Production Technology PDF

Production
Technology
Solutions for Volume – I _ Classroom Practice Questions
04. Ans: (a)

Chapter‐ 1 Sol: Q = 1.6 10-3 m3/sec
Metal Casting A = 800 mm2
Q=AV
01. Ans: (d) 1.6  10-3 = (800 10-6) V
VH
Sol: Permeability number = V = 2 m/sec = 2gh
PAT
2
For standard specimen H = D = 5.08 cm  2 
h =   = 0.203m
P = 5 gm/cm2, V=2000 cc, T= 2 min  2  9.81 
2000  5.08 = 203 mm
PN =  50.1 2

5   5.08  2
2
4 05. Ans: (c)

 2
Sol: Vol. of casting = D L
02. Ans: (c) 4
Sol: Net buoyancy force = Weight of core – 
=  150 2  200
weight of the liquid 4
which is displaced by core  3534291 mm3
= V.g (  – d ) ht = 200+ 50 = 250 mm
 2 AC = Amin = sprue base area
  d h  g    d 
4 400
=  200 mm2
 2
 0.12   0.18  9.81  11300  1600 
2

4 G.R.= 1:1.5:2
= 193.6N Volume of Casting
Pouring time =
A C.  Vmax
03. Ans: (a) 3534291

Volume 200  2  9810  250
Sol: Pouring time =
A C  Vmax 17671
=  8 Sec
2  10 6
2  9810  250

200  2  10000  175
= 5.34 sec
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:2: ME – GATE_ Vol – I_Solutions
06. Ans: (c) 07. Ans: (c)

Sol: The dimension of pouring basin will not Sol: 1 1
hpb =50 mm
affect the pouring time 2 2
Let V = maximum velocity of molten metal
hs= 200 mm
in the gating system,
3
d = dmin = dia. Sprue bottom
h = height of sprue = 200 mm
volume. of casting A2 = 650 mm2
Pouring time = P. T 
A c  Vmax Q = flow rate = 6.5 105 mm3/s
353 g = 104 mm/sec2
 = 25
 2 6.5  105
d V V2 =  1000 mm 2 / Sec
4 650
35 3 = 2gh pb  2  10 4  h pb
V  2183.6 / d 2 …… (1)
 2
d  25
4 hpb = 50 mm = height of molten metal
To ensure the laminar flow in the gating in the pouring basin
system Re  2000 ht = total height of molten metal above
the bottom of the sprue
= 200 + 50mm
For limiting condition Re = 2000
 V d Vd Q  A2 V2  A3V3  A3 2  10 4  250
R e  2000  =
  = 6.5  105 mm 3 / s
Vd  A3 = 290.7 mm2
 2000 

2000 2000 0.9 1800
V   … (2) 08. Ans: (d)
d d d
Sol: dtop = 225 mm
ht = 250 + 100 = 350 mm
From (1) and (2)
Volume flow rate Q = 40×106 mm3/sec
2183.6 1800
 Vbottom = 2  g  ht = 2  9810  350
d2 d
2183.6 = 2620 mm/s
d  1.21mm
1800 Q = Atop×Vtop=Abottom×Vbottom
40  10 6
Abottom = =15267.17 mm2
2620
:3: Production Technology
2
4  15267.17
 SP  M SP   D 6 
2 2
dbottom = =139.42 mm D
    a = 
 Cub  M Cub    a
 6
2 2
09. Ans: (b)  2R   2R 
=  =   1.54
Sol: A2V2 = A3V3  a   1.61R 
 2
 2252  2  9810  100  SP  M SP 
4  
 cyl  M cyl 

  d 2b  2  9810  350
4 D 
2
2 2
 6   D   2R 
 db = 164.5mm =   Sp
   = 1.306
 D   D   1.75 R 
 6  cyl 
So aspiration will not occur.
Common Data for 10 & 11 12. Ans: 1.205

Sol: Casting – 1 (circular)
10. Ans: (a) Diameter = 20mm, length = 50mm
11. Ans: (b) Casting -2 (elliptical)
Sol: 3 castings of spherical, cylindrical and Major/Minor = 2, length = 50mm,
cubical C.S. area of the casting -1 = C.S area of the
Vsp = Vcube casting -2
4 3  solidification time of casting  1 
R  a 3
3  solidification time of casting  2 
 
4 2
a =R 3  = 1.61 R M   V  A c2 
3 =  c1  =  c1 
 M c2   Vc 2  A c1 
Vcyl = VSp
    
D 2 H   R3 Vc1 =  d 2  h =  20 2  50
4 3 4 4 
  = 15707.96 mm3
D 3   R 3 (D  H)
4 3 
Ac1 = 2   d 2  dh
1 4
16 3  16  3
D= 3 R    R  1.75R
3 3  
  20 2  2    20  50
4 
= 3769 mm2

C.S area of cylinder = C.S area of ellipse 13. Ans: 50

    maj.axis  min .axis Sol: m = 2 kg, Q = 10 kW
 4  20  
2
4 Time taken for removing latent heat

  2  (min .axis) 2 = 20 – 10 = 10 sec
=
4 Latent heat
Time 
1 Q
 4  2
Minor axis =   20 2  Latent heat = time  Q
4   2 
= 10  10 = 100 kJ
Minor axis = 14.14mm
100
Major axis = 2  minor axis = 28.3mm Latent heat/kg = = 50 kJ/kg
2
a 2  b2
Perimeter = 2 14. Ans: (a)
2
Sol: Circular disc casting Squared disc casting
28.3
where a = major axis /2  = 14.14 mm C1 C2
2 ;
d  20cm a  20cm
14.14
b = minor axis /2  = 7.07 mm t  10cm ; t  10cm
2
Perimeter = 70.24 mm  As 
 
Surface area of ellipse  V  C1
Freezing ratio (F.R) = X1 =  1.4
= perimeter  length + 2 C.S. area  As 
 
 V R
= 70.2450 + 314  2
 As 
= 4140 mm2 = AC2  
 As   V  C1
Volume of the ellipse   
 V R 1 .4
= C.S area  length
 As   As 
= 314  50 = 15708 mm3 = Vc2    
 V  C2  V  C2
X1    1.4
 solidifica tion time of casting  1   As   As 
 solidifica tion time of casting  2     
   V R  V  C1
2 1.4
M 
=  c1    As  A  
 M c2       s   0.4 
 V   V  C1 
 C2 
2 2
 V  Ac2  15707.96  4140  VR
=  c1    Volumetric ratio,(V.R) = Y1 =  0 .8
 Vc 2  A c1   15708  3769.9  VC
= 1.205  VR = 0.8 VC1
VR 0.8VC1 Common Data for Q.16 & Q. 17

Now Y2  
VC 2 VC2
16. Ans: (a) 17. Ans: (a)
  Sol: In centrifugal casting
0.8  20 2  10 
 4  = 0.628 Centrifugal force = FC = ma = m r 2
20  20  10
a = r2
D
15. Ans: (b) 75 g = (2 N)2
2
Sol: VC = 40 × 30 × 0.3 = 360 cc
VSc = shrinkage volume 4 2
75 ×9810 = N 2 D 
2
3
=  360  10.8 cc 75  9810
100 Constant = N 2 D   37273
2 2
 2
Volume of riser Vr = d h Constant = N 2 D  37273
4
 2 0.5  0.52
=  4  4  50.24 cc D= = 0.51 m = 510 mm
4 2
Vr ≥ 3 Vsc  Vr  3  10.8  32.4cc 37273 37273
N  = 8.55 RPS
Vr ≥ 3 VSc → Satisfied D 510
r C
18. Ans: 51.84 mm
where
2
r = time taken for riser material to solidify R  m R 
Sol:  
C  m C 
C = time taken for casting to solidify
Mr  Mc 80  120  20
mc 
280  120  120  20   80  20
V V
      mc = 7.05
 A s  r  A s  casting
d
V 360 mR   side riser given
 6
As 240  30  30  0.3  0.3  40 
mR
  1.5
V d 4 mC
     = 0.666
 As r 6 6  d = 51.84 mm
360
=  0.147
2442
 r > C
Hence diameter of riser = 4 cm
20. Ans: 0.05 s

Sol: Momentum is considered as constant
Momentum of water = Momentum of liquid Chapter‐ 2
metal Welding
pressure  time pressure  time

density density 01. Ans: (a)
200  0.05 400  time Sol: V0 = 80 V, IS = 800 A

1000 2000 Let for arc welding V = a+bL
 time  0.05 s V0
For power source, Vp = V0– I
Is
For stable V = Vp
V0
 a  b L  V0  I
Is
When L = 5, I = 500
80
 a + b × 5 = 80 –  500  30
800
a + 5b = 30
when L = 7, I = 460
80
a  b  7  80   460  34
800
By solving, b = 2, a = 20
 V = a + bL = 20 + 2L
02. Ans: 4860 W, 1.5 mm

Sol: For power source,
I
Vp = 36 –
60
Va = 2L + 27
At equilibrium conditions
Va = VP
I
27 + 2 L = 36 –
60

I V0 40 4
 36  27  2L  9  2L  
60 I s 50 5
I = 60 (9 – 2L) 4
V0  140   250
If current is 360 Amps 5
360 = 60 (9 – 2L) = 140 + 200 = 340
360 V0 4 V  5 340  5
9 – 2L = 6   Is  0   425 A
60 Is 5 4 4
2L = 9 – 6 = 3
3 04. Ans: 26.7 sec
L=  1 .5
2
Sol: Rated Power = Vr Ir = 50 ×103
If L = 1.5 mm,
50  10 3
V = 27 + 2 ×1.5 = 27+ 3 = 30 V  Ir   2000 A
25
I = 60 (9 – 2 ×1.5) = 360 A
Dr = 50% (rated duty cycle)
P = 30 ×360 = 10800 W
If Id = 1500 A (desired current)
If L = 4 mm, V = 27 + 1.5 ×4 = 33 V
Desired duty cycle,
I = 60 (9 – 1.5 ×4) = 180 A 2
I 2 D  2000 
P = 33 × 180 = 5940 W Dd = r 2 r     0.5  0.89
Id  1500 
Change in power = 10800 – 5940
= 4860 W Arc on time
Dd = = 0.8930
If the maximum current capacity is 360A, Total welding time
the maximum arc length is 1.5mm = 26.7 sec
03. Ans: 425 05. Ans: 27.78 mm/sec

Sol: V = 100 + 40 L , Sol: Power = P = 4 + 0.8L – 0.1L2
L = 1 to 2 mm , I = 200 to 250 A For optimum power
L = 1, I = 250 dP
 0  0.8 – 0.2L = 0
V0 dL
V = 100 + 401 = 140  V0   250
Is 0.8
L  4 mm
L = 2, I = 200 0 .2
V P = 4 + 0.8L – 0.1 L2
V = 100 + 40  2 = 180  V0  0  200
Is = 4 + 0.8 ×4 – 0.1 × 42 = 5.6 kW
V0 Energy losses = 20% ,  = 80%
 40  50 
Is
Area of weld bead (WB) l = 1 m =1000 mm;

