D.E I.

FACULTY OF ENGINERRING

QUESTION BANK

METAL CUTTING AND TOOL DESIGN

Third Year B.Tech MECHANICAL

MEM 603

UNIT-1

MACHINES OF METAL MACHINING

1. Explain the Various elements involved in the machining process.

2. Sketch a single point cutting tool and show various tool angles thereon and discuss their significance.
Discuss the tool with 10, 10, 6, 8, 8, 6,1mm signatures in ASA system.
3. Explain how orthogonal cutting differs from oblique cutting. Discuss the various types of chips formed
during the metal cutting operation and also give the conditions, which favor their production.
4. Discuss the mechanism of formation of built up edges. What conditions promote the formation and growth
and its consequences?
5. (a) Prove Merchant’s relationship in theoretically determining the shear plane angle.
(b) Prove that the shear strain in orthogonal cutting is given by Tan (ø- α) + Cot ø
6 Draw Merchant’s force diagram. State the assumptions made in development of such a diagram.
Develop an expression for power required in metal cutting and derive Merchants shear angle
relationship.
7 What are the uses of cutting fluids? Discuss some of the cutting fluids used during the cutting process
and their methods of applications. Explain the cutting sped and tool life relationship with coolant and
Cutting dry
8 While turning M.S. with a 0, 10,6,7,8,9,0,1 mm shaped orthogonal tool using a feed of 0.19mm/rev and a
depth of cut of 2mm, a chip thickness of 0.385mm has obtained.
Calculate i) chip thickness ratio
ii) shear angle (493 , 260 18’ )

9 The following data refers to orthogonal turning process-

Initial dia = 75 mm
Final dia = 65mm
Length of chip cut =71 mm /rev
Feed =0.2 mm /rev
Back rake=15
Calculate: i) chip thickness ratio
ii) Shear angle (0.322, 180 47’)

11. In an orthogonal turning operation the following data were obtained

Chip thickness = 0.45mm
Width of cut= 2.5mm
 Feed = 0.25 mm/rev
Cutting Force= 29.5 kg

The cutting speed was 150m/min. and the rake angle was + 100
Calculate i) chip thickness ratio
ii) Shear angle
iii) Velocity of chip along tool face
iv) Friction force along the tool force
v) shear stress
(Ans 5560, 29.6, 81.65 H/min, 48.6 kg, 83.9 kg, 6650 kg/cm2)

12. In question no. 11 determine the value of the following graphically F, N, Fn , Fs,and Vf

( Ans 029.6 , 48.6 kg, 108 kg, 83 kg, 81.2 kg, 157m/min, 81.6 m/min)

13. In an orthogonal turning operation the following data were obtained

Chip thickness = 0.25

Width of cut= 2.5mm
Feed force = 10 kg
Cutting Force= 23 kg
Feed = 0.125 mm / rev
Cutting speed =150 m/min

The cutting speed was 150m/min. and the rake angle was + 100
Calculate i) Work done in shear/mm
ii) Shear strain

14. A seamless tubing 35mm outside diameter is turned as a lathe .

The following data are available,
Rake Angle= 350
Cutting speed =15m/min
Feed = 0.10mm /rev
Length of continuous chip in one rev =50mm
Cutting force Fc = 200 kg
Feed Force F= 50 kg

Calculate the coeff. Of friction, shear plane angle, velocity of chip along tool force and chip thickness

(Ans 1.525, 320, 7.875 m/min)

15. In an orthogonal cutting operation the following observations were made-

Rake=20
Cutting speed = 50m/min
Undeformed chip thickness = 0.2mm
Fc = 41.8 kg-f
 Ft = 10.9 kg-f
The length of the chip formed is 125mm. Length of uncut chip is 292mm. Calculate friction angle, shear
angle. Determine the resultant cutting force and its inclination to the shear plane. ( Ans 34.7 0,,0.25, 43.3 kg)

