ME 6402- Manufacturing Technology-II Mechanical Engineering 2017-2018

ME6402 MANUFACTURING TECHNOLOGY – II LT PC

3 0 0 3
OBJECTIVES:
 To understand the concept and basic mechanics of metal cutting, working of standard
machine tools such as lathe, shaping and allied machines, milling, drilling and allied
machines, grinding and allied machines and broaching.
 To understand the basic concepts of Computer Numerical Control (CNC) of machine
tools and CNC Programming

UNIT I THEORY OF METAL CUTTING 9

Mechanics of chip formation, single point cutting tool, forces in machining, Types of chip,
cutting tools– nomenclature, orthogonal metal cutting, thermal aspects, cutting tool materials,
tool wear, tool life, surface finish, cutting fluids and Machinability.

UNIT II TURNING MACHINES 9

Centre lathe, constructional features, specification, operations – taper turning methods, thread
cutting methods, special attachments, machining time and power estimation. Capstan and
turret lathes- tool layout – automatic lathes: semi automatic – single spindle : Swiss type,
automatic screw type – multi spindle:

UNITIII SHAPER, MILLING AND GEAR CUTTING MACHINES 9

Shaper - Types of operations. Drilling ,reaming, boring, Tapping. Milling operations-types of
milling cutter. Gear cutting – forming and generation principle and construction of gear
milling ,hobbing and gear shaping processes –finishing of gears.

UNIT IV ABRASIVE PROCESS AND BROACHING 9

Abrasive processes: grinding wheel – specifications and selection, types of grinding process–
cylindrical grinding, surface grinding, centreless grinding and internal grinding- Typical
applications –concepts of surface integrity, broaching machines: broach construction – push,
pull, surface and continuous broaching machines

UNIT V CNC MACHINING 9

Numerical Control (NC) machine tools – CNC types, constructional details, special features,
machining centre, part programming fundamentals CNC – manual part programming –
micromachining – wafer machining
TOTAL : 45 PERIODS
TEXT BOOKS:
1. Hajra Choudhury, "Elements of Workshop Technology", Vol.II., Media Promoters
2. Rao. P.N “Manufacturing Technology - Metal Cutting and Machine Tools", Tata McGraw-
Hill,New Delhi, 2003.

REFERENCES:
1. Richerd R Kibbe, John E. Neely, Roland O. Merges and Warren J.White “Machine Tool
Practices”, Prentice Hall of India, 1998
2. HMT, "Production Technology", Tata McGraw Hill, 1998.
3. Geofrey Boothroyd, "Fundamentals of Metal Machining and Machine Tools", Mc Graw
Hill,1984
4. Roy. A.Lindberg, “Process and Materials of Manufacture,” Fourth Edition, PHI/Pearson
Education 2006.

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UNIT I - THEORY OF METAL CUTTING

PART – A
1. Classify the process of metal shaping?
Non- cutting shaping process and Cutting shaping process
2. Classify the relative motion between work piece and cutting tool.
(i.) Rotation of work against the tool. Example: turning.(ii). Rotation of tool against work
piece. Example: drilling, milling.(iii) Linear movement of the work piece against the tool.
example: planer. (iv)Linear movement of the tool against the work. Example: shaper.
3. What are all the different types of cutting tool?
(i) Single point cutting tool (ii) Multipoint cutting tool.
4. Mention the various angles in cutting tool. (or) Name the cutting tool nomenclature of
Single point tool. (Nov / Dec 2015)
1. Back rack angle, 2. Side rack angle, 3. End relief angle, 4. Side relief angle, 5. Side cutting
angle, 6. End cutting angle.
5. What is the effect of back rack angle and mention the types. (Nov / Dec 2010)
Back rack angle of the tool is increases the strength of cutting tool and cutting action.1.
positive rack angle2. Negative rack angle.

6. Explain the nose radius.

Joining of side and end cutting edges by means of small radius in order to increase the tool
life and better surface finish on the work piece.
7. What are all conditions for using positive rack angle? (Nov / Dec 2011)
1. To machine the work hardened materials.2. To machine low strength ferrous and non-
ferrous metals.3. To turn the long shaft of small diameters.4. To machine the metal below
recommended cutting speeds.5. Using small machine tools with low horse power.
8. When will be negative rack angle is used. (May/June 2013)
1. To machine high strength alloys. 2. The machine tools are more rigid.3. The feed rates are
high.4. To give heavy and interrupted cuts.
9.Write short notes on Heating Zones in cutting. (May/June 2015)
1. Shear zone (primary zone), 2. Tool chip contact zone( secondary zone) , 3. Tool –
wokpiece contact zone.
10. What is chip thickness ratio? (Nov / Dec 2015)
The ratio of chip thickness before cutting to chip thickness after cutting is called chip
thickness ratio. chip thickness ratio, r= t1/t2=l2/l1
11. What is chip reduction coefficient?
The reciprocal of chip thickness ratio is called chip reduction coefficient. k= 1/r
12. What is the difficulty for long and continuous chip?
During machining, long and continuous chip that formed at high cutting speed will affect
machining; it will spoil tool, work and machine. These chips are hard, sharp, and hot. It will
be difficult to remove metal and dangerous to safety.
13. Classify the different types of chip breakers?
1. Step type, 2. Groove type, 3. Clamp type
14. What are the cutting forces acting on the cutting tool?
During the cutting process, the following the component of cutting forces acting mutually
right angles. (a) feed force fx acts in a horizontal plane, but in the direction opposite to feed.
(b) thrust force fy acts in the direction perpendicular to generated surface (c) cutting force fz
in the direction of the main cutting motion.
15. Define Machinabilty and what are the factors affecting the machinability?
Machinabilty is defined as the ease with which a material can be satisfactorily machined. The
factors are: (a). Chemical composition of work piece material. (b)Microstructure of work

