Manufacturing-Technology-II Question bank By Ravisankar.G

1. SRI ESHWAR COLLEGE OF ENGINEERING, COIMBATORE
DEPARTMENT OF MECHANICAL ENGINEERING
QUESTION BANK
MANUFACTURING TECHNOLOGY-II
SEM:IV YEAR:II
S No Question
Blooms
taxonomy
Remarks
Appearance of
Question
UNIT 1
THEORY OF METAL CUTTING
PART-A
1
Briefly explain the effect of rake angle during
cutting
U Nov 2010
2
What is rake angle? What is the effect of noise
radius in tools?
U June 2009
3
State any two situations where positive rake angle
is recommended during turning.
R Dec 2011
4 When will the negative rake angles be used? R May 2013
5
Name the factors that contribute to poor surface
finish in cutting.
R Dec 2005
6 What is orthogonal cutting? R
Dec 2006 &
May 2014
7 Sketch the orthogonal cutting U Nov 2003
8 Give two examples for orthogonal cutting R Dec 2007
9 Compare orthogonal and oblique cutting R
May 2011 ,
2015,2016&
Nov 2013
10 What is meant by built up edge? R
May & Dec
2012
11
What are the favourable factors for continuous
chip with built up edge
R June 2009
12 What is the function of chip breakers? R Dec 2005
13 Define machinability of metal U Nov 2003
14 How do you classify tool wear? U
(May 2010,
May 2013 &
Nov 2013
15
Name any two reasons for flank wear in cutting
tools.
U Dec 2011
16 What is electro chemical wear in tools? R June 2009
17 Define tool life. R
May 2011 &
2010, Dec
2012
18 Write Taylor’s tool life equation. R
19
What are the four important characteristics of
materials used for cutting tools?
U
Dec
2007,2015,M
ay 2016
20 Name the various cutting tool materials. U Dec 2008

2. 21 What are the advantages of diamond tools? U May 2012
22
What are objectives and functions of cutting
fluids?
R
Dec 2006 &
Nov 2010
23
What are the factors responsible for built up edge
in cutting tools?
R Dec 2009
24 List the essential characteristics of cutting fluid. U Dec 2008
25
Why is lubrication not required while machining
cast iron?
U May 2014
26
Calculate the power required for cutting a steel
rod of 50mm in diameter at 200rpm. Assume
cutting force of 160kg,
E Dec 2006
27 What is tool signature. U
28 What is side rake angle? And mention its effects? U
29 What is clearance angle? And mention its types? U
30 Explain the nose radius. R
31 What is shear plane? U
32 What is cutting force? R
33 What is chip and mention its different types? R
34 Define machinability of metal. R
35 Write Taylor’s tool life equation. R
36 How does metal removed in metal cutting. E May 2010
37
In an experimental on orthogonal cutting, a chip
length of 85mm was obtained from an uncut chip
length of 202mm while cutting with a tool of
20degree rake angle using a depth of cut of
0.5mm.Determine the shear plane angle.
An Nov 2009
38 Define chip thickness ratio. U Nov 2015
39 Write a short note on Heat zones in cutting U May 2015
40
Write a short note on any two modern tool
materials.
R May 2015
41
What are the main requirements of cutting tool
material?
R May 2015
1
How is metal removed in metal cutting? Explain
the process with simple sketch.
U May 2014
2 Describe the mechanism of metal cutting. U
May 2011
&2012
3
What is orthogonal rake system? Show the ORS of
tool analysis with the help of a sketch.
R Dec 2008
4
Explain “Merchant force circle” along with
assumptions.
R May 2010
5
Using merchant‘s circle diagram, derive the
expression for estimating the cutting force during
machining. Mention the assumption made
An Dec 2006
6
Describe an expression for the determination of
shear angle in orthogonal metal cutting.
R Dec 2005
7
Discuss the various produced during metal
machining.
R
Dec
2005,2006,
Nov 2009,

3. Nov 2010,
May 2010
,2011, 2015
8
Explain the conditions that promote the formation
of the following types of chip
1) Continuous chips
2) Continuous chips with Build-up edge
3) Discontinuous chips
R Dec2007
9
What is the use of a chip breaker? Discuss the
various types of chips produced during metal
machining process
R Dec 2008
10
What is meant by orthogonal cutting and oblique
cutting?
R May 2010
11
Define the various tool parts of a single point
cutting tool with a neat sketch
R Dec 2007
12
Explain the geometry of a single point tool with
suitable sketches.
R June 2009
13
What are the standard angles of cutting tool?
Illustrate with an example.
R Dec 2007
14
Enumerate the essential requirements of a tool
material.
U
May
2009,2013
15
List the various tool materials used in industry.
State the optimum temperature of each of the
tool materials.
R
May 2011 &
Nov 2013
16
Discuss the advantages and limitations of the
following cutting tool materials.
a. Cemented carbides
b. Cubic boron nitride
Also state the desirable characteristics of a cutting
tool material.
R Dec 2011
17
Write a short note on different tool wear
mechanism in metal cutting.
R
Nov 2013,
May 2015
18
Describe the forms of wears on the cutting tool
with neat sketches.
R Dec 2006
19 What is tool life? R Dec 2006
20
State the parameters that influence the life of tool
and discuss
R May 2010
21 Mention the functions of cutting fluids. R
Nov 2009,
Nov 2010
22
What is the main function of cutting fluids? And its
types.
R
Dec 2009,
May 2013
&2014
23
Write a short note on cutting fluids in metal
cutting.
R
Nov 2013 &
May 2014
24
What is the measure of metal removing process
machinability? What are the factors that affect it?
R Dec 2005
25
Write briefly about different cutting tool materials
used in metal cutting.
R Nov 2013
26 Write short notes on surface finish.
27 In an orthogonal cutting operation on a work piece An Nov 2010

