Unit-1

Time
Difficulty Questio Requ
Sr.No. Question Level n Marks ired
1A1 What is metal cutting?Define chip removal? M T 2 9
1A2 Discuss basic elements of metal cutting? M T 2 9
1B1 Explain orthogonal cutting and oblique cutting ? M T 2 9
Explain with the help of neat sketch the complex geometry
1C1 of a single point cutting tool. M T 7 18

1C2 How are tools classified?State three examples of each. M T 7 18

1D1 Define tool signature? M T 2 9
Explain each term of a tool designated as
1D2 8,12,10,7,0,15,1.5mm M N 2 9
1E1 What is chip formation? M T 2 9

Name the different types of chips formed in metal

1E2 cutting.Describe each type with the help of neat sketches. M T 7 18
1F1 List the main requirement of cutting tool material. M T 2 9
Name and explain the various materials used for cutting
1F2 tools. M T 7 18
Write short notes on the following:(a) chip breakers (b)
advantages of negative rake angle© curling of chip (d)
1G1 cutting speed (e) feed(f)depth of cut(g)throw-away tips M T 7 18
1G2 What is chip reduction coefficient? M T 2 9
What are the effects of cutting variable on the chip
1G3 reduction coefficient. M T 2 9
1H1 What is a multipoint cutting tool? M T 2 9

During turning a mild steel component with an orthogonal

tool a feed of 0.75mm/revis used at 50 R.P.M.If the chip
thickness is 1.5 mm determine the chip thickness
ratio.Also find the length of chip removed in one minuteif
the work diameter is 50mm before the cut is taken
1I1 .Assume a continuous chip. H N 7 27
In an orthogonal turning operation Cutting
speed=80m/min. Cutting force= 20kg. Feed force= 8kg
Back rake angle=150 Feed=.2 mm/rev Chip thickness=0.4
mm Determine the following:(a) Shear angle (b) Work
1I2 done in shear © Shear Strain H N 7 27
Calculate the power consumed during cutting of a low
carbon steel bar 40mm diameter if cutting force is 150 kg
1I3 at 200 R.P.M. H N 7 18
Determine the time required to turn a brass component
50mm diameter and 100mm long at a cutting speed of
36m/min. The feed is 0.4mm/revolution and only one cut is
1I4 taken. H N 7 18
 In orthogonal cutting if the feed is 1.25mm/rev and chip
thickness after cutting is 2 mm;determine the
following:The tool bit has a rake angle of 100 (b) If shear
strength = 6000Kg/cm2 width of cut= 10mm cutting
speed= 30m/min. Coefficient of friction=0.9 Determine the
following:(i) Shearing force(ii) friction force(iii) cutting
1I5 force(iv) Horse power at the cutting tool. H N 7 27

In orthogonal cutting of a material the feed force is 80 kg

and cutting force is 150 kg. Calculate the following:(i)
Compression and shear force on shear plane (ii)
Coefficient of friction of the chip on the tool face. Take
1I6 chip thickness ratio as 0.3 and rake angle as 80. H N 7 18
Describe how to calculate the resultant force acting on a
1J1 single point cutting tool in turning. M T 2 9
Explain the relationship between variou forces in
1J2 orthogonal cutting. M T 7 18
Sketch Merchant's circle diagram and explain the different
1J3 quantities involved. M T 7 18
What are the three velocities if interest in the cutting
1K1 process. M T 7 18
Explin the relationship betweencutting velocity and chip-
flow velocity and between shear velocity and cutting
1K2 velocity. M T 7 18

Prove that according to Ernst. Merchant theory the relation

between rake angle (α),shear angle (beta) and friction
1L1 angle (gamma)is given by Beta=pi/4-gamma/4+alpha/2 M T 7 18
In orthogonal cutting of a mild steel component if the rake
angle of tool is 10degreeand shear angle is 30degree.
1M1 Calculate the chip thickness ratio. M N 7 18

