UNIT III- SHAPER, MILLING AND GEAR CUTTING

MACHINES
1. Which of the following is used for machining larger jobs?
a) shaper
b) planer
c) can’t say anything
d) none of the mentioned

Answer: b
Explanation: Planer is used for the purpose of machining too large and heavy jobs.
There is a table in planer known as platen on which the work piece is fixed firmly and the
operation is performed.

2. Which of the following is used for machining smaller jobs?

a) shaper
b) planer
c) can’t say anything
d) none of the mentioned

Answer: a
Explanation: Shaper is used for the purpose of machining smaller jobs. It is mainly used
for producing flat and plan surfaces.

3. Which of the following machine is primarily intended for producing flat surfaces?
a) shaper
b) drilling
c) lathe
d) none of the mentioned

Answer: a
Explanation: Shaper is intended for this purpose. It was invented in 1836 by James
Nasmyth.

4. Which of the following operation can be performed in shaper?

a) gear cutting
b) keyways cutting
c) curvilinear contours
d) all of the mentioned

Answer: d
Explanation: All mentioned operations can be performed in shaper. Although it is used
mainly for producing flat surfaces but its a versatile machine and can be used for other
purposes too.

5. In shaper, the job is kept_____

a) stationary
b) rotating
c) reciprocating
d) none of the mentioned
Answer: a
Explanation: The job is kept stationary in this machine. In shaper, cutting tool moves in
order to perform operations.

6. In shaper, the cutting tool is made to reciprocate across the job.

a) true
b) false

Answer: a
Explanation: This is true. cutting tool moves in order to perform the work. Only forward
movement is useful. Work is only done in forward movement.

7. Which stroke is cutting stroke in shaper?

a) forward
b) return
c) can’t say anything
d) none of the mentioned

Answer: a
Explanation: Forward stroke is cutting stroke in shaper because only in forward stroke
work-cutting is done.

8. Which stroke is idle stroke in shaper?

a) forward
b) return
c) can’t say anything
d) none of the mentioned

Answer: b
Explanation: Return stroke is idle stroke in shaper because no useful work is done in this
stroke.

9. No useful work is done in forward stroke in shaper.

a) true
b) false

Answer: b
Explanation: In return stroke, no useful work is done. The return stroke is also known as
idle stroke.

10. At the end of one cycle, job is given a feed motion______ to the direction of tool
movement.
a) parallel
b) perpendicular
c) anti-parallel
d) none of the mentioned

Answer: b
Explanation: At the end of one cycle, job is given a feed motion perpendicular to the
direction of tool movement. Feed is the relative movement of the tool or work.

11. The depth of cut is given by lowering the tool relative to the job.
a) true
b) false

Answer: a
Explanation: This is true. Depth of cut is the thickness of metal that is removed in one
cut.

1. Which of the following operation is performed to ensure the correct location of a hole
by making it concentric with the axis of rotation?
a) parting
b) tapping
c) boring
d) none of mentioned

Answer: c
Explanation: This is the characteristic of boring. After the hole is made by drilling
operation, boring is carried out. It is generally done to enlarge the diameter of the hole.

2. Which of the following operations can be done by same tool?

a) reaming and tapping
b) drilling and facing
c) counterboring and spot facing
d) none of the mentioned

Answer: c
Explanation: Counterboring and spot facing can be performed by same tool. Counter
boring is an operation which nis carried out for providing recess for nuts or bolt heads.

3. Reaming doesn’t improve the surface finish.

a) true
b) false

Answer: b
Explanation: Reaming improves the surface finish. It generally enlarge the holes with
great accuracy and give better dimensional accuracy-better surface finish.

4. Which of the following process is performed to provide seating for washer?

a) counterboring
b) spot facing
c) tapping
d) none of the mentioned

Answer: b
Explanation: As per the definition of spot facing process. In spot facing operation, some
specific part of the workpiece is faced. It gives better flat,smooth surface to that
workpiece.

5. To produce more accurate holes, which of the following operation should be

performed first?
a) drilling
b) reaming
c) centering
d) boring

Answer: c
Explanation: As per the characteristic of all these operation, centering should be
performed first before drilling, reaming and boring in order to produce more accurate
holes. Center drill makes a hole. Now, this hole behave as a center of rotation for
mentioned rest 3 operations.

