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M E 6 4 0 2 - M A N U F A C T U RI N G T E C H N O L O G Y I I
UNIT -1
THEORY OF METAL CUTTING
TWO MARKS QUESTIONS:
1. What is rake angle? What is the effect of nose radius in tools?
The angle between the tool face and the line parallel to the base of the tool is
known as side rake angle. It is used to control chip flow.
2. What is tool?
The various angles of tools are mentioned in a numerical number in particular

order. That is known as tool signature.
3. Explain the nose radius?
It is the 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.
4. Name the factors that contribute to poor surface finish in cutting?
Cutting speed
Feed
Depth of cut.
5. What is orthogonal cutting?
The cutting edge of tool is perpendicular to the work piece axis
6. Define oblique cutting?
Oblique cutting: - The cutting edge is inclined at an acute angle with normal to the
cutting velocity vector is called oblique cutting process
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7. What is cutting force?

The sheared material begins to flow along the cutting tool face in the form of
small pieces . The compressive force applied to form the chip is called cutting
f o rc e
8. What is chip reduction co-efficient ?
The reciprocal of chip thickness ratio is called chip reduction co-efficient.
K=1/r
9. What is the function of chip breakers?
The chip breakers are used to break the chips into small pieces for removal, safety
and to prevent both the machine and work damage
10. Define machinability of metal?
Machinability is defined as the ease with which a material can be satisfactorily
machined
11. How tool life is defined?
Tool life is defined as the time elapsed between two consecutive tool
resharpening. During this period the tool serves effectively and efficiently
12. Write Taylors tool life equation?
n
Taylors tool life equation, VT =C
Wh e re ,
V= Cutting speed in m/min.

T= Tool life in minute
C= Constant
N=
In d ex
depends
upon
tool
and
wo r k .
13. What are the factors affecting tool life?

Cutting speed
Feed and depth of cut
Tool geomentry
Tool material
Cutting fluid
Work material
Rigidity of work, tool and machine
14. What are the four important characteristics of materials used for cutting
tools?
Hot hardness
Wear resistance
High thermal conductivity
Resistance to thermal shock
Easy to grind and sharpen .
Low mechanical and chemical affinity for the work material
15. Name the various cutting tool materials.
Carbon tool steel
High speed steel
Cemented carbides
Ceramics
Di a m o n d s
16. What are the functions of cutting fluids?

It is used to cool the cutting tool and work piece.
It lubricates the cutting tool and thus reduces the co-efficient of friction between
tool and work.
It improves the surface finish as stated earlier.
It causes the chips to break up into small parts.
It protects the finished surface from corrosion.
It washes away the chips from the tool. It prevents the tool from fouling.
It prevents corrosion of work and machine
17. What are the factors responsible for built-up edge in cutting tools?
During cutting process, the interface temperature and pressure are 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 built up edge
18. List the essential characteristics of a cutting fluid?
It should have good lubricating properties to reduce frictional forces and to
decrease the power consumption.
High heat absorbing capacity.
It should have a high specific heat, high heat conductivity and high film coefficient.
High flash point.
It should be odorless
It
s h o u ld
be
non
corrosive
to
work
and
tool.
19. What are the causes of wear?

The tool is subjected to three important factors such as for ce, temperature and
sliding action due tool.
20. Briefly, differentiate between orthogonal cutting and oblique cutting?
Sl.
Orthogonal cutting
Oblique cutting
No.
1.
T he
cutting
edge
of
th e
to o l
is The cutting edge is inclined at an acute
perpendicular to the cutting velocity angle with the normal to the cutting
vector.
2.
velocity vector
The chip flows over the tool face and the The chip flows on the tool face making an
direction of chip-flow velocity is normal angel with the normal on the cutting edge.
to the cutting edge.
3.
The cutting edge clears the width of the The cutting edge may or may not clear the
work piece on either ends.(i.e No side width of the work piece.
f l o w)
4.
The maximum chip thickness occurs at its The maximum chip thickness may not
middle.
occur at the middle.
21. Give two examples for orthogonal cutting.

Turning, facing, thread cutting and parting off
UNI T 2
TURNING MACHINES
1. What is swing diameter?
The largest diameter of work that will revol ve without touching the bed and is twice the
height of the center measured from the bed of the lathe.
2. write the specifications of a typical lathe?
I, The length of bed.
ii, maximum distance between dead and live centres.
iii, Types of bed( i,e) straight, semi gap or gap type.
iv, The height of dead centres.
v, swing over the bed.
vi, width of the bed.
vii, spindle bore.
viii, spindle speed.
ix, H.P. of main motor and rpm.
x, Number of spindle speeds.
xi, spindle nose diameter.
xii, Feeds .
3. Write down the names of any four lathe accessories?

lathe centres, catch plates, carriers, chucks, mandrels and rests.
4. What are the operations can be performed on a lathe?
Turning, facing, forming, knurling, chamfering, thread cutting, drilling, boring, recessing,
tapping, grooving etc.
5. Write down the names of any four lathe accessories?
lathe centres, catch plates, carriers, chucks, mandrels and rests.
6. What are the functions of feed rod and lead screw?
Feed rod:
It is used to guide the carriage in a straight line when it moves along the bed.
Lead screw:
It is used to move the carriage while thread cutting operation is carried out. It also
ensures the proper speed of work relative to the tool thread cutting operation.
7.Mention four types of chucks used in a machine shop?
i, Three jaw chuck (or) self centering chuck
ii, Four jaw chuck (or) independent chuck.
iii, magnetic chuck.

