Explain in brief qualities of tool material?

Tool materials must have following qualities 1) 2) 3) 4) Red hardness : It is the ability of the material to maintain its hardness at elevated temperatures. Toughness: it is the ability of the tool material to absorb shocks Wear resistance: it is related to hardness, wear resistance increases the tool life Low coefficient of friction : it allows for higher cutting rates, without considerable increase in temperature

What are basic qualities of carbide tool steels and carbides? Carbide tool steel: It consists of 0.08-1.5% carbon. They are used for low cutting speed. They lose their hardness above 200-250 degrees Celsius. They are comparatively cheap, easy to forge and can easily be hardened. Threading dies, hacksaw blades, files, taps etc. Carbides: Carbides are powder metallurgy products. Carbide tools have very high wear resistance to abrasion and very high modulus of elasticity. They can operate at high operating speeds (16-25 times that of carbon steels). They are highly brittle, cant resist shock loads. What are various applications of USM? It is used for machining hard materials like stainless steel, glass, ceramics, carbide, quartz and semiconductor are machined. It is used for machining very precise and intricate shaped articles. Holes as small as 0.1mm can be drilled. It is mainly used for 1) drilling 2) grinding 3) profiling 4) coining 5) threading etc. What are main factors to be considered during the design of plain milling cutters? The factors to be considered during the design of plain milling cutter 1) 2) 3) 4) Tool and work piece material Power available at the end of the motor Surface finish required Depth of cut

How will you select a drill bit for a particular application? Drill bit is selected based on following considerations:

1) Work material 2) Hole size required 3) Standard drill bits available in market. Write any five principles of design of jigs and fixtures? 1) The design of jig or fixture should allow for easy loading and unloading of workpiece. 2) The jig and fixture should be as open as possible to minimize chip or burr accumulation and to enable operator to remove the chips easily. 3) Fool proofing should be done. 4) Rigidity: the jigs and fixtures should be sufficiently stiff to secure the preset accuracy of machining 5) Sighting surfaces: machining on a work piece must be clearly visible to the worker. He should not be required to bend his neck for seeing the work surface. What is the shut height of a press? It is the distance from the top of the bed to the bottom of the slide, with its stroke down and adjustment up. What is burnishing ? Burnishing is a super finishing operation which is similar to barrel rolling. The process is based upon plastic deformation of the surface layer (non cutting method). It not only produces good surface finish but also results in higher work hardness of the layer due to shot peening effect. In burnishing, a barrel is filled with medium balls, shots or round pins up to half of the barrel. There should be about two volumes of shots to one volume of work pieces. The rubbing action between shots and the work piece gives good surface finish. What are points to be considered while designing a broach? While designing a broach we should consider following things 1) 2) 3) 4) Tool and workpiece material Type of broach(push type or pull type) and broaching process (internal or surface) Surface finish requirement Depth of cut per tooth

Differentiate between screwing tap and forming tap?

Explain the significance of strip layout in sheet metal working?

Strip layout is the position of the work pieces in the strip and their orientation with respect to each other. This is the first step in sheet metal working. The percent material utilization may be increased by preparing proper strip layout. Name two materials used in EDM process stating their advantages? The two most commonly used materials are 1) Graphite : a big advantage of graphite is its ease of forming by several methods like machining, molding, copy milling, grinding etc. It is low in cost and has exceptional wear resistance. Graphite can generally achieve better metal removal rates than metallic tool electrodes with less wear and fine surface finishes close to those obtainable with copper electrode. 2) Copper- tungsten : it has very low wear ratio and this aspect is of particular importance when detailed features have to be transferred. It is a difficult to machine material. Though it has high cost it is best suited for machining of carbides. When the depth of cut is increased while machining, what will be the effect on specific energy? It remains constant.(pls check) Draw a neat sketch of renewable jig bush? Distinguish between burnishing and polishing? Burnishing: Burnishing is a finishing and a strengthening method. The method is based upon plastic deformation of the surface layer (non- cutting method). Medium balls or shots are used in place of abrasive material. work pieces of all the shapes can be burnished. Polishing: Polishing is a finishing process used to obtain smooth and lustrous surface finish. It is done by two basic mechanisms in which one is fine scale abrasive removal. Soft/resilient wheels or belts made of felt, leather, wood and coated with abrasive particles are used. The limitation of the process is that parts with irregular shapes, sharp corners deep recesses or sharp projections are difficult to polish. What are universal jigs and fixtures and state their applications? Universal jigs are those jigs which are either adjustable or adaptable to more than one drilling job. Usually the main body and operating mechanism remains same and only top plate (burnishing plate) and adapter are changed.

