MT II QB - st.josephs

8/13/2019 MT II QB - st.josephs

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ME2252-Manufacturing Technology-II Mechanical Engineering 2013-2014

The reciprocal of chip thic+ness ratio is calle! chip re!uction coefficient. +7 18r

14. hat is the /iffi!)lty fr l#$ a#/ !#ti#))s !hip%

6uring achining" long an! continuous chip that fore! at high cutting spee! %ill affect achining9 it %ill spoil tool"

%or+ an! achine. These chips are har!" sharp" an! hot. It %ill #e !ifficult to reoe etal an! !angerous to safety.

15. Classify the /iffere#t types f !hip ,reaers%

1. $tep type" 2. :rooe type" 3. Clap type&6. hat is the !)tti#$ fr!e a!ti#$ # the !)tti#$ tl%

6uring the cutting process" the follo%ing the coponent of cutting forces acting utually right angles.

(a) fee! force f& acts in a horiontal plane" #ut in the !irection opposite to fee!.(#) thrust force fy acts in the !irection

perpen!icular to generate! surface (c) cutting force f in the !irection of the ain cutting otion.

&1. hat are the ass)"pti#s "a/e i# lee a#/ shafer;s thery%

a. the %or+ ahea! of the tool #ehaes as i!eal plastic ass.(#) there e&ists a shear plane %hich separates the chip an!

%or+ piece" no har!ening in chip occurs

&&. hat are the fa!trs affe!ti#$ the "a!hi#a,ility%

a. Cheical coposition of %or+ piece aterial. Microstructure of %or+ piece aterial. Mechanical properties li+e

!uctility" toughness etc." ;hysical properties of %or+ aterials. Metho! of pro!uction of the %or+ aterials.

&*. H- the "a!hi#a,ilty !a# ,e e+al)ate/%

The follo%ing criteria suggeste! for ealuating achina#ility.a. Tool life per grin!" #. *ate or reoal per tool grin!"(C) Magnitu!e of cutting forces an! po%er consuption"

(!) surface finish" (e) 6iensional sta#ility of finishe! %or+"(f)


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1. hat is lathe%

,athe is a achine %hich reoes the etal fro a piece of %or+ to the reuire! shape an! sie.

*. hat are the +ari)s perati#s !a# ,e perfr"e/ # a lathe%

Turning" facing" foring" +nurling" chafering" threa! cutting" !rilling" #oring" recessing" tapping" grooing etc."

0. hat are the pri#!iple parts f a lathe%

e!" hea! stoc+" tail stoc+" carriage" cross sli!e" tool post

2. hat are the types f lathe ,e/s%a. Inerte! #e!" @lat #e!.

3. hat are the types f hea/st!%

ac+ geare! type" >ll geare! type.

:. hat are the "ai# /iffere#!e f li+e a#/ /ea/ !e#ters%

,ie center !ries an! rotates along %ith the %or+ piece !ea! center is !rien #y the hea!

stoc+ an! it ust supports the other en! of the %or+s.

4. lathe in %hich all the achining operations are perfore! autoatically an! loa!ing an! unloa!ing of %or+ piece"

coolant on or off is perfore! anually.

1:. hat is a# a)t"ati! lathe%

In a!!ition that to autoatic achining operations loa!ing an! unloa!ing are also perfore! autoatically.

1A. hat are the a/+a#ta$es f a)t"ati! lathe%1. ;ro!uction tie is re!uce! or iniie!. 2. >ccuracy %ill #e ery high. 3. ;ro!uction rate is increase!.

15 List a#y f)r -r hl/i#$ /e+i!es.

1. Chuc+s 2.centers 3.face plates 4.angle plate

&6hat are the +ari)s types f !h)!s%

1.3-a% chuc+- self centering chuc+ 2.4 - a% chuc+- in!epen!ent a% chuc+ 3.Magnetic chuc+.

&1.hat are the perati#s perfr"e/ # a lathe%

1. Centering 2.stright turning 3. $tep turning 4.shoul!er turning 5.facing /.Chafering .+nurling etc."

&&. 7efi#e the ter" f =!#i!ity;.

+7 !-! 8 l ! 7 !ia of the #igger en! !7 !ia of the saller en! l 7 length of the %or+ + 7 conicity.

&*.


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&4. hat are "ai# parts f the t)rret a#/ !apsta# lathe%

1. e! 2.hea! stoc+ 3.turret hea! 4.sa!!le an! cross sli!e

&5. hat are the +ari)s types hea/ st! a#/ e'plai# the pre(sele!ti+e hea/st!%

1. ac+ geare! 2. >ll geare! . pre selectie hea! stoc+ the pre-selectie hea! stoc+ the spee! changing for !ifferent

achining operation can #e !one #y siply pushing a #utton or pulling a leaer to select the spee! of the ne&t

operation in a!ance.