16. Explain the various zones where heat is generated in metal machining. Show graphically the variation of
tool life with work piece temperature and explain.
17. Describe the method commonly employed for measurement of average tool chip interface temp. and state
their limitations.
18. While machining SAF 41 steel with a carbide tool 0,5,6,6,8,9,0,1mm at Vc= 180m/min feed =0.2 mm/rev
and depth of cut d=2.0 mm a chip thickness of 0.42mm was measured. If the value of dynamic shear stress
is 40 kg/cm. calculate the cutting force Fc employing merchant’s modifying relationship in which
2ø+ β –α= 77 0

19. A bar of 75mm diameter is reduced to 73mm by a cutting tool while cutting orthogonally. If the mean length
of the chip is 73.5mm, find the cutting ratio. If the rake angle is 150 , what is the shear angle?
20. In an orthogonal cutting test with a tool of rake angle 100 , the following observations were made:
Chip thickness ratio = 0.3
Horizontal component of the cutting force =1290N
Vertical component of the cutting force=1650N
From Merchant’s theory calculate the various component of the cutting force and the coefficient of friction
at the chip tool interface.

21. An orthogonal cutting of steel is done with 100 rake tools, with a depth of cut 2mm and feed rate of
0.20rev/mm. The cutting speed is 200m/min.the chip thickness ratio is 0.31. The vertical force is 1200N and
the horizontal cutting force is 650N. Calculate from the Merchant’s theory, the various works done in metal
cutting and shear stress.

22. In an orthogonal cutting operation , the following data has been observed:
Uncut chip thickness t =0.127 mm
Width of cut b= 6.35 mm
Cutting speed V= 2m/s
Rake angle =20 0
Cutting force Fc=567N
Thrust force Ft= 227N
Chip thickness = 0.228mm
Determine: shear angle, the friction angle, shear stress along the shear plane and the power for the cutting
operation. Also find the chip velocity, shear strain in chip and shear strain rate.
(Ans. 31.250, 31.8 0, 236.5N/mm2,1.134kw,1.114m/s, 2.037, 0.245min, 86.12X 103 s-1)

23. During orthogonal machining operation of C-40 steel the following data were obtained:

Chip thickness = 0.45mm

Width of cut = 2.5 mm
Feed = 0.25 mm/rev
Tangential cut force = 1130N
Fed thrust force 295 N
Cutting speed = 2,5 m/s
 Rake angle =100
Calculate Force of shear at the shear plane and kinetic coefficient of friction at the chip tool interface
(Ans. 813.4 N, 0.458)

24. The following data relate to an orthogonal turning process :

Chip thickness =0.62 mm
Feed = 0.2 mm/rev
Rake angle = 150
Calculate cutting ration, chip reduction coefficient, shear angle and dynamic shear strain involved in the
deformation. (Ans. 0.322, 18.740, 3.012)

25. The following data relate to an orthogonal turning process:

Chip thickness ratio =0.383
Rake angle = 15 0
Uncut chip thickness =0.5 mm
Width of cut = 3mm
Yield stress of material in shear = 280 N/mm2
Average co-efficient of friction on the tool face= 0.7
Determine the tangential and normal force on the tool face.
( Ans. 858N ,1225.4 N)
26 Why do carbide tools employ negative rake angle more often than HSS tools? When the use of positive
rake and negative rake angle is recommended?

UNIT-2

TOOL WEAR TOOL LIFE , MACHINABILITY AND ECONOMICS

1. What are the various reasons for the failure of cutting tool? Explain how you ensure that the tool has failed.
2. What do you understand by tool wear? Explain the mechanism of flank wear and crater wear. Name the
factors that contribute to the flank and crater wear.
3. Explain what do you understand by the following wears Explain them with suitable examples
(i) Abrasive wear (ii) Adhesion wear (iii) diffusion wear
4. Explain how the adhesion theory of wear has been used to quantitatively describe the wear and land growth
curve formed in metal cutting.
5. Enumerate the factors affecting tool life. Briefly explain the effect of each process parameter on tool life.
6. Discuss the cause of variability of the constant n & c of the tool life equation.
7. What is the significance of tool life to an engineer who is interested in productivity? What different criterion
is used to identify that the tool has reached its limiting value?
8. Discuss the meaning of the terms machinability and tool life. What is machinability Index? Give the
expression for the mach inability Index
9. What are the various criterions for evaluating the machinability? Which of them is of prime importance and
why?
10. How do you interpret machinability of metal on the basis of chip formation?
11. Discuss the effect of tool geometry and microstructure on tool life. Discuss the usefulness of Taylors
equation in selecting the proper cutting sped for machining operation.
12. Stat the general form of the Taylor’s Tool life equation. Is the most productive cutting speed the same as the
most economic speed? Give reasons for your answer?
13. A tool life of 100min is obtained at 25m pm and 60 min at 70 mpm
( a) What is the tool life equation
(b) What is the cutting speed for 1 minute life
(c) What is the cutting speed for 60 min life

