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IES1995Consi er t e o owing statements a out noseradius
1. It improves tool life
2. re uces e cu ng orce
3. It improves the surface finish.Select the correct answer using the codes given below:
a 1 an 2 2 an 3
(c) 1 and 3 (d) 1, 2 and 3
Ans. (c)
IES1994
the following elements:
.
2. Side rake angle
3. End cutting edge angle
4. Side cutting edge angle5. Side relief angle
6. End relief an le
7. Nose radius
correctly specifying the tool geometry is
a 1,2,3, ,5,4,7 1,2, ,5,3,4,7
(c) 1,2,5,6,3,4,7 (d) 1, 2, 6, 3, 5, 4,7 Ans. (b)
IES2009
The following tool signature is specified foint cuttin tool in American s stem:
10, 12, 8, 6, 15, 20, 3
W at oes t e ang e 12 represent?
(a) Side cuttin ed ean le(b) Side rake angle
c Bac ra e ang e
d Side clearance an le
Ans. (b)
IES1993In ASA System, if the tool nomenclature is 8655101 2mm then the side rake an le will be
(a) 5 (b) 6 (c) 8 (d) 10
Ans.
cu ng oo av ng oo s gna ure as 10, 9, , ,
8 8 2 will haveside rakean le
(a) 10o (b) 9o (c) 8o (d) 2o
Ans. (b)
GATE2008In a sing e point turning too , t e si e and orthogonal rake angle are equal.principal cutting edge angle and its range
o o . The value of is closest to
(a) 00
(b) 450
c 600 d 900
Ans. (d) principal cutting edge angle is = 9
GATE2001
During orthogonal cutting of mild steel with ,
was obtained as 0.4. The shear angle (indegrees) evaluated from this data is
a .53 20.22
c 22. d 0.00
Ans.(c)
GATE2011A single point cutting tool with 12 rakused to machine a steel work iece. Thecut, i.e. uncut thickness is 0.81 mm.
1.8 mm. The shear angle is approximately
a 22
b 26(c) 56
76
Ans. b
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IES2004,ISRO2009T e ra e ang e o a cutting too is 15, s earan le and cuttin velocit m min.What is the velocity of chip along the tool
ace
. .(c) 25.3 m/min (d) 23.5 m/min
Ans. (a)
IES2008onsi ert e o owingstatements:
Inanorthogonalcuttingthecuttingratioisfoundtobe075.Thecuttingspeedis60m/minanddepthofcut24mm.Whichofthefollowingarecorrect?
1. Chipvelocitywillbe45m/min.
2. pve oc yw e 0m m n.
3. Chipthicknesswillbe18mm.
4. Chipthicknesswillbe32mm.
(a) 1and3 (b) 1and4
(c) 2and3 (d) 2and4 Ans. b
IES2001I is t e ra e ang e o t e cutting tooshear an le and V is the cuttin velocit velocity of chip sliding along the sheag ven y
(a) (b)cosV sincos
V
c Anssin( ) sin( )
IES2003An ort ogona cutting operation is eingcarried out under the followin conditions:cutting speed = 2 m/s, depth of cut = 0.5 mm,c p c ness = 0. mm. en e c pvelocit is
(a) 2.0 m/s (b) 2.4 m/s
(c) 1.0 m/s (d) 1.66 m/s Ans. (d)
IAS2003nort ogona cutting,s earang eist eang e etween
(a) Shearplaneandthecuttingvelocity
(b) Shearplaneandtherakeplane
(d) Shearplaneandthedirectionofelongationofcrystalsin
t e
c p
Ans.(a)
IAS2002
IAS2000
Ans.(d)
IAS1998e cutting ve ocity in m sec, or turning a wor piece
of diameter 100 mm at the spindle speed of 480 RPM is
(a) 1.26 (b) 2.51
c 8 d 1 1
ns.
IAS1995n an ort ogona cutting, t e ept o cut is
the feed rate is double. If the chip thicknunaffected with the changed cutting condactual chip thickness will be
(a) Doubled (b) halved
.
Ans. b
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IES1998
The gauge factor of a resistive pickup of
ratio of
(a) Applied strain to the resistance of the wire
T e proportiona c ange in resistance to t ea lied strain
(c) The resistance to the applied strain
(d) Change in resistance to the applied strain
ns.
IES2000
Assertion (A): In metal cutting, the normal.
Reason (R : Ver hi h tem erature isproduced at the toolchip interface.
a Bot A an R are in ivi ua y true an R isthe correct ex lanation of A
(b) Both A and R are individually true but R isnot the correct explanation of A
d A is false but R is true Ans. (a
GATE1992The effect of rake angle on the mean fric
(A) sliding (Coulomb) model of friction
(B) sticking and then sliding model of friction
(D) Sliding and then sticking model of frictio
.
IES2004ssertion : e ratio o uncut c ip t ic ness to
actual chip thickness is always less than one and istermed as cutting ratio in orthogonal cutting
Reason (R): The frictional force is very high due to theoccurrence of sticking friction rather than slidingfriction
(a) Both A and R are individually true and R is the correct
(b) Both A and R are individually true but R is not thecorrect exp anat on o
(c) A is true but R is false
(d) A is false but R is true Ans. (b)
GATE1993The effect of rake angle on the mean friction angle in
(a) Sliding (coulomb) model of friction
(b) sticking and then siding model of friction
(d) sliding and then sticking model of friction
Ans. (b)
ToolWear,ToolLife&ToolWear,ToolLife&MachinMachin
y
y Ex lainsuddendeathmechanismoftoolfailure.
[4 marks]
IES2009ConventionalShowcraterwearandflankwearonasinglepoint
.onaturningtool.
