RANGANATHAN POLYTECHNIC COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

SUBJECT: 22052 - MANUFACTURING TECHNOLOGY - II

PREPARED BY: R.SARAVANA VISHNU,

 MANUFACTURING TECHNOLOGY - II

LECTURER / MECHANICAL

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LECTURER/MECHANICAL
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UNIT 1 7. What is the use of sleeve in drilling?

DRILLING MACHINES AND MILLING If the taper shank of the drill is smaller than the spindle taper,
MACHINES sleeve is used.

8. What is the use of socket in drilling?

1. What is the flat drill? If the taper shank of the drill is larger than the spindle taper,
socket is used.
Flat drill has V shaped flat cutting edge.

2. What do you mean by cutting speed? 9. What do you mean by multi-spindle drilling machine?
It has several spindles in this machine. Several hole of different
The peripheral speed of the drill is called cutting speed. size can be drilled simultaneously.

10. Write any two work holding devices used in milling machine.

V= m/min Indexing head
60
Milling head
3. What is reaming?
11. What is plain milling?
The process of sizing and finishing the already drilled Plain milling is the operation of producing flat, horizontal surface.
hole is called reaming.
12. What is face milling?
4. What is counter boring? Face milling is the process of machining flat surface perpendicular
The operation of enlarging the end of a hole cylindrically to the axis of the cutter.
is known as counter boring.
10. Define tool life.
5. What is spot facing?
The operation of squaring and smoothing the surface of a Tool life is defined as the time of tool which operates efficiently
hole is known a spot facing. until it becomes blunt. That is the time between two successive grinds.

6. What is the use of drill jig? 11. List out the advantages of chip breakers.
The drill jig is used to guide the drill bit. To remove the chips easily from the machine
Safety of the operator

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12. Write the types of chip breakers. 17. What are the types of drilling machine?
Step type Portable drilling machine
groove type Radial drilling machine
clamp type Gang drilling machine
Multiple spindles drilling machine
13. Write the properties of cutting tool material.
Hot hardness
18. What are the specifications of drilling machine?
Low friction
Power of the motor
Wear resistance
Net weight
Toughness
Size of the table
Low cost
19. What are the types of drills?
14. Write the cutting tool materials.
High carbon steel Flat drill
High speed steel Twist drill
Stellite Oil tube drill
Carbide Straight flute drill
Ceramics
20. Write the methods for holding drill bit.
15. What are the types of boring tool? Fitting directly on the spindle
Rotating type Sleeve
Non- Rotating type Socket
Chuck
16. What are the factors which affect the tool life?
21. What is drilling?
Cutting speed
Tool material Drilling is the operation of cutting round hole by a rotating tool
Tool geometry named as drill.
Coolant (Cutting fluid) used

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22. What is tapping? UNIT 2

Tapping is the process of cutting internal threads in a hole by PLANER, SHAPER AND SLOTTER
using a tool called tap.
1. What is shaper?
23. What is the use of fine boring machine? Shaper is a reciprocating type of machine. It is used for
Fine boring machine is used for boring accurate holes in parts machining the horizontal, vertical, angular surface, keyways, slots,
like cylinder blocks.
grooves etc.

24. Write the operations of fine boring machine. 2. List out any four important parts of shaper.
Boring Base
Drilling Column
Facing Cross rail
Reaming Ram
Tool head.
25. What is boring? 3. List out any two types of quick return mechanism.
Boring is the process of enlarging the already drilled hole by a Crank and slotted link mechanism.
single point cutting tool. Hydraulic quick return mechanism.

26. Write the types of drills. 4. What is the function of clapper box in shaper tool head?
Flat drill During return stock, the tool block lifts out to avoid rubbing the tool
Twist drill on the job.
Straight fluted drill
27. Define counter sinking. 5. Why rotary table is used in slotting machine?
It is a circular table. It will be rotating about 360 for machining
Counter sinking is the process of producing a conical enlargement
at the end of hole. splines, grooves equally dividing in angle for accurate cutting.