1 t = 30 mm,
= 2   AB  AC
2 d = 4 mm,
= 5 tan 30 × 5 = 14.43 Lt = 450 mm;
5 tan 30 LS = 50 mm,
A B A1 = 4  30 = 120 mm2
300
1
600 5 A2 = A3 =  30 tan 30  30 = 259.8 mm2
2
Total volume of weld bead
C
= volume of weld bead + crowning
Volume of W.B = 14.43 × 1000 = 1.1  volume of weld bead
3
= 14433 mm = 1.1 (A1+2A2)1000 = 703560 mm3
-6
Weight of W.B = 14433 × 10 × 8 
Volume /Electrode =  D2  Le
= 115.5 g 4
Heat required for melting of W.B  2
  4  (450  50) = 1600
= 115.5 ×1400 = 161.66 kW 4
161.66 No of electrodes required
Time for welding =  36 Sec
0.8  5.6 Total volume of weld bead

1000 volume / Electrode
Welding speed =
36
703560
 27.78 mm/sec   139.96  140
1600
x = 200mm (given)
Common data for 06, 07 & 08. 1000
No of electrodes/pass = 5
200
06. Ans: (d) 07. Ans: (d) 140
No of passes =  28
5
08. Ans: (c) Total Arc on time
Sol: 1000
(2) (1) (3) =  28  280 minutes
30mm
30o 30o 100

280
Total weld time =  466.67 minutes
0.6
4mm

09. Ans: 0.64 mm & 2.1 mm 11. Ans: (b)

Sol: Given AC = 10 mm, Sol: Filling rate of weld bead = filled rate by
O1A = O1C = 7 mm, electrode
O2A = O2C = 20 mm 
Area of W.B × Speed = d2  f
O2 4
r=7 
D  1.2 2  4000
Area of W.B= 4  25.12 mm2
A B C 180
r=20 E
Common data for 12 & 13
O1
12. Ans: 2000 J
Sol: H.G = I2 R 
5
Height of Bead = BD = O1D – O1B = (10000)2×200×10-6×  2000 J
50
= O1D– O1 A2  AB 2 13. Ans: 1264 J
= 20 – 20  5 2 2 Sol: h = 2t – 2 × 0.1 t = 1.8 t
= 0.64 mm = 1.8 ×1.5 = 2.7 mm
D = 6 t  6 1.5 = 7.35 mm
Depth of Penetration = BE = O1E–O1B
=  O1 E    O2 A    AB 
2 2 0.1 t
h
= 7  7 2  52 = 2.10 mm
0.1 t
Common Data Q. No 10 and 11
10. Ans: (c) 

Vol. of nugget = D2h
Sol: I = 200, V = 25, speed = 18 cm /min 4
D = 1.2 mm, f = 4 m /min,  = 65%, 
= 7.352  2.7 = 114.5 mm2
VIη 4
Heat input =
speed Heat required = Volume × ×heat required /g
25  200  0.65  60 = 114.5  10 3  8  1380

18 = 1264 J
= 10.83 kJ / cm
: 10 : ME – GATE_ Vol – I_Solutions
14. Ans: 2.3 & 4.6 MJ 17. Ans: (b)

   Sol: Heat dissipated = 360 – 344 = 16 J
Sol: RC = 0.85  
 nr 
 = Resistivity of metal 18. (i) Ans: (a), (ii) Ans: (b)
Sol: P = 2 kW = 2  103 Watt,
2
V V2
(Heat generation)1 = I2R =    R =
R R V = 200 mm/min, L = 300 mm
0.85  2  10 5 Heat required (HR) = 40 Kcal
R C1  = 1.082105
25    0.02 = 401034.2 Joule
0.85  2  10 5 300
R C2  = 5.41  106 Welding time =  1.5 min  1.5  60
50    0.02 200
52 = 90sec
(H.g)1 = = 2310546.04
1.082  10 5 Heat input = 2 103  90 Joule
52 HR 40  10 3  4.2
(H.g)2 = = 4621072.08 HI =   0.9333
5.41 10 6 HI 2  10 3  90
= 93.33%
15. Ans: (c)
19. Ans: (d)
Sol: Heat generated = Heat utilized
Sol: Heat supplied = Heat utilized
I2R = Vol. of nugget × × H. R/g
0.5 J = m (S.H. + L.H) = V (SH+LH)
I 2  200  10 6  0.1
= (a×h)  (Cp (Tm–Tr)+LH)

 0.005  1.5  10 3  8000  1400  103
2
= 0.05 × 10-6 × h × 2700 [896  (933 –
4
303) + 398 × 103]
I = 4060 A
 h = 0.00385 m = 3.85 mm
Common Data Q. 16 & Q. 17
16. Ans: (c) 20. Ans: (c)

Sol: I = 3000 A,  = 0.2, R = 200 Ω Sol: Volume to be melted = (110 2  100 2 )  2
4
Volume of nugget = 20 mm3
2  3298.66 mm3
Heat generation = I R
Total heat required
= 30002 ×200×10-6 ×0.2 = 360 J
= 3298.66 × 10-9 × 64.4 ×106

Heat required = V c p Tm  Tr   LH  = 212.4 Joules
-9 3
= 800020×10 ×500(1520 –20)+1400×10 V V 2 30 2
= 344 J P = VI = V     21.43
R R 42
: 11 : Production Technology
Total heat required = heat to be generated 23. Ans: 61.53 %

212.4 = Pt Heat required
Sol: Thermal efficiency =  100
212.4 Heat supplied
t=  10 sec
21.43 Heat required = 10 × 80 = 800 J
800
thermal =  100 = 61.53 %
21. Ans: (a) 1300
Sol: Frictional force F = Pressure × Area ×
24. Ans: 464.758 A

= 200   10  0.5  7854
2
Sol: Dd = 100% = 1, Ir = 600A, Dr = 0.6
4
D d I 2r
3 
Torque = F   Radius D r I d2
4
3 1 600 2
Torque = 7854   5  10 3  29.45  2  I d2  600 2  0.6
4 0.6 Id
2NT  Id = 464.758A
Power, P =
60000
2  4000  29.45 25. Ans: 17
 = 12.33 kW
60000 Sol: Number of electrodes
Total volume of metal deposited

22. Ans: 0.065 sec Volume deposited from one electrode
Sol: Given: Total Volume of metal deposited
3 
 2
Volume = 80 mm ,
4
 
3  450  50 
Current (I) = 10000 A,
E = 10 J/mm3, 17mm
19mm
Qlost = Heat lost = 500 J, 2mm 30o 30o
R = 0.0002 ohms 2
x
Total energy supplied during process tan 30  o
17 mm
= [(80 × 10) + 500] J
x = 9.814 mm
Qtotal = 1300J = i2Rt
1 
1300 = (104)2 × 0.0002 × t Area    9.814  17  2  2  19  1.1  1.15
2 
 t = 0.065 seconds
Volume  204.85mm 2  1.1  1.15  180
= 46645.30767mm3
 Number of electrodes = 17

cosCS = 1  Cs = 0
Chapter‐ 3  = 90 – CS = 90
Metal Cutting
 tan  b   sin  cos    tan i 
 tan     cos  sin    tan  
 s   
Common Data for Q. 01 & 02
tanb = sin tani+costan
tanb = sin90 tani + 0
01. Ans: (a)
 b = i = 10
02. Ans: (d)

Common Data for Q.04, 05 & 06
Sol:
Vf Vs 04. Ans: (c) 05. Ans: (b)

06. Ans: (d)
90 
Sol: d = t1 = 2 mm, w = b = 15 mm
Vc
VC  0.5m / s, =0
Vc = 40 m/min; Vf = 20 m/min FC  1200, FT  800,   300

Vf 800
 = 10o; r  0 .5     tan 1  33.690
Vc 1200
 r cos     tan   tan 33.69  0.67
  tan 1  
 1  r sin   60
Power = P = FC  VC  1200 
 0.5 cos10  60
 tan 1    28.33
o
 1  0.5 sin 10  = 1200 W

V Length of shear plane = LS
Vs  f  cos 
sin  t1 2
=   4mm
sin  sin 30
20
  cos10 = 41.5 m/min
sin 28.33
07. Ans: (a)
03. Ans: 10 Sol: For theoretically minimum possible shear
Sol: f = 0.25 mm/rev, strain to occur
t1 = 0.25, i = 10,  = ? 2    90
t1 = f cosCS 90   90  6
   48 o
0.25 = 0.25 cosCS 2 2

Common Data for Q. 08 & 09 t1 L 2 60 60

r     0.59
08. Ans: (c) t 2 L1 D 0   32
t1 t 0.1
r  t2  1   0.169
09. Ans: (c) t2 r 0.59
Sol:  = 6 , VC  1 m / s
 0.59 cos 35 
  tan 1   = 36.150
b = w = 3, d = t1 = 1 mm  1  0.59 sin 35 
t2 = 1.5 mm; use 2      90 o FT 80
tan      
t1 1 2 FC 200
r    0.67
t2 1.5 3
 80 
    tan 1  
 0.67 cos 6   200 
  tan 1    35.62 0
 1  0.67 sin 6   35  21.8  56.8o
For minimum energy condition use   tan   tan 56.8  1.52
2 +   = 90 (In general  < 1)
  90    2  90  6  2  35.62 Hence by applying classical friction
= 24.76 theorem
  tan   tan 24.76  0.461 1  1 
ln  ln 
Vf  rv c  0.67 1  60  r  0.59 
 
  
 40.2 m / min   35 
2 2 180
Area of shear plane = As = Ls × b 0.5276
  0.55
t b 1 3 1.04
= 1 =  5.2 mm 2
sin  sin 35.62 Vf
 r  V f  rVc = 0.59 ×10 = 5.9 m/min
VC
Common Data for Q. 10 & 11 Vf 5.9
Vs  cos    cos 35
sin  sin 36.15
10. Ans: (d)  8.42 m / min
11. Ans: (d)

