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TheoryofMetalCutting
BySKMondal
Statement(I):Negativerakeanglesarepreferredonrigid setupsforinterruptedcuttinganddifficulttomachine materials. materials Statement(II):Negativerakeangledirectsthechipsonto themachinedsurface (a) Both Statement (I) and Statement (II) are individually true and Statement (II) is the correct explanation of Statement ( ) (I) (b) Both Statement (I) and Statement (II) are individually true but Statement (II) is not the correct explanation of Statement (I) Ans. (b) (c) Statement (I) is true but Statement (II) is false (d) Statement (I) is false but Statement (II) is true
IES 2012 S 0
Assertion (A): For drilling cast iron, the tool is provided with a point angle smaller than that required for a ductile material. Reason ( ) Smaller point angle results in l (R): ll l l lower rake angle. (a) Both ( ) B h A and R are i di id ll true and R i the d individually d is h correct explanation of A (b) B th A and R are i di id ll t Both d individually true b t R i not th but is t the correct explanation of A (c) A is true but R is false (d) A is false but R is true Ans. (c)
S 2006 IES2006
IES1994
Tool geometry of a single point cutting tool is specified by the following elements: 1. Back rake angle 2. Side rake angle 3. End cutting edge angle 4. Side cutting edge angle 5. Side relief angle d l f l 6. End relief angle 7. 7 Nose radius The correct sequence of these tool elements used for y p y g g y correctly specifying the tool geometry is (a) 1,2,3,6,5,4,7 (b) 1,2,6,5,3,4,7 (c) 1,2,5,6,3,4,7 (d) 1, 2, 6, 3, 5, 4,7 Ans. (b)
Ans.(b)
ISRO2011
A cutting tool having tool signature as 10, 9, 6, 6, 8, 8, 8 8 2 will have side rake angle (a) 10o Ans. (b) (b) 9o (c) 8o (d) 2o
IAS 2009Main
The following parameters determine the model of continuous chip formation: d l f i hi f i 1. True feed 2. Cutting velocity 3. 3 Chip thickness 4. Rake angle of the cutting tool. The Th parameters which govern the value of shear hi h h l f h angle would include (a) 1,2 and 3 (b) 1,3 and 4 (c) 1,2 and 4 (d) 2,3 and 4 Ans. (b)
IES 2004
In a machining operation chip I hi i i hi thickness ratio is 0.3 and the rake angle of the tool is 10. What is the value of the shear strain? (a) 0.31 (b) 0.13 (c) ( ) 3.00 (d) 3.34 ( ) Ans. (d)
If is the rake angle of the cutting tool, is the shear angle and V is the cutting velocity, then the velocity of chip sliding along the shear plane is given by (a) (c)
V cos cos( )
V cos sin( )
(b) (d)
V sin cos ( )
V sin sin( )
Ans. (a)
Ans.(a) A ( )
Ch 1 M h i f B i M hi i O ti Ch1:MechanicsofBasicMachiningOperation
Q. No 1 2 3 4 5 6 7 8 9 10 Option C B D C B D B A B B Q. No 11 12 13 14 15 16 17 18 19 20 Option D D B C D B B D D B
BySKMondal
ForPSU&IES
In strain gauge dynamometers the use of how many active gauge makes the dynamometers more effective (a) Four (b) Three (c) Two (d) One Ans. (a) ( )
i ( ) GATE2006CommonDataQuestions(1)
g g p Inanorthogonalmachiningoperation: Uncutthickness=0.5mm g p / g 5 Cuttingspeed=20m/min Rakeangle=15 Widthofcut=5mm Chipthickness=0.7mm Thrustforce 200N Thrustforce=200N Cuttingforce 1200N Cuttingforce=1200N AssumeMerchant'stheory. Thecoefficientoffrictionatthetoolchipinterfaceis (a)0.23 (b)0.46 (c)0.85 (c)0 85 (d)0.95 (d)0 95 Ans.(b)
i ( ) GATE2006CommonDataQuestions(2)
