METAL FORMING 1.Define the process of Mechanical working of metals. 2.

What is the starting material for mechanical working of metals? 3.Enumerate the advantages of mechanical working of metals over other manufacturing processes. 4.Differentiate between hot working and cold working of metals. Bring out the advantages and disadvantages of each of these techniques. 5.Discuss "worm working" of metals. 6.Define the Rolling process. 7.What is the difference between a bloom and a billet? 8.What is the difference between plate, sheet, strip and foil? 9.What is the difference between wire and rod? 10.Define "Slab". 11.Why is metal cold worked? 12.Explain what happens to a metal, when it is cold worked. 13.Why a cold worked metal is annealed? 14.What is angle of bite in rolling? On what factors does its value depend? 15.Describe and specify the merits and limitations of the different kinds of rolling mills. 16.Sketch and explain the working of "universal rolling mill" and "Planetary rolling mill". 17.Why are a number of passes required to roll a steel bar? 18.Describe what occurs in metal when it is rolled. 19.How is cold rolling done? What benefits are obtained from cold rolling metal? 20.Why for cold rolling, a four high rolling mill is usually used? 21.Define forging process. 22. Define "extrusion ratio" and give its common values for various metals. 23.What is impact extrusion? Give its product applications. 24.Give the advantages and drawbacks of forging process. 25.Describe the common types of forging hammers. 26.How the size of a forging hammer is specified? 27.What is the difference between hammer forging and drop forging ? . 28.What is Press forging? How does it differ from drop forging? 29. What is upset forging and how it is done? 30.Discuss the rules which govern the flow of metals in upset forging process. 31.How are the sizes of presses and upset forging machines specified? 32.What is roll forging and how it is done? 33.What is rotary forging or swaging and how it is done? 34.Describe the common defects in forgings and write about the causes of each. 35.What is the purpose of heat treatment of forgings? 36.Define extrusion process. Compare extrusion and rolling processes, 37.Describe the common ways of extruding metals. Compare direct extrusion and indirect extrusion. 38.What is Tubular extrusion? 39.Describe cold hydrostatic extrusion and give its advantages. 40. List the advantages and disadvantages of extrusion process. Compare open and closed die forging. 41.Describe the operation of hot drawing and cupping of metals. 42.Describe wire drawing and rod drawing.

43.Describe Tube drawing. 44.How the metal is prepared for drawing operation? 45.What is the material of the dies used for drawing operation? 46.Give the advantages of Sheet metal working processes. 47.How do hydraulic presses compare with mechanical presses? 48.What are single action, double action and triple action presses? 49.Compare open and closed frame presses. 50.Sketch a Blanking die and label it properly. Write the function of each part. 51.With the help of a sketch, describe the working of a Cutting Die. 52.Describe a progressive, a combination and a compound die. 53.How can the cutting force be reduced? 54.Define "deep drawing process". 55.With the help of a neat diagram, describe a "deep drawing process' applications. 56.What is "redrawing? 57.Explain the "Bending terminology" with the help of a suitable sketch. 58.What are the various methods of bending? Sketch and describe each. 59.What is "Press brake? 60.Describe "Roll forming". 61.Describe "Stretch forming". 62.Describe "Metal spinning". Write its product applications. Differentiate between cold and hot metal spinning. 63.What is "Power spinning? 64.Compare "metal spinning" with "deep drawing". 65.Name two metals which are hot worked at room temperature. 66.What is the effect of forging on grain structure and why is this beneficial to the properties of the metal? CUTTING TOOL MATERIALS 1.Enumerate the essential requirements of a tool-material. 2.Name the various cutting tool materials. 3.Discuss the role of carbon, manganese, chromium, molybdenum, cobalt, vanadium and tungsten in tool steels. 4.What are the significant characteristics of high-speed steels? 5.Enumerate the advantages of high-speed steel produced by powder metallurgy. 7.How are carbide tools made? Describe the process. 8.Which sintered carbides are employed for machining steels and for machining nonferrous metals? 10.Name the various binding materials used in the manufacture of sintered carbides. 11.Give the advantages of coating the face of tungsten carbide tools with a thin coating of titanium carbide. 12.Enumerate the advantages of ceramic cutting tools over tungsten carbide tools. 13.Give the constituents of stellite tool material. How this is manufactured? 14.List the various tool materials used in industry. State the advantages and disadvantages of each material. CUTTING FLUID

