PT-II QB With Answers Prep - VCM

GOVT TOOL ROOM AND TRAINING CENTRE
Course: Diploma in Tool and Die Making
Course Code 20TD23T Semester 2

PRODUCTION
Course Title Course group Core
TECHNOLOGY-2
Course Category Theory Type of Course Lecture
4HrsPerWeek
CIE Marks 20 Total Contact Hours
64 Hrs Per Semester
SEE MARKS 100 Teaching Scheme (L:T:P)=4:0:0
QUESTION BANK
UNIT 1&2: GENERAL SAFETY & SHAPING MACHINES
PART - A
I. Fill in the blanks:
1. The ratio of cutting stroke to the return stroke in shaper is 3:2
2. In shaper return stroke takes less time.
3. The shaper works on quick return mechanism.
4. In shaper the cutting stroke takes more time.
5. Generally, shaper is used for machining flat surfaces.
6. Shaping is a process of machining a flat surface which may be horizontal, vertical, inclined.
7. James Nasmith was an Englishman who designed a shaping machine in year 1836.
8. The first shaping machine was designed in the year 1836.
9. The universal shaper has the special type of table which can be swiveled and positioned at any
angle about a horizontal axis.
10. The distance of movement of the ram forwards or backward is called the stroke length.
II. Choose the correct answer:
1. Which of the following machines is primarily intended for producing the flat surfaces?
a) Shaper b) drilling c) turning d) none of the these
2. In shaper, the job is kept
a) Stationary b) moving c) Rotating d) none of the these
3. Which of the strokes as the cutting stroke in shaper?
a) Return b) Forward c) backward d) none of the these
4. Which movement of the ram is called stroke
a) movement b) cross wise c) Back and forth d) none of the these
5. The ratio of forward cutting stroke to idle return stroke is
a)3:2 b) drilling c) turning d) none of the these
6. The material removal takes place in shaper during ______ movement.
a) Return b) Forward movement c) crosswise d) none of the these
III. Answer any five questions (write short answers): 2 Marks

1. How is the horizontal surface machined on shaper?
In a shaping machine, a flat horizontal surface is machined by moving the work mounted
on the table in a cross direction to the tool movement.
2. How is the feed given while machining the vertical surface is machined on shaper?
When vertical surfaces are machined on shaper, the feed is given to the tool.
3. Name the parts of shaper.

The parts of shaper are
1. Base
2. Column
3. Cross rail
4. Table
5. Ram
4. What is the function of the base in shaper machine?

The function of the base in shaper is:
1. It provides the necessary support for all the other parts of the machine.
2. It is rigidly bolted to the floor of the workshop.
5. What type of surfaces are machined on a shaper?

1. Horizontal surfaces
2. Vertical surfaces
3. Angular surfaces
4. Slots
5. Grooves
6. Which stroke of the shaper is faster?

Return stroke of the shaper is faster.
7. Who designed the shaping machine, in which year was itdesigned?

A shaping machine is a reciprocating type of machine tool. James Nasmith, in the
year1836.
8. In which shaper is the oil under high pressureused?

In hydraulic shaper the oil under high pressure is used.
9. What is the use of crank & slotted link mechanism?

The mechanism is designed to make the tool move slower during the forward cutting
stroke and tool moves at a faster rate during the idle return stroke.
10. Which part of the shaper is involved in automatic lifting of the toolduring return
stroke of the ram?
On the return stroke, a slight drag of the tool on the work lifts the block out of the clapper
box.
PART – B
A. Answer the following questions 3 Marks
1. How is the inclined surface machined on shaper?
a. When an inclined surface is machined, the vertical slide of the tool head is swiveled.
b. The tool head is swiveled to the required angle.
c. The feed is given to the tool by rotating the down feed hand wheel.
2. How are the shapers classified?

The shaper is classified as follows
a. According to the type of driving mechanism
b. According to the design of the table
c. According to the position and travel of ram.
d. According to the type of cutting stroke.
3. How does the Cross rail functions?

a. It is mounted on the front vertical guide ways of the column.
b. The table may be raised or lowered by adjusting the cross rail vertically.
c. A horizontal cross feed screw is fitted within the cross rail.
4. What is the importance of the table in the shaper?

a. It is an important part useful in holding the work firmly on it.
b. It is mounted on the saddle which is located above the cross rail.
c. The top and sides of the table are accurately machined and have T-slots.
d. Work pieces are held on the table with the help of shaper vise, clamps and straps.
5. Write about the tool head inshaper.

a. The tool head is fitted on the face of the ram and holds the toolrigidly.
b. It provides vertical and angular feed movement of thetool.
c. The swivel tool head can be positioned at any requiredangle.
d. The vertical slide can be moved vertically or at any desired angle to machine
vertical or inclinedangle.
6. Name the three different mechanisms used for quick return of ram inshaper.
The following mechanisms are used for quick return of the ram.
a. Crank and slotted link mechanism
b. Hydraulicmechanism
c. Whitworthmechanism
7.What do you understand by quick returnmechanism?

a. The ram moves at a comparatively slower speed during the forwardcutting stroke.
b. During the return stroke, the tool moves at a faster rate to reduce the idle
returntime.
c. This mechanism is known as quick returnmechanism.
8. What are the advantages of quick returnmechanism?

The advantages of the quick return mechanismare:
a. As the ram moves faster during the return stroke, the time taken isless.
b. The total machining timedecreases.
c. The rate of production increases.
9.What is the angle formed in quick return mechanism for forward cuttingstroke and the
return stroke of theram?
a. The angle P1RP2 (Time taken for forward stroke) is216o.

b. The angle P2LP2 (Time taken for forward stroke) is144o.
B. Answer the following questions 5 Marks

1. Explain the classification of the shaper machine?
The shaping machines are classified as follows:
i. According to the type of driving mechanism
a. Crank type
b. Hydraulic type
c. Geared type
ii. According to the design of the table

a. Plain shaper
b. Heavy duty shaper
c. Standard shaper
d. Universal shaper
iii. According to the position and travel of ram
a. Horizontal shaper
b. Vertical shaper
iv. According to the type of cutting stroke
a. Push cut shaper
b. Draw cut shaper
2. Write about the Advantages of shaper.

The advantages of shaper are:
a. The single point cutting tool used in shapers is inexpensive.
b. Single point cutting tool can be easily grounded to any desirable shape.
c. Holding work is simple and easy.
d. Easy adjustment and the simple tool gives the shaper its great flexibility.
e. Shaper set up is very quick and easy and can be readily changed from one job to
another.
f. Thin and fragile jobs can be conveniently machined on shaper because of lower
cutting forces.
3. Write about the Disadvantages of shaper.

The disadvantages of shaper are:
a. Due to single point tooling shaper is not suited for production work.
b. Slower machining process compare to other machining process
c. single point cutting tool is used.
d. Slower machining process compared to other machining process due to lesser cutting
speed.
e. Shaper is limited in holding close tolerance because of the long unsupported overhang
of the arm at the end of each stroke.
f. Shapers are considered outdated today.
4. What is a crank type shaper?

a. Crank type shaper is one of the types of shaper.
b. Crank type shaper has Crank and slotted link mechanism.
c. This mechanism converts the rotation of an electric motor into reciprocating
movement of the ram.
d. The lengths of both the forward and return strokes are equal.
e. The ram travels at a faster speed during return stroke.
f. This quick return is incorporated in almost all types of shaper.
5. Write about the hydraulic shaper?

a. Hydraulic shaper is one of the types of shaper.
b. The ram of a hydraulic shaper is connected to a piston.
c. Oil at high pressure is pumped to the cylinder of the hydraulic system.
d. As the oil pushes the piston, the ram reciprocates.
e. Hydraulic shapers are high power machines.
f. Hydraulic shapers are used for heavy duty work.
6. Explain the Universal shaper.

a. The universal shaper has a special type of table which can be swivelled and positioned
at any angle about a horizontal axis.
b. The table of a universal shaper can be swivelled to cross and vertical travel.
c. The table of a universal shaper can also be swivelled to any angle to machine inclined
surfaces.
d. In the process, the position of the work in the table need not be changed.
e. These machines are utilized in precision workshops
7. List out different types of shaping machines.

a. Crank type shaper
b. Hydraulic type shaper
c. Geared type shaper
d. Plain shaper
e. Heavy duty shaper
f. Standard shaper
g. Universal shaper
h. Horizontal shaper
i. Vertical shaper
j. Push cut shaper
k. Draw cut shaper
8. What do you understand by ram?

a. Ram supports the tool head on its front.
b. It reciprocates on the accurately machined guide ways on the top of the column.
c. It is connected to the reciprocating mechanism placed inside the column.
d. The position of ram reciprocation may be adjusted according to the location of the
work on the table.
9. Explain about the Tool head in about five sentences.

a. The tool head is fitted on the face of the ram and holds the tool rigidly.
b. It provides vertical and angular feed movement of the tool.
c. The swivel tool head can be positioned at any required angle.
d. The vertical slide can be moved vertically.
e. It can be moved to desired angle to machine vertical or inclined surfaces
C. Answer the following questions 8 Marks

1. Write the general safety to be followed on the shop floor.
The general safety to be followed in the workshop are:
a. Always wear a proper workshop dress.
b. Wear safety shoes.
c. Wear apron while working on the machines.
d. Always walk in the prescribed path or work belt.
e. Wear safety goggles while working in the shop floor.
f. Do not run in the workshop.
g. Maintain the discipline in the workshop.
h. Do not climb on the machines
i. Do not work when you are in sick.
2. Draw a neat diagram of a shaping machine and explain its important parts.
Parts of the shaper

a. Base : The base is hollow part of the shaper.
It provides the support for all the other parts of the machine.
b. Column: It is mounted vertically on top of base.
Two guide ways are machined on the top of the column.
c. Cross rail: It is mounted on the front vertical guide ways of the column.
It helps to lower or raise the table.
4. Table: Table is the important part used for holding the work pieces.
Table have the T slots for clamping the workpieces.
5. Ram: It supports the tool head.
It reciprocates on top of the column.
6. Tool head: The tool head is fitted on the face of the ram.
It holds the tool rigidly.
3. What are the applications of shaper?

The applications of the shaper are:
a. Machining horizontal surface.
b. Machining vertical surface.
c. Machining angular surface.
d. Machining irregular surface.
e. Machining splines.
f. Machining ‘V’ block.
g. Cutting external& internal gears.
h. Cutting slots, T-slots & grooves, etc.
i. Cutting external& internal keyways
4. Write the advantages and disadvantages of shaper.
Advantages Disadvantages
a. The single point cutting tool used in 1. Due to single point tooling
shapers is inexpensive. shaper is not suited for
production work.
1. Single point cutting tool can be 2. Slower machining process
easily grounded to any desirable compared to other machining
shape. process due to single point
cutting tool is used.
3. Holding work is simple and easy. 3. Slower Shaper is limited in
holding close tolerance because of
the long unsupported overhang of
the arm at the end of each stroke.
4. Easy adjustment and the simple tool 4. lesser cutting speed
gives the shaper its great flexibility comparatively
5. Explain the importance of clapper box.

a. Apron consisting of clapper box, clapper block and tool post is clamped on the vertical
slide by a screw.
b. By releasing the clamping screw, the apron can be swivelled either towards left or
towards right with respect to the vertical slide.
c. The clapper box has two vertical walls within which the clapper block is housed.
d. It is connected to the clapper box with the help of a hinge pin.
e. This arrangement provides relief to the tool while machining vertical or angular
surfaces.
f. The tool post is mounted upon the clapper block.
g. The tool post is provided with a slot to accommodate the tool and a screw to hold the
tool rigidly on the tool post.
h. The clapper block fits securely inside the clapper box to provide a rigid tool support
during forward stroke.
i. On the return stroke, a slight frictional drag of the tool on the work lifts the block out
of the clapper box and prevents the tool cutting edge from dragging on the work
surface.
6. Write the specification of shaper.
The shaping machine can be specified as follows:
i. Maximum length of stroke in mm.
ii. Table size, top (length ×width).
iii. Table horizontal travel on slides.
iv. Table vertical travel.
v. Tool head vertical adjustment.
vi. Number and range of speed obtainable.
vii. Number and range of feeds.
7. Explain the quick return mechanism with neats ketch.
Quick returnmechanism
i. Asshowninthediagram,‘KA’indicatesthestartingpointoftheforward
cuttingstrokeand‘KB’theendofthecuttingstroke.
ii. Therotationofthecrank‘OP’inclockwisedirectionthroughtheangle P1RP2 refers
to the forward cutting stroke
iii. The rotation of the crank in the same direction through the angleP2LP1 refers to
the returnstroke.
iv. As the angle P2LP1 is smaller than the angle P1RP2, the time taken forthe return
stroke is less than that of forward stroke.
v. So, it is evident that the speed at which the ram travels during return stroke
ismore.
vi. Time taken for forward cuttingstrokeangle P1RP2 216° 3
= = Time
taken for the idle returnstroke angle P2LP1 144° 2
In some machines this ratio can be set as 7/5.
8. What is crank and slotted link mechanism? Explain with a neatsketch.

Crank and slotted link mechanism
i. An electrical motor runs the driving pinion(S) at a uniformspeed.
ii. This pinion makes the bull gear(M) to rotate at a uniformspeed.
iii. Bull gear is a large gear fitted inside the column.
iv. Thepoint‘O’isthecentreofthebullgear.
v. Aslottedlinkhavingalongslotalongitslengthispivotedaboutthepoint‘K’.
vi. Aslidingblock‘N’isfittedinsidetheslotandslidesalongthelengthofthe
slotted link.
vii. ‘P’isthecrankpinand‘OP’canbeconsideredasacrank.
viii. Fig. shows the crank & slotted link mechanism, When the bull gear rotates,
the sliding block also rotates in the crank pin circle.
ix. This arrangement provides a rocking movement to the rockerarm.
x. As the top of the slotted link is connected to the ram, the ramreciprocates
horizontally.
xi. So, bull gear rotation is converted into the reciprocating movement of theram.
9. Explain whitworth quick return mechanism with neat sketch.

Whitworth quick returnmechanism:
a. The bull gear is mounted on a large fixed pin A upon which it is free to rotate.
a. Thecrankplate‘4’ispivotedeccentricallyuponthefixedpinat5.
b. Fitted on the face of the bull gear is the crank pin 2 on the top of which are
mounted the sliding block3.
c. Sliding block 3 fits into the slot provided on the crank plate4.
d. At the other end of the crank plate 4, a connecting rod 6 connects the crank plate by
a pin 9 and the ram 8 by a pin7.
e. When bull gear will rotate at constant speed the crank pin 2 with the
sliding block 3 will rotate on a crank circle of radius A2 and the sliding block
3will cause the crank plate to rotate about the point 5 with a variable angular
velocity.
f. Pin 9 fitted on the other end of the crank plate 4 will rotate in a circle and the
rotary motion of the pin 9 will be converted in to reciprocating movement of the
ram similar to the crank and connecting rodmechanism
g. The axis of reciprocating of the ram passes through the pin 5 and isnormal to the
pinA5.
h. When the pin 2 is at the position C the ram will be at the extreme backward position
but when the pin is at the position B, the extreme forward position of the arm will
have beenreached.
i. When the pin 2 travels from C to B the crank pin 9 passes through the backward
position to the forward position to the cutting stroke, and the return stroke is
completed when the pin 2 travels from B to C or the pin9 passes from the forward
position to the backwardposition.
j. As the angular velocity of the crank pin in uniform, the time taken from the crank
pin 2 to travel through an arc covering CEB is greater than the time taken to move
through an arc coveringBDC.
k. Thus a quick return motion is obtained by themechanism.
10. Explain the ratchet & pawl mechanism with adiagram.

Ratchet and Pawl mechanism (Automatic feed mechanism for the table)
a. The table of a shaping machine travels in a cross direction when thecross feed screw
isrotated.
b. The cross feed screw is attached to the ratchetwheel.
c. Aspringloaded‘pawl’ispositionedtobeplacedbetweentheteethofthe
ratchet wheel.
d. The pawl is housed within a frame known as rockerarm.
e. The bull gear placed inside the column, There is a diametric slot provided on the
face of the gearB.
f. A crank pin is attached to a slider placed in theslot.
g. The bottom of the rocker arm and the crank pin are connected bya connectingrod.
h. The rotation of the gear B makes the crank pin torotate.
i. This movement makes the rocker arm to rock about the centre of the
ratchetwheel.
j. The pawl makes the ratchet to rotate by a small amount in one direction only.
k. As the cross feed screw is attached to the ratchet wheel, the rotationof the ratchet
wheel will make the table to move in a crossdirection.
l. If the direction of the table feed is to be reversed, the pawl is turned about 180°
from itsposition.
m. The ratchet wheel and the cross feed screw will rotate in theopposite direction
resulting in the table movement in the oppositedirection.
n. When power feed is not necessary for the table, the pawl is disengaged from the
ratchetwheel.
11. Explain the hydraulic shaper mechanism with neat sketch?

Hydraulic shaper mechanism:
a. In a hydraulic shaper the ram is moved forward and backward by apiston moving
in a cylinder placed under theram.
b. The machine mainly consists of a constant discharge oil pump 2, a valve
chamber, a cylinder, and a piston7.
c. The piston rod 6 is bolted to the ram body. As shown in fig. The oil under high
pressure is pumped from the reservoir 1 and is made to pass through the valve
chamber to the right side of the oil cylinder 5 exerting pressure on the piston.
d. This causes the ram 4 connected to the piston 7 to perform forward stroke, and any
oil present on the left side of the cylinder is discharged to the reservoir through the
throttle valve3.
e. At the end of extreme forward stroke, the shaper dog 8 hits against the reversing
lever 9 causing the valve 12 to alter their position within the valve chamber.
f. Oil under high pressure is now pumped to the left side of the piston causing the ram
to perform returnstroke.
g. Oil present on the right side of the piston is now discharged to thereservoir.
h. At the end of the return stroke another shaper dog hits against the reversing lever
alerting the direction of stroke of the piston and the cycle is thus repeated.
i. The quick return motion is affected due to the difference in stroke volumeof the
cylinder at both ends, the left hand end being smaller due to the presence of the
pistonrod.
j. As the pump is a constant discharge one, within a fixed period, the same amount
of oil will be pumped into the right or to the left hand side of the cylinder.
k. This will mean that the same amount of oil will be packed within asmaller stroke
volume causing the oil pressure to rise automatically and increasing the speed
during the returnstroke.
*****
UNIT 3&4: CUTTING TOOL (SHAPER), WORK HOLDING DEVICES

PART-A
1. The cutting tool used in shaper is Single point cutting tool.
2. The most commonly used tool material for shaper is High speed steel.
3. In shaper the work may be supported on Table.
4. The most simplest type of work holding device in shaper is Vice.
5. When work is too large to be held in vice it must be fastened directly on Shaper table.
6. Stop and toes are used to hold thin work on the table.
7. A toe dog is similar in shape to that of Centre punch.
8. Angle plate is used for holding L shaped work pieces.
9. Shaper centers are used for cutting equally spaced grooves or splines on the periphery of round
work.
10. In a shaper tool the amount of side clearance angle is 2 to 3 degree.
11. In a shaper tool the amount of front clearance angle is 4 degree for cast iron and steel.
12. Grippers are also called Hold downs.
13. Parallels are used when the height of the job is less than the height of the jaws of the vice.
14. Grippers are used for holding thin pieces of work in a shaper vice.
15. Tungsten content in HSS cutting tool material is 18%
16. Chromium in H.S.S cutting tool material is 4%
17. Cemented carbide is the hardest manufactured cutting tool material.
18. With H.S.S tools, highest cutting speed is used while machining Aluminium
II. Multiple choice questions:

1. Which of the following material has highest cutting speed:
a) Plain carbon steel b) High speed steel
c) Ceramics d) All of the above
Ans: b) High speed steel.
2. A __________ may be swiveled like a swivel vice in shaper.
a) Plain vice b) Swivel vice
c) Universal vice d) None of these
Ans: c) Universal vice
3. A _________ is a one leg screw clamp
a) Stop pins b) Strip and stop pins
c) Stop pin and toe dogs d) None of these
Ans: a) Stop pins
4. In a shaper tool the amount of side clearance angle is
a) 1 to 2 degree b) 2 to 3 degree
c) 3 to 4 degree d) All of above
Ans: b) 2 to 3 degree
5. In a shaper tool the amount of front clearance angle is
a) 4 degree b) 4.5 degree
c) 3.5 degree d) 5 degree
Ans: a) 4 degree
6. The most commonly used tool material for shaper is
a) Plain carbon steel b) High speed steel
c) Ceramics d) none of the above
Ans: b) High speed steel
7. When work is too large to be held in vice it must be fastened directly on
a) Vice b) Shaper table
c) Stop pin and toe dogs d) None of these
Ans:b) Shaper table
8. In shaper for holding round rods it is used.
a) Vice b) V-Blocks
c) Shaper table d) none of these
Ans: b) V-Blocks
9. _________ is used for holding L shaped work pieces.
c) Universal vice d) Angle plate
Ans: d) Angle plate
10. Hold downs are also called

c) Grippers d) Angle plate
Ans: c) Grippers
11. Which of the following work holding device is preferred for shaping a key-way in a cylindrical
shaft.
a) V-block b) Dividing head
c) An angle plate d) Shaper vice
Ans: a) V-block
12. To shape splines in a shaft which must be accurately spaced, the work mounted in
a) A V-block b) A special fixture
c) Between indexing centre d) Shaper vice
Ans: c) Between indexing centre
13. Chromium in H.S.S cutting tool material is
a) 1% b) 4%
c) 18% d) 0.06%
Ans: b) 4%
14. Which of the following tool material has highest cutting speed?
a) Carbon steel b) Carbide
c) HSS d) Cast alloy
Ans: b) Carbide
15. Tungsten content in HSS cutting tool material is
a) 18% b) 4%
c) 0.01% d) 6%
Ans: a) 18%
16. With H.S.S tools, highest cutting speed is used while machining
a) Cast iron b) Aluminum
c) Brass d) Bronze
Ans: b) Aluminum
17. The cutting speed will be minimum while machining the following material with H.S.S tool
a) Cast iron b) Aluminum
c) Copper d) White metal
Ans: a) Cast iron
18. The hardest manufactured cutting tool material is
a) Diamond b) Diamond
c) Cemented carbide d) Ceramic
Ans: c) Cemented carbide
III. Answer the following questions 2 Marks
1. What is single point cutting?

