solved questions

SOLVED QUESTIONS

1. Define the various tool parts of a single point cutting tool with a neat sketch.

[Dec '07 & June '09]

Refer chapter 1.4.1 on Page 1.6.

2. Detail the nomenclature of single point cutting tool with illustrative sketches. [Nov '18]

Refer chapter 1.4.2 on Page 1.6.

3. Define tool signature. How is it related to tool geometry?

[KTU Dec'17]

Refer chapter 1.6 on Page 1.12.

4. Sketch the top view, front view and end view of a 25-mm square bit having tool signature of 15-15-10-10-15-10-3 and label all parts.

[KTU Dec '17]

Refer chapter 1.6 on Page 1.12 and refer chapter 1.4.2 on Page 1.6.

5. With the neat sketch, describe the various types of chips produced during metal machining. 

[Dec '07, Nov '17 & Nov'18]

Refer chapter 1.12 on Page 1.19.

6. What is meant by orthogonal cutting and oblique cutting?

[May '10]

Refer chapters 1.9.1 and 1.9.2 on Page 1.15.

7. Explain in detail Orthogonal and Oblique cutting.

[Nov '19]

Refer chapter 1.9 on Page 1.15.

8. What is orthogonal rake system? Show the ORS of tool analysis with the help of a sketch.

[Dec '08]

Refer chapter 1.9.1 on Page 1.15.

9. How is metal removed in metal cutting? Explain the process with simple sketch.

[May'11, May 12 & May'14]

Refer chapter 1.10 on Page 1.16.

10. Describe the mechanism of chip formation.

[Apr'17]

Refer chapter 1.11 on Page 1.17.

11. Discuss the various types of chips produced during metal machining.

[Dec '05, Dec '06, Nov '09, May '10, May'11, May'15 & Nov'17]

Refer chapter 1.12 on Page 1.19.

12. Explain the conditions that promote the formation of the following types of chip:

[Dec '07]

(i) Continuous chips.

Refer chapter 1.12.1 on Page 1.19.

(ii) Continuous chips with builtup edge.

Refer chapter 1.12.3 on Page 1.21.

(iii) Discontinuous chips.

Refer chapter 1.12.2 on Page 1.20.

13. Draw the schematic diagram illustrating the characteristics of Built-up-Edge (BUF) formation in the machining process.

[Apr'18]

Refer chapter 1.12.3 on Page 1.20.

14. What is the use of a chip breaker? Discuss the various types of chips produced during metal machining process.

[Anna Univ. Dec '08]

Refer chapter 1.13 on Page 1.24 for chip breaker and refer chapter 1.12 on Page 1.19 for various types of chips produced during metal machining.

15. Identify the four forces that act upon the chip in the orthogonal metal cutting model and draw the merchant circle and identify these forces.

[Apr'19]

Refer chapters 1.14 & 1.15 on Pages 1.25 & 1.27 respectively.

16. Describe an expression for the determination of shear angle in-orthogonal metal cutting.

 [Dec '06 & May'10]

Refer chapter 1.15 on Page 1.27.

17. Explain "Merchant force circle” along with assumptions.

or

Clearly explain the utility of Merchant's Circle Diagram. How it can be plotted?

 [KTU Dec'17]

Refer chapter 1.15 on Page 1.27.

18. Prove that in orthogonal cutting, the kinetic coefficient of friction (μ) is given by

[Anna Univ. May'15]

Refer chapter 1.15 on Page 1.27.

19. What are the three main regions of heat generation in metal cutting?

[Apr'19]

Refer chapter 1.27 on Page 1.63.

20. Enumerate the essential requirements of the tool material. 

[May '13, May'14 & Nov'17] 

Refer chapter 1.26.1 on Page 1.58.

21. Mention the desirable properties of a cutting tool material and the improvements caused by coated carbides. 

[Dec '11 & Nov'15]

Refer chapter 1.26.1 on Page 1.58 for properties of a cutting tool material and Page 1.61 for improvements caused by coated carbides.

