MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)

(ISO/IEC - 27001 - 2005 Certified)

--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the
model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try
to assess the understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more
Importance (Not applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the
figure. The figures drawn by candidate and model answer may vary. The examiner may give credit for
any
equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant
values may vary and there may be some difference in the candidates answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer
based on candidates understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.
------------------------------------------------------------------------------------------------------------------------------Q.1-a) Attempt any three of the following.

12 Mark

i] State the importance of ceramic coatings. Enlist different types of ceramic coatings.
Ans:- Importance

03 Mark

1) Enhance the strength and rigidity of metal ports.

2) Protect metal surfaces from the effects of corrosion at high temperatures.
3) Offer an increased resistance to chemical attack and mechanical abrasion.
4) Highly finished surface on cutting tool.
5) Elimination of any unbalanced forces.
6) High cutting speed.
Types:- Al2O3 (alumina), Sic (silicon carbide) , Si3N4 (silicon nitride)
01 Mark
ii] Differentiate between abrasive and diffusion wear. (any four)
Abrasive
1) This type of wear takes place when hard
particles on the under side of the chip pass
over the tool face and remove total material
by mechanical action.
2) The abrasive action is due to presence of
hard constituents in the microstructure, the
strain hardening induces in the chip and
work

04 Mark
Diffusion

1) This type of wear takes place due to diffusion

process where atoms in a metallic crystal lattice
move from a region of high atomic concentration to
one of low concentration.
2) Wear by diffusion is due to the high temperature
and pressure developed at the contact surface and
rapid flow of chip and the work surface past the
tool.

3) The flank wear is caused due to the 3) The crater wear is primarily due to diffusion
wear.
abrasive materials on the materials

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

4) This can be reduced by the addition of
alloying elements in the microstructure.
Ex. In the case of carbides a fine grain size
and lower percentage of cobalt helps in
reducing the abrasive wear.

4)This can be reduced by using proper lubricant,

also by selecting a material which has less chemical
affinity towards work material and by applying a
coating on tool material.

iii] Draw the geometry of twist drill.

04 Mark

iv] State the normal values of back brake angle for single point cutting tool. What will be its effect if
increased?
Ans:- It measures the down word slope of the top surface of the tool from the nose to the rear along the
longitudinal axis its purpose is to guide the direction of clip flow. Back rake may be positives and
negative. Higher value of rake angle weakens the cutting edge.
If positive rake angle increased than machining work hardening material, low strength ferrous and non
ferrous metals, set up and work piece lack rigidity and strength and using small machine tools with low
horse power.
Larger the rake angle, smaller the cutting angle and larger the shear angle.
Larger the rake angle lower will be cutting forces and power.
Increased rake angle leaves less metal at the point of the tool to support the cutting edge and
conduct away the heat.
If negative rake angle increased leads to increased cutting force during machining, interrupted cuts and
heavy feed rates are to be used and machine tools are more rigid.

Q.1-b) Attempt any one of the following.

i] Enlist type of cutting fluids. Also state the characteristics of cutting fluids and applications of
cutting fluids.
Ans:- Minerals oils, straight fatty acids, sulphurised or chlorinated cutting oils, waxes, compounded
emulsions, conventional emulsions, aqueous solutions, graphite suspensions, compounded mineral oils,
minerals, water and synthetic coolants.
01 Mark
Characteristics:1) It should be chemically stable.
2) It must possess a low evaporation rate and must not fume.

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

3) It should not have any adverse effect on the operator, tool, work piece or machine.
4) It must carry away the neat generated during the process and thus cool the tool and the work piece
rapidly.
5) It must provide sufficient lubrication between the tool and work piece.
6) It should have a high flash point.
7) Low coefficient of friction.

04 Mark

Application : -1.In metal cutting operations like turning, milling , drilling , grinding etc.
2. In superfinishing processes

01 Mark

ii] State the functions of

01 Mark

1) Pilot:- To position the stock strip accurately and bring it into proper register for succeeding
blanking and piercing operations.
Stripper:- It is to remove the stock from the punch after a blanking or piercing operation.
Mis feed Detector:- It senses out of register position of stock and actuates a switch to cut off the electric
power to the press.
Knockouts:- The functions of the knock out is to remove the work piece which adhere to the die opening.
Guide Pins:- The guide pins provide alignment between the die shoe and the punch holder.
Guide bush:- Guides the guide pins.
Q.2- Attempt any two of the following.
a) Explain any two types of chips produced during metal cutting providing conditions of metal
cutting. How the process of chip formation contribute to vibration or chatter of cutting tool.

