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OXFORD ENGINEERING COLLEGE

(An ISO 9001:2000 Certified Institution)
TIRUCHIRAPPALLI 620009

DEPARTMENT OF MECHANICAL ENGINEERING

ME2252 MANUFACTURING TECHNOLOGY II
UNIT I

THEORY OF METAL CUTTING

PART-A
1. Differentiate orthogonal cutting and oblique cutting.(June 2007)

Orthogonal metal cutting

Cutting edge of the tool is perpendicular to
the direction of tool travel.
The direction of chip flow is perpendicular to
the cutting edge.
The chip coils in a tight flat spiral
For same feed and depth of cut the force
which shears the metal acts on smaller
areas. So the life of the tool is less.
Produces sharp corners.
Smaller length of cutting edge is in contact
with the work.
Generally parting off in lathe, broaching and
slotting operations are done in this method.

Oblique metal cutting

The cutting edge is inclined at an angle
less than 90o to the direction of tool
travel.
The chip flows on the tool face making
an angle.
The chip flows sideways in a long curl.
The cutting force acts on larger area and
so tool life is more.
Produces a chamfer at the end of the cut
For the same depth of cut greater length
of cutting edge is in contact with the
work.
This method of cutting is used in almost
all machining operations.

2. State the main functions of cutting fluid.

The primary functions of cutting fluids in machining are :

Lubricating the cutting process primarily at low cutting speeds
Cooling the workpiece primarily at high cutting speeds
Flushing chips away from the cutting zone

Secondary functions include:

Corossion protection of the machined surface
enabling part handling by cooling the hot surface

Process effects of using cutting fluids in machining include:

Longer Tool Life
Reduced Thermal Deformation of Workpiece

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Better Surface Finish (in some applications)
Ease of Chip and Swarf handling
3. Define Machinability and tool life.(Dec 2007)
Machinability can be assessed based on the following parameters:

material removal rate (depends primarily on the cutting speed v c) for a given tool life

cutting forces

surface finish

chip control

Machinability is influenced by the material's characteristics:

4.
5.
6.
7.

mechanical characteristics (resistance, hardness, stretching, work hardening), which depend partly on
the production method used and the heat treatment carried out.

thermal properties (evacuation of the heat cause by cutting).

chemical properties (inclusion, abrasive particle or lubricant content).

Mention any four essential properties of cutting fluids.

Define tool life.(Dec 2008)
Name the different cutting tool materials.
Which machining operation you will prefer to get better surface finish and
justify it? (June 2009)
8. What are the parameters to be considered for calculating tool life for drilling?
Tool?
9. What is meant by oblique cutting? (may 2010)
10. Mention any four methods to measure the tool life.
11. What is oblique cutting? (Dec 2010)
12. List the factors affecting tool life.
13. Which is known as orthogonal cutting? (Apr-2010)
14. What are the uses of diamond cutting tools?
15. Name the cutting fluids used in metal cutting? (dec2009)
16. What is the function of chip breakers?
17. What is Machinability Index? (May 2009)
18. Classify tool wear.
19. Write Taylors tool life equation. (May 2008)

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20. What are the causes of tool wear?

