks, pipelines, gas cylinders, fire-fighters, breathing tanks
Nghd;w nghUl;fis cUthf;Ftjw;F filament winding
Kiw gad;gLfpwJ.
54. What is pultrusion process? State its applications.
 Pultrusion vd;gJ khwhj FWf;Fntl;Lg; gug;G
nfhz;l ePskhd kw;Wk; Neuhd ghfq;fis
njhlh;r;rpahf cw;gj;jp nra;Ak; Kiw MFk;.
 Beam kw;Wk; girderfs; Nghd;w roof structurefs;>
ghyq;fs;> Foha;fs;> Vzpfs;> rl;lq;fs;> kPd;gpb
Nfhy;fs;> rhjdq;fspd; ifg;gpbfs;> NgUe;J
ghfq;fs;> topfhl;b kuq;fs; Nghd;w ghfq;fis
cw;gj;jp nra;a pultrusion nray;Kiw cjTfpwJ.
55. List out the advantages of liquid composite moulding.
1) cw;gj;jp tpfpjk; mjpfk;.
2) Muk;g nryT kw;Wk; cw;gj;jp nryT FiwT.
3) Fiberfis gy;NtW thl;lqfspy; mikj;J
nghUl;fis cUthf;fyhk;.
4) gy;NtW tbtk; kw;Wk; msTfspy; nghUl;fis
jahhpf;fyhk;.
5) ,UGwKk; Neh;j;jpahf finishing nra;ag;gl;l ghfk;
fpilf;fpwJ.
6) cNyhfj;jhy; nra;agl;l mouldfs; Njitapy;iy.
7) nghUspd; jbkid vspjhf fl;Lg;gLj;jyhk;.
8) Curing nra;tjw;F miw ntg;gepiy NghJkhdJ.

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Unit – II

PLANER
1. List out the reciprocating types of machine tools.
1) Planer 2)Shaper 3) Slotter
2. State any four types of planer.
1) Double housing planer 2) Open side planer
3) Pit planer 4) Edge planer
5) Divided table planer
3. Which part reciprocates in planer?
Planery; workpiece MdJ table kPJ itf;fg;gl;L
fpilkl;lkhf Kd;gpd; efUk;.
4. Where is the tool head mounted in planer?
Cross rail kPJ tool head nghUj;jg; gl;bUf;Fk;.
5. What is the purpose of divided table planer?
Machine ,aq;fhky; ,Uf;Fk; Neuj;ij Fiwg;gNj
divided table planerd; Kf;fpa Nehf;fk; MFk;.
6. Give the specifications of planer.
1) ,uz;L columnfSf;F ,ilg;gl;l J}uk;.
2) Table d; ePsk; kw;Wk; mfyk;.
3) Table Kd; gpd; efUk; mjpf gl;r J}uk; (stroke length)
4) Cross rail mjd; mjpfgl;r cauj;jpy ,Uf;Fk;
NghJ> cross raild; fPo;g; ghfj;jpw;Fk; tabled; Nky;
ghfj;jpw;Fk; ,ilapYs;s J}uk;.
5) Planerd; epfu vil.
7. What are the quick return mechanisms used in planer?
1) Open and cross belt drive 2) Electric drive
3) Hydraulic drive
8. What are the methods used for holding workpiece in planer?
1) T-bolts 2) Strap clamps 3)Support blocks
4) Screw jack 5) Planning fixture
9. Mention the operations performed in planer.
1) Machining horizontal surface 2) Machining vertical surface
3) Machining angular surface 4) Machining T-slots
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SHAPER

10. How the shapers are classified according to the table design?
1) Standard or plain shaper 2) Universal shaper
11. What do you mean by vertical shaper?
Slotting machine (slotter) MdJ vertical shaper vdg;gLk;.
12. What are the principal movements in universal shaper?
1) TableI nrq;Fj;jhfTk; fpilkl;lkhfTk;
efh;j;jyhk;>
2) Ramf;F ,izahd xU mr;irg; nghWj;J
Fwpg;gpl;l Nfhzj;jpy; tableI Row;wp mikf;fyhk;.
13. What is draw cut shaper?
draw cut shaper vd;gJ ram MdJ columnj;ij Nehf;fp
tUk;NghJ metal ntl;b vLf;Fk; tifapy; mike;j
xU tif shaper MFk;.
14. Mention the specifications of shaper.
1) mjpf gl;r stroke length
2) Table fpilkl;lkhf efUk; mjpf gl;r J}uk;
3) Table nrq;Fj;jhf efUk; mjpf gl;r J}uk;
4) shaperd; tif
5) Ram ,aq;Fk; tpjk; (type of drive)
6) Shaperd; epfu vil
15. What is the purpose of providing quick return mechanism
in shaper?
Return stroked; NghJ ramI mjpf Ntfj;jpy;
gpd;Ndhf;fp efh;j;JtNj quick return mechianismj;jpd;
Kf;fpa Nehf;fk; MFk;.

16. In which stoke, the sped of the ram is faster?

Return stroked; NghJ ramd; Ntfk; mjpfkhf ,Uf;Fk;.
17. Name the type of quick return mechanism used in shaper.
1) Crank and slotted link mechanism
2) Whitworth quick return mechanism
3) Hydraulic quick return mechanism

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18. What are the methods of holding workpieces in shaper?