g g p Inanorthogonalmachiningoperation: Uncutthickness=0.5mm g p / g 5 Cuttingspeed=20m/min Rakeangle=15 Widthofcut=5mm Chipthickness=0.7mm Thrustforce 200N Thrustforce=200N Cuttingforce 1200N Cuttingforce=1200N AssumeMerchant'stheory. Thepercentageoftotalenergydissipateddueto frictionatthetoolchipinterfaceis (a)30% (b)42% (c)58% (d)70% Ans.(a)
i ( ) GATE2006CommonDataQuestions(3)
g g p Inanorthogonalmachiningoperation: Uncutthickness=0.5mm g p / g 5 Cuttingspeed=20m/min Rakeangle=15 Widthofcut=5mm Chipthickness=0.7mm Thrustforce 200N Thrustforce=200N Cuttingforce 1200N Cuttingforce=1200N AssumeMerchant'stheory. Thevaluesofshearangleandshearstrain, Thevaluesofshearangleandshearstrain respectively,are (a)30.3 and1.98 (a)30 3 and1 98 (b)30.3 and4.23 (b)30 3 and4 23 (c)40.2 and2.97 (d)40.2 and1.65Ans.(d)
i ( ) GATE2003CommonDataQuestions(1)
y g A cylinder is turned on a lathe with orthogonal machining principle. Spindle rotates at 200 rpm. The axial feed rate is 0.25 mm per revolution. Depth of cut is 0.4 mm. The rake angle i 10. In the analysis i i f h k l is h l i it is found d that the shear angle is 27.75 Thethicknessoftheproducedchipis Th thi k fth d d hi i (a)0.511mm (b)0.528mm (c)0.818mm ( ) (d)0.846mm (d) Ans.(a)
i ( ) GATE2003CommonDataQuestions(2)
y g A cylinder is turned on a lathe with orthogonal machining principle. Spindle rotates at 200 rpm. The axial feed rate is 0.25 mm per revolution. Depth of cut is 0.4 mm. The rake angle i 10. In the analysis i i f h k l is h l i it is found d that the shear angle is 27.75 Intheaboveproblem,thecoefficientoffrictionat I th b bl th ffi i t ff i ti t thechiptoolinterfaceobtainedusingEarnestand Merchanttheoryis (a)0.18 (b)0.36 (c)0.71 (c)0 71 (d)0.98 (d)0 98 Ans.(d) Ans (d)
i ( ) GATE2008CommonDataQuestion(1)
g g performed on a cylindrical work y Orthogonal turning is p piece with shear strength of 250 MPa. The following conditions are used: cutting velocity is 180 m/min. feed is i 0.20 mm/rev. d h of cut i 3 mm. chip thickness / depth f is hi hi k ratio = 0.5. The orthogonal rake angle is 7o. Apply Merchant s Merchant's theory for analysis analysis. Theshearplaneangle(indegree)andtheshear forcerespectivelyare (a)52:320N (b)52:400N (c)28:400N (d)28:320N Ans.(d) Ans (d)
i ( ) GATE2008CommonDataQuestion(2)
g g performed on a cylindrical work y Orthogonal turning is p piece with shear strength of 250 MPa. The following conditions are used: cutting velocity is 180 m/min. feed is i 0.20 mm/rev. d h of cut i 3 mm. chip thickness / depth f is hi hi k ratio = 0.5. The orthogonal rake angle is 7o. Apply Merchant s Merchant's theory for analysis analysis. Thecuttingandthrustforces,respectively,are (a)568N;387N (b)565N;381N (a) 68N 38 N (b) 6 N 38 N (c)440N;342N (d)480N;356N [Ans.(b)]
Ans.(b)
( b)2
( c)
( d) 2 2
Ans.(a)
Ans. (c)
Ans. (b)
Ans. (b)
BySKMondal
IAS 2009Main
Explainsuddendeathmechanismoftoolfailure. [4 marks]
Ans.(c)
IFS2009
With the help of Taylors tool life equation, determine the shape of the cur e bet een velocity curve between elocit of cutting and life of the tool. Assume an HSS tool and steel as work material. [10Marks] [ M k ]
Ans.(c) A ( )
Ans.(b)
GATE2009(PI)
In an orthogonal machining operation, the tool life obtained is 10 min at a cutting speed of 100 m/min 0 00 m/min, while at 75 m/min cutting speed, the tool life is 30 min. The value of index (n) in the Taylors tool life equation (a) 0.262 Ans. (a) (b) 0.323 (c) 0.423 (d) 0.521
Ans.(a)
During machining, the wear land (h) has been plotted against machining time (T) as given in the following figure.
