VALLIAMMAI ENGINEERING COLLEGE

SRM Nagar, Kattankulathur – 603 203

DEPARTMENT OF MECHANICAL ENGINEERING

QUESTION BANK

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IV--SEMESTER
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ME 8451 –Manufacturing technology- II

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Regulation – 2017
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Academic Year 2018 – 2019

Prepared by
Mr. G.Ananth, Assistant Professor (Sel.Grade) / Mechanical Engineering
Mr. S.Sivalingam, Assistant Professor (O.G) / Mechanical Engineering
Mr. R.Ashok, Assistant Professor (O.G) / Mechanical Engineering
Mrs.Sony Priyanka D, Assistant Professor (O.G) / Mechanical Engineering
 UNIT I THEORY OF METAL CUTTING

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.

S.No. Part – A ( 2 Marks ) BT COMPETENCE

MARKS LEVEL
1 Write a short note on heat zone in cutting. 2 BT 1 Remember
2 Mention any two modern tool materials. 2 BT 1 Remember
3 Explain the condition that induces the formation of Built up 2 BT 1 Remember
edge.
4 How tool life is estimated? 2 BT 1 Remember
5 Classify the different types of chip breakers. 2 BT 2 Understand
6 List the various metal removal processes. 2 BT 2 Understand
7 Interpret the significance of negative rake angle. 2 BT 2 Understand

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8 Discuss how chip formation occurs in metal cutting. 2 BT 2 Understand

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9 Illustrate the various parts in single point cutting tool.
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10 List the various angles in cutting tool. 2 BT 3 Apply
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11 What are the assumptions made in drawing Merchant’s circle? 2 BT 3 Apply
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12 Examine chip thickness ratio. 2 BT 3 Apply

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13 Classify the cutting fluids. 2 BT 4 Analyze

14 Draw the nomenclature of cutting tool geometry. 2 BT 4 Analyze
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15 Point out the objectives and functions of cutting fluids. 2 BT 4 Analyze

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16 Point out the various cutting tool materials. 2 BT 4 Analyze

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17 Deduce the factors that contribute to poor surface finish in 2 BT 5 Evaluate

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cutting.
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18 Summarize the four important characteristics of materials used 2 BT 5 Evaluate

for cutting tools
19 Explain the advantage of high machinability 2 BT 5 Evaluate
20 Summarize machinability index. 2 BT 5 Evaluate
PART B (13 Marks)
1 (i) Explain various cutting tool materials. 7 BT 1 Remember
(ii)List the properties of cutting tool materials. 6 BT 1 Remember
2 In an orthogonal cutting operation on a work piece of width 13 BT 6 Create
2.5mm, the uncut chip thickness was 0.25mm and 25 degree. It
was observed that the chip thickness was 1.25mm.The cutting
force was measured to be 900N and the thrust force was found
to be 810 N.
(a) Find the shear angle.
(b) If the coefficient of friction between the chip and the tool, was
0.5, what is the machining constant Cm
3 (i).Describe the chip formation with neat sketches. 9 BT 2 Understand
(ii).Explain about chips With Built up edge. 4 BT 2 Understand

4 (i). Mention the functions of Cutting Fluids. 6 BT 2 Understand

(ii). Explain the uses of Cutting Fluids. 7 BT 2 Understand
5 Describe the mechanism of metal cutting and process involved in 13 BT 2 Understand
detail
6 List the various tool materials used in industry. State the 13 BT 1 Remember
optimum temperature of each of the tool materials.
7 A turning tool with side and end cutting edge of 20 degree and 13 BT 6 Create
30 degree respectively operates at a speed of 0.2 mm/rev.
Calculate the CLA of the surface produced if the tool force
radius is 3 mm.
8 (i).Examine the parameters that influence the life of tool and 7 BT 3 Apply
discuss.
(ii).Illustrate the formulas involved in life of tool. 6 BT 3 Apply
9 Explain merchant force circle assumptions, diagram and 13 BT 2 Understand
characteristics.
10 (i).Differentiate between orthogonal cutting and oblique cutting 7 BT 2 Understand
(ii).Discuss their merits and demerits 6 BT 2 Understand
11 Explain the geometry of a single point cutting tool with suitable 13 BT 2 Understand
sketches
12 Explain the basic actions, characteristics and properties of cutting 13 BT 2 Understand