Ans: Single point cutting: A mechanical machining process where a tool with a single sharp cutting
edge is used to remove material from the work piece.
2. Mention the classification of a machine vice?

Ans: A machine vice may be classified as follows
a) Plain vice
b) Swivel vice
c) Universal vice.
3. What are grippers?

Ans: Grippers are used for holding thin pieces of work in a shaper vice. It is placed between two
jaws of the vice and the work piece.
4. What are angle plates.

Ans: Angle plate: Angle plates are work holding devices. These are made of cast iron and is
planed on two sides to an angle of exactly 90 degrees. For holding L shaped work piece angle plates
are used.
5. Write the purpose of using stop pins and toes?

Ans. While holding the thin work on the table stop pins in conjunction with toe dogs are
used. A toe dog is similar in shape to that of a centre punch.
6. What is V –block?
Ans: V – Block is a wok holding device. For holding round rods V –blocks are used. Work
may be supported on two V –blocks at its two ends and clamped to the table by T-bolts and
clamps.
7. Write use of gripper or hold downs?
Ans: Hold downs or grippers are used for holding thin pieces of work in shaper vise, These
are also used for holding work of smaller height than the vice jaws where suitable parallels
are not available.
8. Write the use of parallels?
Ans: When the height of the job is less than the height of the jaws of the vise, parallels
are used to raise
and seat the work piece above the vise jaws and parallel with the vise bottom.
9. List any two advantages of H.S.S used as a cutting tool material?
Ans: Following are advantages of H.S.S used as cutting tool material.
a) H.S.S tool can resist vibrations.
b) It can prevent mechanical shocks.
c) It is suitable for varying thermal changes.
10. Write the any two properties of cutting tools used in shaper.
Ans: Basic properties that cutting must possess are:
a) Tool material must be at least 30 to 50% harder than the work piece material.
b) Tool material must have high hot hardness temperature.
c) High toughness
11. What is clearance?
Ans: CLEARANCE:
The intentional relief provided on the faces of the cutting tool to give a sharp cutting edge and
there by preventing the other portions of the tool from rubbing the job is called as clearance.
12. Define shaper centers.
Ans: It is a special attachment used for cutting equally spaced grooves or
splines on the periphery of a round work piece.
13. What are stop pins?
Ans: It is a one leg screw clamp. These are used to prevent the work from
coming out of position.
14. What are toe-dogs?
Ans: It is similar in shape to that of a center punch or a cold chisel. While
holding the work it is used in conjunction with stop pins.
15. What is shaper vice?

Ans: It is a quick method of holding locating relatively small and regular shaped work
piece. It consists ofbase, table, screw,fixed and movable jaw.
IV. Answer the following questions 3 Marks
1. List the most commonly used cutting tools in shaper.

Ans: The most commonly used cutting in shapers are
a) A left hand roughing tool for planing.
b) A left hand finishing tool for planing.
c) A left hand side facing tool for vertical shaping and for shaping sharp corner.
d) A left hand side facing tool
e) A left hand dovetail cutting tool (roughing)
f) A left hand dovetail cutting tool (finishing)
g) A parting or slotting tool.
2. Mention the work holding devices used in shaper.
Ans: The different work holding devices used in shaper are
a) Machine vice,
b) Direct tables,
c) chucks,
d) collets,
e) centre’s,
f) face plate,
g) mandrels, and
h) Steady rest.
3. List the different types of cutting tool materials.

Ans: The following are different types of cutting tool materials.
a) High carbon steel.
b) High speed steel.
c) Cemented carbides
d) Stelite.
e) Ceramics.
f) Cubic boron nitride.
4. Write a note on clamping work on the shaper table.

Ans: When the work piece is too large to be held in a vice it must be fastened directly on the shaper
table. Inholding work on the table, clamping bolts should not be unduly tightened to produce distortion
of the work.
The different methods employed to clamp different types of work on a shaper table are,
a) T – Bolts and clamps
b) Stop pins
c) Stop pins and toe dogs
d) Strip and stop pins.
5. What are the basic properties of cutting tools?

Ans. Basic properties that cutting must possess are:
d) Tool material must be at least 30 to 50% harder than the work piece material.
e) Tool material must have high hot hardness temperature.
f) High toughness
g) High wear resistance
h) High thermal conductivity
i) Lower coefficient of friction
j) Easiness in fabrication and cheap
6. Sketch and explain roughing tool.
Ans:
Roughing tool: When it is required to remove a good amount of material from the work piece,
roughing tools are used. The cutting edge will be very thick, sharp and strong to withstand the cutting
pressure and to dissipate the heat generated at the cutting point. The surface obtained will be very
rough.
7. Sketch and explain finishing tool.

Ans:
Finishing tool: After the rough machining is performed, the finishing tool is used to obtain a very high
quality of surface finish. The cutting edge will be either flat or slightly convex.
8. Explain the basic properties of High carbon steel used as a cutting tool material?
Ans: The basic properties of high carbon steel as a cutting tool material are
 Its composition is C = 0.8 to 1.3%, Si = 0.1 to 0.4% and Mn = 0.1 to0.4%.
 It is used for machining soft metals like free cutting steels and brassand
used as chiselsetc.
 This tool loose hardness above250°C.
 Hardness of tool is about Rc =65.
 Used at cutting speed of5m/min.
9. Mention the basic properties of cemented carbide cutting tool material?
Ans: The basic properties of cemented carbide as a cutting tool material are
 Produced by powder metallurgy technique with sintering at1000°C.
 Speed can be used 6 to 8 times that ofH.S.S.
 Can withstand up to1000°C.
 High compressive strength is more than tensile strength.
 They are very stiff and their young‘s modulus is about 3 times that of thesteel.
 High wearresistance.
 High modulus of elasticity.
 Low coefficient of thermalexpansion.
 High thermal conductivity, low specific heat, low thermalexpansion
10. What are strip and stop pins?

Ans: Strip is a long bar having a tongue with holes for fitting the T –Bolts. The strip with bolts is fitted
in the T – slot of the table, the tongue of the strip fitting within the slot. Stop pin is a one leg
screwclamp. These are used to prevent the work from coming out of position.The stop pin screws are
then tightened from the other end of the work so that the may be clamped between stop pins and strip
plates.
11. What are cutting tool and shaper tool?
Ans: The cutting tool used in shaper is a single point cutting tool having rake angle,clearence
and other tool angles similar to the lathe tool. Shaper tools are much more rigid and heavier to
withstand shock experienced by the cutting tool at commencement of each cutting stroke.
V. Answer the following questions 5 Marks
1. What are the advantages of H.S.S as a cutting tool material used in shaper?
Ans: Following are advantages of H.S.S used as cutting tool material.
d) H.S.S tool can resist vibrations.
e) It can prevent mechanical shocks.
f) It is suitable for varying thermal changes.
g) It has inherent strength so sharp cutting edges can be produced easily.
h) Easier to machine difficult materials.
i) It gives better surface quality and tolerance of machined parts.
j) It provides longer tool life.
2. Sketch and explain V – Block.

Ans: V – block
V – Block is a metal block having a V-shaped groove on it.It is used for holding
cylindrical work pieces. Operations like keyway cutting, slot cutting and machining flat
surfaces can be performed on the cylindrical work pieces held on a V‘block. The use of a
V‘block is illustrated inFig.
3. Sketch and explain T- bolts and clamps.

Ans: T – bolts and clamps
T – Bolts are fitted into the T - slots of the table. The work is placed on the table. The work
is supported by a rectangular strip at one end and by a stop pin at the other side. The screw is
tightened to secure the work properly on the machine table.
4. With neat sketch explain angle plate.

Ans: Angle plate.
AngleplateresemblestheEnglishalphabet‗L‘.Itisaccuratelymachinedtohave two sides at
right angles. Slots are provided on both the sides. One of the sides is bolted to the machine table
and the work pieces are held on the other side. The use of an angle plate is shown inFig.
5. With neat sketch explain shaper vice.

Ans: Shaper vice.
Vice is the most common and simple work holding device used in a shaper. Different
types of vices are used in a shaping machine according to the need and they are:
a) Plainvice
b) Swivelvice
c) Universalvice
6. Sketch and explain roughing and finishing tool used in shaper.
Ans:
Roughing tool
When it is required to remove a good amount of material from the work piece, roughing
tools are used. The cutting edge will be very thick, sharp and strong to withstand the cutting
rough.
Finishing tool: After the rough machining is performed, the finishing tool is used to obtain a very high
quality of surface finish. The cutting edge will be either flat or slightly convex.
7. With neat sketch explain strip and stop pins.
Ans: Strip and stop pins
Work having sufficient thickness is held on the table by strip and stop pins.A strip is a
long bar having tongue with holes for fitting the T –bolts. The strip with bolts is fitted in the T
slot of the table the tongue of the strip fitting within the slot. The nuts are then tightened so that
the strip plate may rest on one side of the work.Stop pin is a one leg screw clamp. These are used
to prevent the work from coming out of position.The stop pin screws are then tightened from the
other end of the work so that the may be clamped between stop pins and strip plates.
VI. Answer the following questions 8 Marks
1. What are the different work holding devices used in shaper? Explain any one.
Ans: When the work piece is too large to be held in a vice it must be fastened directly on the shaper
table. In holding work on the table, clamping bolts should not be unduly tightened to produce
distortion of the work. The different methods employed to clamp different types of work on a
shaper table are
Work pieces can be held and supported on the shaper table directly or by having some special
devices. Depending on the size and shape of the work, it may be supported on the table by any
one of the following methods.
1. Shaper vise
2. Clamps and stoppins
3. T-bolts and stepblocks
4. Angleplate
5. V –Block
6. Specialfixture
Angle plate.
AngleplateresemblestheEnglishalphabet‗L‘.Itisaccuratelymachinedtohave two sides at right
angles. Slots are provided on both the sides. One of the sides is bolted to the machine table and the
work pieces are held on the other side. The use of an angle plate is shown inFig.
2. With a neat sketch explain the nomenclature of single point cutting tool.
Ans: Single point cutting tool geometry and nomenclature
CLEARANCE:The intentional relief provided on the faces of the cutting tool to give a sharp cutting
edge and thereby preventing the other portions of the tool from rubbing the job is called as clearance.
The tool may get heated up because of the friction caused by the rubbing action if a proper clearance
for the cutting edge is not provided. The side adjacent to the cutting edge is ground and relieved. This is
called as the Side clearance angle. Too much side clearance will weaken the cutting edge and cause the
cutting edge to chip off. Similarly, the front portion is also ground at an angle and this is called the
Front clearance angle. Too much front clearance will weaken the cutting edge. The common angles
provided on a Right hand Roughingtool.
Back Rake: Is to help control the direction of the chip, which naturally curves into the work due to the
difference in length from the outer and inner parts of the cut. It also helps counteract the pressure
against the tool from the work by pullingthe tool into thework.
Side Rake:along with back rake controls the chip flow and partly counteracts the resistance of the
work to the movement of the cutter and can be optimized to suit the particular material being cut.
Brass for example requires a back and siderake of 0 degrees while aluminum uses a back rake of 35
degrees and a side rake of 15degrees.
Nose Radius: makes the finish of the cut smoother as it can overlap theprevious cut and eliminate
the peaks and valleys that a pointed tool produces. Having a radius also strengthens the tip, a sharp
point being quitefragile.
 All the other angles are for clearance in order that no part of the tool besidesthe actual
cutting edge can touch the work. The front clearance angle is usually 8 degrees while the
side clearance angle is 10-15 degrees and partly depends on the rate of feedexpected.
 Minimum angles which do the job required are advisable because the toolgets weaker as
the edge gets keener due to the lessening support behind the edge and the reduced ability
to absorb heat generated bycutting.
 The Rake angles on the top of the tool need not be precise in order to cut butto cut
efficiently there will be an optimum angle for back and siderake.
3. Sketch and explain the different types of tools used in shaper.

Ans: Types of shaper tools: According to the type of work and the type of operation, various
tools are used in a shaper. They are
Right hand ( R. H ) tool
This is a tool used for machining by moving the job from right to the left.
Left hand ( L. H ) tool
This is a tool used for machining by moving the job from left to right.
Roughing tool
When it is required to remove a good amount of material from the work piece, roughing
tools are used. The cutting edge will be very thick, sharp and strong to withstand the cutting
rough.
Finishing tool
After the rough machining is performed, the finishing tool is used to obtain a very high
quality of surface finish. The cutting edge will be either flat or slightly convex. Different types of
shaper tools are shown in Fig.
Goose neck tool
This is a special type of tool used for finish machining. Very good surface finish will be
obtained. The cutting edge of goose neck tool has a springy action. The tip of the cutting edge lies in
the same line with the rear side of the shank.
Slot cutting tool
Wide rectangular or square grooves are known as slots. Rough machining of the slot is carried out
using round nose tool. After that, a slot cutting tool is used for finish machining work.
T-slot cutting tool
The central rectangular (or square) slot is first machined using rough machining tool and then by
using parting tool (or slot cutting tool).After that, a T-slot cutting tool is used to machine
underneath the rectangular groove.
Form tool
Form tools are made to suit some specific requirements for machining V shaped grooves
or similar special shaped grooves in concave or convex form.
Different types of tool used in shaping
4. Sketch and explain the following i) Angle plate

ii) V-block.
Ans:Angle plate.
AngleplateresemblestheEnglishalphabetL‘.Itisaccuratelymachinedtohave two sides at right
angles. Slots are provided on both the sides. One of the sides is bolted to the machine table and the
work pieces are held on the other side. The use of an angle plate is shown inFig.
V – block
V – Block is a metal block having a V-shaped groove on it.It is used for holding
surfaces can be performed on the cylindrical work pieces held on a V-block. The use of a V-
block is illustrated inFig.
5. Sketch and explain shaper centers.

Ans:Shaper centers.
This is a special attachment used for cutting equally spaced grooved or splines on the periphery of
round work. In special cases, it may be used for cutting gears. A shaper centre consists of a headstock
and tailstock, and the work is mounted between two centers. Mounted upon the headstock spindle is
worm gear which meshes with the worm. The handle is connected with worm shaft. Rotation of the
handle causes the worm gear to rotate and the motion is transmitted to the work through a catch plate
and carrier. After cutting a slot or groove on the top of the work, it may be turned to a predetermined
amount by an index plate and index pin. The index plate is mounted on the worm gear shaft. The index
plate has a series of holes around its circumference and is locked in any desired position by engaging
the index pin in the corresponding hole. Index plates are provided with various numbers of holes.
6. List the different work holding devices used in shaper and explain V-block?
Ans: Depending on the size and shape of the work, it may be supported on the table by any
one of the following methods.
1. Shaper vise
2. Clamps and stoppins
3. T-bolts and stepblocks
4. Angleplate
5. V –Block
6. Specialfixture
V – block
V – Block is a metal block having a V shaped groove on it.It is used for holding
surfaces can be performed on the cylindrical work pieces held on a V block. The use of a V
block is illustrated inFig.
7. With neat sketch explain shaper vice and T bolts and clamps.
Ans: Shaper vice.
Vice is the most common and simple work holding device used in a shaper. Different types of
vices are used in a shaping machine according to the need and they are:
a) Plainvice
b) Swivelvice
c) Universalvice
T – bolts and clamps

T – Bolts are fitted into the T - slots of the table. The work is placed on the table. The work
is supported by a rectangular strip at one end and by a stop pin at the other side. The screw is
tightened to secure the work properly on the machine table.
******
UNIT 5&6: CUTTING SPEED & FEED, CALCULATION OF MACHINING

TIME
PART-A
I. Fill in the blanks with appropriate words.

1. The formula for shaper total machining time is………..
Ans. Tm = L x B (1+m)
1000xVxS
2. The formula for cutting speed in a shaper is………..
Ans. V = n L (1+m) min
1000
3. The cutting speed in a shaper, m is expressed as………….
Ans. The ratio of return time to cutting time
4. In a shaper calculation feed (S) is expressed as………..

Ans. mm / double stroke
5. The formula for shaper time of one stroke is……….

Ans. t = L (1+m) min
1000V
6. In a shaper calculation feed (L) is expressed as………..
Ans. Length of stroke
7. In a shaper the cutting speed is considered only during the…………cutting stroke.

Ans. Forward
8. Formula of shaper the time for the working stroke is………….

Ans. tA = L/VR
9. Formula of shaper the time for non-cutting stroke is………….

Ans. tR = L/VA
10. In a shaper time for one cycle (t) =………….

Ans. t= tA+tR
11. The unit of metal removal rate is…………
Ans. mm / minute
12. The full form of R.P.M……….
Ans. Revolutions per minute
13. In a shaper unit of cutting speed is……….
Ans. m/mm
14. In a shaper total machining time unit is expressed in……….
Ans. Minute
15. In a shaper, the unit of feed is expressed in………..
Ans. mm
16. In a shaper Length of stroke (L)=………….
Ans. L= l + l a+ l u
17. The unit of machine time is…………
Ans. Minute
Ans. Minute
19. In a shaper, the feed is expressed in………..
Ans. millimeter
II. Multiple choice questions.