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piece material. (c). Mechanical properties like ductility, toughness etc., (d). Physical
properties of work materials. (e). Method of production of the work materials.
16. What is orthogonal rake system? (May/June 2014)
In orthogonal rake system the cutting face of the tool is 900 to the line of action or path of the
tool, then it is called.
17. Define tool life. (April/May 2010, 2011) (Nov / Dec 2012)
Tool life is defined as time elapsed between two consecutive tool re-sharpening. During, this
period tool serves effectively and efficiently.
18. What are the factors affecting the tool life?
(i) Cutting speed,(ii) Feed and depth of cut,(iii) Tool geometry.(iv) Tool material, (v)Cutting
fluid,(vi) work material,(vii) Rigidity of work, tool and machine.
19. Express the Taylor’s tool life equation. (Nov / Dec 2015)
Taylor’s tool life equation vtn=c , v = cutting speed in m/min, t = tool life in minute, c =
constant, n = index speed upon tool and work.
20. List the various cutting fluids.
(i) Water based cutting fluids, (ii) Straight or heat oil based cutting fluids.
21. What is the composition of high-speed steel?
High-speed steel contains tungsten-18% and vanadium-1%. It has about 0.75% carbon.

22. What are the factors responsible for build up edges in cutting tools? (Nov 2015)
Low cutting speed, low rake angle, high feed, high heat and pressure, Insufficient cutting
fluid.
23. Classify the tool wear. (April/May 2010) (May/June 2013) (Nov / Dec 2013)
(i). Flank wear or crater wear, (ii). Face wear, (iii). Nose wear
24. What are the functions of cutting fluid? (Nov / Dec 2010)
Cooling the cutting tool and work piece, Lubricating the cutting tool, Improves surface finish,
makes the chips to break up, prevents corrosion of work piece and machine.
25. What is built up edges? (May/June 2012) (Nov / Dec 2012)
During cutting process, the interface temperature and pressure is quite high and also high
friction between tool chip interfaces causes the chip material to weld itself to the tool face
near the nose. This is called build up edge.
26. What are the advantages of diamond tool? Or (Write a short notes on any advanced
tool material. (May/June 2012) (May/June 2015)
Low coefficient of friction, High compressive strength, good wear resistance, high hardness
and bending strength. It is Used to machine hard materials like glass plastics, ceramics etc.
27. Differentiate Orthogonal cutting and Oblique cutting. (April/May2011)
(Nov/Dec2013) (May/June 2016)
Orthogonal cutting is known as two dimensional cutting and oblique cutting is known as
three dimensional cutting. In orthogonal cutting chip moves normally outwards from chip
tool interface whereas in oblique cutting chip moves always away from the chip tool interface
at inclination angle.
28. During a tool cutting test on HSS tool material, the following data were recorded.
Tool life & Cutting speed: 5 hrs, 25m/min. Calculate the Tool life when tool operates at
40m/min. (May/June 2016)
Taylor’s tool life equation VTn=C = V1 T1n = V2 T2n = ( 25/40)= (T2/5)0.5 =1.9 (or) 2 hrs
29.What are the conditions that would allow a continuous chip to be formed in metal
cutting? (Nov/Dec 2016)
Continuous chips are formed with ductile materials that are machined at high cutting speed
and with high rake angels.

