Lab Quiz (___day Batch)(Circle your section here)

Name: Roll No. Date: ------------

Total Marks: 10
Note: (1)Attempt all questions in a short and concise manner
(2)Each question carries maximum marks provided in parenthesis adjacent to it.
(3) Please attempt the questions in the question paper by filling up the space given for
this

Q1. How is a milling cutter mounted? [1]

Ans 1: Fit the helical cutter on arbour for horizontal tool positioning or the shank type
cutter for vertical positioning.

Q2. Main scale of a Vernier has 10 divisions /cm and the least count of the
instrument is 0.01mm. What should be the length of each division on the Vernier
scale? [2]

Ans 2: One main scale division = 1 mm

Least count = 0.01mm
Therefore, length of each division on the venier scale = 1-.01=.99 mm

Q3. What is the relation between spindle speed and cutting speed in a Lathe? [1]

Ans 3:

D = Diameter of the workpeice, S= spindle speed

Q4. Describe the driving mechanism on the shaping machine? [2]

Ans 4:When ashaper is switched on, the ram (along with the tool head) reciprocates
and performs two strokes, (1) Cutting Stroke and (2)Return Stroke

Unwanted metal is removed from the workpiece during cutting stroke and during
return stroke (or idle stroke), no metal is removed. For one pass of the ram, there
exists one cutting stroke and one return stroke.

Inorder to reduce the time taken for one pass of the ram, the time taken for return
stroke is made much lesser than the cutting stroke using a a quick return mechanism.
Q5. Which of the following process are intermittent? Explain.

(a) Milling (b) Drilling (c) Shaping (d) Turning [1]

Ans 5: Shaping is an intermittent process as all relative motion between tool and
work-piece does not result in material removal.

Material is removed intermittently.

Q6. Why is the cutting fluid generally not used during drilling cast iron? [1]

Ans 6: Cast Iron is drilled dry as the graphite in Iron makes it a self lubricating
material. So, an additional lubricant like cutting fluid is not needed.

Q7. How are the files in a workshop classified? [1]

Ans 7: Files are split up into the following categories.
Rough, Middle, Bastard, Second Cut, Smooth, and Dead Smooth based on the
roughest to smoothest.

Q8. What are the different components of NC machine tools. [1]

Ans 8: (a) Machine Tool

(b) Machine Control Unit
(c) Communication interface and accessories

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 Lab Quiz (----day Batch) (Circle your section here)

Name: Roll No. Date: ------------

Total Marks: 10
Note: (1) Attempt all questions in a short and concise manner
(2)Each question carries maximum marks provided in parenthesis adjacent to it.
(3) Please attempt the questions in the question paper by filling up the space given for
this

Q1. Why are helical tooth milling cutters usually preferred over straight tooth cutters
for slab milling? [1]

Ans 1: Helical teeth generally are prefer red over straight teeth because the tooth is
partially engaged with the workpiece as it rotate, consequently, the cutting force and
torque on the cutter are lower, resulting in a smoother operation and reduced machine
chatter.

Q2 Calculate the time required for single pass straight turning of a cylindrical bar
(diameter D1 length L) at a spindle speed of N rpm and feed f in appropriate units. [2]
Ans 2: Cutting speed = D1N/1000

Traverse Time = 1000L/ D1N

Q3. Explain the mechanics of material removal in Electro Discharge Machining (EDM)
process. [1]
Ans 3: The material is thermally ablated using spark discharge in a medium of high
dielectric constant fluid.

Q4. What is the relation between feed rate (mm/rev.) and spindle speed on a Lathe
Machine? [1]
Ans 4: Both are independent parameters.
Q5. What are the advantages of up milling? [1]
Ans 5: Increased cutter life is the main advantage due to opposite directions cutter
rotation and feed.

Q6. What happens to the quick return ratio when the stroke length is reduced to a
minimum value in a Shaper? [1]
Ans 6: Quick return ratio becomes 1 when the stroke length is reduced to a minimum
value in shaper.

Q7. Explain how power is transmitted from the drill spindle the drill shank. [1]
Ans 7: Power is transmitted between the drill spindle and drill shank through friction
drive (Taper shank push fitted into spindle taper)

Q8. N0100 G02 X9.000 Y8.000 I5.000 J2.000 F6.000

Explain each .term for this block of part program. [2]

N signifies Block No.

G02 is a preparatory function, X,Y are coordinates, I and J are circular
interpolation along X and Y axis, F is feed rate.

