Solved Questions

SOLVED QUESTIONS

1. Describe the principle of operation of a shaper with a neat sketch.

[Dec '10]

Refer chapter 3.1.4 on Page 3.3.

2. Explain the hydraulic drive mechanism of a horizontal shaper with a neat sketch.

 [May'14 & Apr'18]

Refer chapter 3.1.5.1 on Page 3.6.

3. Enumerate any two advantages of a hydraulic drive.

[Dec '08, May'11 & Dec'11]

Refer Page 3.7.

4. Describe the working of a crank and slotted link mechanism.

[Nov '03, Dec '10 & May '17]

Refer chapter 3.1.5.2 on Page 3.7.

5. Describe with neat sketch Whitworth quick return mechanism used in a shaper.

[June '06 & Nov '15]

Refer chapter 3.1.5.3 on Page 3.8.

6. How the stroke length and position of the ram is adjusted?

 [Nov '15]

Refer Page 3.10 for stroke length adjustment and Page 3.11 for position adjustment.

7. With the help of a fully labelled schematic diagram, explain the kinematic system provided in shaping machine for transmitting power and motion from the motor to the tool and job at desired speeds and feeds. 

[KTU Dec'17]

Refer chapter 3.1.5.2 on Page 3.7.

8. Explain with neat sketches the procedure for carrying out the following operations on a shaper: Horizontal cutting, vertical cutting, concave surface, keyway cutting.

[May'15]

Refer chapter 3.1.9.1-3.1.9.5 on Page 3.16-3.18.

9. With the help of neat sketches explain any two operations (other than machining of flat surfaces) that can be carried out using a shaping machine.

[KTU Dec '17]

Refer chapters 3.1.9.2 & 3.1.19.3 on Page 3.17.

10. How do you specify a planer?

[Apr '04]

Refer chapter 3.2.3 on Page 3.30.

11. Explain with a sketch "Fast and Loose pulleys" quick return mechanism of a planer table.

[Dec '07]

Refer chapter 3.2.4.1 on Page 3.31.

12. State the advantages of Ward-Leonard drive.

 [Dec '07]

Refer chapter 3.2.4.2 on Page 3.32.

13. Explain the different types of table drive and feed mechanisms in a planning machine.

[June'09]

Refer chapter 3.2.5 on Rage 3.33.

14. Write down any four differences between shaper and planer.

[Nov 03, Nov'04 Nov'05 & Dec'06]

Refer chapter 3.2.10 on Page 3.38.

15. Compare and contrast (differentiate) shaping machine, slotting machine and planing machine.

[KTU Dec'17]

Refer chapter 3.2.10 on Page 3.38 and chapter 3.3 on Page 3.39.

16. Make a note on different types of work holding devices used in a slotting machine.

[June '09]

Refer chapter 3.3.7 on Page 3.44.

17. Sketch and explain the working principle of upright drilling machine.

[Dec '06]

Refer chapter 3.4.1.3 on Page 3.50.

18. Sketch a fully labelled schematic diagram of a Radial Drilling Machine. List any four key design features that make it popular. 

[KTU Dec '17 & Anna Univ. Dec '10 & Dec'11]

Refer chapter 3.4.1.4 on Page 3.52.

19. Write a short note on BTA deep hole drilling.

[Nov '13 & May '14]

Refer chapter 3.4.1.8 on Page 3.55.

20. Discuss the various hole making processes.

[May'11]

Refer Page 3.58.

21. Sketch the following operations performed in drilling machine.

(1) Drilling

(2) Reaming

(3) Boring

(4) Counter boring

(5) Counter sinking

(6) Spot facing.

(7) Tapping

(8) Trepanning

Add one or two lines of explanation for each.

[May '10, May '12 & May'16]

Refer chapter 3.4.4 on Page 3.58.

22. With simple line diagram explain the various operations performed in a drilling machine. Also give salient features to explain reasons why a radial drilling machine is called as a versatile machine. 

[Apr '19] 

Refer chapter 3.4.4 on Page 3.58 for operations performed in drilling and chapter 3.4.1.4 on Page 3.52 for radial drilling.

23. Summarize the different operations performed using driller and shaper machine. 

[Nov '18]

Refer chapter 3.4.4 on Page 3.58 for driller operations and chapter 3.1.9 on Page 3.16 for shaper operations.

24. Explain the counter boring and counter sinking operation.

[Nov '04]

Refer Page 3.59 for counter boring and for counter sinking.

25. Sketch a twist drill and label.

[Apr '04, Dec '08, June '09 &May'17]

Refer chapter 3.4.5 on Page 3.61.

26. Write short note on reaming operation.

[Dec '08 & May'14]

Refer Page 3.58.

27. Identify the possible causes for the following problems in drilling:

i) Drill breakage ii) Oversized hole

iii) Rough hole iv) Breakage of outer corners of cutting edges. 

[KTU Dec '17]

Refer chapter 3.4.7 on Page 3.66.

28. With neat sketches, explain the working of a vertical boring machine.

[Apr '04 & May'13] 

Refer chapter 3.6.4 on Page 3.79.

