National Institute of Technology

Silchar
Supplementary (UG) Examination, July 2024
ncy is 30%. Consider Subject Code: ME 210
Semester: 4th Subject: Machining and Machine Tools
Duration: Three Hours Department: Mechanical Engineering
degradable mass. Figure in the right hand margin indicates full marks for Total Marks: 80
the question.
Answer ANY EIGHTquestions
Briefly explain the 4 (a) ldentify the machine tool as shown in the Marks CO
marked components A, B, C, D andE. Also, Fig. 1along with the 5 a
ell is drilled and of the components A, B, C, D and E. mention one function
he temperature
gradient? What A
B C

1lash separator
steam pOwer
4
nt related to
e those two
2

eration and Fig. 1: Machine tool as mentioned in Q. 1(a)

2
enewable (b) Determine the gear ratio and draw the
2 gear train
newable manufacturing of left hand double start thread with pitch 1.5for
mm
the
on
a lathe with the pitch of the lead screw of 6
2 mm.
? What
ewable 2 (a) A lathe operator has to produce a taper of 1:15 on a
length 200 mm with initial diameter of 40 mm. workpiecethe of 5
Determine
amount of the tailstock offset to be provided to the machine.
plume
goes
sure
(b) A workpiece of length 150 mm with initial
air., to be turned to afinal diameter of 30 diameter of 40 mm has 5
10 mm using a centre lathe.
Calculate the total machining time and material removal rate with
the following information. The spindle speed
and the feed to be
selected suitably from the following table.
Maximum cutting 25
speed, m/min
Available spindle60, 100, 160, 220, 480, 780, 850, 1000
speed, rev/min
Feed, mm/rev 0.15 and 0.60
10
Depth of cut, mm Rough turning Finish turning
2 0.5
3 (a) Explain the slider crank quick return
obtaining faster return stroke than themechanism used in shaper for
cutting stroke in shaper with
5 b
suitable diagram.
P.T.O

Page 1 of 3
 (b) Sugg
of in
whic
(b) Ashaper is
tomachine aoperated
at 120 cutting adva
workpiece strokes per minute and is used
of 250 mm length
5
of th
and 120 mm
afeed of 0.6 mm per double
stroke and depth of cut width.
of 6
Ob
Calculate the total machining time for machining the component mm.
(a) In a
and the material removal rate. If the forward stroke is 8 obta
230°, calculate the completed n ofth
percentage of time when the tool is not
Contacting the workpiece. ASSume a total clearance of 50 mm. Wid
4 (a) Explain the Un
for the working of an indexing head ugedin milling machine 5 Chi

diagram. manufacturing
gears from gear blanks with suitable Rat
Cut
(b) Perform an indexing operation on a Thr
agear having teeth of 87 on a universal dividing head to cut 5
gear blank. (b) In
5 (a) Explain the following miling operations with suitable diagram. av?
(0) Straddle milling 5 De
() Form milling
(ii) Pocket milling
(iv) Surface contouring
(V) Angular milling
(b) Aworkpiece with dimension 500 mm x TW
machined
Determine the
to generate a flat surface300 mm x 50 mm has to be
using milling 5
time taken for the machine. D
information machining with the 9 (a)
Diameter of the Cutter =30 mm following
Teeth on the cutter = 60 (
Feed = 0.1
Cutting speedmm/teeth
= 30 m/min (b)
Depth of cut = 2 mm
Approach and over run = 15 mm
6 (a) A each
holemachine
of operator has given the
shop doesdiameter
not
35 mm on a task of
creating and
tool with
create thediameter 30 workpiece.
have the drilling tool
with However, thefinishing a 5
hole with mm. Suggest an diameter 35 mm butmachine
the
(b)
Estimate the totalof apprbach tT the operator
required diameter. havingto
through machining40timemm required
hicknessofholes
tspeed 80 mm diameter
using in to drill 6
1 Assume approach the
spindle an
upright
as 600 drilling
a
stainless
and over rev/min andmachine. Take plate of
numbers
steel of 5
(a)
aExplain the travel of 2 mm feed of 0.4 rotational
andsuiductile fol owing ofrespect of a each.
t) ablGrite materials. in mm/rev.
(i) Grade
combination grade andgrinding wheel. Als0,
grit, Course Ou
(i0) Structure structure for grindiSuggest
ng soft 5
Upon the co
a. have a g
b. identify a
C. select ma
d. classify
e. employ
f. correlate