12. Ans: 56.23
Sol: D 0  32 mm,  = 35, K1 = 0.1 mm,
Sol:  = 10, t1 = 0.125,
FC = 200 N, VC = 10 m/min, Fc = 517 N; FT = 217 N
L2 = 60 mm, FT = 80 N
t2 = 0.43; Cm = 2 +  – 

t 1 0.125 14. Ans: (d)

r   0.29
t2 0.43 Sol:  = 30, FT = 800 N, Fc = 1200 N
 r cos   FC
  tan 1   Fs = cos     
 1  r sin   cos   
 0.29 cos10  FT
 tan 1   = 16.73 tan (  ) =
 1  0.29 sin 10  FC
F   800  
    tan 1  T     = tan 1   = 33.69
 FC   1200 
 217  1200
 10o  tan 1   = 32.77 Fs =  cos(30  33.69)  639.23N
cos 33.69
 517 
Cm = 2  16.73 + 32.77 – 10 = 56.23
Common Data for Q. 15 & 16
15. Ans: (a)
13. Ans: 272 N & 436 W
16. Ans: (b)
Sol: S0 = 0.12 mm = t1,
Sol: D = 100 mm, f = 0.25 mm/sec,
t = 2.0 mm, a 2  t 2  0.22
d = 4 mm
Major cutting for, b = pz = Fc
V = 90 m/min
 S0 .t.S  sec   tan   1
FC
FC = 1500 N FT F
S0 = 0.12,  S  400 FC = N = 1500 N
t = 2 – 0, FT = F
t2 a2 0.22
    1.83
t1 S0 0.12 Common Data for Q. 17 & 18
=0
Pz = 0.12×2.0×400(1.83sec0–Tan0+1) 17. Ans: (b) & 18. Ans: (b)
= 272 N Sol: VT a f b d c  K
Vf a = 0, 3 b = 0, 3, c = 0, 15
Power = p = FC  VC  p Z 
r f1
f2  , d 2  2d
52.6 2
 p Z  Vf    271 1.83
60 T1  T2  60
= 436 W V1T1a f1b d1c  V2T2a f 2b d 2c

V2  f1 
b
 d1 
c
20. Ans: (b)
   
V1  f 2   d2 
Sol: Let Q = no. of parts produced
0.15 T.C on E.L = T. C on T.L
1
= 2 0.3    1.11 30 60
2  Q  80  500   Q  160
V2 1.11 V1 60 60
40Q  500  16Q
V V
% change in speed = 2 1  11% 40 Q  16Q  24Q  500
V1
Productivity is proportional to MRR 500
 Q=  20.83  21
% change in productivity 24
MRR 2  MRR 1
= 21. Ans: (a)
MRR 1
Sol: n = 0.12, C = 130
f d V f d V
= 2 2 2 1 1 1 = 11 % C1 = 1.1 × 130 = 143,
f 1d 1 V1
V = V1 = 90 m/min
19. Ans: 49.2 % 1
Sol: T0 , V0 = original tool life and velocity  130  0.12
VT n  C  T     21.4 min
If V1  1.2V0 T1  0.5 T0  90 
1
V2  0.9V0 , T2  ? 1n  143  0.12
V T C T 
1 1

1
 47.4 min
 90 
V T  V0 T
1 1
n n
0
Increased tool life = 47.4 min
n
 T1  V Increase in tool life = 47.4 – 21.4 = 26 min
   0
 T0  V1
V 
ln  0  ln  1  22. Ans: (a)
V 1.2 
n  1   0.263 Sol: Tool life = T1 
500
 50,
 T1  ln (0.5) 10
ln  
 T0  122
T2   12.2,
V0 T0n  V2 T2n 10
1 1 V1  50rpm , V2  80 rpm
V  n
 V  0.263
T2  T0  0   T0  0  = 1.4927T0 The feed and depth of are same in both
 V2   0.9V0  cases
% change in tool life V1T1n  V2 T2n
T2  T0 1.4927T0  T0
=   0.4927
T0 T0
V2 80 dTC 
ln ln For min TC, 0
V1 50  0.47  0.333 dV
n  
T 50 1.41 1 
ln 1 ln  2 
1 
T2 12.2 270C V  n 
   1
 18C n  0

V T  V3 T
1 1
n n
3
V2 1
Cn
1 1
V  n
 50  0.333
 1


2 
 1 
 T3  T1  1   50   29 270C V  0.25 
  1
 V3   60   0.25   18C
1
V2
C n
23. Ans: 30.8 m/min 270  3 18

 V2  2
Sol: TC = 3min, Tg = 3 min, 150 4
V
Lm = Rs. 0.5/min 18  150 4
V 4
Depreciation of tool regrind = Rs 0.5 270  3
C = 60, n = 0.2  V = 57.91 m/min
Cg = 3  3  0.5 + 0.5 = 3.5
 n Lm 
n
25. Ans: 2.5 & 23
VOpt = C  .  Sol:  =10
1  n C g 
0.2
t1= f.sin = 0.15 sin75 = 0.144
 0.2 0.5 
 60  . = 30.8 m/min t1
1  0.2 3.5  t2 = 0.36, r   0.402
t2
chip reduction coefficient = t2/t1
24. Ans: 57.91
1
18C 270C   K  2.5
Sol: C m  , Ct  , VT 0.5  150 r
V TV
 r cos  
TC = k + Cm + Ct   tan 1  
 1  r sin  
18C 270C
k 
V TV  0.402 cos10 
 tan 1   = 23.18o
18C 270C  1  0.402 sin 10 
k  1
V
 C n
V 
V
1 
 1 
n 
18C 270C V
k  1
V
Cn
27. Ans: 0.944

Sol: T = 60 min Chapter‐ 4
67 Machining
VA   42.70 m / min
600.11
01. Ans: (i) 20 min, (ii) 50 min
77
VB =  45.22 m / min L 576
600.13 Sol: Time / cut = 
fN 0.2  144
 20 min
Under similar conditions with same tool life DN  100 144
V   45.2 m / min
cutting velocity on material B is greater 1000 1000
1
than the material A. Hence the 0.75
 75 
machinability of material ‘B’ is higher than VT 0.75  75  T   
V
the material ‘A’. 1.333
 75 
VA 42.7 =   1.96 min
  0.944  45.2 
VB 45.22
20
No. of tool changes =  1  9.2  10
1.96
28. Ans: 12 (Because 1 tool is already mounted on W.P)
Sol: Given, t1 = 0.2 mm, Total change time / piece = 20 + 10 × 3
w = 2.5 mm, = 50 min
Fc = 1177 N,
Ft = 560 N 02. Ans: (a)
As the cutting is approximated to be Sol: For producing RH threads the direction of
rotation of job and lead screw must be in the
orthogonal.
same direction, for this if the designed gear
tani = cos tan b – sin  tan s
train is simple gear train use 1, 3, 5 odd
tan 0 = cos tanb – sin tan s number idle gear to get same direction of
= cos30 tan7 – sin30 tan s rotation, if the designed gear train is
 s = 12 compound gear train use 0, 2, 4,.. even
number of idle gears to get same direction.
In the given problem the designed gear train
is a compound gear train, to change the
hand of the thread it requires to change the
direction of rotation of job and lead screw
for this use 1, 3, 5… odd number of idle
gears.
03. Ans: (b) 07. Ans: (b)

N follower Sol: No. of D.S/min = 10
Sol: Train value = Gear ratio =
N Driver B = 300 min, f = 0.3 mm /stroke
pitch of job threads B 1
= Time/cut = 
pitch of lead screw threads f No. of D.S
3.175  40 127 300 1
   not possible =    100 min
6  40 240 0.3 10
127 1  20
= 
40 6  20 08. Ans: (b)
127 20 Sol: L = 2m
   possible
40 120 = 50 + 900 + 50 + 50 + 900 + 50
B = 300 + 5 + 5 = 310
04. Ans: (c) f = 1 mm/stroke, VC = 1 m /sec,
Sol: 1. Plane turning 2. Taper turning 1
3. under cutting 4. Thread cutting M=
2
B 1
05. Ans: (d) Time per two pieces =  1  M 
f V
N follower
Sol: Gear Ratio = Train value = 310 2000
N driver =  1  0.5 = 930 sec
1 1000
Tdriver P 930
=  driver Time/piece =  465 sec
Tfollower Pfollower 2
P job Pspindle N L.S
G.R =  
PL.S PLs.S N Spindle 09. Ans: (d)
P = pitch Sol: Shaping operation
N Spindle M = 0.6 , L = 500 mm

PL.S 6 3
 = = Double stroke / time = 15
N L.S PSpindle / job 2 2 2
N = time / D.S = 1/15
L
06. Ans: (d) Average speed, V = 1  M 
V
Sol: With this any change in UV will also
500
changes the speed of lead screw, the pitch  1  0.6 =12000 mm / min
1
of the threads produced depends on the  
 15 
speed of work and speed of lead screw. Us
= 12 m / min
will not affect the speed of the work
10. Ans: (c) 12.

Sol: Total depth to be removed = 30 – 27 Sol: D = 15 mm, Vc = 20 m/min,
= 3 mm 1000 V 1000  20
N = = 425 rpm
2  D  15
Given, m = = 0.67
3 N = 425rpm
feed = 0.5, f = 0.2 mm /rev
depth = 2 T = 100 min, l  45 mm
V = 60 m/min Time for idle time = 20s
Approach  50 m  Tool change time = 300 s
 length wise
Over time  50 min  L   0.5D
Time/hole = 
Approach  5 m  fN fN
 width wise
Over time  5 m  15
45 
2  0.617 min
Time/cut =
L
1  M   B 
0.2  425
V f
l = 800, = Tm = machining time
L = 800 + 50 + 50 = 900 i) No. of holes produced / drill
B = 400 + 5 + 5 = 410 100
=  162
900  2  410 0.617
Time / cut = 1   ii) Total time/hole
60000  3  0.5
= 20.5 min = Tm + idle time + Tool change time
3 20 300
No. of cuts =  1.5  2cuts = 0.617  
2 60 162  60
Total time = 20.5×2 = 41 mins = 0.9812 min = 58.87 = 59 sec
11. Ans: (b) 13. Ans: (b)
Sol: Time per hole = L/f.N

14. Ans: (b)
= 25/(0.25 300)
Sol: Given n = 6, Dmax = 25 mm
= 1/3 min = 20sec.
Dmin = 6.25 mm
Because dia of drill bit was not given, hence
V = 18 m/min
AP1 is zero.
N max
r= n 1
N min

1000V 1000  18 L
Nmax =  Time/cut =
D min   6.25 f t NZ
1000V 1000  18 230
Nmin =    1.2 min
D max   25 0.1159 12
N max 25
r= 6 1 = 5
ii) If offset = 5mm with asymmetrical milling
N min 6.25
= 1.3195 = 1.32 AP1 =
1
2

D  D 2  w i2 
Where, wi = w+ 2(Of)
15. Ans: (d)
= 80 + 2 × 5 = 90
Sol: Hobbing process
No. of teeth = 30 (Not required) AP1 =
1
2

100  100 2  90 2 
Module = 3 mm
= 28.2 mm
Pressure angle = 200 (Not required)
L = 200 + 28.2 + 5 + 5 = 238.2
Radial depth= Addendum+1m+1.25m
L
= 2.25 module = 2.25  3 Time/cut =
f t Nz
Radial depth = 6.75 mm
238.2
  1.25 min
0.1 12 159
16.
Sol: Part size = 200 × 80 × 60 mm
17. Ans: (b)
D = 100 mm, Z = 12,
40
V = 50 m/min, Sol: Crank rotation =
No. of teeths
1000 V 000  50
N=   159 rpm 40
D  100 =
28
f t  0.1 mm , AP = OR = 5 mm
 12  3
= 1  = 1
i) With symmetrical milling  28  7
AP1   1
2
D  D2  w 2  9
= 1 
 21 
= 100 
1
2
100 2  80 2   20 mm 1 complete revolution and 9 holes in 21 hole
circle.
L = l  AP1  AP  OR
= 200 + 20 + 5 + 5 = 230

