SINDHI BOARD OF TECHNICAL EDUCATION KARACHI

DIPLOMA OF ASSOCIATE ENGINEER

TECHNOLOGY :MECHANICAL

SHORT ANSWER QUESTION

1.Differentiate between climb and conventional milling.

(ANS)There are two distinct ways to cut materials when milling: Conventional Milling (Up) and Climb
Milling (Down). The difference between these two techniques is the relationship of the rotation of the
cutter to the direction of feed.
2. Enlist attachment and accessories of milling machine.
ANS) The following are the different attachments used on universal milling machine.
Dividing head
Vertical head
Rotary table
Slotting attachment
Rack milling attachment
3. Enlist Main Part of milling machine.
ANS) Base, Column, Knee, Saddle, Table, Overhanging arm, Spindle, Arbor, Arbor
Supports, Milling head ,Ram ,Working of Milling Machine
4. What are the advantages of using milling attachment?
ANS)A milling machine is, in itself, a most versatile tool, but when equipped with a suitable set of
attachments, the range of work that can be done is greatly increased. Also there are often milling
operations that can be performed without an attachment, but by using one the jobs can be more easily
and quickly done.
5. Describe Briefly the different hold-down device used to hold the work on milling machine.
ANS)It is necessary that the work should be properly and securely held on the milling machine table for
effective machining operations.Types of work holding devices,T- Bolts and clampsAngle, plates
V blockPlain, ViceSwivel, VicesUniversal Vices
6.Enlist different types of milling cutters.
ANS)While each of these features dictate the performance of the cutting tool, the type of cutting done is
determined by the various types of cutting tools as well.
7. Enlist The operation performed on the milling machine.
ANS) There are 12 types of operations which can be performed on a Milling Machine.
Plain milling
Face milling
Side milling
Straddle milling
Angular milling
Gang milling
Form milling
Profile milling
Helical milling
Cam milling
Thread milling
End milling
Die Sinking
8.Different Face end milling operations.
ANS) Milling cutters are cutting tools typically used in milling machines or machining centres to perform
milling operations (and occasionally in other machine tools). They remove material by their movement
within the machine (e.g., a ball nose mill) or directly from the cutter's shape (e.g., a form tool such as a
hobbing cutter).

9. Enlist different types of hydraulic valves and give function of any one.
ANS) A hydraulic valve properly directs the flow of a liquid medium, usually oil, through your hydraulic
system. The direction of the oil flow is determined by the position of a spool. A hydraulic system can
only function - as per requirements - by using valves.
10. Define gear pinion and rack.
ANS)A rack and pinion is a type of linear actuator that comprises a pair of gears which convert rotational
motion into linear motion.
11.Define Machine vise And its uses.
ANS) A vise (American English) or vice (British English) is a mechanical apparatus used to secure an
object to allow work to be performed on it. Vises have two parallel jaws, one fixed and the other
movable, threaded in and out by a screw and lever.
12.Define bonding methods.
ANS) Network bonding is a process of combing or joining two or more network interfaces together into a
single interface. Network bonding offers performance improvements and redundancy by increasing the
network throughput and bandwidth.
13.Explain Plain indexing .
ANS) An indexing head, also known as a dividing head or spiral head,[1] is a specialized tool that allows a
workpiece to be circularly indexed; that is, easily and precisely rotated to preset angles or circular
divisions.
14.Define abrasive And their classification.
AND) An abrasive is a material, often a mineral, that is used to shape or finish a workpiece through
rubbing[1] which leads to part of the workpiece being worn away by friction. While finishing a material
often means polishing it to gain a smooth, reflective surface, the process can also involve roughening as
in satin, matte or beaded finishes
15.What is meant by grade and structure?
ANS) Grade Structure consists of a sequence or hierarchy of grades, bands or levels into which groups of
jobs that are broadly comparable in size are placed
16.Whats down the vise and its gear.
ANS)A vise (American English) or vice (British English) is a mechanical apparatus used to secure an
object to allow work to be performed on it. Vises have two parallel jaws, one fixed and the other
movable, threaded in and out by a screw and lever.
17.Define slottiong. Name the tools use for slotting.
ANS) A slotting fee, slotting allowance,[1] pay-to-stay, or fixed trade spending[2] is a fee charged to
produce companies or manufacturers by supermarket distributors (retailers) in order to have their
product placed on their shelves.[3] The fee varies greatly depending on the product, manufacturer, and
market conditions.
18.Define indexing explain angular indexing.
An indexing head, also known as a dividing head or spiral head, is a specialized tool that allows a
workpiece to be circularly indexed; that is, easily and precisely rotated to preset angles or circular
divisions.
19.what is a vertical knee and cloum types milling machine
They can be broadly classified into the following types:
 Column and knee type of milling machines
 Bed type
 Rotary table
 Tracer controlled

20.Define the dividing head &its types.