1) Clamping in a vise 2) Clamping directly on table
3) Clamping on an angle plate 4) Clamping over a V – block
5) Fixture
19. Mention the various operations performed in shaper.
1) Machining horizontal surface
2) Machining vertical surface
3) Machining angular surface
4) Machining keyways, grooves and slots.
20. What is cutting speed in shaper?
Work piecey; ,Ue;J tool %yk; metal ntspNaw;wg;gLk;
jpir Ntfk; cutting speed vdg;gLk;. ,J m/min. vd;w
myfhy; Fwpf;fg;gLk;.
21. Define depth of cut in shaper.
xU strokey; workpiecey; ,Ue;J ntspNaw;wg;gLk;
metald; jbkd; depth of cut vdg;gLk;.
22. What is the main difference between shaper and planer?
Shapery; tool Kd;gpd; efUk;. Work piece epiyahf
,Uf;Fk;. Planery; work piece Kd;gpd; efUk;. Tool
epiyahf ,Uf;Fk;.

SLOTTER

23. Give the names of different types of slotter.

1) Punch slotter 2) Tool room slotter
3) Productin slotter 4) Keyseater slotter
24. State the functions of rotary table in slotter.
1) ,jd; Nkw;Gwj;jpy; cs;s T-sloty; work holding deviceI
nghUj;jp workpieceI gpbf;fyhk;.
2) Circular tableI Njitahd Nfhzj;jpw;F indexing nra;J
rk ,ilntspapy; gy keyway ntl;lyhk;. ,e;j
Kiwapy; splined shaft kw;Wk; splined hole cUthf;fyhk;.
25. Write the specifications of slotter.
1) mjpf gl;r stroke length
2) Circular tabled; tpl;lk;

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3) Workpiece ePsthf;fpYk; FWf;Fthf;fpYk; efUk;
mjpf gl;r J}uk;
4) Ram ,aq;Fk; tpjk; (type of drive)
5) Slotterd; epfu vil
26. Name the types of quick return mechanism used in slotter.
1) Whit worth quick return mechanism
2) Variable speed reversible electric motor drive
3) Hydraulic drive
27. Mention the various feed given in slotter.
1) Longitudinal feed 2) Cross feed 3) Circular feed
28. What are the diiferent operations performed in slotter?
1) Machining flat surfaces 2) Machining curved surfaces
3) Machining grooves and keyways

BROACHING

29. State the types of broaching machines.

1) Horizontal broaching machine
2) Vertical broaching machine
3) Continuous broaching machine
30. Write down the limitations of broaching.
1) Broachd; tpiy mjpfk;.
2) nghpa work piecefis machining nra;a KbahJ.
3) mjpf depth of cut ju KbahJ.
4) Fiwthd jbkDs;s workpieceI broaching nra;a
,ayhJ.
5) Fiwe;j vz;zpf;ifapy; nghUl;fis cw;gj;jp
nra;a Vw;wjy;y.
31. What are the types of broach tools?
1) Push broach 2) Pull broach 3) Solid broach
4) Progressive broach 5) Burnishing broach
32. Differentiate between pull broach and push broach.
Machining eilngWk;NghJ workpiece topahf push broach
js;sg;gLk;. Machining eilngWk;NghJ workpiece topahf
pull broach ,Of;fg;gLk;.

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33. What is progressive broach?

gbg;gbahf mfyk; mjpfupj;Jf; nfhz;Nl nry;Yk;
tifapy; ntl;Lg; gw;fisf; nfhz;l broach MdJ
progressive broach vdg;gLk;.
34. What is burnishing broach?
Burnishing broachy; cs;s ntl;Lg; gw;fs; Ftpj;J
(rounded) tbtikf;fg; gl;bUf;Fk;. ,it workpieced;
gug;ig mOj;jpj; Nja;j;J ey;y finishing Vw;gLj;Jk;.
35. Mention the uses of rear pilot in broach.
Broachd; filrp gy; workpieceI tpl;L ntspNawpa gpd;G
broachI jhq;fpg; gpbf;f rear pilot ,J cjTfpwJ.
36. Name the broaching operations.
1) Surface broaching 2) Hole broaching
3) Keyway broaching 4) Spline broaching
37. What is spline broaching?
Jisapd; tl;lg; gupjpapy; rk ,ilntspAld; $ba gy
keywayf;fis ntl;Lk; Kiwf;F spline broaching vd;W
ngau;.

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Unit – III

MILLING MACHINES
1. Classify the column and knee type milling machine.
1) Plain milling machine 2) Universal milling machine
3) Omniversal milling machine 4) Vertical milling machine
2. What are the varous movements that can be made in
universal milling machine?
1) Vertical movement 2) Cross wise movement
3) Longitudinal movemetn 4) Angular movement
3. What is the difference between universal and omniversal
milling machine?
Omniversal milling machiney; spindlef;F ,izahd xU
fpilkl;l mr;irg; nghWj;J kneeI Njitahd
Nfhzj;jpy; jpUg;gp mikf;fyhk;. Universal milling
machiney; ,e;j mikg;G fpilahJ.
4. What is plano miller?
Plano miller vd;gJ double housing planerIg;
Nghd;W
mikg;Gk; ,aq;Fk; tpjKk; nfhz;l xUtif milling
machine MFk;.
5. Write the specifications of milling machine.
1)Tabled; ePsk; kw;Wk; mfyk;
2) Table nrq;Fj;jhfTk;> ePsthf;fpYk;> FWf;F thf;fpYk;
efUk; mjpf gl;r J}uk;
3)Spindle speedfspd; vz;zpf;if
4)Spindle nosed; taper msT
5)Milling machined; epfu vil
6. What are the work holding devices used in milling machine?
1) Plain vise 2) Swivel vise 3) Universal vise
4) Indexing head 5) Milling fixture
7. What is the use of indexing head in milling machine?
Work pieced; ghpjpia xU Fwpg;gpl;l vz;zpf;ifapy;
rkkhd ghfq;fshf gphpf;f indexing head gad;gLfpwJ.
Gear, Shaftd; kPJs;s splines, drill kw;Wk; reamer kPJs;s