2mar s
IES2010
an wear occurs on e
a Relief face of the tool
(b) Rake face
(c) Nose of the tool
utt ng e ge
Ans. (a)
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IES 2008W ataret ereasons orre uctiono too i eina
machiningoperation?
1. Temperatureriseofcuttingedge
2. pp ngo oo e ge ue omec an ca mpac
3. Gradualwearsattoolpoint4. Increaseinfeedofcutatconstantcuttingforce
e ec ecorrec answerus ng eco eg venbelow:
(a) 1,2and3 (b) 2,3and4
, , .
IAS 2002Consi ert e o owing actions:
1. Mechanical abrasion 2. Diffusion
3. Plasticdeformation 4. Oxidation
W c o t e a ove are t e causes o too wear?
a 2 and b 1 and 2(c) 1, 2 and 4 (d) 1 and 3
Ans. c
IAS 1999T e type o wear t at occurs ue to taction of the particles in the cuttinreferred to as
(b) Diffusion wear
(c) Erosive wear
Ans. (c)
IAS 2003Consi er t e o owing statements:
Chi in of a cuttin tool is due to
1. Tool material being too brittle
2. Hot ar nesso t e too mater a .
. Hi h ositive rake an le of the tool.
Which of these statements are correct?a 1, 2 an 3 1 an 3
c 2 and d 1 and 2
Ans. (b)
IES 2012InTay or stoo eequat onVTn =C,t econstantsn
andCdependupon
1.Workpiecematerial
.
3.Coolant
(a)1,2,and31an 2on y
(c)2and3only
(d)1and3only
ns. a
e e p o ay or s oo e e
of cutting and life of the tool. Assume an H
and steel as work material.
[10
IES1996C ip equiva ent is increase y
(b) An increase in nose radius and side cuttingedge angle of tool
c ncreas ng t e p ant area o cut
.Ans. (b)
IES 1992Too i eisgenera yspeci ie y
(a) Numberof iecesmachined
(b) Volumeofmetalremoved
c Actua cutt ngt me
d An oftheabove
Ans.(d)
GATE2004In a mac ining operation, ou cuttin s eed reduces the tool life the original value. The exponent n inoo e equa on = , s
1 1 1
8 4 3 a c
Ans. c
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IES 2000In a too i e test, ou ing t e cutting speereduces the tool life to 1/8th of the original. TheTaylor's tool life index is
( ) ( ) ( ) ( )1 1 1 1
a b c d 2 3 4 8
Ans. b
IES 1999Inasing epointturningoperationo steewit a
cementedcarbidetool,Taylor'stoollifeexponentis0.25.Ifthecuttingspeedishalved,thetoollifewillincreaseb
(a) Twotimes (b) Fourtimes
c Eig ttimes Sixteentimes
Ans.(d)
IES 2008InTay or stoo i eequationisVTn =const
Whatisthevalueofnforceramictools?
(a) 0.15to0.25 (b) 0.4to0.55
c 0.6to0.75 0.8to0.9
Ans.(c)
IES 2006W ic o t e o owing va ues o in ex n isassociated with carbide tools when Taylor's tool lifeequation, V.Tn = constant is applied?
(c) 0.45 to 06 (d) 065 to 09
.
IES 1999T e approximate y variation o t e too i eexponent 'n' of cemented carbide tools is
(a) 0.03 to 0.08 (b) 0.08 to 0.20
. . . .
Ans. (c)
IAS 1998a c s u ng oo ma er a w s
(Typicalvalueoftoollifeexponent'n'intheTn . =
thecodesgivenbelowthelists:
s s
A. HSS 1. 0.18
B. Castalloy 2. 0.12
C. Ceramic 3. 0.25
D. Sinteredcarbide 4. 0.5
(a) 1 2 3 4 (b) 2 1
c 2 1 4 3 1 2
n an or ogona mac n ng opera on, e oo e
,
while at 75 m/min cuttin s eed, the tool life is 30
min. The value of index (n) in the Taylors tool life
equation
(a) 0.262 (b) 0.323 (c) 0.423 (d) 0.521
Ans. (a)
ISRO2011
A 50 mm diameter steel rod was turned at 284 rpm and
tool failure occurred in 10 minutes. The speed was
c a nge to 232 rpm an t e too a e n 0 m nutes.
s eed and tool life, the value of Ta lorian Ex onent is(a) 0.21 (b) 0.13 (c) 0.11 (d) 0.23
Ans. (c)
IES2010The above figure shows a typicalrelationship between tool life andcutting speed for differentmaterials. Match the graphs for
, ar e an eram c toomaterials and select the correctanswer us ng e co e g venbelow the lists:
Co e: HSS Car i e Ceramic
(a) 1 2 3
(b) 3 2 1
c 1 2 (d) 3 1 2
ns.
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IAS 2002Usingt eTay orequationVTn =c,ca cu atet e
percentageincreaseintoollifewhenthecuttingspeedisreducedby50%(n=05andc=400)
(c) 100% (d) 50%
Ans.(a)
IAS 2002Optimum cutting spee or minimum cost Vc minand optimum cutting speed for maximumproduction rate (Vr max ) have which one of thefollowin relationshi s?