The dividing head is essentially a horizontal (though sometimes tiltable) shaft with a wormwheel on it
that can be driven round by means of a worm. The shaft has various means of holding a workpiece.
21.Explain the use of t solt in milling machine table
EquipNet is the leading global provider of used milling machines and various other pre-owned
equipment. Our exclusive contracts with our clients yield a wide range of used milling machines from a
number of respected OEMs.
22.Explain the two method of holding cutters on a milling machine.
When the work is fed in a direction that is same as the direction of rotation of cutter, which is also
known as down cut milling. The down cut milling is less commonly used. Though the down cut milling
has certain advantages over conventional milling, down cut milling impose certain restrictions.
23.Explain the working principle of hobbing machine.
Hobbing is a machining process for gear cutting, cutting splines, and cutting sprockets on a hobbing
machine, which is a special type of milling machine. The teeth or splines are progressively cut into the
workpiece by a series of cuts made by a cutting tool called a hob.
24.Define angular indexing.
Differential Indexing. Sometimes a number of divisions are required
which cannot be obtained by simple indexing with the index plates regularly
supplied. To obtain these divisions a differential index head is used
25.what is the difference between tool designer and tool maker?
Tool and die makers are a class of machinists in the manufacturing industries who make jigs, fixtures,
dies, molds, machine tools, cutting tools, gauges, and other tools used in manufacturing processes
26. Define ‘’Fits’’ Limits’’ Accuracy Allowance And tolerance’’.
allowances and tolerances in the design of mating parts. Clearance fit: It is one having limits of zero so
specified that a clearance always results when mating parts are assembled.
27.Skecth a twist drill and label its parts.
Drilling is the process of cutting or originating a round hole from the solid material. There are many ways
of classifying drills. The tool(drill) and not the work piece is revolved and is fed into the material along its
axis.
28.how can lath fixture are clamped.
If the job can be held easily and quickly in the above mentioned standard devices, then there is no need
for special work holding devices. However many jobs particuly casting and forging, because of their
shapes, cannot be conveniently held by any of the standard devices.
29.sate toggle clamp with the help of sketch.
DESTACO Pull-Action Latch Clamps feature a handle that can be moved to place the clamping pull bar
(hook) around the opposing latch and pressed down to reach the locked position. Ideal for sealing
chamber doors, mold closures, and access doors, the latch clamps provide a powerful closing force,
positive holding and convenient operation.
30. Describe how the desigh of jigs is planned.
Jigs and Fixtures:
Some machining operation are so simple’ which are done quite easily, such as turning, the job is held in
position in the chuck and turning operation is done easily.
31.Explan the washer and its types.
A washer is a thin plate (typically disk-shaped) with a hole (typically in the middle) that is normally used
to distribute the load of a threaded fastener, such as a screw or nut. Other uses are as a spacer, spring
(belleville washer, wave washer), wear pad, preload indicating device, locking device, and to reduce
vibration (rubber washer). Washers often have an outer diameter (OD) about twice their inner diameter
(ID), but this can vary quite widely.

32.Define cam and follower.