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 Lab Quiz (____day Batch) (Circle your section here)

Name: Roll No. Date: -------------

Total Marks: 10
Note: (1) Attempt all questions in a short and concise manner
(2)Each question carries maximum marks provided in parenthesis adjacent to it.
(3) Please attempt the questions in the question paper by filling up the space given for
this

Q1. What is the difference between the lead and the pitch of a MUL TISTART
thread? [1]
Ans 1: In a multi-start thread the lead may be several times the pitch of the thread.
This is primarily because Multi-start threads allow far more travel in one turn than
single lead threads.

Q2. Calculate the gear ratio between the spindle and the lead screw for cutting a
screw with X threads per cm. the lead screw pitch is Y mm. [2]
Ans 2: Gear ratio = Pitch to be cut/ Lead screw Pitch

Gear Ratio = (10)/(XY)

Q3. What is Live centre and Dead centre of the lathe? [1]
Ans 3: Live centre is the centre in motion which is normally the head stock on a lathe
machine. Dead centre is the static centre which is normally the tail stock,
although in some cases the tail stock centre may be a revolving centre.

Q4. Explain what is meant by a universal milling machine. [1]

Ans 4: Universal Milling Machines can operate in all three X, Y and Z axes and bed
rotation along the Z-axis.
Q5. Why is clapper box provided on a shaper? [1]
Ans 5: Attachment used to support the tool body which prevents work tool rubbing
during the idle return stroke of the shaper machine.

Q6. Explain how power is transmitted from the drill spindle the drill shank. [1]
Ans 6: Power is transmitted between the drill spindle and drill shank through friction
drive (Taper shank push fitted into spindle taper)

Q7. How are the files classified? [1]

Ans 7: Files are split up into the following categories.
Rough, Middle, Bastard, Second Cut, Smooth, and Dead Smooth based on the
roughest to smoothest.

Q8. What is CNC (computer numerical control), dNC (direct numerical control), DNC
(distributed numerical control)? Specify the advantages of each over other. [2]

The computation is performed in a CNC locally in the Machine Control Unit.

In a DNC there is a central computer which computes and directs drive units on several
machines to operate.
CNC is a flexible system whereas DNC is useful for batch processing.

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 Lab Quiz (___day Batch) (Circle your section here)

Name: Roll No. Date: -------------

Total Marks: 10
Note: (1) Attempt all questions in a short and concise manner
(2)Each question carries maximum marks provided in parenthesis adjacent to it.
(3) Please attempt the questions in the question paper by filling up the space given for
this

Q1. Why is the main spindle of a lathe hollow? [1]

Ans 1: The hollow spindle is used to accommodate longer workpieces and also for
loading/ unloading of workpieces in fast production processes.

Q2 Briefly explain about the different types of tape formats as indicated below in NC machines
a) Fixed sequential format '
b) Tab-sequential format,
c) Word address format [2]
Ans 2:
a) Fixed sequential format: This only contains blocks of numerals with no other symbol'
b) Tab-sequential format: This contains TAB symbol preceding each block.
c) Word address format : This contains words describing various blocks like N described
block no., X,Y,Z with + symbol describe coordinates etc.

Q3. Explain the mechanics of material removal in Electro Chemical Machining (ECM)
process. [1]
Ans 3: The material is electrochemically dissolved by converting this into an ionic
state by a charge transfer process and then precipitating the ion out in the
electrolyte. The electrolyte carries the precipitate into a non working zone.

Q4. Why is down milling generally avoided [1]

Ans 4: It reduces the cutter life as the direction of cutter rotation is similar to the
direction of feed and a small back lash error may result in chatter and tool
damage.
Q5. What makes the simultaneous rotation of the spindle and the feed motion
possible on drilling machines? [1]
Ans 5: Splines cut on the main drill spindle will promote linear translation in Z
direction along with rotation of spindle.

Q6. Why is clapper box provided on a shaper? [1]

Ans 6: Attachment used to support the tool body which prevents work tool rubbing
during the idle return stroke of the shaper machine.

Q7. Explain how power is transmitted from the drill spindle the drill shank. [1]
Ans 7: Power is transmitted between the drill spindle and drill shank through friction
drive (Taper shank push fitted into spindle taper)

Q8. Main scale of a Vernier has 10 divisions/cm and the least count of the
instrument is 0.01mm. What should be the length of each division on the Vernier
scale [2]

One main scale division = 1 mm

Least count = 0.01mm
Therefore, length of each division on the venier scale = 1-.01=.99 mm
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