4. of width 2.5 mm, the uncut chip thickness was
0.25mm and the tool rake angle was zero degree.
It was observed that the chip thickness was
1.25mm. The cutting force was measured to be
900N and the thrust force was found to be 810N.
1) Find the shear angle.
2) If the coefficient of friction between the chip
and the tool was 0.5, what is the machining
constant Cm?
28
a) Describe the different types of chips with neat
sketches.
b) Mention the function of cutting fluids.
R Nov 2010
29
With the help of sketches, explain the following
types of chips produced during metal machining.
a) Continuous chips b) Continuous chips with
built up edge.
U Nov 2011
30
a) With the help of a sketch show crater wear and
flank wear on a cutting tool.
b)Explain the types and applications of different
types of cutting tools.
c)Enumerate the factors that effect the cutting
temperature during machining.
R Nov 2011
31
Draw three views of a single point cutting tool and
indicate various angles.
Nov 2012
32
During an orthogonal turning operation of C20
steel, the following data were recorded:
Rake angle =10degree; Chip thickness = 0.48mm;
Width of the cut =2.0mm; Feed = 0.25mm/rev;
Tangential cutting force= 1200N; Feed thrust
force= 300N; Cutting speed = 2.5m/s;
Find the value of shear force at the shear plane;
find also the kinetic coefficient of friction at the
chip tool interface.
An Nov 2012
33
During straight turning of a 24mm diameter steel
bar at 300rpm with an HSS a tool life a 9min was
obtained. When the same bar was turned at 250
rpm , the tool life increased to 48.5min. What will
be the tool life at a speed of 280rpm?
An Nov 2012
34
Discuss briefly about the following tool materials
with respect to composition and properties: High
speed steel and cemented carbides.
An Nov 2012
35
The end of a pipe was orthogonally cut with a tool
of 20 degree rake angle. The cut chip length was
85mm corresponding to uncut chip length of
202mm.If the depth of cut was 0.5mm, find the
chip thickness and shear plane angle.
Nov 2012
36
In an orthogonal cutting test with a tool of rake
angle 10degree, the following observations were
made:
Chip thickness ratio=0.3
An
May 2012

5. Horizontal component of cutting force=1290N
Vertical component of cutting force=1650N
From merchants theory calculate the various
components of the cutting forces and the
coefficient of friction at the chip tool interface.
37
Describe the mechanism of chip formation in
orthogonal cutting.
R May 2012
38
Explain the following mechanism of tool wear:
Attrition, Diffusion
R May 2012
39
A cutting tool when used for machining work piece
at a cutting speed of 50m/min. lasted for 100min.
Taking n=0.26 in the Taylor’s tool life equation
determine the life of the tool for an increase in
cutting speed by 25% and the cutting speed to
obtain a tool life of 180min.
An May 2012
40
A specimen of 100mm length along the stroke of
shaper is machined with a tool with 15degree rake
angle. The uncut chip thickness is 1.5mm. If a chip
length of 40mm is obtained during the one stroke
of machining. Find the shear plane angle and the
thickness of cut chip.
An May 2012
41
What are the various forms of wear found in
cutting tools? Show with a neat sketch.
U May 2010
42
How do the cutting process parameters affect the
cutting tool wear in single point tools?
U May 2010
43
Derive the expression for shear angle in
orthogonal cutting in terms of rake angle and chip
thickness ratio,
E May 2010
44
How do you define tool life? Explain the
parameters that control the tool life of a single
point cutting tool.
U May 2010
45
The Taylor ’ s tool life equation for machining C-40
steel with a HSS cutting tool at a feed of
0.2mm/min and a depth of cut of 2mm is given by
VT^n = C, where n and C are constants. The
following V and T observations have been noted:
V, m/min 25 35
T, m/min 90 20
Calculate n and C, Hence recommend the cutting
speed for desired tool life of 60min.
An
May 2013,
May 2011
46
Sketch a single point cutting tool under ASA
system. Define various tool angles for machining
mild steel and justify.
R Nov 2009
47
List various types of tool wear and discuss the
factors affecting them.
U Nov 2009
48
The following equation for tool life is given for
turning operations:
VT0.13 f 0.77 d0.37 =C
A 60 min tool life was obtained while cutting at V =
30m/min, f= 0.3mm/rev and d=2.5mm
An Nov 2009

6. Determine the change in tool life if the cutting
speed, feed and depth of cut are increased by 20%
individually and also taken together.
49
Derive the expression for chip reduction
coefficient.
R Nov 2015
50 Discuss purpose of cutting fluids. R Nov 2015
51 Describe the factors affecting tool life. R Nov 2015
52
Draw the merchant force diagram and explain the
force acting on it.
R Nov 2015
53
With reference to orthogonal cutting. Explain the
following terms: shear stress in shear plane, shear
strain, cutting ratio, shear angle.
U May 2015
54
Prove that in orthogonal cutting, the kinetic
coefficient of friction is given by
µ= (Fe sin α + Ft cos α)/ (Fe cos α– Ft sin α)
E May 2015
55
Tool life tests in turning yield the following data:1)
V =110m/min, T= 20min; 2) V =85m/min, T=
40min. A) Determine the n and C values in the
Taylor tool life equation. Based on the equation
compute B) the tool life for a speed of 95m/min
and C) the speed corresponding to a tool life of 30
min.
An May 2015
56
Describe the merchant’s model for orthogonal
cutting.
R May 2015
57
The useful tool life of a HSS machining mild steel
20m/min is 3 hrs. Calculate the tool life when tool
operation at 26m/min. (n=0.125)
An May 2015
58
In an orthogonal cutting process, the following
observations were made uncut chip thickness =
0.25mm; cutting force= 1100N; feed force= 120N;
chip thickness ratio=0.46 ; rake angle =22degree;
width of cut= 4.5mm and cutting velocity =
35m/min. Determine the friction angle, shear
plane angle, resultant cutting force and power
consumption.
An May 2015
59
The following equation for tool life is given for HSS
tool:
VT0.13 f 0.6 d0.3 =C
A 60 min tool life was obtained while cutting at V =
40m/min, f= 0.25mm/rev and d=2mm
Calculate the effect of tool life if the cutting speed,
feed and depth of cut are increased by 25%
individually and also tif they are increased by 25%.
E
60 Describe any four important cutting tool materials. U May 2016
61
Determine the shear angle, friction angle, shear
stress along the shear plane and the power for the
cutting operation.
An
62
In an orthogonal cutting operation, the following
data have been observed.
Uncut chip thickness = 0.127mm
An May 2016

