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Unit-1: Fundamentals of Machining

This document covers fundamentals of machining processes and includes 16 questions about topics like tool wear factors, cutting fluids, tool materials, cutting speed calculations, chip formation mechanics, tool forces, and tool life calculations. The questions are from past examinations for a mechanical engineering course and are intended to test students' understanding of basic machining theory and calculations.

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N Dhanunjaya Rao Borra
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88 views2 pages

Unit-1: Fundamentals of Machining

This document covers fundamentals of machining processes and includes 16 questions about topics like tool wear factors, cutting fluids, tool materials, cutting speed calculations, chip formation mechanics, tool forces, and tool life calculations. The questions are from past examinations for a mechanical engineering course and are intended to test students' understanding of basic machining theory and calculations.

Uploaded by

N Dhanunjaya Rao Borra
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Unit-1: FUNDAMENTALS OF MACHINING

1. (a) Explain the factors influencing tool wear and tool life. (b) What are essential characteristics of
cutting fluid? (Sup Exam, June/July - 2014)
2. (a) Discuss various types of cutting fluids. (b) Explain the constructional features of speed gear box
and speed gear box. (Sup Exam, June/July - 2014)
3. (a) Explain various types of tool materials and their applications. (b) Explain about Machine ability
and Machine ability index. (Sup Exam, June/July - 2014).
4. (a) Derive an expression for optimum value of cutting speed. (b)What is built up edge? Discuss its
effects. (Sup Exam, June/July - 2014)

5. (a) During an orthogonal cutting a chip length of 160mm was obtained from an uncut chip length
of 350 mm. The cutting tool has 220 rake angles and a depth of cut is 0.8mm.Determine the shear
plane angle and chip thickness. (b) Explain constructional features of feed gear box with neat sketch.
(Sup Exam, May/June – 2015)
6. The orthogonal cutting of steel is done with 100 rake tool with a depth of cut 2mm and feed rate
of 0.20 mm/rev. The cutting speed is 200 m/min. The chip thickness ratio is 0.31. The vertical cutting
force is 1200 N and the horizontal cutting force is 650 N. Calculate from the merchant’s theory, the
various works done in metal cutting and shear stress. (Sup Exam, May/June – 2015)

7. (a) In an orthogonal cutting experiment with a tool of rake angle _= 70, the chip thickness was
found to be 2.5mm when the uncut chip thickness was set to 1mm. Find (i) the shear angle and (ii)
the friction angle assuming that Merchant’s formula holds good. (b) Write short notes on crater
wear and flank wear. (Sup Exam, May/June – 2015)
8. (a) How is metal removed in metal cutting? Explain the process with neat sketch? (b) A cutting
tool at 35m/min gave a life of one hour twenty minutes, when operating on roughening cuts. What
will be the probable life when engaged on light finishing cuts? Take n=0.125 for rough cut n=0.1 for
finishing cut. (Sup Exam, May/June – 2015)
9. (a) Define various parts of a single point cutting tool with neat sketches. Explain them. (b) Discuss
the effects of individual machining parameters on cutting tool life. (Reg/Supp Exam, Dec - 2014/Jan
-2015)
10. (a) Draw and Explain the Merchants force diagram. State the assumptions made in the
development of such a diagram. What is the purpose of such diagram? (b) Discuss the measures to
remove built-up edge. (Reg/Supp Exam, Dec - 2014/Jan -2015)

11. (a) What do you mean by i) Red hot hardness ii) Fracture toughness iii) Wear resistance of a
cutting tool. (b) Differentiate between orthogonal and oblique cutting methods. Name a few
applications where each method is used. (Reg/Supp Exam, Dec - 2014/Jan -2015)
12. (a) What are the distinguishing characteristics of i) Ceramics and ii) Cemented carbide cutting
tools? (b)Explain the mechanism of chip formation. (Reg/Supp Exam, Dec - 2014/Jan -2015)
13. (a) Describe the effects of cutting fluids on chip formation. Explain why and how they
influence the cutting operation. (b) Using the Taylor equation for tool wear and letting n = 0.3,
calculate the percentage increase in tool life if the cutting speed is reduced by (a) 30% and (b) 60%.
(Supp Exam, April/May – 2012)
14. (a) Explain the possible disadvantages of a machining operation if a discontinuous chip is
produced. (b) Assume that in orthogonal cutting the rake angle is 150 and the coefficient of friction
is 0.2. Determine the percentage increase in chip thickness when friction is doubled. (Supp Exam,
April/May – 2012)

B.N.Dhanunjayarao, Assistant professor, Dept. of Mechanical Engg., Vignan’s IIt, Duvvada.


Unit-1: FUNDAMENTALS OF MACHINING

15. (a) Describe the advantages of oblique cutting. Which machining process involve oblique
cutting? Explain with neat diagram (b) In a dry cutting operation using a −50 rake angle, the
measured forces were Fc = 1300N and Ft = 740 N. When a cutting fluid was used, these forces were
Fc = 1200 N and Ft = 710 N. What is the change in the friction angle resulting from the use of
a cutting fluid? (Supp Exam, April/May – 2012)
16. The following data are available from orthogonal cutting experiments. In both cases,
depth ofcut (feed) to = 0.13 mm, width of cut w = 2.5 mm, rake angle _= −50 and cutting speed V = 2
m/s.
Determine the shear angle
friction coefficient μ, shear
stress and shear strain on the
shear plane, chip velocity Vc and
shear velocity Vs.
(Supp Exam, April/May – 2012)

B.N.Dhanunjayarao, Assistant professor, Dept. of Mechanical Engg., Vignan’s IIt, Duvvada.

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