PART-B
1. What are the important properties required for cutting tool materials?
(16) (June 2007)
2. What is meant by tool wear? Explain at least four parameters that influence
tool wear. (16)
3. Explain the chip formation process in metal cutting. What is the condition
that favors the formation of continuous chips? (8) (Dec 2007)
4. In Orthogonal cutting of a materials the feed force is 800N and cutting
force is 1500 N. Calculate the following : Normal and shear forces on shear
plane and coefficient of friction of the chip on the tool face. Take chip
thickness
Ratio as 0.3 and rake angle as 8. (8)
5. Write short notes on High Speed Steel (HSS) and Cubic Boran Nitride
(CBN). (12) (Dec 2008)
6. The tool life of an H.S.S.tool at 18 m/min is 3 hrs. Calculate the tool life
when the tool operates at 24/min. Take n=0.125 in the Taylors
Equation VTn =C. (4)
7. Discuss on various forces encountered in metal cutting. With the help of
merchants circle diagram. (16) (June 2009)
8. Explain about various wear mechanisms involved in failure of single
point cutting tool. (16)
9. What are the factors that influence the selection of a proper material for
cutting tool to machine carbon steels and explain how to calculate tool
wear? (10) (May 2010)
10. Explain orthogonal cutting? (6)
11. Write the mechanism of chip formation during turning operation and
explain how you will calculate the chip removal angle for turning tool.
(8)
12. How will you calculate tool life for an end mill cutter? Explain in detail? (8)
13. Explain the way of constructing merchants circle diagram and derive the
Various forces. (16) (Dec 2010)
14. Discuss in detail about any four most commonly used cutting tool materials. (16)
15. Describe the determination of tool life. (8)
16. Discuss the different cutting tool materials. (8)
17. List the general types of chips and explain them in detail with relevant
sketches. Also mention the cutting conditions that tend to produce
such chips. (16) (dec2009)

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18. Explain the expected properties and purposes of cutting fluids. Also
mention the various types of cutting fluids. (16)
19. What are the factors depend upon selection of cutting tool material?
And also mention the properties of cutting tool material. (16) (May
2008)
20. What are the variables affecting Machinability? (8)

UNIT II

CENTRE LATHE AND SPECIAL PURPOSE LATHES

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PART-A
21. Name any four types of cutting tool used in a lathe. (Jun 2007)
22. What is meant by semi-automatic lathe?
23. List down any four difference between capstan and turret lathe. (Dec 2007)
24. How do you specify a lathe?
25. Mention any four components that are produced in automatic machines.
26. Name the specifications of a lathe. (Dec 2008)
27. Compare center lathe and copy turning lathe.
28. What is the purpose of Apron and tumbler gear in Lathe? (Jun 2009)
29. What is the purpose of collapsible tap in capstan Lathe?
30. What is the significance of the specifying diameter over bed in lathe? (May
2010)
31. Compare capstan and turret lathes.
32. What do you mean by maximum bar diameter in the case of lathe? (Dec
2010)
33. Sketch a faceplate.
34. List the applications of speed lathe. (May 2008)
35. Sketch an undercut shoulder.
36. List the benefits of Capstan & Turret lathe over.
37. Name the applications of copy turning lathe.
38. List the advantages of Automats. (dec2009)
39. Compare feeding mechanism and transfer mechanism.
40. List any 4 work holding devices.
PART-B
21. With suitable sketch, explain any two taper turning methods. (16) (Jun
2007)
22. using a neat sketch of a multi-spindle automatic lathe, explain
its construction and working. (16)
23. Explain the apron mechanism of a lathe. (10) (Dec 2007)
24. Explain any one method of turning taper in a lathe. (6)
25. With a neat sketch explain the working of a copy turning lathe. (16)
26. Explain with neat sketch the working of different parts of a center lathe.
(16) (Dec 2010)
27. Describe the working of capstan and turret lathes and give
the applications. (16)
28. Describe the working of cam controlled automats and its applications.(16)

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29. Explain the following with respect to automats:

a. Feeding mechanism (8)
b. Transfer mechanism (8)
30. Sketch and explain the working principle of the back gear mechanism
used for thread cutting operation in a lathe. (10) (Jun 2009)
31. Explain how slotting can be performed in a lathe. (6)
32. Describe the three methods of taper turning operations performed in
lathe with neat sketch. (12)
33. Write the difference between 3 jaw chuck and 4 jaw chuck. (4)
34. Sketch and explain any four machining operations which are performed in
a lathe by holding the work piece by faceplate. (16) (May 2010)
35. List various types of single spindle automats. Explain the working of
SWISS Type automat. (16)
36. Explain any four operations that are performed in a lathe by holding
the work piece between centers. (16) (Dec 2010)
37. Sketch and explain the working of turret indexing mechanism.(16)
38. Sketch and explain the function of apron mechanism available in lathe.
(16) (May 2008)
39. Explain the principal parts of a Capstan lathe with a neat sketch and list
out the differences between a Capstan and a Turret lathe.
40. Explain with neat sketch the working of a copy turning lathe. (16) (Dec
2009)
41. Describe the various mechanisms used in a Centre lathe. (16)
42. Describe the working principles of multispindle automats with sketch.
(16)
43. Explain the transfer mechanism of an automat. (8)