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30.If the Taylor’s tool life constants for a given operation are specified as n=0.5 and C-
400, what is the percentage increases in tool life when the cutting speed is reduced by
half? (Nov/Dec 2016)
Sol: VTn=C
1*T 0.5=400 :::: T1=(400)1/2 :::: T1=20mins
(1/2) * T2 0.5 =400 ::: T2= (800)1/2 :::: T2=28.28mins
% Increased =(T2-T1/T2)*100= 29%
31. What is tool signature? (April/May 2017)
The various angles of the tool are mentioned in a numerical number in particular order. That
order is known as tool signature.
32. Define the term machinability and machinability index? (April/May 2017)
Machinabilty is defined as the ease with which a material can be satisfactorily machined.
It is a comparison of machinability of different material to standard material. US material
standard for 100% machinability is SAE 1112 hot rolled steel. Machinability index, i=cutting
speed of metal investigated for 20 minutes tool life/cutting speed of standard steel for 20
minutes tool life.
UNIT II – TURNING MACHINE
PART – A
1. What is lathe?
Lathe is a machine which removes the metal from a piece of work to the required shape and
size.
2. What are the various operations can be performed on a lathe?
Turning, facing, forming, knurling, chamfering, thread cutting, drilling, boring, recessing,
tapping, grooving etc.
3. What are the principle parts of a lathe?
Bed, head stock, tail stock, carriage, cross slide, tool post
4. What are the main difference of live and dead centers?
Live center drives and rotates along with the work piece dead center is driven by the head
stock and it just supports the other end of the works.
5. State the various parts mounted on the carriage. (May/June 2013)
a) Saddle b) compound rest c) cross slide d) tool post.
6. How are holes drilled in a lathe?
First the centre of the tail stock is replaced by a drill bit. The longitudinal movement of the
tailstock is locked after setting the approach of drill. Finally, the hand wheel of the tailstock is
rotated for making hole on the specimen.
7. What is an apron? (Nov/Dec 2010, 2012)
The integral part of several gears, levers and clutches mounted with the saddle for moving the
carriage along with lead screw while thread cutting.
8. List any four types of lathe.
1. Engine lathe 2.bench lathe 3.tool room lathe 4.semi- automatic lathe 5.automatic lathe

9. What is a semi automatic lathe?

A lathe in which all the machining operations are performed automatically and loading and
unloading of work piece, coolant on or off is performed manually.
10. Why is hollow spindle used in lathe? (Nov/Dec 2009)
In order to hold lengthy work piece in the chuck and also to enable automatic feed of the
workpiece.
11.List any four work holding devices. (Nov / Dec 2015)
1. Chucks 2.centers 3.face plates 4.angle plate
12. What are the various types of chucks? (May/June 2009)
1)3jaw chuck- self centering chuck 2.)4 jaw chuck independent jaw chuck 3.Magnetic chuck.

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13. State the purpose of providing lead cam in single spindle automatic screw cutting
machine? (Nov/Dec 2012) (Nov/Dec 2014)
The turret slide travel is controlled by a lead cam. The lead cam gives a slow forward and fast
return movement to the turret slide.
14. What is the need for automatic lathe? (Nov/Dec 2013)
Mass production of identical parts, High accuracy, Minimize production time, minimize
labour cost.
15. What are the various types head stock and explain the pre-selective headstock?
1. Back geared 2. All geared. Pre selective head stock the pre-selective head stock the speed
changing for different machining operation can be done by simply pushing a button or pulling
a leaver to select the speed of the next operation in advance.
16. What are the advantages of turret over capstan lathe?
1. Heavier and larger work piece chucking can be done 2.more rigid, hence it withstands
heavy cuts.
17. Briefly explain any 4 of the work & tool holding devices for turret and capstan lathe.
(a)Work holding devices 1. Collets 2. Chucks 3.fixtures 4. Power chucks (b) Tool holding
devices 1. Multiple cutter holders 2. Offset cutter holder 3. Sliding cutter holder 4 knee tool
holder.
18. What is collapsible tap?
Collapsible tap is used for making internal threads. During making threads, the cutting edges
of the tap collapses to reduce its overall diameter.
19. What is bar stop?
Bar stop is nothing but work stop. it is used for setting the required length of the work piece.
20. What are the three stages of a tool layout?
1. Planning and scheduling 2. Detailed sketching of various machining operations sequence.
3. Sketching the plan showing various tools.
21. What is centre gauge that is used in threading? (May/June 2014)
Centre gauge is an instrument used to check the form and setting of thread cutting tool.
22. What are the specifications of center lathe? (Nov/Dec 2013)
Length of the bed, speed of the spindle, no of feed drive, driving mechanism, motor rpm, bed
height, swing over bed height
23. What are programmed automatic lathes? (May/June 2014)
If the operating cycle of an automatic lathe is controlled by a CNC program or a set of codes,
then they are called as programmed automatic lathe.
24. Define automatic lathe.
Automatic lathes or simply automats are machine tools in which all the operation required to
finish off the work piece are done automatically without the attention of an operator.
25. State any four advantages of automatic lathes
1. Mass production of identical parts.,2. High accuracy is maintained.,3. Time of production
is minimized.4. The bar stock is fed automatically.
26. Classify automats.
1. Classification according to the type of work material used: a) Bar stock machine,(b)
chucking machine,
2. Classification according to the number of spindle: (a) Single spindle,(b) Multi spindle.
3. Classification according to the arrangement of the spindle: a) Horizontal b) vertical,
4. Classification according to the feed control: a) Single cam shaft rotating at constant speed,
(b) single cam shaft with two speed,(c) two cam shaft,
5. Classification according to the use: (a) Single purpose m/c,(b) General purpose m/c
27. What are the types of single spindle automat lathes? (May/June 2013)
Automatic cutting off machine,· automatic screw cutting m/c,· Swiss type automatic screw
machine.
28. Define screw-cutting machine.

