Machining - Manufacturing Processes II - Production & Industrial Engineering Previous Year Questions

1

2007 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2007

Reaming is primarily used for achieving

A

Higher MRR

B

Improved dimensional tolerance

C

Fine surface finish

D

Improved positional tolerance

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2

2007 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2007

A tool with Side Cutting Edge angle of 30° and End Cutting Edge angle of 10° is used for fine turning with a feed of 1 mm/rev. Neglecting nose radius of the tool, the maximum (peak to valley) height of surface roughness produced will be

A

0.16 mm

B

0.26 mm

C

0.32 mm

D

0.48 mm

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3

2007 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2007

Friction angle during machining will be

A

22.6°

B

32.8°

C

57.1°

D

67.4°

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4

2007 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2007

Chip speed along the tool rake face will be

A

0.83 m/s

B

0.53 m/s

C

1.2 m/s

D

1.88 m/s

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5

2007 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2007

Machining time (in minutes) per hole will be

A

0.08

B

0.31

C

0.44

D

0.86

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6

2007 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2007

During the above operation, the drill wears out after producing 200 holes. Taylor's tool life equation is of the form \(VT^{0.3} = C\), where V is cutting speed in m/minute and T is tool life in minutes. Taylor's constant C will be

A

15

B

72

C

93

D

490

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7

2008 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2008

Brittle materials are machined with tools having zero or negative rake angle because it

A

results in lower cutting force

B

improves surface finish

C

provides adequate strength to cutting tool

D

results in more accurate dimensions

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8

2008 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2008

During machining, the wear land (h) has been plotted against machining time (T) as given in the following figure. For a critical wear land of 1.8 mm, the cutting tool life (in minute) is

A

52.00

B

51.67

C

51.50

D

50.00

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9

2008 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2008

Statement for Linked Answer Questions 82 and 83:
In an orthogonal cutting experiment, an HSS tool having the following tool signature in the orthogonal reference system (ORS) has been used: 0-10-7-7-10-75-1.
Given: width of cut = 3.6 mm; shear strength of workpiece material = 460 N/mm²; depth of cut = 0.25 mm; coefficient of friction at tool-chip interface = 0.7.
Shear plane angle (in degree) for minimum cutting force is

A

20.5

B

24.5

C

28.5

D

32.5

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10

2008 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2008

Statement for Linked Answer Questions 82 and 83:
In an orthogonal cutting experiment, an HSS tool having the following tool signature in the orthogonal reference system (ORS) has been used: 0-10-7-7-10-75-1.
Given: width of cut = 3.6 mm; shear strength of workpiece material = 460 N/mm²; depth of cut = 0.25 mm; coefficient of friction at tool-chip interface = 0.7.
Minimum power requirement (in kW) at a cutting speed of 150 m/min is

A

3.15

B

3.25

C

3.35

D

3.45

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11

2008 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2008

Statement for Linked Answer Questions 82 and 83:
In an orthogonal cutting experiment, an HSS tool having the following tool signature in the orthogonal reference system (ORS) has been used: 0-10-7-7-10-75-1.
Given: width of cut = 3.6 mm; shear strength of workpiece material = 460 N/mm²;
depth of cut = 0.25 mm; coefficient of friction at tool-chip interface = 0.7.
Shear plane angle (in degree) for minimum cutting force is

A

20.5

B

24.5

C

28.5

D

32.5

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12

2008 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2008

Minimum power requirement (in kW) at a cutting speed of 150 m/min is

A

3.15

B

3.25

C

3.35

D

3.45

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13

2009 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2009

Diamond cutting tools are not recommended for machining of ferrous metals due to

A

high tool hardness

B

high thermal conductivity of work material

C

poor tool toughness

D

chemical affinity of tool material with iron

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14

2009 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2009

In an orthogonal machining operation, the tool life obtained is 10 min at a cutting speed of 100 m/min, while at 75 m/min cutting speed, the tool life is 30 min. The value of index (n) in the Taylor's tool life equation is

A

0.262

B

0.323

C

0.423

D

0.521

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15

2009 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2009

The shear plane angle (in degrees) is

A

26.8

B

27.8

C

28.8

D

29.8

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16

2009 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2009

The chip velocity (in m/min) is

A

8

B

10

C

12

D

14

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17

2010 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2010

During turning of a low carbon steel bar with TiN coated carbide insert, one needs to improve surface finish without sacrificing material removal rate. To achieve improved surface finish, one should

A

decrease nose radius of the cutting tool and increase depth of cut

B

increase nose radius of the cutting tool

C

increase feed and decrease nose radius of the cutting tool

D

increase depth of cut and increase feed

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18

2010 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2010

The tool geometry of a single point right handed turning tool is provided in the orthogonal rake system (ORS). The sum of the principal (major) cutting edge angle and the auxiliary (minor) cutting edge angle of the above tool is 90°. The inclination angles of the principal and the auxiliary cutting edges are both 0°. The principal and auxiliary orthogonal clearance angles are 10° and 8°, respectively. The rake angle (in degree) measured on the orthogonal plane is

A

0

B

2

C

8

D

10

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19

2010 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2010

The shear force (in N) acting along the primary shear plane is

A

180.0

B

240.0

C

360.5

D

402.5

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20

2010 · Production & Industrial Engineering · Manufacturing Processes II · Machining

Production & Industrial Engineering (PI) 2010

Assume that the energy expended during machining is completely converted to heat. The rate of heat generation (in W) at the primary shear plane is

A

180.5

B

200.5

C

302.5

D

402.5

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