GATE2008(PI) G 008 ( )
For a critical wear land of 1.8 mm, the cutting tool life (in minute) is ) Ans.(b) Ans (b) (a) 52.00 (b) 51.67 (c) 51.50 (d) 50.00
ISRO2012
What is the correct sequence of the following parameters in order of their maximum to minimum influence on tool lif ? i fl l life? 1. Feed rate 2. Depth of cut 3. Cutting speed Select the correct answer using the codes given below (a) 1, 2, 3 (b) 3, 2, 1 (c) 2, 3, 1 (d) 3, 1, 2 Ans. (d)
Ans.(a)
Ans.(a) ( )
Ans. (c)
Ans.(a)
Ans.(b) A (b)
B 2 1
C 4 4
D 5 2
(b) (d)
A 4 4
B 1 2
C 3 3
D 2 5
Ans.(c)
Ans.(c)
ISRO2007
Machinablity depends on (a) Microstructure, physical and mechanical properties and composition of workpiece material. (b) Cutting forces (c) Type of chip (d) Tool life Ans. (a) ( )
Ans. (b)
Ans.(c)
Ans.(b)
Ans.(b)
Two tools P and Q have signatures 5566830 5 ) p y 0 and 5 5 7 7 55778150 ( (both ASA) respectively. They are used to turn components under the same machining conditions. If hp and hQ denote the peak tovalley heights of surfaces produced by the tools P and Q, the ratio hp/hQ will be
MetalForming M t lF i
BySKMondal d l
ISRO2010
Materials after cold working are subjected to following process to relieve stresses (a) Hot working (b) T Tempering i (c) Normalizing (d) Annealing g Ans. (d)
Ans. ( ) (c)
ISRO2009
In the metal forming process, the stresses encountered are (a) Greater than yield strength but less than ultimate strength (b) Less than yield strength of the material (c) Greater than the ultimate strength of the material i l (d) Less than the elastic limit Ans. (a)
Rolling R lli
BySKMondal
ISRO2006
Which of the following processes would produce strongest components? (a) Hot rolling (b) Extrusion (c) Cold rolling (d) Forging Ans. Ans (c)
ISRO2009
Ring rolling is used (a) To decrease the thickness and increase diameter (b) To increase the thickness of a ring (c) For producing a seamless tube (d) For producing large cylinder Ans. (a) ( )
GATE 2009(PI)
Anisotropy in rolled components is caused by (a) h ( ) changes in d dimensions (b) scale formation sca e o a o (c) closure of defects (d) grain orientation Ans. (d) A
[ForIESConventionalOnly]
A ti i R lli AssumptionsinRolling
1. Rolls are straight, rigid cylinders. 2. Strip is wide compared with its thickness, so that no
widening of strip occurs (plane strain conditions). 3. The arc of contact is circular with a radius greater than the radius of the roll. 4. Th material i rigid perfectly plastic ( The i l is i id f l l i (constant yield i ld strength). 5. Th coefficient of f i ti The ffi i t f friction i constant over th t l is t t the tool work interface.