14. During machining of low carbon steel with H.S.S. cutting tool the following observations have been made
Cutting speed in m/min = 40, 50 Tool Life in min = 40, 10
Derive V.T. relationship.

15. While machining steel with H.S.S. the following data have been received from tool life tests.

Cutting speed (m/min) Feed(mm/rev) Depth of cut(mm) Tool life(min)

8 0.15 1 30
12 0.15 1 20.5
8 0.30 1 14.0

n n
Derive the Taylor’s equation in the form of V f T = Constant
14.A tool wear test has been carried out by turning at two speeds 70m/min and 83m/min, all other conditions
being held constant. The frank lead was measured at five-minute intervals giving the following values.

Flank land wear in mm

Time (min) 70 m/min 83 m/min

start 0 0
5 0.375 0.575
10 0.525 0.775
15 0.65 1.05
20 0.85 1.3

If the 0.75mm wears land is taken as criterion of failure. Estimate the tool life at a speed of 70m/min from the
above cutting conditions

15. For a production turning operations past records have shown that the tool life varies with feed and speed as
shown in the following table.

Cutting speed (m/min) Feed(mm/rev) Tool life(min)

140 0.125 110
170 0.125 37
160 0.2 40

Estimate the tool life for these operations at a speed of 150 m/min and a feed of 0.175 mm/rev .Outline all the
assumptions used to obtain this estimate.
0.13 0.77 0.37
16. The following equation for tool life is given for a turning operation: V .T f d =C
A 60 minute tool life was obtained with cutting at V= 30 m/min, f = 0.3 mm/rev and d =2.5 mm
Determine the change in tool life if the cutting speed and depth of cut are increased by 20% individually and
also taken together.
17. The Taylor tool life equation for machining C-40 steel with a18.41 H.S.S. cutting tool at a feed of
0.2mm/min and a depth of cut of 2mm is given by VT n+= C , where n and C are constants. The following V
and T observations have been made:
V, m/min 25 35
T, min 90 20
Find I) n and C
II) Hence recommended the cutting speed for a desired tool life of 60 minutes.
18. Explain Ideal and Natural Roughness. What are the factors commonly contribute to natural roughness in
Practice.
19. Describe the effect of tool geometry and cutting parameters on surface roughness. What is Ideal Surface
roughness?
20. A Turning Tool has a sharp nose. Side cutting edge angle = 600 and end cutting edge angle of 150. What
Should be the feed rate in order to obtain a Theoretical centre-line average roughness of 15 µm.
21. A Turning Tool has a sharp corner and a side cutting edge angle of 500. What end cutting edge angle should
be provided on the tool, so that under ideal conditions, an arithmetical mean surface roughness of 3 µm can
be obtained at a feed rate of 0.1 mm/rev. (Yc = 80).
22. A Turning Tool has a corner radius of 1.5 mm. What should be the feed rate in order to obtain a theoretical
Centre-line average roughness of 5 µm.
23. What corner radius should be ground on a tool with a rounded corner to give an arithmetical mean surface
roughness of 10 µm, when turning under ideal conditions with a feed of 0.25 mm/rev.? What will be the
expected maximum height of roughness?
24. When turning a cylindrical work piece, two different tools are used. In one tool, no nose radius is provided,
the side cutting and edge cutting angles being 300 and 70 respectively. In the other tool, a nose radius of 0.7
mm is provided. The feed used in both cases is 0.125 mm/rev. Find out the theoretical maximum height of
unevenness in the generated surfaces. Find also the theoretical arithmetical mean value of roughness.
25. Explain what is meant by single pass and multi pass machining operations.
26. What are the various criterions that are considered for economics of machining? Explain.
27. Discuss the variation of cost elements with cutting speed in a single pass machining operation.