7. Width of cut = 6.35mm
Cutting speed = 2m/s
Rake angle = 20 degree
Cutting force = 567 N
Thrust force = 227N
Chip thickness = 0.228mm
Determine the shear angle, friction angle, shear
stress along the shear plane and the power for the
cutting operations.
PART-C
1
Discuss tool wear and its causes and also explain
how to reduce tool wear rate.
R
2
Assume, you have given with 60 HRC materials,
which tool material you will select. Justify
E
UNIT 2
TURNING MACHINES
PART – A
1 What is swing diameter? R Nov 2003
2 Write the specification of a typical lathe. R
Apr 2004,
2015& Nov
2013
3 Explain following parts of a lathe. R Dec 2010
4
Write down the names of any four lathe
accessories.
R
Nov 2003
&2004
5 State the various parts mounted on the carriage. R May 2013
6
What are the functions of feed rod and lead
screw?
R Dec 2005
7
Why is it essential that the cutting point of the tool
should be level with the spindle centre while
machining taper on a work piece?
U Dec 2007
8
Calculate the time taken for one complete cut on a
work piece of 500mm long and 50mm diameter.
The cutting speed is 30m/min and the feed rate is
0.5mm/rev.
E Dec2006
9 What is an apron? R Dec2010
10 What are the various thread cutting methods? R May2011
11 What is a centre gauge that is used in threading? R May 2014
12 Mention two limitations of a centre lathe. R
Dec 2011 &
May 2012
13
What is the difference between a ram type turret
lathe and saddle type turret lathe?
R
14 What are programmed automatic lathes? R May 2014
15 What is the need of automatic lathes? R Nov 2013
16
What is the purpose of tumbler gear mechanism of
a lathe?
R May 2012
17
Mention four different types of chucks used in a
machine shop.
R June 2009
18 Why was power chucks developed? R Dec 2005
19 What is the application of air operated chuck? R Apr 2004
20 What are the advantages of using a collect chuck? Dec 2008

8. 21
What is the purpose of a mandrel? How many
types of mandrels is there in common use?
R Dec 2008
22 List the different taper turning methods. R
May 2011, Dec
2011 & May
2012
23
Determine the angle at which the compound rest
will be swivelled when cutting a taper on a piece of
work having the following dimensions. Outside
diameter-60mmLength of the tapered portion
80mm and smallest diameter-20mm
E Nov 2004
24
Draw a neat sketch of ‘Geneva mechanism’ used in
turret lathes for automatic indexing.
R May2011
25 Define automatic machine. R
26 What are advantages of automatic lathes? R Dec 2006
27
What are the types of single spindle automatic
lathes?
R May 2013
28 What is Swiss type automat? R
29 What is the application of air operated chuck? R
30 Define the term ‘Concity”. U
31
Write down the formula for calculating taper
turning angle by compound rest method.
E
32
Distinguish between capstan lathe from turret
lathe.
R May 2010
33 State the different methods of taper turning U May 2010
34 What is the function of apron of a lathe? R Nov 2012
35
State the purpose of providing lead cam in single
spindle automatic screw cutting machine?
U May 2012
36 How is thread chased in a lathe? U May 2010
37
List the three most commonly employed types of
single spindle automatics.
R May 2010
38 Why is hollow spindle used in lathe? E Nov 2009
39 How is the size of turret lathe specified? E Nov 2009
40
Name the cutting tool nomenclature of single
point tool.
R Nov 2015
41
Mention the work holding and supporting devices
used in lathe.
R Nov 2015
42 What is meant by ‘swing of the lathe’? R May 2015
43 What do you meant by copy turning? R May 2015
44 How are automatic lathe classified? E May 2015
45
With simple sketches show the single point tool
nomenclature.
R May 2016
46 What are the advantages of automats. U May 2016
PART-B
1
Explain the constructions and working principle of
a lathe with sketch
R Dec2006
2
What is lathe carriage? Explain the various parts of
a lathe carriage with a neat diagram.
R Dec2005
3
Mention the specification of lathe with a neat
sketch.
R Dec2010
4 Describe the work holding devices in a lathe. R Dec 2006,

9. 2010 , May
2013 &2014
5
Name the various lathe accessories. How does a
four jaw chuck differ from a three jaw chuck?
R Dec2010
6
Sketch the following work holding devices used in
a lathe and state when they are used:
1) Self cantering three jaw chuck
2) Collet chuck and
3) Angle plate with face plate
R May2012
7
Draw neat sketches of steady and follower rests
and brief their applications.
R May2011
8
Explain the thread cutting operation in a lathe with
a neat sketch. Also make a note on knurling,
grooving, and forming operations in a lathe.
R June2006
9
Explain with neat sketches the working principle of
taper turning operation using a form tool and by
swivelling the compound rest.
R
Nov
2013,May
2016
10
Explain the following with a neat sketch:
Taper turning by swivelling the compound rest
Taper turning attachment method
Taper turning with tailstock set over method
R
Nov
2003,2004,20
12, Dec 2010,
May2011,
May 2014
11
Enumerate the purpose of various attachments
used on a centre lathe.
R
Dec 2005,
2006, May
2011& 2013
12 Discuss the main parts of a turret lathe. U May2010
13
Describe the special features of a turret, with a
line sketch. Also mention any two advantages of it.
R
June 2006 &
Dec 2011
14 Explain the working principle of turret lathe. R May 2013)
15
Write down the difference between a capstan and
a turret lathe.
U
Dec 2006 &
Nov2013,
May 2016
16
Explain the following with suitable sketches. turret
indexing mechanism or Geneva mechanismBar
feed mechanism
R
May 2011
,2015& Dec
2011
17 What is meant by “Tool layout” of a turret lathe. R May2010
18
Explain the tooling layout for the production of a
hexagonal bolt in a capstan lathe.
R
Nov 2003 &
2004
19 Classify transfer machines. R
Nov 2003, Apr
2004 & May
2010
20 What are the advantages of automatic machines. R Nov2004
21
What is a Swiss type automatic screw machine?
How does it function and what are its main
applications?
R
2003, Apr
2004, Dec
2005,2006,
May
2010,2011,20
16 Dec 2011,
Nov 2013
22 Describe with a neat sketch a turret automatic R Dec2006