StressEquilibriumofanElementinRolling
Considering the thickness of the element perpendicular to the plane of paper to be unity, We get equilibrium equation in x direction as, - x h + ( x +d x ) (h + dh) - 2pR d sin
+ 2 x R d cos = 0
For sliding friction, x = p Simplifying and neglecting second order terms, sin and cos = 1, we get , , g d ( x h ) = 2 pR ( ) d 2 p x = 0 = 0' 3 d ' h ( p 0 ) = 2 pR ( ) d d ' p 0 h ' 1 = 2 pR ( ) d 0 d d p p ' 0 h + ' 1 0' h ) = 2 pR ( ) ( ' d 0 0 d
( p / )
' 0 ' 0
)=
2R ) d 2 ( h f + R 2R 2R h f + R 2 d = I II (say)
2Rd I= = 2 h f + R
2Rd h =
2d h h / R = ln R
hf Now h / R = + 2 R d h or R = 2 d 2R II = d 2 h f + R 2 = d 2 hf / R + = 2 R R 1 .tan . h hf f
ln p /
' 0
' 0
h = ln 2 R
R .tan 1 hf
R . + ln C h f
h H p = C e R R .tan 1 hf R . h f
where H = 2
Now at entry , = Hence H = H0 with replaced by in above equation H ith l db i b ti At exit = 0 Therefor p = '0
h ( H0 H ) p= . e h0
' 0
IFS 2010
Calculate the neutral plane to roll 250 mm wide annealed copper strip from 2.5 mm to 2.0 mm thickness with 350 mm diameter steel rolls Take = rolls. 0.05 and o =180 MPa. [10 marks] [10marks]
RollingCh14
Q.No 1 2 3 4 5 6 7 8 9 10 11 12 Option C B D D A A B D C C B C
Forging F gi g
BySKMondal
IFS2011
What advantages does press forging have over drop forging ? Why are pure metals more easily cold worked than alloys ? [5marks]
IAS2011Main
Compare Smith forging, drop forging, press forging and upset forging Mention three points forging. for each. [10 Marks]
IES 2007
Sometimes the parting plane between two forging dies is not a hori ontal plane gi e the main reason horizontal plane, give for this design aspect, why is parting plane provided, in closed die forging? [2marks] [ k ]
St t t (I): is difficult to i t i l Statement (I) It i diffi lt t maintain close t l tolerance i in normal forging operation. Statement (II): Forging is workable for simple shapes and has limitation for parts having undercuts. ( ) (a) Both Statement (I) and Statement (II) are () ( ) individually true and Statement (II) is the correct explanation of Statement (I) (b) B th St t Both Statement (I) and St t t d Statement (II) are t individually true but Statement (II) is not the correct explanation of Statement (I) p () (c) Statement (I) is true but Statement (II) is false ( ) (d) Statement (I) is false but Statement (II) is true () ( ) Ans. (b)
IES 2012
IES 2008
Match ListI with ListII and select the correct answer using g the code given below the lists: ListI(Forging ListII(Process) Technique) A.SmithForging B.DropForging C.PressForging D.Machine Forging Code: A (a) 2 (c) 2 B 3 1 1. Materialisonlyupsettogetthedesiredshape 2. Carriedoutmanuallyopendies 3. Done in closed impression dies by hammers in blows 4. Done in closed impression dies by continuous squeezing force C 4 4 D 1 3 A 4 4 B 3 1 C 2 2 D 1 3
Ans.(a)
(b) (d)
Ans. (a)
Ans. (b)
GATE2008(PI)
Group2 1.Upsetting i 2.Deepdrawing 3.Extrusion 4.Closeddieforging (b)P 3,Q 4,R 1,S2 (d)P 2,Q 4,R 3,S1 Ans.(c)
forging force. [ [Ans. 46.26 MN] 4 ] [Hint. First calculate true strain and put the value in the equation
f = 1030 0.17 = y
. Determine maximum
forging load, mean die pressure and maximum pressure. [ Ans. 9.771 MN, 178 MPa, 221 MPa] 9 77 , 7 , ] [Hint. First calculate true strain and put the value in the equation
f = 200(0.01 + ) 0.41 = y
PracticeProblem5{GATE2010(PI)} { ( )}
During open die forging process using two flat and parallel dies, a solid circular steel disc of initial radius (R IN ) 200 mm and initial N height (H IN ) 50 mm attains a height (H FN ) of 30 mm and radius of R FN . Along the die-disc interfaces.
R IN i. the coefficient of friction ( ) is: = 0.35 1 + e RFN ii. in the region R ss r RFN ,sliding friction prevails, and
p = 3Ke
2 ( RFN r ) H FN
and = p,
where p and are the normal and shear stresses, respectively; K is the shear yield strength of steel and r is the radial distance of any point (contd ........)
Contd.