Page 2of 3
 (b) Suagest a suitable grinding machine arrangement for fine finishing 5 b
of internal cylindrical surface of a hollow cylindrical
strokes perminute and is
Used 5
which cannot be held between centres and explain it.component
Write the
Pd at 120 cutting 120mm wath. Use advantages of this technique towards the precision and accuracy
Dlece of250 mm length and
deoth of cut of 6 mm. of the component.
per double stroke and
component
machining time for machining theCompletedin 8 (a) In an orthogonal cutting operation the following results were
oval rate. If the fonwad stroke is 5
not obtained. Calculate the shear angle and the mean shear strength
percentage of time when the tool is of the work material,
mm.
dece. Assume a total clearance of 50 Width of cut = 2.5 mm
Un-deformed chip thickness = 0.25 mm
f an indexing head uged in miling machine Chip thickness = 1mm
of gears from gear blanis with suitable Rake angle = - 5°
Cutting force = 900 N
eration ona universal dividing head to cut Thrust Force = 75ON
37 on a gear blank
(b) In an orthogonal cutting operation the following information are 5
ing operations with sutable diagram. 5
available. Calculate the shear stress along the shear plane.
Depth of cut = 0.127 mm
Chip thickness = 0.228 mm
Cutting speed = 2 m/s
Rake angle of cutting tool = 10°
Cutting force = 567 N
n500 Thrust force = 227 N
mmx 300 x50 mm has to
fiat surface usimm
ng miling machine.be 5
Width of cut = 6.35 mm
for the
mactining with the folowing 9 (a) Derive a
mathematical relationship
(Vs), velocity of work piece relativecorrelating shear plane velocity
to tool (V), shear plane angle
5 f
(6)and tool rake angle (a).
(b) Select a suitable machine tool for
the development of the part as 5
nm each shown in Fig. 2. Mention all the suitable e
out to generate the part. Also, operations to be carried
develop the turret tool layout for
the tzsk oi Same.

worige HooNeaeivnegs, atnhde firishing a Alldimensions are in mm

sath to the opeamachintoe

80
45
2.5-42.5 20 50
Ana sanless
25,2525, 200
Fig. 2: Schematic of the part mentioned in Q. 9 (b)
Course Outcomes (COs):
5 Upon the completion of this
a. have a course, the students are
D. identify general idea of machine
and select different tools and their uses.expected to:
C. select machine tools for
0. classifymachining parameters and estimate thepractical
the machining machiningapplications.
time.
e. employ
T. Correlate machining
operations and prepare process plans.
the generalprocesses for product
development.
concept of metal cutting to various
****k**ttt machining operations.
PIO Page 3 of 3
 EndNational Institute
Semester of
(UG) Technology Silchar
Subject Code: ME 210
Semester: 4th
Examinations,
May 2024
Duration: Two Hours Subject Machining and Machine Tools
460 Eioure in the right hand nargin Department Mechanical Engineering
Total Marks: 60
indicates full marks for the question.
Answer ANY FIVE questions
ARGsis
4 ia) Explain with
neat Marks
Why thediagrams the up mitling and down CO
operations.
of the cut during up thickness of the chip is maximum at the milling 5 a, b
milling operation? end
Figure 3 ) Àworkpiece surface with dimensions 300 mm x 150 mm has to be
milled using plain miling operation. 5
cexample. with the following information. Determine the machining time
material failure? Explain it in Cutting speed =30 m/min
Diameter of the cutter = 40 mm
Depth of cut = 2 mm
and shear stress is 20 MPa Number of teeth in the cutter = 60
) the tensile stress which Feed per tooth = 0.2 mm/tooth
in ) above, and (iii) the
mprincipal stress as in (i) 2 (a) Explain the following milling operations with suitable diagram. 5
(0) End milling
() Face milling

(b) Suggest a suitable indexing method for obtaining 69 divisions in a 5

workpiece. Justify the selection of the method. Perform the
indexing using the suggested method.
Change Gears:24, 24, 28, 32, 40, 44, 48, 56,64, 72, 86, 100 teeth
Plate No. 1: 15, 16, 17, 18, 19, 20 holes
Plate No. 2: 21, 23, 27, 29, 31, 33 holes
Plate No. 3: 37, 39, 41, 43, 47, 49 holes
5 d, e
3 (a) Explain in brief the following hole making operations to be
performed using a drilling machine with suitable diagram.
() Trepanning
(i) Counter sinking
(ii)Counter boring
(iv) Boring
(V) Reaming
holes of diameter 20 mm each 5 d, e
9) Aworkshop technician has to drill 15 dimension 1000 mm x
and hole depth of 50 mm on a workpiece of
cutting speed to be
500 mm x 50 mm in minimum time. The feed of 0.25
considered during the machining is 15 m/min and each. Suggesta
mm/rev. Assume approach and overrun as 5 mm machining time.
suitable drilling machine and estimate the total P.T.O

Page 1 of 2

Page
2
 National
Institute of Technology Silchar
Mid Semester (UG)
Examinations, March 2024
FieQcurrent
gureOtherbelthrough
obridge
w and ubject Code: ME 210.
emester: Fourth (4th)
Subject: Machining and Machine Tools
Department: MechanicalEngineering
JJuration: One Hour
hen the Total Marks: 30

bridge in
ge resistance isis
utput voltage
Figure in the right hand margin indicates full
Answer all the questions
marks for the question.