The use of universal jigs has the advantages of speed of operations; interchangeability; and saving in tool cost, design cost and times- study cost. Mention two disadvantages of CBN? 1) High cost. 2) Difficult to sharpen. Recommend the cutting fluid while cutting threads on PTFE component? What is the composition of cast alloy? what is its main advantage? Co 40-50% Cr- 27-32% W 14-29% C 2-4% Hardness is relatively low at room temperature but it retains its hardness at elevated temperatures. These can be operated at cutting speeds 2 times higher than HSS. What are the functions of rear and front pilot in a broaching tool? The front pilot centers the broach in the hole before the teeth begin to cut, The rear pilot supports the broach after the last tooth leaves the hole. What is the principle of electrolysis? The principle of electrolysis states that when a current is made to pass through a electrolytic solution anodic dissolution of metal takes place. What are the characteristics of LBM? Tool : laser beams in wavelength range of 0.4-0.6micro meter Material removal technique : heating, melting and vaporization MRR: 5(mm)^3/ min Material of workpiece: all materials except those with high thermal conductivity and high reflectivity Dimensional accuracy : 0.025mm (plus or minus) Applications: drilling micro holes and cutting very narrow slots. How end milling differs from face milling process?

In face milling, the cutter is mounted on a spindle having an axis of rotation perpendicular to the workpiece surface. The milled surface results from the action of cutting edges located on the periphery and face of the cutter.
The cutter in end milling generally rotates on an axis vertical to the workpiece. It can be tilted to machine tapered surfaces. Cutting teeth are located on both the end face of the cutter and the periphery of the cutter body. Briefly explain design features of push type of broaches? 1) 2) 3) 4) 5) Broaching allowance : total thickness of metal to be removed by broaching Pitch of the teeth : it is the distance from one teeth on a broach to the other teeth Rake and relief angles Depth of cut per tooth: Total length of the broach

Sketch and explain the functions of taps? Taps are available in many types, these are used for cutting internal threads.

Bottoming tap: The tap illustrated in the top of the image has a continuous cutting edge with almost no taper between 1 and 1.5 threads of taper is typical. This feature enables a bottoming tap to cut threads to the

bottom of a blind hole. A bottoming tap is usually used to cut threads in a hole that has already been partially threaded using one of the more tapered types of tap. Plug tap : The tap illustrated in the middle of the image has tapered cutting edges, which assist in aligning and starting the tap into an untapped hole. The number of tapered threads typically ranges from 3 to 5

Taper tap The small tap illustrated at the bottom of the image is similar to a plug tap but has a more pronounced taper to the cutting edges. This feature gives the taper tap a very gradual cutting action that is less aggressive than that of the plug tap.
What are the basic elements to consider in the design and manufacture of twist drill? Specify different applications of a die set?

Briefly indicate functional areas of plastic dies? Urethane compounds are used in forming dies, embossing dies etc. Epoxies when combined with metals excellent tools can be produced. Drawing dies, forming dies and stretch dies. Sketch and explain concept of quick action clamp? There are many mechanical clamping devices which can be termed a quick acting. These devices are costlier than the other types but ultimately prove economical since these help in reducing the tool operating time. Eg : C clamps, cam operated clamp and quick acting clamp In a c clamp to unload the work piece, the locking nut is unscrewed b giving it about one turn and this releases the c clamp. For loading reverse procedure is adopted. Explain the role of setting blocks used in jigs and fixtures?

Why the tools for internal machining like drills, reamers etc. are provided with neck? it is the section of reduced diameter between the body and shank. It is provided to allow the overrun of the grinding wheel in drill manufacture.

What are the important properties of cutting tool materials? Mention any three in priority? 1) Hot hardness 2) Wear resistance 3) Toughness How does the magnetostrictive material help in USM? What is that material used which part of USM equipment? the magnetostrictive materials are used to generate ultrasonic waves in USM. This work on the principle that, if a piece of Ferro-magnetic material is magnetized then a change in dimensions occurs. Material used is nickel or any other ferromagnetic material, When do you recommend plastic die? Plastic dies are recommended when the high temperatures are not produced. High surface finish and dimensional accuracy is required when there is no high amount of tool wear.