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helical grooves Nghd;wtw;iw machining nra;Ak; NghJ
indexing head gad;gLfpwJ.
8. Mention the tool holding devices in milling?
1) Arbor 2) Adapters 3) Spring collets
9. What is the difference between standard arbor and stub arbor?
Stub arbord; ePskhdJ standard arborIf; Fiwthf ,Uf;Fk;.
10. Wha is the use of adapter in milling machine?
Spindle taperd; msit tpl cutterd; taper shank msT
rpwpajhf ,Uf;Fk; NghJ adapter gad;gLj;jg;gLfpwJ.
11. Mention the use of spring collet in millin gmachine.
Straight shank cs;s cutterI nghUj;Jtjw;F spring collet
gad;gLfpwJ.
12. Give the types of milling cutters.
1) Plain milling cutter 2) Slab milling cutter
3) Metal slitting saw 4) Side milling cutter
5) Angle milling cutter 6) End milling cutter
7) T- slot milling cutter 8) Wood ruff key slot milling cutter
9) Fly cutter 10) Form cutter
13. What is the use of end mill cutter?
End milling cutterIf; nfhz;L slotfs;> Jy;ypakhd
Jisfs; kw;Wk; FWfpa rkjs gug;Gfis machining
nra;ayhk;. NkYk; ,J profile milling nra;aTk;
gad;gLfpwJ.
14. Mention the use of woodruff key milling cutter.
Shaftfspy; kPJ woodruff key slotfis Vw;gLj;j woodruff
key milling cutter gad;gLfpwJ.
15. When the fly cutter is used?
xU Fwpg;gpl;l operationf;F Njitahd milling cutter
fpilf;fhj NghJ fly cutter gad;gLj;jg;gLfpwJ.
16. Mention the type of cuttter used for milling gears.
Gearfis cUthf;Ftjw;F form milling cutter
gad;gLfpwJ.
17. What are milling cutter angles?
1) Relief angle 2) Primary clearanc angle
3) Secondary clearance angle 4) Lip angle
5) Radial rake angle
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18. What is upmilling?
Cutter Nky; Nehf;fp efUk;NghJ metal ntl;b ePf;fg;Lk;
nray;Kiw upmilling vdg;gLk;. ,jpy; cutter RoYk;
jpirf;F vjph;j; jpirapy; workpiece efh;j;jg; gLk;.
19. Define climb milling.
Cutter fPo;Nehf;fp efUk;NghJ metal ntl;b ePf;fg; gLk;
nray;Kiw down milling vdg;gLk;. ,jpy; cutter RoYk;
jpirapNyNa workpiece efu;j;jg; gLfpwJ.
20. State the types of milling operations.
1) Plain milling 2) Side milling 3) Face milling
4) End milling 5) T- slot milling 6) Form milling
7) Straddle milling 8) Gang milling
21. What is straddle milling?
Work piecey; ,uz;L nrq;Fj;J jsq;fis xNu Neuj;jpy;
mahining nra;Ak; Kiwf;F straddle milling vd;W ngah;.
22. What is gang milling?
xU work pieced; gy;NtW jsq;fis xNu Neuj;jpy;
machining nra;Ak; Kiwf;F gang milling vd;W ngah;.
23. Define indexing? List out the types of dividing head.
Workpieced; gupjpia xU Fwpg;gpl;l vz;zpf;ifapy; rk
ghfq;fshfg; gpupf;Fk; Kiwf;F indexing vd;W ngau;.
,jw;F dividing head vd;w rhjdk; gad;gLfpwJ.
Dividing heady; fPo;f;fz;l tiffs; cs;sd.
1. Plain or simple dividing head
2. Universal dividing head
24. What are the uses of indexing plate and sector arm?
 Indexing plate MdJ xU circular disc MFk;. ,e;j discd;
ikaj;ij ikakhff; nfhz;l gy tl;lg;ghijfspy;
ntt;NtW vz;zpf;ifapy; Jisfs; ,lg;gl;bUf;Fk;.
CankI Njitahd msTf;F rupahf Row;w indexing
plate gad;gLj;jg; gLfpwJ.
 ,uz;L sector armfis tpupj;J my;yJ FWfr; nra;J
Njitahd vz;zpf;ifAs;s Jisfs; ,uz;L
armfSf;F ,ilNa ,Uf;FkhW mikj;Jf;
nfhs;syhk;. ,jdhy; Jis vz;zpf;ifapy; Vw;gLk;
gpio jtpu;f;fg; gLfpwJ.