29. Write short notes on boring operations.

[Dec '08]

Refer chapter 3.6.5 on Page 3.80 for horizontal boring machine operations and chapter 3.6.6 on Page 3.81 for vertical boring machine operations.

30. With a neat sketch, describe the working principle of a Jig boring machine. State its applications.

[Dec '11]

Refer chapter 3.6.8 on Page 3.84.

31. Describe the horizontal knee type milling machine with a suitable sketch.

[June '06, Dec '10 & May'13]

Refer chapter 3.8.1.1 on Page 3.87.

32. With the help of a neat sketch explain a Vertical milling machine.

[Nov '19]

Refer Page 3.89.

33. State the difference between horizontal and vertical spindle column and knee type milling machines (use simple sketches).

[Nov '13]

Refer Pages 3.87-3.89.

34. Describe a Universal type milling machine.

[May'15]

Refer Page 3.91.

35. Compare plain and universal milling machine.

[May'15]

Refer Page 3.92.

36. State the methods of holding milling cutters.

 [Dec '07]

Refer chapter 3.8.6 on Page 3.100.

37. With a neat sketch, indicate the various parts of an arbor assembly.

[Nov '03]

Refer Page 3.101.

38. With the help of simple sketches, explain any three common attachments used in milling Machines. 

[KTU Dec '17]

Refer chapter 3.8.7 on Page 3.103.

39. What are the various types of milling cutters that are used in milling? Discuss any three. 

[Nov '05 & May '16]

Or

Classify the different types of milling cutter and outline each with illustrative sketch.

[Nov'18]

Refer chapter 3.8.8 on Page 3.104.

40. Describe the construction of the following milling cutters.

(1) Plain milling cutters

[Apr '04 & Dec '11]

Refer chapter 3.8.8.1 on Page 3.105.

(2) End mills.

 [June '09 & Dec '11]

Refer chapter 3.8.8.3 on Page 3.106.

41. List out the various milling operations.

[Nov '05, May'13 & Nov '17]

Refer chapter 3.8.13 on Page 3.120.

42. Explain the following milling operations:

[Nov '18]

(1) Form milling

Refer Page 3.122.

(2) Gang milling

Refer Page 3.122.

43. How will you cut the following types of surfaces on milling machines?

[May'11]

( 1) Flat surfaces

Refer Page 3.120.

(2) Slots and Splines.

Refer Pages 3.122 & 3.123.

44. Explain the indexing mechanism of a dividing head on milling machine.

[May '14]

Refer chapter 3.8.16.2 on Page 3.128.

45. Describe the working mechanism of a universal dividing head, with neat diagrams.

[Apr '04 & June’06]

Refer chapter 3.8.16.2 on Page 3.128.

46. Explain simple indexing, compound indexing and differential indexing with suitable examples. 

[Dec '07]

Refer chapter 3.8.17.2 on Page 3.131 for simple indexing, chapter 3.8.17.3 on Page 3.131 for compound indexing and chapter 3.8.17.4 on Page 3.133 for differential indexing.

47. Explain the gear cutting by a formed tool.

[Nov '04 & Dec'10]

Refer chapter 3.8.21.1 on Page 3.141.

48. Enumerate with neat sketch kinematics of gear shaping machine.

Or

[May '10, Dec'10, May'15& May'16]

Write short notes on gear shaping. List the advantages and disadvantages of gear shaping process.

[Apr'18]

Refer chapter 3,8.22.1 on Page 3.144.

49. Describe any two methods of gear generation that suits mass production. 

[May '17]

Refer chapters 3.8.22.1 & 3.8.22.2 on Pages 3.144 & 3.147 respectively.

50. List the advantages, disadvantages and limitations of gear shaping process.

[Nov '17]

Refer Page 3.147.

51. Explain the principle of operation of gear hobbing operation. What are the advantages of gear hobbing? 

[Nov '03, June '06, Nov '06, Nov '07, May '10, Dec '11 Nov '17 & Nov '19]

Refer chapter 3.8.22.3 on Page 3.149.

52. List out the gear finishing processes. Explain any two with neat sketches.

Or

[June '06, May '15 & May'16]

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

[May '14 & Nov'17]

Refer chapter 3.8.24 on Page 3.152.

53. Explain the following with a neat sketch:

[Nov '15]

(i) Gear generation process

Refer chapter 3.8.22 on Page 3.144.

(ii) Gear finishing process.

Refer chapter 3.8.24 on Page 3.152.

54. Give the advantages and limitations of gear hobbing.

[Apr '04& Nov '05]

Refer Page 3.152.

55. Compare the gear hobbing process over any other (One) type of gear generation processes.

[Nov'18]

Refer chapter 3.8.23 on Page 3.152.

56. Explain the gear shaving process. [June '09]

Or

Explain the working principles of gear shaving process.

 [Apr'19]

Refer chapter 3.8.24.1 on Page 3.153.

57. Describe any two gear finishing operations based on plastic deformation. 

 [May '17]

Refer chapter 3.8.24.2 & 3.8.24.3 on Page 3.154 & 3.155 respectively.