8. What is the application of Air operated chuck?
Heavy work piece are mounted with the help of air operated chucks because they will
require more power to hold the work piece.
9. What is the purpose of mandrel? How many types of mandrels is there in

common use?
Mandrels are used for holding hollow work pieces.
1. plain mandrel
2. collar mandrel
3. cone mandrel
4. special mandrel
5. step mandrel
6. Expansion mandrel
7. Gang mandrel
10. What is thread cutting operation?
Thread cutting is the operation of producing continues helical groove on a cylindrical
work piece.
11.Name any four work holding devices?
1, collets
2, chucks
3, Fixtures
4, power chucks
12.Define automatic machine?

Automatic machine or simply automats are machines tools in which all the operations
required to finish off the work piece are done automatically with out the attention of an
operator.
13. What are the advantages of automatic lathes?
a, Mass production of identical parts.
b, High accuracy is maintained.
c, Time of production is minimized.
d, The bar stock is feed automatically.
UNI T 3
SHAPER, MILLING AND GEAR CUTTING MACHINES

1. Compare hydraulic shaper with mechanical shaper?
S L. N O
Hydrulic shaper
Mechanical shaper
1.
smooth cutting operation
Rough and noisy cutting operation
2.
changing of cutting speed is easy
changing of cutting speed is difficult
3.
Higher cutting to return ratio can be Lower cutting to return ratio

obtained
4.
Stroke length can be easily adjusted

without stopping the machine
Change of stroke length is not possible

with out stopping the machine.
2. Write down any four operations performed by a shaper?

Machining horizontal surfaces.
Machining vertical surfaces.
Machining inclined surfaces.
Machining irregular surfaces.
3. Mention the operation performed by planer?
The following operations generally performed in a planer are
a.Planning horizontal surface
b.Planning vertical surface
c.Planning curved surface
d.Planning of an angle
4. What is the function of clapper block in a planer?

During cutting stroke, the tool block fits inside the clapper block rigidly. During
the return stroke, the tool block lifts out of the clapper block to avoid rubbing of
the tool on the job.
5. State the difference between a vertical shaper and a slotter?
vertical shaper
1. vertical shapers generally fitted
slotter
1.The slides are fitted
with rotary table to machine

curved surfaces
2. Rotary table along with tools will
remove.
3. vertical shaper is not fixed in the
vertical plane
2.slides will move to perform

slotting.
3. slotter is fixed in the vertical
plane.
6. What are the common work holding devices used on milling machines?
a.v blocks.
b.machine vises.
c.milling fixtures.
d.Dividing heads
7. What is a shell mill?

A shell mill is a large type of face or end mill that mounts onto an arbor, rather
than having an integral shank. Typicaly, there is a hollow or recess in the center of
the shell for mounting hardware onto a separate arbor.
8. What is meant by up-milling and down milling?
In up milling, cutters rotates opposites to the direction of a feed of the work piece
whereas in down milling, the cutter rotates in the same direction of travel of the
workpiece.
9. What are the differences between up milling and down milling?
S L . NO
EVENT OF
UP MILLING
DOWN MILLING
OPERATION
1.
Direction
of Cutter rotates against the Cutter rotates in the
Travel
direction
of
tr a v e l
of same
workpiece.
2.
C h ip
thickness
3.
M i n i mu m
direction
of
travel of workpiece
at
t he
Maximum
at
the
cut beginnining Greeches
Greeches max when the min at terminates
beginning
of
cut terminates.
cutting force
Decreases from max

Increases from zero to to zero per tooth.
max per tooth
10. What is thread milling?

A thread milling has no chamfer. The mill is inserted into the hole along the axis
of the spindle, deep enough to produce full thread depth required
11. write down the rule for gear ratio in differential indexing
Rule for gear ratio in differential indexing:
Gear ratio = (A-N)/A
A- Selected no which can be indexed by plain indexing and approximately
equal to N.
N- Required no. of divisions to be indexed.
12. How do specify radial drilling machine?
A drilling machine is specified by the job following items.
1. Maximum size of the drill in mm that the machine can be operate.
2. Table size of maximum dimension of a job can mount on a table in square
me t e r .
3. maximum spindle speed and range of spindle speeds in r.p.m
13. Write down any four operations that can be performed in a drilling machine?
1. Drilling
2. counter sinking
3. Tapping
4. reaming.
14. What is meant by sensitive hand feed?
In drilling machines, manual sensing of the hand does feeding of the tools towards
the work piece. it is called as sensitive hand feed
15. What is broaching?

