Enrollment no. ………………..

Total no of pages: 03

SURESH GYAN VIHAR UNIVERSITY

B.TECH MECHANICAL – SEMESTER-VIII
METAL CUTTING & TOOL DESIGN (ME-408)
MAIN/BACK EXAMINATION, MAY-2018

Time: 3 Hours Maximum Marks: - 60

Instructions to candidate:
Attempt over all 5 questions selecting one from each unit
All questions carry equal marks.

Unit 1
Q.1 (a) Show that during orthogonal cutting with a zero degree of rake angle, the ratio of the shear
strength τs of the work material to specific cutting energy Pc is given by;
τs / Pc = r(1-µr)/1+r2 [5]
(b) Two different tools A and B having nose radius 0f 0.6 mm and 0.33 mm respectively are used
to machine C-45 steel employing feed rate of 0.2 mm/rev respectively. The tool that gives better finish
and the find the value of ideal surface roughness. [4]
(c) Explain the variables influencing machinability. How is machinability assessed? [3]
OR
Q.2 (a) During orthogonal turning operation of medium carbon steel rod with a carbide tool having
orthogonal rake angle is 10, the following observations were made,
Width of the chip = 6 mm
Uncut chip thickness = 0.1 mm
Chip thickness ratio = 0.4
Horizontal component of cutting force = 1300 N
Vertical component of cutting force = 1650 N
Determine the component of cutting force along the rake face and shear plane. Also find out coefficient
of friction, resultant force and shear stress. [5]
0.14 0.7 0.4
(b) The tool life equation for HSS tool is VT f D = constant. The tool life (T) of 30 minutes is
obtained using the following cutting conditions:
V = 45 m/min, f = 0.35 mm, d = 2.0 mm
If speed (V), feed (f) and depth of cut (d) are increased individually by 25 %, then find the tool life (in
minutes)? [4]
(c) Minimum shear strain in orthogonal turning with a cutting tool of zero rake angles will be? [3]

Unit 2
Q.3 (a) During turning process 7-α-6-6-8-30-1 mm tool, the undeformed chip thickness of 0.2 mm
and width of cut of 2.5 mm, where used. The side rake angle of tool was chosen such that the
machining operation could be approximated to be orthogonal cutting. The tangential cutting force and
thrust force where 1177 N and 560 N respectively. Calculate
(i) The side rake angle
(ii) Coefficient of friction and
(iii) The dynamic shear strength of the work material. [6]

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 (b) A generalized Taylor’s equation was obtained for H.S.S tool
V = C/ T0.13f0.6d0.3
A 60 minutes tool life was obtained using the following cutting parameters V = 40 m/min, feed f
= 0.25 mm, depth of cut d = 2 mm. Compute the tool life if cutting speed, feed and depth of cut are
increased by 50 % and also if they are increased individually by 50 %. Where V = cutting velocity, f =
feed, d = depth of cut [6]
OR
Q.4 (a) A turning tool with sharp corner and a major cutting edge angle of 60° is to be used at a feed of
0.05 mm. What minor cutting edge angle should be provided to obtain an arithmetical mean surface
roughness of 5µm? [4]
(b) Enumerate the types of cutting fluids and mention the composition and applications any three
types. [4]

(c) Discuss any three important tool materials with respect to composition and applications. [4]

Unit 3
Q.5 (a) Write various gear manufacturing methods. Explain one of them with neat sketches. [4]
(b) Briefly explain the compaction and sintering processes. Write their advantages and
limitations. [4]
(c) How are screw threads manufactured by machining processes? Explain the salient features of
those processes. [4]
OR
Q.6 (a) Compare different gear manufacturing methods with respect to their application, accuracy
and processes. [6]
(b) Discuss the methods of producing gears. Mention the relative merits and demerits of each
method. [6]

Unit 4
Q.7 (a) A researcher conducts electrochemical machining (ECM) on a binary alloy (density 7000
3
kg/m ) of iron (atomic weight 56, valency 2) and metal Q (atomic weight 24, valency 4). Faraday’s
constant = 96540 coulombs/mole. Volumetric material removal rate of the alloy is 60 mm 3/s at a
current of 2300 A. What are the percentages of the metal Q in the alloy? [6]
(b) Name various new machining methods. Explain process capabilities and limitations of AJM,
EDM, EBM and LBM. [3]
(c) Write various properties required of the ECM electrolyte. Name some of the electrolytes
used with their advantages. [3]
OR
Q.8 (a) Estimate the MRR (in cc/sec) of an alloy containing 18% cobalt, 62% nickel, and 20%
chromium during ECM with current of 500 ampere. The density of the alloy is 8.28 g/cc. The following
data is available:
Metal Gram atomic weight Valency
Cobalt 58.93 2
Nickel 58.71 2
Chromium 51.99 6
Assume Faraday’s constant = 96500 coulombs/mole. [6]
(b) Explain the mechanism of material removal in the EDM process. How do the EDM process
parameters affect the material removal rate? [3]
(c) Describe the working principle of AJM with the help of a neat diagram. [3]

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 Unit 5
Q.9 (a) With the help of sketches, show the geometry of a single point cutting tool and explain the
significance of each parameter. [6]
(b) Explain, with examples, the method of specifying a grinding wheel. [3]
(c) Name various tool materials and discuss the advantages of carbide over high speed steel and
carbon steel. [3]
OR
Q.10 (a) In what respect the electro-chemical grinding differs from ordinary grinding process? [4]
(b) How are grinding wheels specified? What are the functions of cutting fluids in a machining
Operation? [4]
(c) Name finishing processes and explain any one of them with the help of a neat sketch. [4]