58. Explain with neat sketches the following operation: honing and lapping.

[Nov '08 & June '09]

Refer chapter 3.8.24.6 on Page 3.160 for honing and chapter 3.8.24.5 on Page 3.159 for lapping.

59. Write a short note on the self-sharpening characteristic of a grinding wheel.

[KTU Dec '17 & Anna Univ. Nov '07]

Refer Page 3.164.

60. Classify the grinding machines.

[May'13]

Refer chapter 3.9.2 on Page 3.165.

61. Explain the working principle rough grinders and discuss any two in brief.

Refer chapter 3.9.2.1 on Page 3.167.

62. Explain the abrasive belt grinding with diagram.

[Nov'06 & May'14]

Refer chapter 3.9.2.5 on Page 3.168.

63. With the help of sketches, describe any two methods of cylindrical grinding.

[Dec'11]

Refer Page 3.171.

64. Explain the working mechanism of cylindrical and surface grinding.

[Nov '04, June '06, Dec '10 & Apr'18]

Refer chapter 3.9.3.1 on Page 3.171 for cylindrical grinding and chapter 3.9.4 on Page 3.173 for surface grinding.

65. Discuss in detail any two types of surface grinding process with neat sketches. 

[Nov'18] 

Refer chapters 3.9.4.1 & 3.9.4.2 on Pages 3.174 & 3.175 respectively.

66. With the help of a block diagram describe a Vertical spindle rotary-table grinder.

[Apr'19]

Refer chapter 3.9.4.4 on Page 3.176.

67. Explain the working principle of centreless grinding process.

 [June '09, May '13, Nov '17, Apr'18 & Apr'19]

Refer chapter 3.9.5 on Page 3.177.

68. Explain with neat sketches the three methods of external cylindrical centreless grinding. 

[Nov 04, May '10, May '12 & May '16]

Refer chapter 3.9.5.1 on Page 3.178.

69. Enumerate the advantages and disadvantages of centreless grinding.

[May'15]

Refer Page 3.179.

70. Define the term grinding ratio, G, and discuss the parameters which influence the grinding ratio.

[Apr'19]

Refer chapter 3.9.7.3 on Page 3.184.

71. The base of a brass bracket has to be rough ground to remove the unevenness. Suggest the most suitable grinding wheel for this purpose. Justify the choice of the wheel also. 

[KTU Dec '17 & Anna Univ. Nov'13]

Refer chapter 3.9.8.7 on Page 3.187.

72. Describe the use of cutting fluids in grinding.

[Nov '07]

Refer chapter 3.9.9 on Page 3.188.

73. Explain the applications of various types of abrasives.

 [Nov '19]

Refer chapter 3.9.10.1 on Page 3.189.

74. Why is aluminium oxide preferred to silicon carbide in grinding steel?

[Apr'19]

Refer Page 3.190.

75. List out various abrasives used in grinding wheel. Explain any three.

[June '09 & May'16]

Refer chapter 3.9.11 on Page 3.191.

76. Discuss the various bonding materials used for making grinding wheels. 

[Nov 04, May 11, May 14, May'16 & Nov'17]

Refer chapter 3.9.11 on Page 3.191.

77. What is the short coming of vitrified bond?

[Apr'19]

Refer Page 3.192

78. Discuss briefly the standard specification of grinding wheel.

[May '17]

Refer chapter 3.9.12 on Page 3.194.

79. Why is coarse grain and open structured wheel is preferred for stock removal grinding?

[Apr'19]

Refer chapter 3.9.12.1 on Page 3.194.

80. Give the specification of grinding wheel.

[Nov '05 & May'10]

Refer chapter 3.9.12 on Page 3.194.

81. The performance of a grinding wheel depends upon type of abrasive, grain size, grade, structure and bonding material. Discuss the effect of each.

[May '15]

Refer chapter 3.9.12.1-3.9.12.3 on Page 3.194 & 3.195.

82. Explain the factors to be considered to select a grinding wheel and recommended parameters. 

[May'12 & May'17]

Refer chapter 3.9.14 on Page 3.196.

83. Explain the following in grinding (1) Dressing and (2) Truing.

[Nov'07, May'10, May'15 & Nov'15]

Refer chapter 3.9.17 on Page 3.199 for dressing and chapter 3.9.18 on Page 3.200 for truing of grinding wheels.

84. Explain how a wheel is balanced and mounted?

[Nov '15]

Refer chapter 3.9.20 on Page 3.202.

85. Discuss the concept of surface integrity.

Or

 [Nov '17]

State the effect of surface grinding on deciding the surface roughness of a component.

[Nov '18]

Refer chapter 3.9.21 on Page 3.202.

86. Explain with neat sketches the following operation: honing and lapping.

[Nov '08 & June '09]

Refer chapter 3.10.3 on Page 3.209 for honing and chapter 3.10.2 on Page 3.206 for lapping.

87. Differentiate between up-milling and down milling operations.

[KTU Dec'17]

Refer Q86 on Page 3.232.