1. What is the full form of R.P.M?
a) Revolutions per motors
b) Revolutions per miles
c) Revolutions per minute
d) none of the above
2. The cutting speed in a shaper, ‘’L” is expressed as
a) Length of cutting stroke
b) Width of cutting stroke
c) Height of the job
d) Width of the job
3. The cutting speed in a shaper, n is expressed as

a) The ratio between return time to cutting time
b) The length of cutting stroke
c) R.P.M of the bull gear
d) None of the above
4. In a shaper unit of cutting speed is……….
a) m/min
b) mm/m
c) m/sec
d) mm
5. In a shaper the………….is considered only during the forward cutting stroke.
a) Cutting speed
b) Return speed
c) Depth of cut
d) Machining time
6. In a shaper Length of stroke (L)=………….
a) L= l a+ l U
b) L= l + l a+ l u
c) L= l + lu
a) Hour
b) Second
c) Minute
8. In a shaper (t) is known as…….
a) Depth of cut
b) Feed
c) Machining time
d) Cutting speed
9. The depth of cut is the…………distance measured between machined surface and non
machined surface of the work piece.
a) Vertical
b) Horizontal
c) Perpendicular
10. In a shaper, the feed is expressed in………..
a) mm
b) cm
c) km
d) inch
11. What is the unit of metal removal rate?
a) mm2/minute
b) mm3/minute
c) mm/minute
d) none of the mentioned
12. What is the unit of machine time?
a) Minute
b) Mm/minute
c) Mm
13. The formula for shaper total machining time?

a) Tm = L x B (1+m)
1000xVxS
b) Tm = L (1+m)
1000xVxS
c) Tm = L x B (1+m)
1000xV
d) Tm = L x B (1+m)
1000xS
14. The formula for cutting speed in a shaper?

a) V = L (1+m) min
1000
b) V = n L (1+m) min
1000
c) V = n (1+m) min
1000
d) V = n L (1+m) min
100
15. The cutting speed in a shaper, m is expressed as
a) Non cutting time
b) Feed
c) The ratio of return time to cutting time
d) None of the mentioned
16. In a shaper calculation feed (S) is expressed as

a) Over travel
b) Return speed
c) Feed per cycle in mm
17. In a shaper time for one cycle (t) =
a) t = tA+tR
b) t = t+tu
c) t = ta+t
18. In a shaper calculation feed (L) is expressed as
a) Approach length
b) Length of cutting stroke
c) Over travel of job
III. Answer the following questions 2 Marks

1. Define cutting speed in a shaper.
ANS: In a shaper, the cutting speed is the rate at which the metal is removed by the cutting
tool. This is expressed in meter per minute.
2. Define feed in a shaper.

ANS: Feed (s) is the relative movement of the tool or work in a direction perpendicular to
the axis of reciprocation of the ram per double stroke and is expressed in mm.
3. Define depth of cut in a shaper.

Ans: Depth of cut (t) is the thickness of metal that is removed in one cut. It is the
perpendicular distance measured between machined surface and non-machined surface of
the work piece.
4. What is machine time?

Ans: Machining time is a term used to describe the amount of time a machine spends
actually cutting, milling, shaping or otherwise altering a piece to be machined. It is part of
what is known as the cycle time, which the total amount of time it takes to load and unload a
piece of material as well as the amount of time takes it takes to actually cut that material.
5. Find the machining time required for non cutting stroke length of the stroke is 0.4m
and return speed is 20m/min.
Ans,
 Given data; length of the stroke (L) = 0.4m
Return speed (VR)= 20m/min
 Time required for non-cutting stroke (tR)= Length of the stroke

Return speed
tR = L/VR
tR = 0.4m = 0.02min.
20m/min
6. What are the factors upon which the cutting speed depends?
Ans. The factors upon which the cutting speed depends are
i) Material of the job to be machined
ii) Hardness of cutting tool
iii) Grinding and setting of tool
iv) Feed rate and depth of cut
v) Capacity of machine
7. If the length of shaper stroke is 300mm, the number of strokes per minutes is 30, the
ratio between returns and cutting strokes is 2:3, what would be the cutting speed?
Ans.
Solution; V = n L (1+m) min
1000
V = 30 x 300 (1+2/3) min

1000
V = 30 x 300 x 5 min
1000 x 3
V = 15 meter / min.
8. If the length of shaper stroke is 300mm, the cutting speed is 20 m/min, the ratio
between return and cutting stroke 2:3, what would be the number of strokes per
minute?
Ans.
Solution; N = V x 1000 min
L (1+K)
N = 20 x 1000 min
300(1+2/3)
N = 20 x 1000 min
300 (5/3)
N = 40 strokes per min.
9. If the length of shaper stroke is 250mm, the number of strokes per minutes is 25, the
ratio between returns and cutting strokes is 2:3, what would be the cutting speed?
Ans.
Solution; V = n L (1+m) min
1000
V = 25 x 250 (1+2/3) min

1000
V = 25 x 250 x 5 min
1000 x 3
V = 10.41 meter / min.
10. If the length of shaper stroke is 280mm, the cutting speed is 25 m/min, the ratio
between return and cutting stroke 2:3, what would be the number of strokes per
minute?
Ans.
Solution; N = V x 1000 min
L (1+K)
N = 25 x 1000 min
280(1+2/3)
N = 25 x 1000 min
280 (5/3)
N = 53 strokes per min.
PART-B
IV. Answer the following questions 5 Marks
1. In a shaper work, the length of stroke 250mm, number of double strokes per minute is 30 and the
ratio of return time to cutting time is 2:3, Find the cutting speed.
Ans:
 Cutting speed = n L (1+m)
1000
V = 30X200 (1+2/3)
1000
V = 30X200X5 = 30,000 = 10 m/min.

1000X3 3000
2. Find the machining time required for machining surface 600x800mm on a shaping machine.
Assume cutting speed as 8m/min, the return to cutting time ratio is 1:4 and the feed is 2mm /
double stroke. The clearance at each end is 70mm.
ANS:
Given data;
 Length of machining = 600x800mm
 Cutting speed (v) = 8m/min
 Cutting and return ratio = 1:4
 Feed (s) = 2mm/ double stroke
 Clearance at each end = 70mm.
In a shaper a stroke length of more than 800mm is not ordinarily available so the work is
placed on the table a cut of 600mm plus the clearances.
Total length of stroke = 600+70+70 = 740 mm.
 Cutting time = 740 x 60 = 5 sec.

1000 x 8
 Return stroke time = 1/4
Cutting stroke time
 Return time = 5 x 1/4 = 5/4
Total time of one complete double stroke = 5+ 5/4 = 25/4 sec.
Total number of double stroke necessary to complete the cut = 800/3 = 267
 Total time required to complete the cut = 25 x 267 = 6675/240 = 27.81 min.
4 X 60
3. In a shaper work, the length of stroke 300mm, number of double stroke per minute is 25 and the
ratio of return time to cutting time is 1:4, find the cutting speed.
Ans:
Given data;
 Length of machining = 300mm
 Cutting speed (v) =?
 Number of stroke per min = 25

1000
V = 25X300 (1+1/4)
1000
V = 25X300X5 = 37,500 = 9 m/min.

1000X4 4000
4. Find the time required for taking a complete cut on a plate 600x900mm, if the cutting speed is
9m/min. The return time to cutting time ratio is 1:4 and the feed is 3mm, the clearance at each end
is 75mm.
ANS:
Given data;

1000 x 9
Cutting stroke time
 Return time = 5 x 1/4 = 5/4
 Total time required to complete the cut = 25 x 300 =125/4 = 31.25 min.
4 X 60
5. A plate is to be shaped with a roughing cut, calculate the machining time the length of plate
260mm, shaping width 90mm approach length is 30mm, over travel is 10mm, if the cutting speed
is 10m/min and return speed is 20m/min and feed is 1mm/cycle.
Ans.
 Given ; L = 260mm, width= 90mm, la= 30mm, lu= 10mm

VA = 10mm/min
Vr = 20m/min
Feed = 1mm/cycle
Allowance from the left= 5mm
Allowance from the right= 5mm each.
L= l + l a+ l u
L= 260+30+10
L=300mm
 Time for working stroke tA = L/VR
tA = 0.3 m = 0.03min
10m/min
 Time for non-cutting stroke tR = L/VR
= 0.3 m = 0.015min
20m/min
 Time for one cycle (t) = tA+tR = 0.03 + 0.015 = 0.045min
 Shaping width B= b + 2x5 = 90 + 2 x 5 = 100mm
 Number of required cycles Z= 100 = 100 cycles

1mm/cycle
 Machining time tm = Z+t = 100 x 0.05 min/cycle = 4.5min
6. Define cutting parameters in case of the shaper machine.

Ans.
 Cutting speed; in a shaper, the cutting speed is the rate at which the metal is removed by the
cutting tool. This is expressed in meter per minute
 Feed (s); is the relative movement of the tool or work in a direction perpendicular to the axis of
reciprocation of the ram per double stroke and is expressed in mm.
 Depth of cut (t); is the thickness of metal that is removed in one cut. It is the perpendicular
distance measured between machined surface and non-machined surface of the work piece.
Ans;
Given data;

1000
V = 28X280 (1+1/4)
1000
V = 28X280X5 = 39,200 = 10 m/min.
1000X4 4000
Ans;
Given data;

1000
V = 20X300 (1+2/3)
1000
V = 20X300X5 = 30,000 = 10 m/min.

1000X3 3000
9. Find the machining time required for machining surface 750x900mm on a shaping machine.
Assume cutting speed as 9m/min, the return to cutting time ratio is 1:4 and the feed is 2mm /
double stroke. The clearance at each end is 75mm.
ANS;
Given data;

1000 x 9
Cutting stroke time
 Return time = 5 x 1/4 = 5/4
 Total time required to complete the cut = 25 x 250 = 6250/240 = 26.04 min.
4 X 60
Ans;
Given data;

1000
V = 30X380 (1+1/4)
1000
V = 30X380X5 = 57,000 = 14 m/min.

1000X4 4000
******
UNIT 7, 8 & 9: SAFETY, LATHE & WORK HOLDING DEVICES

Part - A
I. Fill in the blanks
1) Lathe machine was invented by Henry moudslay
2) Lathe machine invented in the year 1797
3) Lathe is also called as mother of all machines
4) Lathe is the machine removes excess material and give required shape and size
5) 3-jaw chuck is also called as self-centering chuck
6) Self-centering chuck is also called as 3-jaw chuck
7) 4-jaw chuck is also called as independent chuck
8) Independent chuck is also called as 4-jaw chuck
9) Hexagonal type of workpieces can be hold in 3-jaw chuck
10) Irregular type of workpieces can be hold in 4-jaw chuck
11) Magnetic chuck can hold magnetic type workpieces
12) Face plate is made up of material is cast iron
13) Two types of lathe rests are steady rest and follower rest
14) Lead screw having acme type of threads
15) Metric thread angle is 60
16) Leg break is used to stop main spindle
II. Multiple choice question and answers
1) Lathe isinvented by _____________
a) John c) Henry moudslay
b) James nasmith d) Henry
2) Lathe is also called as __________________
a) Machine c) Mother of all machine
b) Main machine d) None of these
3) 3-jaw chuck is also called as __________________
a) Self-centering chuck c) Independent chuck
b) Magnetic chuck d) Collet chuck
4) Independent chuck is also called as ________________
a) 3-jaw chuck c) 4-jaw chuck
b) Universal chuck d) Collet chuck
5) 3-jaw chuck hold the _______________ workpieces
a) Irregular c) Square
b) Eccentric d) Circular
6) Main parts of lathes are ___________________
a) Head stock c) Tail stock
b) Tool post d) All of these
7) Chuck is used to hold the ___________________
a) Tool c) Workpiece
b) Carriage d) Tail stock
8) Which is the work holding device in lathe ______________
a) Lead screw c) Feed rod
b) Tail stock d) Chuck
9) Lathe Bed is made up of _________________
a) Mild steel c) Aluminum
b) Cast iron d) Copper
10) Universal chuck is also called as ___________________
a) 4-jaw chuck c) collet chuck
b) Magnetic chuck d) 3-jaw chuck
III. Answer the questions (2 marks)

1) Define Lathe
Ans: lathe is a mother of all machines which is used to remove excess material and given the
required shape and size
2) Write any 2 safety precautions in lathe
Ans: 1) wear hand glows
2) Do not touch the machine while in running
3) Write any 4 types of lathe machines.

Ans: 1) Bench lathe 2) Engine lathe
3)Capstan &turret lathe 4) Automatic lathe
4) Write the main parts of lathe.
Ans: 1) Headstock 2) Tailstock 3) Tool post 4) Carriage
5) List the work holding devices used in lathe.
Ans:1) Chucks 2) Collets 3) Centers 4) Mandrels
6) Define chuck.
Chuck is a devices used to hold the work pieces in lathe
7) Write the type of chuck
1) 3-jaw chuck 2) 4-jaw chuck 3) magnetic chuck
8) Define mandrels
Mandrels are work holding device used to hold the hollow workpieces
9) Write the two types of rest method in lathe
1) Steady rest 2) follower rest
10) Write the types of mandrels any 2
1) Plain mandrel 2) step mandrel 3) gang mandrel
11) Write the type of lathe centers any 2
1) Ordinary centre 2) tipped centre 3) pipe centers
PART - B
I. Answer the following questions (3marks)
1. List the types of lathes

Ans: 1) Speed lathe
2) Bench lathe
3) Engine lathe
4) Tool room lathe
5) Capstan lathe
2. Define chuck. Write the types of chuck
Ans: Chuck is a device used to hold the work piece
Types of chuck: 1) 3-jaw chuck
2) 4-jaw chuck
3) combination chuck
4) magnetic chuck
5) collet chuck
6) drill chuck
3) mention the work holding device in lathe

Ans: 1) chucks 2) collets 3) centers 4) mandrels
4) write about face plate

Ans: A face plate consists of circular disc bored and threaded to fit on lathe spindle. This has radial
plain and T-slots for holding work by bolts and clamps
5) what do you mean by lathe rests
Ans: A lathe rests is a mechanical device which supports a long standard work pieces when it is turned
between centers
6) Define tool post. Write the types of tool post
Ans: Tool post is mounted on compound rest to hold the cutting tool
Types: 1) single screw tool post 2) four bolt tool post 3) open side tool post 4) four way tool post
7) write construction of angle plates
Ans: The angle plate having two faces machined perpendicularly to each other. The holes and slots
provided on both the faces
8) Why carriers and catch plates are used
Ans: The carriers and catch plates are used to drive the work pieces when held between centers
9) write about step mandrels
Ans: The step mandrels have different steps for holding different sizes of work pieces having different
diameters of holes without replacing mandrels every time
10) what do you know about magnetic chuck
Ans: The magnetic chuck is one type of chuck used to hold the thin work piece made up of magnetic
material.
II. ANSWER THE FOLLOWING QUESTION (5MARKS)

1) Explain briefly about speed lathe
1) The speed lathe in construction and operation is the simplest among all the lathe
2) It is also consisting head stock, tail stock, Tool post
3) The spindle speed available from 1200 to 3600rpm
4) The cutting tool will be hand controlled
5) The different speed lathe is wood working lathe, spinning Lathe, centering lathe, polishing
lathe
2) Write the specification of lathe
specification of lathe
1) Name of the lathe
2) The height of the centers measured from lathe bed
3) The swing diameter over the bed
4) The swing diameter over the carriage
5) The length between centers
6) The maximum bar diameters
7) The length of bed
3) Write the difference between 3-jaw chuck and 4-jaw chuck
3-jaw chuck: 1) in 3-jaw chuck all the jaws are made to slide simultaneously
2) it consists of 3-jaws
3) it is also called as self- centering chuck
4) it can hold cylindrical and circular work pieces
4-jaw chuck: 1) in4-jaw chuck all the jaws are move independently
3) it is also called independent chuck
4) it can hold hexagonal work pieces
4) Explain briefly lathe centers.
Lathe center: the most common method of holding work between centers like live center and
dead center
Common type of centers: 1) ordinary centre 2) tipped center 3) ball center 4) half center
5) insert type center 6) revolving center 7) pipe center
1) Ordinary center: used for general work
2) Tipped center: this point consist hard alloy tip brazed into ordinary steel shank this has more
wear resistant
3) Half center: this can be used for facing operation
5) Briefly explain a) Screwed mandrel b) gang mandrel
Screwed mandrel: this mandrel has collar at one end and screw end at another end. Work piece
having different diameter of holes without replacing mandrel every time.
External surfaces of screwed flanges, nuts, back plates of chucks etc. are machined on lathe by
locking on screwed mandrel
Gang mandrel: this has fixed collar at one end and movable collar at the threaded end. May
adjust by nut.
This mandrel is used to hold hollow work pieces between two collars
6) List the safety precautions in lathe
Safety precautions in lathe
1) Fix the job rigidly in the chuck
2) Fix the tool point at central axis of the work pieces
3) Arrange proper speed and feed
4) Initially take light cut and tool does not rub the work piece
5) Do not try to stop chuck with hand after switched off
6) Do not leave the chuck key in the chuck only
7) Clean the machine and oil after completing the operation
7) Explain automatic Lathe
Ans: 1) automatic lathes are high speed heavy duty and mass production with complete automatic
control
2) In this lathe once the tool set the machine work automatically by programmed and finished the
job
3) In this lathe the changing the tools,feeds,speeds,are automatically done by machine itself
4) one operator can look after five to six automatic lathe at a time
5) the best example of automatic machine is CNC Machine
8) Write a note on Special purpose lathe
Ans: As the name specifies these are used for special purpose. which cannot be machined on standard
lathe
1) The wheel lathe: used to turn and finish locomotive wheels
2) The gap bed lathe: used to turn large diameter work pieces
3) The duplicating lathe: used to reproduce shape of template of round shape by the help of
mechanical, air and hydraulic devices
4) The missile lathe: used to swing over bed diameter for accommodating large missile
9) Discuss briefly Tool room lathe
Ans: This lathe has same features of engine lathe, and wide range of spindle speed from low speed to
high speed up to 2500 RPM, This is also equipped with chuck, taper turning attachment, draw in collet
attachments, draw in collet attachments, thread chasing dial Steady rest , follower rest, Pump for
coolant etc,
This lathe is used for Precision work for manufacturing TOOLS, Dies, Gauges, Etc.
10) Write The Difference Between Tool Room Lathe And Engine lathe
Tool Room Lathe Engine Lathe
1) This Lathe is equipped with chuck taper 1) It Consists of parts head stock, Tail stock,
turning attachments Steady rest and follower Tool post, Lead Screw Etc,
rest
2) In this lathe only spindle speed only by 2) The lathes belt driven or motor or general
motor drive and this lathe used for precission head lathe and this lathe can be used for
work manufacturing Tools ,Dies, gauges Etc. general purpose of works.
11) Write about Air Or Hydraulic operated chuck

1) This type of chuck is used in mass production work for fast and effective gripping Capacity
2) The mechanism may has hydraulic or Pneumatic cylinder mounted on back of head stock spindle
3) air or hydraulic oil made to slide piston rod and made sliding unit to slide and tight in the work piece
12) explain a) Ball centre b) pipe centre c) Half centre d) revolving centre
a) Ball center: It is used to minimize wear and strain on ordinary centre while taper turning by tail
stock off set method
b) Pipe centre: It is used for supporting open end of pipes,shells,etc
c)Half Centre: It is used for facing operation
d) Revolving centre: It is used in Tail stock for holding heavy jobs at high speed
13) Write note on head stock
Ans: 1) The head stock is permanently secured on left side of the lathe machine
2) It is used to hold the workpiece
3) Head stock provides mechanical means of rotating the work at multiple speeds and mechanism
for driving and altering the spindle speed
III Answer the following question ( 8marks)

1 Draw a neat sketch of lathe.
2. Explain with neat sketch steady rest method.
Ans: 1) The steady rest may slide on the bed ways and clamped at desired position where support is
necessary
2) there are 3-jaw on steady rest two at the bottom and another at top
3) the work is adjusted at the center by adjusting these screws
4) the carriage cannot be fed to the full length of the work when the steady rest is used
3) Write the difference between turret lathe and Capstan lathe.