28. Derive the relationship for optimum speed and feed for min. cost of production. State clearly the
assumptions made.
29. Derive the relationship for optimum speed and feed for min. time of production.
30. Explain what do you meant by high efficiency range? Explain meaning of max. Profit rate.
31. What are the variables, which affect the economics of machining?
32. Explain the various restrictions encountered while selecting economic conditions.
33. A 1 mm long cut is to be given 100mm dia. Steel bar on an engine lathe. The depth of cut is 6mm and the
feed rate is 0.5 rev/min.
The following costs were considered for this operation
Machine labor Rs 2.00 per hour
Machine Burdon rate 400% of labor
Tool grinding labor Rs 3.00 per hour
Tool Grinding burdon rate 500% of labor
Loading time 5 minutes per part
 The carbide tool is available for this purpose either in the brazed form of throw away insert form. The
various cost for which are as follows:
(1) For Brazed Tool
Original tool cost Rs.18.00
Grinding time 6 minute (1 cutting edge per grind)
Tool changing Time 2.00 Min.( 5 Regrinds possible before discard)
(2)Throw away tool
Original Cost Rs.10.00 per insert
Cutting edge per tool 8
Tool changing time 0.5 min.
0.25
VT =150
Indicate in the above cases when
1 When Brazed tool is to be used
2 When throwaway tool is to be used
34. A 200 mm long and30 mm dia bar is turned on a lathe machine with a feed of 0,25 mm per revolution. The
operating cost is 5 paisa per minute while the tool cost is Rs, 1 per edge. Tool changing time is 1 min.. The
requirements are such that that either of the tool material X or Y can be used. Compare the machining cost
per component whilst operating under most economical conditions forth two materials.
Material Tool Life Equation
X VT 0.10=67
Y VT 0.10=90
35. The following Taylor tool life equation for carbide tool-steel work piece pair was obtained experimentally
VT 0.25=650. A batch of 1000 steel parts, each 100mm dia. and 250 mm length, is to be rough machined
Using a feed of 0.2 mm/rev. If the cost per cutting edge of the throw-away carbide insert is Rs.50, time
required to reset the cutting edge is 1 min, and the total machine rate (including operator cost) is Rs.300/hr,
Calculate (1) optimum cutting speed for minimum cost.(11)corresponding tool life (111) total production
cost if time taken to load and unload the component is 2 min, and the initial setup time is 2 hr., and (iv)
total production time for given batch.
(271m/min., 33 min., Rs.20,267., 3614 min.)
36 Solve the above question by using maximum production rate as the optimizing criterion.
( 494 m/min., 3 min., Rs 29,150., 3180 min.)
37 Cost of brazed carbide tip tool is Rs.500. It can be reground 10 times at a cost of Rs. 50 per regrind. The
Operator wage is Rs. 25 per hour and the overheads are 200 percent on wages. The constants in the Taylor
Tool life equation VTn=C are n= 0.33 and C=320. The tool change time, which includes regrinding, is 5
min and the handling time per component is 8 min. Find the (1) minimum unit production cost (ii) minimum
unit production time for turning of a work piece of diameter 100 mm and length 300 mm using a feed of .25
mm/rev.
38 A cylindrical bar is to be turned. The maximum allowable feed is 0.2 mm/rev. ,and at this feed rate the
m/min. and T is tool life in minutes. The labor cost and overheads is 0.15 Rs/min. and the total cost
involved in each grinding is 2.5 Rs. On average it takes about 2 minutes to change the tool.
Estimate the cutting speed that will lead to the minimum cost, and corresponding tool life. Also, estimate
the cutting speed for maximum production rate. (Ans: Vopt.=27.42 m/min.,T=56 min.,Vmpr=47.92
m/min.)
 UNIT 3
MULTI POINT CUTTING TOOLS, CASTING DESIGN

