Mid-semester examination-2022

5th Semester, Mechanical Engineering

Course: Machining and Machine Tools (MEC 302)
Time: 2hrs, Max.mark:60
Answer all the questions.
Any missing data may be assumed suitably and that must be clearly indicated in the respective answer.
Marks
Q.1 Manufacturing process is a value addition process, justify with a suitable example. (include figures
and explain within 05 lines of texts) 02
Write different parameters to measure the machinability index of any material. 02
(any four parameters)
Reaming operation is required for the drilled holes, but the same is not required after the boring 02
operation, justify. (within 5 lines)
Under what geometrical condition of a turning tool, the values of all rake angles become same? 02
02
AT-slot is to be machined on a cast iron block as shown in the left side figure,
suggest the machining operations and name of the cutter to be used.
02
What is the purpose of lead screw and(0Yfeed rod in a lathe? (one sentence each)
Complete the table below, one raw is done for you. 02
Operation Cutting Speed Feed Depth of cut
Lathe turning work rotation Longitudinal tool movement Cross tool movement
Facing in lathe
Face milling
Shaping
Drilling
(h) Draw the possible combinations of generatrix and directrix for producing external and internal 02
cylindrical surfaces.
Draw and indicate the features of a turning tool in "Tool in Hand system" of reference. 02
Draw and indicate different axes used in ASA and ORSwhich are used for finding different angles in a 02
turning tool. (draw in a single figure)
In a production turning operation, the foreman has announced that the single pass must be 06
completed on the cylindrical workpiece in 5.0 min. The piece is 400 mm long and 150mm in
diameter. Using a feed = 0.30 mm/rev and a depth of cut = 4.0 mm, what cutting speed must
be used to meet this machining time requirement?
A drilling operation is performed to create a through hole on a steel plate that is 15 mm thick. 06
Cutting speed = 0.5 mls,and feed = 0.22 mm/rev. The 20-mm diameter twist drill has a point
angle of18. Determine (a the machining time and (b metal removal rate once the drill
reaches full diameter.
A face milling operation is used to machine 5 mm from the top surface of a rectangular piece 06
of aluminum 400 mm long by 100 mm wide. The cutter has four teeth (cemented carbide
inserts) and is 150 mm in diameter. Cutting conditions are: v =3 m/s,f=0.27 mm/tooth, and
d= 5.0mm. Determine: (a time to make one pass across the surface, and ( metal removal
rate during cutting.
Draw the required projections of the single pointturning tool to find the master line. Indicate 06
different axes, angles and planes on which different sections are dravwn.
During turning of a mild steel rod at speed of 400.rpm and feed :0.3 mm/rev by acarbide tool 08
of geometry: 10°, -10°, 8°, 7°, 15°, 45°, 0 ( ) the average chip thickness was 0.5 mm, For
the above machining, find the values of (Y Coefficient of friction at rake face and (j shear
angle.
The plain milling of an aluminium plate is carried out by a straight fluted slab milling cutter 08
of diameter 60 mm and 12 teeth at speed of 400 rpm, feed 40 cm/min and depth of cut 8 mm. (3+3+2)
Findexpected value of Maximum uncut chip thickness ( Average uncut chip thickness
(ijif Approximate chip length
1) a, =So Sin

f- Seno

Sih Po

am
So = Sm

%-(%
am 2So

Am 28So 3)
S
AD

Aavg BSo
 Monsoon semester examination (2022-23)
gth Semester B.Tech., Mechanical Engineering
Course: Machining and Machine Tools (MEC 302)
Time: 3hrs, Max.mark:100
Question no. 1is compulsorv, answer any four questions from the remaining
Any missing data may be assumed suitably and that must be clearly indicated in the respective answer.
Q.1
In the conventional machining operation, the material is subjected to compression, but the 02
failure takes place due to the shear, justify this within 5lines of texts.
Why the specific grinding energy is always higher than that of the machining process? Justify. 02
Write two main causes ofbuilt up edge (BUE) formation. 02
A square through hole (side: 20mm) with sharp coners is to be prepared on a 02
cylindrical metal work piece of axial length 30mm, suggest the machining
processes to accomplish this job.
There are many spark-in and spark-out passes in grinding, explain within 5lines of texts. 02
The taper tuming operation is to be carried out at one end of a cylindrical work piece of 02
diameter 50mm and axial length of 150mm. If the required taper angle and the length of the
taper is given as 45° and 20mm respectively, findthe minimum diameter of the taper.
Differentiate between the orthogonal and oblique cutting. (Within 05 lines) 02

The left side figure shows a portion of a drillbit, write the 02

name of the part indicated from 1 to 5.

