JAYARAM COLLEGE OF ENGINEERING AND TECHNOLOGY DEPARTMENT OF MECHANICAL ENGINEERING SUBJECT NAME: MANUFACTURING TECHNOLOGY - II SUB.

CODE: ME 1252 TWO MARKS QUESTIONS & ANSWERS UNIT I

1. Classify the process of metal shaping. Process of metal shaping is classified into two types namely Non-cutting shaping process Cutting shaping process

2. Explain the non-cutting shaping process. The metal is shaped under the action of force, heating or both. Since there is no cutting of metal, chip formation will not be there. So it is called non-cutting process.

3. Explain the cutting and shaping process. The required shape of metal is obtained by removing the unwanted material from the work piece in the form of chips is called shaping process.

4. Classify the relative motion between work piece and cutting tool. Rotation of work against the tool. eg. Turning. Rotation of tool against the work piece. eg. Drilling, Milling. Linear movement of the work piece against the tool. eg. Planer. Linear movement of the tool against the work piece eg. Shaper.

5. Mention the various parts of Single Point cutting tool. Shank Face

Flank Base Nose Cutting Edge

6. Classify the various angles in cutting tool. i. ii. iii. iv. v. vi. Back rake angle End relief angle Side cutting angle Side rake angle Side relief angle End cutting angle

7. What is tool signature? The various angles of tools are mentioned in a numerical number in particular order. That order is known as tool signature.

8. What is the effect of back rake angle and mention the types? Back rake angle of tool increases the strength of cutting tool and cutting action. Its types are: (i) Positive rake angle, (ii) Negative rake angle.

9. What is side rake angle? Mention its effects. The angle between the tool face and the line parallel to the base of the tool is known as side rake angle. It is used to control chip flow.

10. What is clearance angle and mention its types? These are the slopes ground downwards from the cutting edges. The clearance angle can be classified into two types. (i) Side relief angle, (ii) End relief angle.

11. Explain the nose radius.

It is the joining of side and end cutting edges by means of small radius in order to increase the tool life and better surface finish on the work piece.

12. What are all conditions for using positive rake angle? To machine the work hardened materials. To machine low strength ferrous and non-ferrous metals. To turn the long shaft of small diameters. To machine the metal below recommended cutting speeds. To machine the work piece using small machine tools with low horse power.

13. When will the negative rake angles be used? To machine high strength alloys. The machine tools are more rigid. The feed rates are high. To give heavy and interrupted cuts.

14. Classify the types of metal cutting process. The metal cutting process are classified as (a) Orthogonal cutting process (Two dimensional cutting), (b) Oblique cutting process (Three dimensional cutting).

15. Define Orthogonal and Oblique cutting. Orthogonal cutting The cutting edge of tool is perpendicular to the work piece axis. Oblique cutting The cutting edge is inclined at an acute angle with normal to the cutting velocity vector.

16. What is chip and mention its different types? The sheared material begins to flow along the cutting tool face in the form of small pieces called as chip. The types are (i) continuous chip, (ii) Discontinuous chip, (iii) Continuous chip with built up edge.

17. When will be continuous chip formed? The following factors favour the formation of continuous chip. (i) Ductile material, (ii) Smaller depth of cut, (iii) High cutting speed, (iv) Large rake angle, (v) Sharp cutting edge, (vi) Proper cutting fluid, (vii) Low friction between tool face and chips.

18. What are the purposes of chip breakers? The chip breakers are used to break the chips into small pieces for removal, safety and to prevent both the machine and work damage.

19. What is metal removal rate? It is defined as the volume of metal removed in unit time. It is used to calculate time required to remove specified quantity of material from the work piece.

20. What are the factors affecting the machinability? Chemical composition of work piece material. Microstructure of work piece material. Physical properties of work materials. Method of production of the work materials.

21. Define Machinability. It is defined as the ease with which a material can be satisfactorily machined.

22. How tool life is defined? Tool life is defined as the time elapsed between two consecutive tool resharpening. During this period the tool serves effectively and efficiently.