1. Describe the general geometry of twist drill and discuss the essential features of the cutting action.
2. Discuss the effect of variation of web thickness, helix angle and point angle on the thrust and torque.
3. Explain why the forces and powers consumption’s in drilling are usually determine by the empirical
method.
4. Classify various milling operations. Differentiate between up milling and down milling operations. State in
reference to chips formed and the limitations in each case.
5. Show how the mean chip thickness cut during plain milling is given by tavg = ft (d/D)1/2 =tm/2
State the assumptions made.
6. Determine the power required foe the following plain milling operations-
Material = soft steel
Cutter dia= 75mm
No. of teeth = 25m/min
Cutting speed = 75m/min
Width of cut =100mm
Depth of cut = 5mm
(Ans. HP= 2.5)
7. Determine the power required for the following face milling operations-
Material = mild steel
Tool material = H.S.S
Cutter dia= 50mm
No. of teeth = 10
Cutting speed = 25m/min
Width of cut =50mm
Depth of cut = 5mm

(Ans. HP=1.25)
8. Explain the broaching operation. Give some practical applications where broaching operations are used.
9. Explain the procedure of designing a push type of broach.
10. Calculate the No. of teeth in an internal key way broach for finishing a key way to 12mm wide and 6mm
deep in the boss of 40mm.
11. Find the power consumed in broaching a key way in cast pulley. The size of the key way is 10mm width X
5mmdepth X 30mm length. If broaching is performed at 3m/min and feed for rough and finishing broaching
are respectively 0.10 mm/tooth and 0.03 mm/tooth. Determine the size of the broach.
12 What do you understand by effective feeding distance? How it is effective in the placement of risers in a
casting?
13 Explain principles of Risering. Explain the function of a Riser .Explain the different types of Risers
commonly used in casting processes.
14 What is Chvorinov’s Rule used in designing the Risering systems.
15.Using-(a) Caine method (b) NRL method , designing a risering system, taking into account ease of riser
removal and molding procedure that will produce sound casting with max. yield for the following simple
shapes-
i) Plate of dimensions 10˝ X10˝X2˝
ii) A cube of dimensions to 6˝X6˝X6˝
 iii) A pipe of 30˝ long, outside diameter 5˝ inside dia 3˝

17 Calculate on economical risering system that will ensure soundness in the casting (0.30 steel) shown in
figure.
18 The volume of a cube of side l and volume of a sphere of radius r are equal. Both the cube and the sphere
are solid and of the same material. They are being cast. Compute the ratio of solidification time of the cube to
the same of the sphere.
19 What is meant by hot tears? How they can be prevented?
20 What are Chills? Why and where they are used in castings?
21 What is meant by aspiration effect? How it can be prevented?
22 Explain the different kinds of Gating Systems with suitable sketches. Explain the purpose of finger gates,
Relief sprue, Knife gates, Swirl gates and where they are used?.
23 Derive a relation for determining the area of cross section of an aspiration free vertical gating system.
24 Derive the relation for determining the time required to full a casting by bottom gating system.
25 Calculate A2 required pouring an entire mode (riser and casting) in 10 second without aspiration after the
cope surface. Neglect frictional and orifice effects.
26 In the pouring cup down sprue system shown derive the relationship between A1 and A2 which will avoid
aspiration using Bernoulli’s equation.
27 Determine the time of filling up the casting using Vertical gating system
Length of the sprue =5 cm.
Area of the ingate is 1 cm2
Casing Dimensions are 20x10x5 cm
28 A mould has downsprue whose length is 20 cm. and crossectional area at the base of downsprue is 1 cm2 .
The downsprue feeds a horizontal runner leading in to the mould cavity of volume 1000 cm 3.Find the time
required to fill the mould cavity. (Ans: 5.05 Sec.)
29 A 200mm long down sprue has an area of cross section of 650mm2 where the pouring meets the down
sprue. A constant head of molten metal is maintained by the pouring basin. The molten metal flow rate is
6.5x105mm3/sec.Considring the end of the down sprue to be open to atmosphere and acceleration due to
gravity of 104 mm/sec2, calculate the area of down sprue in mm2 at its end avoiding aspiration effect. ( Ans
A=290.7mm2)
30 For the above problem if we use bottom gating system what will be the time of filling up the casting.

