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This section includes InterviewSolutions, each offering curated multiple-choice questions to sharpen your knowledge and support exam preparation. Choose a topic below to get started.
| 51. |
In a machining operation the chip thickness ratio is 0.3 and the back rake angle of the tool is 10o. What is the value of the shear strain? |
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Answer» In a machining operation the chip thickness ratio is 0.3 and the back rake angle of the tool is 10o. What is the value of the shear strain? |
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| 52. |
Common Data:An orthogonal operation is carried out at 20m/min cutting speed, using a cutting tool of rake angle 15 degree. The chip thickness is 0.4mm and uncut chip thickness is 0.2mmThe shear angle (in degrees) is |
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Answer» Common Data: |
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| 53. |
In an orthogonal machining operation,if U = specific cutting energy, β= friction angle, ϕ= shear plane angle, α= Tool rake angle, then the shear stress (τ) will be expressed as: |
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Answer» In an orthogonal machining operation, |
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| 54. |
In a rolling operation using rolls of diameter 500 mm if a 25 mm thick plate cannot be reduced to less than 20 mm in one pass, the coefficient of friction between the roll and the plate is_____.0.1414 |
Answer» In a rolling operation using rolls of diameter 500 mm if a 25 mm thick plate cannot be reduced to less than 20 mm in one pass, the coefficient of friction between the roll and the plate is_____.
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| 55. |
A single point cutting tool with a nose radius of 0.4mm was used to turn a component in a lathe employing feed rate of 0.3mm/rev. If the feed rate is double, the ideal surface roughness (peak-to-valley height) produced on the components will increase by a factor of |
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Answer» A single point cutting tool with a nose radius of 0.4mm was used to turn a component in a lathe employing feed rate of 0.3mm/rev. If the feed rate is double, the ideal surface roughness (peak-to-valley height) produced on the components will increase by a factor of |
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| 56. |
A gear with 84 teeth is to be machined usign a milling process with indexing. The index plate has the following four hole circles: 36,38,42,48. The change gear ratio required is |
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Answer» A gear with 84 teeth is to be machined usign a milling process with indexing. The index plate has the following four hole circles: 36,38,42,48. The change gear ratio required is |
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| 57. |
Common Data QuestionA cup is to be drawn to a diameter of 70mm with 35mm depth from a 0.5mm thick sheet metal. The cup is drawn in one operation. Assume σu=430MPaThe maximum drawing force is |
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Answer» Common Data Question The maximum drawing force is |
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| 58. |
A 600mm×30mm flat surface of a plate is to be finish machined on a shaper. The plate has been 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, the time required for machining will be |
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Answer» A 600mm×30mm flat surface of a plate is to be finish machined on a shaper. The plate has been 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, the time required for machining will be |
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| 59. |
A straight turning operation is carried out using a single point cutting tool on an AISI1020 steel rod. The feed is0.2mm/rev and the depth of cut is 0.5mm. The tool has a side cutting edge angle of 60o. The uncut thickness (in mm) is0.1 |
Answer» A straight turning operation is carried out using a single point cutting tool on an AISI1020 steel rod. The feed is0.2mm/rev and the depth of cut is 0.5mm. The tool has a side cutting edge angle of 60o. The uncut thickness (in mm) is
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| 60. |
The quick return mechanism used in the shaper has rocker arm drive of length 200mm. If the crank radius is 50mm and the offset between crank centre and rocker arm pivot is 20mm, length of the stroke (in meters) is |
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Answer» The quick return mechanism used in the shaper has rocker arm drive of length 200mm. If the crank radius is 50mm and the offset between crank centre and rocker arm pivot is 20mm, length of the stroke (in meters) is |
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| 61. |