Turret lathe Capstan lathe
1) It is heavy duty semi-automatic It is light duty semi-automatic lathe
lathe
2) The turret head is mounted on The turret head is mounted on ram
saddle
3) Longer workpieces can be Only shorter workpieces can be machined
machined
4) This is suitable for heavy works This is suitable for machining small
workpieces
5) It is suitable for machining longer It is used for machining small job up to 60mm
and heavier work pieces up to dia
200mm dia
6) The saddle with turret head can be The ram with turret head can be moved small
moved over entire length distance
4) Write the difference between capstan lathe and engine lathe
Engine lathe Capstan lathe

1) Usually lower power motor is used 3 Power full motor is used 15 Horsepower
horsepower
2) Number of speed is less Wide range of speed is available
3) Only single tool post is available Front and rear tool post is available
4) Tailstock is available for holding Turret head is available
drill, reamer, tap, etc.
5) Only one tool can be held in tail No tail stock instead tail stock turret head is
stock available
6) Only one cut is taken Combination cuts are applied
7) Lathe stopped when tool is changed Lathe is not stopped when tool is indexed
8) Single piece production Mass piece production
5) Draw a neat sketch of 4-way tool post and explain.

Ans: this type of tool post can be accommodating four tools at a time for doing different
operations screw hold the tool independently and locking bolt is located at the center
The tool post is mounted on compound rest to hold the cutting tool for doing different
operation
6) Explain with a neat sketch lathe Bed.
Ans: Lathe bed:
1) It should be sufficiently rigid
2) It must be strong with sufficient depth and width to absorb vibration
3) The bed material should have high compression strength
4) The bed is seasoned and cooled after casting. The guide way of the lathe having inverted
v having angle 90 degrees.
5) The material used for manufacturing lathe bed is grey cast iron.
7 ) Draw a neat sketch of carriage.

The carriage has several parts to supports and control the cutting tool
It consists of the following parts
1) Saddle: the saddle is the H-shaped casting fits over the bed
2) The cross slide: the cross slide attached to saddle on compound rest and tool post
are located
3) The compound rest: this is mounted on top of the cross slide and has circular
graduated based in degrees .it is used for taper turning operation on the compound
rest tool post is mounted
4) Apron: The front part of carries below the saddle is known as apron.
8) Explain with neat sketch Collet chuck.
Ans:
1) The Collet chuck is used for holding bar stock in production work
2) The inside bore of collet may have cylindrical, hexagonal or square Etc.
3) After completion of work the job bar stock moved forward, stopped automatically and held by
collet.
4) This type of chuck mainly used in Capstan and Turret Lathe
9) Draw a neat Sketch of open side Tool post.
Ans:
Tool Post: The tool post is mounted on compound rest to hold the cutting tool for doing different
operation
Open side Tool post: 1) The tool post has central bolt for locking
2) 2 Independent screw for holding the cutting tool
3) The center height can be adjusted by using parallel below the cutting tool
10) Explain 3-jaw and 4-jaw chuck with neat sketch.
3-Jaw chuck.
1) In 3-jaw chuck all the jaws are made to slide simultaneously

3) It is also called as self-centering chuck
4) It can hold cylindrical or irregular work pieces
4-jaw chuck:
1) in 4-jaw chuck all the jaws are made to slide independently
2) it Consists of 4-Jaws
3) it is also called Independent chuck
4) It can hold round hexagonal workpieces
11) Draw a neat sketch of single screw Tool post.
Ans:
Single Screw Tool post:

1) This consists of round bar with slotted at the center for fixing the tool by means of screw
2) The tool post has convex rocker to adjust the height of tool post to of lathe center
3) The tool post can be swiveled about its vertical axis and tightened in the T-slots provided on
compound rest.
12) Explain with neat sketch Tail stock.

Ans:
1) The tail stock is located at right side of the lathe
2) Tail stock is slides over the bed
3) The tail stock is used for support the workpiece when machined between two centers
4) Tail stock is also used to hold the cutting tool for performing operations like
drilling,reaming,etc
5) The tail stock can be adjusted for different angles
13) write the factors for speed changing on lathe.
Ans: Factors for speed changing on lathe:
1) The type of material to be cut- Hard material like cast iron require slower speed than soft material
like brass or aluminium
2) Type of cutting tool material used- The spindle speed may be increased while using hard cutting
tool material like tungsten carbide,
3) The type of finish required- The finishing requires small depths while rough turning requires larger
depth of cut and slower speed
4) The type of cutting fluid used- Proper selection of coolant and lubricants permits high spindle speed
5) The rigidity and condition of machine: A new rigid machine can work at a higher speed than an old
and worn out machine
6) The diameter of work- The turning work of large diameter requires slow speed
7) The type of operation- operation like turning,boring, drilling requires higher spindle speed than that
required by thread cutting, tapping, reaming, parting off and knurling operation
14) Explain lathe centers.
Ans:
Lathe centers: The most Common method of holding work between center like live center and dead
center.
The lathe center are made of hardened material and has included angle of 60 degrees
1) ordinary centre: used for general purpose of work
2) Tipped centre: The point consist hard alloy tip brazed in to ordinary steel shank this has more wear
resistant
3) Ball centre: It is used to minimize wear and strain on ordinary centre
4) Half centre: it is usd for facing operation
5) Insert type center: This centers are economical as the insert centers worn out.it is replaced by other
instead of whole center replacing
6) Revolving center: it is used in tail stock for holding heavy jobs at high speed
7) pipe center: The pipe centre is used for supporting open end of pipes,shells etc.
15) Define mandrel. Write the types of mandrel,Explain with sketch any one.
Mandrel: mandrel is device used for machining hollow workpieces, which has drilled or bored hole
Different types of mandrel:
1) Plain mandrel
2) step mandrel
3) collar mandrel
4) screwed mandrel
5) cone mandrel
6) Gang mandrel
7) Expansion mandrel
1) Step mandrel: The step mandrel has different steps for holding different sizes of work pieces having
different diameters of holes without replacing mandrel every time.
This type of mandrel is suitable for turning collars,washers and odd sized job in workshop.
******
UNIT 10 & 11: TURNING TOOL GEOMETRY & TOOL HOLDER
PART-B
I. Answer the following 3 marks

1. Mention the different types of tool holders
Answer: Types of tool holders:
a. Tool holder for round or square tool bits for boring or internal thread cutting.
b. Tool holder for square tool bits.
c. Tool holder for parting-off tool bit.
2. Write the types of tool post?

Answer: The types of tool posts are
a. single way tool post
b. Four bolt tool post
c. Open side tool post
d. Four-way tool post
e. Quick change tool post
3. Why can relief or clearance angle never be zero or negative?

Ans: Relief angles are provided to prevent the end which is parallel to work and the side, which
is at the cutting edge, from rubbing on the work. If these are made zero or negative or even very
small, then these will wear down and rubbing starts. This will lead to heating up of tool, chatter
marks and marking up of smeared surface on the work. Thus relief or clearance angle can never be
zero or negative.
4. What are the factors influencing in the selection of cutting speeds and feeds for machining
operation?
Ans: Important factors influencing speeds and feeds for metal cutting are:
a. Machinability of work piece material
b. Material of cutting tool
c. Objective criteria i.e. whether cost or time or surface finish, are of priority
d. Cutting fluid used
5. What should be done to remove maximum material per minute with the same tool
life and at the same time keeping good finish?
Ans: the best method to increase material removal rate is to increase depth of cut, as tool life is least
affected by increase in depth of cut. If depth of cut is increased, speed needs to be decreased for
same tool life. However, depth of cut is also restricted by the strength of the work piece and amount
of stock to be removed. Increase in feed rate has smallest decrease in tool life in relation to the
increased metal removal rate. Increasing feed rate beyond finish requirements is not possible. Thus
increase in feed is best method, of course, within limits of allowable finish.
6. What do you mean by tool signature, Explain briefly?
Ans: The seven important elements comprise the signature of the cutting tool and are always
stated in the following order:
a. Back rake angle
b. Side rake angle
c. End relief angle
d. Side relief angle
e. End cutting edge angle
f. Side cutting edge angle
g. Nose radius
It is usual to omit the symbol for degrees and mm, simply listing the numerical value of each
component:
 A typical tool designation or signature is:
i. 10 – 6 – 6 – 8 – 90 – 1 mm
7. Mention the different cutting tool materials?
Ans: COMMONLY USED CUTTING TOOL MATERIALS:
a. Plain carbon steels d. Super high-speed steels

b. High-speed steels e. Cemented carbides
c. Ceramics f. Diamonds
8. Write a short note on diamond for cutting tools?

Ans:DIAMONDS FOR CUTTING:
Diamonds are used as turning tools grinding wheels, dressers, etc. They are considered to be
the hardest. They have high abrasion resistance. Their other characteristics are high strength, high
thermal conductivity and a high melting point. They are used in turning jobs which are usually difficult
to machine. Jobs be turned to get a high surface finish with close tolerance. They are used only for
finishing work with light cuts, fine feeds and high cutting speeds.
9. Draw a neat sketch of tool bit and tool holder for lathe and label the parts?
Ans:
10. Illustrate the positive, negative and zero rake angle with figure?
Ans:
11. Draw a neat sketch of tool holder for round, square tool bits for boring or internal thread cutting?
Ans:
12. Draw a neat sketch of tool holder for square tool bits?
Ans:
13. Draw a neat sketch of tool holder for parting – off tool bits?
Ans:
14. Draw a neat sketch of tool holder for carbide tipped tool bits?
Ans:
15. Draw a neat sketch of tool holder for diamond tool?

Ans:
16. List out the factors affecting tool life?
Ans: Following are the factors to be considered for tool life:
a. Cutting speed
b. Feed
c. Depth of cut
d. Tool geometry
e. Tool material
f. Cutting fluid
I. Answer the following 8 marks

1. List out the commonly used cutting tool materials & write their important characteristics?
Ans: Commonly used cutting tool materials are as follows:

d. Plain carbon steels d. Super high-speed steels
e. High-speed steels e. Cemented carbides
f. Ceramics f. Diamonds
Characteristics of an ideal cutting tool material
a. Toughness – Combination of strength and ductility to withstand shocks and vibrations to prevent
breakage.
b. Wear resistance – Capacity to withstand excessive wear.
c. Heat resistance – The tool should possess “red hardness’ or ‘hot hardness’.
This is the ability of steel to retain its hardness at high temperatures when being increased operational
temperatures.
d. Fractional co-efficiency – Fractional co-efficiency at chip tool interface should be low for minimum
wear.
The above four characteristics are essential for any cutting tool.
2. Draw a neat sketch of roughing tool, finishing tool & explain?

ROUGHING TOOL: A roughing tool has a larger side cutting edge angle, side relief angles
and end cutting edge angles for giving heavier cuts.
The main function of a rough turning tool is to
remove maximum amount of excess stock on a
work piece in minimum time.
FINISHING TOOL:Finishing tools are normally

knife edge tools. The cutting edge angle is absent in
this tool. The side rake angle is lesser when compared
to roughing tool. Also the nose radius provided is
minimum as the depth of cut given is less.
3. Draw a neat sketch of tool geometry nomenclature & explain their angles briefly?
Answer: Tool geometry nomenclature fig is as follows:
CLEARANCE: The intentional relief provided on the faces of the cutting tool to give a sharp cutting
edge and thereby preventing the other portions of the tool from rubbing the job is called as Clearance.
SIDE RELIEF ANGLE: This the angle between the portion of the side flank immediately below the
end side cutting edge and a line drawn through this cutting edge is perpendicular to the base. It is
usually measured in a plane at right angles to the side flank.
END RELIEF ANGLES: This is the angle between the portion of the end flank immediately below
the end cutting edge and a line drawn throughout that cutting edge is perpendicular to the base. It is
usually measured in a plane at right angles to the end flank.
SIDE CUTTING EDGE ANGLE: This is the angle between the side and the side of the tool shank or
holder.
END CUTTING EDGE ANGLE:
This is the angle between the cutting edge on the end of the end of the tool and a line at right angles to
the side of the tool shank.
RAKE ANGLE: The top face of the turning tool behind the cutting edge slopes downwards or
upwards from the cutting edge thereby giving a relief to the cutting edge. This slope it is called as a
Negative rake and if the slope is downwards from the cutting edge it is called Positive rake.
Rake angles have two functions:
a. It helps to give the cutting edge a relief thus reducing friction and allowing free cutting action.
b. It acts as a guide for the chips to clear away from the job thereby preventing clogging. Lathe tools
are provided with a side rake and a back rake.
SIDE RAKE: This is the angle between the face of the tool and the plane to the cutting edge, parallel
to the base of the shank or holder. Side rake is usually measured in a plane to the base and
perpendicular to the side cutting edge.
BACK RAKE: This is the angle between the face of the tool and the base of the shank or holder,
usually measured in a plane through the side cutting edge and at right angles to the base. The back rake
is positive if theface slopes downwards from the point towards the shank, tending to reduce the
included angle of the tool point. It is negative if the face slopes upwards towards the shank.
NOSE RADIUS: Nose radius is provided on a cutting tool to obtain a good finish on the job. Too
large a radius may cause chatter and a bad finish. Too small a radius may be weaken the cutting edge.
SIDE CUTTING EDGE ANGLE: This angle is provided where the cutting edge of the tool touches
the job. It safeguards the tools negative side and can be either positive or negative.
a) End cutting edge angle (25°)
b) Front clearance angle (6° - 8°)
c) Nose angle (65°)
d) Side rake angle (14°)
e) Side clearance angle (63°)
f) Plain angle (90°)
4. What are the advantages of providing side cutting edge angle on the cutting tools?
Ans: 1. Large side cutting edge angle decreases the chip thickness, measured perpendicular to the
cutting edge. Smaller chip thickness means less load on the tool and decreased wear. Or for keeping
the same loading and wear conditions, feed can be increased and thus production rate will be high.
2. Further if side cutting edge is more than zero, then the tool will first make contact at a point only
which will gradually keep on increasing, thus load comes gradually on the tool. Also the first
contact is at a position back of the point where the tool is quite strong. Due to gradual pick up of
load, it is especially advantageous when hard surface as of castings are to be machined. On the
other hand, a tool with side cutting edge angle of ‘0’ will pick up the full load on the first contact
resulting in a shock or impact loading and reduced tool life. Increasing side cutting edge angle too
much is also not desirable as it would result in increase of radial force which can bend the work and
cause chattering unless the work is stiff or well supported.
5. State the condition under which positive and negative rake angles are recommended?
Ans: following are the conditions under which positive and negative rake angles are recommended:
Positive rake angle:
a. When cutting at low cutting speeds
b. When machining long shafts of small diameters
c. When machining low strength ferrous and non-ferrous materials and work hardening materials.
d. When using low power machines
e. When the set up lacks strength and rigidity
Negative rake angle:
a. For rigid set ups and when cutting at high speeds
b. When machining high strength alloys
c. When there are heavy impact loads such as in interrupted machining
6. Explain plain carbon steel and high speed steel?
Ans: PLAIN CARBON STEELS:
Plain carbon tool steels are also called as carbon tool steels. These steels have only carbon and
iron with no appreciable amount of other alloying elements. The carbon content generally varies from
0.6-1.5%. Though carbon tool steels are easy to machine and they develop a good cutting edge, they
are not widely used due to their low red hardness. At temperatures above 200°C, these steels
permanently to there low red hardness. Therefore they are suitable only for applications involving
lower speeds and feeds and where high temperatures are not likely to develop.
HIGH SPEED STEEL (HSS):
When appreciable amounts of alloying elements like, Chromium, Magnesium, Vanadium,
Cobalt, Tungsten etc. are added to carbon steels, High-speed steels are obtained. As the name
indicates, H.S.S. is used for cutting at higher speeds and feeds. These steels can retain their cutting
edge hardness upto 6000°C.
Popularly used high-speed steels are tungsten based.
18-4-1 (Tungsten -chromium – Vanadium)
18-4-2 (Tungsten – chromium – Vanadium)
18-4-1-5 (Tungsten – chromium – Vanadium – Cobalt)
Molybdenum based :
6-5-4-2 (Tungsten – Molybdenum – Chromium – Vanadium)
7. Explain cemented carbide and ceramics?

Ans: CEMENTED CARBIDES:
These are manufactured by sintering. The powdered metals are compressed and sintered at a
temperature of approximately 1315°C. Cemented carbides are: harder than H.S.S., brittle, can be
worked at speeds upto two and half times more than H.S.S. Cemented carbides have excellent wear
resistance properties. Because of the high cost of this material they are made in the form of tips for
machining different materials and for different applications. Cemented carbides are mainly of three
types: Tungsten carbide, Titanium carbide and Tantalum carbide.
CERAMICS:
These are also known as “cemented oxide” tools. Fine grains of aluminum oxide are sintered together
into a dense structure to make ceramic cutting tools materials. Small amounts of titanium oxide,
chromium oxide or magnesium oxides are also added. They are sintered at 1650°C. These are next to
industrial diamonds in hardness and strength and can work with very high cutting speeds (nearly
600meters per minute). They resist abrasive wear, chipping and breakage. Lathes generally used in
machine shops and tool rooms are not provided with such high RPM to get the desired cutting speed to
use the ceramic tools. These tools need very rigid machines. Since they have poor thermal
conductivity they do not get heated up while cutting.
8. How single point cutting tools for lathe are classifieds?
Ans: single point lathe tools are classified under the following groups:
1. According to the method of manufacturing the tools:
1. Forged tool.
2. Tipped tool brazed to the carbon steel shank
3. Tipped tool fastened mechanically to the carbon steel
2. According to the method of holding the tool:
a. Solid tool b. Tool bit inserted in the tool post
3. According to the method of using the tool:
a. Turning f. Forming
b. Chamfering g. Boring
c. Thread cutting h. Internal threading
d. Facing i. Parting - off
e. Grooving
4. According to the method of applying feed:
a. Right – hand b. Left – hand c. Round nose
******
UNIT 11&12: TURNING OPERATIONS & TAPER TURNING METHODS
PART-A
1. Lathe is primarily used for producing Cylindrical surfaces.
2. Traversing of tool parallel to the axis of job is termed as Cross Feed
3. In tailstock offset method, the job is held at an angle and the tool moves Parallel to the axis.
4. In tailstock method, the angle at which the axis of rotation of the job is shifted is equal to Half the
angle of taper.
5. In tailstock method, body of the tailstock is made to slide on its base either away or towards from
the operation.
6. The taper turning attachment consists essentially of a frame which is attached to the Rear end of the
lathe bed.
7. In attachment method, cross-slide must be made freefrom the lead screw.
8. In attachment method, the angle of swivelling the guide bar can be determined from this equation,
tan of angle = (D-d) / 2L
9.Flattype of surface is produced in facing operation.
II. Multiple choice questions

1. Which machine tool is known as the mother machine tool?
a. Drill c. Milling
b. Lathe d. None of the mentioned
2. Lathe is primarily used for producing __surfaces.
a. Flat c. Curve
b. Taper d. None of the mentioned
3. Which type of surface is produced by turning operation in lathe machine?