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fluids

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13 (i).Express the formulae in Orthogonal metal cutting. C 4 BT 4 Analyze
(ii).Describe the expression for the shear angle in Orthogonal 9 BT 4 Analyze
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metal cutting
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14 Explain the standard angles of cutting. Illustrate with an example 13 BT 2 Understand

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PART C (15 Marks)

1 Give your understanding of the basic metal-cutting process,
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what are the important physical and chemical Properties of a
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cutting tool.
2 Maximum temperature in orthogonal cutting is located at about 15 BT 5 Evaluate
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the middle of the tool-chip interface - Evaluate

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3 Why is it not always advisable to increase cutting speed in order 15 BT 6 Create

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to increase production rate?

4 Describe in detail your thoughts regarding the technical and 15 BT 6 Create
economic factors involved in tool material selection
 UNIT 2 TURNING MACHINES
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: semiautomatic – single spindle: Swiss type, automatic screw type-Multispindle

S.NO. PART – A (2 MARKS) MARKS BT COMPETENCE

LEVEL
1 List out the factors to be considered while specifying a lathe. 2 BT 1 Remember
2 Explain the meaning of “swing of the lathe". 2 BT 4 Analyzing
3 Discuss the difference between feed rod and lead screw. 2 BT 2 Understand
4 Define the term “Conicity”. 2 BT 1 Remember
5 Illustrate the methods of taper turning on lathe. 2 BT 3 Apply
6 Express the formula for calculating taper turning angle by 2 BT 2 Understand
tailstock set over distance and compound rest method.
7 Calculate the angle at which the compound rest will be swiveled 2 BT 3 Apply
when cutting a taper on a piece of work having the following
dimensions. OD = 60 mm; Length of the tapered portion 80 mm

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and smallest diameter – 20mm.

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8 Describe the term “Thread cutting”. 2 BT 2 Understand
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Explain how the number of teeth on various change gears be 2 BT 5 Evaluate
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calculated?
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10 Generalize the formula to find the following parameters 2 BT 6 Creating

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(i) Machining time (ii) Total length of tool travel (iii)

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Number of passes or cut.

11 Define automatic machine. 2 BT 1 Remember
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12 Examine the three stages of a tool-layout? 2 BT 3 Apply

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13 Compare the advantages of turret lathe over capstan lathe. 2 BT 4 Analyze

14 Recommend different drives used in copying lathes. 2 BT 5 Evaluate
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15 Explain the term "copy turning". 2 BT 4 Analyze

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16 Differentiate automatic lathe and capstan lathe. 2 BT 2 Understand

17 Support the sketch illustrating the principle of operation of Swiss 2 BT 5 Evaluate
type automatic lathe.
18 Tabulate the difference between parallel action and progressive 2 BT 1 Remember
action multi spindle automatic lathes.
19 Discover the four major parts of swiss type automatic lathes. 2 BT 3 Apply
20 Discuss the purpose of providing lead cam in single spindle 2 BT 2 Understand
automatic screw cutting machine.

PART B (13 Marks)