PracticeProblem5{GATE2010(PI)}
iii.In the region 0 r R SS ,sticking condition prevails The value of R SS (in mm), where sticking condition changes to sliding friction, is (a) 241.76 (b) 254.55 (c) 265.45 (d) 278.20
Ans.(b) ( )
Extrusion&Drawing g
BySKMondal d l
GATE2008(PI)LinkedS1 G 008 ( ) ed S
A 10 mm diameter annealed steel wire is drawn through a die at a speed of 0.5 m/s to reduce the diameter by 20%. The yield stress of the material is 800 MPa. y Neglecting friction and strain hardening, the stress required for drawing (in MPa) is (a) 178 5 (b) 357 0 178.5 357.0 Ans. (b) (c) 1287 5 1287.5 (d) 2575 0 2575.0
GATE2008(PI)LinkedS2 G 008 ( ) ed S
A 10 mm diameter annealed steel wire is drawn through a die at a speed of 0.5 m/s to reduce the diameter by 20%. The yield stress of the material is 800 MPa. y The power required for the drawing process (in kW) is (a) 8.97 Ans.(a) Ans (a) (b) 14.0 (c) 17.95 (d) 28.0
Ans. (b)
Ans. (b)
Ans. (a)
1. 2. 3. 4. D 3 4 (b) (d)
Shear force Tensile force Compressive force Spring back force A B C D 2 1 3 4 4 3 2 1 Ans.(c)
A. A B. C. C D.
1. 2. 3. 4. 5. (b) (d)
A. Seamless t b A S l tubes 1. B. Accurate and smooth tubes 2. C. Surfaces h i hi h C S f having higher 3. hardness and fatigue strength4. Codes: A B C A (a) 1 4 2 (b) 2 (c) 1 3 2 (d) 2
Ans. (c)
WireDrawingAnalysis(HomeWork) g y ( )
( x + d x ) ( r + dr )
Dividing by r dr and taking dx/dr = cot we get d x 2 2 x + ( x + Px ) + cot = 0 dr r r Vertical component of Px Px due to small half die
2
angles and that of x can be neglected. neglected Thefore, two principal stresses are x and Px Both Tresca's and Von-Mises criteria will give x + Px = o
and x = Px = ( o x )
or B x (1 + B ) o = ( rC ) B.C s at r = ro , x = b B b (1 + B ) o C = ro
1 2B
2B
r 2 B r 2 B o (1 + B ) 1 + . b or x = B ro ro Drawing stress ( d ) =
o (1 + B )
B
rf rf 1 + . b ro ro
2B 2B
ExtrusionAnalysis(HomeWork) y ( )
For a round bar both wire drawing and extrusion will give same equation except B.Cs BC B x (1 + B ) o = ( rC ) B.C s at r = rf , x = 0 (1 + B ) o C = rf
1 2B 2B
o (1 + B ) r 1 or x = B rf
2B
at r = ro
xo
o (1 + B ) ro 1 = B rf
2B
xo =
o (1 + B )
B
SheetMetalOperation
BySKMondal
Example
Determine the die and punch sizes for blanking a circular disc of 20mm diameter from a sheet whose thickness is 1.5 di f di t f h t h thi k i mm. Shear strength of sheet material = 294 MPa Also determine the die and punch sizes for punching a circular hole of 20mm diameter from a sheet whose thickness is 1.5 mm.
Example
g 5 Estimate the blanking force to cut a blank 25 mm wide and 30 mm long from a 1.5 mm thick metal strip, if the ultimate shear strength of the material i 450 N/ li h h f h i l is N/mm2. Also determine the work done if the percentage penetration is 25 percent of material thickness.