*6. C"pare the spe!ifi!ati# f t)rret a#/ !apsta# lathe@ a#/ !"pare the a/+a#ta$es f t)rret +er !apsta#lathe.

C"paris# 1.nu#er of spin!le spee! 2.nu#er of fee!s for the tuuret or sa!!le a!antages 1" heaier an! larger

%or+ piece chuc+ing can #e !one 2.ore rigi!" hence it %ithstan!s heay cuts.

*1. riefly e'plai# a#y f)r f the -r a#/ tl hl/i#$ /e+i!es fr t)rret a#/ !apsta# lathe.

>a?r hl/i#$ /e+i!es 1. Collets 2. Chuc+s 3.fi&tures 4. ;o%er chuc+s (#) Tl hl/i#$ /e+i!es 1. Multiple cutter

hol!ers 2. ffset cutter hol!er 3. $li!ing cutter hol!er 4 +nee tool hol!er.

*&.hat is !llapsi,le tap%

Collapsi#le tap is use! for a+ing internal threa!s. 6uring a+ing threa!s" the cutting e!ges of the tap collapses to

re!uce its oer all !iaeter.

**. hat is ,ar stp%

ar stop is nothing #ut %or+ stop. it is use! for setting the reuire! length of the %or+ piece.

*0. hat are the three sta$es f a tl lay)t%1. ;lanning an! sche!uling 2. 6etaile! s+etching of arious achining operations seuence. 3. $+etching the plan

sho%ing arious tools.

*2. hat are the +ari)s types f spe!ial p)rpse lathes%

1. $ei autoatic lathes 2. Car %heel turning lathes cashaft turning lathes

*3. hat are the /iffere#t /ri+es )se/ i# !pyi#$ lathes% i# a//iti#@ -hat are the !"p#e#ts that !a# ,e

pr/)!e/ # a !pyi#$ lathe%

1. Mechanical !ries 2.air !ries 3. utoatic lathes or siply autoats are achine tools in %hich all the operation reuire! to finish off the %or+ piece

are !one autoatically %ithout the attention of an operator.

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a) u&iliary attachents for perforing

arious operations. $uch as +nurling" !rilling" tapping" scre%ing" slotting" an! recessing etc.

16. ccor!ing to the type of the %or+ piece use! #ar type 8c" chuc+ing type 8c(#) >ccor!ing to the arrangeent of

the spin!le" horiontal type spin!le"G ertical type spin!le"(c). >ccor!ing to the principle of operation" parallel action

type" progressie action type

11. C"pare the parallel a!ti# a#/ pr$ressi+e a!ti# ")lti spi#/le a)t"ati! lathes.

Parallel a!ti# pr$ressi+e a!ti#

1 sae operation is !one on all o#s in all the spin!les !ifferent operations are !one on o#s at each stations one after

another.2 in one cycle in nu#er of coponents pro!uce! siultaneously is eual to the no of spin!le it is not so (i.e)

the no of coponents pro!uce! in one cycle is not eual to the no of spin!le for eery in!e&ing of coponent onecoponent is pro!uce!.3 rate of pro!uction is ery high rate of pro!uction is o!erate4 if any thing goes %rong in

one station" the pro!uction in that particular station only is affecte! if any thing goes %rong in one station" the

pro!uction is copletely affecte! in all the station.

1&. hat are the p)rpses f )si#$ !a"%

1. To control purposes in autoates scre% 8c 2. To control oeent of the turret for controlling rapi! approach"

%or+ing trael" rapi! return 3. To control the oeent of the cross sli!e 4. To proi!e unifor rate of fee! to tool

!uring achining .

UNIT( III(OTHER MACHINETOOL

1. hat is shaper%

The achine %hich is haing a reciprocating type of achine tool %ith single point cutting tool use! to pro!uce flat

surfaces calle! as shaper.

&. List a#y f)r i"prta#t parts f a shaper.

1. Ta#le 2. Tool hea! 3. *a 4. Cross rail an! 5. $a!!le

*. 7efi#e #e pass f the !)tti#$ tl.

The co#ination of one for%ar! an! one return stro+e is +no%n as one pass no. of passes 7 stoc+ to #e reoe! 8

!epth of cut.

0. 7efi#e !)tti#$ rati f a shaper.

The ratio #et%een the cutting stro+e tie to return stro+e tie is calle! cutting ratio. It is !enote! as .