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.
16. Why is sawing a commonly used process?
1. Easy handling of machines and spindle construction
2. Fast operation and cost of machinery is less
UNI T 4
ABRASIVE PROCESSES AND BROACHING

1. What are the types of surfaces that could de produced using plain cylindrical
grinders?
Plain cylindrical parts, cylindrical parts, cylinders, tapers, shoulders, fillets,
cams, crankshaft etc.
2. State the abrasives sed in manufacture of grinding wheels?
a, corundum (75 to 90% crystalline Al2O3 +IRON OXIDE)
b, Diamond
Artificial abrasives:
a, Aluminium oxide
b, silicon oxide
3. What do you mean by loading of grinding whells?
During the operation , the chips formed get entrapped in the linner granular
space of abrasive particles. This is called loading.
The surface of the wheel becomes smooth and gets a glassy appearance.
This is known as glazing wheel.
4. What is meant by dressing and truing?
Dressing is the process of loading and breaking away the glazed surface so
that new sharp abrasive particles are again present to work for efficient
cutting.
Truing is the process of trimming the cutting surface of the wheel to true
with the axis.
5. Mention four important factors that influence the selection of grinding
wheel?
1. constant factors
i. physical properties of material to be ground
ii. Amount and rate of stock to be removed.
iii. Area of contact.
iv. Type of grinding machine
2. variable Factors
i.work speed.
ii. wheel speed.
iii. condition of the grinding machine
iv. personal factor
6. What for lapping is used?
a, Removing small amounts of material from the surfaces of tools.
b, Removing small defects and surface cracks left during previous
operations
c, Eliminating small distortion.

7. What is meant by honing?
An abrading process of finishing previously machined surfaces is known as
honing.
8. What are the advantages of honing process?
1. Simple process which can be done on any general purpose machines
such as lathes and drilling machines.
2. This process can be applied for both internal cylindrical and flat
surfaces.
3. Honing enables the maximum stock removing capacity out of entire
surface finishing operations.
9. What is meant by dressing and truing?
Dressing is the process of loading and breaking away the glazed surface so
that new sharp abrasive particles are again present to work for efficient
cutting.
Truing is the process of trimming the cutting surface of the wheel to run
true with the axis.
10. What is roller burnishing process?
Roller burnishing is a method of cold working metal surfaces in which
hardened sphere or cylindrical roller is pressed against the work to be
processed. For exampl e, in roller burnishing on a lathe, the burnishing tool
is moved across the surface to be spanned.
UNI T 5
C NC M A CH I NI NG
1. Define NC?
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. What are G-codes and M-codes? Give examples.
G-codes are preparatory function codes which prepare the machine are
for different modes of movement like positioning, contouring, thread
cutting etc.
Eg. G00 Point to point positioning
G01 linear interpolation
M- codes are miscellaneous function codes which denote the
auxillary or switching information such as coolant on/off, spindle
speed etc.
Eg. M00 Program stop
M01 Optional stop.
4. What is the role of computer for NC machine tool?

computer numerical control is an NC system that utilizes stored progr am to
perform basic numerical control functions. mini or micro computer based
controller unit is used.
5. Name the various elements of CNC machines?
1.Tape reader
2.Mini computer
3. servos and interface logic
4. Motion feedback
6. What is the role of computer for NC machine tool?
computer numerical control is an NC system that utilizes stored program to
perform basic numer ical control functions. mini or micro computer based
controller unit is used.
7.What is point to- point (PTP) system?
It is also called positioning system. The objectives 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
8. Mention the main differencebetween CNC and DNC?
CNC system can do operations on only one machine at a time. But direct
numerical control involves that at a time a large central computer to direct the
operations of a number of separate NC machines
9. List the commonly used co ordinate system of CNC machine tools?

Cantilever construction
Bridge construction
Column construction
Gantry construction
10. 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 measurement will be made from the particular point
only.
11. Write down the types of statements in APT language.?
1. Geometric statements
2. Motion statements
3. postprocessor statement
4. special control or Auxiliary statements
12. Define subroutine?
If the same machining operations, 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

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The various angles of tools are mentioned in a numerical number in particular

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7. What is cutting force?

V= Cutting speed in m/min.

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13. What are the factors affecting tool life?

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16. What are the functions of cutting fluids?

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19. What are the causes of wear?

is The cutting edge is inclined at an acute

occur at the middle.

21. Give two examples for orthogonal cutting.

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3. Write down the names of any four lathe accessories?

ii, Four jaw chuck (or) independent chuck.

iii, magnetic chuck.

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9. What is the purpose of mandrel? How many types of mandrels is there in

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12.Define automatic machine?

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SHAPER, MILLING AND GEAR CUTTING MACHINES

smooth cutting operation

Rough and noisy cutting operation

changing of cutting speed is easy

changing of cutting speed is difficult

Higher cutting to return ratio can be Lower cutting to return ratio

Stroke length can be easily adjusted

Change of stroke length is not possible

2. Write down any four operations performed by a shaper?

b.Planning vertical surface

c.Planning curved surface

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4. What is the function of clapper block in a planer?

with rotary table to machine

2.slides will move to perform

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7. What is a shell mill?

of Cutter rotates against the Cutter rotates in the

Decreases from max

max per tooth

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10. What is thread milling?