What are the main functions of a cutting fluid? 2. List the essential characteristics of a cutting fluid. 3. Discuss the various types of cutting fluids. 4. Discuss the various methods of applying the cutting fluid at the cutting zone. 5. Give the advantages of C.B.N, as a cutting tool material. 6. What are EP additives ? Why are these added to a cutting fluid ? 7. Write the note on "selection of a cutting fluid". 8. Explain the application and limitation of ceramic tools ? 9. Why are tools coated ? 10. List the additives added to water to improve its properties as a cutting fluid. 11. List the major elements in cast-cobalt tools.
1.

LATHE MACHINE 1.List some of the operations that can be done on the Engine Lathe. 2.Name the four main parts of a Lathe. 3.Sketch a Tool Post. 4.What are the four major parts of a Carriage ? 5.Sketch and describe the geared main drive of the Engine Lathe. 6.Sketch and explain the feed drive of the engine lathe. 11.What is the difference between the 'live' and 'dead centre' ? 12.When is the split nut or half nut used ? 13.Sketch and explain the use of a Face Plate. 14.Sketch and explain the working of a Mandrel. 15.What are the advantages of using a Collet Chuck ? 16.What is the use of Steady Rests ? What is the difference between a steady rest and a follower rest ? 17.Sketch and explain the various methods of turning a Taper.\ 18.Name some of the advantages of using a 'taper turning attachment'. 19.When cutting odd number of threads per cm, when is the split nut or half nut closed ? 20.Sketch a block diagram of a Turret Lathe. Name its major parts. 21.Sketch and describe a Vertical Turret Lathe. SHAPER 1.What is a Shaper used for? 2.Draw the block diagram of a horizontal Shaper and write about its important parts 3.How the jobs are held on the table of a horizontal Shaper? 4.Sketch the Tool Head of a Shaper and write how it functions. 5.What is the difference between a Push cut Shaper and a Pull cut Shaper? 6.Sketch and explain the mechanical feed drive of a horizontal Shaper. 10.Sketch and explain the hydraulic drive of a horizontal Shaper. 11.Write the advantage of hydraulic drive over mechanical drive. 12.How will you give the size of a horizontal Shaper? 13.Write the applications of shapers. 14.What is the difference between a vertical shaper and a slotter? 15.Write the uses of a slotter.

16.Sketch and explain the working of a slotter. 17.How will you give the size of a vertical shaper or a slotting machine? 18.Describe the difference in operation between a planer and a shaper. 19.Write the advantages of planers. 20.Write about the various types of planers. 21.How will you give the size of a planer ? 22.Write the product applications of planers. 23.List the advantages of Shapers. 24.List the Limitations of Shapers, Planers and Slotters. DRILLING MACHINES 1.Define drilling operation. 2.Sketch a Twist Drill. Write its main parts and their functions. 3.Why the body of a Drill is made slightly less in diameter than the full nominal diameter ? 4.Why the Drill bodies are given a slight back taper? 5.Write about the materials for Drills. 6.How drills are held in a drilling machine ? 10.Sketch and explain the following allied operations : reaming, counterboring, countersinking and spot facing. 11.How the different drilling machines are classified ? 12.What is a 'multispindle drilling press' ? 13.What is a radial drilling machine ? Sketch and describe it. 14.How is the size or capacity of a radial drilling machine is specified ? BORING MACHINE 1.Define boring operation. 2.Compare 'boring' and 'reaming' operations. 3.Name the various types of HBM. Discuss them with the help of neat sketches. 4.Sketch a double column VBM and explain its working. 5.How the size of boring machines is specified ? MILLING MACHINE 1. Define the "milling" process. 2. Define a "milling cutter". 3. What type of surfaces can be produced by a milling process? 4. Sketch and explain the two basic types of milling operations. 5. Sketch and contrast the two milling methods of machining flat surfaces. 6. What is the basic type of milling machine? 7. Sketch and explain the working of a plain column and knee type milling machine. 8. What are the three motions on a plain milling machine? 10. Sketch and describe a vertical milling machine. 12. Describe the difference between a horizontal milling machine and a vertical milling machine, 13. What is feed on a milling machine? 14. How is the size of a column and knee type milling machine given? 15. Sketch and describe a Bed type milling machine. 19. What is a plain milling cutter ? 21. What is face milling ?