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It is mainly mounted the tool is used in turret having single spindle. a lead cam controls the
turret slide travel. The lead cam gives a slow forward and fast return movement to the turret
slide.
29. What are the four major parts of Swiss type automatic lathes? (Nov/Dec 2015)
(i) The sliding headstock through which the bar stock is passed and gripped by a carbide lined
guide push.(ii) The camshaft, controlling the bar stock and cutting tool movements. (iii) The
tool bracket supporting five tool slides and a push for stock. (iv) Auxiliary attachments for
performing various operations. Such as knurling, drilling, tapping, screwing, slotting, and
recessing etc.
30. State the advantages of swiss type screw cutting machine.
b) It has five tool slides, (c) Wide range of speeds,(d) Rigid construction,(e) micrometer tool
setting(f) Inter changeability of cams,(g) simple design of cams,(h) Tolerances of 0.005 to
0.0125 mm are obtained.(h) Numerous working stations.

31. What are the purposes of using cam?

1. To control purposes in automates screw m/c 2. To control movement of the turret for
controlling rapid approach, working travel, rapid return 3. To control the movement of the
cross slide 4. To provide uniform rate of feed to tool during machining.
32. What is meant by “Swing of lathe”? (May/June 2015)
The largest diameter of the work piece that can be rotated on the spindle with out hitting the
bed is called as swing of lathe.
33. What do you meant by copy turning . (May/June 2015)
Copy turning is carried out on special lathes that control the cutting tool to produce identical
items. It is also called as wood turning.
34 . Differentiate Center lathe and Capstan lathe. (May/June 2016)
S.no Capstan Lathe Automatic lathe
1 It is manually operated lathe It is semi automatic lathe
2 Only one tool post. Tool changing time Front and rear tool post are available. So
is more tool change time is less
3 It has tail stock It has turret head instead of tail stock
4 No of speed is less No of speed is more
5 It is suitable for batch production It is suitable for mass production
35. What are the various methods available for taper turning operation? (Nov/Dec 2016)
(May/June2017)
1. Compound rest method 2. Form tool method 3. Tail stock set over method 4. Taper
turning attachment method.
36. Differentiate between an automatic and a semi automatic lathe. (Nov/Dec 2016)
A lathe in which all the machining operations are performed automatically and loading and
unloading of work piece, coolant on or off is performed manually.
Automatic lathes or simply automats are machine tools in which all the operation required to
finish off the work piece are done automatically without the attention of an operator.
37. What are the specifications of lathe? (May/June 2017)
1.Maximum diameter of the rod that can be passed through the spindle 2.Swing diameter of
the work 3.No.of spindles 4.No.of feeds available to the carriage and turret saddle 5.Net
weight of the machine 6.Floor space requirement 7.Power requirements etc.,
UNIT- III – SHAPER, MILLING AND GEAR CUTTING MACHINES
PART – A
1. What is the specification shaper? (May/June 2012, 2013)
1. Maximum length of stroke, 2. Type of driving mechanism, 3. Power of the motor, 4. Speed
and feed available
2. List any four types of work holding devices?
1. Vice 2. Table 3. V-block 4. Fixture 5. Clamps 6. T-bolts etc.
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3. State the type of mechanism followed on a shaper.
Rack and pinion mechanism is used. the rotary motion of electrical drives is converted into
reciprocating motion of the ram by using crank and slotted link mechanism or with worth
mechanism or hydraulic mechanism.
4. Define feed and depth of cut.
Feed (f) :- the relative movement of tool with respect to the work piece axis is known as feed
Depth of cut (t):- amount of metal removed in one revolution or in cut is known as depth of
cut.
5. Define universal shaper.
It has all principal parts as in standard shaper. Its table has three movements. They are
vertical, horizontal and swivel. The table has a swivel base with degree markings.
6. Classify drilling machines.
Drilling machines are classified as follows
1. Portable drilling machine, 2. Sensitive drilling machine, a. bench type, b. floor type 3.
upright drilling machine a. round column type or pillar type, b. Box column type or square
section type. 4. Radial drilling machine a. plain type b. semi-universal type c. Universal type
5. Gang drilling machine 6. Multiple spindle drilling machine,7. Automatic drilling
machine,8. deep hole drilling machine
7. What is gang-drilling machine?
When number of single spindle with essential speed and feed are mounded side by side on
one base and have common worktable, is known as the gang-drilling machine.
8. Mention the specifications of drilling machine.
1. Maximum size of the drill in mm that the machine can operate. 2. Table size of maximum
dimensions of a job can mount on the table, 3. Maximum spindle travel in mm 4. Number of
spindle speed and range speed in r.p.m
9. List the machining operation that can be performed on drilling machine.
1. Boring 2. Counter sinking 3. Tapping 4. Trepanning
10. Define drilling and reaming.
Drilling is the process of producing hole on the work piece by using a rotating cutter called
drill. Reaming is sizing and finishing the already drilled hole. The tool used for reaming is
known as reaming.
11. What are the nomenclatures of drilling tool? (Nov/Dec 2013) (Nov/Dec 2015)
1. Body 2.shank 3.neck 4.point 5. Land or margin.
12. How the reamer tool differs from drilling tool?
Reamer is multi tooth cutter which rotates and moves linearly into an already existing hole.
13. What is the use of a tapping tool?
A tap is a tool which is used for making internal threads in a machined component.
14. What is boring?
It is the process of enlarging & locating previously drilled holes with a single pt cutting tool.
15. What is the main difference between boring bar and boring tool?
Boring bar:- the tool which is having a single point cutting edge known as boring bar Boring
tool:- the tool which is having multipoint cutting edge known as boring tool.
16. What are the specifications of milling machine?
(a) The table length and width,(b) Maximum longitudinal cross and vertical travel of the table
(c) Number of spindle speeds and feeds, (d) Power of motor,(e) Floor area and net weight.
17. Classify milling machine.
1. column and knee type(a) plain milling(b) vertical milling,© universal milling,(d) ram type
milling (e)omniversal milling
2.Bed type milling machine (f)simplex,(g) duplex, h. triplex,
3. Plano type milling machine,4. special purpose type milling machine a. rotary table, b. drum
type,c. profile milling
18. Compare the plain and universal milling machine. (Nov/Dec 2012) (May/June 2015)

