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Sathishkumar
ANNA UNIVERSITY-CHENNAI - 600025

QUESTION BANK

2013 REGULATION

DEPARTMENT OF MECHANICAL ENGINEERING

Subject Code : ME 6402

Subject : Manufacturing Technology-II

Year/Semester: II/IV

Author:

Prof.S.Sathishkumar. BE (Mechanical Engineering)., ME (Engineering Design).,(MBA)-Operations

Management.,MISTE

Assistant Professor in Department of Mechanical Engineering

Vel Tech, Avadi, Chennai-62.

Email: kssathishkumar.93@gmail.com & sathishkumar@veltechengg.com

Mobile Number: 9994274071, 9597178818

Face Book: K.s. Sathishkumar

Twitter : K.s. Sathishkumar

 www.Vidyarthiplus.com S.Sathishkumar
ME6402 MANUFACTURING TECHNOLOGY – II LTPC
3003
OBJECTIVES:
To understand the concept and basic mechanics of metal cutting, working of standard machine tools
such as lathe, shaping and allied machines, milling, drilling and allied machines, grinding and allied
machines and broaching.
To understand the basic concepts of Computer Numerical Control (CNC) of machine tools and CNC
Programming
UNIT I THEORY OF METAL CUTTING 9
Mechanics of chip formation, single point cutting tool, forces in machining, Types of chip, cutting
tools – nomenclature, orthogonal metal cutting, thermal aspects, cutting tool materials, tool wear, tool
life, surface finish, cutting fluids and Machinability.
UNIT II TURNING MACHINES
Centre lathe, constructional features, specification, operations – taper turning methods, thread cutting
methods, special attachments, machining time and power estimation. Capstan and turret lathes- tool
layout – automatic lathes: semi automatic – single spindle : Swiss type, automatic screw type – multi
spindle: 43
UNITIII SHAPER, MILLING AND GEAR CUTTING MACHINES 9
Shaper - Types of operations. Drilling, reaming, boring, And Tapping. Milling operations-types of
milling cutter. Gear cutting – forming and generation principle and construction of gear milling,
hobbing and gear shaping processes –finishing of gears. 9
UNIT IV ABRASIVE PROCESS AND BROACHING
Abrasive processes: grinding wheel – specifications and selection, types of grinding process– cylindrical
grinding, surface grinding, centre less grinding and internal grinding- Typical applications – concepts of
surface integrity, broaching machines: broach construction – push, pull, surface and continuous
broaching machines
UNIT V CNC MACHINING 9
Numerical Control (NC) machine tools – CNC types, constructional details, special features, machining
centre, part programming fundamentals CNC – manual part programming – micromachining – wafer
machining TOTAL : 45 PERIODS
OUTCOMES: Upon completion of this course, the students can able to understand and compare the
functions and applications of different metal cutting tools and also demonstrate the programming in
CNC machining.
TEXT BOOKS:
1. Hajra Choudhury, "Elements of Workshop Technology", Vol.II., Media Promoters
2. Rao. P.N “Manufacturing Technology - Metal Cutting and Machine Tools", Tata McGraw-Hill, New
Delhi, 2003.
REFERENCES:
1. Richerd R Kibbe, John E. Neely, Roland O. Merges and Warren J.White “Machine Tool Practices”,
Prentice Hall of India, 1998
2. HMT, "Production Technology", Tata McGraw Hill, 1998.
3. Geofrey Boothroyd, "Fundamentals of Metal Machining and Machine Tools", Mc Graw Hill, 1984
4. Roy. A.Lindberg, “Process and Materials of Manufacture,” Fourth Edition, PHI/Pearson Education
2006.
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UNIT-1- THEORY OF METAL CUTTING

PART-A
1. Define Tool life?

2. What are the factors affecting tool life?

3. What is orthogonal cutting? Example

4. Name the factors that contribute to poor surface finish in cutting?

5. What is the function of chip breakers?

6. What are the important characteristics of cutting tool?

7. What are the functions of cutting fluids?

8. List out different between orthogonal and oblique cutting?

9. Write significant Characteristics of a cutting fluid?

10. Name the various cutting tool materials?

11. What is rake angle? What is the effect of nose radius in tools?

12. What is meant by built-up-edge?

13. How can built-up edge formed during machining be avoided?

14. Write any two reasons for flank wear in cutting tools?

15. What are the advantages of diamond tools?

16. Classify the tool wear?

17. Define Machinability index?

18.What the factors considering selection of cutting fluids?