Definition of cam follower. : the peg or roller which follows the curvature of a cam and to which the
motion of the cam is thereby directly communicated.
34. Define toggle clamp.
A toggle clamp has a single clamping plate and is designed to hold a workpiece down on a work surface,
such as a bench top. The clamp is fixed, as it is permanently bolted to the work surface.
35.explain conical locators.
Jigs and fixtures ease for the production of components in mass within a very economical manner. These
serve as most important role in mass production system. These are a special kind of work holding and
tool guiding devices.
36.Define negative allowance.
This allowance is a negative allowance, and a common way of going around this allowance is to
increase the draft allowance. Shaking of the pattern causes an enlargement of the mould cavity and
results in a bigger casting
37.Enlist the elements used in gang milling fixture.
Types of fixtures,Adjustable fixture: ,Grinding fixtures
Welding fixtureAssembly, fixtureInspection, fixturesMilling fixtures
38.Sketch and enlist the parts ob press
Press tools are commonly used in hydraulic, pneumatic, and mechanical presses to produce the sheet
metal components in large volumes. Generally press tools are categorized by the types of operation
performed using the tool, such as blanking, piercing, bending, forming, forging, trimming etc.
39.Define shift hole norminal size and basic size
Metrology is the science of measurement
Dimensional metrology is that branch of Metrology
which deals with measurement of “dimensions“ of
a part or
workpiece
(lengths, angles, etc.)
a part or
workpiece
(lengths, angles, etc.)
40.Name the different types of clamping device.
 G Clamp. Sometimes referred to as 'C-clamps'. ...
 Hand Screw Clamps. Metal Hand Screw Clamps (known as 'Toolmaker's clamps') are mainly
used in metalwork, however they do have a use to clamp small items. ...
 Sash Clamp. ...
 Pipe Clamps. ...
 Bench Clamps. ...
 Web Clamp. ...
 Mitre Clamp. ...
 Quick Action Clamp
41.describe the methods of drwing cam profiles.
am profile dictates how the cam is designed which ultimately dictates movement of the follower, now
this cam and follower mechanism use in many places like to operate IC engine's rocker arm to ensure
how the engine will breath, when the inlet valve should open and when the outlet valve should.

41.Enlist Different materials used in construction of jig and fixtures

Elements of Jigs and Fixtures.
Various elements of jigs and fixtures and their details are follows.
1: Body 2: Locating devices
3: Clamping devices
4: Tool guide(jigs bushing)
42.Decsribe external and internal cylindrical grinding fixtures.
The cylindrical grinder is a type of grinding machine used to shape the outside of an object. The
cylindrical grinder can work on a variety of shapes, however the object must have a central axis of
rotation. This includes but is not limited to such shapes as a cylinder, an ellipse, a cam, or a crankshaft.[1]
43.Name the classes of fits also describe (LN) location Interference fit
Engineering fits are generally used as part of geometric dimensioning and tolerancing when a part or
assembly is designed. In engineering terms, the "fit" is the clearance between two mating parts, and the
size of this clearance determines whether the parts can move independently from each other, or are
temporarily or even permanently joined.
44.satae the meaning and classification SAE&AISI Steels.
SAE International, as a standards organization, maintains several alloy numbering systems, one of which,
for steel grades, is the SAE steel grades system. In the 1930s and 1940s the American Iron and Steel
Institute (AISI) and SAE were both involved in efforts to standardize such a numbering system for steels.
45.Describe the work of a hydraulic press.
A hydraulic press is a device (see machine press) using a hydraulic cylinder to generate a compressive
force. It uses the hydraulic equivalent of a mechanical lever, and was also known as a Bramah press
after the inventor, Joseph Bramah, of England.
 DETAIL ANSWER QUESTIONS
1(a) Sate the safety precaution while using the grinding wheels.
Grinding wheels are safe tools when they are used in accordance with some basic rules.
However if they are used incorrectly or not installed carefully onto the machine, there is the possibility
that the grinding wheel may fracture.
Be sure to observe the “Dos” and “Don’ts” for safe work.
The following basic rules are based on the Ordinance on Industrial Safety and Health and on Structural
Standard for grinders and Related Equipment.
1(b)enlist main parts of a cylinder grinding machine and explain the function of each.
A grinding machine, often shortened to grinder, is any of various power tools or machine tools used for
grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each grain of abrasive
on the wheel's surface cuts a small chip from the workpiece via shear deformation.Grinding is used to
finish workpieces that must show high surface quality (e.g., low surface roughness) and high accuracy of
shape and dimension.
2(a) Define the term tooling and tools life.
Tool life is a general term and there is no single definition that defines it. In production and
manufacturing fields, tool life can signify following definitions.(1)The volume of material
removed by a machining tool during its total usage span. The volume may be in cubic mm or
cubic cm at a standard cutting speed.(2)The duration for which the tool is usable for
machining, i.e, the time taken till there is tool failure. Here failure can mean fracture, crater
formation on tool surface, softening of edges etc.