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25. List out the methods of indexing.
1) Direct indexing or rapid indexing
2) Plain indexing or simple indexing
3) Compound indexing
4) Differential indexing
5) Angular indexing
6) Linear indexing
26. Mention the rule for direct indexing and simple indexing.
24
𝐹𝑜𝑟 𝑑𝑖𝑟𝑒𝑐𝑡 𝑖𝑛𝑑𝑒𝑥𝑖𝑛𝑔, 𝐼𝑛𝑑𝑒𝑥 𝑐𝑟𝑎𝑛𝑘 𝑚𝑜𝑣𝑒𝑚𝑒𝑛𝑡 =
𝑁
40
𝐹𝑜𝑟 𝑠𝑖𝑚𝑝𝑙𝑒 𝑖𝑛𝑑𝑒𝑥𝑖𝑛𝑔, 𝐼𝑛𝑑𝑒𝑥 𝑐𝑟𝑎𝑛𝑘 𝑚𝑜𝑣𝑒𝑚𝑒𝑛𝑡 =
𝑁
𝑊ℎ𝑒𝑟𝑒, 𝑁 – 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑖𝑣𝑖𝑠𝑖𝑜𝑛𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑜𝑛 𝑡ℎ𝑒 𝑤𝑜𝑟𝑘 𝑝𝑖𝑒𝑐𝑒.
27. How compound indexing is performed?
jdpj;jdpahd ,uz;L simple indexing efh;Tfisf;
nfhLg;gjd; %yk; compound indexing ngwg;gLfpwJ :
(a) Index plateI epiyahf itj;J> handle cjtpahy;
crankI Njitahd msT Row;w Ntz;Lk;.
(b) Lock pinI release nra;j gpd;G> handle cjtpahy;
crank kw;Wk; index plate ,uz;ilAk;
NjitahdmsT Row;w Ntz;Lk;.
28. Write the rules for differential indexing.
(𝐴 − 𝑁)
1) 𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜 = × 40
𝐴
40
2) 𝐼𝑛𝑑𝑒𝑥 𝑐𝑟𝑎𝑛𝑘 𝑚𝑜𝑣𝑒𝑚𝑒𝑛𝑡 =
𝐴
3) 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑖𝑑𝑙𝑒𝑟𝑠
 (A – N) kjpg;G + ve Mf ,Ue;jhy;> xU idler.
 (A – N) kjpg;G - ve Mf ,Ue;jhy;> idler
Njitapy;iy my;yJ ,uz;L idlerfs;.
,q;F> A = Cfpj;Jf; nfhs;Sk; rkghfq;fspd;
vz;zpf;if
N = cz;ikapy; indexing nra;a Ntz;ba
ghfq;fspd; vz;zpf;if
29. What is angular indexing? Give its rule.
Work pieced; gujpia xU Fwpg;gpl;l Nfhz msT
nfhz;l rk ghfq;fshfg; gpupf;Fk; Kiwf;F angular
indexing vd;W ngau;.
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Index crank movement

Nfhzthf;fpy; nghUs; efu Ntz;ba msT (bfphpapy;)
=
𝟗
Nfhzthf;fpy; nghUs; efu Ntz;ba msT (minutey;)
=
𝟓𝟒𝟎
30. What is linear indexing? State its rule.
ePsthf;fpy cs;s njhiyit xU Fwpg;gpl;l msT
nfhz;l rkghfq;fshfg; gpupf;Fk; Kiwf;F linear
indexing vd;W ngau;.
𝑰𝒏𝒅𝒆𝒙 𝒄𝒓𝒂𝒏𝒌 𝒎𝒐𝒗𝒆𝒎𝒆𝒏𝒕
𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑜𝑛𝑒 𝑑𝑖𝑣𝑖𝑠𝑖𝑜𝑛
= × 𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜
1
𝑃𝑖𝑡𝑐ℎ 𝑜𝑓 𝑙𝑒𝑎𝑑 𝑠𝑐𝑟𝑒𝑤 × ( )
40

GEAR GENERATING PROCESSES

31. Mention the vaious gear generating processes.
1) Gear shaping 2) Gear planning 3) Gear hobbing
32. Write the advantages of gear shaping.
1) xU Fwpg;gpl;l module nfhz;l cutterI gad;gLj;jp>
ntt;NtW vz;zpf;ifapy; gw;fs; nfhz;l gy gearfis
ntl;lyhk;.
2) Internal gearfis vspjpy; ntl;lyhk;.
3) njhlh;rr ; pahf machining eilngWtjhy; cw;gj;jp
tpfpjk; mjpfk;
4) Elliptical gear, face gear kw;Wk; cluster gear
Nghd;wtw;iw cUthf;fyhk;.
33. Mentin the advantages gear planning.
1) xU Fwpg;gpl;l module nfhz;l cutterI gad;gLj;jp
gy;NtW vz;zpf;ifapy; gw;fs; nfhz;l gy
gearfis cUthf;fyhk;.
2) Cluster gearfis cUthf;fyhk.;
3) ,k;Kiwapy; cUthf;fg;gLk; gw;fspd; msT kw;Wk;
tbtk; kpfj; Jy;ypakhf ,Uf;Fk;.
34. Mention the limitations in gear planning.
1) Internal gear kw;Wk; worm gearfis cUthf;f KbahJ.
2) mjpf jbkd; nfhz;l gearfs; nra;tJ fbdk;.
3) cw;gj;jp tpfpjk; FiwT.

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35. What is hobbing?
Helical thread cld; $ba hob vdg;gLk; cutter gad;
gLj;jp gearfis cUthf;Fk; Kiw hobbing vdg;gLk;.
36. What are the types of gears that can be generated in hobbing?
Hobbing Kiwiag; gad;gLj;jp spur gear, helical gear
kw;Wk; worm gearfis cUthf;fyhk;.
37. Name the finishing processes for gears.
1) Gear burnishing 2) Gear shaving
3) Gear grinding 4) Gear lapping
38. Define gear shaving.
Gear shaving vd;gJ mjpf fbdj;jd;ik nfhz;l rack
my;yJ pinion tbt cutterIg;g gad;gLj;jp gearfis
finishing nra;Ak; Kiw MFk;.
39. What is gear burnishing?
,J xU gear finishing nray;Kiw MFk;. ,jpy; finishing
nra;ag;gl Ntz;ba work gear MdJ %d;W burnishing
gearfSf;fpilNa itf;fg;gl;L midj;J gearfSk;
,ize;J RoYk;.
40. What are the methods of gear grinding?
a) Formed wheel gear grinding
b) Generation gear grinding
41. Define gear lapping.
fbdg;gLj;jg;gl;l gearfis kpfj;Jy;ypakhf finishing
nra;a gad;gLk; Kiw gear lapping vdg;gLk;. ,jpy;
finishing nra;ag;gl Ntz;ba work gear MdJ %d;W
lapping gearfSf;fpilNa itf;fg;gl;L midj;J
gearfSk; ,ize;J RoYk;.
42. Name the materials used for producing gears.
1) Cast iron 2) Steel 3) Alloy steel 4) Brass
5) Bronze 6) Aluminium 7) Nylon 8) Fibre
43. Write down the uses of brass gears.
rpwpa motorfs;> mstpLk; fUtpfs;> camera, nghk;ikfs;
kw;Wk; kpd; rhjdg; nghUl;fspy; brass gearfs;
gad;gLfpd;wd.