10. screw machine.
23
Explain parallel action and progressive action multi
spindle automatics.
R
June 2006,
Dec 2006 &
May 2014
24
(i) Differentiate between parallel action and
progressive action multi-spindle automatics
(ii) Make a comparison of operational and other
features of single spindle and multi spindle
automatic lathes.
R
Apr 2004 &
May 2012
25
Explain the working of Swiss type auto lathe with a
neat sketch (May 2010),
Describe a single spindle automatic lathe.
R
Apr 2004,
May 2013 &
2012,2015,
Nov 2009
26
Name the various lathe accessories. How does a
four jaw chuck differ from a three jaw chuck?
R
27
Sketch and describe the thread cutting operation
in an engine lathe using compound slide.
R May 2011
28
How will you specify the capacity of a lathe?
Indicate the specifications on a line diagram.
U May2012
29
Sketch a line diagram of a capstan lathe and
indicate its principle parts. State also the function
of these parts.
R May2012
30
Explain with the neat sketch, the turret indexing
mechanism of a turret lathe.
May2015
31
A blank 180mm long and 70mm diameter is to be
machined in a lathe to 175mm long and 60mm
diameter. The work piece rotates at 450rpm, the
feed is 0.3mm/rev and the maximum depth of cut
is 2mm. For turning operation, the approach plus
over travel distance is 6mm.Assuming that the
facing operation is done after the turning calculate
the machining time.
An May 2012
32
What are the various methods available for taper
turning in a lathe? Explain their specific
advantages and limitations.
U May 2010
33
Calculate the change gears to cut a single start
thread M16 to 2mm pitch on a center lathe,
having a lead screw of 6mm pitch. Calculate the
depth of cut and number of passes preferred. (A
typical set contains the following change gears
with number of teeth: 20,25,30,35,40,45,
50,55,60,65,70)
An May2011
34
Explain the bar feeding mechanism used in turret
lathe while machining bar stock.
R May 2011
35
Explain with the neat sketch how movement of
carriage of lathe is reversed.
R Nov2009
36
Explain with the neat sketch how a face plate is
used for machining asymmetrical components.
R Nov2009
37
Explain the types of possible machining operation
on a turret lathe.
R Nov 2009

11. 38
Explain different machining operation performed
on lathe with sketches.
U Nov 2015
39
Name the taper turning methods and explain any
two with sketch.
U Nov 2015
40
How does a turret lathe differ from a capstan
lathe? Explain
E Nov 2015
41
Discuss the features of single spindle and multi
spindle automatic lathe.
U Nov 2015
42
Enumerate the purpose of various attachments
used on a center lathe
U May 2015
43 Define Engine lathe. R
44
Explain the salient features of automatic screw
machine.
U May 2015
45 Explain various types of chucks used in lathe. U May 2015
46 Describe bar feed mechanism of capstan lathe. R May 2015
PART-C
1
Could you select CNC machine for rough turning
operations. Explain.
R
2
In which case you will select conventional
machines, semi automatic and fully automatic
A
UNIT 3
SHAPER ,MILLING AND GEAR CUTTING MACHINES
PART A
1 Write any four shaper specifications. R May2013
2
Compare hydraulic shaper with mechanical
shaper.
R Dec2006
3 How are shaping machines specified? R May2012
4
Write down any four operations performed by a
shaper.
R Nov2004
5 Give the functions of flutes on taps. U May2004
6 What is deep hole drilling? State its applications. R Dec2011
7 How do you specify radial drilling machine? U Nov2004
8
Write down any four operations that can be
performed in a drilling machine.
R Nov2003
9 What is meant by “Sensitive hand feed”? R Apr2004
10
Define cutting speed, feed and machining time for
drilling.
R Dec2010
11
Calculate the tap drill size to cut an internal thread
for bolt of outside diameter 10mm, pitch 1.5mm
and depth of the thread 0.61 pitch.
An Apr2004
12 State the nomenclature of a standard drill. R
13
What are the differences between drilling and
reaming?
R May2011
14
What do you know about straight fluted drill and
fluted drill?
R June2009
15
Write the differences between drilling and
tapping.
R Dec2008
16
What are the common work holding devices used
on milling machines?
R Dec2007

12. 17 How do you classify milling cutters? E May2010
18 What is a shell mill? R
Nov 2005 &
June 2006
19 What is meant by up milling and down milling? R
Dec 2006 &
June 2009
20 What is climb milling? Mention its advantages. R Dec2011
21
What are the differences between up milling and
down milling?
R
Nov 2003,
2004, 2013 &
May2011,
2016
22 What is thread milling? R June2006
23
Write down the rule for gear ratio in differential
indexing.
U (Nov 2003
24 List the gear generating process. R May2013
25 What is gear hobbing? R May2011
26 Mention any two advantages of gear hobbing. U Dec2011
27 What is roller burnishing process? R June2009
28
Compare gear forming with gear generation
method.
R May2010
29 Define feed and depth of cut. U
30 What is the function of clapper block in a planner? U
31
What are the differences between up milling and
down milling .
U
32 Define “Face milling “. R
33
Write down the rule for gear ratio in differential
indexing.
R May 2015
34 How do you specify radial drilling machine. E
35
Distinguish between polishing and buffing
processes.
U May2015
36
What is a difference between a plain milling
machine and an universal milling machine?
U May2012
37 How are work pieces held in a shaper? R May2010
38 What are the various types of end mills in milling? U May2010
39
What are all the parameters that would affect the
MRR in abrasive jet machining?
R May 2011
40
What are the differences between face and end
milling.
U Nov 2009
41
List the types of driving mechanisms used in a
slotter for driving the ram.
R Nov 2009
42 What is an arbor? U
43 How does a vertical shaper differ from a slotter. E Nov 2015
44 What do you meant by differential indexing? R May 2015
45 Why is milling a versatile machining process? E
46 What is a reamer? R May 2015
47 What is straddle milling? R May 2015
48 What is the need of milling operations? R May 2013
49 State the uses of planer U May 2013
PART-B
1 Describe the principle of operation of a shaper R Dec2010