2(b)Explain the classification of cutting tools.

From the perspective of a machinist, cutting tools may be classified on the basis of material. The material
classifications for cutting tools are: carbon tool steels, high speed steels, cast alloys, carbides, and
ceramics. Natural and artificial diamonds have been excluded as they fall outside of the normal use of a
production shop.
The most important properties of a single point cutting tool are:
1)Strength or toughness - the ability to withstand cutting pressure particularly under adverse conditions
such as interrupted cuts.
2)Hot hardness or wear resistance - the ability to retain a sharp cutting point at high temperature.
3(a)Define Stoppers.
Definition of stopper
1 : one that brings to a halt or causes to stop operating or functioning : check: such as
a : a playing card that will stop the running of a suit
b : a baseball pitcher depended on to win important games or to stop a losing streak; also : an effective
relief pitcher
2 : one that closes, shuts, or fills up; specifically : something (such as a bung or cork) used to plug an
opening
3(b)Enlist the types of stopper with suitable sketches.
Stopper may refer to:
Bung, a plug used to stop the opening of a container
Plug (sanitation), used to stop a drainage outlet
Defender (association football), in soccer (association football)
Milkor 37/38mm and 40mm Stopper, a gun
Alternative name for a whitewater hole, in whitewater kayaking
Stopper, in the game of bridge
Stopper, in baseball, a key starting or relief pitcher
4(a) Define Cam and follower
In automotive terms a cam follower may also refer to a tappet (or lifter) or rocker arm.
A cam follower, also known as a track follower,[1] is a specialized type of roller or needle bearing
designed to follow cam lobe profiles. Cam followers come in a vast array of different configurations,
however the most defining characteristic is how the cam follower mounts to its mating part; stud style
cam followers use a stud while the yoke style has a hole through the middle.
4(b)Compare types of followers
A cam is a rotating or sliding piece in a mechanical linkage that drives a mating component known as a
follower. From a functional viewpoint, a cam-and-follower arrangement is very similar to the linkages.
The cam accepts an input motion (rotary motion or linear motion) and imparts a resultant motion (linear
motion or rotary motion) to a follower.
5. enlist at least five methods of holding working on surface grinder and explain each.
The grinding machine is a type of tool that is utilized for grinding work pieces. It basically use an abrasive
wheel as the cutting tool. The rough surface of the abrasive wheel shreds off small portions of the work
piece as required. It is also known as a grinder.
6.Explain the procedure and method of producing project.
Job Production is used when a product is produced with the labor of one or few workers and is rarely
used for bulk and large scale production. It is mainly used for one-off products or prototypes (hence also
known as Prototype Production), as it is inefficient; however, quality is greatly enhanced with job
production compared to other methods. Individual wedding cakes and made-to-measure suits are
examples of job production. New small firms often use job production before they get a chance or have
the means to expand.
7. explain simple indexing method in detail.
An indexing head, also known as a dividing head or spiral head,[1] is a specialized tool that allows a
workpiece to be circularly indexed; that is, easily and precisely rotated to preset angles or circular
divisions. Indexing heads are usually used on the tables of milling machines, but may be used on many
other machine tools including drill presses, grinders, and boring machines. Common jobs for a dividing
head include machining the flutes of a milling cutter, cutting the teeth of a gear, milling curved slots, or
drilling a bolt hole circle around the circumference of a part.
8.explain broaching machine and its function.
Broaching is a machining process that uses a toothed tool, called a broach, to remove material. There
are two main types of broaching: linear and rotary. In linear broaching, which is the more common
process, the broach is run linearly against a surface of the workpiece to effect the cut. Linear broaches
are used in a broaching machine, which is also sometimes shortened to broach. In rotary broaching, the
broach is rotated and pressed into the workpiece to cut an axisymmetric shape.
9.Differentiate the following milling cutters.
Lathes and milling machines both used for cutting raw materials, but have very different ways of doing
it. Lathes spin the material while the milling machines uses a rotary tool for multiple cutting operations.
To use, you should know the differences between the two, and that everyone is capable of.
10.whats is the purpose of arbor?
Trees provide shelter, shade, and very often, fruits or nuts. ... Arbor Day is an internationally recognized
day for the planting of trees with the goals of conservation and forestation. Basically, it's a chance to
protect the trees we have, and bring trees to places without them.