a. Flat c. Cylindrical
b. Taper d. None of the mentioned
4. What is the necessary condition for turning?
a. Material of work piece should be harder than the cutting tool
b. Cutting tool should be harder than the material of work piece
c. Hardness of the cutting tool and material of of piece should be same
d. None of the mentioned
5. The swing diameter over the bed is the largest diameter
a. True
b. False
6. Lathe cannot produce internal features like holes.
a. True
b. False
7. Which type of feed is needed in facing operation?
a. Longitudinal c. Cross
b. Both cross and longitudinal d. None of the mentioned
8. Which type of surface is produced in facing operation?
a. Cylindrical c. Taper
b. Flat d. None of these
9. Traversing of tool at any angle to the job axis produces curve surfaces.
a. True
b. False.
10. In taper operation, which type of surface is produced?
ii. Flat iv. Curve
iii. circular v. None of the mentioned
11. Which type of feed is needed in turning operation?
a. Longitudinal c. Cross
b. Both cross and longitudinal d. None of the mentioned
12. In taper operation, which type of surface is produced?
a. Flat c. Curve
b. circular d. none of the mentioned
13. Which of the following is not the method of taper turning?
a. Compound rest method c. Tailstock offset method
b. Attachment method d. none of the mentioned
14. From tool method is used where accuracy is the major criterion.
a. True
b. False
15. From tool method is generally used for_____ production for producing_____ length of taper.
a. Mass, small c. Mass, long
b. Little, small d. Little, long
16. Tailstock method is highly suitable for producing steep tapers.
a. True
b. False
17. Attachment method can produce only small taper.
a. True
b. False
18. In compound slide method, which of the following is swivelled?
a. Top slide c. Swivel base
b. Apron d. None of the mentioned
19. In compound slide method, one part of compound rest is swivelled to_____ the included angle of
the taper.
a. The same as c. Half
b. Double d. None of the mentioned
20. In compound rest method, the amount of taper for setting the angle is calculated from this
formula, tan of angle of taper =_____
a. (D-d) / L c. (D-d) / 2L
b. (D-d) / 4L d. none of the mentioned
21. Which type of tapers can be produced by using compound rest method?
a. Internal c. External
b. Both internal and external d. none of the mentioned
22. Which of the following is not true for compound slide method?
a. Threads, which are there on taper portion cannot be produced
b. Steep taper cannot be produced
c. Taper length is limited to the movement of the top slide
d. None of the mentioned
23. In attachment method, the bar having graduations in degree is set at the_____ with the lathe axis.
a. 0 degree c. 90 degree
b. Any desired angle d. 180 degree
24. In compound slide method, taper length is limited to the movement of_____
a. Apron c. Swivel base
b. Top slide d. none of the mentioned
25. The taper can be turned up to maximum setting angle of_____ for both outside and inside tapers
with taper attachment and automatic feed.
a. 5 to 6 degree c. 1 to 2 degree
b. 10 to 12 degree d. none of the mentioned
26. Attachment method is most suitable for producing duplicate tapers.
a. True
b. False
27. Which of the following is not true for attachment method?
a. Lengthy tapers can be produced c. the alignment of the lathe centre is
disturbed
b. Power feed can be given d. none of the mentioned
28. For lathe operations, work piece can be hold _____
a. Between centres c. on mandrel
b. Either between centres or on mandrel d. none of the mentioned
29. Which of the following is used to drive the work piece?
a. Carriers c. catch plates
b. Both carriers and catch plates d. none of the mentioned
30. Drilling is performed by holding the work by a chuck.

a. True
b. false
31. Knurling can be performed by special attachments.
a. True
b. false
32. Grinding can be performed by______
a. Using faceplates or angle plates c. using chucks
b. Special attachments d. none of the mentioned
33. Taper boring and the under boring can be performed by______
a. Centres c. face plates or angle plates
34. Milling can be performed by _____
a. Centres c. face plates or angel plates
b. Chucks d. special attachments
35. Spinning can be done by_____
a. Centres c. face plates or angle plates
36. Reaming and counter boring can be performed by______
a. Centres c. face plates and angle plates
37. Eccentric turning can be performed by using special attachments.
a. True
b. False
III. Write short answers 2 marks

1. What is centring operations?
Ans: Centring is a cutting operation with primarily double-edged tool (centre drill) but also with single-
edged tool (turning tool). It is used prior to other cutting operations, such as turning between centres,
taper turning, drilling and grinding.
2. What is reaming?
Ans: A reamer is a type of rotary cutting tool used in metalworking. Precision reamers are designed to
enlarge the size of a previously formed hole by a small amount but with a high degree of accuracy to
leave smooth sides. There are also non-precision reamers which are used for more basic enlargement of
holes or for removing burrs. The process of enlarging the hole is called reaming.
3. What is facing?
Ans: Facing is machining the ends and shoulders of a piece of stock smooth. flat, and perpendicular to
the lathe axis. Facing is used to cut work to the desired length and to produce a surface from which
accurate measurements may be taken.
4. What is plane turning?

Ans: Plain turning is the operation of removing excess amount of material from the surface of a
cylindrical job.
5. What is tapping?
Ans: Tapping is the process of cutting a thread inside a hole so that a cap screw or bolt can be threaded
into the hole. Also, it is used to make thread on nuts. Tapping can be done on the lathe by power feed
or by hand.
6. Where roughing tool s are used.

Ans:Roughing operation/tool is used to remove large amounts of material rapidly and to produce a part
geometry close to the desired shape.
7. What is clapper box?
Ans:A hinged part on the tool head of a reciprocating machine (as a planer or shaper) that permits the
tool to clear the work piece on the return stroke.
8. What is the function of lathe chuck?
Ans:A lathe chuck is mounted on the headstock of a lathe and can be actuated manually or under
power. Typically, it is used to hold a rotating work piece, such as a bar, and some can also hold
irregularly shaped objects that lack radial symmetry.
9. List out types of lathe dogs used in lathe.

Ans:
a. Straight Tail Lathe Dog
b. Bent Tail Lathe Dog
c. Clamp type Lathe Dog
d. Safety clamp type Lathe Dog
e. Straight Tail Lathe Dog
10. What is taper turning in lathe?

Ans:Taper turning is a machining operation is the gradual reduction in diameter from one part of a
cylindrical work piece to another part. Tapers can be either external or internal.
11. How tapping done on lathe?

Ans:Tapping is the process of cutting a thread inside a hole so that a cap screw or bolt can be threaded
into the hole. Also, it is used to make thread on nuts. Tapping can be done on the lathe by power feed
or by hand.
12. What is mandrel?

Ans:A flanged or tapered or threaded bar that grips a work piece to be machined in a lathe. In addition
to lathes, arbores are used to hold buffing wheels, circular saws, and sanding discs. Typically, these
mandrels consist of a cylinder that is threaded on one end.
13. Where finishing tools are used.

Ans:A finishing operation/tool follows roughing and is used to achieve the final geometry and surface
finish.
PART-B
I. Answer the following 3 Marks
1. Explain types of boring?
(a) Counter boring:
it is an operation of enlarging a previously drilled hole to a particular depth and is generally employed
for the seating of socket screw heads
(b) Taper boring:
is usually done with either the. Generally used for transmitting motion, such as. Compound rest or the
taper attachment. The rules that. Between the lead screw and lathe carriage.
2. Difference between Drilling and Reaming?

Drilling:
For making a standard size of hole in a work piece by means of drill is known as drilling operation. For
this operation, drill is held in tail stock spindle.
Reaming:
It is the operation of finishing a drilled hole to an accurate dimension with the help of reamer as a tool.
The reamer is held on the tail stock spindle.
e. Calculate the machining time for complete cut on work piece 250 mm long and 35
mm diameter the cutting speed is equal to 20 m/min feed is 0.25 m/rev.
f. What is thread cutting?
Thread cutting on the lathe is a process that produces a helical ridge of uniform section on the work
piece. This is performed by taking successive cuts with a threading tool bit the same shape as the
thread form required.
g. What is eccentric turning?
Eccentric turning on a lathe refers to the turning off the centre or not on the normal centre axis, it
can be done on 3 jaw self-centring chuck or 4 jaw chuck in different situations, the 4 jaw chuck
with independently moved jaws allows parts to be moved off-centre. The outer circle of the
eccentric parts is parallel to the axis of the inner hole or outer circle without overlapping. In
mechanical transmission, rotary motion to reciprocating linear motion or reciprocating linear
motion to rotary motion is generally accomplished with an eccentric component, like the engine
crankshaft in the automobile.
h. Write the formula for taper turning.
i. What is taper turning?

It is defined as when the diameter of a piece changes uniformly, from one end to the other, the piece is
said to be tapered. Taper turning as a machining operation is the gradual reduction in diameter from one
part of a cylindrical work piece to another part. Tapers can be either external or internal.
j. What is turning tool and list their types.
Turning tools are used on lathes for cutting or finishing the outside diameter of a work piece.
Turning tools can be used to produce cylindrical parts. In its basic form, turning can be defined as
the machining of an external surface with the work piece rotating, or with a single-point cutting
tool.
Types: •spindle gouge
•roughing gouge
• Oval skew chisel
• Round nose scraper
• parting tool
• hollowing tool
• Bowl gouge
k. List the different types of mandrels.

Types of mandrels are:
• Plain Mandrel.
• Step Mandrel.
• Gang Mandrel.
• Collar Mandrel.
• Screwed Mandrel.
• Cone Mandrel.
• Expansion Mandrel.
l. Write about steady rest.
Steady rest: A rest in a lathe or grinding machine in which long round pieces of work may rotate
but without eccentric movement. It is also called as centre rest.
m. Mention the different methods of taper turning.

a. Form tool method
b. Tail-stock set over method
c. Compound rest method
d. Taper turning attachment method
n. Write aboutfollower rest.
a. A tool rest that travels with the slide rest of a lathe.
b. A rest that is fixed as to position relative to a grinding wheel and used for supporting cylindrical
work.
II. Answer the following 5 Marks

1. What are the general operations carried out in lathe?
(a) Turning
(b) Facing
(c) Parting off
(d) Knurling
(e) Thread cutting
(f) Grooving
(g) Drilling
(h) Boring
(i) Reaming
(j)Chamfering
2. Explain facing operations with a neat sketch?

Ans-This is usually the first step of any lathe operation on the lathe machine. The metal is cut from the
end to make it fit in the right angle of the axis and remove the marks.
3. What is chamfering? Explain with neat sketch?

Chamfering is an essential operation after thread cutting so that the nut may pass freely on the threaded
work piece. It removes the burrs and sharp edges, and thus makes the handling safe. Chamfering can be
done by a form tool having an angle equal to chamfer which is generally kept at 45°.
Attachments area
4. Explain knurling operations with a neat sketch?
Ans: The knurling is a process of embossing (impressing) a diamond-shaped or straight-line pattern
into the surface of work piece. Knurling is essentially a roughening of the surface and is done to
provide a better gripping surface.
5. Explain Eccentric turning? With neat sketch.

Ans: Eccentric turning on a lathe refers to the turning off the centre or not on the normal centre axis, it
can be done on 3 jaw self-centring chuck or 4 jaw chuck in different situations, the 4 jaw chuck with
independently moved jaws allows parts to be moved off-centre. The outer circle of the eccentric parts
is parallel to the axis of the inner hole or outer circle without overlapping. In mechanical transmission,
rotary motion to reciprocating linear motion or reciprocating linear motion to rotary motion is generally
accomplished with an eccentric component, like the engine crankshaft in the automobile.
6. Explain boring with neat sketch?
Ans: Boring is the operation of enlarging a drilled hole by means of a boring tool. The boring tool is
fitted on a boring bar which is held in tail stock spindle
7. Explain thread cutting with neat sketch?

Ans: Threading is the act of cutting of the required form of threads on the internal or external
cylindrical surfaces.
Threading is the process of creating a screw thread. More screw threads are produced each year than
any other machine element.
8. Explain tailstock with a neat sketch?
Ans: Tailstock used for drilling
A tailstock also known as a foot stock, is a device often used as part of an engineering lathe, wood-
turning lathe, or used in conjunction with a rotary table on a milling machine.
It is usually used to apply support to the longitudinal rotary axis of a work piece being machined. A
lathe centre is mounted in the tailstock, and inserted against the sides of a hole in the centre of the work
piece. A tailstock has a Dead Centre, while headstock has Live Centre. A Tailstock is particularly
useful when the work piece is relatively long and slender. Failing to use a tailstock can cause "chatter,"
where the work piece bends excessively while being cut.
9. Different between Grinding and Taping?

i) Grinding is a metal finishing process. Grinding is usually followed after all metal cutting operations
are done by a smoother finish to the components.
ii) Tapping is a combination of Ancient Chinese Acupressure and Modern Psychology that works to
physically alter your brain, energy system, and body all at once. The practice consists of tapping with
your fingertips on specific meridian points while talking through traumatic memories and a wide range
of emotions.
10. Calculate the set over for taper turning. major dia= 35mm, minor diameter = 33 mm
length of taper = 150 mm
Given data:
here L= Length of work piece= l = Length of taper=150mm
D= Large diameter =35mm d= Small diameter=33mm
Therefore:- Off set, h =(D – d) L/2 l
h=((35-33)*150)/(2*150)
h=1mm
III. Answer the Questions 8 Marks

1. What is taper turning? Explain taper turning methods with a neat sketch?
Taper turning: When the diameter of a piece changes uniformly from one end to the other, the piece is
said to be tapered. Taper turning as a machining operation is the gradual reduction in diameter from one
part of a cylindrical work piece to another part. Tapers can be either external or internal.
It is one of the simplest methods used to produce short taper. A broad nose tool having straight cutting
edge is set on to the work at half taper angle and is fed straight into the work. It requires excessive
cutting pressure which may distort the work piece due to vibration
The following are the methods to find the taper angle
FORM TOOL METHOD:
This is one of the simplest methods to produce short taper. This method is shown in the figure. To the
required angle the form is grounded. The tool is fed perpendicular to the lathe axis, when the work
piece rotates.The tool cutting edge length must be greater than the taper length. Since the entire cutting
edge removes the metal, it will produce a lot of vibration and hence a large force is required. It is done
in slow speed.
TAPER TURNING ATTACHMENT METHOD:
The taper attachment is used for turning and boring tapers. It is bolted to the back of the carriage
saddle. In operation, it is connected to the cross-slide so that it moves the cross-slide laterally as the
carriage moves longitudinally. This action causes the cutting tool to move at an angle to the axis of the
work piece to produce a taper. The angle of the desired taper is set on the guide bar of the attachment,
and the guide bar support is clamped to the lathe bed. Since the cross-slide is connected to a shoe that
slides on this guide bar, the tool follows along a line that connected to the cross-slide so that it moves
the cross-slide laterally as the carriage moves longitudinally. This action causes the cutting tool parallel
to the guide bar and hence at an angle to the work piece axis corresponding to the desired taper.
COMPOUND REST METHOD:

The compound rest is generally used for turning or boring short steep tapers, but it can also be used for
longer, gradual tapers, providing the length of the taper does not exceed the distance the compound rest
will move upon its slide. This method can be used with a high degree of accuracy, but is somewhat
limited due to the lack of an automatic feed and the length of the taper being restricted to the movement
of the slide. The compound rest base is graduated in degrees and can be set at the required angle for
taper turning or boring. With this method, it is necessary to know the included angle of the taper to be
machined. An included angle is formed by and between two intersecting straight lines.)
The angle of the taper with the centreline is one-half the included angle and will be the angle that the
compound rest is set for. For example: To true up a lathe centre which has an included angle of 60 0 ,
the compound rest would be set at 300from parallel to the ways If the taper is given in taper inches per
foot, the angle for the compound rest setting will have to be computed or taken from an appropriate
taper sizes and angles table.
TAILSTOCK OFF SET METHOD:

The tailstock offset method is generally used to cut a taper when no taper attachment is available. This
involves moving the tailstock centre out-of-line with the headstock centre. However, the amount that
the tailstock may be offset is limited. This method will not permit steep tapers to be turned or standard
tapers to be turned on the end of a long piece of work. Since the work will be essentially at an angle it
will need to be machined between centres. Thus, a chuck or collet cannot be used to hold the work
piece. Great care must be exercised in setting the tailstock back to centre when the taper turning
operation is completed.
2. Explain taper turning? Mention the different methods of taper turning?
Ans : SAME AS ABOVE
3. Explain with neat sketch tail stock off set method?

Ans: TAILSTOCK OFF SET METHOD:
The tailstock offset method is generally used to cut a taper when no taper attachment is available. This
involves moving the tailstock centre out-of-line with the headstock centre. However, the amount that
the tailstock may be offset is limited. This method will not permit steep tapers to be turned or standard
tapers to be turned on the end of a long piece of work. Since the work will be essentially at an angle it
will need to be machined between centres. Thus, a chuck or collet cannot be used to hold the work
piece. Great care must be exercised in setting the tailstock back to centre when the taper turning
operation is completed.
4. Explain facing operation with neat sketch.
Ans. This is usually the first step of any lathe operation on the lathe machine. The metal is cut from
the end to make it fit in the right angle of the axis and remove the marks.
Facing is the process of removing metal from the end of a work piece to produce a flat surface.
Most often, the work piece is cylindrical, but using a 4-jaw chuck you can face rectangular or odd-
shaped work to form cubes and other non-cylindrical shapes.
5. Draw a neat sketch of turning tool and explain the following angles i) top rake ii) front clearance iii)
side clearance iv) side rake. v) Side cutting edge
Top rake:
Rake angle is a parameter used in various cutting and machining processes, describing the angle of the
cutting face relative to the work. There are three types of rake angles: positive, zero or neutral, and
negative.
Front clearance:
Clearance angle is the angle of orientation of tool’s principal flank surface from the cutting velocity
vector and measured on some other plane. Sometime, instead of using cutting velocity vector, cutting
plane is used in definition as cutting plane itself contains cutting velocity vector.
Side Rake:
This is the angle between the face of the tool and the plane to the cutting edge, parallel to the shank or
holder. Side rake is usually measured in a plane to the base and perpendicular to the side cutting edge
Side cutting edge:
This angle is provided where the cutting edge of the tool touches the job. It safeguards the tools
negative side and can be either a positive or negative.
6. Calculate the machine time for one complete cut on work piece 300 mm long and 35 mm diameter.
The cutting speed = 22 m/ min and speed is 0.25 mm/rev
Given data:
L=300mm D=35mm N=? V=22mtrs/min
Feed f=0.25 mm/rev Machine time (Tm)=?
πDN
Cutting speed (V),V=
1000
22=π*35*N/1000
22000
N=
π∗35
N=200.08rpm
Machine time(Tm),Tm=L/f*N
Tm=300/(0.25*200.08)
Tm=5.9976min
7. Write a short note on taper turning attachment.

Taper Turning Attachment is very much popular and fits on all lathe machines. In ordinary straight
turning, the cutting tool moves along a line parallel to the axis of the work, causing the finished job to
be the same diameter throughout.
The taper attachment is used for turning and boring tapers. It is bolted to the back of the carriage
saddle. In operation, it is connected to the cross-slide so that it moves the cross-slide laterally as the
carriage moves longitudinally. This action causes the cutting tool to move at an angle to the axis of the
work piece to produce a taper. The angle of the desired taper is set on the guide bar of the attachment,
and the guide bar support is clamped to the lathe bed. Since the cross-slide is connected to a shoe that
slides on this guide bar, the tool follows along a line that is. Parallel to the guide bar and hence at an
angle to the work piece axis corresponding to the desired taper.
When the diameter of a piece changes uniformly, from one end to the other, the piece is said to be
tapered. Taper turning as a machining operation is the gradual reduction in diameter from one part of a
cylindrical work piece to another part. Tapers can be either external or internal. If a work piece is
tapered on the outside, it has an external taper; if it is tapered on the inside, it has an internal taper.
TAPER TURNING ATTACHMENT ADVANTAGES:

 Fast and consistent accuracy up to 300 mm Taper Turning job
 It’s useful in threading on the work piece inside as well as outside.
 Any length of the work piece can be tuned.
 At the set, the position accessory can be left.
 With taper turning, we can easily do narrow boring.
8. Explain with a neat sketch thread cutting operation and lead screw?
Thread cutting on the lathe is a process that produces a helical ridge of uniform section on the
work piece. This is performed by taking successive cuts with a threading tool bit the same shape as
the thread form required
.
Lead screw:
The most commonly used of the three terms, “lead screw” simply refers to a type of power screw
that relies on sliding motion between the nut and the screw shaft. ... Lead screws can have either
square or trapezoidal threads.
******
UNIT 13&14: THREAD CUTTING & CUTTING SPEED

1. -----------is the formula of cutting speed for lathe
πdn
Ans: …. m/min
1000
2. The distance consecutive threads is known as..,...........
Ans: Pitch
3. The angle of metric thread is..............
Ans: 60º
4. The standard pitch of M10 tap is...............
Ans: 1.5mm
5. Turning tool is made from...............
Ans:HSS
6. The top of tool nose should be set at the............ height as the center of the work piece.
Ans:- Same
7. The speed of the spindle by.............. to one - fourth of the turning speed required for thread
cutting.
Ans:-one half
8. A............. groove has produced up to the end of the work is quickly with drown by use of the
cross slide.
Ans:-Helical
9. The................ is special attachment used in modern lathes for accurate picking up of thread.
Ans:-Chasing dial
10. A vertical shaft with a.............. gear engaged with the lead screw.
Ans:-Worm
11. A.................. chaser is multipoint threading tool.
Ans:-Thread
12. The................ screw of a lathe is always single started.
Ans:- Lead
13. A................... turning attachment is used to produce an accurate thread.