13. with a neat sketch
2
Explain the hydraulic drive mechanism of a
horizontal shaper with a neat sketch.
R May2014
3
Describe the working of a crank and slotted link
mechanism.
R
Nov 2003 &
Dec 2010
4
Describe with neat sketch whit worth quick return
mechanism used in a shaper
R
June
2006,Dec
2015
Enumerate any two advantages of a hydraulic
drive.
R
Dec
2008,2011 &
May 2011
6
Sketch and explain the working principle of upright
drilling machine.
R Dec2006
7
With a line diagram, describe the construction of
radial drilling machine.
R
Dec
2010,2011
8 Write a short note on BTA deep hole drilling. R
Nov 2013 &
May 2014
9
Sketch the following operations performed in
drilling machine. Drilling, Reaming, Boring, Counter
boring, Counter sinking, Spot facing, Tapping,
Trepanning Add one or two lines of explanation for
each.
R
May 2010,
2012, Dec
2015
10 Write short note on reaming operation. R
Dec 2008 &
May 2014
11 Discuss the various hole making processes. R May2011
12
Explain the counter boring and counter ringing
operation.
R Nov2004
13
Explain the twist drill nomenclature and define
various elements of twist drill.
R
Apr 2004,
Dec 2008 &
June2009
14
Write short notes on expanding hand reamers and
adjustable machine reamers.
R Dec 2006
15
With neat sketches, explain the working of a
vertical boring machine.
R
Apr 2004 &
May 2013
16 Write short notes on boring operations. R Dec2008
17
With neat sketches, describe the working
principles of a jig boring machine. State its
applications.
R Dec2011
18
Describe the horizontal knee type milling machine
with a suitable sketch.
R
June 2006,
Dec 2010 &
May 2013
19
State the difference between horizontal and
vertical spindle column and knee type milling
Machines.
R Nov2013
20 State the methods of holding milling cutters. R Dec 2007
21
With a neat sketch, indicate the various parts of an
arbor assembly.
R Nov 2003
22
Sketch and describe the basic types of milling
cutters.
R Nov 2005
23 Describe the constructions of the following milling R June2009, Apr

14. cutters.
a. Plain milling cutters.
b. End mills.
2004 & Dec
2011
24 List out the various milling operations. R
Nov 2005 &
May 2013
25
How will you cut the following types of surfaces on
milling machines?
c. Flat surfaces
d. Slots and Splines.
R May2011
26
Explain the indexing mechanism of a dividing head
on milling machine.
R May 2014
27
Describe the working mechanism of a universal
dividing head, with neat diagrams.
R
Apr 2004&
June 2006
28
Explain simple indexing, compound indexing and
differential indexing with suitable
examples.
R Dec2007
29 Explain the gear cutting by a formed tool. R
Nov 2004 &
Dec 2010
30
Describe gear cutting by shaping and list the
advantages and disadvantages of gear shaping
Process.
R
May 2010 &
Dec 2010
31
Explain the principle of operation of gear hobbing
operation. What are the advantages of Gear
hobbing?
R
Nov 2003,
2006, 2007,
June 2006,
May 2010 &
Dec 2011
32 Explain the gear shaving process. R June2009
33
List out various methods used for gear finishing
and explain any four methods. R
June 2006,
May 2015
34
Give the advantages and limitations of gear
hobbing.
R
Apr 2004 &
Nov 2005
35
Why is gear finishing required? Discuss the various
types of gear finishing operations.
U May 2014
36
Differentiate between gear forming and
generating.
R Apr 2004
37
Explain with neat sketches with its process
parameters: honing and lapping. Explain with neat
sketches with its process parameters: honing and
lapping.
R
Nov 2008
&June 2009,
Nov 2013
38
With a simple sketch, explain the working of the
crank and slotted link quick return motion
mechanism used in shaper and explain the
arrangements used for adjusting the position of
stroke
R
May 2016
39 State the differences between shaper and planer. R Nov2013
40
With a neat sketch, indicate the various parts of an
arbor assembly.
41
With a simple sketch, explain the principal parts
and angles of a plain milling cutter .Explain them .
R

15. 42
What are the operations performed on a milling
machine?
U May 2010
43
Explain different types of drilling machine with
their specific features?
R May 2010
44
Discuss the common work holding devices used on
shapers, slotters and planers.
R May 2010
45
Sketch the drive mechanism of a shaping machine
having crank and slotted lever type of quick return.
Explain briefly how the ram is made to reciprocate.
R May2012
46 Explainhowthe stroke lengthof the ram isaltered. R May2012
47
Explain how the ends of stroke of the ram are
positioned relative to the work piece.
R May2012
48
Sketch a twist drill and indicate on it the helix
angle, the point angle, chisel edge angle and other
names and parameters.
R May 2012
49
With a neat sketch, describe the major parts of a
radial drilling machine.
U May 2012
50
With a help of neat diagram, describe the parts of
a planning machine. Also explain a working of this
machine.
U May 2012
51
Sketch and briefly explain the following operation
performed in milling machine.
1. Plain milling
2. Face milling
3. End milling
Dovetail milling
U May 2012
52
Compare a shaper and planar in terms of
operation and type of work piece.
E May2010
53 Write a small note on slotting machine. U May 2010
54
What are the differences between compound
indexing and differential indexing? Explain the
relative merits.
U May2010
55
Sketch and explain the hydraulic drive of a
horizontal shaper.
R May 2011
56
Sketch the quill mechanism. Write its main parts
and their functions.
R May 2011
57
With the help of neat sketch, discuss the working
of surface broaching machine.
R May 2011
58
Explain the various operations performed by a
broaching machine.
R May 2013
59
Sketch and explain the mechanical feed drive of a
horizontal shaper.
R Nov 2009
60
Distinguish between climb and conventional
milling. Explain their characteristics.
U Nov 2009
61
Name and describe the four work holding devices
or methods used in drilling machines.
R Nov 2009
62
Classify the various boring tools and explain how
they are used for boring operations.
E Nov 2009
63 What is a boring bar? Explain its utility R Nov2015
64 Differentiate between reciprocating saw and band E Nov 2015