(a) Vc min = Vr max (b) Vc min > Vr maxc Vc min < Vr max V
2c min = Vr max
Ans. (c)
IES2010ncreas ng cu ng ve oc y,
time for machining a component
(a) Decreases
(b) Increases
d First decreases and then increases
Ans. (d)
IAS 2000Consi ert e o owingstatements:
Thetoollifeisincreasedb
1. Built upedgeformation
2. Increas ngcutt ngve oc ty
. Increasin backrakean leu tocertainvalue
Whichofthesestatementsarecorrect?a 1an 3 1an 2
c 2and d 1 2and
Ans.(a)
IAS 1997In t e Tay or s too i e equation, VTn = C, t e va ueof n = 0.5. The tool has a life of 180 minutes at acutting speed of 18 m/min. If the tool life is reducedto minutes then the cuttin s eed will be
(a) 9 m/min (b) 18 m/min
c 36 m/min 72 m/min
Ans. (c)
IAS 1996T etoo i eincreaseswit t e
(a) Increaseinsidecuttin ed ean le
(b) Decreaseinsiderakeangle
c Decrease nnosera us
d Decreaseinbackrakean le
Ans. a
IAS 1995
Inasing epointturningoperationwit acemente carbideandsteelcombinationhavingaTaylorexponentof0.25,ifthecuttingspeedishalved,thenthetoollifewillbecome
(a) Half
(b) Twotimes
c Ei httimes(d) Sixteentimes.
Ans. d
IAS 1995
Assertion A : An increase in ept o cut s ortensthe tool life.
Reason(R): Increases in depth of cut gives rise to.
(a) Both A and R are individually true and R is thecorrect explanation of A
b Both A and R are individuall true but R is not thecorrect explanation of A
c s rue u s a se
(d) A is false but R is true [Ans. (a)]
IES 2006
conventional
An HSS too is use or turning operatool life is 1 hr. when turnin is carm/min. The tool life will be reduced to
e cu ng spee s ou e . n s eed in RPM for turnin 00 mm dithat tool life is 30 min.
Ans. (36.66 rpm)
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IES 1995 IES 1992
IAS 1996
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IES 1995In owcar onstee s,presenceo sma quantities
sulphur improves
(a) Weldability (b) Formability
c ac na y ar ena y
Ans.(c)
IES 1992Mac iningo titaniumis i icu t ueto
(a) Hi hthermalconductivit oftitanium
(b) Chemicalreactionbetweentoolandwork
c Lowtoo c pcontactarea
d None
of
the
above
Ans. b
IAS 1996Assertion A :T emac ina i ityo amate
bemeasuredasanabsolutequantity.
Reason(R):Machinabilityindexindicates
(a) BothAandRareindividuallytrueandRcorrectexp anationo A
b BothAandRareindividuall truebutRicorrectexplanationofA
c s rue u s a se
(d) AisfalsebutRistrue
Ans.(d)
GATE2009Frictionatt etoo c ipinter acecan e
reducedb
(a)decreasingtherakeangle
(b)increasingthedepthofcut
c ecreas ngt ecutt ngspee
Ans.(d)
IES 2002T e va ue o sur ace roug ness o taine uringthe turning operating at a feed 'f' with a round nosetool having radius 'r' is given as
.
IAS 1996Given t at
S = feed in mm/rev. and
R = nose radius in mm,
t e max mum e g t o sur ace roug produced by a singlepoint turning tool is give
(a) S2
/2R4
(c) S2/4R
(d) S2/8R
ns.
IES
1999In turning operation, t e ee cou e ou e toincrease the metal removal rate. To keep the samelevel of surface finish, the nose radius of the toolshould be
(a) Halved (b) Kept unchanged
(c) doubled (d) Made four times
Ans. d
GATE
1997Acuttingtoo asara iuso 1.8mm.T e ee rate
foratheoreticalsurfaceroughnessofRa =5 mis
(a) 0.36mm/rev
.
(c) 0.036mm/rev
(d) 0.0187mm/rev
Ans.(none)
GATE 2007
(PI)
oo w e u ng ge ang e oEnd Cutting Edge angle of 10o is useturning with a feed of 1 mm/rev. Negle
,height of surface roughness produced w
(a) 0.16 mm (b) 0.26 mm
c 0.32 mm 0.48 mm.
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IES 2011 GATE 2003
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IES2011Assertion (A): Lead, Zinc and Tin are always hotworked.
Reason (R) : If they are worked in cold state.
(a) Both A and R are individually true and R is thecorrect explanation of A
the correct explanation of A
(c) A is true but R is false
d A is false but R is true Ans. b
GATE2003Co wor ing o stee is e ine as wor in
(a) At its recr stallisation tem erature
(b) Above its recrystallisation temperature
c Be ow ts recrysta sat on temperature
d At two thirds of the meltin tem erametal
Ans. (c)
GATE2002,ISRO2012Hotro ing o mi stee iscarrie out
(a) At recr stallisation tem erature
(b) Between 100C to 150C
c Be ow recrysta sat on temperature
d Above recr stallisation tem erature
Ans.
a er a s a er co wor ng are su ec e o
o ow ng process o re eve s resses
a ot wor ng
(b) Tempering(c) Normalizing
(d) Annealing Ans. (d)
IES 2006W ic one o t e o owing is t e procesthe grains of metal after it has been dihammering or cold working?
(c) Recrystallizing (d) Normalizing
Ans. (c)
IES 2004
Consi er t e o owing statements:
In com arison to hot workin , in cold workin ,
1. Higher forces are required
2. No eat ng s requ re
. Less ductilit is re uired
4. Better surface finish is obtained
Which of the statements given above are correct?a 1 2 and b 1 2 and
(c) 1 and 3 (d) 2, 3 and 4
Ans. (b)
IES 2009
Consi er t e o owing c aracteristics:
1. Porosit in the metal is lar el eliminated.
2. Strength is decreased.
3. C ose to erances cannot e ma nta ne .
Which of the above characteristics of hot workin is arecorrect?
a 1 on y 3 on y (c) 2 and 3 (d) 1 and 3
Ans. (d)
IES 2008
Consi er t e o owing statements:
1. Metal formin decreases harmful impurities and improves mechanical strength
.process.