23. Name any four tool materials. o o Carbon tool steel High speed steel

o o o

Cemented carbides Ceramics Diamonds

UNIT II

1. What are the various operations performed in Lathe? (i) Turning, (ii) Facing, (iii) Forming, (iv) Knurling, (v) Chamfering, Drilling, (viii) Boring, (ix) Recessing, 2. What is Swing diameter? The largest diameter of work that will revolve without touching the bed and is twice the height of the centre measured from the bed of the Lathe. (vi) Thread cutting, (vii)

(x) Tapping, (xi) Grooving.

3. Write the various Lathe accessories. Lathe centres, catch plates, carriers, chucks, mandrels and rests.

4. What is the difference between live centre and dead centre? Live centre drives and rotates along with the work pieces. Dead centre just supports the other end of the work piece.

5. What are the principle parts of Lathe? i. Bed, ii. Headstock, iii. Tailstock, iv. Carriage, v. Cross-slide, vi.Tool post.

6. State the various parts mounted on the carriage. a. Saddle, b. Compound rest, c. Cross slide, d. Tool post.

7. What are the four types of tool post? (1) Single screw tool post, (2) Open side tool post, (3) four bolt tool post, (4) Four way tool post.

8. What is an Apron? Apron is an integral part of several gears, levers and clutches which are mounted with the saddle for moving the carriage along with lead screw while thread cutting.

9. List some types of Lathe. (i) Engine Lathe, (ii) Bench Lathe, (iii) Tool room Lathe, (iv) Semi-automatic Lathe, (v) Automatic Lathe.

10. Define Tool room lathe. A tool room lathe consists of all the necessary attachments required for accurate and precision machining.

11. What are the various types of chucks? i. Three jaw chuck or self centering chuck, ii. Four jaw chuck or independent chuck iii. Magnetic chuck.

12. Differentiate Automatic Lathe and Semi-automatic Lathe. Automatic Lathe Machining operations, loading and unloading performed automatically. Semi-automatic Lathe Machining operations are performed automatically, but loading and unloading operations are performed manually.

13. What are the advantages of semi-automatic Lathe? i. Production time is minimized. ii. Accuracy will be high. iii. Production rate is increased.

14. Define Feed and what are the various feed mechanisms used in automatic feed. It is defined as the movement of the tool relative to the work and the work piece by form tool. The various feed mechanisms are (i) Tumbler gear mechanism, (ii) Quick change gear box, (iii) tumbler gearQuick change gear box, (iv) Apron mechanism.

15. Differentiate Chucks and Mandrels. Chucks used to hold the work piece of small length and large diameter. Mandrels used for holding hollow work pieces.

16. What is the application of Air operated Chuck? Heavy work pieces are mounted with the help of air operated chucks. Because they will require more power to hold the work piece.

17. What is meant by forming operation? Forming is the process of producing concave, convex and any irregular shape.

18. State the various methods of taper turning operation. i.Form tool method. ii.Tailstock set over method. iii.Compound rest method. iv.Taper turning attachment method

19. What is milling operation? The operation of removing the metal by using rotating cutter having multiple cutting edges is known as milling.

20. What is reaming and boring? Reaming operation of finishing and sizing of already drilled hole.

Boring process of enlarging a already drilled hole.

21. What is thread cutting operation? It is the operation of producing continuous helical groove on a cylindrical work piece.

22. Compare the advantages of Turret lathe and Capstan lathe. Heavier and larger work piece chucking can be done. More rigid, hence withstands heavy cuts.

UNIT III

1. What is shaper? The machine which is having a reciprocating type of machine tool with a single point cutting tool used to produce flat surfaces called as shaper.

2. Mention any four shaper specifications. Maximum length of stroke Type of driving mechanism Power of the motor Speed and feed available

3. State the type of mechanism followed on a shaper and how it works. Rack and Pinion mechanism is used. The rotary motion of electric drive is converted into reciprocating motion of the ram by using gears and slotted link. 4. Define Feed and Depth of cut. Feed The relative motion of tool with respect to the work piece axis. Depth of cut Amount of metal removed in one revolution or in cut.

5. How the planer differs from Shaper? In Planer The work reciprocates while the tool is stationary. In Shaper The tool reciprocates while the work is stationary.