16. saw
65
Explain with neat sketches the procedure for
carrying out the following operations on a shaper:
Horizontal cutting, Vertical cutting, Concave
surface, Keyway cutting.
R May 2015
66 Enumerate with a neat sketch Gear shaping. R May 2015
67 Compare plain and Universal milling machine. E May 2015
68 What is tap? How are taps classified? U May 2015
69
Discuss the operation that can be effectively
performed by planer and also indicate the tools for
the operations.
R May 2015
70
Illustrate the hydraulic quick return mechanism in
shaper and also its function?
R May 2015
71
How mass production of small parts is done in
broaching? Explain with sketches.
R May 2015
72 Describe the various sawing machines. R May 2016
73 Describe the Universal milling machine R
May2015
PART-C
1
Why milling machine is most widely used in the
production shop? Justify.
U
2
Explain procedure of gear milling process. Explain
its advantages and disadvantages
R
UNIT 4
ABRASIVE PROCESS AND BROACHING
PART-A
1
What are the types of surfaces that could be
produced using plain cylindrical grinders?
R Nov2006
2 What are the types of surface grinders? R Dec2011
3 What is a tool post grinder? R May2014
4
State the abrasives used in manufacture of
grinding wheels.
R
5
What is meant by “grade” and “structure” of a
grinding wheel?
R May2011
6 What are the specifications of grinding wheel? R
Dec 2010 &
May 2013
7
What are grinding points? Sketch the various
grinding points?
R May 2014
8 What do you mean by loading of grinding wheels? R Nov 2005
9 What is meant by dressing and truing? R
Dec 2008 &
Nov 2013,
2009
10
Mention four important factors that influence the
selection of grinding wheel.
R June 2009
11
Under what conditions planning operations would
be proffered over other machining processes like
milling, broaching, shaping, etc?
U Dec 2007
12 What is broaching? U Dec 2007
13
What are the advantages and limitations of
broaching (2 points from each )?
R May 2012

17. 14 List four applications of broaching machines. R May 2011
15 List some of the materials of broaching tools. R May 2014
16
What is the process of self sharpening of the
grinding wheel
U
17
What are the four moments in a cylindrical centre
type grinding.
U
18 What is meant by centerlessgrinding. U
19 Define the terms abrasive grains. U
20 what is open and dense structure U
21
state the application of honing and lapping
finishing methods
R
22 Define hardness of the grinding wheel. U Nov 2010
23 Define lapping U
Nov 2010,
May 2016
24 Name two artificial abrasive materials R May 2012
25 Write any four applications abrasive jet machining. R May 2012
26
How is grinding different from other machining
operations?
U May 2010
27
What is the difference between forming and
generation of gears with respect to principle?
U May 2010
28 How is the grinding wheel designated. U
29 How is broaching machine specified. U Nov 2009
30`
State the difference between push and pull
broaching
U Nov 2015
31 Name the indexing methods. E Nov 2015
32
How does loading differ from glazing in grinding
process?
U May 2015
33
What are the principal types of broaching
machines?
U May 2015
34
How does wheel dressing differ from wheel
truing?
U
May 2015
35 What are natural and artificial abrasives? U May 2015
36 List the various grinding process. U
37 What is the need of broaching operations? U May 2016
PART-B
1
Explain self -sharpening characteristics of grinding
wheel.
R Nov 2007
2
Briefly discuss about the different types of
abrasives used in a grinding wheel.
R June 2009
3
Discuss the various bonding materials used for
making grinding wheels.
R
Nov 2004,
2009, May
2011, 2014
4 Give the specifications of grinding wheel. R
Nov 2005 &
May 2010
5
Explain the factors to be considered to select a
grinding wheel and recommended parameters.
R May 2012
6 Classify the grinding machines. R May 2013
7 Explain the abrasive belt grinding with diagram. R
Nov 2006 &
May 2014

18. 8
With the help of sketches, describe any two
methods of cylindrical grinding.
R Dec 2011
9
How do you classify cylindrical grinders? What is
the difference between “plain and universal”
cylindrical grinder?
U Nov 2005
10
Explain the working mechanism of cylindrical and
surface grinding.
R
Nov 2004,
June 2006 &
Dec2010
11
Explain the working principle of centre less
grinding process.
R May 2013
12
Sketch and explain the three methods of external
cylindrical centre less grinding.
R
Nov 2004,
May 2010,
2012
13
Explain the salient features of a centreless grinding
machine and discuss the different operations that
can be carried out in it. Mention some advantages.
R June 2009
14 Write briefly about tool and cutter grinder. R Nov 2013
15 Explain wheel truing and dressing. R
Nov 2007 &
May 2010
16 Describe the use of cutting fluids in grinding. R Nov 2007
17 Discuss the various types of broaches. R May 2010
18
Write briefly about broaching machines and its
operation with neat sketches.
R
May 2013 &
Nov2013
19
Discuss push and pull type broaching machines
with neat sketches.
R May 2011
20
Explain the construction and working principles of
continuous broaching machine.
R
Dec 2006,
2008, & May
2011
21
Sketch a typical broach and indicate important
elements.
R June 2006
22 State the advantages and limitations of broaching. R Dec 2007
23
Name the process parameters involved in the
lapping process.
R Nov 2013
24 Explain the vitrified and resinoid bonding process. R
25 Explain the gear cutting by a formed tool. R
26
Differentiate between gear forming and
generating
E
27 Give advantages and limitations of gear hobbing. R
28
List the advantages and limitations of gear
shaping.
RR May 2010
29
Explain the working principle and various methods
of centreless grinding with a neat sketch.
R Nov 2010
30
1) Write short notes on gear forming.
2) Write short notes on gear shaping.
R Nov 2010
31
With a neat diagram describe the working
principle of abrasive jet machining. State its
product applications.
R May 2011
32
Explain the working principle and product
application of the following processes.
a)Honing
R May 2011