3. Very intricate shapes can be produced
rocess as com ared to castin rocess.Which of the statements given above are corr
a 1, 2 an 3 1 an 2 on y
c 2 and onl d 1 and onl
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IAS 1996
IAS 2004
IAS2002
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IAS 1996For mi stee , t e ot orging temperature range is
(a) 000C to 6000C
(b) 7000C to 9000C
c 10000C to 12000C
d 1 000
Cto 1 000
C
Ans. c
IAS 2004Assertion A : Hot wor ing oes not pro uce strainhardening.
Reason (R): Hot working is done above the re.
(a) Both A and R are individually true and R is the
correct exp anation o Ab Both A and R are individuall true but R is not the
correct explanation of A
c s rue u s a se
(d) A is false but R is true Ans. (a)
IAS 2002Assertion A : T ere is goo grain re inemworking.
Reason (R): In hot working physical prop.
(a) Both A and R are individually true an
correct exp anation o Ab Both A and R are individuall true but R
correct explanation of A
c s rue u s a se
(d) A is false but R is true
Ans. (b) Ulta hai. Assertion reason me hon
IES2008W ic one o t e o owing is correct?
Malleabilit is the ro ert b which a metal oralloy can be plastically deformed by applying
(c) Shear stress (d) Compressive stress
ns.
y on a
c o e o ow ng processes wou
a Hot rollin
(b) Extrusion
(c) Cold rollin
(d) Forging Ans. (c)
Rin rollin is used
(a) To decrease the thickness and increaseameter
(b) To increase the thickness of a rin
(c) For producing a seamless tube
orpro uc ng arge cy n er
Ans. (a)
IES 2006
W ic one o t e o owing is a continuous en ingprocess in which opposing rolls are used to producelong sections of formed shapes from coil or stripstock?
(a) Stretch forming (b) Roll forming
(c) Roll bending (d) Spinning
Ans. (c)
n so ropy n ro e componen s s caus
d rain orientation
Ans. d
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StressEquilibrium
of
an
Element
in
Rolling
xFor sliding friction, = p Simplifying and neglecting
secon or er erms, s n an cos , we ge
d h
=
'
0Due to cold rolling, increases as h decrease
'
0thus nearly a constant and itsderivative zeh
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Considering the thickness of the element perpendicular to the
,
direction as,- + + + -
x
+ 2 R d cos = 0
x x x
d h2 ( )x pR
d
=
'
0 0
2x
p = =
'
2
d
h R =
d
( )'0 '0
1 2h pRd
=
' d p p 'd
0 ' '
0 0d 0
d
( )'0/ 2p Rd
'
0/p h
( )
'
2 1 cosf f
h h R h R = + +
( )0
2'
/ 2d p Rd
=
0 fp
' 2R d 2R0
nf
ph
=+ 2 2
fR h R
=+
2
2Rd 2Rd 2d hI ln
= = = = f
2fh
=R
d hor 2
d R=
2
2 II d
h R=
+
22 d=f
+
f f
2 . tan .h h
=
( )
= + ' 10 h R Rl n p / ln 2 . tan . ln C
f f
' h =
0p e
R
= 1R Rwhere H 2 . tan .
h h
=Now at entry,
=
=0
Hence H H with replaced by inabove equation
= '0
Therefor p
= ' ohIntheentry zone, p C. e
= oH
o
and C .eh
( )= 0 H H'h
. e0
h
n e ex zone
= ' H
0
f
p .eh
At the neutral po int above equati
willgivesameresults
( ) =0 n n H H Hn n
h h. e . e
0 f
. .h h
( )= 0 n H 2Ho
f
or eh
= 0
h1 1
n 0
f2 h
= 1R RFrom H 2 . tan .
f f
=
f f nn
. tan .R R 2
( )= + n f nand h h 2R 1 cos
b
H H
,h
= o b
0
p . eh
fIf front tension is thereat Exit,
( )= Ho fh
p . ef
Calculate the neutral lane to roll 2 0 mannealed copper strip from 2.5 mm to thickness wit 0 mm diameter steel rolls .0.05 and o =180 MPa.
1
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RollingCh14.
1 C
GATE 2010(PI)
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2 B
3 D
4 D
6 A
7 B
8 D
9 C
11 B
12 CB SKMondal
Hot die steel, used for large solid dies in dr
s ou necessari y ave
a g strengt a n g copper content
g ar ness an ow ar ena y
.
a a van ages oes press org ng ave over rop
for in ? Wh are ure metals more easil cold worked
than alloys ?
[5
marks]
ompare m org ng, rop org ng, press
.
for each.
[10 Marks]
ome mes e par ng p ane e ween wo
,
for this design aspect, why is partin
provided, in closed die forging?
[
GATE2007
In open ie orging, a isc o iameter 200 mm anheight 60 mm is compressed without any barrelingeffect. The final diameter of the disc is 400 mm. Thetrue strain is
(a) 1.986 (b) 1.686
(c) 1.386 (d) 0.602
Ans. (c)
GATE1992,
ISRO
2012
Thetruestrainforalowcarbonsteelbarwhichis
(a) 0.307
(b) 0.5
.
(d) 1.0
.
GATE2012
SameQ
GATE
2012
A solid cylinder of diameter 100 mm and
mm is forged between two frictionless fla
.
diameter is
(a)0 (b)2.0 (c)20. (d) 1.
Ans.(d)
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IES 1993Assertion A : Direct extrusion requires arger orce
IES 1994Meta extrusion process is genera y use or
IES 2009W ic one o t e o owing statements is
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q gthan indirect extrusion.
