IILMCETFORM-017

Tutorial Sheet
Review Date: 26/8/19

School : Engineering Subject Name : Manufacturing Science &

Year: 3rd Technology II
Department : Mechanical Engineering
Semester: 5th Subject Code : RME503
Course : B.Tech

Course Outcome
(At the end of the course , Description
student will be able understand)
To understand the technique and concept of Metal Cutting
CO1

CO2 Knowledge of commonly used machine tools in industry various tasks.

Demonstrate the use of grinding and super finishing in manufacturing

CO3
industries.

CO4 Identify and use metal joining methods (welding).

CO5 Learn the basics of unconventional machining and welding.

UNIT No. 1

TUTORIAL No.1

Q.No Question CO No.

1. During orthogonal machining with a rake angle 10 0 and an uncut thickness 0.125 mm, the value 1
of FC and FT are found to be 517 N and 217 N, respectively. The average chip thickness is also
measured and found to be 0.43 mm. Evaluate the machining constant for the work material.
[Cm = 56.40 ]

2. During an orthogonal cutting test, the observations made are: 1

t1 = 0.25 mm, t2 = 1.2 mm, b = 2.5 mm, α = 00, FC = 900 N, FT = 810 N.
Calculate the mean shear strength of the work ma [τs= 233.4 MPa]
3. 1
Estimate the three components of the machining force during shaping of a mild steel block,
using the following data: depth of cut = 2.5mm, feed = .125mm/stroke, normal rake angle of
tool = 70, side cutting edge angle = 200, coefficient of friction between chip and tool = 0.8, and
ultimate shear stress of work material = 450 N/mm2. [FC = 730.8 N, Ff= 423.5 N, Fr =154.1 N]

4. A 300 mm diameter job is turned at 450 rpm with depth of cut = 2mm and feed = .3 mm/rev. 1
The forces measured at the cutting tool are FC = 1850 N, Ff = 450 N find:
I. Cutting power and Feed power [ P C = 13.076 Kw, Pf = .10 W]
II. Specific cutting energy [ UC = 3.083 KJ/mm3 ]
III. Total energy consume [ 77.07 X 105 KJ]

5. Q5. In a certain machining operation with a cutting speed of 50 m/min, tool life of 45 min was 1
observed. When the cutting speed was increased to 100 m/min, the tool life decreased to 10
min. Estimate the cutting speed for maximum productivity, if tool change time is 2 minutes.
[194.5m/min]

6. A turning tool with sharp corner and a major cutting edge angle of 60 0 is to be used at a feed of 1
0.05mm. What minor cutting edge angle should be provided to obtain an arithmetical mean
surface roughness of 3µm under ideal condition? [ 22.33 0]
 UNIT No. 2

TUTORIAL No.2

Q.No Question CO No.

1. Sketch the single point cutting tool under ASA system. Define various tool angles and discuss 2
their importance.
2. What is meant by built-up-edge? Explain condition which promotes the growth of built-up-edge 2
with its consequences.

3. Identify the forces involved in metal cutting process. Derive the relationship between them in 2
orthogonal cutting
4. How do you define tool life? Explain the parameters that control the tool life of a single point 2
cutting tool
5. Describe the mode of tool failure. What are the mechanisms of tool wear? Explain the types of 2
wear of cutting tool.
6. How the cutting process parameter does affect the cutting tool wear in single point tool? 2

7. Why crater is formed at some distance above the tool tip on the rake face? 2
8. What is machinability? Explain the factors which affect the machinability of a material 2
9. A metal is being cut orthogonally with a tool with zero rake angles. Show that the rate of heat 2
generation in the shear plane can be expressed as FCVC(1-µr).

10. .When the rake angle is zero during orthogonal cutting, show that 2
𝜏𝑠 (1−µ𝑟)𝑟
=
𝑈𝑐 1+ 𝑟 2
Where 𝜏𝑠 is shear stress, 𝑈𝑐 is specific cutting energy, r is chip thickness ratio, µ is coefficient
of friction.
Note: 1. Do all the questions and submit complete assignment.
2. Give the reference of each answer.
3. Draw the diagrams neatly wherever necessary.

UNIT No. 3.

TUTORIAL No.3

Q.No Question CO No.

1. Q1. What are the important factors which need to be considered for specifying a grinding 3
wheel? Explain with suitable example.
2. Briefly explain external cylindrical Centre less grinding with a neat sketch. Mention the 3
advantages and limitation of same over center type grinding.

4. Describe attritious wear, grain fracture and bond fracture 3

5. Explain in details: - Dressing and Truing of grinding wheel 3
6. Briefly explain Honing and Lapping process with the help of a neat sketch. State their 3
advantages and disadvantages.
7. What do you understand by GRIT SIZE, STRUCTURE and GRADE of grinding wheel? Why 3
soft grade wheel is preferred for machining hard material work piece?
 8. Describe different part of lathe, operation briefly with labeled diagram. 3
UNIT No. 4

TUTORIAL No. 4

Q.No Question CO No.