1 (i) What are the different types of machining operations that can 8 BT 4 Analyze
be performed on a lathe? Explain any four in
detail.
(ii) A hollow work piece of 50 mm diameter and 200mm long is 5 BT 3 Applying
to be turned over in 4 passes. If the approach length is 20mm over
travel 10mm, feed 0.8mm/rev and cutting speed 30m/min, Find
machining time.
2 Explain the construction and working principle of a lathe with a 13 BT 5 Evaluate
neat sketch.
3 (i) Describe the difference between a steady rest and follower 7 BT 2 Understand
rest. Give an application of each.
(ii) Summarize various types of chucks. Explain any two. 6 BT 2 Understand
4 (i) Explain taper turning operation in a lathe by taper turning 7 BT 4 Analyze
attachment method.
(ii) Point out why the boring operation on a lathe be a difficult 6 BT 4 Analyze
operation?
5 Describe the following methods of taper turning in lathe by 7 BT 1 Remember
i. Swiveling the compound rest.
ii. Form tool method. 6 BT 1 Remember
6 (i) Explain the thread cutting operation in a lathe with a neat 7 BT 5 Evaluate
sketch. Also make a note on knurling, grooving and forming
operations in a lathe.
(ii) Illustrate the purpose of various attachments used on a centre 6 BT 3 Apply
lathe.
7 (i) Calculate the gears for cutting metric threads of following 6 BT 3 Apply
pitch. i) 4mm pitch, ii) 5.25 mm pitch. The lead screw of lathe
contains 6 TPI. The lathe is supplied with 20 to 120 teeth in step
of 5and an additional gear wheel of having 127 teeth.

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(ii) Calculate the time required for one complete cut on a piece of 7 BT 3 Apply

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work having 250 mm long and 40 mm diameter. The cutting
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speed is 32 m/min and feed is 0.4 mm/rev.
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8 Discuss about the Geneva mechanism of turret lathe with neat 13 BT 2 Understand
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sketch.
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9 (i) Explain the classification of automatic lathes. 5 BT 3 Apply

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(ii) Describe the features of Swiss type automatic lathe and bar 8 BT 1 Remember
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type automatic lathe. 10

10 Discuss the features of Ram type and Saddle type turret with neat 13 BT 2 Understand
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Sketch.
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11 (i) Explain the tooling layout for the producing of a Hexagonal 7 BT 5 Evaluate
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bolt in a Capstan lathe.

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(ii) Discuss the tooling layout for production of a hexagonal nut 6 BT 2 Understand
in Turret lathe.
12 (i) Classify transfer machines. Sketch and explain the working 7 BT 3 Apply
of Swiss type automatic screw machine.

(ii) What are the advantages of automatic machines? 6 BT 3 Apply

13 (i) Briefly explain the principle of working of sliding head type 7 BT 4 Analyze
single spindle automatic machine.

(ii) Differentiate between parallel action and progressive action 6 BT 4 Analyze

multi spindle automatics.

14 Describe the working principle of multi spindle automatics. Give 13 BT 1 Remember

its advantages and applications.
 PART C (15 Marks)
1 A badly oxidized and uneven round bar is being turned on a 15 BT 6 Create
lathe. Would you recommend a small or in large depth of cut?
Explain.
2 Describe the problems, if any, that may be encountered in 15 BT 2 Understand
clamping a work piece made of a soft metal in a three- jaw chuck.
3 We have seen that cutting speed, feed, and depth of cut are the 15 BT 6 Create
main parameters in a turning operation. In relative terms, at what
values should theses parameters be set for a (a) roughing
operation and (b) finishing operation?
4 Explain the economic justification for purchasing a turret lathe 15 BT 4 Analyzing
instead of a conventional lathe.

UNIT-III SHAPER, MILLING AND GEAR CUTTING MACHINES

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.

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S.No. PART- A (2 MARKS) C MARKS BT COMPETENCE
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1 Mention the differences between shaper and planer. 2 BT 1 Remembering
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2 What are the differences between drilling and reaming? 2 BT 1 Remembering

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3 Briefly describe the importance of quill mechanism. 2 BT 1 Remembering

4 List the types of sawing machines. 2 BT 1 Remembering
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5 Define the cutting speed, feed and machining time for 2 BT 1 Remembering
drilling.
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6 What is broaching? 2 BT 1 Remembering

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7 What is the difference between up milling and down 2 BT 2 Understanding

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milling?
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8 List four applications of broaching machines 2 BT 2 Understanding