Reason (R): In indirect extrusion of cold steel, zinc.
(a) Both A and R are individually true and R is the
correct exp anation o Ab Both A and R are individuall true but R is not the
correct explanation of A
c s rue u s a se
(d) A is false but R is true Ans.(b)
p g yproducing
(a) Uniform solid sections
n orm o owsec ons
(c) Uniform solid and hollow sections
(d) Varying solid and hollow sections.
ns. c
g
(a) In extrusion rocess, thicker walls can bby increasing the forming pressure
x rus on s an ea process or o a n nmetal having poor density
(c) As compared to roll forming, extruding sp
including the flow of metal being in the same
Ans. (c)
IES 1999W ic one o t e o owing is t e correcttemperature range for hot extrusion of aluminium?
(a) 300340C (b) 350400C
Ans. (c)
IES 2000ons er e o ow ng s a emen s:
In forward extrusion process
1. The ram and the extruded product travel in the samedirection.
2. The ram and the extruded product travel in the oppositedirection.
3. The speed of travel of the extruded product is same as that
of the ram.4. The speed of travel of the extruded product is greater than
that of the ram.
Which of these Statements are correct?
(c) 1 and 4 (d) 2 and 4 Ans. (c)
IES 2009W at is t e major pro em in ot extrusio
(a) Desi n of u nch (b) Desi n of d
(c) Wear and tear of die (d) Wear of pu
Ans. (b)
IES2012
Extrus on process can e ect ve y re uce t e cost oproduct through
(a) Material saving
(c) Saving in tooling cost
(d) saving in administrative cost
Ans. (c)
IES 2008
W ic one o t e o owing met o s is use or t emanufacture of collapsible toothpaste tubes?
(a) Impactextrusion (b) Directextrusion
Ans. (a)
IES 2003
T e extrusion process s use or t e protoothpaste tube is/are
1. Tube extrusion
.
3. Impact extrusion
Select the correct answer using the codes give
o es:(a) 1 only (b) 1 and 2
(c) 2 and 3 (d) 3 only
ns.
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2B =
.
x o
sB C at r r = =
1
For a roundbar both wiredrawing and extrusion willgive
ssame equationexceptB C
oat r r =
( )11
B
o oB r
+
=
fB r
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2Bb o
Cr
=
2 2
o
B B
1 .ox bo o
orB r r = +
2 2B B ( ) 1 .o
d b
o o
Drawing stressB r r
= +
same equationexceptB.C
( ) ( )2
1B
x oB B rC + =
. , 0 (at exit stressis zero)s f xB C at r r = =
( )1
21 Bo
B +
fr
=
( )2
1B
o B r +
= xfB r
2
Extrusion ratio for round baro oA r
R
= =f f
A r
for flat stockoh= f
21o B
xo RB
=
rampressurerequiredbycontainer frictionfp =
uniforminterfaceshear stressbetweeni =
billetandcontainerwall
2
0 0. 2i
f i fp r r L or pr
= =
tTotalExtrusion Pressure(P )
o
xo fp = +a 20nd Extrusion Load .tp r=
Ch17:Extrusion
. o p on . o p on
1 D 8 B
2 C 9 B
4 D 11 B
6 C 13 A7 B
Ch16:Drawing
. No O tion
1 A
3 C
4 B
5 C
6 D
B SKMondal
Exampleeterm ne t e e an punc s zes or an ng a c rcu ar
disc of 20mm diameter from a sheet whose thickness is 1.5mm.
Shear strength of sheet material = 294 MPa
Also determine the die and punch sizes for punching a
circular hole of 20mm diameter from a sheet whosethickness is 1.5 mm.
ExampleEstimate the blanking force to cut a blank 2
and 30 mm long from a 1.5 mm thick metal
Also determine the work done if the
penetration is 25 percent of material thicknes
Ans. 74.25 kN, 27.84 Nm
For-2013 (IES, GATE, PSUs) Page 41
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ISRO2009
The force required to punch a 25 mm hole in a
GATE2007T e orce requirement in a an ing operation olow carbon steel sheet is 5 0 kN The thickness of
GATE200410 mm iameter o es are to e punc e sheet of 3 mm thickness Shear streng
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q p 5
mild steel plate 10 mm thick, when ultimate shear
stress of the plate is 500 N/mm2will be nearly
(a) 78 kN (b) 393 kN (c) 98 kN (d) 158 kN
Ans. (b)
low carbon steel sheet is 5.0 kN. The thickness ofthe sheet is t and diameter of the blanked part isd. For the same work material if the diameter ofthe blanked part is increased to 1.5 d and thickness
. ,
(a) 3.0 (b) 4.5
(c) 5.0 (d) 8.0
.
sheet of 3 mm thickness. Shear strengmaterial is 400 N / mm2 and penetratiShear rovided on the unch is 2 mm. Thforce during the operation will be
a 22. 37.7(c) 61.6 kN (d) 94.3 kN
ns. a
GATE2003A meta isc o 20 mm iameter is to e punc efrom a sheet of 2 mm thickness. The punch and thedie clearance is 3%. The required punch diameter is
. .
(c) 20.06 mm (d) 20.12 mm
.