A steel flat surface of 150 mm is to produced by a horizontal axis milling machine where spindle speed is 65 rpm. The milling cutter has 8 teeth, 100 mm diameter and the machining time assuming that the entire stock can be removed in one pass and depth of cut 2 mm and feed rate of 0.15 mm/tooth is________sec136.92 |
Answer» A steel flat surface of 150 mm is to produced by a horizontal axis milling machine where spindle speed is 65 rpm. The milling cutter has 8 teeth, 100 mm diameter and the machining time assuming that the entire stock can be removed in one pass and depth of cut 2 mm and feed rate of 0.15 mm/tooth is________sec
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| 62. |
The relationship between true strain (ϵT) and engineering strain (ϵE) in a uniaxial tension test is given as |
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Answer» The relationship between true strain (ϵT) and engineering strain (ϵE) in a uniaxial tension test is given as |
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| 63. |
Linked Question Orthogonal turning is performed on a cylindrical workpiece with shear strength of 250MPa. The following conditions are used: cutting velocity is 180m/min, feed is 0.20mm/rev, depth of cut is 3mm, chip thickness ratio =0.5. The orthogonal rake angle is 7o. Apply Merchant's theory for analysis.The cutting and thrust forces, respectively, are |
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Answer» Linked Question |
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| 64. |
A bar of 75 mm diameter is reduced to 73 mm by a cutting tool while cutting orthogonally. If the rake angle is 15∘ and shear angle is 0.3328 radian. The mean length of cut chip is _____ mm. 76.137 |
Answer» A bar of 75 mm diameter is reduced to 73 mm by a cutting tool while cutting orthogonally. If the rake angle is 15∘ and shear angle is 0.3328 radian. The mean length of cut chip is _____ mm.
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| 65. |
Linked QuestionA low carbon steel bar of 147mm diameter with a length of 630mm is being turned with an uncoated carbide insert. The observed tool lives are 24min and 12min for cutting velocities of 90m/min and 120m/min respectively. The feed and depth of cut are 0.2mm/rev and 2mm respectively. Use the unmachined diameter to calculate the cutting velocity.Neglect over-travel or approach of the tool. When too life is 20min, the machining time in min for a single pass is |
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Answer» Linked Question |
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| 66. |
Common Data:A disc of 200mm outer and 80mm inner diameter is faced at a feed of 0.1mm/rev with a depth of cut of 1mm. The facing operation is undertaken at a constant cutting speed of 90m/min in a CNC lathe The main (tangential) cutting force is 200NNeglecting the contribution of the feed force towards cutting power, the specific cutting energy in J/mm3 is |
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Answer» Common Data: |
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| 67. |
Two tools P and Q have signatures 8−30o−0 and 5o−5o−7p−7o−8o−15o−0 (both ASA) respectively. They are used to turn components under the same machining conditions. If hP and hQ denote the peak-to-valley heights of surfaces produced by the tools P and Q, the ration hP/hQ will be |
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Answer» Two tools P and Q have signatures 8−30o−0 and 5o−5o−7p−7o−8o−15o−0 (both ASA) respectively. They are used to turn components under the same machining conditions. If hP and hQ denote the peak-to-valley heights of surfaces produced by the tools P and Q, the ration hP/hQ will be |
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| 68. |
A ϕ−20mm through hole is to be drilled in a 30mm thick plate using a double fluted, 120o lip angle drill. The drill tip is at a distance of 3mm from the plate surface when cutting is started and an overtravel of 2mm is recommended as a margin to ensure drilling through the full thickness of the plate. If the drill rotates at 500rev/mn and the feed per tooth is 0.01mm, the machining time of the operation (in min) will be |
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Answer» A ϕ−20mm through hole is to be drilled in a 30mm thick plate using a double fluted, 120o lip angle drill. The drill tip is at a distance of 3mm from the plate surface when cutting is started and an overtravel of 2mm is recommended as a margin to ensure drilling through the full thickness of the plate. If the drill rotates at 500rev/mn and the feed per tooth is 0.01mm, the machining time of the operation (in min) will be |
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| 69. |
The diameter and rotational speed of a job are 100m and 500rpm respectively. The high spots (chatter marks) are found at a spacing of 30deg on the job surface. The chatter frequency is |