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6. What are the types of shaper?
According to the types of cutting stroke
Push cut shaper.
Draw cut shaper.
7. What is the main advantage of using pit planner?
In this type planner is used for machining very heavy work piece.
Ex: Base, Work table surface.
8. Mention the different feeds available in slotter.
Longitudinal feed -> Moving table X-axis
Cross feed -> Moving table Y-axis
Circular feed -> Rotating the table in 360.
9. What is the use of planner?
Planner is used for machining large work pieces.
10. What is the main use of edge planner?
The main use of edge planner is machining the edges of steel
plates.
11. How many tables are used in divided table planner?
Two tables are used in divided table planner.
12. What is the different drive mechanism used to drive the
table of planner?
Open and cross belt drive.
Electric drive.
Hydraulic drive.
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13. Write any one difference between sharper and slotter.
SHARPER
The tool movement in Horizontal direction.
SLOTTER
The tool movement in vertical direction.
14. What is the main use of draw cut sharper?
Draw cut sharper is used for machining heavy cuts on the job.
15. What is meant by draw cut sharper?
The metal is removed while the ram moves towards the column. This
sharper is called draw cut sharper.
16. How cylindrical job is clamped in sharper?
Using wedge strip and step pen.
Clamping over a V - block.
17. Why return stroke is made faster in sharper?
Return stoke is ideal stroke. In this stroke material is not removed.
18. State any two types of slotter tool.
Roughing tool.
Slotting tool.
19. State any two specification of slotter.
Power of motor.
Diameter of rotary table.
Net weight of machine.
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20. Write any two quick return mechanisms in slotter.

White worth quick return mechanism.
27. What is the difference between shaper and planer?
Hydraulic drive.
PLANER
21. List out the types of planner. Table reciprocates and tool is fixed
Double housing planner.
Open side planner. SHAPER
Pit planner. Tool reciprocates and table is fixed
Edge planner.
28. What is the use of index plate in shaper?
22. Name any two operations which are performed in a slotter.
Machining grooves, slots. The required movement of the crank is obtained with the help of
Machining keyways and splines. the index plate.

23. Which mechanism of automatic feeding is sharper?

Pawl and ratchet mechanism.

24. Any two work holding devices of sharper.

Clamping in a vice.
Clamping on an angle plate.
Clamping over a V block.
Fixture.
25. Mention any two types of slotter.
Puncher slotter.
Precision slotter.

26. What is the puncher slotter?

This type of slotter is heavy and rigid machine and to remove large
amount of metal from castings.
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UNIT-3 7. What is the use of gears?

MILLING MACHINE AND GEAR GENEATING Gears are used to transmit the rotating motion from one shaft to
PROCESSES another shaft.

1. What is the use of bevel gear?
Bevel gear is used to transmit motion between two shafts which
are inclined at an angle to each other.
2. Write any two alloy metals of gear material.
8. Name the cutters used to produce T-slot.
First end mill cutter and then T-slot cutter.
9. What is the use of Wood ruff cutter?
Wood ruff cutter is used to cut wood ruff key slots on shafts.

Nickel - To improve toughness 10. What is the function of fly cutter?

Chromium To increase wear resistance A single point cutting tool is fitted to the end of the bar. The bar is
3. What do you meant by gear generating process? fitted to the spindle, then cutting to the required shape using fly cutter.
Gear generating process is for producing gear teeth by the use of
certain relative motions between the work gear and the cutter during 11. What are the cutter holding devices?
machining. Arbor
4. Name various form cutters. Adaptor
Convex form cutter Spring collet
Concave form cutter
12. What is meant by slap milling?
5. What is meant by straddle milling? This cutter is used for rough machining with coarse fee.
Straddle milling is the operation of machining two vertical surface 13. Define gang milling.
of work piece at the same time.
Gang milling is the operation of milling several surfaces of
6. When adaptor is used in milling? the work piece at the same time.
Adaptor is used in milling machine to hold the tool.

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14. Define up milling. 20. Write the advantages of up milling.

Process is safer
Metal is removed when the cutter teeth moves upwards than cutter
Cutting force is maximum at the end of cut
rotate opposite side feed of work piece.