Ans:- Taper
14. For feed motion, split nut has to be_____
Ans:- Either Opened or Closed

15. In thread chasing dial, the half nut is_____ when any live on the dial coincides with a reference
live already set.
Ans:- Closed
16. In chasing dial, dial rotate as long as the half nut is_____
Ans:- Not engaged
17. The chasing dial is mounted on the right end of the _____
Ans:- Apron
18. The lead screw obtains_____ motion from the working spindle.
Ans:- Rotary
19. The split is mounted in the_____ of the carriage.
Ans:- Apron
20. In thread cutting, the _____ feeds should be equal to the pitch of the thread, which is to be cut
per revolution of the work piece.
Ans:- Longitudinal feed
II. Multiple choice:

1. Which tool is used in a lathe machine
a. Multipoint cutting tool c. Drill
b. Saw tooth cutting tool d. single point cutting tool
Ans: d single point cutting tool
2. Formula for finding cutting speed in lathe is
πdn D−d
a. c.
1000 2l
D−d L
b. πr2h d. X
2 l
Ans: A
3. During turning operation the tool moves
a. Parallel to the axis of lathe c. Perpendicular to the axis of lathe
b. At an angles to the axis of machine d. None of the above
Ans: A Parallel to the axis of lathe
4. The main function of removing maximum amount of metal in work piece is for
a. Finish turning tool b. Rough turning tool
c. Forming tool d. Shoulder turning tool
Ans: b Rough turning tool
5. Turning tool is made from
a. HSS c. Mild steel
b. Copper d. Cast iron
Ans:A HSS
6. In turning, the depth of cut which usually varies from

a.0.01 to 0.1 mm c. 0.02 to 0.1 mm
b. 0.05 to 0.2 mm d. 0.06 to 0.3 mm
Ans:- B 0.05 to 0.20 mm
7. Which method is very tedious and requires considerable time

a. Marking the lathe parts c. Using a thread indicator
b. Reversing the machine d. None of this
Ans:- b Reversing the machine
8. Thread chasing is done at 1/3 to 1/2 of the speed of
a. Turning c. Milling
b. Grinding d. Shaping
Ans:-A turning
9. When there is a movement of more than one thread the screw is called
a. Single threaded screw c. Double threaded screw
b. Multiple threaded screw d. None of this
Ans:- b Multiple threaded screw
10. The lead screw of a lathe is always
a. Zero c. Single started
b. Double started d. Multiple started
Ans:- c Single started
11. The lead screw obtains_____ motion from the working spindle.
a) rotary c) both rotary and transmitting
b) transmitting d) none of the mentioned
Ans: a rotary
12. The _____ motion is converted into_____ motion of the tool slide
in thread cutting.
a) rotary, feed c) transmitting, longitudinal
b) feed, rotary d) none of the mentioned
Ans: a rotary feed
13. The split is mounted in the_____ of the carriage.

a) saddle c) top slide
b) apron d) cross slide
Ans: b apron
14. In thread cutting, which type of feed motion is possible?

a) engaging c) either engaging or disengaging
b) disengaging d) none of the mentioned
Ans: c either engaging or disengaging
15. In thread cutting, the _____ feeds should be equal to the pitch of the thread, which is to be cut per
revolution of the work piece.
a) cross feed c) angular feed
b) longitudinal feed d) none of the mentioned
Ans: b longitudinal feed
16. In thread cutting, which of the following receives traversing motion from the lead screw of the
lathe?
a) apron c) cross slide
b) top slide d) none of the mentioned
Ans: d none of the mentioned
17. In thread cutting, definite ratio is calculated between the_____ feed and rotation of the_____
spindle.
a) longitudinal, headstock c) cross, tailstock
b) cross, headstock d) longitudinal, tailstock
Ans: A longitudinal, headstock
18. Which of the following is not true for thread cutting?
a) tool post is driven by lead screw axially against the work piece
b) the lead screw has a trapezoidal thread
c) the relative type of speeds of rotation of the work and the lead screw can result in the
cutting of a screw of the desired pitch
Ans: d none of the mentioned
19. In thread chasing dial, the half nut is_____ when any live on the dial coincides with a reference live
already set.
a) opened c) partially opened and partially closed
b) closed d) none of the mentioned
Ans: b closed
20. In thread chasing dial, half nut is closed when any numbered live coincides with reference live
for_____ thread.
a) even c) can’t say anything
b) odd d) none of the mentioned
Ans: b odd
III. Answer the following. 2 marks

1. Define single threaded screw.
For one complete turn round the screw when there is movement of one thread the screwis called
single threaded screw
2. Define multiple threaded screw.
Whenthereisamovementofmorethanonethreadthescrewiscalled multiple threaded screw.
3. What is a thread chaser?
A thread chaseris multipoint threadingtool having thesame form and pitch of the thread to be
chased.
4. List any two methods of picking of a thread.

The methods of picking up a thread are listed below
a. Reversing the machine
b. Marking the lathe parts
5. Define cutting speed.
The cutting speed (v) of a tool is the speed at which the metal is removed by the tool from the work
piece
6. Write the cutting speed formula.
πdn
Formula : V= …. m/min
1000
7. What is cutting tapered thread.

The surface is first turned taper to the required angle is known as cutting tapered thread.
8. What are the different drives used in copying lathe?
a) Mechanical drives
b) Air drives
c) Hydraulic drives
9. What is pitch?
The distance between consecutive threads is known as pitch
10. What is the lead of a thread?

Lead is the axial advance of a helix or screw during one complete turn (360°). The lead for a screw
thread is the axial travel for a single revolution.
11. What is internal threading?

A screw thread on an inner or concave surface is called internal thread.
12. What is external threading?

A screw thread on an outer or convex surface is called external thread.
13. Define right hand thread cutting.

When cutting a right-hand thread the carriage must move towards the head stock.
14. Define left-hand thread cutting.

When cutting a left-hand thread the carriage moves away from the head stock and towards the
tailstock.
15. What is metric thread pitch?

In international standard ISO 68-1. Each thread is characterized by its major diameter, and its pitch.
ISO metric threads consist of a symmetric V-shaped thread.
16. What is the screw pitch?

A thread gauge, also known as a screw pitch gauge or pitch gauge, is used to measure the pitch or
lead of a screw thread.
17. Define lead screw?

lead screw is a long threaded soft used as a master screw, and is brought into operation only when
the threads have to be cut in all other times the lead screw is disengaged from the gear box and
remains stationery.
18. How internal threads are formed?
Internal thread are formed using an unscrewing mechanism within the tooling
19. What is the depth of thread?
The distance between the crest and the base of a screw thread measured radially.
20. List out any two types of turning tool.

a. Rough turning tool
b. Finish turning tool
Part B
IV. Answer the following. 3 marks

1. Define cutting speed in turning operation?
Ans: the cutting speed (v) of a tool is the speed at which the metal is removed by the tool from the work
piece
πdn
Formula : V= …. m/min
1000
2. Write the short note of thread chaser.
Ans:- A thread chaser is multipoint threading tool having the same form and pitch of the thread to
be chased. It is used to finish a partly cut thread to the size and shape required.
3. Write the short note of lead screw.

Ans:- The lead screw is a long threaded soft used as a master screw, and is brought into operation only
when the threads have to be cut in all other times the lead screw is disengaged from the gear box and
remains stationery.
4. What is thread cutting operation?
Ans:-Thread cutting is one of the most important operations performed in lathe different standard forms
and proportions of screw threads have been described.
5. What is necessity of using coolant in turning?

Ans:- The critical function of coolant in the machining process include reducing and removing the
head build up in the cutting zone and work piece.
6. What is tapered thread cutting?

The surface is first turned taper to the required angle is known as tapered thread cutting.
7. List any two methods of picking of a thread.

The methods of picking up a thread are listed below
Reversing the machine
Marking the lathe parts
8. What is the screw pitch?
A thread gauge, also known as a screw pitch gauge or pitch gauge, is used to measure the pitch or lead
of a screw thread. The uppermost gauge in the image is an ISO metric pitch gauge, the larger gauge in
the centre is for measuring the Acme thread form, and the lower gauge is for Whitworth screws.
9. How can you measure the pitch of a thread?

Metric fasteners are specified with a thread pitch instead of a thread count. The thread pitch is the
distance between threads expressed in millimetres (measured along the length of the fastener). For
example a thread pitch of 1.5 means that the distance between one thread and the next is 1.5mm.
10. The pitch of a lead screw is 6 mm. and the pitch of the thread to be cut is 1 mm. Find change gears.
Driverteeth Pitchofthework
=
Driventeeth Pitchoftheleadscrew
1 1 X 20 20 Driverteeth
= = or
6 6 X 20 120 Driventeeth
The driver will have 20 T and the driven gear on the lead screw 120 T
11. What is thread cutting operation?

Thread cutting is one of the most important operations performed in lathe different standard forms and
proportions of screw threads have been described.
12. List the types of thread
V-thread
Square thread
Butter thread
Acme thread
Knuckle thread
13. What are the different drives used in copying lathe?

Mechanical drives
Air drives
Hydraulic drives
14. Define right and left hand thread cutting.
When cutting a right-hand thread the carriage must move towards the head stock, for a left-hand thread
the carriage moves away from the head stock and towards the tailstock.
15. What is internal and external thread cutting?

A screw thread on an inner or concave surface is called internal thread.
A screw thread on an outer or convex surface is called external thread
16. Write a short note on thread indicator.

It is a special attachment used in modern lathes for accurate picking up of the thread. This dial indicates
when to close the split nuts.
17. A steel shaft of 35 mm diameter is turned at a cutting speed of 22 m/ min. Find the right r.p.m. of
the shaft.
Given data:
D=35 mm
C.S (V)= 22 m/min
N=?
πdn
V= …. m/min
1000
1000 XV
n=
πd
1000 X 22
n=
πX 35
n= 200 rpm
18. Define tumbler gears?

Tumbler gears are used to give the desired direction of movement to the lathe
carriage, via lead screw or the feed shaft.
The tumbler gearing comprises of two Pinions mounted on a bracket..
19. What are change gears?
The train of gears through which the motion is transmitted from the stud shaft to the lead screw is
called change gears.
20. What is single threaded screw?
For one complete turn round the screw when there is movement of one thread the screw is called single
threaded screw.
V.Answer the following. 5 marks

1. 1. A steel shaft of 25 mm diameter is turned at a cutting speed of50 m/ min. Find the r.p.m of
the shaft.
Given data:
D=25 mm
C.S (V)= 50 m/min
N=?
πdn
V= …. m/min
1000
1000 xV
n=
πd
1000 x 50
n=
πx 25
n= 636.94 rpm
2. Explain the necessity of using coolant in turning
Ans: The critical function of coolant in the machining process include reducing and removing the
head build up in the cutting zone and work piece.
Provides lubrication to reduce friction between the tool and removal of chips.
3. Explain cutting tapered thread in turning.

Ans:-
 The surface is first turned taper to the required angle is known as cutting tapered thread.
 By any one of the taper turning methods described before.
 The thread cutting tool is then set perpendicular to the lathe axis.
 To produce an accurate thread a taper turning attachment is used.
 This is swiveled to be the half taper angle.
4. Calculate the change gears to cut a 3- start thread having a pitch of 1.5 mm, the lead screw has a
pitch of 6 mm.
Ans:- lead of the work =Pitch X no. of starts = 3 X 1.5 = 4.5mm
Driverteeth Leadofthework
=
Driverteeth 4.5 45
= =
Driventeeth 6 60
5. Explain the steps in checking a screw cutting set up.

Ans:-
 The gear train; this must be correct for the thread to be cut.
 The tumbler gears must give the carriage the movement in the right direction
 The slide must be so adjusted that vibration is avoided.
 The tool and all portions of the machine should be clear of any rotating mass.
 The feed shaft must be disengaged.
6. The pitch of a lead screw is 6 mm. and the pitch of the thread to be cut is 1 mm. Find change
gears.
Ans:- =
1 1 X 20 20 Dr iverteeth
= = or
6 6 X 20 120 Driventeeth
The driver will have 20 T and the driven gear on the lead screw 120 T.
7. The pitch of a lead screw is 6mm.and the pitch of the thread to be cut is 1.25 mm. Find the
change wheels.
Ans:- =
Driverteeth 1.25 1.25 X 4 5 5 1
= = = = X
Driventeeth 6 6X4 24 4 6
5 X 10 1 X 20 50 20
= X = X
4 X 10 6 X 20 40 120
The driving gears will have 50 and 20 T and driven gears 40 and 120T.
8. Explain with a neat sketch of thread chaser.

 A thread chaser is multipoint threading tool having the same form and pitch of the
thread to be chased.
 A chaser is used to finish a partly cut thread to the size and shape required.
 Thread chasing is done at 1/3 to 1/2 of the speed of turning
9. A steel shaft of 50 mm diameter is turned at a cutting speed of 35 m/ min. Find the right r.p.m.
of the shaft
Given data:
D=50 mm
C.S (V)= 35 m/min
N=?
πdn
V= …. m/min
1000
1000 XV
n=
πd
1000 X 35
n=
πX 50
n= 223 rpm
of the shaft
Given data:
D=40 mm
C.S (V)= 30 m/min
N=?
πdn
V= …. m/min
1000
1000 XV
n=
πd
1000 X 30
n=
πX 40
n= 238 rpm
of the shaft
Given data:
D= 32 mm
C.S (V) =22 m/min
N=?
πdn
V= …. m/min
1000
1000 XV
n=
πd
1000 X 22
n=
πX 32
n= 218rpm
of the shaft
Given data:
D = 32 mm
C.S (V) = 50 m/min
N=?
πdn
V= …. m/min
1000
1000 XV
n=
πd
1000 X 50
n=
πX 32
n= 497rpm
of the shaft
Given data:
D=25 mm
C.S (V)= 35 m/min
N=?
πdn
V= …. m/min
1000
1000 XV
n=
πd
1000 X 35
n=
πX 25
n= 445 rpm
14. Name the different method of using the cutting tools in turning.
Ans:-
 Turning tool
o Finishing tool
o Roughing tool
 Chamfering tool
 Threading tool
 Facing tool
 Grooving tool
 Forming tool
 Boring tool
 Internal thread cutting tool
 Parting-off tool
15. Explain tumbler gears?

Tumblergearsareusedtogivethedesireddirectionofmovementtothelathe carriage, via lead
screw or the feed shaft.
The tumbler gearing comprises of two Pinions mounted on a bracket.
The bracket is pivoted about the 1 st stud shaft.
The design provides three positions of the bracket.
II. Answer the following. 8 marks

1. Explain thread cutting operation and lead screw.
Thread cutting is one of the most important operations performed in lathe different standard
forms and proportions of screw threads have been described.
The principle of thread cutting is to produce a helical groove on a cylindrical or conical surface
by feeding the tool longitudinally when the job is revolved between the centres or by a chuck.
The longitudinal feed should be equal to pitch of the thread to be cut per revolutions of the work
piece. The lead screw of the lathe, though which the saddle receives its traversing motion, has a
definite pitch.
Lead screw: the lead screw is a long threaded soft used as a master screw, and is brought into
operation only when the threads have to be cut in all other times the lead screw is disengaged
from the gear box and remains stationery. But these may be used to provide motion per turning,
boring, etc. In lathes that are not equipped with a feed rod.
2. Draw the Threading tool nomenclature.
3. List out Classification of turning tools

According to the method of manufacturing the tool:
a. Forged tool.
b. Tipped tool brazed to the carbon steel shank.
c. Tipped tool fastened mechanically to the carbon steel shank
According to the method of holding the tool:

a. Solid tool
b. Tool bit inserted in the tool holder
According to the method of using the tool:

a. Turning
b. Forming
c. Chamfering
d. Boring
e. Thread cutting
f. Internal thread cutting
g. Facing
h. Parting-off
i. Grooving
According to the method of applying feed:

a. Right hand
b. Left hand
c. Round nose
of the shaft.
Given data:
D=35 mm
C.S (V)= 22 m/min
N=?
πdn
V= …. m/min
1000
1000 XV
n=
πd
1000 X 22
n=
πX 35
n= 200 rpm
5. Draw a neat sketch of finishing turning tool and show their nomenclature?
6. Name the different method of using the cutting tools in turning and explain any one.
a. Turning tool
i. Finishing tool
ii. Roughing tool
b. Chamfering tool
c. Threading tool
d. Facing tool
e. Grooving tool
f. Forming tool
g. Boring tool
h. Internal thread cutting tool
i. Parting-off tool
j. Shoulder turning tool.
Facing tool: The facing tool removes metal by its side cutting edges. So no top rake is necessary
in a facing tool. The tool having 00 side cutting edge angle and 340 end cutting edge angle can
be accommodated in the space between of the work and 600 dead centre leaving a clearance 20
0n both sides.
7. While cutting threads with the help of a tool, What are the requirements are to be fulfilled:
i. There should be a certain relation between job revolutions and the revolutions of the lead screw
to control linear movement of the tool parallel to the job when the half nut is engaged with the
lead screw.
ii. The tool should be ground to the proper shape or profile of the thread to be cut.
iii. In modern engine lathe, quick change gear box is provided in which different ratios of the
spindle and lead screw revolutions can be easily obtained by simply shifting the change gear
lever. In ordinary engine lathe, every time one has to change the gears.
iv. For cutting a lathe an accurate screw is necessary, that the relation between the movement of the
saddle, and the revolution of work be carefully controlled. This is brought about by means of a
lead screw which is driven by a train of gears as shown in a set up described in Fig.
v. Usually the drive is first carried to the spindle called the stud which for all purposes may be
assumed to be the spindle itself as it rotates at the same speed and in the same direction, unless
made to reverse by the tumbler mechanism. From the stud, the drive is conveyed to the lead
screw by a train of gears.
vi. To vary the relationship between the revolutions of the lead screw and those of the stud, the
train of gears may be varied. Note that the spindle gear is never changed for cutting different
pitches of thread. The stud gear (driver gear) and the lead screw gear (driven gear) are changed
whenever a particular ratio is needed between the spindle and lead screw.
8.list out various types of gears
Spur gear-sliding mesh gear box, machine tool gearbox

 Helical gear- automobile gear box
 Rack & pinion- lathe carriage, steering gear box
 Worm & worm wheel- wiper mechanism, material handling equipments gear box, steering gear box
 Bevel gear- automobile differential gear box
 Spiral gear-drives in textile machineries
9. Explain the Cutting Safety in lathe?

As you cut with the lathe, follow the manufacturer's recommendations for rotation speed, feed and
depth of cut for the metal you are working on. Keep your hands and fingers away from any moving
parts or cutting tools. Avoid reaching a cross the rotating chuck or work piece when you are filing or
burnishing. Never use your hand to stop a moving chuck. Instead, move the cutting tool away from
the metal, turn off the lathe and remove the work piece.
depth of cut for the metal you are working on.
Avoid reaching a cross the rotating chuck or work piece when you are filing or burnishing.
10. Explain tumbler gears?

