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Unit 1

This document contains questions about machining processes and metal cutting. It addresses topics like chip formation, tool geometry, tool wear, cutting fluids, and tool materials. Key points covered include that tool life in orthogonal cutting is less than in oblique cutting, the surface chips slide on is called the tool face, cutting speed has the greatest effect on tool wear, and functions of cutting fluids include reducing forces/power and removing heat.

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vijayakumar
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© © All Rights Reserved
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Download as TXT, PDF, TXT or read online on Scribd
172 views

Unit 1

This document contains questions about machining processes and metal cutting. It addresses topics like chip formation, tool geometry, tool wear, cutting fluids, and tool materials. Key points covered include that tool life in orthogonal cutting is less than in oblique cutting, the surface chips slide on is called the tool face, cutting speed has the greatest effect on tool wear, and functions of cutting fluids include reducing forces/power and removing heat.

Uploaded by

vijayakumar
Copyright
© © All Rights Reserved
Available Formats
Download as TXT, PDF, TXT or read online on Scribd
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1. In an orthogonal cutting, the depth of cut is halved and feed rate is double.

If the chip thickness ratio is unaffected with the changed cutting conditions,
the actual chip thickness will be
{ Doubled
Halved
Unchanged
None of the above}
2. Cast iron during machining process produces
{ Continuous chips
Discontinuous chips
Continuous chips with built up edge
None of the above }
3. In metal cutting operation the shear angle is the angle made by the shear pla
ne with the the
{ Direction of the tool axis
Direction of tool travel
Perpendicular to the direction of tool axis
None of the above }
4. The lip angle of a single point tool is usually
{20 degree to 40 degree
40 degree to 60 degree
60 degree to 80 degree
None of the above}
5. The parameter which completely define the chip formation, in a metal cutting
process is
{ Shear angle
Chip tool contact length
Both a and b
None of the above}
6. Which of the following are examples of operations that create nonrotational g
eometries (two best answers):
{ boring
drilling,
milling,
planing,
turning}
18.2
Which of the following are examples of generating the workpart geometry
in machining, as opposed to forming the geometry (two best answers):
{ broaching
contour turning
drilling,
profile milling }
18.3
In a turning operation, the change in diameter of the workpart is equal
to which one of the following:
{ 1 x depth of cut,
2 x depth of cut
1 x feed
2 x feed }
18.4
A lathe can be used to perform which of the following machining operatio
ns (three correct answers)
{ boring
broaching
drilling
milling}
18.5

A facing operation is normally performed on which one of the following m

achine tools
{ drill press
lathe
milling machine
planer }
17.10 The mechanism of chip formation in machining is best described by which
one of the following:
{ compression
fracture failure,
shear deformation,
tensile failure}
17.11 The chip thickness ratio in orthogonal cutting is which one of the follo
wing:
{ tc/to
(b) to/tc,
to/w,
none }
17.12 Which one of the four types of chip would be expected in a turning opera
tion conducted at low cutting speed on a brittle work material{
{continuous,
continuous with built up edge,
discontinuous,
serrated}
17.13 According to the Merchant equation, an increase in rake angle would have
which of the following results, all other factors remaining the same (two best
answers):
{ decrease in friction angle,
decrease in power requirements,
decrease in shear plane angle,
increase in cutting temperature }
17.14 In using the orthogonal cutting model to approximate a turning operation
, the chip thickness before the cut to corresponds to which one of the following
cutting conditions in turning:
{ depth of cut d,
feed f,
speed v?
tool}
The point at which the cutting tool reaches, beyond which it will not function
satisfactorily until it is reground, is called as
{tool wear
tool failure
tool diffusion
none of the above}
Which cutting condition affects the cutting temperature predominantly?
{depth of cut
cutting speed
feed
none of the above has any effect on cutting temperature}
3) In metal cutting operation, maximum heat (i.e. 80-85%) is generated in
{the shear zone
the chip-tool interface zone
the tool-work interface zone
none of the above}