18. Ans: (d)

Sol: d = 70 mm , Z = 12 teeth
O1 O2
V = 22 m/min
ft = 0.05 mm/tooth A d
1000 V
fm = ftZN, N  B
d t
AP1
1000  22
fm = 0.05  12  = 60 mm/min
3.14  70
l
19. Ans: (b)
10 1 4 1000V 1000  120
Sol: Crank rotation = 1  1   360 N=  = 254.64 rpm
30 3 3 D   150
= 480 Approach = AP1 + O1O2 = d D  d 
CR 480
Job rotation = = = 12 = 0.5150  0.5 = 8.645 mm
40 40
Total time/machining
= No. of cutsTime/cut
20. Ans: (b)
Sol: Given, Total depth 2
No. cuts =  =4
Dtool = 15 cm = 150 mm depth per cut 0.5
Feed = 0.08 mm/rev L   AP

Time/cut = =
Depthmax = 0.5 mm = d fN fN
Length of workpiece, l = 200 mm 200  8.645
= = 10.227 min
Cutting Velocity, V = 120 m/min 0.08  255
Total depth to be cut = 2 mm Total time = 10.227  4 = 40.91

= 41 min
21. Ans: 8.05 min

Sol: Broaching machine
P = 1.5 kW
d1 = 20 mm enlarged to df = 26 mm
t = 25 mm
p = 10 mm/tooth
h = 0.075 mm/tooth
V = 0.5 m/min d r 4.4

nr    44 teeth
Equation for time for broaching operation h r 0.1
Length of tool travel Cutting length = effective length = Le
=
Linear velocity of tool = L r  LS  L f
Length of tool travel = L = 44 × 22 + 8 × 20 + 4 × 20
= t + Le + AP + OR = 1208mm
As (AP + OR) is not given so take it zero
Le = effective length or cutting length 23. Ans: (b)
26  20 Sol: Out of all conventional method grinding is
Depth of cut d = =3
2 one which required largest specific cutting
n = no. of teeth = d/h = 3 / 0.075 = 40 energy.
Le = np = 40  10 = 400mm 1) Because of random orientation of
Le = 400 mm abrasive particles, rubbing energy losses
t  Le will be very high
Time for broaching =
V 2) Lower penetration of abrasive particle
25  400 3) Size effect of the larger contact areas
= = 8.05 min
0.5  100 between wheel and work.
Time for broaching = 8.05 min
24. Ans: (a)

22. Ans: (c) Sol: Common alignment test for shaper and lathe
Sol: are (1) Straightness (2) Flatness.
4.5 mm Runout is used in lathe.
Parallelism used in shaper.
25. Ans: (a)

Sol: The curvature given is the concave
d total  4.5 mm curvature hence it increases the stress
df  0 concentration factor therefore it is used for
d S  n s  h s  0.0125  8  0.1 supply of lubricating oil to bearing
mounting
d r  d total   d f  d s 
= 4.5 – 0.1 = 4.4

26. Ans: 18
Sol: The output per annum = 800  52
= 41600 units. Chapter‐ 5
The rejection rate is 20%. Metal Forming Process
 The quantity to be produced (including
Re quiredoutput 01. Ans: (a)
rejection) =
(1  rejection rate) Sol:  y  1400 0.33
41600 1
 = 52,000 units At maximum load, true strain 
(1  0.2) 3
Total time required for turning 1
0.33
 y  1400   971 MPa

= 52,000  40/60 3
= 34666.6 hours
Production time required with 80 per cent 02. Ans: (b)
efficiency = 34666.6 /0.8 = 43333.3 hours Sol: A0p = C.S area of P originally
Time available per lathe per annum A1p = C.S area of P after 1st reduction
= 48  52 = 2496 hrs = 0.7 A0p
 Number of lathes required A2p = 0.8 × 0.7 × A0p = 0.56 A0p
Time required (hrs)  Aop 
=  p  True strain in " P"  ln 
Time available hrs  A 
 2p 
43333.33
= = 17.36 = 18  Aop 
2496  ln  = 0.58
 0.56 A 
 No. of lathes required = 18  op 
A0Q = C.S area of Q originally
A1Q = C.S area of Q after 1st reduction
= 0.5 A0Q
 A0Q 
Q  ln   ln 1  = 0.693
A   0.5 
 1Q 
03. Ans: (a)

Sol: do = 25, di = 5mm
 y  315 0.54

A d 
2
06. Ans: (a)
  n o   n  o  Sol: Ho = 20 mm,
A1  di 
2
b = 100 mm
 25 
  n    3.22 H1=18 mm,
 5 
R = 250 mm,
 y  315 (3.22) 0.54  592 MPa. N  10 rpm,  y  300 MPa
H  20  18  2mm
04. Ans: 1.98 MN
Sol: Given: H0 = 4.5 mm H
 = 0.089
R
H1 = 2.5 mm
H = 2 L  length of deformation zone  RH
Droll = 350, Rroller = 175 mm  250  2  22.36 mm
Strip wide = 450 mm = b 20  18
H  19
Average coefficient of friction = 0.1 2
y = 180 MPa 2  L 
Favg  R.S.F   y b  L 1  
RSF = Pavg  projected area 3  4H 
2  L  2  0.089  22.36 
=   y 1  bL   300  100  22.36 1  
3  4H  3  4  19
L= RH = 175  2 = 18.7 = 795 kN.
H 0  H1 4.5  2.5
4=  = 3.5 T  Favg  a ,
2 2
2  0.1  18.7  Where
  1801    450  18.7
3  4  3.5  a = moment arm   L
RSF = 1982.64 kN = 1.98 MN  0.3L to 0.4  L
T  Favg  0.4L  795  10 3  0.4  22.36
05. Ans: (a)
Sol: Ho = 4, H1 = 3mm, R = 150mm, = 7110 kN-mm
N = 100 rpm. = 7.11 kN-m
Velocity of strip at neutral point 2 NT 2  10  7.110
Pav  
= Surface Velocity of rollers 60 60
DN   300  100  7.44 kW / roller
 
1000  60 1000  60 Total Power = 7.44 × 2 = 14.88 kW
= 1.57 m/sec
07. Ans: (d) 10. Ans: (b)

Sol: Ho = 16 mm, Sol: do = 15 mm,
H1 = 10 mm, df = 0.1 mm
R = 200 mm dia reduced in the draw
%Reduction=
H dia before draw
Angle of Bite    tan 1
R d 0  d1
  Ist draw
16  10 do
 tan 1  9 .9
200 d1  d 2
  2nd draw
d1
08. Ans: (a) a) 3 stages with 80% reduction at each stage
Sol: Given rolling process d o  d1
0 .8 
Initial thickness H0 = 30 mm do
Final thickness = H1 = 14 mm d1  0.2 d o  3mm
Droller = 680 = R = 340 mm d2 = 0.2. d1 = 0.6mm
y = 200 MPa d3 = 0.2 .d2 = 0.12mm (Error is 20%)
Thickness at neutral Hn = 17.2
b) 4 stages with 80% reduction in 1st 3 stages
V1 H
Forward slip = 1= n 1 followed by 20% in 4th stage
Vn H1
d1 = 0.2. d0 = 3
17.2 d2 = 0.2. d1 = 0.6
=  1 = 0.2285 = 23%
14
d3 = 0.2. d2 = 0.12
V H
Backward slip = 1  0  1  n d4 = 0.8. d3 = 0.096 (Error is 4%)
Vn H0
17.2 c) 5 stages, with 80, 80, 40, 40, 20 etc
 1 = 42.6%  43%
30 d1 = 0.2. d0 = 3
d2 = 0.2. d1 = 0.6
09. Ans: (b) d3 = 0.6. d2 = 0.36
Sol: Roll separation distance d4 = 0.6. d3 = 0.0216
= 2  R + H1 = 2  300 + 25 d5 = 0.8. d4 = 0.1728 (Error is 72%)
= 625 mm
From the given multiple choice B, the final
diameter of wire close to 0.1 mm.

11. Ans: (a) Common data for Q 12, 13 & 14

Sol: Given wire drawing process
d0 = 6 m, d1 = 5.2 mm 12. Ans: (b) , 13. Ans: (c), 14. Ans: (a)
0
Die angle = 18 , diameter land = 4 mm Sol: Initial inside diameter of tube
Coefficient of friction = 0.15 d0 = 52 mm, H0 = 2.6
Yield dress = 260 MPa H1 = 1.8, D1 = 50 mm
 2  2d = 24=12, =0.12
A0 = 6 = 136 = 21.237
4 4
 2  2.6mm
A1 = 5.2 = = 21.237
4 4
1.8 mm
Drawing stress = 2
52mm
 1  B   A 1 
B 50 mm
 
= y   1 
 B   A 0  

B = cot
1 1
= Die angle =  18 =90
2 2
=9 1   2
For stationary mandrel B =
Tan
B = 0.15  cot90 = 0.947
0.12  0.12
2 = 126.958MPa B= =1.29
Tan (12)
 1  0.947   21.27  
0 0.947
= 260  
  1  B    H1  
B
 1  
 0.947   28.270   2   y  1    
  B    H 0  
= 260(2.056)(0.2375)
1  1.29    1.8  
1.19
2 L
2 / y   1    
Total drawing stress 2 = y + (2y) e  1.129    2.6 
R1

(By considering friction)
2/y = 0.64
20.154
= 260 + (130260) e 2.6
total = 260  81.94 = 178.05 MPa 13. Movable mandrel

B = cot = (0.12)cot(12) = 0.564
Total drawing load = tA1
1  0.564    1.8  
0.564
= 178.05  21.237 2 / y   1      0.519

 0.564    2.6  
= 3.781 kN

14. Floating mandrel

d2 = d1 2 B 1
B=0 1 B
2 h  1
 n  0   1  2B
y  h1 
C=   = 0.756
1 B 
 2.6 
= n   = 0.367
 1.8  Dia of wire in 2nd stage = 3.424 mm
d1 = d0  c
Common data for Q 15. & 16. d2 = d1 c = 4.530.756
= 3.424 > 1.34
15. Ans: 6 & 16. Ans: 3.4 d3 = d2  c
Sol: d0 = 6 mm, df = 1.34 mm
= 3.424 0.756
Given ideal condition
= 2.589>1.34
 = 0.2  = 60
d4 = d3c = 1.957>1.34
f = 60 MPa
d5 = d4  c = 1.4797 > df
Maximum reduction condition
d6 = d5c = 1.1186 < df
 1  B   d1  
2B
2  Hence No. of stages = 6
=11=   1
y  B   d 0  
B = cot; B = 1.9 Common data for Q 17, 18

2B
B d 
 1   1  17. Ans: (c) & 18. Ans: (b)
1 B  d0 
Sol: 400
2B
 d1  B y
  1
 d0  1 B
1 200
=
1 B
d1 2 B 1 0.2 0.4
 
d0 1 B
1 do = 12.214, Lo = 100m
 1  1  21.9
d1 = d 0  2 B   6  df = 10mm, Lf =?

