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What are the main characteristics that a cutting tool material should possess?
What are the main cutting tool materials? Describe each in brief stating its principal
characteristics and applications.
How are the cutting tool classified? Name a few tool of each type.
Explain the terms cutting speed, feed, and depth of cut, as applicable to metal cutting. Explain
the basis of their selection.
With the help of neat sketches, indicate the different parts and angles of a single point tool.
Explain the importance and functions of different tool angles and other parameters
associated with the geometry of a single point cutting tool.
What is tool signature? Explain with an example the tool signature used in ASA system.
What do you understand by Orthogonal and Oblique cutting? How do they differ from each
other?
Give two examples each of orthogonal cutting and oblique cutting.
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1 r sin
of shearing surface measured from tool direction, and = Rake angle, slant angle of tools
leading edge.
With the help of suitable diagram, derive expression for finding out shear velocity and chip
flow velocity when cutting velocity, shear angle and rake angle are known.
What are the assumptions made in the study of orthogonal cutting?
Explain the procedure to construct a merchants force circle diagram.
Explain merchants force circle diagram.
Draw a merchants circle diagram and derive expressions to show relationship among the
different forces acting on the cutting tool.
How is coefficient of friction determined for and orthogonal cutting process?
With the help of merchant circle diagram establish the relationship of various forces acting
on the chip with the horizontal and vertical cutting force.
What assumptions were made by merchant in arriving at his famous merchants theory?
Prove with the help of Merchants circle diagram that for orthogonal cutting:
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= ( ) where, = Shear angle = Friction angle = Rake angle
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r cos
With a suitable diagram find out an expression for shear strain in orthogonal metal cutting.
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In orthogonal turning of a 50 mm diameter mild steel bar on a lathe he following data were
Obtained: Rake angle = 15o, cutting speed =100m/min, feed 0.2 mm/rev, cutting force
=1800 N. Feed force=600 N. Calculate the chip thickness ratio, shear plane angle,
coefficient of friction, cutting power, the chip flow velocity and shear force, if the chip
thickness is 0.3 mm.
During orthogonal machining of a mild steel part, a depth of cut of 0.8 mm is used at 55 rpm.
If the chip thickness is 1.6 mm determine the chip thickness ratio. Also calculate the length of
chip removed in one minute if the work diameter is 50 mm before the cut is taken. Assume a
continuous type of chip.
For orthogonal cutting of a component, the feed force was 750N and cutting force was 1500N.
Find out the shear force and normal to shear force (compressive force) on the shear plane and
the coefficient of friction of the chip on the tool face. Assume chip thickness ratio as 0.28 and
tool rake angle as 100.
Module II
Different types of chips, chip breakers, tool wear: mechanism and types, tool life, machinability, cutting
fluid
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How many types of chips are formed in metal cutting? What factors are responsible for
formation of these different types of chips? What is built up edge and how it is formed?
Discuss the conditions favorable for formation of continuous and discontinous chips.
Why are chip breakers necessary? Discuss. What are the common methods of chip breaking?
What are the different sources and areas of heat generation during metal cutting? Explain.
What are the indications for inefficient performance of a cutting tool?
Explain the reasons and theory of tool failure.
What are the common mechanisms causing wear on cutting tools? Explain in brief.
Discuss the crater wear, flank wear, and nose wear of a cutting tool.
What do you understand from the term tool life as applicable to metal cutting? In what terms
it is expressed.
What are the main factors that influence tool life?
Explain the effect of cutting speed on tool life.
How is tool life affected by variations in feed and depth of out?
What is the effect of tool geometry on tool life? Discuss.
What is the Taylors tool life equation? Define each term.
A rod of diameter 150 mm machined at a cutting speed of 25 m/min has a life of 1 hr in
roughing cut. Determine its life in finishing cut, if tool life index is 1/8 and 1/10 in roughing
and finishing cut respectively.
While machining a mild steel work-piece with HSS tool the following data were recorded:
cutting speed 32 m/min, tool life 50 minutes. If the cutting speed is increased by 50%, how
tool life will be affected? Assume exponent n of Taylors equation = 0.2.
Calculate the percentage change in cutting speed required to give 65% of reduction in tool
life Assume n = 0.2.