Calculate the unch size in mm for a circular blankinoperation for which details are given below.
ze o t e an 25 mm
Thickness o f the s heet 2 mm
Radial clearance between punch and die 0.06 mm
e a owance 0.05 mm
(a) 2 .8 (b) 2 .8
(c) 25.01 (d) 25.17
Ans. a
sheet of 2.5 mm thickness. The require
clearance between the die and the punch
sheet thickness. The punch and die diameters
, ,
(a) 50.00 and 50.30 (b) 50.00 and 5
(c) 49.70 and 50.00 (d) 49.85 and 5
Ans. (c)
GATE2002
In a an ing operation, t e c earance is provi eon
(a) The die
(c) The punch
(d) Brittle the punch nor the die
Ans. (c)
GATE2001
T e cutting orce in punc ing an an ingoperations mainly depends on
(a) The modulus of elasticity of metal
(c) The bulk modulus of metal
(d) The yield strength of metal
Ans. (b)
GATE1996
A 50 mm iameter isc is to e punc e carbon steel sheet 1.0 mm thick. The dithe punch should be
. .
(c) 50.075 mm (d) none of the above
.
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IES 2007W ic one o t e o owing meta ormingprocesses is not a high energy rate forming process?
IES 2009W ic one o t e o owing is a ig energy rateforming process?
IES 2005Magnetic orming is an examp e o :
(a) Cold formin (b) Hot f
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(a) Electromechanical forming
o orm ng
(c) Explosive forming
(d) Electrohydraulic forming
Ans. (b)
(a) Roll forming
ec ro y rau c orm ng
(c) Rotary forging
(d) Forward extrusion
Ans. (b)
(c) High energy rate forming (d) Roll f
Ans. c
Writefouradvanta esofhi hvelocit formin rocess.
[2marks]
GATE2000A 1.5 mm t ic s eet is su ject to unequa iaxiastretching and the true strains in the directions ofstretching are 0.05 and 0.09. The final thickness ofthe sheet in mm is
(a) 1.414 (b) 1.304
c 1.362 289
Ans. (b)
e en ng orce requ re or en bending and Edge bending will be in the ra
(a) 1 : 2 : 0.5 (b) 2: 1 : 0.5
Ans. (a)
GATE2005
A 2 mm t ic meta s eet is to e ent at an ang e oone radian with a bend radius of 100 mm. If thestretch factor is 0.5, the bend allowance is
(c) 101 mm (d) 102 mm
2mm
1 radian
Ans. (c)
GATE2007
a c e correc com na on or o ow ng me aworking processes.
Processes Associated state o f stress
P. Blankin 1. Tension
Q. Stretch Forming 2. Compression
. o n ng 3. ear
S. Deep Drawing 4. Tension and Compression
5. Tension and Shear
(a) 2 1 3 4 (b) 3 4 1 5
c 5 4 3 1 3 1 2 4
Ans.(d)
GATE2012
SameQ
in
GATE
201
Match the following metal forming processeassociated stresses in the work iece.
Metalformingprocess Typeofstress
1.Coining P.Tensile
. .
3.Blanking R.Tensileand
compress ve.Dee Drawin S.Com ressive
(a) 1S, 2P, 3Q, 4R (b) 1S, 2P, 3R, 4
(c) 1P, 2Q, 3S, 4R (d) 1P, 2R, 3Q,
For-2013 (IES, GATE, PSUs) Page 48
GATE2004Matc t e o owing
Product Process
IAS 1999a c s rocess w s ro uc on o par s
and select the correct answer using the codes given
IAS 1997Matc ListI meta orming process w(Associated feature) and select the correusing the codes gi en below the Lists
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P. Moulded luggage 1. Injection moulding
Q. Pac ag ng conta ners or qu 2. Hot ro ng
R. Lon structural sha es . Im act extrusion
S. Collapsible tubes 4. Transfer moulding
5. B ow mou ing
6. Coinin
(a) P1 Q4 R6 S3 (b) P4 Q5 R2 S3
(c) P1 Q5 R3 S2 (d) P5 Q1 R2 S2Ans. (b)
ListI ListII
A. Rolling 1. Discrete parts
B. Forging 2. Rod and Wire
C. Extrusion 3. Wide variety of shapes with thinwalls
D. Drawing 4. Flat plates and sheets
. .
Codes:A B C D A B C D
a 2 5 3 4 1 2 5 4
(c) 4 1 3 2 (d) 4 1 5 2
using the codes given below the Lists:
A. Blanking 1. Shear angle
B. Flow forming 2. Coiled stoc. .
D. Embossing 4. Closed mat
Codes:A B C D A B
(c) 1 3 2 4 (d) 3 1
IES2010
ons er e o ow ng s a emen s:
The material ro erties which rinci alldetermine how well a metal may be drawn are
1. a o o y e s ress o u ma e s ress.
2.Rate of increase of ield stress relative toprogressive amounts of cold work.
3. ate o wor ar en ng.
(a) 1 and 2 only (b) 2 and 3 only
(c) 1 only (d) 1, 2 and 3 Ans. (d)
Ch18:SheetMetalForming
. o p on . o p on
1 C 10 C
2 B 11 C
4 A 13 C
6 A 15 A7 A 16 B
9 A
By SKM
Which of the followin owder roductionmethods produces spongy and porous
(a) Atomization
(b) Reduction of metal oxides
(d) Pulverization
Ans. (b)
IES2012
In e ectro ysis
(a) For makin co er owder, co er late is madecathode in electrolyte tank
,made anode
(c) High amperage produces powdery deposit of cathodemetal on anode
(d) Atomization process is more suitable for low meltingpo n me a s
Ans. (b)
e a pow ers are compac e y many me
sinterin is re uired to achieve which ro er
is hot isostatic pressing?
For-2013 (IES, GATE, PSUs) Page 49
n pow er me a urgy, s n er ng o a componen
y Whatisisostatic ressin ofmetal owders?
c o e o ow ng process s
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p gy, g p
Ans. b
y Whatareitsadvantage?