 1 B   1  1.9 
 y before  200 MPa ,
d1 = 4.53 ……… (1) stage
 y after  400 MPa

Ao Lo = Af Lf 22. Ans: 1
A d 
2
Sol: Let, d1 = d2 = d
L f  L o  o  L o  o 
Af h1 = height of first cylinder
 df 
2
h2 = height of second cylinder
 12.214 
 100     150m Assume h1 < h2
 10 
Let % reduction in height = 10%
True strain in the drawing process
2
A d  Ist cylinder
    n o   n  o   0.4
A1  d1  h0  hf
 0.1
From the graph  y at   0.2 , h0
 y  300 MPa h0 – hf = 0.1 h0

hf = h0 – 0.1 h0 = 0.9 h0
19. Ans: (b)

A0h0 = Af hf
d02h0 = df2 hf
20. Ans: (c)
h0 h0
Sol: (Extrusion force)min =  y  A 0 df  d0  d0
hf 0 .9 h 0

 10  10 2 = 78539.8N = 1.054 d0 = 1.054 (d0)1
4
(E.F) min 78539.8
Extrusion force   IInd cylinder
 ext 0.4
A0h0 = Afhf
= 196346.5 N
d02h0 = df2 hf
= 196 Tons
h0
df  d0
hf
21. Ans: (b)
Sol: Extrusion constant = K = 250 h0
 d0 = 1.054 (d0)2
do = 100 mm, df = 50 mm 0 .9 h 0
Ao d 0 1 1.054d 0 1
Extrusion Force = A o K ln Ratio   1
Af d 0 2 1.054d 0 2
2
  100 
 100 2  250 ln  = 2.72 MN.
4  50 

Common data for Q 23 & 24 27. Ans: 7.26

Sol:
23. Ans: 7068 J & 24. Ans: 0.354 m 0.3= 1.328
O
Sol: do = 100 mm, ho = 50 mm, 
A
h f  40 mm ,  y  80 MPa B C
H0 H1
ho 50
df  do  100  111.8mm
hf 40
Fi min  A 0   y
O
 Ho = 10 mm,
  1002  80  628.318 kN
4 H1 = 7 mm, 500 0.3
 1000
Ff min  A f   y  (111.8) 2  80 R= = 500 mm
B D
4 2
 785.350 kN C
1 H
Angle of bite () = tan
F  Ff min R
Fmin  i min  706.834 kN
2
10  7
W.D  Fmin  (h o  h f )  7068J = tan 1 = 4.429
500
 2 W  H OD
1.328 
7068 OB
H  0.354 m
2  10  103 OD = 500cos1.328 = 499.865
DC = 500 – OD = 0.1343 mm
25. Ans: (b) Thickness of neutral point = At point B
= 7 + 2  0.1343 = 7.2686 mm
26. Ans: 58%
Sol: Area after 1st pass = A1 = (1 – 0.4)A0
= 0.6 A0
29. Ans: 7.687 MPa, 19.7 %
Area after 2nd pass = A2 = (1 – 0.3)A1
Sol: d0 = 6.25 mm; d1 = 5.60 mm;
= 0.7  0.6  A0 = 0.42 A0
 = 0; y = 35 N/mm2
Overall % reduction = (1 – 0.42)  100
B = cot = 0
= 58 %
 1  B   A1   0
B
2   y   1   
 B   A 0   0

By applying L – Hospital rule 31. Ans: 20.52 kW

A  Sol: d0 = 10 mm;
 2   y n  0 
 A1  A 0  A1 A
0 .3   1 1
A0 A0
d 
  y  2n  0 
 d1  d 12
0.3  1 
d 02
= 7.687 MPa
d1 = 8.36 mm
A 0  A1 d 02  d12
% reduction in area =  B = cot = 0.1cot(6o) = .951
A0 d 02
 1  B   A 1 
B
= 19.71%  
2  y   1 
 B   A 0  

30. Ans: 29.85 tons
Sol: Initial size = 2525150mm
 1  0.951 
 240 
 1  0.7 
0.951

 0.951 
Final size = 6.25100150mm = 141.687 MPa
 = 0.25;  2
y = 0.7kg/mm 2 Drawing load =  2  A 1  141 
4
d 1 
As given piece is pressed; height is reduced 
Fd  141.687 d12
h0 = 25; 4

hf = 6.25 = 141 
4
8.36 2  = 7777.364 = 7.8 kN
A0 = 25150;
Af = 100150 Fd  v
P (motor) =
motor
 2hrf 
Forging force =  y A f 1   7.8  2.5
 3h f  P
0.95
(Ac)circular = (Ac)non – circular
 P = 20.52 kW
rf2  100  150
rf = 69.098mm
Forging force
 2  0.25  69.098 
= 0.7  15  10 3 1  
 3  6.25
= 29847.44kg = 292.80kN

05. Ans: (b)

Fp max .Kt
Sol: Fp 
Chapter‐ 6 Kt  I
Sheet Metal Operation
40  0.6  1.25
  17.14 kN
0.6  1.25  1
Common data for Q. 1 to 5 Fb max kt
Fb 
kt  I
01. Ans: (b) 80  0.6  1.25
  34.28 kN
0.6  1.25
Sol: For punching operation
F  FP  Fb  51.42 kN
Punch size = Hole size = 12.7
Die size = punch size + clearance
Common data for Q. 06, 07 & 08
= 12.7 + 2  0.04 = 12.78
06. Ans: 83.6 N
Sol:
02. Ans: (a) 100
Sol: Die size = Blank size = 25.4mm
30
Punch size = Die size  2(radial clearance) 50mm
= 25.4  2(0.04) 450 20

Punch size = 25.32 mm
80mm 20
P  100  30  20 2  80  50  288.28
03. Ans: (b)
Fmax  Pt u  288.28  2  145  83.6 kN
Sol: Fmax = Fp max + Fb max
=   12.7  1.25  800    25.4  1.25  800
07. Ans: 66.88 J
= 40 +80 = 120 kN
Sol: Work done in blanking open
= Fmax.K.t
04. Ans: (c) = 83.61030.42103
Sol: Force required is Max [Fpunch, Fblank] = 66.88 J
 force required is Max [40, 80]
 force required = 80 kN 08. Ans: 1.98 mm
Sol: I = ?
F = 24 kN
Fmax = 83.6 kN 12. Ans: (d)

F(Kt + I) = Fmax  Kt Sol: d = 25 mm, t = 2.5 mm → piercing
Fmax  Kt  u  350 MPa
I= Kt
F Diameter clearance  C
 83.6  0.4  2   0.0064 K t
=  0.4  2  = 1.98 mm
 24 
 0.0064  2.5 350 = 0.3 mm
In piercing
09. Ans: (a)
P.S = H.S = 25 mm.
5
Sol: Fmax  5  dt  u  dt u  D.S = P.S + C = 25 + 0.3 = 25.3

Fmax    1.5d  0.4t   u Fmax  dt  u    25  2.5  350
= 68.72 kN.
   1.5  0.4  dt u
2
   1.5  0.4   3 KN 13. Ans: (a)

Sol: Die size = Blank size = 25 – 0.05
= 24.95
Common Solution for Q. 10 & 11
Punch size = Die size – clearance
= 24.95 – 2  0.06 = 24.83
10. Ans: (a)
11. Ans: (b)
Common data for Q. 14 & 15
Sol: t = 5 mm, L = 200 mm, τu = 100 MPa,
K = 0.2
14. Ans: (b)
W.D = Fmax Kt = L × t × τu × K.t
Dia.before
= 200 × 5 × 100 ×0.2 × 5 Sol: Draw Ratio =
Dia.after
100  10 3
  100 N  m (or ) J only 13.22
1000  d1 = = 7.34 > 5cm
1.8
Shear provided over a length of
7.34
20  d2 = = 4.08<5 cm
200 mm   200 = 10 mm 1.8
400
n=2
Fmax Kt = F (Kt + I)
100  10 3  0.2  5
F  9.09  10 kN 15. Ans: (a)
0.2  5  10
Sol: D  d 12  4d 1 h 1

4d 1 h 1  D 2  d 12 d 2  82.48  0.8  65.984  30
D 2  d 12 13.22 2  7.34 2 d 3  65.984  0.8  52.7  30

h1   = 4.11 mm
4  d1 4  7.34 d 4  52.7  0.8  42.2  30
P1  Dt y d 5  42.2  0.8  33.7  30
=   132.22  1.5  315 d 6  33.7  0.8  27  30
 196238 N = 196.238 kN n=6
–3
E = P1h1 = 196.2384.1110 = 806.6 kJ
19. Ans: 52.7 mm
16. Ans: (b) Sol: d3 = 52.7 mm
D  d1
Sol: DRR 1  0.4 
D 20. Ans: 144.42
d 1  D1  0.4   30.2  0.6  18.12 d 100
Sol:   16.66  15 to 20
d 2  d 1 1  0.25  18.120.75  13.59 r 6
d 3  d 2 1  0.25  13.590.75  10.19 D  d 2  4dh 
r
2
d3 < 12  n = 3
6
 100 2  4  100  25 
2
17. Ans: (b)
= 138.42 +23
Sol: P1  Dt y    30.2  2  35  6641.3
D total  D  2  3  144.42 mm
P1
 21 
 2
4

d 1  d 1  2 t 
2
 21. Ans: (d)
6,641.3
 22. Ans: (c)

4

18.12 2  18.12  2  2
2
 Sol: Number of earing defects produced =2n
= 65.5 MPa Where n is an integer
So possible option is 64.
Common data for 18 & 19
18. Ans: 6 23. Ans: 467 mm

Sol: D  d 2  4dh  30 2  4  30  150 Sol: B1  15  0.5  2  180 
180
 137.47
= 50.265 mm
d 1  D  0.6  137.47  0.6  82.48  30
 C = Clearance = 0.0032 t 
B 2  6  0.5  2  90  = 10.99 mm
180 t = thickness = 1 mm
L 0  98  204  92  B1  2B 2 where,  = 240 N/mm2
= 466.245 mm C = 0.0032×1× 240
= 0.0495 mm = 0.05 mm
2mm
15
Die size = 10 + 2 × 0.05 = 10.1 mm
Force required = s × d × t
92
98 100 = 240 ×  × 10 × 1
6 mm = 7.536 kN
8m
8 204 8
220m
24. Ans: (b)
25. Ans: 3
Sol: D  d 2  4dh
 50 2  4  50  100  150mm
D  d1
0 .4 
D
0.4150 = 150 – d1
d1 = 90mm > 50
d2 = d1(1–0.4) = 54 > 50
d3 = 32.4 < 50
n=3
26. Ans: 7.536 kN