PART-B&C
1. Discuss the different types of chips produced during machining process with neat
sketches?

2. What are the various type of cutting tool material used in metal cutting and briefly
explain about its properties?

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3. Discuss the various type of cutting fluids?

4. Describe the forms of wear on the cutting tool with neat sketches?

5. List the important characteristics of cutting tool materials?

6. List the various type of tool wear and discuss the factor affecting them?

7. Explain parameters control the tool life in a single point cutting tool?

8. Comparision between the orthogonal and oblique cutting?

9. Explain detail about different type of tool wear mechanisms?

10. Derive the Merchant metal cutting theory with suitable diagram?

11. Write short notes of thermal aspect in metal cutting?

12. What are the possibilities for tool failure?

UNIT-2- TURNING MACHINES

PART-A
1. What is chuck? State different types of chucks?

2. What are the functions of feed rod and lead screw?

3. What are automatic lathe?

4. What are the needs and advantages of automatic lathes?

5. Differenciate capstan and turret lathe?

6. Write the specifications of typical lathe?

7. State the need for tumbler gear mechanism?

8. What are the limitations of centre lathe?

9. How is the size of a turret lathe specified?

10. What is swing diameter?

11. List the three most commonly employed types of single spindle automatic lathe?

12. What is the purpose of abron?

13. State various parts mounted on the carriage?

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14. What do you meant by copy turning?

15. Draw neat sketch of “Geneva Mechanism” used in turret lathe?

16. Write taper turning methods in centre lathe?

PART-B&C
1. Explain the construction and working principle of a lathe with suitable diagram?

2. What is the principle of taper turning & explain briefly various taper turning methods?

3. Write different between the capstan and turret lathe?

4. Explain with neat sketch swiss type automatic lathe?

5. Explain parallel action and progressive action multispindle automatics?

6. List some work holding devices in lathe & briefly explain any five work holding devices
with neat sketch?

7. Explain the method of thread cutting using compound slide in a lathe?

8. Describe single spindle automatic lathe and automatic screw type machines?

9. Discuss special attachment on lathes?

10. Explain the construction and working principle of a capstan and turret lathe with neat
sketch?

11. Explain with neat sketch the turret indexing mechanism and bar feeding mechanism of
a automatic lathe?

12. Sketch line diagram of a single spindle automatic lathe and briefly describe its feature?

13. Make comparison of operational and other features of single spindle and multi spindle
automatic lathe?

UNIT-3- SHAPER, MILLING AND GEAR CUTTING MACHINES

PART-A
1. How are work pieces held in a shaper?

2. Wirte differentiation between the Mechanical & Hydraulic shaper?

3. How are shaping machine specified and mention few specifications?

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4. What is Shell mill?

5. Compare Up Milling and Down Milling?

6. How are milling cutters classified? Write types?

7. What is climb milling and mention its advantages?

8. Write difference between face milling and end milling?

9. What are the various types of end mills used in milling operations?

10. List the gear generation process?

11. What is meant by ‘sensitive hand feed”?

12. What is gear hopping? Give few examples

13. What is difference between plain milling and universal milling machine?

14. Draw the Nomenclature of Drill Bit?

15. What do you mean differential indexing?

16. Why is milling a versatile machining process?

17. What is gear finishing & why gear finishing required?

18. Define indexing? State different methods of indexing?

PART-B&C
1. With a neat sketch explain the column and knee type milling machine and name its main
parts?

2. Explain the hydraulic dive of a horizontal shaper with neat sketch?

3. Briefly explain about drive mechanisms of shaper machine?

4. What are the different type milling cutters that are used in milling and explain any four
types with neat sketch? (Plain and end milling cutter very important)

5. Compare plain and universal milling machine?

6. List out and describe the various milling operation with suitable diagram with example?

7. Explain the indexing Mechanism of a dividing head on milling machine?

8. Describe the construction and types of surface milling machines?

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9. Distinduish between climb and conventional milling. Explain their characteristics?