Unit-2

Time
Reqd
Sr.No. Question LOD Type Marks .
How do you explain tool life.Explain the parameters that
1A1 control the tool life of a single point cutting tool. M T 7 18
What are the various forms of wear found in cutting
2B1 tool.Show with a neat sketch. M T 7 18
How do the cutting process parameters affect the cutting
2B2 tool wear in single point tools. M T 2 9
Show diagrammatically the variation of flank wear of
cutting tool with time and explain its temperature from the
2B3 tool life point of view. M T 7 18
Enumerate the factors on which tool wear and tool life
2B4 depend. M T 7 18
2B5 Discuss various types of tool wear. M T 7 18
2B6 Why tool wear is important in metal cutting. M T 2 9
What are the types of cutting tool wear patterns observed
in single point tools. How do they affect the metal cutting
2B4 performance. M T 7 18
Which are the suitable tool failure criteria that are
generally practised in industries. Explain your answers
3C1 with examples. M T 7 18
What is meant by machinability. Explain the method of
4D1 representing the machinability. M T 2 9
If Taylor's tool life constants for a given operation are
specified as n=0.5 and c=400, what is the percentage
increasse in tool life when the cutting speed is reduced by
4D2 half. M T 7 27

The tool life of a high speed steel (HSS) tool and carbide
tool have the same tool life of 60minutes at a cutting
speed of 75 m/min.The exponent of tool life in Taylors
equation (n) is 0.15 for HSS while it is 0.2 for
carbide.Compare the life of the two tools at a speed of 90
4D3 m/min. M T 7 27
In a normal turning operation the tool life varies with the
cutting speed as shown in the following table.Cutting
Speed V,m/min. Tool Life T/min. 25 30 70 2
Estimate the tool life for this operation at a speed of
60m/min.
4D4 M T 7 27
5E1 What are the main application of cutting fluids. M T 7 18
What are the mechanisms that are generally responsible
for the effectiveness of cutting fluid in improving machining
5E2 performance. M T 2 9
What are the points from which a cutting fluid may be
5E3 applied in machining operation. M T 2 9

Explain the basis for the selection of a specific cutting fluid

for a given application.Take the example of turning, milling
5E4 & grinding, and suggest the type of cutting fluid used. M T 7 18

In a turning operation, it was observed that the tool life

was 100minutes and 50 minutes at cutting speeds of
25m/min., and 100 m/min. respectively. Find out the tool
5E5 life of 200 m/min. under the same cutting conditions. M T 7 27
In Taylor equation, If n=0.25 and c=300 m/min. What
5E6 should be v for a tool life of one hour. M T 7 27

Unit-3

Time
Difficulty Questio Reqd
Sr.No. Question Level n Type Marks .
 List the properties which should be possessed by machine
1A1 tool parts for their proper performance M T 7 27
1A2 What is the purpose of machine tool. M T 2 9
Which is the best section for machine body .Justify your
1A3 answer. M T 2 9
1A4 How the machine bodies are stiffened. M T 2 9
2B1 What is the purpose of guideways. M T 2 9
2B2 What are the principal requirements of guideways M T 7 18
2B3 Name the different types of guideways. M T 7 18
3C1 Name and discuss the various types of slideways. M T 7 18
Write on:(a) Anti-friction slideways (b) Hydro-statically
3C2 lubricated slideways M T 7 18
Discuss the different materials used for machine body and
4D1 guideways. M T 7 18
Compare the cast and welded structures for machine
4D2 bodies. M T 2 9
4D3 What are: (a) attached ways (b) Plastic guideways M T 2 9
4D4 Write briefly on design of slideways. M T 7 18
4D5 What is the function of machine spindle. M T 2 9