UNIT III

OTHER MACHINE TOOLS

PART-A

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41. List any two types of planning machine. (Jun-2007)

42. Differentiate drilling and reaming.
43. What is broaching?
44. What is quick return motion mechanism? What is its advantage? (Dec 2007)
45. What is the function of a reamer? What is the function of a tap?
46. Differentiate up milling and down milling.
47. List the types of boring machines. (Dec 2008)
48. What is the application of quick return mechanism in shaper machine? (Dec
2009)
49. Give the difference between boring and reaming operation.
50. How is stroke length adjusted to the size of the job in a shaper? (May 2010)
51. Differentiate drilling and boring.
52. Classify the broaching according to the method of operation.
53. What are the uses of vertical shapers? (Dec2010)
54. What is counter boring?
55. Mention the various headings under which shapers are classified.
56. What is countersinking?
57. Differentiate between shaper and planer.
58. Name the machine tools for super finishing process.
59. Give the nomenclature of plain milling cutter.
60. What is meant by up-milling and down-milling.
PART-B - ( 30 MARKS)
44. What is meant by quick return motion? With a neat sketch explain the
quick return mechanism of a shaper. (16) (Jun-2007)
45. With suitable sketch, write notes on any four types of milling methods.(16)
46. What is indexing in milling operation? Explain simple and
compound indexing. (16) (Dec 2007)
47. With a neat sketch explain the nomenclature of a broaching tool. (8)
48. Compare shaping and planning machines. (10) (Dec 2008)
49. Derive the relation for material removal rate in shaping machines. (6)
50. Describe the different types of milling processes with its cutters. (16)
51. With a neat sketch explain the working principle of planer and explain
the different types of work holding devices in planer. (10) (Jun-2009)
52. Sketch a milling cutter and indicate rake, clearance and lip angle. (6)
53. With a neat sketch explain the quick return mechanism. (10)

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54. Sketch and show the nomenclature of a reamer.(6)

55. With a neat sketch explain the working of the table drive mechanism of
a planer. (16) (May 2010)
56. Sketch and explain any four standard milling cutters. (16)
57. Explain any two standard clamping devices used for holding most of
the work on a planer table with suitable sketches.(16) (Dec 2010)
58. With suitable sketches, explain any two types of power
sawing machines. (16)
59. Sketch and explain the working of crank and slotted lever mechanism used
in shaper. (16)
60. With neat sketches explain any two of the work holding devices
commonly used for holding the work in a drilling machine.(16)
61. Explain the mechanisms of cam and thread milling with sketch.
62. Describe the different types of boring operations with its toolings.
63. Explain the construction and working principles of continuous
broaching machine.(16)
64. State the advantages & limitations of broaching. (10)
65. Describe the push and pull type broach with neat sketches. (16)
66. Explain the principles of a broaching machine. (8)

UNIT IV

ABRASIVE PROCESSES AND GEAR

CUTTING

PART-A
61. Explain buffing.

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62. Explain truing and dressing of a grinding wheel.

63. Write down the names of any four gear finishing methods.
64. How do you select grinding wheel for a vertical surface grinder?
65. Narrate the types of gear cutters.
66. Differentiate between gear shaping and gear hobbing.
67. What are the various factors to be considered in selection of grinding
wheel?
68. Give the specification of a grinding wheel.
69. State the advantages of precision grinding.
70. What are the two combination movements used in differential indexing?
71. Which is chucking grinder?
72. What is the use of template gear cutting process?
73. Define the principles of gear generation?
74. List the gear generating process.
75. What are the limitations of gear hobbing?
76. What are the applications of gear shaping?
77. What is the process of lapping?
78. State the process of grinding.
79. What is meant by honing?
80. What is super finishing?