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In plain milling machine the table is provided with three movements longitudinal, cross and
vertical. In universal milling machine the table is provided with three movements
longitudinal, cross and vertical in addition to there is a fourth movement to the table that can
be swiveled horizontally and can be fed at angle to the milling m/c spindle. The universal
milling machine is provided with auxiliaries such as dividing head, vertical milling
attachment and rotary table etc. hence it is possible to make spiral, bevel gear, twist drills,
reamers etc on universal milling m/c.
19. List the various types of milling attachments.
Vertical milling attachment, Universal milling attachment, High speed milling attachment,
Rotary milling attachment, Slotting milling attachment, Rack milling attachment.
20. Classify milling cutters. (April/May 2016)
According to the shape of the tooth, milling cutters are classified as: Milled tooth cutters,
Form relieved cutters According to the type of operation: Plain milling cutters, side milling
cutters, end milling cutters, angle milling cutters, t- slot milling cutters, slitting saws, form
milling cutters, fly cutters, wood ruff key slot milling cutter. According to the way of
mounting on the machine: arbor cutters, shank cutters, face cutters.
21. Define Up milling and Down milling. (Apr/May 2011, Nov/Dec 2011, 2013,Nov / Dec
2015) (May/June 2016)
Up milling is a process in which milling cutter rotates opposite to the direction of feed of the
work piece. The chip thickness is minimum at the beginning and maximum at the end of the
cut. So the stress is minimum at the beginning of the cut. Down milling is a process in which
milling cutter rotates in the same direction of feed of the work piece. The chip thickness is
maximum at the beginning and minimum at the end of the cut. So the stress is maximum at
the beginning of the cut
22. List out the various milling operations. (May/June 2016)
Plain or slab milling, face milling, angular milling, straddle milling, gang milling, form
milling, end milling, T- slot milling, gear cutting.
23. Define straddle milling and gang milling. (April/May 2016, 2017)
Straddle milling operation is the production of two vertical flat surfaces on the both sides of
the job by using two side milling cutters which are separated by collars. Gang milling is the
production of many surfaces of a job simultaneously by feeding the table against a number of
required cutters.
24. What are the other forming methods for manufacturing gears?
a. Gear cutting by single point form tool, b. Gear cutting by shear speed shaping process, c.
Gear milling using formed end mild. d. Gear broaching, e. Template method.
25. List the gear generating process. (May/June 2013)
Gear shaping process, gear planning process, gear hobbing process.
26. Give the functions of flutes on taps. (May/June 2014)
Flutes serve to provide clearance to the chips produced at the cutting edges. They also allow
the cutting fluid to reach the cutting edges.
27. List the materials used for broaching tool. (May/June 2014).
Tungsten-chromium-vanadium (18-4-1) steel, Carbide.
28. What do you meant by differential Indexing. (May/June 2015)
This method is used for divisions that could not be indexed by simple indexing.
The required divisions is obtained by combination of;
1. movement of the index crank is similar to simple indexing.
2. Simultaneous movement of the index plate when the crank is turned.
29. Why milling a versatile machining process. (May/June 2015)
Milling machine performs drilling, boring, thread and gear cutting and slotting operations,
which used to be performed by different machines that were designed to perform each
different work. So it milling machine is a versatile machining process.
30.Make a comparison between gear shaping and gear hobbing. (Nov/Dec 2016)