4)What is the angle F shown in the below diagram of basic mechanism of chip form
ation?
{Shear angle
Tool rake angle
Chip angle
Cutting angle}
5)The forces required for metal cutting operation
{increases with increase in the feed of the tool and decreases with increase in
the depth of cut
decreases with increase in the feed of the tool and increases with increase in t
he depth of cut
=increases with increases in both the feed of the tool and the depth of cut
decreases with increases in both the feed of the tool and the depth of cut}
Calculate the power required for machining of a workpiece on lathe having effici
ency of 85% on full load, when tangential force required is 1200 N and cutting s
peed 195 m/min.
{= 4.59 kW
b. 275.29 W
c. 3.315 kW
d. insufficient data}
Tool life in orthogonal cutting is
{more than the tool life in oblique cutting
less than the tool life in oblique cutting
equal to the tool life in oblique cutting
cannot say}
8)The angle between side cutting edge and end cutting edge is called as
{ approach angle
= nose angle
side relief angle
end relief angle}
Lead angle in the single point cutting tool is the angle between
{the end cutting edge and the normal to the tool shank
the portion of side shank immediately below the side cutting edge and the line
perpendicular to the base of the tool
c. the tool face and the parallel to the base of the tool
= side cutting edge and the side of the tool shank}
The surface of the single point cutting tool on which the chips formed in cutti
ng operation slide is called as
{flank
heel
=face
d. shank}
The cutting tool removes the metal from workpiece in the form of
{solid blocks
powder
chips
all of the above}
Continuous chips are formed during metal cutting operation due to
{ductile work materials
large rake angle

high cutting speed


all of the above}
Which type of chips form while machining of brittle materials?
{continuous chipsq
discontinuous chips
Built-up chips
all of the above with some proportion}
In the metal cutting process, when the compression limit of the metal in front
of the cutting tool has been exceeded then is separated from workpiece and flow
s
{elastically
plastically
rigidly
none of the above}
In metal cutting process
a. material removal is affected by relative motion between too and the workpiece
b. material removal is not affected by relative motion between too and the workp
iece
View Answer
View Explanation
Tool life in orthogonal cutting is
{ more than the tool life in oblique cutting
less than the tool life in oblique cutting
equal to the tool life in oblique cutting
cannot say
The angle between side cutting edge and end cutting edge is called as
{approach angle
nose angle
side relief angle
end relief angle}
Lead angle in the single point cutting tool is the angle between
{the end cutting edge and the normal to the tool shank
the portion of side shank immediately below the side cutting edge and the line
perpendicular to the base of the tool
the tool face and the parallel to the base of the tool
side cutting edge and the side of the tool shank}
The surface of the single point cutting tool on which the chips formed in cutti
ng operation slide is called as
{ flank
wheel
face
shank}

26) When the the finishing is more important than the dimension then
{honing operation is carried out for finishing
lapping operation is carried out for finishing
grinding operation is carried out for finishing
all of the above}

which one will be the cutting tool in lathe


{static
smaller
larger
little}
in single piont cutting tool the end of high tool speed bit is
{wooden
one
two
three}
the overall shape of the lathe tool bits can be
{rounded
square
any shape
all of these}
the cutting tool is hold in
{head stroke
centre rest
chuck
tool post}
the most common tool bit is in the general all purpose bit made of
{higgh speed steel
cast iron
rubber
all of these}
22.2
Which of the following are the two main types of gradual wear on a cutti
ng tool
{ clearance wear
crater wear
flank wear
nose wear}
22.3
The basic Taylor tool life equation defines the relationship between whi
ch two of the following variables:
{cutting speed
depth of cut
feedrate
tool life}
22.4
which one Of the following cutting conditions, which one has the greates
t effect on tool wear
{(a) cutting speed
(b) depth of cut
(c) feed}
22.5
Which of the following are the three most important properties of a tool
material that are suggested by the three modes of tool failure
{(a) ductility
(b) hot hardness
(c) impact resistance
(d) tensile strength }
22.6
As an alloying ingredient in high-speed steel, tungsten serves which of
the following functions (two best answers):

{ depth hardenability during heat treatment


forms hard carbides to resist abrasion,
improves strength and hardness,
increases corrosion resistance, }
22.16 Sialon is a cutting tool material containing which of the following as i
ts principal ingredients (two correct answers):
{ aluminum oxide
cubic boron nitride
silicon carbide
silicon nitride}
22.17 How many elements of tool geometry are required to completely specify a
single-point tool (one correct answer):
{ two
five
seven
eight
22.19 Which of the following drill types would be the most likely choice to dr
ill a hole with a 100 mm (4.0 in) diameter (one best answer):
{ gun drill,
spade drill
straight-flute drill
twist drill}
22.20 Which of the following are the two main functions of a cutting fluid in ma
chining (two best answers):
{ improve surface finish on the workpiece
(b) reduce forces and power
(c) reduce friction at the tool chip interface
(d) remove heat from the process}

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