[2Marks]
g p
a Castin
(b) weldin
(c) formation
(d) Powder metallurgy An
The bindin material used in cementedcarbide cutting tools is
a grap te
(b) tun sten
(c) nickel
co a t
Ans. (d)
IES2010
ons er e o ow ng par s:
1. Grindin wheel
2. Brake lining
3. Selflubricating bearings
ic o t ese parts are ma e y pow e r
metallur techni ue?(a) 1, 2 and 3 (b) 2 only
(c) 2 and 3 only (d) 1 and 2 only
ns. c
IES2010
e a c pow ers can e pro uce y
a Atomization
(b) Pulverization
(c) Electrodeposition process
o t e a o v e
Ans. (d)
IES 2002
T e rate o pro uction o a pow er meta urgy partdepends on
(a) Flow rate of powder
(c) Apparent density of compact
(d) Compressibility of powder
Ans. (c)
IES 2001
Matc ListI Components wit ListII(Manufacturing Processes) and select the correctanswer using the codes given below the lists:
A. Car body (metal) 1. Machining
B. Clutch lining 2. Casting
. .
D. Engine block 4. Powder metallurgy Ans.(d)
Codes:A B C D A B C D
(c) 4 3 2 1 (d) 3 4 1 2
GATE2011
The operation in which oil is permeatedores of a owder metallur roduct is kno
(a) mixing
s nter ng
c im re nation
(d) Infiltration
Ans. (c)
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IAS 2004T e o owing are t e constituent steps in t eprocess of powder metallurgy:
1. Powder conditioning
IAS 2003ssertion : tomization met o or pro uction o
metal powders consists of mechanical disintegration ofmolten stream into fine particles.
IAS 2007Consi er t e o owing asic steps invo production of porous bearings:
1. Sintering
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1. Powder conditioning
2. n er ng
3. Production of metallic powder
4. Pressing or compacting into the desired shapen en y e correc or er n w c ey ave o e
performed and select the correct answer using the codesgiven below:
a 12 b 1 2
(c) 2413 (d) 4321 Ans. (b)
Reason (R): Atomization method is an excellent meansof making powders from high temperature metals.
explanation of Ao an are n v ua y rue u s no e
correct explanation of A
(c) A is true but R is false
d A is false but R is true Ans. c
1. Sintering
2. x ng
3. Repressing
4. Impregnation5. o ecompac on
Which one of the following is the correct sequabove steps?
ConventionalQuestions1. Exp a n w y meta pow ers are en e . Descr e w at
happens during sintering. [IES2010, 2 Marks]
ConventionalQuestions1. scuss e erms neness an par c e s ze
distribution in powder metallurgy. [IES2010, 2ar s
Ans.
Fineness: Is the diameter of spherical shaped particleand mean diameter of nons herical sha ed article.
Particle size distribution: Geometric standarddeviation (a measure for the bredth or width of adistribution), is the ratio of particle size diameterstaken at 84.1 and 50% of the cumulative undersized
weight plot, respectively and mean mass diameterdefine the particle size distribution.
ConventionalQuestionsEnumerate t e steps nvo ve n pow er process. Discuss these steps. Name the main powder metallurgy. What are the lim
owder metallur ? IES200 , 1
Q. No Option Q. No Option
1 D 5 C
2 B 6 B
3 C 7 D
For-2013 (IES, GATE, PSUs) Page 53
Tolerancesares ecified
(a) To obtain desired fits
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Limit Tolerance&Fits
By SKMondal
(a) Toobtaindesiredfits
(b) becauseitisnotpossibletomanufactureexactl
(c) toobtainhigheraccuracyto avepropera owances
Ans.(b)
xpress ng a mens on as 25.3 . mm s e c ase o
Ans. b
GATE 2010,
ISRO
2012
A shaft has a dimension0.0090.02535
The respective values of fundamental deviation and
(a) 0.025, 0.008 (b) 0.025, 0.016
(c) 0.009, 0.008 (d) 0.009, 0.016
.
GATE
1992Twos a tsAan B avet eir iameterssp
100 0.1mmand0.1 0.0001mmrespect
Whichofthefollowingstatementsis/aretrue
(b) TherelativeerrorinthedimensionisgreaA
(d) Therelativeerrorinthedimensionissam
AandshaftB
Ans.(a)
GATE
2004In an interc angea e assem y, s a ts o size
mm mate with holes of size mm.0.040
0.010025.000
+
0.020
0.00025.000
+
The maximum possible clearance in the assembly
(a) 10 microns
(b) 20 microns
(d) 60 microns
.
ISRO2010
0.02 0.02
0.00 0.00Dimension of the hole is 50 mm and shaft is 50 mm.+ +
+
(a) 0.02 mm (b) 0.00 mm
(c) -0.02 mm (d) 0.01 mm
.
GATE
20070 . 0 5 0A o e is speci ie as mm. Tshaft has a clearance fit with minimum cl
0 . 0 0 04 0
0.01 mm. The tolerance on the shaft is 0.0maximum clearance in mm between thethe shaft is
a 0.04
(b) 0.05
(c) 0.100.11
Ans. (c)For-2013 (IES, GATE, PSUs) Page 54
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GATE 2003T e imensiona imits on a s a t o 25 7 are
(a) 2 .000, 2 .021 mm
(b) 25.000, 24.979 mm
GATE2010(PI)A small bore is designated as 25H7. The lower
(minimum) and upper (maximum) limits of the bore
a s e erence e ween o e as s sy
shaft basis s stem ? Wh is hole basis s stem
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c 25.000, 25.007 mm
d 2 .000 2 . mm
Ans.
are 25.000 mm an 25.021 mm, respec ve y. en e
bore is desi nated as 2 H8 then the u er maximum
limit is 25.033 mm. When the bore is designated as
25H6, then the upper (maximum) limit of the bore (in
mm) is
a 25.001 25.005 c 25.009 25.013
Ans. d
shaft basis s stem ? Wh is hole basis s stem
extensive in use ?