22. Name four types of side-milling cutters. 23. What is the difference between face milling and end milling ? GRINDING MACHINE 1.Define grinding operation. 2.What is the difference between 'rough' grinding and 'precision' grinding? 3.Why the natural abrasives are not suitable for making grinding wheels? 4.What is meant by 'grain size' of an abrasive material ? 5.Discuss the various types of bonding materials used for making grinding wheels ? 10.Define a grinding wheel. 11.Discuss the various methods of making grinding wheels. 12.Sketch the various shapes'of grinding wheels and write their fields of application. 13.What is meant by "grade" and "structure" of a grinding wheel ? 14.What is meant by standard marking of grinding wheels ? 15.What is meant by dressing and truing of grinding wheels ? 16.Sketch and explain the working of an external cylindrical grinding machine. 17.What are the advantages and disadvantages of centreless grinding ? 18.Sketch and explain the three methods of external cylindrical centreless grinding. 19.Sketch and explain internal centre less grinding process. BROACHING MACHINE 1.Define a broaching operation. 2.Sketch and discuss a typical Internal Broach. 3.Write briefly about the materials of broaching tools. 4.Write briefly about the construction of broaching tools. 5.With the help of neat sketches, explain the horizontal pull broaching operation and the vertical push broaching operation. 6.With the help of a neat sketch, discuss the working of a surface broaching machine. 7.Write the advantages and limitations of broaching process. SAWING MACHINE 1.Define "sawing operation". 2.Discuss the materials for saw blades. 3.Sketch and explain the working of a Power Hacksaw. 4.Sketch and explain the working of a Circular Sawing Machine. 5.Sketch and explain the working of a Horizontal Band Saw. 6.Sketch and explain the working of a Vertical Band Saw. 10.Discuss the field of applications of the Various Sawing Machines. 11.What is friction sawing ? POWDER METALLURGY 1.Define "Powder metallurgy" process. 2.Write in brief the basic steps of P/M process 3.Define the following terms: mixing and blending, compacting or briquetting, sintering, Green compact. 4.Name the two major advantages in favour of P/M process.

5.List the limitations of P/M process. 6.Discuss the various methods of powder manufacture. 10.What are the sources of the strength of a green compact ?
15.How

the final strength is imparted to the green compact during the sintering operation ? 16.Why special precautions are needed about the furnace atmosphere during sintering ? 17.What are the functions of the following secondary operations done on a sintered product :Sizing, Coining, Hot densification, Infiltration, Impregnation. How these operations are carried out. 18.How the self lubricated bearings are made ? 19.What is the advantage of irregular-shaped particles in powders ? 20.Write on: Properties of P/M products. 21.List the major product application of P/M process. 22.Discuss the design factors of a P/M part. 37.Explain why metal powders are blended ? 38.What is green strength ? 39.Under what conditions, powder metallurgy technique is superior to conventional manufacturing processes ? 40.Explain the important of powder metallurgy. 41.List the advantages of powder metallurgy 42.List the products of Powder metallurgy. 54.Define Compression ratio.