IAS2011Main
For punching a 10 mm circular hole, and cutting a rectangular blank of 50 x 200 mm from a sheet of 1 mm thickness ( ild steel, shear stress = 240 hi k (mild l h N/mm2), Calculate, in each case : (i) Si of punch Size f h (ii) Size of die (iii) F Force required. i d [10Marks] [ M k ]
Ans.(c)
E l Example
A hole, 100 mm diameter, is to be punched in steel plate hole diameter 5.6 mm thick. The ultimate shear stress is 550 N/mm2 . With normal clearance on the tools, cutting is complete 4 p p p at 40 per cent penetration of the punch. Give suitable shear angle for the punch to bring the work within the capacity of a 30T press. it f T
Ans. 4.2o
Example
A washer with a 12.7 mm internal hole and an outside diameter of 25.4 mm is to be made from 1.5 mm thick 25 4 15 strip. The ultimate shearing strength of the material of the washer is 280 N/mm2. (a) Find the total cutting force if both punches act at the same time and no shear is applied to either punch or the die. (b) What will be the cutting force if the punches are staggered, so that only one punch acts at a time. (c) ( ) Taking 60% penetration and shear on punch of 1 k % d h h f mm, what will be the cutting force if both punches act g together. Ans. 50.25 kN, 33.51 kN, F = 45.24 kN
Assuming force vs displacement curve to be rectangular, the work d h k done (i J) i (in is (a) 100 (b) 200 (c) 250 (d) 300 [Ans. (a)]
A shear of 20 mm (S = 20 mm) is now provided on the blade. blade Assuming force vs displacement curve to be trapezoidal, the maximum force (in kN) exerted is (a) 5 (b) 10 (c) 20 (d) 40 [Ans. (b)]
Ans. (c)
Ans. (b) A
GATE 2012
Calculate the punch size in mm, for a circular blanking operation for which details are given below. Size of the blank 25 mm Thickness of the sheet 2 mm Radial clearance between punch and die 0.06 mm Die allowance 0.05 mm (a) 24.83 (b) 24.89 ( ) 5 (c) 25.01 ( ) 5 7 (d) 25.17 Ans. (a)
GATE2008(PI)
A blank of 50 mm diameter is to be sheared from a sheet of 2.5 mm thickness. The required radial clearance between the die and the punch is 6% of sheet thickness The punch and die diameters (in mm) thickness. for this blanking operation, respectively, are (a) 50.00 and 50.30 (c) 49.70 and 50.00 Ans. (c) (b) 50.00 and 50.15 (d) 49.85 and 50.00
(a) 35+0.00 and 35+0.040 (b) 350.040 and 350.080 4 (c) 350.080 and 35+0.00 (d) 35+0.040 and 350.080 Ans.(c)
Ans. (a) A ( )
IFS 2009
What is deep drawing process for sheet metal forming? E plain the function of a blank holder Explain holder. What is drawing ratio and how is the drawing ratio increased ? [10 [ marks] k ]
ISRO2011
The initial blank diameter required to form y p a cylindrical cup of outside diameter 'd and total height 'h' having a corner radius 'r' is g obtained using the formula
(d ) Do = d + 4dh 0.5r
2
Ans.(d)
IFS2011
Comparemetalspinningwithpresswork. [2marks]
IFS2011
Writefouradvantagesofhighvelocityformingprocess. [2marks]
1 radian
Ans. (c)
GATE2012SameQinGATE2012(PI)
Match the following metal forming processes with their associated stresses in the workpiece. Metalformingprocess 1.Coining 2.WireDrawing g 3.Blanking 4.DeepDrawing ( ) , (a) 1S, 2P, 3Q, 4R , 3 Q, 4 (c) 1P, 2Q, 3S, 4R Typeofstress P.Tensile Q Q.Shear R.Tensileand compressive S.Compressive ( ) , (b) 1S, 2P, 3R, 4Q ,3 ,4 Q (d) 1P, 2R, 3Q, 4S
Ans.(a)
Ans. (d)
PowderMetallurgy
BySKMondal
GATE2011(PI)
Which of the following powder production methods produces spongy and porous particles? i l ? (a) Atomization (b) Reduction of metal oxides (c) Electrolytic deposition (d) Pulverization Ans. (b)
IES 2007Conventional
Metal powders are compacted by many methods, but sintering is required to achieve which property? What is hot isostatic pressing?