22. List the various tool materials used in industry. State the optimum temperature of each of the tool materials. 

[Anna Univ. May '11, May'13, Nov '13, May '14 & May'16]

Refer chapter 1.26.2 on Page 1.59.

23. With a suitable example, explain the technical and economic factors involved in cutting tool material selection.

[Nov '17]

Refer chapter 1.26.3 on Page 1.63.

24. Discuss the advantages and limitations of the following cutting tool materials.

[Dec '11]

( 1) Cemented carbides

Refer Page 1.61.

(2) Cubic Boron Nitride.

Refer Page 1.63.

Also state the desirable characteristics of a cutting tool material.

Refer chapter 1.26.1 on Page 1.58.

25. Write a note on heat generation in metal cutting. What is the importance of analysing the thermal aspects of machining?

[Anna Univ. Apr'18]

Refer chapter 1.27 on Page 1.63.

26. Enumerate with a neat sketch, measurement of cutting temperature using work-tool thermocouple method.

[Anna Univ. May'16]

Refer chapter 1.28.1 on Page 1.65.

27. Explain in detail tool wear and also factors influencing tool wear.

[Nov '19]

Refer chapters 1.29 & 1.29.1 on Pages 1.66.

28. Name the three models of tool failure in machining and identify the two principal locations on a cutting tool where tool wear occurs?

[Apr'19]

Refer chapter 1.29 on Page 1.66.

29. Explain the mechanism associated with progressive tool wear. 

[Apr'17]

Refer chapter 1.29.2 on Page 1.67.

30. Discuss briefly the various types of tool wear with neat sketches.

[Dec '06, Nov'13 & Nov'15]

Refer chapter 1.29.2 oŋ Page 1.67.

31. What is tool life?

 [Dec '06]

Refer chapter 1.30 on Page 1.69.

32. What is useful life of a tool? What are the factors affecting the tool life? How these factors are related in Taylor's tool life equation?

[Anna Univ. Apr'17]

Refer chapter 1.30 on Page 1.69.

33. State the parameters that influence the life of tool and discuss. 

[Dec '05 & May'10]

Refer chapter 1.30.1 on Page 1.69.

34. Define machinability. What are the factors influencing machinability of a cutting tool?

[Nov '19]

Refer chapters 1.32 & 1.32.1 on Page 1.74.

35. What is the measure of metal removing process machinability? What are the factors that affect it?

[Dec '05]

Refer chapter 1.32 and 1.32.1 on Page 1.74.

36. Write short notes on the following:

[Nov '18]

(1) Rake angles

Refer chapter 1.5 on Page 1.9.

(2) Cutting fluids.

Refer chapter 1.35 on Page 1.90.

37. Detail on the desirable properties of cutting fluids. 

[Nov 19]

Refer chapter 1.35.2 on Page 1.91.

38. What is the main function of cutting fluids? And its types.

 [Dec '09, May '13, Nov '13 & May'14]

Refer chapter 1.35.1 on Page 1.90 for main function and chapter 1.35.3 on Page 1.92 for types.

39. Describe the following:

[Apr'18]

 (i) Mechanisms and pattern (geometry) of cutting tool wear.

Refer chapter 1.29.1 on Page 1.66.

(ii) Essential properties of cutting fluids.

Refer chapter 1.35.2 on Page 1.91.

40. What are the functions of a cutting fluid? Explain in detail, the guidelines adopted for the selection of cutting fluid based on material and tool characteristics.

[Nov '09 & Nov '15]

Refer chapter 1.35.1 on Page 1.90 for main function and on Page 1.93 for selction of cutting fluids.

41. Describe the various methods of applying cutting fluid at the cutting zone.

[May'15]

Refer chapter 1.35.4 on Page 1.94.

42. State any six advantages of using cutting fluids during machining.

 [KTU Dec'17]

Refer chapter 1.35.5 on Page 1.94.