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1. Answer any five of the following. (5 x1 )

(i) Which type of chip is produced during machining of cast iron?
(ii) By which parameter the size of shaper is given by?
(iii) In horizontal milling process _______ (up/down) milling provides better surface
finish and _______ (up/down) milling provides better tool life.
(iv) What is the main purpose of reaming operation?
(v) Which part of Lathe serves as housing for the driving pulleys and back gears?
(vi) Which component is used to support a very long jobs on lathe?
(vii) Give four examples of non-conventional machining process.
(viii) What is the value of include angle in drill tool?
(ix) In ECM material removal is due to which process?
(x) Which mechanism is used in a shaper for metal cutting?

2. Answer any Three. (3 x2)

(a) What is meant by orthogonal and oblique cutting?
(b) What is flank wear? With neat sketch show it on a cutting tool.
(c) In a single point turning operation of steel with cemented carbide, Taylor’s tool life
exponent is 0.25. If the cutting speed is halved what will happen to tool life?
(d) The rake angle of a cutting tool is 15°, shear angle is 45° and cutting velocity is
30m/min. What is the velocity of the chip along the tool face?
(e) Explain the Taylor’s tool life equation.
(f) Differentiate between up and down milling.
(g) Explain about grade and structure of grinding wheel.
(h) Differentiate between traditional and non-traditional machining.
(i) What is Direct Indexing?
(j) Make a list of product applications of LBM.
(k) What is positive and negative rake angle, how do they affect tool life?
(l) Differentiate between turret and capstan lathe.

(Answer any One)
3. (a) In an orthogonal cutting operation, following data have been observed:
Uncut chip thickness= 0.127mm, width of cut= 6.35mm, cutting speed = 2m/s, Rake angle
=10°, Cutting and thrust force are 567 and 227 N, Chip thickness is 0.228mm. Find shear
angle, friction angle, shear stress along shear plane, power for cutting and chip flow
velocity. (2.5)
(b) Write short notes on Wire EDM. (1.5)
4. (a) Sketch a single point cutting tool under ASA and define various tool angles and discuss
their importance. (2)
(b) Explain the mechanism of chip formation and various types of chips produced during
machining. (2)
4. (a) Explain with a neat sketch about the working of ultrasonic machining process. (2)

(b) Explain the various job and tool holding methods of lathe machine. (2)

5. (a) Explain the various parts of a turret lathe and how it is different from engine lathe (3.5)
(b) With example explain the different types of indexing mechanisms. (1.5)