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Gear shaping is a process which follows basic law of machining while gear hobbing works on
principle of meshing of two gears.
In gear shapping tooth is cut one by one while in gear hobbing all tooth are cut
simultaneously till the completion of process.
31. What is gear finishing why it is done? (April/May 2017, Nov/Dec 2016)
(a)Gear shaving, (b) gear burnishing, (c) Gear grinding, (d) Gear lapping
To get a good surface finished and highly dimensionally accurate gears this process is
important one.
UNIT- IV – ABRASIVE PROCESS AND BROACHING
PART – A
1. Define Grinding and State the purpose of grinding.
Grinding is a metal removal process in which the metal is removed with the help of rotating
abrasive wheel. Purpose are: To remove small amount of metal from work piece and finish
then close tolerance, To obtain better surface finish. To machine hard surfaces that cannot be
machined by high- speed steel, sharpening of cutting tools
2. Specify the importance of precision grinders.
To manufacture parts of accurate dimensions and good surface finish.
3. What are the four movements in a cylindrical center type grinding?
a. rotation of the work piece about its axis b. rotation of the grinding wheel about its axis, c.
Longitudinal feed movement of the wok past the wheel face. d. Movement of wheel into the
work, perpendicular to the axis of the work piece to give depth of cut.
4. What are the main difference of traverse and plunge grinding?
In traverse grinding, this method is used when the job length is more than the width of the
grinding wheel. In plunge grinding, this method is used when the job length is lesser than the
width of the grinding wheel.
5. What is meant by center less grinding?
Centre less grinding is performed on work piece which do not have centers, such as pistons,
valves, rings, tubes, balls, wrist pins, drills, bushings, shafts etc. center less grinding can be
done on both external and internal cylindrical surfaces.
6. What are the uses of internal grinders? and specify the types of internal grinders.
Internal grinders are used to finish straight, tapered or formed holes to the correct size, shape
and finish. Types of internal grinders: 1. Chucking type2. Planetary type3.centre less type
7. What are the three types of grinding wheels?
1. The straight or disc shaped wheel 2. The cup type 3. The disc type
8. Define the term of ‘abrasive grains’ and also classify the abrasive.
An abrasive is a hard material. it can be used to cut or wear away other materials. Small
abrasive particles are used in grinding wheels. They are classify as follows 1. Natural
abrasive 2. Artificial abrasive
9. Compare the natural and artificial abrasives.
Natural abrasives1. Corundum (75 to90% crystalline al2 o3 + iron oxide) 2. Diamond
Artificial abrasive 1. aluminum oxide 2. silicon carbide
10. What are the different types of bonds used in grinding?
1. Vitrified bond 2. Rubber bond 3. Silicate bond 4. Shellac bond5. Resinoid bond 6. oxy
chloride bond
11. What is meant by grit or grain size?
The grain size is denoted by the number. This number is equal to the number of meshes in
254 cm of a sieve through which the grains can pass through.
12. How the grinding wheel is designated? (May/June 2013)
1. Types of abrasive 2. Grain size or grit number 3. Grade of the wheel 4. Structure 5. Types
of bond 6. Manufacturers code

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13.What are the factors considered to select the grinding wheel? (May/June2009)
(Nov/Dec 2015)
1. constant factor 2. Variable factor
14. Define the following terms used in grinding wheel: i) loading and ii) glazing
(May/June 2015, 2017)
Loading: During the operation, the chips formed get entrapped in the inner granular space of
abrasive particles. Glazing: The surface of the wheel becomes smooth and gets a glass like
appearance.
15. What is meant by dressing and truing? (May/June 2009) (Nov/Dec 2013) (May/June
2015)
Dressing: The process of loading and breaking away the glazed surface so that new sharp
abrasive particles are again present to work for efficient cutting is called dressing. Truing: It
is the process of trimming the cutting surface of the wheel to run true with the axis.
16. What is the process of super finishing?
The process of obtaining a surface of the highest class of finish is known as super finishing.
17. What is the process of lapping? (Nov/Dec 2010)
Lapping is surface finishing process used for producing geometrically accurate flat,
cylindrical and spherical surfaces.
18. State the methods of centreless grinding. (May/June 2016)
Through feed, In feed, End feed.
19. What are the types of surface grinders? (Nov/Dec 2011)
Horizontal spindle reciprocating table surface grinder, Horizontal spindle rotary table surface
grinder, Vertical spindle reciprocating table surface grinder, Vertical spindle rotary table
surface grinder
20. What are the types of abrasives?
Natural abrasives, artificial abrasives.

