Continuous Assessment Question Paper

GMRIT/IA/F-5
REV: 03
U.G. Mechanical Engineering Degree Bachelor of Technology
Date of
Academic Year 2021-22 Test I 11/04/2022
Exam
Course
Course Code
20ME403 Title Metal cutting and Machine Tools
Duration 90 Minutes Maximum Marks 40
Remember (%) 9 Understand (%) 77 Apply (%) 14 Analyze (%)
SECTION I (Short Answer Questions)
(Answer all the Questions)
5 x 2 = 10 Marks
No. Questions (1 to 5)
1 Name the factors that contribute to poor surface finish in cutting.
Cutting speed, feed depth of cut
2 Write any two differences between drilling and boring operation.
Drilling is a process for removing material from a workpiece in order to create a hole. Boring, on the
other hand, is a process of enlarging a hole that has already been made by another process (such as
drilling or casting). In short, boring is a secondary finishing operation.
3 List any four specifications of lathe machine.

 Swing- the largest work diameter that can be swung for the lathe bed.
 The distance between the headstock and tailstock center.
 Length of the bed in a meter.
 The pitch of the lead screw.
 Horsepower of the machine.
 Speed range and the number of speeds of HS spindle

4 Write the various tool holding devices used in drilling machine.

Drill chuck, Sleeve and socket

5 How the tool geometry is specified in ASA system?
SA system of tool designation specifies two different rake angles, two different clearance angles,
two different cutting edge angles, and the nose radius value in inch. Various features of a single
point turning tool (SPTT) that ASA system displays are provided below.
 Side Rake Angle (γX)—It is the angle of orientation of tool’s rake surface from the
reference plane (πR) and measured on machine longitudinal plane (πX).
 Back Rake Angle (γY)—It is the angle of orientation of tool’s rake surface from the
reference plane (πR) and measured on machine transverse plane (πY).
 Side Clearance Angle (αX)—It is the angle of orientation of tool’s principal flank surface
from the cutting velocity vector (Vc) and measured on machine longitudinal plane (πX).
 Back Clearance Angle (αY)—It is the angle of orientation of tool’s principal flank surface
from the cutting velocity vector (Vc) and measured on machine transverse plane (πY).
 Approach Angle (Φs)—It is the angle between principal cutting edge and the machine
transverse plane (πY), measured on reference plane (πR).
 End Cutting Edge Angle (Φe)—It is the angle between auxiliary cutting edge and the
machine longitudinal plane (πX), measured on reference plane (πR).
 Nose Radius (r)—This is nothing but the curvature at the tool tip. It is to be noted that in
ASA system, nose radius value is expressed in inch.

SECTION II (Long Answer Questions)

 (Answer all the Questions)
3 x 10 = 30 Marks
a. In orthogonal turning of a 50 mm diameter mild steel bar on a lathe the following data were
obtained: Rake angle = 150, cutting speed =100m/min, feed = 0.2 mm/rev, cutting force = 180kg,
feed force =60kg. calculate the shear plane angle (Ø), coefficient of friction, if the chip thickness
=0.3mm

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 b. List the various types of chips and summarize the factors that are likely to influence the formation of
various types of chips.

• Discontinuous chips
• Continuous chips
• Continuous chips with built up edge
Discontinuous chips: Listing three types of chips – 1M
CONDITIONS
 Low cutting speed Conditions – 4M
 Brittle work material
 Small/negative rake angle
 Large uncut thickness ,
 Coarse feed
Continuous chips:
 Ductile material
 Small uncut chip thickness
 High cutting speed
 Large rake angle
 Suitable cutting fluid
 Fine feeds
Continuous Chips with BUE:
 Stronger adhesion between
chips and tool face

 Small/negative rake angle

 Large uncut thickness

OR
a A seamless tubing 35mm outside diameter is turned orthogonally on a lathe. The following data
. available; rake angle 35°, cutting speed l5m/min, feed 0.10 mm/rev, length of continuous chip in
one revolution is 50mm, cutting force 200 kg, feed force 80 kg. Calculate the coefficient of friction,
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shear plane angle and chip thickness.
 b How the cutting tool life is affected by the cutting speed, feed and Depth of cut?
. Cutting speed:
 Cutting speed has the maximum influence on tool life.
 Tool life decreases as the cutting speed increases.
 The criterion of wear is dependent on cutting speed because the predominant wear may be
flank wear or crater wear if speed is excessive.

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B) Feed & Depth of cut
 An increase in the feed rate and depth of cut will reduce the tool life.
 for a constant tool life, cutting speed will decrease if the feed rate and depth of cut are
increased
 Feed and depth of cut has a similar effect as speed

Write short notes on 4-jaw independent chuck ii) 3-jaw chuck iii) Magnetic chuck
Following are the different types of chucks used in lathe machine:
1. Four jaws independent chuck
2. Three jaws universal chuck
3. Combination type chuck
4. Magnetic type Chuck
8 5. Collet chuck
ANSWER 6. Air or hydraulic operated chuck
7. Drill Chuck

Four-Jaw Independent Chuck

The figure shows a four jaw chuck diagram. The arrangement of four jaws independent chuck, which
has four jaws, located at an angle of 90° to each other.
Here all the four jaws are opened independently. Four screws are used in place of scroll disk, Hence it
is called as four jaw independent chuck.
Each jaw made of tough steel has three inner and one outer gripping surface. The outer gripping
surface is used for holding larger sizes of the work piece by reversing the jaw.
Three Jaw Chuck
A three-jaw chuck is shown in the figure. This is the most commonly used types of chuck in
the lathe machine. The three jaws are generally made of high-quality steel and are arrogated at an
angle of 120° to each other.