19. b)Lapping
33
Sketch a block diagram of a plain cylindrical
grinding machine and briefly explain its working.
Distinguish clearly between “traverse grinding and
plunge grinding” done in this type of cylindrical
grinding machine.
R May 2012
34
Sketch the set up of grinding wheel and workpiece
for the following and add few lines of brief
explanation:
a) Chucking type internal grinding
b) Centreless internal grinding
R May 2012
35
Explain the ’lapping’ and ‘buffing’ processes
indicating clearly the tool involved.
R May 2012
36
Explain the working principle and product
application of the following processes.
a)Honing b)Lapping c) polishing
d) buffing e) super finishing
R May 2012
37
Sketch the following:
a) The setup of wheels and work piece for a
through feed centre less grinding:
b) The setup of wheels for in-feed and end feed
centre less grinding add few lines of brief
explanation for the above sketches.
R May 2012
38
Describe a grinding wheel structure with the help
of neat sketch and different bonding and abrasive
materials used in it? What would u like as an
abrasive for grinding steel?
R May 2010
39
Compare gear shaping and gear hobbing giving the
processes and product requirement.
E May 2010
40
Sketch and explain the three methods of external
cylindrical centre less grinding.
R
Nov 2009,
May 2011
41
List the advantages and disadvantages of gear
shaping process.
R May 2011
42
Explain how a spur gear is machined in a gear
shaping machine.
R Nov 2009
43 Discuss two types of lapping operations. R May 2013
44
Explain the principle of operation of gear hobbing
process.
R
May 2013,
May 2011
45
Sketch a broaching tool and explain the different
nomenclature.
R Nov 2009
46
Discuss the factors influencing the selection of
grinding wheel.
R Nov 2015
47
Explain the centreless grinding wheel with neat
sketch
R Nov 2015
48 Explain buffing and polishing R Nov 2015
49
Explain the Indian standard marketing system for
grinding wheel.
R Nov 2015
50
List the advantages and disadvantages of centre
less grinding.
R May 2015
51 Explain the following in grinding: Dressing and R May 2015

20. Truing.
52
The performance of a grinding wheel depends
upon types of abrasive grain size, grade, structure,
and bonding material. Discuss the effect of each.
R May 2015
53
Discuss with neat sketch vertical broaching
machine.
R May 2015
54
How do you select a grinding wheel for a given
application?
U May 2015
55 Explain the honing process with suitable sketches. R May 2015
56
Give a block diagram of a tool and cutter grinder
and also indicate its principal parts.
May 2015
57
Describe the gear hobbing process with neat
sketch.
U May 2015
58
How a grinding wheel is specified? And describe
the various factors involved in selection of a
grinding wheel.
U May 2016
59 Describe with a neat sketch, centerless grinding. R May 2016
60
With neat sketch, explain any one gear shaping
process.
R May 2016
61
With a neat sketch, Explain the various elements
of broach tool?
R May 2016
PART-C
1
Which grinding process is used for grinding long
shaft? Explain
R
2
Which process is used for mass production of
internal keyways? Explain.
R
UNIT 5
CNC MACHINING
PART-A
1
What is meant by numeric control? State their
advantages.
U
June 2009 &
Nov 2013
2
What is meant by ‘tool magazine’ in a CNC
machine?
U June 2012
3
Compare a closed loop NC systemwith open loop
system.
R
May 2012,
Nov 2009
4 What are the classifications of NC machines? U
Dec
2008,2010
5 What is point to point system? U Dec 2006
6
Distinguish between point to point and continuous
path systems.
U Dec 2011
7
What is a preparatory function? How is it
important in CNC programming?
U
May 2012,
Nov 2009
8 What are G-codes and M-codes? Give examples. U Dec 2006
9 What is the role of computer for NC machine tool? U Dec 2007
10 Name the various elements of CNC machines. R
Dec 2008,
June 2009 &
May 2014
11 State the limitations of CNC machine tools. R May 2010
12 List the differences between NC and CNC. R
May 2011,
Nov 2015

21. 13 State the difference between CNC and DNC. R Nov 2013
14
What do you meant by machining centre with
respect to NC machines?
U Dec 2011
15 Mention the advantages of stepping motor. R May 2013
16 What are linear bearings? U May 2011
17 Mention the types of ball screws. R May 2011
18 What are feed drives? U May 2011
19
What is the difference between incremental and
absolute system?
U Dec 2007
20 Define subroutine. R May 2013
21
What is the function of a subroutine in part
programming?
U June 2012
22 What is a canned cycle? U
May 2010,
2014
23 What is meant by APT program? U Dec 2010
24
Write down the types of statements in APT
languages.
R Dec 2005
25 What is ‘Adaptive control’? U
May 2014,
2015
26 Draw the simple configuration of CNC machine R
27 What is the function of servo valve. U
28 Define absolute and incremental programming. R
29
What are the important steps to be followed while
preparing part programming.
U
30 What is meant by MACRO U
31 What is meant by APT programme U
32
What are the types of motion control system used
in NC machine. (Nov 2010)
U
33
With reference to CNC manual part programming
state what is linear interpolation.
R May 2012
34
A stepping motor of 200 steps per revolution is
mounted on a lead screw of a NC machine table.
The pitch of a screw is 2.5mm/rev. If the stepping
motor receives pulses at a frequency of 2000Hz.
What is the linear speed of table?
An May 2012
35
Show the axes of the CNC horizontal boring
machine.
R May 2010
36
What are the basic assumptions made while
programming in APT language?
U May 2010
37
Compare a closed loop NC systemwith open loop
NC system.
E May 2011
38
What is a preparatory function? How is it
important in CNC programming.
U May 2011
39 List the feed drives used in CNC machine. R Nov 2015
40 Define CNC and DNC R May 2015
41 List the advantages of CNC machine. R
May 2015,
2016
42 Name any four motion statements used in APT? R May 2015
43 Write the general format of a block in CNC part R May 2016