Sol: Punching a 10 mm circular hole from 1 mm
thickness sheet:
Punch size = Blank size = 10 mm
Die size = Punch size + 2 C
04. Ans: (c)

Sol: D
Chapter‐ 7
Metrology
t
7.1 Limits, Fits & tolerances t = 0.01 to 0.015mm
When, t = 0.01 mm
01. Ans: (a) D = 30.01 + 20.01 = 30.03 mm
Sol: For Clearance fit = 30.05 + 2 0.01 = 30.07 mm
L- hole > H- shaft When, t = 0.015 mm
D = 30.01 + 20.015 = 30.04 mm
02. Ans: (c) = 30.05 + 2 0.015 = 30.08 mm
0.050
0.000 0.08
Sol: Hole = 40 mm , D  30 0.03 mm
Min. clearance = 0.01 mm,
Tolerance on shaft = 0.04 mm , 05. Ans: (d)
Max. clearance of shaft = ? 0.01
0.01 = L.hole – H.shaft Sol: A = 25.2 0.02

0.01 = 40.000 – H.shaft B = 30.4  0.01
 H.shaft = 40.000 – 0.01 = 39.99mm C = 32.7  0.02
H.shaft – L.shaft = 0.04 Tmax = Lmax  Amin  Bmin – Cmin
L.shaft = 39.99 – 0.04 = 39.95 = (118 + 0.08)  (25.2  0.02)  (30.4
Max. clearance = H.hole – L.shaft  0.01) – (32.7 – 0.02)
= 40.05 – 39.95 = 0.10 mm = 29.83 = 300.17
Tmin = Lmin  Amax  Bmax  Cmax
03. Ans: (d) = (118  0.09)  (25.2 + 0.01)  (30.4
Sol: Xmax = 50.02 – (37.985 + 9.99) = 2.045 + 0.01) (32.7+ 0.02)
Xmin = 49.98 – (38.015 + 10.01) = 1.955 = 29.57
X = Xmax  Xmin= 0.09
Tmin = 30 0.43
Dimension X = 2 ± 0.045 0.17
 T = 30 0.43

06. Anc: (c) (i) Ans: (c)

Allowance = (L.L)hole  (H.L)Shaft
07. (i) Ans: (d)  0.09 = 65 – (H.L)shaft
Sol: Let the vertical distance between the holes  (H.L)shaft = 65  0.09= 64.91 mm
is ‘y’ Tolerance = (HL)shaft  (LL)shaft
2450.05  0.05 = 64.91 – (LL)shaft
 (LL)shaft = 64.86 mm
x
0.09
 0.14
25 Shaft = piston = 65
y 2500.2
30
0.2 (ii) Ans: (a)
 0.0
60 (L.L)hole = 65 mm
(Tolerance)hole = (HL)hole  (LL)hole
y  0.05 = (HL)hole – 65
sin30 = y = 245sin30
245
 (HL)hole = 65.05 mm
ymax = 245maxsin30max 0.05
0.00
= (245 + 0.05)sin(30 +15/60) = 123.45 Hole = Bore = 65
0
ymin = (245 0.05)sin(30 15/60) = 121.55
(iii) Ans: (b)
(ii) Ans: (c) Max Clearance = 65.05 – 64.86
xmax = 250max– (60min+(30/2)min+ymin+(25/2)min) = 0.19 mm
= (250 + 0.2) (60 +15+121.55+12.5)
= 41.15mm 09.
xmin = 250min –(60max+(30/2)max + ymax + (25/2)max) Sol: Amax = 15max + 30max
= (2500.2)  (60.2 + 30.025/2 + 123.45 + = 15.06 + 30.1 = 45.16
25.025/2) Amin = 15min + 30min = 44.84
= 38.625 mm A = 45 ± 0.16. = A ± ∆A
Tolerance on X = Xmax – Xmin = 2.525 mm Bmax = Amax – 20min
= 45.16 – 19.93 = 25.23 mm
08. Bmin = Amin – 20max
Sol: L Hole = BS = 65mm = 44.84 – 20.07 = 24.77 mm
H Hole = BS + Tolerance = 65.05mm  B ± ∆ B = 25 ± 0.23.

10. 0.075
 0.275
 C  100
Sol: Let
C = center distance between holes
11.
Cmax = max. Outer distance of pins –
Sol: For the given conditions
sum of min rod holes.
14.875 9.875
C =100±0.1 X  100.1  
2 2
9.9  0.025
= 112.475 mm
14.9  0.025
 15.05 10.05 
C  X  
 2 2 
C = 99.925 mm
15  0.05 10  0.05
x Because C is lying in between the limits, the
assembly is possible.
 9 .9   14.9 
Xmax = 100 max    
 2  max  2  max
12. Ans: (b)
9.925 14.925
 100.1   Sol: Fundamental deviation of hole ‘h’ is zero.
2 2
= 112.525 mm
13.
 9 .9   14.9 
Xmin = 100 min     0.03
 2  min  2  min Sol: Hole = 20 0.00

9.875 14.875 Min. interference = 0.03mm,
 99.9  
2 2 Max. interference = 0.08 mm
= 112.275 mm 0.03 = L.shaft – H.hole
 15  L.shaft = 0.03 + 20.03 = 20.06 mm
 10  
C max  X max        0.08 = H.shaft – L.hole
 2  min  2  min 
H.shaft = 0.08 + 20.00 = 20.08mm
 14.95 9.95 
 112.525     0.08
 2 2  shaft  20  0.06
= 100.075 mm
 15   10   14.
C min  X min       
 2  max  2  max  Sol:
H 0.021
 15.05 10.05  H. Limit
 112.525     B.S
 2 2  L. Limit
= 99.725 mm
= H.hole – L.shaft
B.S
F.D=0.02mm = (25.021)  (24.947)
f
= 0.074 mm
H. Limit Tol = 0.033mm
L. Limit (iv) Ans: (a)

Size of the GO plug gauge = max. material
D  18  30  23.24mm limit of hole = L.hole = 25 mm
i  0.453 D  0.0010  1.3m

(v) Ans: (b)
FD of hole H = 0
Size of the NOGO plug gauge = min.
FD Shaft = 5.5(23.24)0.41 = 20m
material limit of hole = H.hole = 25.021 mm
Hole tolerance, IT7 =16i = 20.8m
= 21m = 0.021 mm
(vi) Ans: (c)
Shaft tolerance, IT 8 = 25i
Size of the GO ring gauge = max. material
= 32.5m = 33m limit of shaft = H.shaft = 24.98 mm
= 0.033mm
L - hole = basic size =25 mm (vii) Ans: (d)
H - hole = 25 + 0.021 = 25.021 mm Size of the NOGO ring gauge = min.
H - shaft = 25 – 0.02 = 24.98 mm material limit of shaft = L.shaft = 24.947
L - shaft = 24.98 – .033 = 24.947 mm mm
(i) Ans: (a)

(viii) Ans: (a)
L- hole > H- shaft  Clearance fit
(ii) Ans: (b) 15. Ans: (c)

Allowance = difference between max. Sol: D  18  30  23.2
material limits = L.hole – H.shaft i  0.45 3 D  0.001 D  1.3
= 25.00 – 24.98 = 0.02 mm IT8 = 26i = 26 × 1.3 = 33.8
= 34 m = 0.034 mm
(iii) Ans: (b)
0.034
0.02
0.021 Hole size  25H 8  25  0.000
Shaft  250.053 , Hole = 25  0.00
Max clearance = different between

minimum material limits
16. Ans: (a) 0.025

 0.000
Hole  50
Sol: D  50  80  63.24 mm
i = 1.86 microns = 1.9 microns p
H. Limit 0.042
IT8 = 25i = 47.5 microns
0.026
Tolerance = 0.0475 mm B.S =50
L. Limit
F.D = –5.5 D0.41 = – 5.5 × 63.240.41
= 30 Microns = 0.03 mm
H. shaft = 60 – F.D = 60 – 0.03 = 59.97 mm 0.042
L. shaft = H. shaft – Tolerance Shaft  50 0.026
= 59.97 – 0.047 = 59.923 mm. L.hole = B.S = 50

H.hole – L.hole = Tolerance = 0.025 mm
17. Ans: (d) H.hole = L.hole + Tolerance = 50.025 mm
Sol: Case (i) 25H7 Max. interference = difference between
L.L = 25.00 max. material limits = H.shaft – L.hole

U.L = 25.021 = 50.042 – 50.00 = 0.042 mm
Case (2) 25 H8 Min. interference = difference between min.

UL = 25.033 material limits = L.shaft - H.hole
Case (3) 25H6, UL - ? = 50.026 – 50.025 = 0.001 mm
(UL)H8 (UL)H7 = (UL)H7  (UL)H6

19. Ans: (c)
25.03325.021 = 25.021  (25 + x)
x = 0.009
20. Ans: (b)
 (UL)H6 = 25.009
Sol: To calculate exactly the data was not given
in the problem. But for shaft “h”,
18. (i) Ans: (a) , (ii) Ans: (a),
H – Shaft = 25.000
(iii) Ans: (a), (iv) Ans: (c)
L – Shaft = less than 25.
And h7 → 7 indicates IT 7 not 7 microns.
Sol:
21. Ans: (a)

H. Limit H 0.025
50
Sol: GO size = max. material limit of hole
L. Limit = 20.01 mm
NOGO size = min. material limit of hole
= 20.05 mm
22. Ans: (d) 03. Ans: (d)

Sol: To produce an interference fit, L-shaft must
be greater than H-hole. For this with 04. (i) Ans: (c)
multiple choice D it is possible because h
Sol: sin  =
For D: L-shaft = 20 – 0.02 = 19.98 mm, L
H-shaft = 20 + 0.02 = 20.02 mm h = sin30o  125=62.5 mm
L-hole = 20 – 0.035 = 19.965mm,
H-hole = 20 – 0.03 = 19.97mm, (ii)
Hence, L-shaft (19.98) > H-hole (19.97) (A) Ans: (a)
 0 0.005 
d  tan 30  = 4.76
7.2 Angular Measurements  62.5 125 
(B) Ans: (a)
01. Ans: (a) d 2  d1 0.002
dh  r2  r1    0.001
Sol: 2 2
Sine bar
Slip gauges
 0.001 0 
d  tan 30  = 2

 62.5 125 
Given sine bar length = 200 = l (C) Ans: (b)
 
Angle =325 6 = 32.085 dh = 0.002
Slip gauge height = h say  0.002 0 
d  tan 30   = 4
h  62.5 125 
sin  
 (D) Ans: (d)

sin 32.085 0   h
200
dh =  0.005
  0.005 0 
 h = 106.235 d  tan 30   = 10
 62.5 125 
02. Ans: i-(b), ii-(a)