9 How do you classify milling cutters? 2 BT 2 Understanding
10 What do you know about straight fluted drill and fluted 2 BT 3 Apply
drill?
11 What is meant by up milling and down milling? 2 BT 3 Apply
12 State the differences between a vertical shaper and slotters. 2 BT 3 Apply
13 Write the differences between drilling and tapping. 2 BT 3 Apply
14 What is a shell mill? 2 BT 4 Analyze
15 Mention the operations performed by a planner. 2 BT 4 Analyze
16 Why is sawing a commonly used process. 2 BT 4 Analyze
17 List out the various elements of a plain milling cutter with 2 BT 4 Analyze
a with neat sketch.
18 Give the two principal methods of gear manufacturing. 2 BT 4 Analyze
19 List out the gear finishing processes. 2 BT 4 Analyze
20 Explain gear hobbing. 2 BT 6 Creating

PART B (13 Marks)

1 Explain various milling cutters with neat sketches? 13 BT 2 Understanding
2 Discuss various hole making processes. 13 BT 2 Understanding
3 With a neat sketch explain the column and knee type 13 BT 3 Applying
milling.
4 Explain hacksaw and band saw with neat sketches. 13 BT 3 Applying
5 Discuss boring and reaming operation with neat sketches. 13 BT 4 Applying
6 Discuss the principle of operation of boring operation with 13 BT 4 Analyzing
a neat sketch.
7 Describe the working of a crank and slotted link 13 BT 4 Analyzing
mechanism.
8 Sketch and explain the hydraulic drive of a horizontal 13 BT 6 Creating
shaper.
9 What are the operations performed on a drilling machine? 13 BT 4 Analyzing
10 Sketch a twist drill and explain. 13 BT 5 Evaluating
11 Explain different types of milling cutters. 13 BT 5 Evaluating
12 With the help of a neat sketch, discuss the Tapping and 13 BT 5 Evaluating
gear hobbing operation.
13 Sketch the Quill mechanism .write its main parts and their 13 BT 6 Creating
function.
14 (i).How will you cut the following types of surfaces on 13 BT 5 Evaluating
milling machines? (a)Flat surfaces (b)Slots and splines
(ii).Make a note on different types of work holding devices 13 BT 6 Creating
used in a slotting machine.

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PART C (15 Marks)

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(i).Explain the different types of table drive and feed mechanisms in 8 BT 5 Evaluate
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a planning machine
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(ii).State the advantages of Ward- Leonard drive. 7 BT 6 Creating

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2 (i).Explain with a sketch “Fast and loose pulleys” quick return 8 BT 5 Evaluate
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mechanism of a planer table.

(ii).Write short notes on expanding hand reamers and adjustable 7 BT 6 Creating
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machine reamers.
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3 (i).Sketch and explain the main parts of a band saw. 8 BT 5 Evaluate

(ii).Explain different types of drilling machines with their special 7 BT 6 Creating
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features.
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4 List the difference between shaper and planner. 15 BT 5 Evaluate

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 UNIT-IV ABRASIVE PROCESS AND BROACHING
Abrasive processes: grinding wheel – specifications and selection, types of grinding process– cylindrical
grinding, surface grinding, centre less grinding and internal grinding- Typical applications –concepts of
surface integrity, broaching machines: broach construction – push, pull, surface and continuous broaching
machines
Sl.NO MARK BT COMPETENCE
S LEVEL
1 How does loading differ from glazing in grinding process? 2 BT-1 Remembering
2 List out the factors involved in the selection of a grinding 2 BT-1 Remembering
wheel.
3 Why most abrasives are now made synthetically? 2 BT-1 Remembering
4 Narrate the working principle of abrasive jet machining. 2 BT-1 Remembering
5 What is an abrasive? What are super abrasives? 2 BT-1 Remembering
6 Define hardness of the grinding wheel. 2 BT-2 Understanding
7 Define lapping. 2 BT-2 Understanding
8 How will you express “grade” and “structure” of a grinding 2 BT-2 Understanding
wheel?