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

Continuous chip:- A continuous chip is obtained when cutting ductile materials such as low carbon steel,
aluminium and copper. This chip is severely deformed and either comes off in the form of a long string
or curls into a tight roll.
Some very soft and ductile materials with a low strength tend to tear away form the parent metal of the
workpiece rather than shear clearly. This results in a rough surface that has to be cleaned up by a very
keen cutting edge. In addition to ductile workpiece material the other conditions which favour their
formation are fine feed, sharp cutting edge, higher cutting speeds and larger rake angles.
This type of chips are produced when machining more ductile material. Due to large plastic
deformation possible with ductile materials longer continuous chips are produced. This type of
chips are most desirable, since it is stable cutting, resulting in generally good surface finish, the
power consumption is low, friction between chip and tool is low, and excessive heat is not
generated. The conditions like small chip thickness, high cutting speed, large rake angle helps in
the production of continuous chips.
These chips are difficult to handle and dispose off.
Discontinuous chip:- Brittle materials such as grey cast iron lack the ductility necessary for appreciable
plastic chip formation. Consequently the compressed material ahead of tool fails in a brittle manner
along the shear zone producing small fragments. Such chips are called discontinuous chips. Lower
cutting speeds and insufficient rake angles cause the formation of such chips.
04 Mark
Process contribute to vibration If the nose radius of tool is greater then it results in stick slip type
vibration known as chatter.
The mechanics of chip formation in any machining operation is a rapid series of plastic flow and
slip movement ahead of the cutting edge. This produces a vibration of high frequency at the tool
tip.
Excessive overhang of the tool or a poorly supported workpiece aggravates this vibrations of the
tools and the result may be chatter marks on the finished surface and reduced tool life.
02 Mark
b) Name four tool materials along with most important characteristics. Explain the necessity of heat
treatment for tool steels.
Ans:1) High speed steels are superior hardness, toughness and wear resistance.

04 Mark

2) Cemented carbides have high thermal conductivity, low specific heat and low thermal expansion.
3) Ceramics are very hard with good compressive strength.
4) Diamond has high heat conductivity, lowest thermal expansion, hardest and poor electrical
conductivity.
Heat treatment of tools steels are necessary in order to cause relief of internal stresses developed during
cold working, welding, casting forgings etc.
04 Mark
Harden and strengthen metals, improve machinability, ductility, toughness, electrical and magnetic
properties. Increase heat, wear and corrosion resistance of materials. Homogenize the structure to remove
coring or segregation.

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

c) Draw a well labeled diagram of combination die. Write construction and working of combination
die.
Ans:-

OR

Construction and working:- In this die more than one operations may be performed at one station. It
differs from compound die in that in this die, a cutting operation is combined with a bending or drawing
operation figure shows the working of a combined die. The die ring which is mounted on the die sleeve, is
counter bored at the bottom to allow the flange of a pad to travel up and down. This pad is held flush with
the face of the die by a string. A drawing punch of required shape is fastened to the die shoe. The
blanking punch is secured to the punch holder. A spring stripper strips the selection from the blanking
punch. A knockout extending through the centre opening and through the punch stem eject the part on the
upstroke as it comes in contact with the knockout bar on the press. In operation the blank holding ring
descends as the part is blanked, then the drawing punch contacts the forces the blank into the drawing die
which is made in the blanking punch.