During the operation, the jaw teeth are made to mesh with scrawl spiral teeth (Bevel teeth). The
meshing causes a moment of all three jaws either towards or away from the chuck centre, depending
upon the direction of rotation of the bevel pinion. The pinion is operated by square end key called
“chuck key”.

Magnetic Chuck
The chuck is used for holding a very thin work piece made of magnetic material which cannot be held
in an ordinarily chuck. It is also used where any distortion of the work piece due to the pressure of the
jaws is undesirable.
The holding power of the chuck is obtained by the magnetic flux radiating either from the
electromagnets or from the permanent magnets introduced within the chuck.

In the ON position, the flux passes through the work piece and grips it. In OFF position the magnets are
set aside bringing them in contact with high permeable ” keepers” which short-circuit the flux and
prevent them from passing through the work piece.
 Magnetic Chuck
OR
List and explain the essential elements of a twist drill.

Twist drill nomenclature

Axis It is the longitudinal centerline of the drill running through the centres of the tang and the chisel
edge.

Body It is the part of the drill from its extreme point to the commencement of the neck, if present.
Otherwise, it is the part extending upto the commencement of the shank. Helical grooves are cut on the
body of the drill.

Shank It is the part of the drill by which it is held and driven. It is found just above the body of the drill.
The shank may be straight or taper. The shank of the drill can be fitted directly into the spindle or by a
9 tool holding device.

Tang The flattened end of the taper shank is known as tang. It is meant to fit into a slot in the spindle
or socket. It ensures a positive drive of the drill.

Neck It is the part of the drill, which is diametrically undercut between the body and the shank of the
drill. The size of the drill is marked on the neck.

Point It is the sharpened end of the drill. It is shaped to produce lips, faces, flanks and chisel edge

Lip It is the edge formed by the intersection of flank and face. There are two lips and both of them
should be of equal length. Both lips should be at the same angle of inclination with the axis (59°).
Land It is the cylindrically ground surface on the leading edges of the drill flutes adjacent to the body
clearance surface. The alignment of the drill is maintained by the land. The hole is maintained straight
and to the right size.

Angles Chisel edge angle The obtuse angle included between the chisel edge and the lip as viewed
from the end of the drill. It usually ranges from 120° to 135°.

Helix angle or rake angle The helix or rake angle is the angle formed by the leading edge of the land
with a plane having the axis of the drill. If the flute is straight, parallel to the drill axis, then there
would be no rake. If the flute is right handed, then it is positive rake and the rake is negative if it is left
handed. The usual value of rake angle is 30° or 45°.

Point angle This is the angle included between the two lips projected upon a plane parallel to the drill
axis and parallel to the two cutting lips. The usual point angle is 118°. When hard alloys are drilled the
value increases.

Lip clearance angle The angle formed by the flank and a plane at right angles to the drill axis. The
angle is normally measured at the periphery of the drill. The lip clearance angle ranges from 12° to
15°.
 List and explain any five operations performed on lathe machine with neat sketch.

In lathe operations, the headstock spindle holds the job and it rotates with the same speed as the spindle. The
carriage holding the tool on the tool post, also the carriage gives the tool post moves longitudinally or crosswise
direction to give the desired feed on the job. This two motions (longitudinally and crosswise) helps to remove
the chips of the metal and giving the proper shape of the job. The Lathe is such a versatile machine that it can
produce another lathe. It is tough to mentioned which operations are not performed in a lathe machine tool,
though we discuss some important lathe operations in details.
1. Centering
2. Facing
3. Turning
4. Chamfering
5. Knurling
6. Thread cutting
7. Drilling
8. Boring
9. Reaming
10. Spinning
11. Tapping
12. Parting off
Centering operation in the lathe: We use this operation for producing a conical hole in the face of the job
to make the bearing support of the lathe center when the job is to hold between two centers. (Headstock and
Tail-stock).

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Facing operation is for making the ends of the job to produce a smooth flat surface with the axis of
operation or a certain length of a job. In this operation, 1. Hold the job on Head-stock spindle using Three
or four-jaw chuck. 2. Start the machine on desire RPM to rotate the job. 3. Give a desirable feed on the
perpendicular direction of the axis of the job.
Turning operation in the lathe: The operation by which we remove the excess material from the
workpiece to produce a cone-shaped or a cylindrical surface.

A taper is defined as a uniform decrease or increase in diameter of a workpiece along with its length. The
operation by which a conical surface of the gradual reduction in diameter from a cylindrical workpiece is
produced is called taper turning.