What do you understand by machinability? By which parameter it is generally influenced?
Which criteria determine machinability? Explain the term machinability index.
What is a cutting fluid? What are the important functions of a cutting fluid?
How do you classify the cutting fluid?
Why cutting fluid acts only as a coolant at higher cutting speed?
Tutorial sheets of Manufacturing Processes I (PE 5005)
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What are the properties of diamond and what precautions are necessary while cutting with
diamond?
The friction between the chip and the tool plays a significant role in the cutting process. How
this friction can be reduced?
Sketch three view diagram of a 25 mm square tool bit having tool signature
a) 12, 12,10,10,15, 10 (3mm)
b) -8,+8,10,10,10,6 (6mm)
Explain the significance of providing rake angle and clearance angle on a tool?
Compare the coordinate system with orthogonal system of tool nomenclature.
Establish the tool life equation and calculate the cutting speed for 5 minutes tool life from the
following data. A tool life of 75 mm was obtained at a speed of 25 mpm and that of 10 min
when cutting at 60mpm.
When machining at 50 mpm, the tool life noted was 100 mins. Calculate the tool life if a
similar tool cuts at 20% higher speed. Also find out the value of cutting speed if the tool is
required to machine for 170 mins without failing. Take n = 0.27 in the Taylor tool life
equation.
A carbide tipped tool of designation 0-10-6-6-8-90-1 mm is used to turn a steel work piece of
50 mm dia., with a cutting speed of 240 mpm and feed of 0.25 mm/rev. The data obtained
shows the cutting force= 1800N, feed force= 1000N and chip thickness = 0.32 mm. Calculate
shear angle, shear force, normal force acting on the shear plane, friction force, coefficient
of friction, friction angle and chip flow velocity.
For an orthogonal cutting operation, using the data given below, calculate (1) shear angle, (2)
work done in shear, and (3) shear strain. Cutting velocity= 85 m/min, Cutting force = 250N,
Feed force 100N, Rake angle = 18o, Depth of cut = 0.25 mm, Chip thickness = 0.5 mm.
Reference Books
1. B.S.Raghuwanshi, A course in Workshop Technology-Dhanpat Rai & Sons.
2. Hajra Choudhury, Elements of Workshop TechnologyVol.-II, Media Promoters and
Publishers.
3. P.N. Rao, Manufacturing Technology Metal Cutting and Machine Tools, TMH.
4. DeGarmo et al., Materials and processes in Manufacturing, PHI.
5. Klapakjian et al., Manufacturing Processes for Engineering Materials, Pearson.
6. O P Khanna, Production Technology-(Vol. II)
7. R K Jain, Production Technology
8. HMT, Production Technology, HMT
9. Amitabha Battacharya , Metal Cutting Theory and Practice
10. George Schneider,Jr. CMfgE, Cutting Tool Applications
11. William J Patton, Machine tool Operations, Reston publishing company
12. O W Boston, Metal Processing, 2nd edition 1951, John Wiley and Sons
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32 mm
75 mm
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Calculate the actual machining time required for machining the product shown in figure
below. The available spindle speeds are 70, 110, 176, 210, 440, 700, and 1000 rpm. Use a
roughing speed of 25 m/min and finishing speed of 45m/min. Feed for roughing speed is
0.24 mm/rev while that for finishing 0.1 mm/rev. Maximum depth of cut for roughing is 1
mm and finishing allowance is 0.5 mm. The initial diameter of the workpiece is 40 mm.
50 mm
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36 mm
32 mm
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16 mm
Hexagonal Bolt
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Explain with the help of neat sketch the working principle of a shaper. Also discuss its
various parts.
How the different type of shaper is classified?
What are the common mechanisms used for quick return of ram of the shaper. Explain any
one of them.
With a neat drawing explain the crank and slotted link driving mechanism used in a shaper.
Also explain how the adjustment of length and position of stroke is done.
With a schematic diagram explain the working of hydraulic drive used in shaper. Also explain
how quick return mechanism is achieved in this drive.
With a neat diagram explain the feed mechanism of a shaper
Name and explain the common work holding devices used on a shaper.