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

Q.3a) Find the force required to shear a 35 mm diameter hole in a 3 mm thick M.S. sheet having
ultimate shear strength of 400 Mpa.
Ans:- Given diameter D = 35 mm,

04 Mark

thickness t = 3 mm
Ultimate shear strength fs = 400 Mpa.
P=?
We know
P = D t.fs
= x 35 x 3 x 400
= 131946.89 N
b) Enlist eight operations performed on a press. Also suggest suitable press operation for
production of a mild steel washer.
Ans:- Blanking, punching, piercing, notching, perforating, trimming, shoving, lancing, slitting, bending,
embossing, bulging, deep drawing, cupping, coining, sizing, swaging etc. (any eight)02 Mark
Suitable press operation :- Piercing for inner hole and blanking for outer hole of washer. 02 Mark
c) How the presses are classified? Write specification of C frame press.
Ans:- Power Presses may further be Classified as follows

03 Mark

1. On the basis of source of power i.e. using

i)

Electric motor

ii)

Pneumatic system

iii)

Hydraulic system

2. On the basis of the design of the press frame

i) Inclined ii) Inclinable

iii) Gap

iv) Arch

v) Straight side vi) Horn

3. On the basis of drive mechanisms

i) Crank
v) Knuckle joint

ii) Eccentric

iii) Rack and gear

vi) Toggle drive

iv) Hydraulic/Pneumatic
viii) Screw

4. On the basic of number of slides

i)

Single action presses (using one slide only)

ii)

Double action presses

iii)

Triple action presses

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

5. On the basis of the intended use of the press
i) Shearing press

ii) Brake press

Specification of C frame press :- size of table, shut height of press, Tonnage

01 Mark

d) Define the following with a neat sketch i) Chip Thickness ratio ii) Shear angle.
Ans:-

02 Mark

Chip thickness ratio:- The ratio of thickness of uncut material (t1) to thickness of chip (t2) is defined as
chip thickness ratio (r).

t1
t2

01 Mark

Shear angle:() or () shear angle is the angle made by the shear plane with the direction of tool travel.

01 Mark

e) Define the machinability and explain three factors affecting machinability.

Ans:- Machinability is the ability of the material which governs the ease or difficulty with which it can
be machined under a given set of conditions.
01 Mark
Factors affecting machinability:1) Tool variable:- Tool material, tool geometry, Nature of engagement of tool with work.:
Different tool materials have different properties.Tool material like HSS, carbides, ceramics,
diamond can operate at different cutting speed which affect on machinability.The anfles like
back rake angle, clearance angle & nose radius greatly affect on machinability.The proper
tool geometry machinability can be improved.
2) Cutting conditions:- Cutting speed ,feed, depth of cut: Increased value of depth of cut & feed
reduces machinability.
3) Work material variables Hardness, Tensile strength, chemical composition: The properties
like hardness, tensile strength, chemical composition largely affects machinability. If the
material is hard, it is difficult to machine & leads to poor machinability.If some constituents
are present in the microstructure of work material, it leads to poor machinability
4) Cutting fluid : Use of proper cutting fluid reduces the friction between work & tool interface
which reduces power consumption & increases tool life.For certain range of cutting speed,

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

there is considerable increase in machinability with the use of proper cutting fluid.
5) Machine variables (power, accuracy of the machine, rigidity of the machine):
03 Mark

Q.4-a)
i] How milling cutter is designated? Write the material used for milling cutter.
Ans- Designation of milling cutter, milling cutters are designated by following way.
1) The first letters indicate the type of milling cutter e.g. face milling cutter (FMC), plain milling
cutter (PMC) etc.
2) This is followed by number which indicates dia. of bore of cutter.
e.g. FMC 22
FMC Face milling cutter
22 dia. of bore is 22 mm.

02 Mark

Materials used for milling cutters 1) H.S.S. 2) Carbides. 3) Alloy steels ect
ii] Define :-

(any two 01 Mark)

01 mark each

1) Cropping It is process of removing distorted excess material form drawn shapes to provide
smooth edge.
2) Lancing It is combined bending and cutting operation along a line in work material.
3) Curling It is press operation in which edges of metal sheet are formed into roll or curl.
4) Coining It is process of pressing material in a die so that it flows into the spaces in the detail
of die face.
iii] The washer of 50 mm outside diameter and 20 mm inside dia. Are to be made by press
operation from mild steel sheet of 2 mm thickness. Calculate 1) Clearance 2) Punch and die
size.
For M.S. considering clearance as 7% of stock thickness.
For piercing 20 mm dia hole.
Clearance =

7
2 0.14mm
100

02 Mark

Dia of punch = dia of hole

= 20 mm

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

Dia of die = 20 + 2 x clearance
= 20 + 2 x 0.14
= 20.28 mm
For blanking 50 mm dia hole
Clearance =

7
2 0.14mm
100

Dia of die = dia of hole

= 50 mm
Dia of punch = 50 2 x clearance
= 50 2 x 0.14
= 49.72 mm.