21. Define the term Grade used in grinding wheel. (Apr/May 2011)
Grade or hardness indicates the strength, with which the bonding material holds the abrasive
grains in the grinding wheel.
22. What is broaching? (Nov/Dec 2010, 2012) (Nov/Dec 2015)
Broaching is a process of machining a surface with a special multipoint cutting tool called
“broach” which has successively higher cutting edges in a fixed path.
23. Write the specification of broaching machine. (May/June 2009)
1. Maximum length of the stroke in mm, 2. Maximum force developed by the slide in tones.
24. What are the advantages and limitations of broaching? (May/June 2012)
Advantages:- 1.roughing , semi – finishing cuts are completed in one pass of the broach 2.
Broaching can be used for either external or internal surface finish. Limitations: - 1. high
initial cost of the broach tools compared to other tools. 2. Job work or batch work is not
available due to the high tool cost.
25. What are the types of broaching machine? (May/June 2015)
a. According to the nature and direction of primary cutting motion. Horizontal, vertical and
continuous
b. According to the purpose:- internal & external surface. c. According to method of
operation: -pull or push d. According to the construction of the broach tool: - solid, inserted
tooth, progressive cut, built-up etc. e. According to the function:- key way, burnishing
,splines, round hole etc. f. According to the number of main slides or stations:- single
,multiple or double.g. According to the motion of the broach tool relative to the work:-
straight line motion or stationary broach tool.
26. What are the application of Broaching machine? (Apr/May 2011)
Used for machining through holes of any cross section shape, straight and helical slots,
External surface of various shape, external and internal toothed gears.

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27. What is a tool post grinder? (May/June 2014).
Tool post grinder is used for miscellaneous and small grinding work on a lathe.

28. Name the process parameters involved in the lapping process. (Nov/Dec 2013)
Speed, Pressure, Allowances, Lap materials, Lapping Abrasive.
29. How does loading differs from glazing in grinding process. (May/June 2015)
When the surface of a grinding wheel develops a smooth and shining appearance, it is said to
be glazed. This indicate the abrasive particles on the wheel face are not sharp. These are
worked down to bond level. When soft materials like al, copper, lead etc are ground the
metal particles get clogged the abrasive particles. This condition is called as loading.
30. Give the specification of a grinding wheel. (May/June 2016)
1) The type of grit material 2) The grit size 3) The bond strength of the wheel, commonly
known as wheel hardness 4) The structure of the wheel denoting the porosity i.e. the amount
of inter grit spacing 5) The type of bond material 6) other than these parameters, the wheel
manufacturer may add their own identification code prefixing or suffixing (or both) the
standard code
31. Why Gear finishing is required? (May/June 2016)
Surface of gear teeth produced by any of the generating process is not accurate and of good
quality (smooth). Dimensional inaccuracies and rough surface generated so become the
source of lot of noise, excessive wear, play and backlash between the pair of gears in mesh.
These all result in loss of power to be transmitted and incorrect velocity ratios. This can be
summarized as inefficient power transmission. In order to overcome these problems some
finishing operations are recommended for the produced gears.
32. What are the advantages and limitations of using centreless grinding?
No axial thrust is imposed on the work while grinding. The absence of end pressure makes it
possible to grind long pieces of brittle materials and to grind easily distorted parts. Because
the error of centering is eliminated, a true floating condition exists during the grinding
process. This results in less stock needed and longer wheel life / yield.
A disadvantage to this type of centerless grinding is that it cannot grind complex shapes. The
through-feed mechanism can grind only cylindrical pieces with right circular surfaces.
33. Define grinding ratio.
Grinding wheel wear is generally correlated with the amount of workpiece material ground
by a parameter called the grinding ratio.
G=(volume of material removed/ volume of wheel wear)
34. What is duplex broach machines?
In some cases a machine having two rams is also used i.e. one in the horizontal direction and
the other in vertical direction. Machines having double ram arrangement are called duplex
surface broaching machines.
UNIT-5 CNC MACHINING
PART - A
1. Define NC. (May/June 2009) (Nov/Dec 2013)
Controlling a machine tool by means of a prepared program is known as Numerical Control
or NC.
2. What are the classifications of NC machines?
1. Point to point NC system. 2. Straight cut NC system. 3. Contouring NC system.
3. State the advantages of NC machines. (Nov/Dec 2013)
1. Greater accuracy, 2. Lesser production cost per piece due to reduction in lead time and also
setup time. 3. Improved product quality and provision of high order of repeatability,
4 .Reduced inventory in work -in-process (WIP) , 5. Less operator skill is used, 6. Machine
utilization is better.
4. What is point – to – point (PTP) system?

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It is also called positioning system. The objective of the machine tool Control is to move the
cutting tool to a predefined location. The speed Or path is not important in this system
5. What is then role of the computer for NC mode? (Nov/Dec 2015)
Computer numerical control is an NC system that utilizes stored program to perform basic
numerical control function. Mini or micro computer based controller unit is used.
6. Name the various elements of CNC machines? (May/June 2009) (May/June 2014)
1. Tape reader, 2. Minicomputer. 3. Servos and interface logic. 4. Motion feedback.
7. List the various components of DNC?
1. Central computer.2. Bulk memory which stores the NC part programs.3.
Telecommunication lines.4. Machine tools.
8. State the advantages of CNC.
1. An increase in flexibility. 2. An improvement in the possibilities for correcting errors in
part programming. 3. The possibility of using the computers peripheral equipment. 4. Tape
and Tape reader are used only once for resulting improved reliability.