Tumbler gears are used to give the desired direction of movement to the lathecarriage, via lead screw or
the feed shaft.
The tumbler gearing comprises of two Pinions mounted on a bracket.
The bracket is pivoted about the 1 st stud shaft.
The design provides three positions of the bracket.
******
UNIT 15&16: CALCULATION OF RPM, FEEDS & DEPTH OF CUT
PART-A
I. Fill in the blanks: 1 mark

1. RPM stands for-----revolution per minute
2. Formula for calculating cutting speed in lathe is------CS=∏dn/1000 m/min.
3. Formula for calculating RPM for lathe machine is ------n=V x 1000/∏ x d
D −D f
4. D= o ------ is the formula for depth of cut in lathe machine
2
5. The cutting speed for lathe is denoted by the letter is-----V
6. The feed for lathe is denoted by the letter is ------S
7. The RPM for lathe is denoted by the letter is ------n
8. The average cutting speed for mild steel in turning operation is---25 – 31 m/min
9. 10 – 15 m/min----- is the average cutting speed for mild steel in reaming operation.
10. The feed is expressed in----------mm/ revolution
11. The cutting speed expressed in-----m/min
12. The average depth of cut of cast iron material for finishing operation is ------0.5 to 1 mm
13. N=1000 x V /πx d ------ is the formula for calculating RPM for lathe machine
14. CS¿ π dn/1000----- is the formula for calculating cutting speed for lathe machine.
15. The unit of cutting speed is --------meter per minute, m/min
16. 16. The unit of feed is _____mm/revolution
17. 17. The unit of depth of cut is_____mm
18. 18. Feed is the distance the tool advance for each revolution of the work
19. 19. The depth of cut is the Perpendicular distance measured from the machined surface to the
surface of work piece.
πdn
20. 20. CS= in the formula “d” represents_________diameter of the workpiece
1000
II. Multiple choice questions: 1 mark
1. The tool life increases with the-----
a) Increase in side cutting edge angle c. Decrease in side rake angle
b) Decrease in nose radius d. Decrease in back rake angle.
2. ------ is the speed at which metal is removed by the tool from the work piece.
a. Feed c. cutting speed
b. Depth of cut d. none of the mentioned.
3. Which of the following represent the unit of cutting speed?
a. Meter x minute. c. Meter/minute.
b. Meter x meter x minute. d. None of the mentioned.
4. Which of the following represent the formula for the depth of cut?
a. d1 +d2 c. (d1 + d2)/2
b. d1 – d2 d. (d1 – d2) /2
5. For general purpose ratio of the depth of cut to the feed varies from-----
a. 10:1 c. 100:1
b. 1:10 d. 1:100
6. The tool life is most affected by machine-----
a. Cutting speed c. Tool geometry
b. Feed & depth of cut d. not using coolant & lubricant.
7. Determine the cutting speed of the shaft diameter 25mm & rpm is 50.
a. 3.92 m/min c. 1.25m/min
b. 7.85m/min d. none of the mentioned.
8. If rpm=200,feed/revolution is 0.05mm then feed/min will be -----
a. 100mm. c. 4mm.
b. 10mm. d. 1mm.
9. If feed=0.01mm/rev,rpm is 500 then feed/min will be-----
a. 5mm c. 50mm
b. 10mm d. 500mm
10. For a give rpm if the diameter of a work piece increase then cutting speed will-----
a.Increase c. Decrease
b. Same d. none of the mentioned
11. What is the roughing feed rate for aluminium material is -----
a. 0.5mm/rev c. 0.8mm/rev
b. 1.0mm/rev d. 2.0mm/rev
12. The cutting speed is expressed in------
a. mm/min c. m/min
b. cm/min d. none of the mentioned
13. The feed is expressed in ------
a. m/revolution c. cm/revolution
b. mm/revolution d. none of the mentioned
14. The RPM for lathe is denoted by the letter is ------
a. N c. n
b. S d. v
15. Which of the following represents the formula for cutting speed?
πdn 1000 xV
a. CS= c. n=
1000 πxd
1000 xn
b. V= d. none of the mentioned
πxd
16. ------ is the distance the tool advance for each revolution of the work
a. Feed c. Depth of cut
b. Metal removal rate d. none of the mentioned
17. The depth of cut is the ----------distance measured from the machined surface to the surface of
work piece.
a. Parallel c. Perpendicular
b. At 45 degree d. none of the mentioned
18. Which of the following is the unit of feed--------?

a. mm/min c. mm/revolution
b. mm x min d. none of the mentioned.
πdn
19. CS= in the formula “n” represents____
1000
a. Cutting speed c. Feed
b. Depth of cut d. RPM
πdn
20. CS= in the formula “d” represents____
1000
a. Cutting speed c. Diameter of workpiece
b. RPM d. none of the mentioned
21. The cutting speed for machining cast iron with a HSS tool is of the order of----
a. 30 – 50 m/min c. 60 – 90 m/min
b. 100 – 150 m/min d. 160 – 250 m/min
1000 xV
22. n= in the formula “V” represents____
πxd
c. Feed c. depth of cut
d. Cutting speed d. RPM
PART-B
III. Answer the following 3 Marks
1. Define cutting speed for lathe machine?
The cutting speed of a tool is the speed at which the metal is removed by the tool from the
workpiece.In the lathe it is peripheral speed of the work past the cutting tool expressed in meters
per minute.
2. Define depth of cut for lathe machine?
The depth of cut is the perpendicular distance measured from the machined surface to the uncut
surface of the work piece.
3. Define feed in lathe machine?
The feed of a cutting tool in a lathe work is the distance the tool advances for each revolution of
the work. Feed is expressed in millimeters per revolution.
4. What is cutting speed for lathe machine?
per minute.
5. What is depth of cut for lathe machine?
The depth of cut is the perpendicular distance measured from the machined surface to the
uncut surface of the work piece.
6. Define cutting speed?

work piece. In the lathe it is peripheral speed of the work past the cutting tool expressed in
meters per minute.
7. Define feed in lathe machine?
The feed of a cutting tool in a lathe work is the distance the tool advances for each revolution
of the work. Feed is expressed in mille meters per revolution
8. State what is meant by feed?
The feed of a cutting tool in a lathe work is the distance the tool advances for each revolution
of the work. Feed is expressed in millimeters per revolution
9. State the factors for determining the cutting speed
Determined of cutting speed is
π xdxn
V¿ m/min
1000
V= Cutting speed.
d= Diameter of work piece.
n= Revolution per minute.
π=3.14
10. State what is meant by depth of cut?
uncut surface of the work piece.
11. What are the determining the feed rate?
The feed rate is dependent upon a number of factors.
a) Finish required
b) Types of cutting tool used
c) Material of workpiece
d) Rigidity of machine
e) Holding of workpiece
f) Holding of cutting tools
12. What is roughing and finishing feedrate for mild steel?
Roughing feed rate for mild steel is 0.8mm/revolution
Finishing feed rate for mild steel is 0.2mm/revolution.
13. What is roughing and finishing depth of cut for aluminium?
Roughing depth of cut for aluminium is 2 to 5mm
Finisging depth of cut for aluminium is 0.5 to 1 mm
14. What is feed in cutting?

Feed is defined as the distance to the tool travels during one revolution of the part is called
feed.it is expressed in millimeter per revolution
15. What is cutting speed?
per minute
16. What is depth of cut?
uncut surface of the work piece. The formula for calculating depth of cut is
Depth of cut= (d1 – d2) /2
17. State what is meant by cutting speed?
workpiece.In the lathe it is peripheral speed of the work past the cutting tool expressed inmeters per
minute.
18. State what is meant by depth of cut?
uncut surface of the work piece. The formula for calculating depth of cut is
19. What is the formula for calculating cutting speed and depth of cut in lathe?
π dn
Formula for calculating cutting speed in lathe is V¿ m/min
1000
Formula for calculating depth of cut in lathe is Depth of cut= (d1 – d2) /2
20. Calculate the RPM as following data, d= 125mm and v=20m/min

Data given
d=125mm.
Cuting speed (v)=20m/min.
n =?
1000 x V
Formula for calculating RPM is n=
π xd
1000 x 20
n=
3.14 x 125
25000
n=
392.5
n =63.69RPM
21. Calculate the cutting speed as following data d=60mm and n=270.
Data given
D=60mm.
Cuting speed (v) =?
n =270
πdn
Formula for calculating cutting speed isCS=
1000
3.14 X 60 X 270
v=
1000
50.868
=
1000
=50.86m/min
IV. Answer the following 5Marks

1. A steel shaft of 35mm diameter is turned at a cutting speed of 40 m/min.Find the RPM of shaft.
Given data
Diameter of work piece (d)=35mm.
Cutting speed (v) =40 m/min.
RPM (n) =?
The formula for calculating the RPM is
n=1000 x V/∏ x d
=1000 x 40/3.14 x 35
=40000/109.9
=363.96 RPM
2. Calculate the cutting speed of a work piece 30mm diameter& rpm is 60. Given data
Diameter of work piece (d) =30mm.
Cutting speed (v) =?
RPM (n) =60
Formula for calculating cutting speed is CS=(πx d x n)/1000
CS = (3.14 X30 X60)/1000
=5652/1000
=5.65M/min
3. A MS shaft of 20mm diameter is turned at a cutting speed of 25 m/min.Find the RPM of shaft.
Given data
Cutting speed (v) =25 m/min.
RPM (n) =?
n=1000 x V/∏ x d
=1000 x 25/3.14 x 20
=25000/62.8
=398.08 RPM
4. Calculate the RPM for High speed steel, a mild steel material of diameter 25mm.
Given data
Cutting speed (v) =25 m/min. (the cutting speed of HSS material is 25 – 31 in the
table reference)
RPM (n) =?
n=1000 x V/∏ x d
=1000 x 25/3.14 x 25
=25000/78.5
=318.47 RPM
5. Calculate the cutting speed, the diameter of the work piece is 30mm & rpm is 350.
Given data
RPM (n) =350
Formula for calculating cutting speed is CS=π x d x n/1000
CS = 3.14 X30 X350/1000
=32970/1000
=32.97m/min
6. If the diameter of work piece is 50mm and RPM is 450, find the cutting speed?
Given data
RPM (n) =450
CS = 3.14 X50X450/1000
=70650/1000
=70.65M/min
7. A work piece of 40mm diameter is turned with 150 rpm. What is the cutting speed?
Given data
RPM (n) =150
CS = 3.14 X40 X150/1000
=18840/1000
=18.84M/min
8. If the diameter of work piece is 120mm and cutting speed is 35m/min find the rpm?
Given data
Cutting speed (v) =35m/min.
RPM (n) =?
n=1000 x V/π x d
=1000 x 35/3.14 x 120
=35000/376.8
=92.88 RPM
9. Calculating the rpm of a job diameter 100mm, and cutting speed is 20m/min
Given data
RPM (n) =20
CS = 3.14 X100 X20/1000
=6280/1000
=6.28M/min
10. What would the RPM be if we were turning a 25mm diameter workpiece made out of cast iron,
using HSS cutting tool?
Data given
D=25mm.
Cuting speed (v)=15 - 19m/min.
n =?
1000 x V
π xd
1000 x 15
n=
3.14 x 25
15000
n=
78.5
n =191.08RPM
11. What would the RPM be if we were turning a 25mm diameter workpiece made out of cast iron,
using carbide cutting tool?
Data given
D=25mm.
Cuting speed (v) =63 m/min.
n =?
1000 x V
π xd
1000 x 63
n=
3.14 x 25
63000
n=
78.5
n =802.54RPM
12. If the cutting speed of mild steel is 30m/min and workpiece diameter is 100mm what is the
RPM?
Data given
D=100mm.
Cuting speed (v) =30 m/min.
n =?
1000 x V
π xd
1000 x 30
n=
3.14 x 100
30000
n=
314
n =95.54RPM
13. What is the cutting speed when the RPM is 700 and diameter of workpiece is 50mm?
Data given
D=50mm.
Cuting speed (v) =?
n =700
πdn
1000
3.14 X 50 X 700
v=
1000
109900
=
1000
=109.9m/min
14. What is feed cutting speed depth of cut?

FEED:Feed is defined as the distance to the tool travels during one revolution of the part is
called feed.it is expressed in milimeter per revolution
CUTTING SPEED:The cutting speed of a tool is the speed at which the metal is removed by
the tool from the workpiece.In the lathe it is peripheral speed of the work past the cutting tool
expressed in meters per minute
15. Describe the cutting speed feed and depth of cut?
CUTTING SPEED:The cutting speed of a tool is the speed at which the metal is removed by
the tool from the workpiece.In the lathe it is peripheral speed of the work past the cutting tool
expressed in meters per minute.
FEED:Feed is defined as the distance to the tool travels during one revolution of the part is
called feed.it is expressed in milimeter per revolution.
DEPTH OF CUT: The depth of cut is the perpendicular distance measured from the
machined surface to the uncut surface of the work piece. The formula for calculating depth of
cut is
16. What are the determining the feed rate?

The feed rate is dependent upon a number of factors.
a) Finish required
b) Types of cutting tool used
c) Material of workpiece
d) Rigidity of machine
e) Holding of workpiece
f) Holding of cutting tools
17. What are the factors to be considered for the determination of cutting speed?
For the determination of cutting speed the following points to be observed
a) Material of workpiece
b) Cross section of chips
c) Material of tool
d) Cooling
e) Design of the machine
18. If the diameter of the workpiece is 125mm and the cutting speed is 20m/min find the RPM.
Data given
D=125mm.
Cuting speed (v) =20m/min.
n =?
1000 x V
π xd
1000 x 20
n=
3.14 x 125
20000
n=
392.5
n =50.95RPM
19. What would the RPM be if we were turning a 45mm diameter workpiece made out of Brass,
using HSS cutting tool?
Data given
D=45mm.
Cuting speed (v) =120m/min.
n =?
1000 x V
π xd
1000 x 120
n=
3.14 x 45
120000
n=
141.3
n =849.25RPM
20. If the diameter of workpiece is 55mm and RPM is 250 find the cutting speed.Data given
D=55mm.
Cuting speed (v) =?
n =250
πdn
1000
3.14 X 55 X 250
v=
1000
43175
=
1000
=43.17m/min
*******
UNIT 17&18: CALCULATION OF MACHINING TIME &

SAFETY

1. The formula for machining time is
L Tm = Machining Time (Min.)

Tm =
ft
L = Length of Cut
fr = Feed Rate (In./Min.)
2. For machining time particular operation speed and depth needed
3. For cleaning, oiling and setting, the machine should be stopped.
4. Sliding parts of the lathe should be and oiling periodically.
5. Chuck key should be removed after tightening the job in the chuck.
6. Tools and instruments should not be placed over lathe bed.
7. No attempt should be made to clean the revolving job with cotton waste.
8. Chips should be clean using a brush.
9. Chuck should be secured properly.
10. Revolving chuck should not be stopped by hand.
11. Never try and stop the lathe from moving with you hands true
12. A lathe machine is only used for turning metal yes
13. The lathe uses a chuck to hold the material.
14. You should remove all baggy clothing, jewellery and tie long hair up out of the way yes
15. Always remove the chuck wrench before engaging the lathe.
16. A space of one inch is yes safe between the tool rest and the work.
17. It is not safe to feel for smoothness while turning yes.
18. It is safe to turn work that is not balanced wrong.
19. The cutting tool may be held loosely wrong.
20. Always power off the machine and place a chuck carrier on the ways before you assemble or
remove a chuck.
21. The speed of the machine is not important for safe operation wrong.
II. Multiple choice questions

1. In lathe machine time will be calculated with
a. Diameter c. speed and depth
b. Thickness d. None of these
2. Turning operation machine time measure with
a. Thickness c. diameter
b. depth of cut d. all of these.
3. Safety goggles are preferred to avoid damage to eyes by
a. Work pieces c. flying chips
b. chuck d. cutting tool
4. Sliding pars of the lathe should be
a. Brush c. cleaned & lubricated
b. Washing d. blowing
5. Good housing keeping i.e., clean and tidy work area is free from
a. Oil c. chips
b. Waste d. all of these
6. Formula for the machine time for Chamfering
a. T= L / (F×N) c. f × d s
b. π/ 4 d. f× π /d
7. Mention terms used in the study of machining time

a. All of these c. feed
b. depth of cut d. cutting speed
8. Always remove the before engaging the lathe.

a. Safety guard c. cutting
b. chuck wrench d. metal chips
9. Always power the machine and place a chuck carrier on the ways before you
Assemble or remove a chuck.
a. On c. off
b. struggle d. boost
10. Check the boxes that are correct. The lathe performs what kind of
functions
a. Sanding c. knurling
b. welding d. cutting
11. When using the metal lathe, safety glasses are needed when?
a. while turning pieces at high speeds
b. while turning pieces at slow speeds
c. only when starting the machine
d. during all lathe operations
12. The machine tool, in which calculation and setting of the operating conditions like depth
of cut, feed, speed are done during the machining by the control system itself, is called
a. Computer numerical control system
b. Direct numerical control system
c. Adaptive control system
d. Machining centre system
13. Which machine tool reduces the number of set-ups in machining operation, time spent in
setting machine toolsand transportation between sections of machines?
a. Computer numerical control machine tool
b. Direct numerical control machine tool
c. Adaptive control systems
d. Machining centre
14. Which machine tool is known as the mother machine tool?
a. drill c. milling
b.lathe d.none of mentioned
15. Number of revolution = 50, rpm = 100. Find out the machining time.
a. 0.5 c. 2
b. 4 d. none of the mentioned
16. Find the metal removal rate from the given data (in mm3/minute). cutting speed(cs) =50
mm/minute, depth of cut(d)=10mm, feed(f)= o.1 mm/revolution.
a. 50 c. 500
17. If the diameter of the work surface before machining(d1) is 100 mm and diameter of the
machined surface(d2) is 50 mm. Then the depth of the cut is mm.
a. 50 c. 25
18. Determine the diameter (d) of the shaft in mm. rpm(n)=25mm /revolution, cutting speed( c
s )=100 mm/min.
a. 21.23 c. 405.47
b. 1273.2 d. none of the mentioned
19. Determine the rpm (n) of the shaft. Diameter (d )=25 mm, cutting speed, v=50 m/min.
a. 636.9 c. 202.83
b. 10.615 d. none of the mentioned
20. Which one of the following on a lathe is used to give depth of cut
a. Cross slide c. By adjusting the tool
b. Top slide d. Compound slide
III. Write short answers 2 Marks
1. What is the purposes of housekeeping?

The purposes of housekeeping is needed clean and tidy work area free from oil and chips in
essential to avoid accidents.
2. What is machining time?
It is the time for which the machine works on the component, i.e. fromthe time when the
tooltouches the work piece to when the tool leaves the component after completion of operation.
The machining time depends on the type and extent of machining required, material being
machined, speed, feed, depth of cut and number of cuts required.
3. Why one revolution by hand before starting the lathe spindle by power?
Before starting the lathe spindle by power, lathe spindle should be revolved by one revolution by
hand to make it sure that no fouling is there.
4. Machining time will set up by

Feed Rate: fr (Dist/Min)
5. Why feed rate is needed for machining time.

The feed rate is needed for machining time diameter of the work piece and type of material and
also types of operation and cutting tool required as per the raw material example: ferrous like
stainless steel, mild steel, cast iron etc. non- ferrous like aluminium, brass, bronze etc.
6. What is the machine time for turning operation?

Turning is the process of removing excess material from the work piece by means of a single
point cutting tool.
T= L / (F×N).
7. What is the machine time external relief turning?

It is the operation of removal of material from a previously turned surface along the same axis
and within the limits of turned area.
T = L/ (F×N) × NUMBER OF CUTS
8. What is the machine time for Chamfering?
It is the operation of removing material from the edges of external or internal diameters.
T= L / (F×N)
9. What is the machine time for Facing?

It is the process of removing material from the ends of the job by moving the tool perpendicular
to the axis of the job.
10. What are the common hazards occurring while using lathe?
The Consumer Product Safety Commission says that the most common injuries caused by lathe
accidents are broken fingers, cuts to the hands and hot shrapnel in the eyes. When using a lathe, it's
important to take safety precautions such as wearing proper clothing, maintaining the proper speed and
practicing safe cutting techniques.
PART-B
IV. Answer the following 3 marks
1. How machining time is calculated for an operation in lathe?
The machining time in lathe work can be calculated for a particular
operation if the speed of the job, feed length of the job is known.
if s is the feed of the job per revolution expressed in mm per revolution
and l the length of the job in mm, then number of revolutions of the job required for a
complete cut will be.
2. Define speed?
V
Rotational Speed: N (RPM’s) N= π D 0 where, N= rotational speed
V= cutting speed (sfpm)

D0= original diameter
3. What are the instructions to operating machine?