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9 Discuss the parameters that would affect the MRR in abrasive 2 BT-2 Understanding

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jet machining.
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Give four important factors that influence the selection of 2 BT-3 Applying
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grinding wheel.
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11 Discuss the need of truing and dressing operations in a 2 BT-3 Applying

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12 Point out the abrasives used in manufacture of grinding wheels. 2 BT-3 Applying
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13 Classify the types of external grinders. 2 BT-4 Analyzing

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14 Discuss the operations done in centre less grinders. 2 BT-4 Analyzing

15 Explain the work holding and supporting devices used in 2 BT-6 Creating
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grinders.
16 Explain why the centre less grinders are called as specialized 2 BT-4 Analyzing
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machines for Cylindrical parts?

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17 Classify the different types of fine finishing process. 2 BT-5 Evaluate

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18 Discuss surface integrity. 2 BT-5 Evaluate

19 What is the principle of a broaching process? 2 BT-5 Evaluate
20 What are the principal types of broaching machines? 2 BT-6 Creating
 PART B (13 Marks)
1 (i) Explain the working mechanism of cylindrical and 6 BT-4 Applying
surface grinding.
(ii) Discuss the various bonding materials used for making 7 BT-3 Analyzing
grinding wheels.
2 (i) What are the consequences of allowing the temperature 6 BT-4 Analyzing
to rise during grinding?
(ii) The performance of a grinding wheel depends upon the
type of abrasive, grain size, grade, structure and 7 BT-4 Analyzing
bonding material. Discuss the effect of each.
3 (i)What do you understand by grinding as an abrasive 6 BT-6 Creating
process? Explain with a neat sketch.
(ii) What precaution should you take when grinding high 7 BT 5 Evaluating
precision?
4 (i) What is Surface grinding? What are the different types 4 BT 3 Applying
of surface grinding machines?

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(ii) Explain why there are so many different types and sizes 9 BT 3 Applying

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of grinding wheels? C
5 Explain the working principle and various methods of 13 BT 3 Applying
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centre less grinding with a neat sketch.
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6 (i)Sketch and explain the three methods of external 9 BT 4 Analyzing

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cylindrical centre less grinding.

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(ii)Why speed is so much higher in grinding than in 4 BT 4 Analyzing

cutting?
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7 (i)Explain dressing and truing of grinding wheel. 6 BT-4 Analyzing

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(ii)What factors could contribute to chatter in grinding? 7 BT-3 Analyzing

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8 (i) Explain the factors to be considered to select a grinding 7 BT-6 Creating

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wheel and recommended parameter.

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(ii)What are the effects of wear flat on the grinding 6 BT 5 Evaluating

process?
9 (i)How do you classify cylindrical grinders? 6 BT-5 Evaluating
(ii)What is the difference between “Plain and universal
“cylindrical grinder? 7 BT 6 Creating
10 (i) Briefly discuss about the different types of abrasives 6 BT 3 Applying
used in a grinding wheel.
(ii) Discuss with neat sketch vertical broaching machines. 7 BT 5 Evaluating
11 (i) Describe the factors that contribute to broaching force 6 BT-2 Understanding
and explain why.
(ii) Describe the conditions under which broaching would 7 BT-4 Analyzing
be the preferred method of machining.
12 (i) Describe the concept of surface integrity. 7 BT-6 Creating
(ii) Explain the generalized classification of broaching
machines. 6 BT 5 Evaluating
13 Explain Surface and continuous broaching. Give the 13 BT-4 Analyzing
advantages and disadvantages of surface and continuous
broaching
14 Explain the construction of a Push type and pull type 13 BT-4 Analyzing
broaching machine.
 Part C (15 Marks)
1 Describe as many parameters as you can that could affect the 15 BT-5 Evaluating
final surface finish in grinding
2 Jeweler applications required the grinding of diamonds into 15 BT-5 Evaluating
desired shapes, How is this done, since diamond is the hardest
material known?
3 Would you encounter any difficulty in manufacturing 15 BT-6 Creating
thermoplastics and thermo sets? If so, what precautions
would you take ?
4 Would you recommend broaching a keyway on gear 15 BT-6 Creating
blank before or after machining the teeth ,Why?