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44. Mention the uses of aluminium gears.
mstpLk; fUtpfs;> nghk;ikfs;> camera kw;Wk; gy
kpd;rhjdg; nghUlfspy; gad;gLk; gearfs; aluminium
nfhz;L jahupf;fg; gLfpd;wd.
45. Write down the uses of nylon gears.
T.V., radio, mstpLk; fUtpfs;> time gearfs;, camera,
projector Nghd;wtw;wpy; nylon gearfs; gad;gLfpd;wd.
46. What are the uses of fibre gears?
mstpLk; fUtpfs;> tape recorder, projector, TV, comparator
Nghd;wtw;wpy; fibreMy; nra;ag;gl;l gearfs;
gad;gLj;jg; gLfpd;wd.

Unit – IV
ABRASIVE PROCESSES
1. What is abrassive process?
Ntfkhf Rod;W nfhz;bUf;Fk; xU abrasive wheelIf;
nfhz;L cNyhfj;ij Ez;zpa chipsfshf
ngau;j;njLf;Fk; Kiwf;F abrassive process vd;W ngah;.
2. Mention the types of rough grinders.
1) Floor stand grinders 2) Bench grinders
3) Portable grinders 4) Abrasive belt grinder
5) Swing frame grinder
3. Classify precision grinders.
1) Cyliindrical grinders 2) Internal grinders 3) Surface grinders
4. Write down the uses of portable grinders.
kpfg;nghpa forging, casting kw;Wk; welded jointfis mit
,Uf;Fk; ,lj;jpw;Nf vLj;Jr; nrd;W rough grinding nra;a
,t;tif grinderfs; gad;gLfpd;wd.
5. Give the uses of abrassive belt grinder.
rpwpa kw;Wk; xOq;fw;w tbtKila nghUl;fis ,jpy;
ghJfhg;ghf rough grinding nra;ayhk;.
6. What are the methods used in centre type cylindrical grinding?
1) Traverse grinding 2) Plunge cut grinding 3) Taper grinding

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7. When the transverse grinding is used?
Grinding wheeld; ePsj;ij tpl work pieced; ePsk; mjpfkhf
,Uf;Fk; NghJ traverse grinding gpd;gw;wg; gLfpwJ.
8. What is plunge cut grinding?
Wheeld; ePsj;ij tpl> workpiecey; grinding nra;ag;gl
Ntz;ba gFjpapd; ePsk; Fiwthf ,Uf;Fk;NghJ
gad;gLj;jg;gLk; Kiw plunge cut grinding MFk;.
9. What do you mean by centrless grinding?
,uz;L wheelfSf;F ,ilapy; work restd; kPJ kpjg;gJ
Nghy; workpiece itf;fg;gl;L grinding nra;Ak; Kiwf;F
centreless grinding vd;W ngah;.
10. What are the methods of centreless grinding?
1) Through feed 2) In feed 3) End feed
11. What is the use of planetary type centreless grinding?
Chucky; nghUj;jp Roy itf;f Kbahj ngupa kw;Wk;
fdkhd workpiecefspd; cl;Gwkhf grinding nra;a
,t;tif grinder gad;gLfpwJ.
12. Classify the sufrace gdinders.
1) Horizontal spindle - reciprocating table surface grinder
2) Horizontal spindle - rotary table surface grinder
3) Vertical spindle - reciprocating table surface grinder.
4) Vertical spindle - rotary table surface grinder.
13. Classify tool and cutter grinder.
1) Bench type tool and cutter grinder
2) Universal type tool and cutter grinder
3) Radius toll grinder
14. Write down the specifications of grinding machine.
1) Machiney; nghUj;jf;$ba workpieced; mjpfgl;r msT
2) Grinding wheeld; tpl;lk;
3) Wheel head efUk; mjpfgl;r J}uk;
4) Tabled; msT
5) Motord; ,af;fj;jpwd;
6) Grinding machined; epfu vil
15. Name the natural abrasives.
1) Sand stone or solid quartz 2) Emery
3) Corundum 4) Diamonds
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16. Mention the artifical abrasives.
1) Aluminium oxide 2) Silicon carbide
17. What are the types of bonds used in grinding wheesl?
1) Vitrified bond (V) 2) Silicate bond (S)
3) Resinoid bond (B) 4) Rubber bond (R)
5) Shellac bond (E)
18. Define grit.
Abrasive Jfs;fisg; gpupj;njLf;fg; gad;gLk;
ry;yilapd; 25.4mm (1 inch) ePsj;j;jpy; cs;s Jisfspd;
vz;zpf;ifia Fwpg;gNj grid vdg;gLk;.
19. What is grade in grinding wheels?
xl;Lk; nghUl;fs; (bonds) %yk; abrasive Jfs;fs;
vt;tsT gyj;NjhL gpizf;fg;gl;Ls;sd (bonding
strength) vd;gij Fwpg;gNj grade vdg;gLk;. Grinding
wheeld; fbdj; jd;ikia Fwpg;gjhFk;.
20. Define structure.
Grinding wheely; mLj;jLj;j ,uz;L abrasive
Jfs;fSf;F ,ilNaAs;s ,ilntspiaf; Fwpg;gJ
structure vdg;gLk;.
21. What are the types of grinding wheels?
1) Peripheral grinding wheel 2) Face grinding wheel
3) Form grinding wheel 4) Mounted wheel or points
22. Give the example of standard marking system.
Example : 51–A–46–L–6–V–23
51 – Prefix; A – Aluminium oxide (abrasive);
46 – Grain size; L – Grade; 6 – Structure;
V – Vitrified bond; 23 – Manufacturer’s record
23. What is glazing?
ePz;l Neuk; grinding nra;a gad;gLj;jpa gpd;G wheeld;
ntl;L Kidfs; kOq;fp fz;zhb (glass) Nghd;w
Nkw;gug;ig ngWfpwJ. ,jw;F glazing vd;W ngau;.
24. Define loading in grinding wheels.
Grinding nra;Ak;NghJ cUthFk; Ez;zpa Jfs;fs; wheely;
cs;s abrasive Jfs;fSf;F ,ilNa cs;s ,ilntspapy;
GFe;J xl;bf; nfhs;Sk;. ,jw;F loading vd;W ngau;.
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25. What is dressing?