22. programming.
PART-B
1
Under what conditions of production the
numerically controlled machine tools are
employed?
R May 2010
2
Explain the working of a NC machine tool with the
help of a diagram. Also state any two advantages
and limitations of NC machines.
R
Dec 2005,
2011 & May
2014
3
Discuss about the closed loop system open loop
system and adoptive system with a neat sketch
and with suitable example.
R
Dec 2006,May
2010 & Nov
2013
4
Discuss about the straight cut system and
continuous system with a neat sketch and with
suitable example.
R
May 2010 &
Dec 2010
5
With a help of an example explain the differences
between point to point and continuous path type
of numerically controlled machine tools.
R
Dec 2007, Dec
2011& May
2010
6
How is manual programming of a NC machine
done?
R
Dec 2005,May
2015
7 Write briefly about machining centres. R
May 2013 &
Nov 2013
8
Describe in brief the basic components of a tape
operated NC machine tool.
R
Dec2007 &
May 2012
9
Explain the following terms with reference to CNC
machines.
I. Tool length compensation
II. Cutter radius compensation
R Dec 2011
10
State a few typical applications where the use of
numerical control would be justified.
R Dec 2007
11 Discuss the major elements of CNC machine tools. R Dec 2005
12
Describe the spindle drives used in CNC machine
tools.
R May 2011
13
What are the special requirements of feed drives
of CNC machines? Name also the method of speed
control for each type.
R May 2012
14
Discuss about slide ways used in CNC machine
tools.
R
May
2011,2015
15 What are the requirements of sideways? R May 2013
16
Sketch and explain the following features of CNC
machines.
I. Hydrostatic slide ways
II. Linear bearing with balls
R May 2012
17 With a neat sketch, explain the working of ATC? R May 2012
18 Narrate the design consideration of CNC machines. R
June 2009 &
May 2011
19 Compare NC machines with CNC machines. U Dec 2005
20
List the difference between manual and computer
assisted part programming.
R May 2011
21
List the advantages of CNC systems over
conventional systems.
R
Dec 2007 &
May2014

23. 22
Explain the various steps to be followed while
developing CNC part programs
R
Dec2006, May
2013 & 2014
23
List and explain G and M code for turning and
milling operations.
R May 2013
24
List any five motions and control statements of
computer assisted NC programming and explain.
R May 2010
25
Explain the following in CNC machining.
I. Linear interpolation
II. Circular interpolation.
III. Cubic interpolation.
R
Dec 2010 &
May 2013
26 Write short notes on APT language. R Dec 2005
27 Explain APT geometry and motion statements. R Dec 2006
28 Explain various types of CMM R
29 Explain NC axis conventions. R
30
Explain the various elements of NC machine with
closed loop control system.
R May 2010
31
Describe the spindle and feed drives. State the
requirement of the drives of CNC machine tools.
R Nov 2010
32
Write a part program for that part shown in fig
C Nov 2010
33
Write a part program for drilling holes in the part
shown in fig. 2 The plate thickness is 20mm.
C Nov 2010
34
Discuss the functions of following with reference
to NC machine.
a) Linear bearings
b) Ball screws
R 2011
35
State the specific advantages of recirculation ball
screws in CNC machines. Also explain briefly the
R May 2011

24. purpose and method of pre loading of ball screws.
36
What are the special requirements of motors for
spindle drives of CNC machines? What types of
motors are used for spindle drives? Name also the
method of speed control for each type.
U May 2012
37
The bracket shown in fig is 15mm thick. Its profile
is slightly oversized by about 1mm. Write a APT
program to do finish milling of the profile of the
bracket. The following data may be assumed:
a) A 20mm end mill cutter is to be
used.
b) The X,Y,Z axes are as shown.
c) The start point is at (0,30,25)
d) For milling, the spindle speed is
1740rpm and feed rate is
500mm/min.
The post processor statement is MACHIN/UNI.
C May 2012
38
Write a manual part program to turn the
component shown on a CNC lathe from 75mm bar
stock. The following data can be assumed:
1. There will be two rough turnings and one
finish turnings. The first cut is with a depth of
3 mm for a length of 58 mm:the second with
a depth of 3 mm for a length of 59 mm:and
the third with a depth of 1.5 mm for the
length of 60 mm.
2. The shoulder of the workpiece is also
machined during each cut
3. The spindle speed is 400 rpm and the fee
rate is 0.5 mm/rev.
Make a free hand sketch showing relevant points
of tool positions for each of the three turning
operation and then write the manual part
programs.State also what each line of the program
C May 2012

25. does.
Note: If the exact G codes and M codes are not
known, the student can use his/her own code
numbers, but the function of such codes must be
clearly stated. (May 2012)
39
Describe the main features of CNC machines which
distinguishes them conventional machine tool.
R May 2010
40
How does cutter compensation given in the case
of machining centre? Explain with an example.
R May 2010
41 Describe the functions of post processor? R
42
List the main components of an NC machine tool
and explain their functions.
R
( Nov 2009,
May 2011,
May 2015
43
With a neat sketch, explain any one type of axis
feed drive of a CNC machine and list its advantage.
R May 2011
44 With a neat sketch, explain the working of ATC. U May 2011
45
A 110 mm long cylindrical rod of 75mm diameter is
to be turned into a component as shown. Write a
CNC program for manufacturing this component.
C May 2011
46 List down the various features of CNC machine R Nov 2009
47
Explain point to point and contour path
programming with simple program statement.
R Nov 2009
48
Write a program ( manual part program) to drill
five holes in the location shown in the fig. and
pause at each location where a hole should be
drilled.
C Nov 2009

26. 49
Describe the numerical control elements present
in NC system.
R Nov 2015
50
Describe the actuation system employed in CNC
machine tools.
R Nov 2015
51
Explain the following:
1). Canned cycles
2) preparatory functions
3) Motion commands in computer
aided part programming.
U Nov 2015
52
List and explain the advantages of CNC systems
over conventional NC systems.
U May 2015
53
Explain the main difference between point to
point and continuous path type numerically
controlled machine tools.
U May 2015
54
Describe the constructional details of CNC
machine tools.
U May 2015
55
With the aid of block diagram explain the steps
involved in computer assisted part programming.
U May 2015
56
Write a part program for the part shown in fig.
C May 2015
57
What are the components of NC system? Describe
them.
U May 2016
58
Explain with the neat sketch, the slide ways and
ball screws used in CNC machine.
R May 2016
PART-C
1
When do you select CNC turning centre and CNC
machining centre? Justify
R
2
What is G code and M code? Explain with suitable
diagram as example.
R