4D6 Discuss the principal requirements for machine spindles. M T 2 9

4D7 Write on: Materials for spindles. M T 2 9
4D8 Write on the design features of spindles. M T 7 18
4D9 Write on:Mounting on spindles. M T 2 9
What is the purpose and importance of machine tools
4D10 tests. M T 7 18
List the various tests to which the machine tools are
5E1 subjected.Give their sequence. M T 2 9
5E2 Explain Idle-run tests. M T 2 9
5E3 Discuss performance tests under load. M T 2 9
On what factors the machining accuracy of a machine tool
5E4 depends.Write these. M T 7 18
Write about the following tests for slideways: (a)
5E5 Straightness (b) Flatness © parallelism M T 7 27
List various instruments used for the geometrical accuracy
6F1 tests of machine tools. M T 7 18
6F2 Write on:Test mandrel M T 2 9
6F3 Write on:Levelling of the machine tool bed. M T 7 18

Unit-4

Time
Difficulty Questio Reqd
Sr.No. Question Level n Reqd. Marks .
1A1 Describe about speed daigram structure M T 7 18
1A2 Define chatter in machine tools. M T 2 9
2B1 What the drive for rotational movements. M T 7 9
What are the factors for designing the stepped drive.Write
2B2 in detail. M T 7 27
3C1 How is kinematic advantages of geometrical progression. M T 7 18
3C2 What is PHI=2. M T 7 18
What is preferred numbers.Write evolution of preferred
4D1 numbers. M T 2 9
4D2 What is Saw diagram for machine tool spindle speeds. M T 2 9
4D3 What are the number of spindle speed steps. M T 2 9
4D4 What is speed stucture diagram for 6,9,12 speed drive. M T 7 27

Unit-5

Time
Reqd
Sr.No. Question LOD Type Marks .
What are the following requirements for a gear box for
1A1 machine tool. M T 2 9

1A2 What are the methods for changing speeds in gear boxes. M T 7 18
1A3 What are the various drive for feed gear boxes. M T 7 27
1A4 What is Norton Gear Box. M T 2 9
What is feed gear box of Meander Type,Clutched System
1A5 and Ruppert Drive. M T 7 18
2B1 What is Ray Diagram. M T 2 18
3C1 What is meant by machine tool installation. M T 2 9
3C2 What are the main objectives of machine foundations. M T 2 9
3C3 Write in detail about the machine foundation. M T 7 9
Write in detail about the analytical design of machine
3C4 foundation. M T 7 18
4D1 What is the aim of machine tool maintenance. M T 7 18
4D2 what is the need for machine tool maintenance. M T 2 9
4D3 Discuss the various types of maintenance. M T 7 9
4D4 Write on: Planned Maintenance System. M T 2 18
5E1 Write on: Machine Tool Lubrication. M T 2 9
Write on the various methods of doing machine tool
5E2 lubrication. M T 7 9
5E3 Write on : Reconditioning of Machine Tools. M T 2 18

6F1 What is the purpose and importance of machine tool tests. M T 2 9

List the various tests to which the machine tools are
6F2 subjected. M T 7 18
6F3 Explain "Idle-run"tests. M T 2 18
6F4 Discuss "performance tests under load.' M T 2 9
On what factors the machining accuracy of a machine tool
6F5 depends.Write these. M T 2 9
List various instuments used for the geometrical accuracy
6F6 tests of machine tools. M T 7 18
7G1 Write on "Test Mandrel" M T 2 18
7G2 Write on "Levelling of the machine tool bed." M T 7 9
 Write on the following methods of testing the straightness
7G3 of slideways. M T 2 18
Write on the following methods of testing the straightness
of slideways.(a) Straight edge method (b) Taut wire
7G4 method © Optical slighting method. M T 7 9
7G5 Write briefly on "Testing on main spindle. M T 2 27
What is axial float of main spindle.What are its
7G6 causes.How is it tested. M T 7 9
7G7 Write on rigidity tests of machine tools. M T 2 18
7G8 Write on vibration -resistance tests. M T 2 9