Dresser vdg;gLk; toold; cjtpahy; grinding wheely; ,Ue;J
glazing kw;Wk; loadingI ePf;FtNj dressing vdg;gLk;.
26. Defing truing.
xU diamond tip tool %yk; grinding wheeld; Kfj;ij
xoq;fhd tbtpw;F nfhz;L tUk; Kiwf;F truing vd;W
ngah;.
27. What is the need for balancing of grinding wheels?
Grinding wheeld; vil mjd; midj;Jg; gFjpfspYk;
rPuhf distribute Mfp ,Uf;f Ntz;Lk;. mt;thW
,y;iynadpy;> mjpf Ntfj;jpy; wheel RoYk;NghJ>
rkg; gLj;jg;glhj (unbalanced) ika tpyf;F tpirapd;
fhuzkhf wheel cile;J tpl tha;g;G cs;sJ. vdNt
gad;gLj;Jtjw;F Kd;G wheelI rupahf balancing nra;a
Ntz;Lk;.

NON-CONVENTIONAL MACHINING PROCESSES

28. Name the widely used unconventional maching processes.

1) Ultrasonic Machining (USM)
2) Chemical Machining (CHM)
3) Electro Chemical machining (ECM)
4) Electro Chemical Grinding (ECG)
5) Electrical Discharge Machining (EDC)
6) Plasma Arc Machining (PAM)
7) Laser Beam Machining (LBM)
29. How metal is removed in ultrasonic machining process?
Anrasive Jfs;fpd; mhpg;G kw;Wk; rpuha;g;G %yk; work piecey;
,Ue;J kpf Ez;zpa Jfs;fshf metal ePf;fg; gLfpwJ.
30. Write down the applications of ultrasonic machinging? (Or)
Name the process used to machine carbide and tungsten.
1) Glass, ceramics, carbides, diamond kw;Wk; fbd khf;fg;gl;l
steel Nghd;w vspjpy; cilaf; $ba fbdkhd
nghUl;fspy; Jisfis Vw;gLj;jg; gad;gLfpwJ.

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2) Wire drawing nray; Kiwapy; gad;gLj;jg;gLk;;
tungsten carbide kw;Wk; diamondMy; Md diefis
,k; Kiwapy; cUthf;fyhk;.
3) kpd; flj;Jk; kw;Wk; kpd; flj;jhg; nghUl;fspYk;
machining nra;ayhk;.
31. Write down the steps involved in chemical machining.
1) Cleaning 2) Masking 3) Edging 4) Demasking
32. What is etching?
Etchant vdg;gLk; #lhd xU jputj;jpy; workpieceI
itj;J %o;fr; nra;Ak; chemical machining
nray;Kiwapd; xU gb MFk;.
33. Write down the applications of chemical machining.
1) tisthd kw;Wk; xOq;fw;w tbt gs;sq;fis
Vw;gLj;j ,e;j Kiw rpwe;jjhFk;.
2) kpd;zZ rhjdq;fs;> Mfha tpkhd ghfq;fs;
kw;Wk; automobile ghfq;fspy; rpf;fyhd tbt
gs;sq;fs; Vw;gLj;j cjTfpwJ.
3) ,k; Kiwapy; jahhpf;fg;gl;l ghfq;fs; tape recorder,
computer, T.V., Camera, Telephone Nghdwtw;wpy;
nghpJk; gad;gLj;jg;gLfpwJ.
34. What are the applications of electro chemical machining?
1) kpfTk; fbdkhd cNyhfq;fspy; rpf;fyhd tbt
gs;sq;fis Vw;gLj;j ,k;Kiw gad;gLfpwJ.
2) Gas turbine bladefs;> impeller kw;Wk; Mfha tpkhd
ghfq;fis ,k;Kiwapy; cw;gj;jp nra;ayhk;.
3) Blind holes, through holes kw;Wk; xOq;fw;w tbt
gs;sq;fis Vw;gLj;j ,k;Kiw cjTfpwJ.
4) nghpa kw;Wk; fdkhd forgingfspy; rough machining
nra;a ,k;Kiw gad;gLfpwJ.
35. Mention the method of metal removal in ECG process.
,k;Kiwapy; electro chemical kw;Wk; grinding wheeld;
abrasive action %yk; cNyhfk; ePf;fg;gLfpwJ.
36. How metal is removed in EDM process?
,k;Kiwapy; electric spark %yk; cUthFk; mjpf
ntg;gj;jpy; workpieceI R+LgLj;jp mg;gFjpapypUe;J
cNyhfk; erosion (mhpj;jy;) %yk; ePf;fg;gLfpwJ.