02 Mark

( clearance value of 5% of thickness if assumed by the students should also be considered.)

iv] Determine developed length of component for bending.

l1 50 (5 3) 42mm
l5 50 (10 3) 37 mm
l3 100 (5 3) (10 3) 79mm
2
( IR kt)
360
90 0
l2

IR 5mm
t 3mm
IR 2t k 0.33
l2

2 90
(5 0.33 3) 9.424mm.
360

02 mark

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

2
( IR kt)
360
90 0
l4

IR 10
t 3
IR 2t
k 0 .5
2 90
(10 0.5 3)
360
18.064mm.

l4

Developed length l1 l 2 l3 l 4 l5
= 42 + 9.424 + 79 + 18.064 + 37
= 185.488 mm.

02 mark

Q.4-b)
i] Define spring back. With reference to bending. State the causes of spring back. How harmful
effects of it can be avoided?
Ans:- Spring Back After bending a sheet when force is removed the sheet deforms and tries to get
straighten. As a result the bend angle reduces. This effect is known as spring back effect. 02 Mark
OR
After bending a sheet when force is removed there is an elastic recovery by the material. As a result
the bend angle decreases . This effect is known as spring back effect.
Causes It is due to following factors.
a) Elasticity of material

02 Mark

b) Thickness of material
c) Hardness of material
d) Bend radius
Its effects can be avoided by following ways.

02 Mark

1) Over Bending- It is best way to resolve the spring back effect. In this method the sheet is bent
through greater angle than required. After bending i.e. after removal of force sheet springs
back to required angle.
2) Corner Setting- The metal is squeezed at corner to relieve elastic stresses. At corners high
force is applied so that stresses increases and metal deforms plastically.
3) Ironing This method is useful in wiping dies. To iron effectively the gap between punch and
die is kept slightly less than sheet metal thickness so that stresses increases and metal deforms
plastically.

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

ii] Define strip layout. What are the principles to followed for good strip layout ?
Ans:- Strip layout It is layout on stock for spacing blanks to take effective utilization of material.
02 mark
It is defined as to layout the position of the workpiece in the strip and their orientation with respect
to one another.
Following principles are to be followed while designing strip layout.
1) Economy The wastage of material should be avoided. The distant spacing waste the
material.
2) Maximum utilization of material should be taken.

It L is length of given strip, max. no. of blanks

For 0.625 < t < 0.75

B = 0.75 mm

For 0.75 < t < 4.5

B=t

For t > 4.5

B = 4.5 mm

LB
D

3) The spacing should be kept enough to have further bending operation if any.

04 Mark

4) Economy of material:- The different ways of arranging to blank, the given workpiece can be
worked at single row, single pass with a single punch or the strip have to be fed twice, once
for each row, or double blanking will have to be employed. The per cent material utilization
changes as the arrangement changes.
5) Direction of material grain or Fiber :- This factor is to be consider if the cut blank have to
undergo any subsequent operation, such as bending or deep drawing.

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

6) Direction of Burr:- when the sheet metal is cut in a die, a burr is produced on the die side of
the scrap strip and on the punch side of the blank. If the burr has to be on the hidden side then
expensive operation of removing the burr need not be done
7) Press Used :- It includes the amount of shear provided on punch and die, bed area of the press
and centre line of the press ram.
8) Production Required
Q.5- a) Find the blank diameter of 80 mm outside dia. x 110 mm high x 1 mm thick for following
corner radii. 1) 10 mm 2) 5 mm in drawing operation.
d = 80 mm; h = 110 mm; t = 1 mm
For corner radius 10 mm

04 Mark

r = 10
d/r = 80/10 = 8

d/r < 10

d 2r 2 4d h r 2 r d 0.7r

80 202 4 80110 10 2 1080 0.7 10

D 200.46mm.
Dia. of blank = 200.46 mm.
For corner radius 5 mm;
r = 5 mm

04 mark

d/r = 80/5 = 16

d/r = 16

D d 2 4dh 0.5r

802 4 80 110 0.5 5

201.46mm.
Dia. of blank = 201.46 mm.