6. List the various types of Planers. i.Double housing planer ii.Open side planer iii.Pit planer iv.Edge planer v.Divided table planer

7. What are the specifications of Milling machine? i.The table length and width ii.Maximum longitudinal cross and vertical travel of the table iii.Number of spindle speeds and feeds iv.Power of driving motor v.Floor space and net weight

8. Mention the various movements of universal milling machine table. a. Vertical movement through the knee b. Crosswise movement through the saddle c. Longitudinal movement of the table. d. Angular movement of the table by swiveling the table on the swivel base.

9. List the various types of milling attachments. a. Vertical milling attachment b. Universal milling attachment c. High speed milling attachment d. Rotary attachment e. Slotting attachment f. Rack milling attachment

g. Universal spiral milling attachment

10. Define Face Milling. It is the operation performed by a milling cutter to produce flat machined surfaces perpendicular to the axis of rotation.

11. What is the function of Clapper block in a planer? During cutting stroke, the tool block fits inside the clapper block rigidly. During the return stroke, the tool block lifts out the clapper block to avoid rubbing of the tool on the job.

12. Classify milling cutters. i.Milled tooth cutters ii.Form relieved cutters iii.Plain milling cutters iv.End milling cutters v.Slitting saws vi.Arbor cutters

13. What are the differences between up milling and down milling? Up milling (i) Cutter rotates against the direction of travel of work piece. (ii)Cutting force increases from zero to maximum per tooth. Down milling (i) Cutter rotates in the same direction of travel of work piece. (ii) Cutting force decreases from maximum to zero per tooth.

14. Write down any four operations that can be performed in drilling machine.

Drilling Counter sinking Tapping Trepanning

15. What is meant by sensitive hand feed? In drilling machine, manual sensing of the hand does feeding of the tool towards the work piece. It is called sensitive hand feed.

16. How the reamer tool differs from the drilling tool? A reamer is a multi-tooth cutter which rotates and moves linearly into an already existing hole.

17. What is the use of tapping tool? A tap is a tool which is used for making internal threads in a machine component.

18. What is the main difference between the boring bar and boring tool? Boring bar tool which is having single point cutting edge. Boring tool tool which is having multi point cutting edge.

19. What are the types of boring machine? a. Horizontal boring machine b. Vertical boring machine c. Precision boring machine d. Jig boring machine

20. What are the types of boring tools? Boring bar, boring head, facing head.

UNIT IV

1. What is meant by Grinding? Grinding is a metal removing process in which the metal is removed with the help of rotating grinding wheel.

2. What is the process of self-sharpening of the grinding wheel? During machining, the blunt abrasive grains will be released from the wheel surface. In their place, new abrasive grains project from the surface of the wheel. This process is called self-sharpening of the grinding wheel.

3. What are the four movements in a cylindrical center type grinding? Rotation of cylindrical work piece about its axis. Rotation of the grinding wheel about its axis. Longitudinal feed movement of the work past the wheel face. Movement of wheel into the work which is perpendicular to the axis of the work piece to

give depth of cut.

4. What is the main difference between transverse and plunge grinding? Transverse Grinding This method is used when the job length is greater than the width of the grinding wheel. Plunge Grinding This method is used when the length of the work piece is lesser than the width of the grinding wheel.

5.

What is meant by centreless grinding? Centreless grinding is performed on work pieces which do not have centres such as pistons, valves, rings, tubes, balls, wrist pins, drills, bushings, shafts etc. Centreless grinding can be done on both external and internal cylindrical surfaces.

6.

Define the term Abrasive grains. An abrasive is a hard material. It can be used to cut or wear away other materials. Small abrasive particles are used in grinding wheels. They are called abrasive grains.

7.

What is meant by Grit or Grain size? The grain size is denoted by the number. This number is equal to the number of meshes in 254cm of a sieve through which the grains can pass through.

8.

What is meant by dressing and truing? Dressing - process of loading and breaking away the glazed surface so that new sharp abrasive particles are again present to work for efficient cutting. Truing process of trimming the cutting surface of the wheel to run true with the axis.

9.

State the use of rough Grinding process. Rough grinding is used for removing projections like sprue pins from castings, projections in forgings, finishing weldments, sharpening of hand tool etc.

10.

State the various methods of centreless grinding. (i) (ii) (iii) Through feed In feed End feed

11.

What are the uses of Internal Grinders? They are used to finish straight, tapered or formed holes to the correct size, shape and finish.