2. 7efi#e a#y t- types f 8)i! ret)r# "e!ha#is".

1.


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3. Me#ti# a#y f)r spe!ifi!ati# f pla#er.

1. Ma&iu length of the ta#le"2. Total %eight of the planner"3. ;o%er of the otor 4. *ange of spee!s an! fee!

aaila#le" 5. Type of !ries reuire!.

:. hat is "ea#t ,y e/$e pla##er%

It is use! for achining the e!ges of plates . it is also calle! as plate planner. The #e! an! ta#le are stationary .

the tool hea! is ounte! on a carriage. The carriage trael longitu!inally on gui!e %ays. There is a platfor in the

carriage.Milli#$

1. hat are the spe!ifi!ati#s f "illi#$ "a!hi#e%

a. the ta#le length an! %i!th"(#) Ma&iu longitu!inal cross an! ertical trael of the ta#le

c. nu#er of spin!le spee!s an! fee!s" (!) po%er of otor"(e) floor area an! net %eight

&. Classify "illi#$ "a!hi#e.

1. colun an! +nee type(a) plain illing(#) ertical illing"J uniersal illing"(!) ra type illing

(e)oniersal illing 2.#e! type illing achine (f)siple&"(g) !uple&"h. triple&"3. plano type illing achine"4.

special purpose type illing achine

a. rotary ta#le"#. !ru type"c. profile illing

*. Me#ti# the +ari)s "+e"e#ts f )#i+ersal "illi#$ "a!hi#e ta,le.

G ertical oeent through the +nee"G cross%ise oeent through the sa!!leG ,ongitu!inal oeent of the ta#le." angular oeent of the ta#le #y the s%elling the ta#le on the

s%iel #ase

0. C"pare the plai# a#/ )#i+ersal "illi#$ "a!hi#e.

In plain illing achine the ta#le is proi!e! %ith three oeents longitu!inal" cross an! ertical.In uniersal

illing achine the ta#le is proi!e! %ith three oeents longitu!inal" cross an! ertical in a!!ition to there is a

fourth oeent to the ta#le that can #e s%iele! horiontally an! can #e fe! at angle to the illing 8c spin!le.

the uniersal illing achine is proi!e! %ith au&iliaries such as !ii!ing hea!"ertical illing attachent an! rotary

ta#le etc. hence it is possi#le to a+e spiral"#eel gear" t%ist !rills" reaers etc on uniersal illing 8c.

2. hat are the /iffere#t -ays fr "a!hi#i#$ -r pie!es i# pla# "illi#$%

1. #y oing the ta#le the cutters rotating in position 2. y +eeping the ta#le stationary an! fee!ing the cutters #y

oing the illing hea!s. 3. y oing the ta#le an! the illing hea!s is siultaneously.4. y +eeping the ta#le

stationary" oing the cross rail !o%n%ar!s an! the si!e cutters up an! !o%n.3. hat are the types f spe!ial p)rpse "a!hi#e a+aila,le%

*otary ta#le or continuous illing 8s"G !ru type illing 8c"G profile or contour illing 8c.

:. ccor!ing to the shape of the tooth" illing cutters are classifie! as

G Mille! tooth cutters." @or reliee! cutters ">ccor!ing to the type of operation"G plain illing cutters

G si!e illing cutters"G en! illing cutters"G angle illing cutters"G t- slot illing cutters"G slitting sa%s

G for illing cutters"G fly cutters."G %oo! ruff +ey slot illing cutter. >ccor!ing to the %ay of ounting on the

achine" ar#or cuttersG shan+ cutters"G face cutters.

16.rite a#y te# #"e#!lat)re f plai# "illi#$ !)tter.

G o!y of cutter" cutting e!ge" face" fillet" gash" lea!" lan!" out si!e !iaeter" root !iaeter" cutter angles.

11.hat are the t- "ai# $r)p f "illi#$ pr!esses%

En! illing"@ace illing

1&.7iffere#tiate )p "illi#$ a#/ /-# "illi#$.

G It !oes not reuire a #ac+lash eliinator"G $afer operation !ue to separating forces #et%een cutter an! %or+.

G ,ess %ear on fee! scre% an! nut !ue to the a#sence of preloa!e!" Mille! surface !oes not hae #uilt up e!ge.

1*. List )t the +ari)s "illi#$ perati#s.