15. What are the advantages of down milling? 21. What are types of arbor used in milling machine?
Standard arbor
Cutting force gets downwards Stub arbor
Machining surface is not spilled 22. What are the types of gears?
16. What is meant by form milling? Spur gears
Helical gears
Form milling is the operation of producing the required profiles on Worm gears
the work piece. Bevel gears
17. Write the milling operations. 23. What do you meant by indexing?
Plain milling Indexing is the process of dividing the periphery of the work piece into
Face milling any number of equal divisions.
End milling
24. List the gear generating process.
Gang milling

18. What is the use of spring collet? Gear shaping

Gear planning
Spring collet is used for holding straight shank milling cutter. Gear hobbing

19. What is counter sinking? 25. What is pressure angle of a gear?

Counter sinking is the process of producing a conical enlargement of It is an angle between the common tangent to the pitch circles and
the end of the hole. the perpendicular line through the point of contact of two meshing gears.

Standard pressure angle 14.5& 20.

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26. What is the use of gear shaping? 33. Mention any two advantages of bevel gear generation.

External & internal spur gears can be cut in gear shaping method. Any angle to generating gear
Very quick time to generate bevel gear
27. Write two advantages of gear planning process.
34. Write any two advantages of gear shaping.
Any given module can be cut using a single cutter
More accurate Rate of production is high
Very high degree of accuracy
28. What are the limitations of gear hobbing?
35. What are the applications of gear hobbing?
Internal gears cannot be generate
Cost of hob is high Gear hobbing is used for generating spur, helical & worm gear.

29. Mention any two gear finishing process? 36. Write any four gear materials.
Gear shaving
Cast iron
Gear lapping
Nylon
30. Write down the uses of fibre gears?
Brass
Measuring instruments Steel
Tape recorders
Projectors 37. What type of cutter is used in gear shaping?
Televisions Pinion type cutter is used in gear shaping.
31. State any two advantages of aluminium as gear material. 38. What are the two types of gear grinding?
Light weight Formed wheel gear grinding
The surface of gear is hardened by anodizing Generation gear grinding
32. Write the other name of gear planning process.

Rack cutter generation process

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39. Mention any two tool holding devices used in milling machine? UNIT-4
Arbor ABRASIVEPROCESS AND BROACHING
Adaptors
1. What is meant by grinding?
Spring collets
Grinding is the metal cutting process. In this process the metal is
40. What is gear shaving? removed by rotating the abrasive wheel.
When the gear and cutter rotate, the cutter reciprocates in a 2. State purpose of grinding.
direction parallel to the gear axis. This operation is called gear
shaving. Grinding is used for finishing operation. It gives good surface finish
with high accuracy.

3. Write any two rough grinders.

Floor stand grinder
Portable grinder
Bench grinder

4. State the other name for floor stand grinder.

The other name for floor stand grinder is Pedestal grinder.

5. What are the uses of portable grinder?

It is used for grinding large forgings, welded joints and sheet

metal work.

6. State the uses of Swing frame grinder.

This grinder is used for rough grinding of large castings and

forgings.

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7. What do you meant by Centre less grinding? 13. Mention any one artificial abrasive.

In this machine work piece is not held between the centres. The work Aluminium Oxide (A)
piece is placed on a work rest in between the grinding wheels. Silicon carbide(C)
8. Mention the types of grinding performed on a cylindrical grinding.
14. Name the two types of bond.
Trance verse Grinding
Taper Grinding Shellac bond
Plunge Grinding Silicate bond

9. What is the use of plunge grinding? 15. What is meant by grit?

This plunge grinding is used for grinding shoulder, stepping and It refers to an actual size of the abrasive particles. Grain size is
various contours on the work piece. denoted by the grit number.

10. What is the use of internal grinding? 16. Define the term grade.

This internal grinding is used for finishing straight, tapered or formed Grade of the grinding wheel denote the bond strength. This
holes to required size, shape and finish. grade also hardness of the wheel.

11. State the various types of internal grinder. 17. What for the truing operation is used?

Checking type Truing operation is used to bring back the original shape of
Planetary type the grinding wheel by using a diamond typed tool.
Centre less type 18. Define Loading.
12. What is planetary grinding? The space between the abrasive particles is filled up
The rotating grinding wheel also revolves around a circular path at the with fine particles. This is called Loading.
inner side of the hole. So it is called planetary grinder.