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Answer» The diameter and rotational speed of a job are 100m and 500rpm respectively. The high spots (chatter marks) are found at a spacing of 30deg on the job surface. The chatter frequency is |
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| 70. |
Linked Data:Blind hole 10mm diameter, 50mm deep are being drilled in steel block, drilling spindle speed is 600rpm, feed 0.2mm/rev, point angle of drill is 120Machining time (in min) per hole will be |
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Answer» Linked Data: |
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| 71. |
In a single pass turning operation the cutting speed is the only variable based on the cutting time cost and the cutting edge cost. The tool life for minimum cost given that cost of 1 cutting edge is Rs5, operator wages including the machine tool cost is Rs.75/hour and tool life equation is VT0.1 is 100 |
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Answer» In a single pass turning operation the cutting speed is the only variable based on the cutting time cost and the cutting edge cost. The tool life for minimum cost given that cost of 1 cutting edge is Rs5, operator wages including the machine tool cost is Rs.75/hour and tool life equation is VT0.1 is 100 |
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| 72. |
A drilling machine has to be designed with 8 spindle speeds ranging approximately between 120 to 100rpm. The 5th spindle speed is |
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Answer» A drilling machine has to be designed with 8 spindle speeds ranging approximately between 120 to 100rpm. The 5th spindle speed is |
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| 73. |
A three-start external square thread of 12 mm pitch and outside diameter of 65 mm is to be cut on a centre lathe which has a 7 mm pitch lead screw. Depth of thread to give 0.14 clearance is _______ mm.6.14 |
Answer» A three-start external square thread of 12 mm pitch and outside diameter of 65 mm is to be cut on a centre lathe which has a 7 mm pitch lead screw. Depth of thread to give 0.14 clearance is _______ mm.
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| 74. |
If α is the rake angle of the cutting tool, ϕ is, the shear angle, V is the cutting velocity and Vc is the velocity of chip relative to tool, the velocity of chip sliding along the shear plane is given by |
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Answer» If α is the rake angle of the cutting tool, ϕ is, the shear angle, V is the cutting velocity and Vc is the velocity of chip relative to tool, the velocity of chip sliding along the shear plane is given by |
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| 75. |
In orthogonal turning of low carbon steel pipe with principal cutting edge angle of 90o, the main cutting force is 1000N and the feed force is 800N. The shear angle is 25o and the orthogonal rake angle is zero. Employing Merchant's theory, the ratio of friction force to normal force acting on the cutting tool is |
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Answer» In orthogonal turning of low carbon steel pipe with principal cutting edge angle of 90o, the main cutting force is 1000N and the feed force is 800N. The shear angle is 25o and the orthogonal rake angle is zero. Employing Merchant's theory, the ratio of friction force to normal force acting on the cutting tool is |
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| 76. |
Linked Data:During orthogonal machining of a mild steel specimen with a cutting tool of zero rake angle, the following data is obtained:Uncut chip thickness =0.25mmChip thickness =0.75Normal force =950Nthrust force =475NThe ultimate shear stress (in N/mm2) of the work material is |
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Answer» Linked Data: |
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| 77. |
The time taken to drill a hole through a 25mm thick plate with the drill rotating at 300rpm and moving at a feed rate of 0.25mm/rev is |
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Answer» The time taken to drill a hole through a 25mm thick plate with the drill rotating at 300rpm and moving at a feed rate of 0.25mm/rev is |
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| 78. |
If the index crank of a dividing head is turned through one complete revolution and 10 holes in a 30 hole circle plate, the workpiece turns thorugh (in degrees) |
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Answer» If the index crank of a dividing head is turned through one complete revolution and 10 holes in a 30 hole circle plate, the workpiece turns thorugh (in degrees) |
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| 79. |
In a cutting test with 0.3 mm flank wear as tool failure criterion, a tool life of 10 min was obtained at a cutting velocity of 20 m/min. Taking tool life exponent as 0.25, the tool life in minutes at 40 m/min of cutting velocity will be |