6. To produce more accurate holes, which of the following operation should be

performed last?
a) drilling
b) reaming
c) centering
d) boring

Answer: b
Explanation: As per the characteristic of all these operation, reaming should be
performed last in order to produce more accurate holes. By using all rest 3 method, we
make the hole with almost accuracy. But for final finish and extremely high accuracy,
reaming is performed at the last.
7. Tapping is a forming process.
a) true
b) false

Answer: a
Explanation: As per the definition of taping process. The main advantage of taping is
that is requires less operating conditions.

8. Which of the following process requires abundant coolant?

a) drilling
b) tapping
c) boring
d) none of the mentioned

Answer: b
Explanation: Tapping needs abundant coolant. Cutting fluid is the coolant generally
designed for metal working process.Different types of fluids are there like oil, gel,
aerosols and so on.
9. Tapping process is carried out on ______ machines.
a) drilling
b) tapping
c) both drilling and tapping
d) none of the mentioned

Answer: c
Explanation: Tapping process is carried out on both drilling and tapping machines. Taper
is a shape which is produced and it has different diameter at both the ends

10. Which of the following operation is carried out for cutting internal threads?
a) drilling
b) tapping
c) boring
d) none of the mentioned

Answer: b
Explanation: Tapping is carried out for cutting internal threads because tapping process
generally don’t need high operating conditions. They require less operating conditions.

1. Shaping can be performed more effectively by ______ milling machine.

a) horizontal
b) vertical
c) can’t say anything
d) none of the mentioned

Answer: b
Explanation: Vertical milling machines are of two types: bedmill and turrent mill and due
to its construction features these vertical type milling machines can performed shaping
easily.
2. surfacing can be performed more effectively by ______ milling machine.
a) horizontal
b) vertical
c) can’t say anything
d) none of the mentioned

Answer: b
Explanation: Surfacing can be performed more effectively by vertical milling machine.
This machine has a spindle. It rotates in vertical direction over the table.

3. Form cutting can be performed more effectively by ______ milling machine.

a) horizontal
b) vertical
c) can’t say anything
d) none of the mentioned

Answer: a
Explanation: Form cutting can be performed more effectively by horizontal milling
machine. The spindle in the horizontal milling machine is mounted on the horizontal
arbor above table.

4. Slab milling can be performed more effectively by ______ milling machine.

a) horizontal
b) vertical
c) can’t say anything
d) none of the mentioned

Answer: a
Explanation: Slab milling can be performed more effectively by horizontal milling
machine. This slab mill is also used in gang milling.

5. Drilling can be performed more effectively by ______ milling machine.

a) horizontal
b) vertical
c) can’t say anything
d) none of the mentioned

Answer: b
Explanation: In vertical milling, the workpiece is held by a horizontal table and this
horizontal table rotates about a vertical axis. There are none-rotating tools which can be
fed by crossrail and then drilling operation is performed which is more effective in nature.

6. Boring can be performed more effectively by ______ milling machine.

a) horizontal
b) vertical
c) can’t say anything
d) none of the mentioned

Answer: b
Explanation: Vertical boring milling is more effectively as it has wide application in ring
gear blanks, turbine casting and locomotive tires and so on.

7. Dovetailing can be performed more effectively by ______ milling machine.

a) horizontal
b) vertical
c) can’t say anything
d) none of the mentioned

Answer: b
Explanation: As per the classification of milling operations. Dovetailing means joint
something like link together with the help of dovetail.

8. Straddle milling can be performed more effectively by ______ milling machine.

a) horizontal
b) vertical
c) can’t say anything
d) none of the mentioned

Answer: a
Explanation: Sometimes we machine two or more vertical parallel surfaces at a single
cut, this type of operation is known as straddle milling. Horizontal milling can perform it
more nicely.
9. Angular milling can be performed more effectively by ______ milling machine.
a) horizontal
b) vertical
c) can’t say anything
d) none of the mentioned

Answer: c
Explanation: Angular milling is a type of milling that mills flat surfaces which are neither
parallel or perpendicular to the axis of milling cutter. It is performed more accurately by
both milling machines: horizontal and vertical.