UNIT-V CNC MACHINING

Numerical Control (NC) machine tools – CNC types, constructional details, special features,

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machining centre, part programming fundamentals CNC – manual part programming –micromachining

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– wafer machining C
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Sl.N PART A (2 Marks) MAR BT COMPETENCE
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1 List the differences between NC and CNC. 2 BT 1 Remembering

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2 Define linear bearings. 2 BT 1 Remembering

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3 Mention the type of ball screws. 2 BT 1 Remembering

4 Define feed drives. 2 BT 1 Remembering
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5 Discuss the types of motion control system used in NC machines 2 BT 2 Understand

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6 Express the meaning of APT language. 2 BT 2 Understand

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7 Discuss closed loop NC system with open loop system. 2 BT 2 Understand

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8 Give the uses of preparatory function. How is it important in 2 BT 2 Understand

CNC programming?
9 Illustrate the limitations of CNC machine tools. 2 BT 3 Apply
10 Examine - canned cycle. 2 BT 3 Apply
11 Define NC. 2 BT 1 Remembering
12 Explain the major elements of NC machines. 2 BT 1 Remembering
13 Compare the different NC machines 2 BT 4 Analyse
14 Compare incremental and absolute system 2 BT 4 Analyse
15 Explain the role of computer for NC machine tool. 2 BT 4 Analyse
16 Explain point –to – point (PTP) system. 2 BT 4 Analyse
17 Assess G-Codes and M-Codes. 2 BT 5 Evaluate
18 Summarize the commonly uses of coordinate Systems. 2 BT 5 Evaluate
19 Assess the types of statements in APT language. 2 BT 5 Evaluate
20 Evaluate the process involved in wafer forming. 2 BT 5 Evaluate
PART B (13 Marks)
1 (i) Narrate the design considerations of CNC machines. 7 BT-5 Evaluate
Discuss about slide ways used in CNC machine tools.
(ii) Describe the spindle drives used in CNC machine tools 6 BT 2 Understand
2 List the difference between manual and computer assisted part 7 BT 1 Remembering
programming
3 Explain the following in CNC machining. (i)Linear 6 BT-4 Analyzing
Interpolation (ii)Circular Interpolation
(iii) Cubic interpolation
4 Describe the spindle and feed drives. State the requirement of 13 BT-3 Applying
the drives of CNC machine tools
5 Explain the various elements of NC machine with closed loop 13 BT-5 Evaluating
control system.
6 (i) Explain the main difference between point to point and 6 BT-2 Understanding
continuous path of numerically controlled machine too
(ii) List any five motions and control statements of computer 7 BT-4 Analyzing
assisted NC programming and explain.
7 Write the steps involved in APT language 13 BT-4 Analyzing
8 Explain the various elements of NC machine with closed loop 13 BT-6 Creating
control system
9 List any five motions and control statements of computer 13 BT-4 Analyzing
assisted NC programming and explain
10 Describe the spindle and feed drives. State the requirement of 13 BT-4 Analyzing
the drives of CNC machine tools

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11 Write the part program for the part shown below 13 BT-5 Evaluating

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12 Write the part program for drilling holes in the part shown
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below. The plate thickness is 20mm
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13 How is manual programming of a NC m a c h i n e done. 13 BT-4 Analyzing
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14 Discuss the advantages of computer numerical control system 13 BT-4 Analyzing

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PART C (15 Marks)

1 (i).Describe in brief the basic components of a tape operated NC 7 BT-5 Evaluating
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machine tool
(ii).State a few typical applications where the use of numerical 8 BT-5 Evaluating
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control would be justified

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2 (i).Write short notes on APT language 7 BT-6 Creating

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(b).Under what conditions of production the numerically 8 BT-6 Creating

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controlled machine tools are employed

3 (i).Define CNC and DNC. With a help of a diagram explain the 7 BT-5 Evaluating
working of NC machine tool
(ii).Discuss the important design features of CNC machine tools 8 BT-5 Evaluating
4 Describe in brief the basic components of a tape operated NC 15 BT-6 Creating
machine tool