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37. State the applications of EDM.
1) Nozzlefspy; rpwpa Jisfis Vw;gLj;Jtjw;F
,k;Kiw gad;gLfpwJ.
2) Nghd;w vspjpy; cilAk;
Tungsten carbide, stellite
jd;ik nfhz;l fbdkhd nghUl;fspy; machining
nra;a ,k;Kiw cjTfpwJ.
3) Tool kw;Wk; cutterfis $h;ikahf;fg; gad;gLfpwJ.
4) Work pieceI ,uz;lhf ntl;bg; gphpf;fTk; ,k;Kiw
cjTfpwJ.
38. What is plasma?
mjpf ntg;gepiyf;F thAit R+lhf;Fk; NghJ mJ
ionize MfpwJ. ,e;j ionised gas MdJ plasma vdg;gLk;.
39. What are the applications of plasma arc machining?
1) Stainless steel kw;Wk; mYkpdpa cNyhff;
fyitfis ntl;Ltjw;F gad;gLfpwJ.
2) fbdkhd alloy steelfspy; Njitahd tbtj;ij
Vw;gLj;j gad;gLfpwJ.
40. Write down the method of metal removal in LBM.
xU lens %yk; laser beam MdJ work pieced; Njitahd
,lj;jpy; Ftpf;fg;gLk;. ,g;NghJ mq;F cUthFk;
mjpf ntg;gj;jhy; me;j ,lk; cUfp Mtpahfp tpLk;.
41. List out the applications of LBM.
1) kpfr; rpwpa Jisfis (0.005mm) Vw;gLj;j ,J
kpfTk; gad;gLfpwJ.
2) Surgical needlefspy; JisapLtjw;F gad;gLfpwJ.
3) Ceramic Nghd;w fbdkhd nghUl;fspy; JisapL
tjw;Fk; gad;gLfpwJ.
42. State the limitations of LBM.
1) ,jpy; gad;gLj;jg;gLk; cgfuzq;fspd; tpiy mjpfk;.
2) Machining nra;ag;gl;l Jisfs; xOq;fhd tl;l
tbtpy; ,Uf;fhJ.
3) ,e;j nray; Kiwapd; efficiency FiwT.
4) mjpf cNyhfj;ij machining nra;a ,ayhJ.

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Unit – V
CNC MACHINES

1. Define numerical control.

vOj;Jf;fs;> vz;fs; kw;Wk; FwpaPLfs; Mfpatw;wpd;
%yk; machine toolfspd; gy;NtW nray;ghLfis
fl;Lg;gLj;Jk; Kiw Numerical Control (NC) vdg;gLk;.
2. What are the components of NC system.
1. Program of instructions
2. Machine Control Unit (MCU)
3. Machine tool
3. Define CNC.
Computer numerical control (CNC) vd;gJ mjd; rpy
my;yJ midj;J fl;Lg;ghl;Lr; nray;fisAk;
Nkw;nfhs;tjw;fhf> mjw;nfd xJf;fg;gl;l xU
microcomputerIf; nfhz;l NC system MFk;. NC system
vd;gJ vOj;Jf;fs;> vz;fs; kw;Wk; FwpaPLfs;
Mfpatw;wpd; %yk; machine toolfspd; gy;NtW
nray;ghLfis fl;Lg;gLj;Jk; Kiw MFk;.
4. List out the components in MCU.
1) Central processing unit
2) Memory
3) Input / Output interface
4) Controls for machine tool axes and spindle speed.
5) Programmable logic controller
5. Mention the advantages (features) of CNC machines.
1) CNC controllery; xd;Wf;Fk; Nkw;gl;l programfis
Nrkpj;J itf;fyhk;.
2) CNC controllerfspy; punched tape, magnetic tape, floppy
disketter, compact disc kw;Wk; manual data input Nghd;w
gy;NtW topKiwfspy; jfty;fis cs;sPL nra;a
,aYk;.

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3) MCU computer memoryy; cs;s part programfis me;j

,lj;jpNyNa jpUj;jp mikj;J Nkk;gLj;jp Nrkpf;f
,aYk;.
4) CNC systemj;jpy; linear, circular, helical, parabolic, kw;Wk;
cubic interpolationfs; gad;gLj;jg; gLfpd;wd.
5) Part programI machine toolf;F mDg;Gtjw;F Kd;G
mjd; simulationI computery; ghh;f;ff; $ba jpwid
CNC machine fs; nfhz;Ls;sd.
6. State the features of CNC machines.
1) Part programfis computer memoryy; Nrkpj;J
itj;jy;.
2) kpfTk; cfe;j tool pathI jhdhfNt jPh;khdpj;jy;.
3) xNu Neuj;jpy; gy;NtW functionfis ,af;Fjy;.
4) jhdfNt toolI khw;wpf;nfhs;Sjy;.
5) jhdfNt workpieceI kpfr;rhpahf nghUj;Jjy;.
6) nra;J Kbf;fg;gl;l nghUspd; msTfis jhdfNt
NrhjidapLjy;.
7) rpf;fyhd tbtikg;GfisAk; kpf Ntfkhf ntl;b
cUthf;Fjy;.
8) Tool ciltij fz;lwpe;J mjid jpUk;gg; ngWjy;.

7. What is CNC turning centre?

CNC turning centre vd;gJ CNC system cjtpAld;> xU
work piecey; gy;NtW turning kw;Wk; mJ njhlh;ghd
nray;ghLfis xNu setupy; nra;aty;y xU machine
MFk;.
8. What is turn-mill centre?
CNC turn–mill centre vd;gJ CNC system cjtpAld;
turning kw;Wk; milling nray;ghLfis Nkw;nfhs;Sk;
machine MFk;.
9. What is CNC machining centre?
CNC machining centre vd;gJ work pieced; xNu setupy;
gy machining operationfis nra;aty;y xU CNC
system MFk;.