[2Marks]
GATE2010(PI)
In powder metallurgy, sintering of a component (a) ( ) Improves strength and reduces h d h d d hardness (b) Reduces brittleness and improves strength educes b e ess a d p o es s e g (c) Improves hardness and reduces toughness (d) Reduces porosity and increases brittleness Ans. (b) A
IES 2011Conventional
Whatisisostatic pressingofmetalpowders? Whatareitsadvantage? [2Marks]
GATE 2009(PI)
Which of the following process is used to manufacture products with controlled porosit ? ith porosity? (a) Casting (b) welding (c) formation (d) Powder metallurgy Ans. Ans (d)
GATE 2011(PI)
The binding material used in cemented carbide cutting tools is (a) graphite (b) tungsten (c) nickel (d) cobalt Ans. (d) ( )
Ans. (c)
Ans. (c) ( )
Ans. (b)
Ans. (d)
Ans. (a)
Ans. (b)
Ans. (b)
St t t (I): Parts d by d t ll Statement (I) P t made b powder metallurgy d do not have as good physical properties as parts casted. Statement (II): Particle shape in powder metallurgy influences the flow characteristic of the powder. ( ) (a) Both Statement (I) and Statement (II) are () ( ) individually true and Statement (II) is the correct explanation of Statement (I) (b) B th St t Both Statement (I) and St t t d Statement (II) are t individually true but Statement (II) is not the correct explanation of Statement (I) p () (c) Statement (I) is true but Statement (II) is false ( ) (d) Statement (I) is false but Statement (II) is true () ( ) Ans. (b)
IES 2012
Ans. (c)
Ans. (d)
C ti l Q ti ConventionalQuestions
1. Explain why metal powders are blended. Describe what
C ti l Q ti ConventionalQuestions
1. Discuss the terms fineness and particle size
distribution in powder metallurgy. [IES2010, 2 metallurgy [IES 2010 Marks] Ans. Fineness: Is the diameter of spherical shaped particle and mean diameter of nonspherical shaped particle. Particle size distribution: Geometric standard deviation (a measure for the bredth or width of a ( distribution), is the ratio of particle size diameters taken at 84.1 and 50% of the cumulative undersized weight plot respectively and mean mass diameter plot, define the particle size distribution.
C ti l Q ti ConventionalQuestions
Enumerate the steps involved in powder metallurgy process. Discuss these steps. Name the materials used Di h N h i l d in powder metallurgy. What are the limitations of powder metallurgy? [IES2005, [IES2005 10 Marks]
Ch12:PowderMetallurgy
Q. No 1 2 3 4 Option D B C A Q. No 5 6 7 8 Option C B D C
Limit,Tolerance&Fits ,
BySKMondal
ForPSU
Tolerancesarespecified (a) Toobtaindesiredfits (b) becauseitisnotpossibletomanufactureasize exactly (c) toobtainhigheraccuracy (d) tohaveproperallowances Ans.(b) ( )
ISRO2010
Expressing a dimension as 25.30.05 mm is the case of (a) ( ) Unilateral tolerance l l l (b) Bilateral tolerance a e a o e a ce (c) Limiting dimensions (d) All of the above Ans. A (b)
Ans. (c)
Ans.(c)
between 10 - 15 microns, diameter of the hole before plating should be (a) 30+0.070 mm +0.030 (c) 30
+0.080 +0.030 0.065 (b) 30+0.020 mm +
mm
(d) 30
+0.070 +0.040
mm
Ans.(d)
mm. The
corresponding shaft is of dimension The resulting assembly has (a) loose running fit g (b) close running fit (c) transition fit ( ) (d) interference fit Ans. (c)
+0.010 +0.001
mm.
GATE2012SameQinGATE2012(PI)
In an interchangeable assembly, shafts of size mm mate with holes of size
25
+0 04 0.04 0.01
25
+0.03 +0.02
mm.