PART-B
67. Write short notes on surface finishing processes. (16)
68. With a neat sketch, describe any two gear cutting methods. (16)
69. With a neat sketch, explain the working of gear hobbing machine. (16)
70. Explain the construction and working of a surface grinder. (8)
71. Explain the different types of grinding machines with neat sketch. (16)
72. Explain the kinematics of gear shaping and gear hobbing. (16)
73. With a neat sketch briefly explain the principle of Centre less grinding (10)
74. Describe the compound indexing and differential indexing methods. (6)
75. Explain the working principle of abrasive jet grinding; write their
applications and what are the commonly used abrasive materials. (12)
76. Explain thermo-forming process and write its relative merits and
demerits. (4)
77. Discuss in detail about the specifications and selection of grinding
wheels.(16)
78. With a neat sketch explain the working of a gear shaping machine.(16)

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79. How a grinding wheel is specified? (6)

80. Sketch and explain the Centre less grinding operation. (10)
81. Explain lapping process with a sketch. (6)
82. Sketch and explain abrasive jet machining process. (10)
83. Sketch and explain cylindrical grinding operation. (10)
84. Explain the honing process with a sketch. (6)
85. Sketch and explain a gear shaping machine. (10)
86. Explain the kinematics of bevel gear generators. (16)
87. with neat sketchs, explained the way of dressing a grinding wheel and
mention its necessity. (10)
88. Describe the working principles of lapping and honing. (8)

UNIT V

CNC MACHINE TOOLS AND PART PROGRAMMING

PART-A
89. Differentiate NC and CNC.
90. List any four auxiliary statements in APT language.
91. Write the function of G50 and M19? (jun2009)
92. Write the applications of computer assisted part programming?

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93. State the functions of MCU in CNC machine tools. (may2010)

94. Give two motion and two control commands of APT language.
95. Define numerical control. (dec2010)
96. Classify the NC machines based on control systems.
97. List the main elements of a NC machine tool.
98. Which is closed loop control system?
99. Distinguish between CNC & DNC system.
100. Enumerate the various feedback devices used in CNC system.
101. Explain the function of codes of G28 and M30.
102. What are the four statements in APT language?
103. State any four applications of CNC.
104. Classify linear interpolation.
105. Mention the various types EDM.
106. Write down the types of statements in APT language?
107. What do you mean by canned cycle?
108. What are the requirements of spindles in CNC?
PART-B
109. With suitable sketch, describe the types of CNC machine tools.(12)
110. Explain the special features available in a CNC machine. (4)
111. Describe the motion statement in APT language. Give the general form of
motion statement and explain with suitable example the PTP and
Contouring motions. (6+10)
112. Explain the components of machining center with neat sketch and
describe the various operations that can be performed on it. (12)
113. Explain the motion statements in APT programming. (4)
114. Explain Computer aided part programming and its application in
industries. (10)
115. Explain manual part programming with an example.(6)
116. Discuss in detail about the design considerations of CNC machines for
improving machining accuracy.(8)
117. Write a note on spindle drives and feed drives of CNC machines.
118. Sketch and explain a turning center and mention its superiority over the
CNC lathe.(10)
119. What are the components and types of DNC and briefly explain
Them. (12)
120. Explain the various compensation features of CNC system. (8)
121. What are the requirements of spindle drives and feed drives of CNC
Machine tool. (8)

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122. Discuss about a) closed loop & open loop system (b) straight line &
Continuous system with neat sketch. (16)
123. What is the difference between positioning machines and contouring
machines? (12)
124. How is manual programming of a NC machine done? (8)
125. Explain the part programming procedure with a good example. (10)
126. List the various drive systems. Explain the principle of any 2 drive
systems. (16)
127. Discuss the advantages of computer numerical control system. (8)
128. Discuss the major elements of CNC machine tools. (8)
129. Explain NC axis conventions. (8)