10. What are the different between compound indexing and differential indexing and
explain its relative merits ?

11. Describe the principle of operation of a shaper with neat sketch?

12. Why is gear finishing required? Discuss the various types of gear finishing operations?

13. Explain the principle of operation of gear hobbing process?

14. Write advantages and disadvantages of gear shaping process?

15. Compare gear shaping and gear hopping giving the process and product requirements?

16. Explain about gear generation and gear finishing process with suitable diagram?

17. Discuss with neat sketches gear grinding and gear lapping methods?

18. List out the different operation carried out on drilling machine& explain any two
process?

19. What are the various method used for gear finishing? Discuss any two methods?

UNIT-4- ABRASIVE PROCESS AND BROACHING

PART-A
1. What do you meant by loading of grinding wheel?

2. State the abrasives used in the manufacture of grinding wheel?

3. What is meant by centreless grinding?

4. What is meant by grain size or grit?

5. What is the need of truing and dressing operations in a grinding wheel?

6. What is meant by honing and write its advantages?

7. Write grinding wheel specified letters?

8. Write important factors involved selection of grinding wheel?

9. What is different between the grinding operation and other operations?

10. Define hardness of grinding wheel?

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11. What is roller burnishing process?

12. What is meant by “grade” and “structure” of grinding wheel?

13. Write the applications of abrasive jet machining?

14. Distinguish between polishing and buffing process?

15. Write parameters involved in the lapping process?

16. What is meant by broaching and write its principle?

17. How to Broaching machine specified?

18. Write advantage, disadvantage and applications of broaching?

19. List some of the material of broaching tools?

20. How does loading differ from glazing in grinding process?

PART-B&C
1. Explain the working principle and various methods of centreless grinding with neat
sketch?

2. Enumerate the advantages and disadvantages of centre less grinding?

3. Describe the terms dressing and trueing of grinding wheel?

4. Explain with neat sketches the four different types of surface grinding operations?

5. Honing, 2.Super finishing, 3.Lapping, 4.Polishing, 5.Buffing

6. Describe the any two methods of cylindrical grinding with neat sketch?

7. Explain how a wheel balanced and mounted?

8. Discuss various bonding materials used for making grinding wheel?

9. Sketch a schematic diagram of abrasive jet machining setup and name of major
components and briefly explain the process?

10. Write briefly about broaching machines and its operations with neat sketch?

11. Discuss the working of surface broaching machine with neat sketch?

12. Explain the “lapping” and “buffing” process indicating clearly the tool involved?

13. Sketch a broaching tool and explain the different nomenclature?

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14. Explain with simple sketches the working principles and process parameters of honing
process?

UNIT-5- CNC MACHINE TOOLS AND PART PROGRAMMING

PART-A
1. What is Numerical Control? Write its elements?

2. State the advantages of NC system?

3. What are G-Codes and M-Codes? Give example

4. List the commonly used co-ordinate system of CNC Machine tools?

5. What is point to point (PTP) System?

6. Mention main different between CNC and DNC?

7. Write different between incremental and absolute system?

8. What is meant by APT Program?

9. Compare closed loop NC System and open loop NC system?

10. With reference to CNC Manual part programming, state what is liner interpolation?

11. What is meant by canned cycle?

12. What is meant by “Tool Magazine” in a CNC machine?

13. What is a preparatory function? How to important in CNC Programming?

14. Mention advantages of stepping motor?

15. What is adaptive control

PART-B&C
1. Explain the various steps to be followed while developing the CNC part programs?

2. Explain the working of NC Machine tools with help of a diagram?

3. Write briefly about open loop, closed loop and adoptive control systems in CNC Machine
tools?

4. Write briefly about machine centre?

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5. Explain part programming procedure with suitable example?

6. Describe the main constructional features of CNC machines, which distinguish them from
conventional machine tools?

7. Explain the main difference between point to point and continues path type numerically
controlled machine tools?

8. Explain the advantages and limitations of NC Machines?

9. Explain the various types of statements used in APT language, with suitable examples?

10. Discuss the various types of CNC Machine based on tool motion?

11. Enumerate various steps involved in wafer preparation?

12. Explain the following in CNC Machining

1. Liner interpolation 2.Circular interpolation 3.Cubic interpolation

13. Describe the spindle the feed drives. State the requirement of the drives of CNC machine
tools?

………All the Best My Dear Students…………

By

Author (S.Sathishkumar)

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