9. List the commonly used coordinate systems of CNC machines

1. Cantilever construction 2. Bridge construction 3. Column construction 4. Gantry
construction
10. List the methods of creating part programming.
1. Manual part programming.2. Computer –assisted part programming (CAD/CAM based
programming system. 3. Manual data input.5. Computer automated part programming.
11. Write the types of statements in APT language.
1. Geometric statements.2. Motion statements.3. Postprocessor statements.4. Special control
or Auxiliary statements.
12. What is meant by MACRO?
Macro is similar to subroutine used in FORTRAN language. It would be used where certain
motion sequences would be repeated several times, within a program.
13. What is the difference between incremental and absolute system?
In absolute programming the distance at my point at any Instant will be measured from the
origin (X=0, Y=0). Whereas in incremental programming, the instant point will be noted as
(X=0, Y=0). Further measurements will be from the particular point only.
14. Classify linear interpolation.
1. Linear interpolation 2. Circular interpolation 3. Helical interpolation 4. Parabolic
interpolation
15. Mention the advantage of steeping motor.(May/June 2013)
(a). Used in open loop NC system, (b). The system is cheaper, (c). More accuracy
16. Classify machining Centers.
1. Horizontal spindle machining centre 2.Vertical spindle machining centre 3.Universal
machining centre.
17. What is mean by canned cycle? (Apr/May 2010) (May/June 2014)
A Canned cycle is a combination of machine moves that performs anyone particular
Machining function such as drilling, turning, milling, boring, tapping.
18. What are the steps to be followed while preparing part program?
1. Fixation of coordinate system.2. Reference of G and M codes.3. Dimensions of work and
tools. 4. Locating the fixtures and machine table.5. Speed and feed according to the work and
tool material.

19. What are the data essentially needed to prepare a part program?
1. Job Dimension/workpiece.2. Work holding 3. Feed/cutting speed.4. Manual data input
20. Define Subroutine. (May/June 2013)

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If the same machining operation, which was carried out already, is to be performed at many
different positions on the work piece, it can be executed by means of a program called as
Subroutines.
21. Write down the types of statement in APT Language
1. Geometric statements 2. Motion Statements 3. Postprocessor Statements 4. Special control
or Auxiliary statements.
22. How the hydrostatic sideways classified.
Oil lubricated slide ways, Air bearing slide ways
23. What is G-codes and M-codes? (Nov/Dec2009) (Apr/May 2011)
G-codes are preparatory function codes which prepare the machine or tool for different
modes of movements like positioning, contouring, thread cutting etc. M-codes are
miscellaneous function codes which denote the auxiliary or switching information such as
coolant on/off, spindle speed etc.,
24. What is meant by APT program? (Nov/Dec 2010)
APT program is used to command the cutting tool through its sequence of machining process.
APT is also used to calculate the cutter positions. APT is a three dimensional system
controlling up to five axes including rotational co-ordinates.
25. What are the types of motion control system used in NC Machines? (Nov/Dec 2010).
Point to point or positional system, Straight line or paraxial system, Continuous path system.
26. What is meant by tool magazine? (May/June 2012)
In CNC machine, tool magazine is an indexable tool holding device which accommodates
several tools in the form of packets along with specified packet number in such a way to
easily identify it. This arrangement helps to obtain automatic tool changing.
27. State the difference between CNC and DNC. (Nov/Dec 2013) (May/June 2015)
CNC system can do operations on only one machine at a time. But DNC involves that at a
time a large central computer directs the operations of separate NC machine.
28. What is Adaptive control. (May/June 2015)
Adaptive control is the control of the cutting process by on-line calculation and setting of the
optimal parameters subject to machining constraints.
29. Define “Micromachining” (May/June 2016)
The removing (as in drilling, planning, or shaping) of small amounts of material (such as
metal) by action other than that of a sharp-edged tool.
30. State the functions of the following codes. (May/June 2016)
G00- Rapid linear motion; G03-circular motion counter clockwise; M06-Automatic Tool
change; M03-Spindle on Clockwise
31.State the functions of the following G and M codes.(Nov/Dec 2016).
G01- Linear Interpolation,G04-Dwell, M04-Spindle counter clockwise M30-Program stop.
32.Compare bulk and surface micro machining processes.
Bulk micro-machining involves removing material from silicon wafer itself. It is typically
wet etched, traditional MEMS industry and inexpensive equipment.
Surface micro-machining leaves the wafer untouched, but adds/removes additional layers
above the wafer surface. It is typically plasma etched.
33.Distinguish Mechanisation and Automation.
Mechanization is labour being substituted by machinery, but labour still operates the
machines. Automation means labour is replaced by machines and machines work
automatically and are computer controlled. Workers supervise it.
Reasons for automation and mechanization are to reduce costs and increase productivity.

34. What is the need for micromachining? Mention the four categories of
micromachining?
To get nano level surface finish on complex geometries, to get complex 3D components, to
get extra ordinary properties of materials with high strength and corrosion resistant etc.

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