(Please donot draw anything, write the names only indicating

the label 1-5)

Draw the voltage waveform that is used for generating the sparks in electro-discharge 02
machining process. Write different parameters related to this.
Why the master line in a single point cutting tool is important.
Q2.a) Draw a schematic and indicate different parts to represent material removal mechanism in 05
grinding process. (description is not required)
Q2.b) | How grinding specific energy and the grinding force varies with the material removal rate? 05
Draw the theoretical plots andexplain within 5 lines of texts.
Q2.c) The surface grinding operation is to be carried out on 200mm x200mm surface area of asteel 10
plate using Al,03 abrasive grinding wheel of thickness (width) 40 mm. The depth of material
to be removed during the grinding operation from the surface is 30 microns. The allowable size
error is 5 microns. Assuming the stiffness factor to be 0.3, find the total no of passes required
to grind the whole surface in (i) incremental feed mode of grinding with step feed of 10 microns
(ü) single feed mode grinding.
03.a Draw the merchant circle diagram and indicate different forces and different angles involved
05
in it.
Determine the values of Ps (shear force) and Pn using the following given values associated 05
with a turning operation: P1000N, P 400N, P200N, Yo= 150, chip reduction cefficient
=2.0.

03.c Withthe help of MCD, state for whatvalue of orthogonal rake angle of the too, the coefficient 10
of friction and the shear angle, the fllowing conditions will occur.
i) P,= Py= F=N
ii) P-0.5 R
Where, Pz, Pxy, F, N, Ps and R: represents the main cutting force component, thrust force,
friction force, normal reaction, shear force and resultant force respectively.
Q4.7 Write the essential properties ofthe cutting fluids which are used in conventional machining 2.5+).
opezation.
Draw (write any five)to indicate the location and write causes of the heat generation in
a schematic
conyentional machining.
Q4.b/ How does a conventional cutting tool fails? (write in points only ) 2.5+2.5
KDWrite the essential properties of the cutting tool materials. (write at least five)
Q4.7 YDetermine the value ofthe constant C' and theexponent 'n' of Taylor's tool lite equation 05+05
for a cutting condition, if the life of the tool increases from 30 min to 60 min due to reduction
of çutting velocity from 200 m/min to 160 m/min.
During the turning operation of a brass rod by HSS tool, the life increased from 20min to
40minutes when cutting yelocity is reduced from 50 m/mim to 40 m/min. At what cutting
velocity the life of the same tool under the same condition willbe 30 min?
5Draw a schematic to represent the voltage drop in the inter-electrode gap in the electrochemical 2.5+2.5
machining process. State the causes for each component of voltage drops.
Explain (with the help of diagram and equations)the material removal mechanism in UItrasonic
machining process.
Q5.¢ The composition (% by weight) of the Nimonic super alloy is as given here: 10
Ni Cr Fe Ti Si Mn Cu
72.5 19.5 5.0 0.4 1.0 1.0 0.6
Calculate the removal rate (in cm³/min)when a current of 1000 amp is passed. Use the given valency
of dissolution for each element (Ref. Table 6.3).

Q6.a) YDraw the diagram and explain how the spark is produced in the inter-electrode gap in electrical 2.5+2.5
discharge machining process.
i Write the advantages and the limitations of electrical discharge machining process.
Q6.b, During the turning operation of aluminumrod under dry condition by a HSS tool of geometry 05
0°,12°,8°,6°,159,60°, 0(mm), at feed,0.2 mm/rev,the chip thickness was found to be 0.5 mm. Findthe
,valueof shear angle.
O6.c) Determine the value of average cutting strain (e) that will occur if a mild steel rod of diameter 10
100mm is turned at 300 rpm, feed (S)=0,24 mm/rev by cutting toll of geometry = 0 , Yo
-15°, Ø=60° and chip thickness becomes 0.6 mm.
TabBe 6.3 Atomic weight, valency of dissolution, and density
of important clements 0.1035 x 10-2 1
Gram atomic Valency of Density
Metal
weight dissolution (gicm')
Ahuminiunm 26.97 2.67
Chromium 51.99 7.19
100
Cobalt
Copper
Iron
Nickel
58.93
63.57
S5.85
2/3

3
8.85
8.96
7.86
pz/p)
S8.71 8.90
Tin 118.69 2/4 7.30
Titanium 47.9 4.51
Tungsten 183.35 6 193
Zinc 65.37 2 7.13
Silicon 28.09 2.33

Mangancse $4.94 467 7.43

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