12.

Classify the types of abrasives. (i) Natural abrasives (ii) Artificial abrasives.

13.

What are the types of bonds used in grinding? Virtified bond Silicate bond Resinoid bond Rubber bond Shellac bond Oxy chloride bond

14.

How is the grinding wheel specified? Types of abrasives Grain size Grade Structure Type of bond Manufacturers code

15.

Define (i) Loading, (ii) Glazing. Loading During the operation the chips are formed get entrapped in the inner granular space of abrasive particles. Glazing Surface of the wheel becomes smooth and gets a glass like appearance.

16.

Differentiate Lapping and honing. Lapping It is a surface finishing process used for producing geometrically accurate flat, cylindrical and spherical surfaces. Honing An abrading process of finishing previously machined surfaces.

17.

List the gear generating process. 1) Gear shaping process 2) Gear planning process 3) Gear hobbing process

18.

What is broaching? It is the process of machining a surface with a special multi-point cutting tool called broach which has successively higher cutting edges in a fixed path.

19.

Classify vertical broaching machine. Pull up type Pull down type Push down type

20.

List all the Nomenclature of a broaching tool. o o o o o o o o Roughing teeth Semi-finishing teeth Finishing teeth Pull end Front pilot Back off or clearance angle Pitch Rake or face angle

UNIT V

1. Define NC machine Controlling a machine by means of a prepared program is known as Numerical Control or NC

2. List out the various types of NC machines a. Point to point NC system b. Straight cut NC system c. Contouring NC system

3. List the various components of DNC a. Central computer b. Bulk memory c. Telecommunication lines d. Machine tools

4. Mention the main difference between CNC & DNC CNC systems can do operations on only one machine at a time. But DNC involves that at a time to direct more than one of machines.

5. What is the function of servo valve? The electro-hydraulic servo valve controls the flow of the high-pressure oil to the hydraulic motor. The servo valve receives a voltage actuating signal & it drives a solenoid device to move the valve spool .

6. Classify the machining centres a. Horizontal spindle machining centre b. Vertical spindle machining centre c. Universal machining centre

7. State the various types of CMM a. Cantilever construction b. Bridge construction c. Column construction d. Gantry construction

8. Define absolute & incremental programming In absolute programming, the distance at any point at any instant will be measured from the origin( X=0,Y = 0) Where as in incremental programming, the instant point will be noted as (X=0, Y=0) .Further measurement will be made from the particular point.

9. What is meant by MACRO? MACRO is similar to subroutine used in FORTRAN language. It would be used where the certain motion sequences would be repeated several times, with in a program.

10. What is meant by canned cycle? A canned cycle is a combination of machine moves that perform anyone particular machining function such as drilling , turning , milling etc.,

11. Mention the types of statement in APT language. a. Geometric statements b. Motion statements c. Postprocessor statements d. Special control or Auxiliary statements

12. What is meant by APT program?

APT program is used to command the cutting tool through its sequence of machining process. APT is also used to calculate the cutter positions. APT is a three dimensional system controlling up to five axis including rotational co-ordinates.

13. What are the important steps to be followed while preparing part program? a. Fixation of coordinate system b. Reference of G & M codes c. Dimensions of work & tools d. Locating the fixtures & machine table e. Speed & feed according to the work & tool material

14. Define subroutine If the same machining operation , which was carried out already , is to be performed at many different positions on the work piece , it can be executed by means of a program called as subroutine.

15. List the methods of creating part programming . a. Manual part programming b. Computer assisted part programming c. Manual data input d. Computer automated part programming

16. List the benefits of in process-probing a. it reduces the inspection personal b. 100% inspection is achieved c. High quality is ensured d. Inspection time & cost are reduced

17. Classify CNC machines. a. CNC machining centre b. CNC turning centre c. CNC lathe

d. CNC milling / drilling machine e. CNC special purpose machines

18. Mention the advantages of stepping motor. a. the system is cheaper b. More accuracy is achievable

19. List the factors involving in trouble shooting of CNC machines. a. Spares are not available b. Delay in getting spares c. Lack of manpower to trouble shoots

20. Define interpolation. Interpolation is the process of developing coordinate points in between start & finish coordinates.