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10. What is universal machining centre?

rpy horizontal machining centrefspy;> computer fl;Lg;
ghl;bd; cjtpahy; horizontal mr;ir nrq;Fj;J
epiyf;F jpUg;gp mikf;f ,aYk;. ,j;jifa
machinefs; universal machining centre vdg;gLk;.
11. What is CMM?
Coordinate Measuring Machine (CMM) vd;gJ xU nghUs;
my;yJ ghfj;jpd; location, orientation, dimension kw;Wk;
geometry Nghd;wtw;iw fz;lwptjw;Fg; gad;gLk; xU
electro-mechanical rhjdk; MFk;.
12. What are the components of CMM?
1) Workpieced; Nkw;gug;igj; njhLtjw;F cjTk;
probe head kw;Wk; probe
2) xt;nthU mr;rpYk; mr;Rj;J}uq;fis mstpl
cjTk; displacement transducerfs;
3) Probef;F efh;itj; jUk; mechanical structure
4) xt;nthU mr;irAk; efh;j;j cjTk; drive system
kw;Wk; control unit.
13. List out the benefits of CMM.
1) Inspection cycle time Fiwf;fg; gLfpwJ.
2) mstpLjy; kw;Wk; nghUj;Jjy; Mfpatw;wpy; Vw;gLk;
operator gpiofs; Fiwf;fg; gLfpd;wd.
3) Manual Mf NrhjidapLtij tpl CMM %yk; kpfj;
Jy;ypakhfTk; rhpahfTk; Nrhjidapl KbAk;.
4) CMMd; repeatability rpwg;ghf ,Uf;Fk;.
5) CMMI ,af;FtJ kpfTk; Rygk;.

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COMPONENTS OF CNC MACHINES

14. State the requirements of a good slideway system.

ntt;NtW Ntfq;fspYk; Fiwthd friction coefficient
,Uf;f Ntz;Lk;.
 Static kw;Wk; dynamic friction coefficientfSf;F ,ilNa
Fiwthd tpj;jpahrk; ,Uf;f Ntz;Lk;.
Nja;khd tpfpjk; Fiwthf ,Uf;f Ntz;Lk;.
 Sliding jointfspy; mjpf stiffness ,Uf;f Ntz;Lk;.
rpwe;j damping gz;Gfisg; ngw;wpUf;f Ntz;Lk;.
 Stick-slip gz;G kpff; Fiwthf ,Uf;f Ntz;Lk;.

15. Mention the types of slideways.

1) Friction slideways (Guideways with sliding friction)
2) Anti-friction slideways (Guideways with rolling friction)
16. List out the advantages of linear motion bearings.
1) ,af;fr; rhjdq;fs; mstpy; rpwpajhf ,Uf;Fk;.
2) Fiwthd vibration kw;Wk; shock cld; $ba
kpUJthd efh;itg; ngw KbAk;.
3) Stick-slip gpur;rpid KOtJkhf ePf;fg;gLk;.
4) kpff; Fiwe;j msT lubricant NghJkhdJ.
5) Nja;khdk; kpff;FiwT. vdNt ePbj;J ciof;Fk;.
17. State the advantages of recirculating ball screw and nut.
1) Friction coefficient kpfTk; FiwT.
2) Transmission efficiency kpfTk; mjpfk;.
3) Stick-slip gz;G KOtJk; ePf;fg; gLfpwJ.
4) Backlash KOtJk; ePf;fg; gLfpwJ.
5) Nja;khdk; Fiwf;fg; gLtjhy;> tho;ehs;
mjpfhpf;fg; gLfpwJ.
18. What is ATC?
Automatic tool changer (ATC) vd;gJ CNC machined; xU
Kf;fpa ghfk; MFk;. ,J Njitg;gLk;NghJ spindley;
Vw;fdNt cs;s toolI mfw;wp tpl;L tool magaziney;
,Ue;J xU toolI vLj;J spindley; nrUFfpwJ.

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19. What is tool magazine? List out its types.

 CNC machinefspy; toolfis Nrfhpj;J itg;gjw;F
cjTk; rhjdk; tool magazine MFk;.
 CNC machinefspy; fPo;f;fz;l tiffs;
gad;gLj;jg;gLfpd;wd:
(1) Tool turret (2) Drum or disc type magazine
(3) Chain type magazine
20. What is transducer?
CNC machinefspy; cs;s ghfq;fspd; velocity kw;Wk;
efh;tpid mstplg; gad;gLk; feed back rhjdq;fs;
transducerfs; MFk;.
21. What is the difference between rotary encoder and linear
transducer?
 Lead screwd; RoYk; Ntfj;ij mstpLtjw;F
rotatary encoder gad;gLj;jg; gLfpwJ.
 xU epiyahd datumj;ij mbg;gilahff; nfhz;L
machine slidefspd; efh;it mstpl linear transducer
gad;gLj;jg; gLfpwJ.
22. Define in-process probing?
cw;gj;jp nra;ag;gLk; nghUspd; msit mt;tg;NghJ
Nrhjidapl;L> mjw;Nfw;g mstPLfis jhdhfNt
rhpnra;J nfhs;tjw;fhd nray;Kiw in-rpocess
probing vdg;gLk;.
23. List out the cutting tool materials for CNC machines.
1. High Speed Steel (HSS)
2. Cemented Carbides
3. Ceramics
4. Cermets
24. What are the materials used as tool inserts?
Cemented carbide, polycrystalline, diamond, kw;Wk; cubic
boron nitride.
25. Mention the different shapes of tool inserts.
Round, triangle, square, rhombus kw;Wk; diamond.


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