Define cutting speed, feel and depth of cut for shaping operations.
Find out the expression for average cutting speed and total time required for one cut in a
shaper.
Derive an expression for machining time for shaper.
A shaper is operated at 120 cutting strokes per minute and is used to machine a work piece of
250mm length and 120mm in width. Use a feed of 0.6mm per stroke and a depth of cut of
6mm. The forward stroke is completed in 2300. Calculate the machining time for machining
the component and percentage of time when the tool is not in contact with the work piece.
Also calculate the material removal rate.
Calculate the cutting speed of the shaper when it makes 60 strokes/min each 30 cm long.
Assume cutting stroke to return stroke ratio of 3:2.
Calculate the time required to machine 250 mm long plate, 100 mm wide. Tool clearance at
each end of stroke is 30 mm and 20 mm respectively. Cutting speed is 10 m/min and return
speed is 20 m/min. Feed is 1 mm per cycle and the distance the tool moves on either side of
the work in width direction is 10 mm each.
Describe the various operations which can be performed on a shaper machine.
Explain the method of cutting gear teeth on shaper.
Describe the operations of cutting T-slots on a shaper.
What are the different types of planers? Discuss in short each one of them.
What are the different parts of a double housing planer? Discuss in brief.
How will specify a double housing planer?
With a neat diagram explain the belt drive mechanism of a planer.
With a neat diagram explain the friction disc feed mechanism of a planer.
What is difference between following:
a) Planer and shaper
b) Shaper and slotter.
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Describe with a neat sketch the working principle of planer. Also describe its various parts.
What are the main driving mechanisms used in a planer? How belt drives is used for quick
return motion of the planer table.
Describe in detail the feed mechanism of planer.
What the common work holding devices used in planer?
Define cutting speed, feed and depth of cut for planer.
Explain the different parts of a slotter with a neat sketch.
Describe the different drive mechanism of the slotter.
Explain the different work holding devices used on slotting machine.
Explain the principle of Milling. What are the different types of milling machine?
Differentiate between:a) Plain milling machine and universal milling machine.
b) Plain milling machine and vertical milling machine.
Sketch and describe a planner type milling machine.
Describe the working principle of planetary milling machine.
What are the principal parts of column and knee type milling machine. Explain in brief.
How will you specify the milling machine?
What are the standard and special types of milling attachments?
With the help of suitable sketches describe the construction and working of the following:a) Spindle
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Arbor c)
Adapter
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Collets.
a) What are the common work holding devices used in milling machine?
c) What are the different devices for holding and rotating milling cutter?
What are the various milling operations? Explain them with suitable sketches.
What do you mean by milling operations? Explain the relative merits of up and down milling
operation.
With sketch discuss the differences between up milling and down milling.
In short discuss the following milling operations: Gang milling, straddle milling, form
milling, and end milling.
What materials are used in the manufacture of milling cutters? Discuss their relative
advantages.
Classify and explain the various types of milling cutter. What materials are used in the
manufacture of milling cutters? Discuss their relative merits.
With a neat sketch show the various elements of a plain milling cutter.
What is negative rake milling? What are its various advantages?
Discuss various milling cutters. What are its specific advantages?
Define the terms cutting seed feed and depth of cut as applied to milling operation.
What are the different methods of expressing feed in milling machine?
What do you mean by indexing and what is its purpose?
What are the common methods of indexing? Describe their basic principles.
Explain the procedure for differential indexing.
Explain the procedure for compound indexing.
What is angular indexing?
How you can mill a hexagonal bolt head? Describe the different steps.
Find the indexing movement needed of milling the sides of a hexagonal nut using direct
indexing. The index plate has 24 holes.
Tutorial sheets of Manufacturing Processes I (PE 5005)
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What do you understand by location of a work piece & what are the important principles of
location and the type of locations commonly used?
What do you understand by principle of least points and principle of extreme positions?
What is meant by 3-2-1 principle of location?
What are the disadvantages of locating a piece against an inclined surface compared to
perpendicular plane?
What are the advantages and disadvantages of four locating points in a plane?
What are the cause of errors in the design and operations of jigs & fixture? What measures
should be taken to minimize the effects of the causes of error?
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