What are the differences between interchan
and selective assembly ?
1
GATE
2003
[Ans.(b)]
GATE
1997ree oc s 1 , 2 an 3 are
to be inserted in a channel of
minimum gap of width T =. , .
For P = 18. 75 0.08;
= 25.00 0.12;
R = 28.125 0.1 and
S = 72.35 + X, (where alldimensions are in mm), thetolerance X is
(a)+0.38 (b) 0.38 (c)+0.05 (d) 0.05
Ans.(d)
IES
2000W ic one o t e o owing to erances sediameter and outer diameter respectivelyjig bush for press fit is correct?
(c) H 7h 6 (d) F7j6
.
Plu au es are used to
(a) Measure the diameter of the workpieces
easure e ame er o e o es n eworkpieces
(c) Check the diameter of the holes in theworkpieces
(d) Check the length of holes in the workpieces
Ans. (c)
GATE
2004GO an NOGO p ug gagesare to e esigne or a
hole mm. Ga e tolerances can be taken as 10%0.0520
of the hole tolerance. Following ISO system of gage
.
,respectively
(a) 20.010 mm and 20.050 mm
b 20.01 mm and 20.0 6 mm
(c) 20.006 mm and 20.054 mm20.014 mm an 20.054 mm
Ans. b
GATE
1995C ec ing t e iameter o a o e using Ggauges is an, example of inspe..(variables/attributes)
(a) Variables
(b) Attributes
(d) Insufficient data
.
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ee ergauge suse oc ec e
s ne ar s spec e y
GATE 2012(PI)
A sine bar has a length of 250 mm. Eac
has a diameter of 20 mm. During tape
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Ans. c Ans. c
measurement o a component, t e
is 100 mm.
The calculated taper angle (in degrees)
(a) 21.1 (b) 22.8 (c) 23.6 (d) 68.9
Ans. (a)
The best wire size in mm for measurineffective diameter of a metric thread
o
2.5 mm pitch using two wire method is
(a) 1.443 (b) 0.723
. .
Ans. (a)
IES
1992W ic gra e sym o represents sur ace roug obroaching?
(a) N12 (b) N8
4 1
Ans. (b)
IFS2011What is meant by interchangeable manufa
Laser light has unique advantages for inspe
What are they ? Define the terms 'ro
' ' ' ' 'e g , wav ness w an ay n co
.
10
va uean va uesareuse or
measurementof
(a)Metalhardness
(b)Sharpnessoftooledge
(c)Surfacedimensions
(d)Surfaceroughness
Ans.(d)
IES
2006The M and Esystem in metrology are related to
measurement of:
a crew t rea s atness
c ngu ar y ur ace n s
.
IES
2007W at is t e ominant irection o t e tooscratches in a surface texture having a dquality, called?
(c) Lay (d) Flaw
.
For-2013 (IES, GATE, PSUs) Page 60
IES 2008
What term is used to designate the direction of the
pre ominant sur ace pattern pro uce y
IES2010Match List I with List II and select the correct answerusing the code given below the lists:List I List II
(Symbols for direction of lay) (Surface texture)
IES 2008
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Ans. (b)
A B C D A B C D
ns.
(a) 4 2 1 3 (b) 3 2 1 4(c) 4 1 2 3 (d) 3 1 2 4
Ans.(c)
b
(a) Triangles
(b) Circles
(c) Squares
(d) Rectangles
Ans. (a)
GATE
1997
s s
(A) Surface profilometer 1. Calibration
(B) Light Section Microscope 2. Form tester
.measurement
n er erome er 4. en re ne average
5. Comparator
6. Surface lay measurement
(a) 4 1 2 3 (b) 4 3 5 1
c 4 2 1 3 3 1 2 4Ans.(b)
GATE
2003Two s p gauges o 10 mm w t measur ngand 1.002 mm are kept side by side in contacother lengthwise. An optical flat is kept ressli au es as shown in the fi ure. Monochroof wavelength 0.0058928 mm is used in the
on both slip gauges is
(a) 2 (b)6
Ans.(a)
MiscellaneousofMetrology
By SKMondal
GATE
1998
Auto co mator s use to c ec
(a) Rou hness
(b) Flatness
c Ang e
d Automobile balance.
Ans. (c)
n au oco ma or s u se o
d measure roundness error between centers
Ans. c
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LinkedAnswerQuestionsGATE2013 S1
In orthogonal turning of a bar of 100 mm diameter
with a feed of 0.2 mm rev de th of cut of mm
and cutting velocity of 90 m/min, it is observed that
LinkedAnswerQuestionsGATE2013 S2
In orthogonal turning of a bar of 100 mm diameter
with a feed of 0.2 mm rev de th of cut of mm
and cutting velocity of 90 m/min, it is observed that
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g y 9 ,
the main (tangential)cutting force is perpendicular
.
The main (tangential) cutting force is 1500 N.
y The orthogonal rake angle of the cutting tool in degree is
(a) zero (b) 3.58 (c) 5 (d) 7.16
g y 9 ,
the main (tangential)cutting force is perpendicular
.
The main (tangential) cutting force is 1500 N.
y The normal force acting at the chiptool interface in N is
(a) 1000 (b) 1500 (c) 20oo (d) 2500
GATE-2013 Asked Questions Page 2 of 2