Reg. No.

Question Paper Code :

33520

Common to M.E. CAD/CAM/M.E. Computer Aided Design/M.E. Engineering Design/M.E. Product Design and Development Elective

220077 ADVANCED TOOL DESIGN (Regulation 2010) Time : Three hours

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Answer ALL questions.

1. 2. 3.

What is a design procedure? Why is it necessary? What are the major characteristics of Group H tool steels? In an orthogonal cutting operation, the tool has a rake angle of 15, the chip thickness before the cut is 0.3 mm and the cut yields a deformed chip thickness = 0.60 mm. Calculate (a) Shear plane angle (b) the shear strain for the operation. Generally speaking, why should milling cutters with straight flutes be avoided? Sketch a screw clamp, and when it is used? Why are keys mounted to the base of milling fixtures? Give a sketch

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4.

5. 6. 7.

Calculate the percentage utilization of material to punch the mild steel washer in single row feeding, which is having outside diameter of 30 mm, inside diameter of 18 mm and thickness of 2 mm. (Assume margin is equal to thickness).

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PART A (10 2 = 20 marks)

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M.E./M.Tech. DEGREE EXAMINATION, NOVEMBER/DECEMBER 2011.

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Maximum : 100 marks

8.

Find the force required for V bending of work piece having ultimate tensile strength 360 N/mm2 and if sheet metal thickness is 2 mm and the constant length of the V to be bent is 50 mm? (Width of V die is 20 mm).

9. 10.

What is the advantage of a universal grid plate for N/C tooling? What is the advantage of spade drills?

PART B (5 16 = 80 marks) 11. (a) (i) (ii)

List and briefly describe the six principles of economic design. What are the basic groups of tungsten carbide cutting tools? Explain the selection criterion for various conditions. Or

(b)

(i) (ii)

Briefly discuss about non metallic tool materials What are the characteristics of a good quenching oil? Why should tools be tempered immediately after quenching?

12.

(a)

An insert type carbide tool is required to be designed for a turning

Material : C45 steel, Cutting speed : 200 m/min, Max depth of cut : 5 mm, Max feed rate: 0.5 mm/rev, Permissible deflection at the cutting edge 0.1 mm, specific cutting resistance of the steel material 3 kN /mm2 Suggest a suitable material of the shank. Specify the angles. Or

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(b)

The bore of an alloy steel component is to be finish broached to 21 .75 mm diameter, the bore prior to broaching being 21.24 mm diameter. Determine (i) Pitch of teeth (ii) Length of cutting portion (iii) Force to pull broach through work if length of hole is 36 mm and rise per tooth is 0.025. Number of finishing teeth is 3 and force to remove 1 sq mm of metal is 4800 N. Sketch the broach.

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operation with the following data available.

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13.

(a)

(b)

Fig. 1 Or Design a turning fixture to bore 32 hole in the component shown in Fig. 2. All the operations are complete except for the hole.

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(a)

Fig. 2 Design and draw any two view of a progressive die to make a component as shown Fig. 3 from 0.5 mm steel sheet. The ultimate shear stress of the material is 350 N/mm2.

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Matl : Steel Thick : 0.5 mm max 350 N/mm2

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Fig. 3 Or 3

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Design a milling fixture to gang mill the slots in the sight bracket shown in Fig. 1.

(b)

15.

(a)

Or (b) (i)

(ii)

Select an N/C machine tool and design a system of universal tooling that will allow the setup of a wide variety of work pieces.

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What is the most common and least complicated method of tool presetting? What is meant by a tool offset that is built into the control of a N/C lathe?

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Select a carbide tool for the component of your choice, and discuss the selection criteria for insert geometry, shape, tool holder, cutting speed, and machining time. Work material C45. (Machine : CNC Turning Centre).

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A steel cup of height 30 mm and internal diameter 40 mm, is to be deep drawn from a sheet 1 mm thick. Design a drawing die. Determine the diameter of the blank and drawing force. What is the draw ratio? Can the cup be drawn in a single operation? The properties of steel are: Yield Point = 150 MPa, Ultimate tensile strength = 350 MPa,