05. Ans: 0.048 mm/m
Sol: l = 50 , L = 500
Sol: Gradient of spirit level
50  0.08 = Sensitivity specified in mm/m
0.08 10 
200  200   0.32    1000 = 0.04845 mm/m.
50 3600 180
h = h + 0.32 = 28.87 + 0.32 = 29.19
h 29.19 06. Ans: (d)
Sin     82332
L 200
07. 7.3 Taper Measurement

Sol: (i) Ans: (b)
01. Ans: 19.2
h  h1
sin = 2 Sol:
w
2.5 30
h2  h1 = 100sin30 = 50
O2
h2 = h1 + 50 = 75 50
/2
(ii) Ans: (d)

15
h  25 O1
sin(30)  h1 h2
100.005
 h = 75.0025 mm
d 2  d1
 h2 = 75.0025 + 0.005 = 75.0075 mm sin  / 2 
2h1  h 2   d 2  d1 
30  15
08. Ans: (a) sin  / 2  
252.5  30  15
Sol: L = 250 mm, d = 20 mm
15
h = 100 – (d/2) = 100 – 10 = 90 mm  = 1/6
105  15
90
sin     = 19.2
250
  = 21.2 deg
02. Ans: 60
5
09. Ans: 11.556 mm Sol: tan  / 2 
8.66
Sol:  = 2732
  = 60
o
 32 
= 27 o   
 60  125
= 27.533 h O2
105=5 O1
h 
sin =
25
h = 11.556 mm
36.345=31.34
36.34
40
50
03. Ans: 112.41 mm 05. Ans: 78.074 mm

Sol: Sol:
70 mm 30 mm
h2
h1 h1+r1=O2A+r2+h2
O2
D B A
O1 12.5mm 12.5mm
C
d1 = 100 m A C
M 


Diameter = O1C+O1A+O2D
d1 d2 O
  O1O 2 2  O 2 A 2 
X
2 2
O1O 2  r1  r2 =75
 +  = 4550 + 2910 = 75
O2A = h1 + r1 – r2 – h2

= 70 + 50  30  25 = 65  37.5 
2
D  50  75 2  65 2  25 75
   = 37.5 –  = 37.5 – 2910
2
= 112.4165 mm
= 820
le OBC
04. Ans: 43.33 mm
BC
Sol: sin 37.5 =
OB
BC 12.5
 OB    20.533
d = 25 O2 sin 37.5 sin 37.5
le OAB
42
35 OA
cos 820 =
O1 A OB
 OA = OB cos 820 = 20.316 mm
X = M – (OA + R)
O1A = 25  17  18.33
2 2
= 110.89 – (20.316 + 12.5)
D = r + O1A + r = 78.074 mm
= 25 + 18.33 = 43.33 mm

06. Ans: 1.1   3 

 Tan 1  = 6
Sol: d2 – d1 = 10 ; h2 – h1 = 12.138 2  28.54 
 d 2  d1 
sin    Taper angle    6 0
 2  2  (h 2  h 1 )  d 2  d1  2
 = 88.9 Included angle = 120
Error = 90 – 88.9 = 1.1
09. Ans: (c)
07. Ans: 38.94 10
Sol: tan     = tan-1(1/3)    18.434
Sol: 30
10mm 10mm
Z=40
h  D2
 D 30mm
2 2

10mm
Z=10
D
  2 D
Sin    
2 hD 2h  D Z=0
2 10 – (10/3)
 D
Sin 
2 2h  D Distance at Z = 0,
If D = 0, h = 0
 10 
D = 1, h = 1 D 0  210  10 tan 30  210  
 3
  1 1 = 6.67  2 = 13.33 mm
Sin    
 2  2 1  1 3
  1sec
 2   19.47   = 38.94 
  1
08. Ans: (d) With probe diameter compensation

 3 Dactual  13.334  2  r sec 
Sol: Tan   
 2  28.54
= 13.334 + 2 ×(1 sec 18.435)
= 15.442 mm.
 3
3
2
10. Ans: (d)
15.54 + 8 + 5 = 28.54

7.4 Screw Thread Measurements 1  71  0.11667 2.04103

2 = 91 = 0.15 2.618103
01. Ans: (d)
P = 0.004
Sol: Major diameter = s + (R2 R1)
De = 30.6651
= 35.5 + (11.8708 9.3768)  = 60 (metric thread)
= 37.994 mm Virtual correction
VC = (0.004  cos30) + (0.0131 
02. Ans: (a)
3.5(0.11667 + 0.15) )
Sol: Minor diameter
VC = 0.01569
= 30.5 + (15.3768  13.5218)
VED = De + VC
= 32.355 mm = 30.6651 + 0.01569 = 30.6807
Correct answer is (a)
05. Ans: (a)

03. Ans: (a)
p  06. Ans: (d)
Sol: best wire diameter, d =   sec 
2 2
 R 2  R1
Sol: Sin   
 3.5   60 
=  sec  = 2  2  M 2  M1  R 2  R 1 
 2   2  1.4434  0.8660
=
M = 30.5 + (12.2428  13.3768) 22.06  20.32  1.4434  0.8660
= 29.366 mm  = 59.5566 = 593323
 p 
De = M  d  tan 
 2 2
07. Ans: 16.433 mm
 3.5   p 
= M  2   tan 30  Sol: De = M   d  tan 
 2   2 2
= 29.366 – 3.010366 = 26.355 mm 2
M = 14.701 + (1.155+ tan30) =16.433
2
04. Ans: (a)
Sol: VED = De  VC
08. Ans: (d)

VC  P cos  0.0131P 1   2  Sol: Lead = pitch  no of starts
2 lead 3
Pitch = = =1.5
P = pitch error no of starts 2
1, 2  flank angle errors in deg
09. Ans: (d) 7.5 Surface Finish Measurement

Sol: Rollers will not used to measure pitch
diameter. 01.
p  (i) Ans: (c)
Best size diameter d =   sec 
2 2 Sol: Rt = max. peak – min.valley
 2   60  = 4 2  18 = 24
=   sec 
2  2 
(ii) Ans: (c)
= 1.1547 = 1.155
Sol: CLA(Ra) = (h1+h2+h3+……+h10)/n
10. Ans: (d) 300

= = 30
10

Sol: V.C =  P.cos    0.0131 P(1+ 2) (iii) Ans: (b)
2
Sol: Peaks 35 40 35 42 35
= 0.2 cos30 = 0.346
Valley 25 22 18 25 23
peaks  valleys
Common data Q 11 & 12 Rz =
no of peaks
(35  40  35  42  35)  (25  22  18  25  23)
11. Ans: (a)  =15
5
p 
Sol: Best size diameter, d =   sec 
2 2 (iv) Ans: (b)
 2   60 
=   sec  =1.155 mm h 12  h 22  h 32  ........  h 2n
2  2  Sol: RMS = = 33
n
(or) RMS = 1.1  R a=1.1  30=33
12. Ans: (a)
 p  (v) Ans: (c)
Sol: Deff = M –  d  tan 
 2 2
Sol: If Ra value from 18.75 to 37.5 international
= 16.455 – 1.155.tan30 = 14.7226 mm grade of roughness is given by N11.
13. Ans: 1.732 mm 02. Ans: (c)

Sol: The best wire size = (p/2) sec(/2)
Sol: Ra =
A  1

1000
= (3/2) sec(60/2)
w HM VM
= 1.732 mm
480  480 1 1000
=   = 0.8
0.8 100 15000
03. Ans: (d)
Sol: Rt =
0.05
=50  m Chapter‐ 8
tan 45 Advanced Machining Methods
Numerical Control (NC)
04. Ans: (c)
Sol: 01. Ans: (a)
Sol: Pitch of lead screw = 5mm
1 rev = 5mm
50 40
Am = 0.105
1mm = 1/5 rev
200mm = 1/5  200 = 40rev
10
= 40 360 = 14400 deg.
2.5
Am act = 0.105  0.01 2.5 = 0.08 02. Ans: (b)

A m act Sol: Pitch of lead screw = 5mm,
K= 3
(10  2.5)  0.04 BLU = 0.005mm
0.082 1  Distance travelled /pulse
  = 0.8
 3
2.5  10  0.04 1000  Length of travel = 9mm
No.of pulses = L/BLU = 9 / 0.005
05. Ans: (c) = 1800 pulse.
06. Ans: (c) 03. Ans: (b)

Sol: For 1 rev of motor 360 are required
07. Ans: (a)  360 pulses are required
When motor is rotated by 1 rev
08. Ans: 2  lead screw will rotate by 1 rev
h 16  4  16  0 64 When Lead screw is rotated by 1 rev 3.6
Sol: R a     2 m
n 32 32 mm distance is travelled by axis
In total
For 360 pulses  360 deg of motor
 1 rev of motor
1 rev of lead screw
 3.6 mm of linear movement of axis  Pulses per min = feed / BLU

360 pulses = 3.6mm = 50/0.01 = 5000
1 pulse = 3.6/360 = 0.01mm
= 10 microns 07. Ans: (a)
Sol:
CNC drill table
04. Ans: (b) X axis
pulses
Sol: 10V = 100 rpm
= 100  5 = 500 mm/min Pulse
Driver
Stepper
generator motor
That is for 500mm/min = 10V
1mm /min = 10/500
3000mm/min = 10  3000 / 500=60 V
BLU = the distance traveled by the table for
Common Data 05 & 06 one pulse of electrical energy input to the
motor.
05. Ans: (b) & 06. Ans: (a) Hence 200 pulse = 1 revolution of motor
Sol: A, Stepper motor  200 steps / rev = 1 revolution of lead screw = 4mm
 200 pulses /rev That is 1 pulse = 4/200 = 1/50 = 0.02mm,
Pitch = 4 mm, no. of starts = 1, hence BLU does not depends on the
Gear ratio = N0/Ni= 1/4 = U frequency of pulse generator. But if the
F = 10000 pulses per min speed of the table means it will get doubled.
200 pulses  1 rev of motor

08. Ans: 20
 1/4 rev of lead screw
Sol: p = 5 mm
= 1/4  4  1 mm linear distance.
1000 pulses  1 rev of motor
= 1mm linear distance
 1 rev of lead screw
1 pulse = 1/200 = 0.005mm
Velocity of table = 6 m/min
= 5 microns = 1 BLU
= 6000 mm/min
Feed = BLU  pulse /min
= 100 mm/sec
= 0.005  10000 = 50mm/min
1000 pulses  1 rev of lead screw  5 mm
For changing BLU = 10 microns
5
= 0.01mm 1 pulse   0.005 mm
1000
 Gear ratio has to be reduced to 1/2
BLU = 0.005 mm
Feed = BLU  pulse /min
Table speed = BLU × Rate of Pulses 13. Ans: (d)