St. Josephs College of Engineering

St. Josephs Institute of Technology ISO9001:2008

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G ;lain or sla# illing"G face illing"G angular illing"G stra!!le illing"G gang illing" fro illing" en! illing" T-

slot illing" gear cutting

10. 7efi#e stra//le "illi#$ a#/ sla, "illi#$%

$tra!!le illing operation is the pro!uction of t%o ertical flat surfaces on the #oth si!es of the o# #y using t%o si!e

illing cutters %hich are separate! #y collars. :ang illing is the pro!uction of any surfaces of a o#

siultaneously #y fee!ing the ta#le against a nu#er of reuire! cutters.

12. hat /es the ter" i#/e'i#$ "ea#%In!e&ing is the process of !ii!ing the periphery of a o# in to eual nu#er of !iisions.

13. hat are the three types /i+i/i#$ hea/s%

1. ;lain or siple !ii!ing hea!"2. niersal !ii!ing hea!" 3. ptical !ii!ing hea!.

1:. hat is /-ell peri/%

It is the resisting perio! of the follo%er %hen the ca rotates

14. hat is !a" "illi#$%

Ca illing is the operation of the pro!ucing cas in a illing achine #y the use of a uniersal !ii!ing hea! an! a

ertical illing attachent.

15. List the a/+a#ta$es a#/ li"itati#s f threa/ "illi#$%

1. The threa! %ill #e soother an! ore accurate than those in a lathe. 2. The threa!s can #e cut closer to shoul!ers of

%or+ piece" 3. It is a faster etho!"4. It is ore efficient than cutting threa!s in a lathe.

,iitation of the threa! cutting.1. it is !ifficult to pro!uce internal threa!s"2. Threa! illing can not #e use! for a+ing threa!s %ith ore than

30heli& angle.

&6. hat are the ther fr"i#$ "eth/s fr "a#)fa!t)ri#$ $ears%

a. gear cutting #y single point for tool" #. gear cutting #y shear spee! shaping process" c. gear illing using fore!

en! il!. gear #roaching" e. Teplate etho!.

&1. List the $ear $e#erati#$ pr!ess.

G gear shaping process"G gear planning process"G gear ho##ing process

&&. Me#ti# the appli!ati#s f $ear shapi#$ pr!ess.

I. :ear shaping is use! for generating #oth internal an! e&ternal spur gears.

II. ny gien o!ule can #e cut using a single cutter. II. The rate of pro!uction is higher %hen copare! to fore!cutter etho! III. it is a siple fle&i#le an! accurate etho! of generating gears

&0. hat are the li"itati#s f $ear h,,li#$%

I. internal gears cannot #e generate!" II.


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7ressi#$9 The process of loa!ing an! #rea+ing a%ay the glae! surface so that ne% sharp a#rasie particles are again

present to %or+ for efficient cutting is calle! !ressing. Tr)i#$9It is the process of triing the cutting surface of the

%heel to run true %ith the a&is.

13. hat is the pr!ess f lappi#$%

,apping is surface finishing process use! for pro!ucing geoetrically accurate flat" cylin!rical an! spherical surfaces.

1:. hat is the pr!ess f h#i#$%

>n a#raing process of finishing preiously achine! surfaces is +no%n as honing.14. hat is the pr!ess f s)per fi#ishi#$%

The process of o#taining a surface of the highest class of finish is +no%n as super finishing.

UNIT(2 CNC MACHINE< TOOL< AN7 PART PROGRAMMING

1. 7efi#e NC.

Controlling a achine tool #y eans of a prepare! progra is +no%n as Nuerical Control or NC.

&.hat are the !lassifi!ati#s f NC "a!hi#es%

1. ;oint to point NC syste. 2. $traight cut NC syste. 3. Contouring NC syste.

*.n iproeent in the possi#ilities for correcting errors in part prograing.

4. The possi#ility of using the coputers peripheral euipent. 5. Tape an! Tape rea!er are use! only once for

resulting iproe! relia#ility.

5. Me#ti# the a/+a#ta$es f steppi#$ "tr.1. $tepping otors can #e use! in open loop NC syste.2. The syste

is cheaper.3. More accuracy is achiea#le

16. List the !""#ly )se/ !r/i#ate syste"s f CNC "a!hi#es

1. Cantileer construction2. ri!ge construction3. Colun construction4. :antry construction

11. List the "eth/s f !reati#$ part pr$ra""i#$.

1. Manual part prograing.2. Coputer Lassiste! part prograing (C>68C>M #ase! prograing syste.

3. Manual !ata input.5. Coputer autoate! part prograing.

1&. rite the types f state"e#ts i# APT la#$)a$e.

1. :eoetric stateents.2. Motion stateents.3. ;ostprocessor stateents.4. $pecial control or >u&iliary stateents.

1*. hat is "ea#t ,y MACRO%

Macro is siilar to su#routine use! in @*T*>N language. It %oul! #e use! %here certain otion seuences %oul!