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19. What is meant by dressing? 24. Write the uses of jig boring machine.

Dressing is the process of removing the glazing and loading from In the jig boring machine accurate setting, drilling, reaming,
the grinding wheel counter sinking, grinding, tapping and milling operations are done.

20. What is broaching? 25. Write any two types of surface grinding.
Horizontal spindle surface grinding.
Broaching is the process of machining the surface with a special
Vertical spindle surface grinding.
multipoint cutting tool.
26. What is glazing?
21. What are the types of broaching tool?
The grinding wheel cutting edge becomes smooth and gets a glass
Two types of broaching tool. like appearance it is called glazing.

Rotating type. 27. Write any two examples of natural abrasives.

Non- rotating type. Sand stone (or) solid quartz.
Emery.
22. What are the different types of broaching machine? Corundum.
28. Write the various operations of horizontal boring machines?
Horizontal type.
Vertical type. Boring
Drilling.
23. What are the broaching operations?
Reaming.
Surface broaching. Facing.
Hole broaching.
29. Name any two natural abrasives.
Key way broaching.
Sand stone
Spline broaching.
Emery
Diamond

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UNIT 5 6. What are two main types of V locators?

JIGS AND FIXTURES, PRESS WORKING AND Fixed V locators.
NON CONVENTIONAL MACHINING Sliding V locators.
1. Define jig.
7. What is the work of setting block in fixture?
Jig is a device that holds and locates work piece and guides
the cutting tool. The work of setting block in fixture is supporting job in like dowel pin
and screws.
2. Define fixture.
8. Why locators are necessary in jigs?
Fixtures are a device that holds and locates work piece but it
does not guide the cutting tool. Locators are used in, locating work pieces correctly with respect the
position of cutting tool.
3. What are the types of drill Jigs?
9. State uses of clamps.
Drill bush Jig
Diameter Jig Clamps are used in holding work piece.
Plate Jig 10. What are the types of press?
Leaf Jig.
Hand press
4. What are the types of fixtures? Power operated press
Keyway milling fixtures Hydraulic press
String milling fixtures Pneumatic press.
Plain milling fixtures 11. What is mechanical press?
Vice Jaw milling fixtures.
Open back inclinable press is called mechanical press.
5. What is the work of fool proof element?
The work of fool proof element is guiding the drill bit.

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12. What is angle bending? 18. What are the types of bending operation in steel metal?
Angle bending.
Angle bending is an operation of bending a sheet metal to a sharp acute
Roll forming.
angle.
Curling.
13. What is notching? Seaming.

Notching is an operation of cutting and removing excess metal 19. State any two non-conventional machining processes.
from the edges of sheet metal.
Ultra sonic machining.
14. What is plasma? Chemical machining.
When a flowing by gear is heated to a very high temperature it
20. Write the various types of seaming.
gets ironized. The ironized gas is called plasma.
15. What is masking? Lap seam.
Ground seam.
Masking is the process of covering the portion of work
Single seam.
piece which are not to be machined.
Double seam.
The portion is covered with masking sheet.
21. What are the advantages of ultrasonic machining?
16. What is seaming?
Accuracy is more.
Seaming is an operation of inter locking sheet metal product such as
cans, drums, tins. Simple in construction.
Production cost is low.
17. What are the applications of electro chemical grinding?
22. What is trimming?
It is used for machining very thin sheets.
Trimming is the operation of removing the unwanted projection on
It is used to grinding tungsten carbide tip tools.
forged (or) press worked parts.

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23. Write any two advantages of laser beam machining. 28. Define Blanking.

Any material can be machined. Blanking is the shearing operation of cutting the sheet metal into
It is no tool wear. required shape by using die and punch.
It can be used for non-metal.

24. What are the types of press accessories?

Stops
Pilots
Knock out
Strippers.

25. What are the uses of pressure pad?

Pressure pad is used to hold the sheet metal at correct position by

applying sufficient pressure.

26. What do you meant by lancing?

Lancing is the operation of cutting a sheet metal through a small

length and bending it.

27. Define Punching.

Punching is the shearing operation of producing the circular hole in

the sheet metal by a punch.

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