The maximum interference (in microns) in the assembly is (a) 40 (b) 30 (c) 20 (d) 10 Ans. (c)
IAS2011Main
An interference assembly, of nominal diameter 20 mm, mm is of a unilateral holes and a shafts The shafts. manufacturing tolerances for the holes are twice that for the shaft. Permitted interference values are 3 9 0.03 to 0.09 mm. Determine the sizes, with limits, for the two mating parts. [10Marks] [ M k ]
Ans.(a)
ISRO2011
Ashaftandholepairisdesignatedas50H7d8.This assemblyconstitutes (a)Interferencefit (b)Transitionfit ( ) (c)Clearancefit (d)Noneoftheabove Ans.(c) ( )
Ans. (d)
Ans. (b)
Ans. (b)
ISRO2008
Basic shaft and basic hole are those whose upper deviations de iations and lo er de iations respecti el are lower deviations respectively (a) +ve, ve (c) Zero, Zero (b) ve, +ve (d) None of the above
Ans. (c)
Ans.(d)
IAS2010main
What is the difference between hole basis system and shaft basis system ? Why is hole basis system the more extensive in use ? What are the differences between interchangeability and selective assembly ? y [12Marks]
[Ans.(b)]
ISRO2008
Plug gauges are used to (a) Measure the diameter of the workpieces (b) ( ) Measure the diameter of the holes in the workpieces (c) Check the diameter of the holes in the workpieces (d) Check the length of holes in the workpieces Ans. (c) ( )
MeasurementofLines&Surfaces
BySKMondal
ISRO2010
The vernier reading should not be taken at its face value before an actual check has been taken f k for (a) Zero error (b) Its calibration (c) Flatness of measuring jaws (d) Temperature equalization Ans. (a)
ISRO2008
The least count of a metric vernier caliper having 25 divisions ha ing 2 di isions on vernier scale matching ernier scale, with 24 divisions of main scale (1 main scale divisions = 0.5 mm) is (a) ( ) 0.005 mm ( ) (c) 0.02 mm Ans. (c) (b) 0.01 mm ( ) (d) 0.005 mm 5
ISRO2009,2011
In a simple micrometer with screw pitch 0.5 mm and di isions on thimble 50, the reading divisions 0 corresponding to 5 divisions on barrel and 12 divisions on thimble is (a) 6 ( ) 2.620 mm ( ) (c) 2.120 mm Ans. (a) (b) 2.512 mm ( )5 (d) 5.012 mm
S1 S1
A displacement sensor (a dial indicator) measures the lateral displacement of a mandrel mounted on the taper hole inside a drill spindle. The mandrel axis is an extension of the drill spindle taper hole axis and the p protruding portion of the mandrel surface is perfectly g p p y cylindrical. Measurements are taken with the sensor p placed at two positions P and Q as shown in the figure. p g The readings are recorded as Rx = maximum deflection minus minimum deflection, corresponding to sensor position at X, over one rotation.
Ans.(c)
ISRO2008
Standards to be used for reference purposes in laboratories and workshops are termed as orkshops (a) Primary standards (b) Secondary standards (c) Tertiary standards (d) Working standards Ans. Ans (d)
PSU
Afeelergaugeisusedtocheckthe (a)Pitchofthescrew ( ) h f h (b) Su ace oug ess (b)Surfaceroughness (c)Thicknessofclearance (d)Flatnessofasurface Ans.(c) A ( )
ISRO2011
A sine bar is specified by (a) ( ) Its total l l length h (b) The size of the rollers es eo e o es (c) The centre distance between the two rollers (d) The distance between rollers and upper surface Ans. (c) A ( )
GATE2012(PI)
A sine bar has a length of 250 mm. Each roller mm has a diameter of 20 mm. During taper angle measurement of a component, the height p from the surface plate to the centre of a roller is 100 mm. The calculated taper angle ( degrees) is (in ) ( ) (a) 21.1 Ans. (a) ( ) (b) 22.8 ( ) 3 (c) 23.6 ( ) (d) 68.9 9
GATE 2011(PI)
The best wire size (in mm) for measuring effective diameter of a metric thread (included (i l d d angle i 6 o) of 20 mm di l is 60 f diameter and d 2.5 mm pitch using two wire method is (a) ( ) 1.443 (b) 0.723 (c) 2.886 (d) 2.086 Ans. (a)
ISRO2011
CLAvalueandRMSvaluesareusedfor measurementof (a)Metalhardness (b)Sharpnessoftooledge (c)Surfacedimensions (d)Surfaceroughness Ans.(d)
Ans. (d)
machining operation? hi i i ? ( ) (a) Roughness g (c) Waviness Ans. (b) ( ) (b) (d) Lay y Cut off
Ans.(c) ( )
ISRO2010
Surface roughness on a drawing is represented by (a) Triangles (b) Circles (c) Squares ( )S (d) Rectangles Ans. (a)
Ans.(a)
MiscellaneousofMetrology
BySKMondal
GATE 2009(PI)
An autocollimator is used to (a) ( ) measure small angular d l ll l displacements on fl surface flat f (b) compare known and unknown dimensions co pa e o a d u o d e so s (c) measure the flatness error (d) measure roundness error between centers Ans. (c) A ( )
Ch13:Metrology
Q.No 1 2 3 4 5 6 7 8 9 Option C C A C C B C B B Q.No 10 11 12 13 14 15 16 17 Option D A B B D B C B