100 Sol: Appropriate answer but the correct answer
Rate of pulses =
0.005 is
= 20000 pulses/sec N05 X5 Y5
= 20000 Hz = 20 kHz N10 G02 X10 Y10 R5
Because in CNC part program we are not
09. Ans: (c) suppose to indicate information about one
Sol: axis more than once in one block.
75
14. Ans: 60
centre
55 Sol: In the combined movement, the tool is
(50,55)
moving for 50mm with a speed of
50
100mm/min. whereas in the same time tool
70
is traveling x-axis by only 30mm.
Hence,
10. Ans: (b) For 50mm 100mm/min
100
For 30mm   30  60mm / min
11. Ans: (a) 50
Sol: G02 – circular interpolation clockwise
G03 – circular interpolation counter clockwise 15. Ans: (a)
Sol: Because diameter of milling cutter is 16mm,
12. Ans: (c) the radius is 8mm. the dotted line indicates
Sol: Because the tool has to travel from P1 to P2 cutter center position, which is shifted by 8
in clock wise. mm all around the rectangular slot
(–8,58) (108,58)
Y P2 = (10, 15) S R
  Center (15, 15) (0,50) (100,50)
(0,0) (100,0)
 P Q
P1 = (15, 10) (–8,–8) (108,–8)
X If the given shape is rectangular hole, then
the answer is
(8,8), (92,8), (92,42), (8,42), (8,8)
16. Ans: (a) 18. Ans: (b)

Sol:
Y Q (4,5)
19. Ans: (a)
Sol: Given coordinates (0,0) to (100, 100)
36.9
P
33.7 R D Mean, L = 100, depth, d = 2 m
3.2
(1,3)
C
Diameter, D = 10
O APC = d D  d 
X
PQ  2 2  32 = 3.6055 = PC = 210  2  = 4
PD = PC  cos 3.2 = 3.6 104 104
Time/slot = =
x co-ordinate of point C = 1 + 3.6 = 4.6 fN 50
DC = 3.6 sin 3.2 = 0.2 = 2.08 min
y co-ordinate of point C = 3.0 – 0.2 = 2.8 = 124.8 sec  120
17. Ans: (a) 20. Ans: 54.166 mm/sec, 10 micron

Sol: “P” after translation = (1+2, 3+3, –5 –4) Sol: f = 500 pulse/rev
= (3, 6, –9) p = 5 mm, N = 650 rpm
Rotation about z- axis means 650  5
(i) v = Np =
 x  cos   sin  0 0 x  60
 y   sin  cos  0 0  y
    v = 54.166 mm/sec
 z  0 0 1 0 z  Now, 1 min = 650 rev
     
1  0 0 0 1 1  650
1 sec = rev
0  1 0 0 3 60
1 0 0 0 6 650
    f  500 
0 0 1 0   9 60
    f = 5416.66 pulse/sec
0 0 0 1 1
And, v = B.L.U. f
0  6  0  0    6 
3  0  0  0   3  = 54.166  BLU  5416.66
   
0  0  9  0    9  B.L.U. = 0.01 mm
    B.L.U. = 10 microns
 0  0  0  1  1 
Final point = [–6, 3, –9]

21. Ans: 287

Sol:  = 0.9 Chapter‐ 9
0.9 = 1 pulse NTM, Jigs and Fixtures
360
360  pulse  400 pulses
0.9 01. Ans (c) 02. Ans: (d)
 1 revolution = 4 mm pitch = 400 pulses
03. Ans: (c)
  2.87 mm = 287 pulses
Sol: In EDM the mechanism of MR is due to
melting and vaporization associated with
22. Ans: 100 pulse, 60 mm/min
cavitation and also erosion & cavitation or
Sol: Pulse rate = N  pulse/rev
spark erosion and cavitation
400
 15   100 pulse / sec
60 04. Ans: (d)
Feed rate = 15 rpm  4 mm/rev Sol: The high thermal conductivity of the tool
= 60 mm/min material will have high electrical
conductivity hence the heat generated with
in the tool is low and what ever heat
generated it will be distributed easily
therefore tool melting rate reduces and tool
wear reduces. Where as due to specific heat
of work material, the rise in temp of W.P is
faster and more amount of MR is possible.
05. Ans: (b)

Sol: Given w = 1 + (2  0.5) = 2
t =5, f = 20 mm/rev
MRR = wtf = 2.5.20 = 200 mm/min
06. Ans: (a)

Sol: As the thermal conductivity of tool material
is high the heat dissipation from the tool is
taking place and if the specific heat is high,
it needs large amount of heat for raising the
temps of tool material up to MP.
10. Ans: (a)

07. (i) Ans: (a) , (ii) Ans: (c) Sol: In ECM
Sol: D = 12mm, t = 50mm, R = 40 , MRR  gram atomic weight of material
C = 20 F, Vs = 220V, Vd = 110V  Current density
 Vs  1

Cycle time = R.C ln    tc dis tan ce between tool and work
 Vs  Vd 
 Thermal conduction of electrolyte.
 220 
= 40 2010–6 × ln  
 110  11. Ans: (b)
6
 554  10 sec  0.55 milli sec Sol: I = 5000 A
Average power input = W A = 63, Z = 1, F = 96500
 E   0.5  CVd 2  AI 5000  63
MRR  
=   ZF 1  96500
 t c   tc 
 3.264 g / sec .
= 218 W = 0.218 kW
12. Ans: (a)

08. Ans: (b)
Sol: A = 55.85, Z = 2, F = 96540
Sol: For Rough machining i.e. stock removal the
Specific resistance = 2Ω-cm
electrolyte should have high electrical
Voltage = 12V
conductivity, called passivity electrolyte,
Inter electrode gap = 0.2 mm
where as for finish machining the
Resistance
electrolyte should have low electrical
Sp. Resis tance  Inter electrode gap
conductivity called non–passivity R
Suface area
electrolyte will be used.
2  10  0.2
  0.01
20  20
09. Ans: (b)
V 12
Sol: In ECM I   1200A
R 0.01
MRR  gram atomic weight of material AI 55.85  1200
MRR  
MRR  Current density ZF 2  96540
1  0.3471 g / sec
MRR 
dis tan ce between tool and work
MRR  Thermal conduction of electrolyte.

13. Ans: 51.542 18. Ans: (d)

1 Sol: Relative motion between tool and work
 0.009
L 50  0.009
Sol: R   0.02  piece is not necessary.
Area Area Area
V 12  1.5  Area 19. Ans: (c)
I   23.333  Area
R 50  0.009
Sol:
L = 3 + 6 = 9 m = 0.009
AI 55.85  23.333  Area A
MRR   B
ZF 7860  10 6  2  96500
= 0.98189  Area
MRR If D = Dmin = 59.9
 0.8590 mm / sec
Area X1 = distance between center of shaft and
 0.8590  60 mm / min 59.9
= 51.542 mm/min
corner of V – block  2  34.583
sin 60
14. Ans: 680 60.1
15. Ans: (c) X 2  2  34.698

sin 60
Sol: EDM, ECM and AJM are used for
Error in depth = 2(X2 – X1) = 0.223 mm
producing straight holes only but in LBM
by maneuvering or bending laser gun 20.
slightly it is possible perform the Zig – Zag Sol: Resolving the force “F” into Horizontal
hole. F sin   100 ………. (1)
F cos   100  100  200 …… (2)
16. Ans: (b) (Both are Correct)
(1) 100
Sol: In EBM Vacuum is provided to avoid the  tan  
(2) 200
dispersion of electrons after the magnetic
lense, but this vacuum is giving an addition 1
  tan 1    26.565
2
function of providing efficient shield to the
weld bead. 100
F  223.6 kg
Sin 
17. Ans: (d) Taking the moments about vertical axis
Sol: Out of all the NTM’s ECM will give large xF cos   100  30  100  30  100  20
MRR and EBM will give very small MRR.  x = 10 mm
21. (i) Ans: (d), (ii) Ans: 10.6 mm Positional error = 30.025 – 30 = 0.025 mm
Sol:
P
(b) Fixed V – block and movable rectangular
block
O1 O2
A
X1 X2
Clamping
Q 30 30.025
O1
O2
4 3
30
A x1   34.64
Sin 60
O1 O 2  4 2  3 2 = 5 30.025
x2   34.66
Sin 60
O1O 2  5  x 2  x 2
(c) Positional error = x2 – x1 = 0.0298 mm
x = 3.5
The positional error is mainly depends on
Block of uniform thickness is preferable
the fixed element. So when fixed V – block
because of balanced condition.
and marble V – block is used, the positional
error is remains same as (b).
22.
Out of the 3 cases, case (a) is giving lower
Sol:
positional error, hence preferable.
(a) Fixed rectangular block and movable V –
clamp.
O1 O2 Clamping
· ·
30
30.025

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04. Ans: (a)

4 05. Ans: (c)

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06. Ans: (c) 07. Ans: (c)

Common Data for 10 & 11 12. Ans: 1.205

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C.S area of cylinder = C.S area of ellipse 13. Ans: 50

4 Time taken for removing latent heat

VR 0.8VC1 Common Data for Q.16 & Q. 17

20. Ans: 0.05 s

02. Ans: 4860 W, 1.5 mm

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the maximum arc length is 1.5mm = 26.7 sec

03. Ans: 425 05. Ans: 27.78 mm/sec

Area of weld bead (WB) l = 1 m =1000 mm;

30o 30o 100

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09. Ans: 0.64 mm & 2.1 mm 11. Ans: (b)

10. Ans: (c) 

14. Ans: 2.3 & 4.6 MJ 17. Ans: (b)

Total heat required = heat to be generated 23. Ans: 61.53 %

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02. Ans: (d)

Vf Vs 04. Ans: (c) 05. Ans: (b)

Vc = 40 m/min; Vf = 20 m/min FC  1200, FT  800,   300

 1  0.5 sin 10  = 1200 W

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Common Data for Q. 08 & 09 t1 L 2 60 60

11. Ans: (d)

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t 1 0.125 14. Ans: (d)

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23. Ans: 30.8 m/min 270  3 18

27. Ans: 0.944

03. Ans: (b) 07. Ans: (b)

N Spindle M = 0.6 , L = 500 mm

10. Ans: (c) 12.

Total time = 20.5×2 = 41 mins = 0.9812 min = 58.87 = 59 sec

11. Ans: (b) 13. Ans: (b)

Sol: Time per hole = L/f.N

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18. Ans: (d)

Feed = 0.08 mm/rev L   AP

Total depth to be cut = 2 mm Total time = 10.227  4 = 40.91

21. Ans: 8.05 min

V = 0.5 m/min d r 4.4

24. Ans: (a)

25. Ans: (a)

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 y  1400   971 MPa

03. Ans: (a)

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L= RH = 175  2 = 18.7 = 795 kN.

07. Ans: (d) 10. Ans: (b)

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11. Ans: (a) Common data for Q 12, 13 & 14

total = 260  81.94 = 178.05 MPa 13. Movable mandrel

= 178.05  21.237 2 / y   1      0.519

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14. Floating mandrel

B = cot; B = 1.9 Common data for Q 17, 18