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

b) Draw neat sketches of 1) stamping 2) Notching 3) bending 4) Forming. State two products
manufactured by using each of above operations.

04 Mark
Stamping Automobile body, air craft
Notching Frames, razor blades
Bending Stair case panel, automobile pares
Forming Mudguard of two wheeler, bonnet of automobile.
Q.5- c) Draw a neat labeled diagram of injection moulding set up. Explain
construction features of injection moulding dies.

04 Mark
the

04 mark

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

1) Hopper, 2) Heater, 3) Barrel, 4) Control panel, 5) Mould, 6) Tie Bar, 7) Hyd. Cylinder, 8) Screw,
9) Nozzle.
Injection moulding setup is shown in figure.
It consists of mainly three units.
1) Injection unit It consist of hopper heater, screw, motor, nozzle etc.
2) Clamping unit Consisting hydraulic cylinder, tie bar, mould etc.
3) Machine bed and control panel for mounting the other unit.
Injection mould consists of
1) Core plate which forms the interior of the product.
2) Cavity plate forms the exterior of product.
3) Feed system consisting runner, spruce and gate which transfer the molten plastics into mould cavity.
4) Ejection system which removes the product from cavity.

04 Mark

Q.6- a) State two products each manufactured by i) Plastic extrusion dies ii) Die casting dies.
Ans:- i] Plastic extrusion dies - plastic sheet, pipes, hoses, rods etc.
ii] Die casting dies rim of wheel of vehicle, cover of gear box of automobile, carburetor bodies, valve
bodies, transmission cases etc.
02 Mark each

b) Label four major parts in figure. Also name the figure.

i] Pilot ii] Guide pin iii] Automatic button die stop iv] Die block
Name of figure - progressive die.

02 Mark

02 Mark

c) What do you mean by clearance? Explain its importance in shearing operation.

Ans:- Clearance is international difference kept between cutting edge of die and punch. 01 Mark
In shearing operation punch has to enter in die. Hence dimensions of punch has to be smaller than
that of die. The difference in their dimensions results in clearance. Clearance has lot of importance in
shearing.
Excessive clearance It produces greater roll over radius, angular blank and long burr. The
plastic deformation (penetration) is more which causes material to be drawn rather shearing.

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Insufficient clearance This causes fracture to miss cutting edges of punch and die do not meet
each other as shown in figure. This results in two burnishing edges.
Correct clearance This produces moderate roll over which is followed by single burnishing
edge. This results in correct break. The fracture meets each other.
Effect to clearance is shown in figure. It affects mostly on quality of shearing operation. 03 Mark

Q.6- d) State the most commonly used values of i) Nose radius ii) Back rake angle iii) Side cutting
edge angle iv) Side rake angle.
Ans:-

01 Mark each

i) Nose radius 0.5 mm

ii) Back rake angle 70 to 90 5o to 14o
iii) Side cutting edge angle 100 to 120 15o 300
iv) Side rake angle 80 to 100
e) Explain single action dies with neat sketch.
Ans:-

02 Mark

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--------------------------------------------------------------------------------------------------------------------WINTER 13 EXAMINATION Subject Code: 12158 Model Answer

Single action simple die is shown in figure. The punch holed is fitted to ram of press while die shoe is
fitted to boltster plate. Guide pins gives better and perfect alignment. This construction is also known as
die set. The guide pins can be at centre or at rear or diagonally opposite.
The lower end of guide pins are press fitted in lower shoe. There is slip fit between punch holder
and guide pin. This can be achieved by special bush.
The punch is fitted to punch holder. The die block is fitted to die shoe. In working as punch
moves downward the shearing action takes place and piece of slug falls through die. To avoid jamming of
slug in die the angular clearance is provided to die.
The stripper is used which restricts the movement of stock along with punch in return (upward)
stroke.
02 Mark
--------THE END-------

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