#e repeate! seeral ties" %ithin a progra.

10. hat is the /iffere#!e ,et-ee# i#!re"e#tal a#/ a,sl)te syste"%

In a#solute prograing the !istance at y point at any Instant %ill #e easure! fro the origin (O70" P70).

Dhereas in increental prograing" the instant point %ill #e note! as (O70" P70). @urther easureents %ill

#e fro the particular point only.

12. Me#ti# the +ari)s types E7M%

1. *>M type E6M.2. r#ital type E6M.3. Dire cut E6M.



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13. Classify li#ear i#terplati#.

1. ,inear interpolation 2. Circular interpolation 3. Canne! cycle is a co#ination of achine oes that perfors anyone particular Machining function such as

!rilling" turning" illing" #oring" tapping.

&6. hat are the steps t ,e fll-e/ -hile prepari#$ part pr$ra"%

1. @i&ation of coor!inate syste.2. *eference of : an! M co!es.3. 6iensions of %or+ an! tools. 4. ,ocating the

fi&tures an! achine ta#le.5. $pee! an! fee! accor!ing to the %or+ an! tool aterial.

&1. hat are the /ata esse#tially #ee/e/ t prepare a part pr$ra"%

1. o# 6iension8%or+piece.2. Dor+ hol!ing 3. @ee!8cutting spee!.4. Manual !ata input

&&.hat is the /iffere#!e ,et-ee# i#!re"e#tal a#/ a,sl)te syste"%

In a#solute prograing" the !istance at y point at an instant %ill #e easure! fro the origin. ( O70"P70)

Dhereas in increental prograing the instant point %ill #e note! as ( O70"P70). @urther the easureent %ill #e

a!e fro the particular point only.&*. Classify li#ear i#terplati#.

1. ,inear Interpolation (:01 co!e is use! in part progra)

2. Circular Interpolation (:02" :03 co!es are use! in part progra)

3. u&iliary stateents.

&:. h- the hy/rstati! si/e-ays !lassifie/.

-oil lu#ricate! sli!e %ays

-air #earing sli!e %ays

Part

U#it 1( THEORY OF METAL CUTTING

1.(i) > cutting tool a!e of t %hat spee!

shoul! the tool hae to #e operate! in or!er to hae a tool life of 2 hrs 15in. >ssue n70.1A5.

(ii)$tate the functions of cutting flui!s an! their types

&.6ra% the erchants circle an! !erie the relationship #et%een arious cutting forces. Mention the assuptions

a!e.

*.(i) E&plain orthogonal etal reoal process.

(ii) Dhat are the iportant properties reuire! for cutting tool aterial an! e&plain the !ifferent cutting tool aterials

in !etail.



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0.Dhat is eant #y tool %ear E&plain the !ifferent types of tool %ear an! the paraeters influencing tool %ear %ith

e&aples.

2.E&plain the con!itions that proote the foration of the follo%ing chip %ith $+etches.

(i) Continuous chip %ithout uilt up e!ge (ii) Continuous chip %ith #uilt up e!ge (iii) 6iscontinuous chips

3. (i)6efine the arious tool parts of a single point cutting tool %ith a neat s+etch

(ii)Dhat are the stan!ar! angles of the cutting tool Illustrate %ith an e&aple

:. (i) 6uring a tool cutting test on


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2.Dhat is a planar Drite the classification of planer Drite the !ifferent echanis use! for ta#le !rie

3.Drite !ifferent type of $lotting operation %ith neat s+etch

:. Drite !ifferent type of illing operation %ith neat s+etch

4.E&plain in !etail %ith neat s+etch on in!e&ing an! types of in!e&ing

5.Dhat is up-illing" !o%n-illing

16. ,ist the types of illing cutter use! in illing %ith a neat s+etch

11.Dhat is a sa% E&plain in !etail types of sa% use! in achining

1&.E&plain in !etail push an! pull roach %ith neat s+etch

UNIT I ( ARAM" an! :roup Technology

:. Dhy is >TC se! in CNC Dhat is the co!e use! for >TC

4. E&plain all scre%" linear scre% %ith neat s+etch use! in CNC achines Drite the ;urpose of all $cre%

5.E&plain %ith neat s+etch the spin!le !rie an! fee! !rie use! in CNC

16.Drite a#out the autoatic chip !isposa#le syste use! in CNC

11.Drite the !ifference #et%een anual part prograing an! coputer assiste! part prograing

1&.Drite a progra (co!ing) for illing an! turning centre %ith an e&aple.



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MT II QB - st.josephs