Marks CO
Carmelate the cuting motion (CM) and the feed motion (FM) with the 3
Ceneratrix (G) and the Directrix (D) for generating a flat surface using the a, b
following machine tools with suitable diagrams.
() Lathe
(i) Planer
Suggest a suitable taper tuning method with justifications for generating a full 3 b, c, d
taper of 2° over a length of 300 mm on a workpiece of length 500 mm in a
lathe with centre to centre distance of 800 mm. The maximum swiveling angle
of the compound rest is 6° with maximum travel distance of 200 mm. Itis also
to note that the lathe is not equipped with any attachment. Explain the
suggested method with suitable diagram.
Identify the parts marked as A, B, C, D, E and F of the shaper as shown in 3 c, d
Fig. 1 and mention one function of each of the parts.
asuroutputing 4

itially
teady
rder.
f15
ure
a
le

Fig. 1: Schematic representation of the shaper as referred in Q. 1(c)

3 b, c, d
(a) Aright hand double start thread having a pitch of 1.5 mm is to be cut on a
latne having a lead screw of pitch 6 mm. Calculate the gear ratio for the
Cnange of gears and draw the gear train. Aset of change gears having 20 to
120number of teeth at an interval of 5 teeth and an additional gear of 127
number of teeth is available with the machine.
(e) Suggest a suitable machine tool with proper justification for machining a flat 3 c, d
surace on a workpjece having dimension 2000 mm x 750 mm x 50 mm.
P.T.O

Page 1of 2
 2 Aworkoiece of length 200 mm withinitial diameter of 50 mm has to be turned to : ME-21
final diameter of 40 mm using a centrelathe. Calculatethe total machining time and
mateial removalrate withthe followinginformation. The spindle speed and the fee
the following table.
tobe selected suitably from
Maximum cuttingspeed, m/min 30
Available spindle speed, rev/min 60, 100, 160, 220, 480, 780, 850, 1000 plain the
0.2 and 0.8 ssil fuelc
Feed, mm/rev
iciency
Depth of cut, mm Rough turning Finish turning nversiom
2
0.5 iScuss th
enerators
3 Estimate the time
the cutting speed is required for taking a
9 m/min. The return complete cut on a plate 300 x 600
lectricity
is 3mm/stroke. The
depth of cut
time to cutting time ratio is 1:4
and the
mm, if xplore th
over travel can be can be assumed to be 2 mm. The feed xisting P
considered
calculate the approach
operation. as 75 mm each. Also and
MRR for this fficienc
4 ldentify the Nte beo
suitable
the partmachine tool and the An IC eng
manufact ure as shown in
operations to be performed Fig. 2.
various operations to be of about
for the Develop a turret performed to
compe
20 manufacturing this part. layout for the pdet
of tool
consider,
)the cu
40 60 (im) heat s
24 (iüi) cycl
5 30 (iv)Wha
For the S
followin
45 ()
(i1)
150 What ar
two type
All 10 An idea

Schematic dimensions
Fig. 2: followir
are in mm Temper
representation of the
part as
at the e
Quality

k****kk***kk* mentioned in Q. 4 (1) draw

(ii) the
(ii) ratie
(iii) rat
(iv) cyc
b) How d
 National Institute of Technology Silchar
Mid
Semester (UG) Examinations, March 2023
Subject Code: ME 210
Subject: Machining and Machine Tools
Semester: Fourth (4th)
Duratión: One Hour Department: Mechanical Engineering
Eigure in the right hand margin indicates full Total Marks: 30
marks and CO for the question.
Answer all the questions.
4 (a) Describe the arrangement of Marks CO
Cvlindrical and flat surfaces using Generatrix and Directrix for generating
lathe and name the respective operations. 3
) Define cutting speed, feed and depth of cut for the turning
willvou select these parameters for soft and hard operation, How 3
different surface finish? materials and also to obtain
(c) What is the purpose of turret indexing
mechanism and bar feedina 3
mechanism in capstan and turret lathe?
() Aight hand double start thread having a pitch of 0.75
mm is to be cut on a 3 C
lathe with the lead screw having a pitch of 12 mm and a set of
having the range of teeth from 20 to 120 at a step of 5 and an change gears
of 127 teeth. Calculate the gear ratio and select the change additional gear
gears. Also draw
the gear train.
(e) A 1:20 taper of length 100 mm is to be cut on aworkpiece of length 200 mm 3
in lathe. Determine the offset of the tailstock to be provided for
obtaining the
desired taper.

2 Suggest a suitable machine tool and identify the operations to be performed and 5 b,d,e
their sequence to produce the job as shown in Fig. 1. Prepare the tool layout and
describe it.
60
20
40 o 24
5 30

45

10
150

Allthe dimensions given are in mm

Fig. 1: Schematic representation of the job referred in Q. 2
3 A cylindrical bar of diameter 60 mm and length 390 mm has to be turned to a 5

diameter of 50 mm using centre lathe having an eight speed gear box with the
following spindle speeds.
60, 100, 160, 220, 480,780, 850, 1000
The approach length and over run for the machining is taken as 5 mm each. Find
the number of cuts required to carry out the machining operations. Also, estimate
the machining time and material removal rate for the following conditions.
Parameters Rough Turning Finishing
Maximum Cutting speed 30 m/min 50 m/min
Feed 0.5 mm/rev 0.1 mm/rev
Depth of cut 2 mm 0.5 mm

5
4 Describe the principle associated in shaper for the following conditions with
suitable diagrams.
) Return stroke is faster than the cutting stroke
(i) Adjustment of the length of the stroke
***k***k**