10. Cutting T-slots can be performed more effectively by ______ milling machine.
a) horizontal
b) vertical
c) can’t say anything
d) none of the mentioned

Answer: b
Explanation: This process depends upon the size of the T bolts which are going to be
used and its typical milling process which can be performed by vertical milling more
effectively.

11. Slotting can be performed more effectively by ______ milling machine.

a) horizontal
b) vertical
c) both horizontal and vertical
d) none of the mentioned

Answer: c
Explanation: Slotting is the removal of material in the form of chips by a relative
movement of a tool with a cutting edge relative to a workpiece along a non-circular
trajectory.

1. Hobbing process is also used for which of the following application?

a) Punching
b) Metal bending
c) Rust removal
d) Sprocket cutting

Answer: d
Explanation: Hobbing is a machining process widely used for cutting gears, splines and
sprockets. The tool used for cutting is called as a hob.

2. Hobbing is a special type of which of the following?

a) Casting
b) Grinding
c) Drilling
d) Milling

Answer: d
Explanation: Hobbing is a special type of milling in which teeth are cut by a series of cuts
made by a tool known as a hob.

3. In the process of gear cutting by hobbing, the angle between the hob’s spindle axis
and the workpiece’s spindle axis is fixed.
a) True
b) False

Answer: b
Explanation: The angle between the hob’s spindle axis and the worpiece’s spindle axis
varies depending upon the type of product being manufactured.

4. For spur gear manufacturing, angle between the hob’s spindle axis and the
workpiece’s spindle axis should be equal to____
a) (helix angle of the hob)/2
b) 2*(helix angle of the hob)
c) (helix angle of the hob)
d) (helix angle of the hob)2

Answer: c
Explanation: As hob has helical threads, it has to be oriented making some angle with
the workpiece as per the requirement and then it is fed into the workpiece. For spur
gears, that angle should be equal to the helix angle of the hob.

5. For helical gears, the angle between hob’s spindle axis and workpiece’s spindle axis
must be _____ as the helix angle of the helical gear.
a) increased by the same amount
b) increased by the half amount
c) decreased by the same amount
d) decreased by the half amount

Answer: a
Explanation: For manufacturing the helical gear, one has to consider helix angle of the
gear. While hobbing the helical gear, angle between hob spindle axis and workpiece
spindle axis should be increased by an angle equal to helix angle of the gear.

6. Hobbing machines are characterised by _____

a) production rate
b) largest module or PCD it can generate
c) accuracy of the machine
d) size of the machine

Answer: b
Explanation: Hobbing machines are characterised by the largest module or pitch
diameter it can generate as they can produce anything from tiny instrument gears to 10ft
diameter marine gears.

7. 5in (125 mm) capacity machine can generate gears upto_____ pitch diameter.
a) 5in
b) 10in
c) 15in
d) 20in

Answer: a
Explanation: The number signifies the maximum pitch diameter of a gear that can be
produced by that machine. Therefore 5in capacity means the largest gear manufactured
by that machine will have pitch diameter equal to 5in.

8. The gear hob is a formed tooth milling cutter with helical teeth.
a) True
b) False

Answer: a
Explanation: The gear hob is a formed tooth milling cutter with helical teeth arranged like
the thread on a screw. These teeth are fluted to produce required cutting edges.

9. As the number of threads on the hob increases, it’s accuracy_____

a) increases
b) decreases
c) remains same
d) can’t say

Answer: b
Explanation: More number of threads means more difficulties to manufacture them.
Therefore, accuracy varies inversely with a number of hob threads.

10. As the number of threads on the hob increases, production rate______

a) increases
b) decreases
c) with each thread, increases by 25%
d) can’t say

Answer: a
Explanation: Production rate increases with an increase in the number of threads on the
hob as more number of threads means less machining time. Directly it cannot be said
that production rate will increase by 25% per thread.

11. Ideally how many gear threads should be there or each hob thread?
a) 20
b) 30
c) 45
d) 10 times the number of hob threads

Answer: b
Explanation: For best results, there should be about 30 gear threads for each hob
thread. Therefore four-thread hob should not be used to cut fewer than 120 gear teeth.