Operator should follow various precautions to ensure safe working conditions. Accidents will occur
without instruction to operating machine chuck is moving forward, reverse switch should not be
operated revolving chuck should never be stopped by hand.
4. Safety guidelines &main points for lathe operation?

a) All safety guards should be in position.
b) Before operating the machine, one should fully understand its operation controls,
and how to stop it.
c) Limit switches should not be meddled with or removed.
d) Since loose garments are likely to be caught in the revolving job, these
should be avoided.
e) Long and unruly hair are not desirable for safety.
f) Safety goggles are preferred to avoid damage to eyes by flying chips.
g) Machine should not be left running but operator should be alert when
doing a job.
5. Define Turning equation?
v
N= N = Rotational Speed (RPM’s)
πD 0
v = Cutting Speed (SFPM)
DO = Original Diameter
fr= Nf fr = feed rate in dist./min
N = Rotational Speed (RPM’s)
f = feed in dist./rev
6. What is safety training for lathe machines?

Safety Training for Lathe Machines 1 Hazards and Safeguards. Lathe hazards include rotating
parts, flying material chips or dust and possible material kickbacks. 2 Emergency Controls.
Material could become unstable in a lathe, causing a hazardous condition. The ability to shut
down a lathe quickly during this or other emergencies is essential. 3 Personal Protective
Equipment. OSHA prefers that companies design or engineer out machine hazards where
possible. When this is not feasible, companies can use personal protective equipment.
7. How is the machining time calculated in lathe?

The machining time depends on the type and extent of machining required, material
being machined, speed, feed, depth of cut and number of cuts required. N = Number of
stroke/min f = Feed/stroke in mm V = Cutting speed m/min K = Return time/Cutting time.
8. How do you calculate machining cycle time?
Calculate the required total machining time T with the
following cutting conditions: Cutting speed V=80 m/min, Feed is f=0.8 mm/rev, Depth of cut =
3 mm per pass. f=0.8 mm/rev The turning will be done in 2 steps.
9. How do you calculate turning time?

a. Divide by 1000 to change to m from mm.
v (m/min): Cutting Speed.
Dm (mm): Work piece Diameter. π (3.14): Pi. ...
b. f (mm/rev): Feed per Revolution. I (mm/min): Cutting Length per

Min. n (min-1): Main Axis Spindle Speed. ...
c. h (µm):Finished Surface Roughness. f (mm/rev):Feed per

Revolution. RE (mm):Insert Corner Radius.
10. What is the cutting time when 100mm work piece is machined at 1000m/min with feed =
0.2mm/rev?
First, calculate the cutting length per min. from the feed and spindle speed.
l= f × n =0.2×1000=200(mm/min)
Substitute the answer above into the formula.

T c =lm ÷ l =100 ÷ 200 = 0.5 (min) 0.5×60 = 30(sec)
The answer is 30 sec.
11. A cylindrical workpiece 200 mm in diameter and 700 mm long is to be turned in an engine lathe.
Cutting conditions are as follows: cutting speed is 2.30 m/s, feed is 0.32 mm/rev, and depth of
cut is 1.80 mm. Determine (a) cutting time, and (b) metal removal rate.
Solution:
N = v/(πD) = (2.30 m/s)/0.200p = 3.66 rev/s
f r = Nf = 6.366(.3) = 1.17 mm/s
Tm = L/f r = 700/1.17 = 598 s = 9.96 min
Alternative calculation using Eq.(5),
Tm = 200(700)π/(2,300 x 0.32) = 597.6 sec = 9.96 min

MRR = vfd = (2.30 m/s)(103 )(0.32 mm)(1.80 mm) = 1320 mm3 /s
12. Define terms used in the study of machining time?

Length of cut Length of cut = approach length + length of work piece
to be machined + over travel.
Feed
Depth of cut
Cutting speed
πdn m
Cutting speed =
1000 min
13. Define formula calculate time for knurling?
Calculate Time for Knurling
14. Explain formula calculate time for drilling?
Calculate Time for Drilling
V. Answer the following 5 marks

1. Define Major Factors of parting Machining Time?
Parting is the operation of cutting a work piece after it has been machined to the desired size
and shape. A parting operation the process involves rotating the work piece on a chuck or
faceplate at half the speed that of turning and feeding by a narrow parting tool perpendicular
to the lathe axis by rotating the cross slide screw by hand. Before the operation is started,
carriage is locked in position on the lathe bed and the cutting tool is held rigidly on the tool
post with the compound slide set parallel to the lathe axis machining time will be the different
feed various from depth of cut.
2. Estimation of machining time by calculations in case of turning in lathes?
The major aim and objectives in machining industries generally are;
a. Reduction of total manufacturing time, T
b. Increase in MRR, i.e., productivity
c. Reduction in machining cost without sacrificing product
quality
d. Increase in profit or profit rate, i.e., profitability.
All those objectives are commonly and substantially governed by the total machining time
per piece, Tp, where again,
TC
Tp=Ti+Tc+ T L TCT
Where, Ti = idle time per piece, min

TC= actual cutting time per p
per piece
b. TL= Tool life
TCT= average tool change time per piece.
For, D = 100 mm, Lw = 200 mm, A = O = 5 mm, VC = 120 m/min &
so=0.2 mm/rev,
() 100 200 5 5) 1000 120 0.2C xx T xx π+ = + min = 2.75 min
The machining time for facing, grooving, taper turning, threading, parting etc. in lathes can
also be determined or estimated following the same principle and method.
3. The shaft shown in the figure below is to be machined on a lathe from a Ø 25mm bar. Calculate
the machining time if speed V is 60 m/min. turning feed is 0.2mm/rev, drilling feed is 0.08
mm/rev and knurling feed is 0.3 mm/rev.
Step 2
Turn ø20mm from ø 25 mm
L 45
Tm= = = 0.29 min.
f x N 0.2 x 764
4. Find the time required for one complete cut on a piece of work 250mm
Long and 40mm in diameter. The cutting speed is 30 meters per minute
and the feed is 0.3mm per revolution.
Cutting speed =πdn/1000=πx40xn/1000x30
Or
n=1000x30/πx40=30000/125.6=238.8
No. of revolutions required for complete cut=250/0.3 =833.3
Time required for complete cut = 833.3/238.8=3.48 min
5. Calculate the machining time for one complete cut on work piece 300mm long and 35mm
diameter, cutting speed is 20m/min and feed is 0.25mm/rev.
Cutting speed =πdn/1000=πx35xn/1000x20

Or
n=1000x20/πx35=20000/109.9=181.9
No. of revolutions required for complete cut=300/0.25=1200
Time required for complete cut = 1200/181.9=6.59 min
6. Explain Taper operation machining time will difference to step turning Machining time?
In taper operation machining time depends on the inclination of the work pieces
calculated degree to making operation and extent of machining required, material being removed by
giving depth of cut is less than to the step turning. Step turning operation machining time will
faster.
7. Estimation of Machining Time by calculations in case of drilling and boring operation in lathe?
In case of drilling and boring. The basic principle and procedure of estimation of machining
time in drilling and boring are almost same as that of turning operations. Fig making through
hole by drilling and boring.
.
For drilling a through hole
The machining time, TC is estimated from,' C C o L T Ns =
where, LC’ = Lh + A + O + C A, O = approach and over run and
C = cot 2 D ρ D = diameter of the hole, i.e., drill ρ = half of the drill point angle. Speed, N
and feed so are selected in the same way as it is done in case of turning. Therefore, the drilling
time can be determined from () 1000 h C Co D L A O C T Vs π + + + =
In the same way TC is determined or estimated in boring also. Only the portion ‘C’ is not
included. For blind hole, only over run, ‘O’ is excluded.
Example
For D = 25 mm, ρ = 60o, VC = 44 m/min L = 60 mm, so = 0.25 mm/rev A = O = 2 mm TC =
πx25{60 +2 +2 + (25/2) cot600} / (1000x44x0.25) = 0.5 min.
8. Define tool approach and tool travel time?

Length of cut: It is the distance travelled by the tool to machine the work piece and
is calculated as follows:
Length of cut (L) = Approach length + Length of work piece to be machined + Over
travel
Approach is the distance a tool travels, from the time it touches the work piece until it is
cutting to full depth. Over travel is the distance the tool is fed while it is not cutting. It is the
distance over which the tool idles before it enters and after it leaves the cut. These terms are
explained in the Fig. for
A cutting operation on lathe
9. Derive an expression for machining time for plain turning in lathe?
Turning, on a lathe, is the removal of excess material form the work piece by means
of a pointed tool, to produce a cylindrical or cone shaped surface. From cutting
speed, r.p.m. of job are calculated by using the formula.
where N = r.p.m. of job
S = Surface cutting speed in meters/minute

D = Diameter of the stock to be turned (in mm) if f = Feed per
revolution (in mm)
L = Length of stock to be turned (in mm) T = Time required

for turning (in minutes)
Then T =
10. Write steps involved in cutting time calculation?

Step 1: Calculation of length of cut (L)
Step 2: Calculation of feed (f) and depth of cut
Step 3: Calculation of speed (S); [rpm (N) = 1000 S/ D]
Step 3:
Calculation
of machining
time by using the
formula ()
11. Explain
machine
time will change
for mild steel
and cast iron in
turning operation?
The factors that govern machining time will be understood from a simple case of
machining.
A mild steel rod has to be reduced in diameter from D 1 to D2 over a length L by straight turning
in a centre lathe as indicated in Fig.
Clearly indicates that in turning to a given diameter and length, the cutting time, tc is governed
mainly by the selection of the values of cutting velocity, vc and feed, so.This is true more or less in
all machining operations being done in different machineTools. A number of factors are
essentially considered while selecting or deciding theValues of vc and so for any machining work.
The major factors considered for selecting vc are :
Cutting tool material (type, strength, hardness, heat and wearresistance,

toughness,Chemical stability, thermal conductivity etc.); for instance; Hss tools are used at
within 40 m/min only in turning mild steel whereas for the same Work cemented carbide
tools can be used at vc, 80 to 300 m/min
High performance ceramic tools and CBN tools are used at very high speed in
machiningSteels of different strength and hardness
Diamond tools can be used in machining various materials (excepting fe-base)
at vc. Beyond 500 m/min.
12. Explain MRR in turning equation?

Material Removal Rate(in. cu./Min)
MRR = Material Removal Rate (in.cu./ Min )
MRR = v f d
f = Feed (Dist./ Rev )
d = Depth of Cut
13. Explain cutting safety?

depth of cut for the material you are working on. Keep your hands and fingers away from any moving
parts or cutting tools. Avoid reaching across the rotating chuck or work piece when you are filing or
burnishing. Never use your hand to stop a moving chuck. Instead, move the cutting tool away from the
metal, turn off the lathe and remove the work piece.
14. Write a clean-up safety?
Remember the old adage that "a clean workshop is a safe workshop." Thoroughly clean your work area
after using the lathe. Sweep up any metal pieces from the floor or work area with a brush or broom. Do
not touch the metal pieces with your hands as they may cut or burn you.
15. Explain the clothing and accessory safety in lathe operation?

Lathes can easily catch long sleeves and loose clothing. It's best to wear short sleeves or long sleeves
with fitted cuffs that cannot get caught and drawn into the lathe. Wear long pants and sturdy work
shoes to protect your legs and feet from hot metal. Remove any jewelry or wrist watches that could get
caught on the lathe. Pull back longhair as well.
16. Explain the securing work and starting the lathe operation?
Before you begin working the lathe, make sure the work piece is centered and tightly clamped to the
lathe's chuck. Adjust the cutting tool and rest so that they are just above the center of the work piece.
Remove the chuck key from the chuck before you turn on the power. When you start the lathe, begin on
a low rotational setting and gradually increase the speed as necessary.
17. Explain the Protective Eyewear in lathe operations?
Lathes often spit out chips and other pieces of hot, sharp metal. Wear industrial safety glasses with side
shields to protect your eyesight.
VI. Answer the following. 8 Marks

1. A mild steel bar 100 mm long and 38 mm in diameter is turned to 35 mm dia and was again
turned to a diameter of 32 mm over a length of 40 mm. The bar was machined at both the
ends to give a Chamfer of 45° × 5 mm after facing. Calculate the machining time. Assume
Cutting speed of 60 m/min and feed 0.4 mm/rev. The depth of cut is not to exceed 3 mm in
any operation.
2. Calculate the machining time required to produce one piece of the component. Given below
starting from f 25 mm bar. The following data is available. For turning: Cutting speed = 40
m/min. Feed = 0.4 mm/rev. Depth of cut = 2.5 mm/per Thread cutting: Cutting speed = 8
m/min.
3. How much machining time will be required to reduce the diameter of a cast iron rod from 120
mm to 116 mm over a length of 100 mm by turning using Carbide inserts. Reasonably select
values of VC and So.
LCT C Nso = for single pass L C = 100 + 5 + 5 = 110 mm

1000VCN D = π
For turning C.I. by carbide insert, VC is taken as 100 m/min and so = 0.2 mm/rev
1000 100 250 .120 x Nr p m∴ =≅ π
Nearest standard speed, N = 225 110 2.5min 225 0.2C T x ∴ == Ans.
4. The part shown below will be turned in two machining steps. In the first step a length of (50 +
50) = 100 mm will be reduced from Ø100 mm to Ø80 mm and in the second step a length of
50 mm will be reduced from Ø80 mm to Ø60 mm. Calculate the required total machining
time T.
Cutting speed V=80 m/min,
Feed is f=0.8 mm/rev,

Depth of cut = 3 mm per pass.
SOLUTION: V=80 m/min
f=0.8 mm/rev
The turning will be done in 2 steps. In first step a length of (50 + 50) = 100 mm will be
reduced from Ø100 mm to Ø80 mm and in second step a length of 50mm will be reduced from Ø80
mm to Ø60 mm.
5. What are the safety precautions to be followed while working on lathe?

a. Sliding parts of the lathe should be cleaned and lubricated periodically.
b. Speed selector control should not be changed when the spindle is rotating.
c. Before moving the carriage, the carriage clamping screw should be unlocked.
d. If chuck is moving forward, reverse switch should not be operated.
e. Chuck should secured properly.
f. Chips should be cleared using a brush.
g. Correct size of lathe centers should be used.
h. On hearing unusual noise, machine should be stopped.
i. The jibs of the cross slide and the top slide should be checked and adjusted periodically.
6. A cylindrical stainless steel rod with length L=150 mm, diameter D0 = 12 mm is being
reduced in diameter to D f =11 mm by turning on a lathe. The spindle rotates at N = 400 rpm,
and the tool is travelling at an axial speed of υ=200 mm/min calculate machine time.
Calculate:a) The cutting speed V (maximum and minimum) b) The material removal rate
(MRR) c) The cutting time t d) The power required if the unit power is estimated to 4
w.s/mm3.
SOLUTION:
a. The maximum cutting speed is at the outer diameter D 0, and is obtained from the expression
V = π D0 N
Thus,
Vmax = (π) (12) (400) = 15072 mm/min
The cutting speed at the inner diameter Df is
Vmin = (π) (11) (400) = 13816 mm/min

b. From the information given, the depth of cut
is d = (12 – 11) / 2 =0.5 mm
and the feed is

f=υ/Ν
f = 200 / 400 = 0.5 mm/rev
thus the material removal rate is calculated as
3
MRR = (π) (Davg) (d) (f) (N) = (π) (11.5) (0.5) (0.5) (400) = 3611 mm /min
3
=60.2mm /s
c. The cutting time is
t = l / (f. N) = (150) / (0.5) (400) = 0.75 min

d. The power required is
Power = (4) (60.2) = 240.8
7. The shaft shown in the figure below is to be machined on a lathe from a Ø25mm bar.
Calculate the machining time if speed V is 60 m/min., turning feed is 0.2mm/rev, drilling feed
is 0.08 mm/rev and knurling feed is 0.3 mm/rev.
Step 2
Turn Ø20 mm from Ø25 mm
L 45  0.29
Tm   min
fxN 0.2 x 764
8. Define the following: i) setting time ii) machine time iii) auxiliary time iv) delay time v) total
time
i) setting time
If “s” is the feed of the job per revolution expressed in mm per revolution and “l” the length of the
job in mm, then a number of revolutions of the job required for a complete cut will be: l/s.
Therefore, the time is taken for a complete cut = l / s X n min.
ii) Machine time
The machining time for facing, grooving, taper turning, threading, parting etc. in lathes can also be
determined or estimated following the same principle and method
Machine time = length to be machined / Feed rate

Longitudinal turning - ( rpm known )
l = length to be machined
Sr = Feed rate
n = rpmhine Tme = l / x n
Longitudinal turning - ( rpm unknown )

d = Diameter
v = Cutting speed
Sr = Feed rate
l = Length to be machined
iii) Auxiliary time
The operator of a lathe machine performs the handling or auxiliary operations in the machine,
the more WPs can be produced in the same period of time Each type of automatic lathe has an
optimum range of lot size in which the diameter, length, no of work pieces .
iv) Delay time
Machine Unavoidable delay time is that time during which the employee must wait because the
operation is temporarily interrupted due to causes beyond the ... Consider, for example, the task
of turning a large shaft on a modern automatic lathe.
v) Total time
The machining time for facing, grooving, taper turning, threading, parting etc. in lathes can
also be determined or estimated following the same principle and method. The basic principle
and procedure of estimation of machining time in drilling and boring are almost same as that
of turning operations.
9. Define turning example formula for machining time?
L
Machining time (min.) Tm= Tm = Machining Time (Min.)
fr
L = Length of Cut
fr = Feed Rate (In./Min.)
Material Removal Rate (in. cu./Min)
MRR = v f d
MRR = Material Removal Rate (in.cu./ Min)
f = Feed (Dist./ Rev )
d = Depth of Cut
******

PT-II QB With Answers Prep - VCM

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GOVT TOOL ROOM AND TRAINING CENTRE

Course: Diploma in Tool and Die Making

Course Code 20TD23T Semester 2

III. Answer any five questions (write short answers): 2 Marks

3. Name the parts of shaper.

4. What is the function of the base in shaper machine?

5. What type of surfaces are machined on a shaper?

6. Which stroke of the shaper is faster?

7. Who designed the shaping machine, in which year was itdesigned?

8. In which shaper is the oil under high pressureused?

9. What is the use of crank & slotted link mechanism?

2. How are the shapers classified?

3. How does the Cross rail functions?

4. What is the importance of the table in the shaper?

5. Write about the tool head inshaper.

7.What do you understand by quick returnmechanism?

8. What are the advantages of quick returnmechanism?

a. The angle P1RP2 (Time taken for forward stroke) is216o.

B. Answer the following questions 5 Marks

ii. According to the design of the table

2. Write about the Advantages of shaper.

3. Write about the Disadvantages of shaper.

4. What is a crank type shaper?

5. Write about the hydraulic shaper?

6. Explain the Universal shaper.

7. List out different types of shaping machines.

8. What do you understand by ram?

9. Explain about the Tool head in about five sentences.

C. Answer the following questions 8 Marks

Parts of the shaper

3. What are the applications of shaper?

4. Write the advantages and disadvantages of shaper.

5. Explain the importance of clapper box.

8. What is crank and slotted link mechanism? Explain with a neatsketch.

9. Explain whitworth quick return mechanism with neat sketch.

10. Explain the ratchet & pawl mechanism with adiagram.

11. Explain the hydraulic shaper mechanism with neat sketch?

UNIT 3&4: CUTTING TOOL (SHAPER), WORK HOLDING DEVICES

II. Multiple choice questions:

10. Hold downs are also called

III. Answer the following questions 2 Marks

1. What is single point cutting?

2. Mention the classification of a machine vice?

3. What are grippers?

4. What are angle plates.

5. Write the purpose of using stop pins and toes?

15. What is shaper vice?

1. List the most commonly used cutting tools in shaper.

3. List the different types of cutting tool materials.

4. Write a note on clamping work on the shaper table.

5. What are the basic properties of cutting tools?

7. Sketch and explain finishing tool.

10. What are strip and stop pins?

2. Sketch and explain V – Block.

3. Sketch and explain T- bolts and clamps.

4. With neat sketch explain angle plate.

5. With neat sketch explain shaper vice.

3. Sketch and explain the different types of tools used in shaper.

4. Sketch and explain the following i) Angle plate

5. Sketch and explain shaper centers.

T – bolts and clamps

UNIT 5&6: CUTTING SPEED & FEED, CALCULATION OF MACHINING

I. Fill in the blanks with appropriate words.