Knurling operation: It is the process of producing a rough surface on the workpiece to provide effective
gripping. Knurling tool is held rigidly on the tool post and pressed against the rotating job so that leaving
the exact facsimile of the tool on the surface of the job.

Thread cutting operation : 13/19 It is the operation which is used to produce a helical groove on a
cylindrical or conical surface by feeding the tool longitudinally when the job revolved between the two
centers
Drilling operation: Drilling is an operation by which we can make holes on a job. In this operation, the job
is rotated at the turning speed on the lathe axis and the drilling tool fitted on the tail-stock spindle. And the
tail-stock is moved towards the job by hand feed.
Boring operation: In this operation, we can enlarge the diameter of the existing hole on a job by turning
inside with some farm tool known as a boring tool. The boring tool is also fitted on tail-stock

Reaming operation: Reaming is the operation for sizing or finishing a drilled hole to the required size by a
tool called reamer. This tool is fitted on tail-stock.

Spinning operation: In this operation, the job of this sheet metal is held between the former and the tail-
stock center rotates at high speed with the former. the long round nose forming tool rigidly fixed on special
tool post presses the job on the periphery of the former. So the job is taken exactly the shape of the former.

Parting-off operation: It is the operation of cutting off a bar type job after complete the machining
process. In this operation a bar type job is held on a chuck, rotates at turning speed, a parting off tool is fed
into the job slowly until the tool reaches the center of the job. I also wrote an article on drilling machine,
you may check that out.
 OR
Classify drilling machines. Give brief description about any two types of drilling machines.
The different types of drilling machines are:
1. Portable drilling machine (or) Hand drilling machine
2. Sensitive drilling machine (or) Bench drilling machine
3. Upright drilling machine
4. Radial drilling machine
5. Gang drilling machine
6. Multiple spindle drilling machine
7. Deep hole drilling machine
Sensitive drilling machine It is designed for drilling small holes at high speeds in light jobs. High
speed and hand feed are necessary for drilling small holes. The base of the machine is mounted either
on a bench or on the floor by means of bolts and nuts. It can handle drills upto 15.5mm of diameter.
The drill is fed into the work purely by hand . The operator can sense the progress of the drill into the
work because of hand feed. The machine is named so because of this reason. A sensitive drilling
machine consists of a base, column, table, spindle, drillhead and the driving mechanism
Base The base is made of cast iron and so can withstand vibrations. It may be mounted on a bench or
on the floor. It supports all the other parts of the machine on it.
Column The column stands vertically on the base at one end. It supports the work table and the drill
head. The drill head has drill spindle and the driving motor on either side of the column
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Table The table is mounted on the vertical column and can be adjusted up and down on it. The table has ‘T’-
slots on it for holding the work pieces or to hold any other work holding device. The table can be adjusted
vertically to accommodate work pieces of different heights and can be clamped at the required position.
Drill head Drill head is mounted on the top side of the column. The drill spindle and the driving motor are
connected by means of a V-belt and cone pulleys. The motion is transmitted to the spindle from the motor by
the belt. The pinion attached to the handle meshes with the rack on the sleeve of the spindle for providing the
drill the required down feed. There is no power feed arrangement in this machine. The spindle rotates at a speed
ranging from 50 to 2000 r.p.m.
Radial drilling machine
The radial drilling machine is intended for drilling on medium to large and heavy work pieces. It has a heavy
round column mounted on a large base. The column supports a radial arm, which can be raised or lowered to
enable the table to accommodate work pieces of different heights. The arm, which has the drill head on it, can
be swung around to any position. The drill head can be made to slide on the radial arm. The machine is named
so because of this reason. It consists of parts like base, column, radial arm, drill head and driving

Base Guide ways on the radial arm Motor for driving the spindle Drill head Radial arm Handle Spindle Table
Base Fig 2.3 Radial drilling machine The base is a large rectangular casting and is mounted on the floor of the
shop. Its top is accurately finished to support a column at one end and the table at the other end. ‘T’-slots are
provided on it for clamping work pieces.
Column The column is a cylindrical casting, which is mounted vertically at one end of the base. It supports the
radial arm and allows it to slide up and down on its face. The vertical adjustment of the radial arm is effected by
rotating a screw passing through a nut attached to the arm. An electric motor is mounted on the top of the
column for rotating the elevating screw.

Radial arm The radial arm is mounted on the column parallel to the base and can be adjusted vertically. The
vertical front surface is accurately machined to provide guideways for the drillhead. The drillhead can be
adjusted along these guideways according to the location of the work. In some machines, a separate motor is
provided for this movement. The arm may be swung around the column. It can also be moved up and down to
suit workpieces of different heights.

Drillhead The drillhead is mounted on the radial arm and houses all mechanism for driving the drill at different
speeds and at different feed. A motor is mounted on top of the drillhead for this purpose. To adjust the position
of drill spindle with respect to the work, the drillhead may be made to slide on the guideways of the arm. The
drillhead can be clamped in position after the spindle is properly adjusted.
 Universal radial drilling machine It is a machine in which the spindle can be swiveled to any required angle in
vertical and horizontal positions.

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