1. A surface 160 X 80 mm2 is rough machined using a face milling cutter of 150 mm diameter 4
having 10 teeth. The cutter center is offset by 15mm from the line of symmetry of workpiece.
Estimate he time to rough machine the surface if the feed per tooth 0.25 and cutting speed
20m/min. [1.73 min]
2. A 600X30mm flat surface of a plate is to be finish machined on a shaper. The plate has been 4
fixed with the 600mm side along the tool travel direction. If the tool over travel at each end of
the plate is 20mm, average cutting speed is 8m/min, feed rate is 0.3mm/stroke and the ratio of
return time to cutting time of the tool is 1:2 what is the time required for machining? [12min]

3. In a slab milling operation with straight teeth cutter, the cutter has 15 teeth with 10 0 rake angle 4
and rotates at 200rpm. The diameter of cutter is 80mm and table feed is 75mm/min, the depth
of cut is 5mm. the width of mild steel slab is 50mm ultimate shear stress is 420N/mm 2.
Assume the coefficient of friction between chip and cutter to be 0.7 and using Lee and Shaffer
relation, plot variation of resultant torque with cutter rotation and estimate average power
consumption. [481.426 W]

4. A slot 25 mm is to be cut through a workpiece 200mm long with the help of HSS side and 4
face cutter whose diameter is 150 mm and has 10 teeth. The cutting speed is 50 m/min and
feed is 0.25 mm per teeth find
1. Table feed in mm/min [265.26mm/min]
2. Total cutter travel [255.9mm]
3. Time required to machine the slot [57.88s]

5. In a drill of 20 mm diameter hole in a mild steel solid block of 25mm thickness, the feed rate 4
used is 0.25mm/rev. The drill must be changed after making 10 holes if it is rotated at
250rpm. But the drill can produce 50 holes if it is rotated at 200rpm. How many holes can be
produced if its rpm is 150? [398]

UNIT No. 5

TUTORIAL No. 5

Q.No Question CO No.

1. What is explosive welding process? Describe in brief giving its field of applications. Name 5
some explosive commonly used in explosive welding

2. Describe the use of laser beam in welding and machining processes. 5

3. Describe the principle of ECM process. In an ECM process with a pure iron workpiece, a 5
removal rate of 5g/min is desired. Determine the current required? (Gram atomic weight =
56g, valancy = 2)

4. Explain the principle of USM process with diagram. Also write its advantages and 5
disadvantages
5. With the help of neat sketch, explain the principle and working of AJM. List the variables and 5
limitation of AJM process.
6. Explain with neat sketch, plasma arc welding. Write down its advantages and limitation. 5
 Subject Name: Manufacturing Science-II
Session: 2019-2020
Subject: RME -503
Semester: 5th
Assignment-III
Q1. Describe the type of bonds for bonding the abrasive in grinding wheel.
Q2.what is the advantage of vitrified bond?
Q3. How grinding wheels specified? Clearly differentiate between grade and structure of a
grinding wheel.
Q4.Distinguish between dressing and truing in grinding wheel.
Q5. Explain centre less grinding with both its advantage and dis- advantage in detail.
Q6.Discuss wear mechanism of grinding wheel.
Q7. Describe the grinding machines in detail.
Q8. Define the interchangebility and why it is so important.
Q9. Write a short note on:
(a). Allowance
(b). Clearance
(c). Interference
Q10. Discuss the various methods used for expressing the surface roughness.
Q11. What do you mean by fit? Discuss various types of fits.
Q12. Define upper deviation, lower deviation and fundamental deviation
 Subject Name: Manufacturing Science-II Session: 2019-2020
Subject: RME -503 Semester: 5th

Assignment-IV

Q1. What are the various methods available for taper turning in a lathe? Explain their specific
advantages and limitations.
Q2. How does a turret lathe differ from a capstan lathe? What special tooling is associated
with the turret lathe?
Q3. Describe the different types of cutters used in milling operations with application of each.
Q4. What are the difference between compound indexing and differential indexing? Explain
the relative merits.
Q5.With the help of suitable sketch, describe the geometry of a twist drill.
Q6. What are the main difference between a shaper and a planer? What are the different drive
mechanisms used in shaper?
Subject Name: Manufacturing Science-II Session: 2019-2020
Subject: RME -503 Semester: 5th

Assignment-V

1. Discuss any one type of AMP’s, with suitable diagram.

a). LBM
b). EBM

2. What is the difference between Conventional and Unconventional Manufacturing

Process? Enlist some of the examples of both manufacturing process.

3. Discuss the working principle and application of Electro-discharge machine (EDM).

4. Discuss the working principle of diffusion welding process briefly.

5. What is explosive welding process? Describe in brief giving its field of applications.
Name some explosive commonly used in explosive welding.
 Sessional -1 Marks

S.No Roll No. Name 1st 2nd (15) Total Of Assignment Attendance Total (5
(15) sessional (10) (10)
(30)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
CO attainment (based on Sessional-1)
 Annexure-2

CO wise Internal Marks distribution

Internal assessment End Semester Examinations

Target

CO# Attainment in Attainment in Sessional-2 End Semester

Sessional-1 Examinations
1
2
3
4
5
List of Bright Students (Sesional-1)
Bright Student Motivation Scheme
List of Weak Students (Sesional-1)
 Annexure-3

Follow-up of CO attainment (after Sessional-1) (in case of poorly attained COs -weak
students)

S.No Roll No. Name of the student Remedial action taken

Follow-up of CO attainment (after Sessional-2) (in case of poorly attained COs -weak
students)

S.No Roll No. Name of the student Remedial action Remarks-Improvement

taken observed since
Sessional-1
Weak Student Development Program
Sessional -2Question Paper
Sessional -2Marks
CO attainment (based on Sessional-2)
CO attainment Bar Chart
List of Bright Students (Sesional-2)
List of Weak Students (Sesional-2)
 Follow-up of CO attainment (Annexure-3)
Annexure-3

Follow-up of CO attainment (after Sessional-2) (in case of poorly attained COs -weak
students)

S.No Roll No. Name of the student Remedial action Remarks-Improvement

taken observed since
Sessional-1I