UNIT –4

PRESS AND PRESS TOOL DESIGN

1. Differentiate clearly between Blanking and Piercing die?

2. Explain the following respect to blanking and piercing dies, clearance, and shear on dies. What is the effect
of each on size and shape of the cut blank? What is optimum clearance? What is the effect of excessive
clearance or too small clearance?
3. What is the difference between a progressive die, compound die, and a combination die?
4. What is the function of stripper? What are the various types of stripper use in dies?
5. Calculate the press tonnage for blanking the part of figure 1(a,b,c)
6. Calculate the Centre of pressure of the parts shown in figure 1 ( a,b,c)
7. What is the basic principal involved in a bending die? What cause a spring block?
8. Calculate the bending pressure for the following bends-
(a) 90 degree bend is 7.5 mm metal 12 mm IR 30 cm long
(b) 90 degree bend is 3 mm metal 12 mm IR 40 cm long
9. What is a progressive die? What operations can be performed on a progressive die?
10. Why is piloting required?
11. Find the total pressure, dimension of the tool to produce a washer 5 cm. outside diameter with a 2.4 cm.
diameter hole, from material 4 mm thick, having a shear strength of 360 N/mm2
12. Explain coming, embossing, curling and wiring processes.
13. How drawing is different from cupping? Give the design procedure of drawing dies. State the formula for
determining the blank die for drawing operation.
14. Determine the drawing pressure for a 1.5-mm thick shell of 75-mm diameter of steel having yield stress of
21 kg/mm2.
15. A cup without flanges and height 10 cm. and diameter 5 cm. is to be made from sheet metal 2.5 mm thick.
Find the suitable numbers of draws.
16. A 37.5 cm. long, 19 mm wide and 2.5 mm thick strip is to be bent in a v-shaped die. Calculate the bending
force necessary if the steel has tensile strength of 630 N/mm2
17. Estimate the bending force to cut a blank 25mm wide and 30 mm long from a 1.5 mm thick metal strip, if
the ultimate shear stress of the material is 450 N/mm2. Also determine the work done if percentage
penetration is 25 percent of material thickness.
18. A symmetrical-cup work piece shown in fig. is to be made from rolled steel 0.8 mm thick. Make the
necessary calculations for designing the drawing die for this part.
19. Calculate the bending force for channel bending for the following data.
Thickness of blank 3.2 mm
Bending length 900 mm
Die radius = punch radius = 9.5 mm.
Ultimate tensile strength of the material 400 N/mm2

UNIT-5

JIGS AND FIXTURES

1. Define Jig and a Fixture. Clearly establishing the difference between the two. How are Jigs and Fixture
useful to us?
2. List the main components of jigs and fixtures. How are jigs and fixtures classified? Briefly explain the
principles of jigs and fixtures design.
3. Classify the drilling Jigs and make a sketch of each class. How does a Template Jig differ from a Plate Jig.
4. What are the principles of locating a drilling jig? Describe the degree of freedom of work piece located in
space. Draw a simple sketch to show the 3-2-1 locating principle.
5. List the kind of locators commonly used and explain each with sketch.
6. What is the function of a clamp in tool design? State the requirement’s of a good clamping system.
7. With the help of sketches show the various clamping devices in use.
8. Classify the bushes used in drilling jigs. State each kind of bush.
9. What is an indexing jig? What are the various kinds of indexing devices?
10. What do you understand by Degree of freedom in regard to jigs and Fixtures Design? Briefly describe the
Principle of Locations. What is the main function of a locating device?
11. Explain the following briefly
1 Cylindrical locators 2 V-Locators 3.Diamond Locators
12. Enumerate various types of Fixtures. Explain the following types of Fixtures briefly
1 Turning Fixtures 2. Indexing Fixtures 3.Milling Fixtures
12. Explain the Economics of Jigs and Fixtures. Derive an expression for number of years for recovering the
investment as depreciation.
14. How are the jigs broadly classified? Explain the following types of jigs briefly
Template jigs
Ring jig
Universal jig and leaf jig.
15 Enumerate various types of clamps. Explain the following briefly
Quick acting clamps
Clamping screw