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Answer» In a cutting test with 0.3 mm flank wear as tool failure criterion, a tool life of 10 min was obtained at a cutting velocity of 20 m/min. Taking tool life exponent as 0.25, the tool life in minutes at 40 m/min of cutting velocity will be |
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| 80. |
Common Data:An orthogonal operation is carried out at 20m/min cutting speed, using a cutting tool of rake angle 15 degree. The chip thickness is 0.4mm and uncut chip thickness is 0.2mmThe chip velocity (in m/min) is |
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Answer» Common Data: |
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| 81. |
In orthogonal turning of a low carbon steel bar of diameter 150mm uncoated carbide tool the cutting velocity is 90m/min. The feed is 0.24mm/rev and the depth of cut is 2mm. The chip thickness obtained is 0.48mm. If the orthogonal rake angle is zero and the principal cutting edge angle is 90o, the shear angle in degree is |
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Answer» In orthogonal turning of a low carbon steel bar of diameter 150mm uncoated carbide tool the cutting velocity is 90m/min. The feed is 0.24mm/rev and the depth of cut is 2mm. The chip thickness obtained is 0.48mm. If the orthogonal rake angle is zero and the principal cutting edge angle is 90o, the shear angle in degree is |
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| 82. |
An aluminium wire is drawn from 14.5 mm to 12.2 mm diameter at a speed of 1.5 m/sec. Coefficient of friction between wire and dies is 0.12, semi die angle is 6o. Mean flow stress of aluminium is 200 MPa. Drawing load will be ____kN. 14.29 |
Answer» An aluminium wire is drawn from 14.5 mm to 12.2 mm diameter at a speed of 1.5 m/sec. Coefficient of friction between wire and dies is 0.12, semi die angle is 6o. Mean flow stress of aluminium is 200 MPa. Drawing load will be ____kN.
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| 83. |
For cutting double start screw threads of pitch 1.0mm on a lathe, the thread cutting tool should have a feed rate of |
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Answer» For cutting double start screw threads of pitch 1.0mm on a lathe, the thread cutting tool should have a feed rate of |
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| 84. |
A ϕ25mm hole is pierced in a t=2.5mm thick steel sheet having shear strength τ=350MPa. If the diametral clearance is given by the expression c=0.0064√τ, the die diameter (in mm), punch diameter (in mm) and punch force in (kN) respectively are |
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Answer» A ϕ25mm hole is pierced in a t=2.5mm thick steel sheet having shear strength τ=350MPa. If the diametral clearance is given by the expression c=0.0064√τ, the die diameter (in mm), punch diameter (in mm) and punch force in (kN) respectively are |
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| 85. |
During machining, the wear land (h) has been plotted against machining time T as given in the following figureFor a critical wear land to 1.8mm the cutting tool life (in min) is |
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Answer» During machining, the wear land (h) has been plotted against machining time T as given in the following figure |
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| 86. |
Details pertaining to an orthogonal metal cutting process are given below:Chip thickness ratio 0.4Undeformed thickness 0.6mmRake angle +10oCutting speed 2.5m/sMean thickenss of primary shear zone 25 microns The shear strain rate in s−1 during the process is |
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Answer» Details pertaining to an orthogonal metal cutting process are given below: |
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| 87. |
The base of a brass bracket has to be rough ground to remove the unevenness. The 4 wheels available in the store. The appropriate wheel is |
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Answer» The base of a brass bracket has to be rough ground to remove the unevenness. The 4 wheels available in the store. The appropriate wheel is |
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| 88. |
Two identical cylindrical jobs are turned using (a) a round nosed tool of nose radius 2mm and (b) a sharp corner tool having principal cutting edge angle =45o and auxiliary cutting edge angle =10o. If the operation is carried out of the feed of 0.08mm/rev, the height at micro irregularities on the machined surfaces (in mm) in the two cases will be |
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Answer» Two identical cylindrical jobs are turned using (a) a round nosed tool of nose radius 2mm and (b) a sharp corner tool having principal cutting edge angle =45o and auxiliary cutting edge angle =10o. If the operation is carried out of the feed of 0.08mm/rev, the height at micro irregularities on the machined surfaces (in mm) in the two cases will be |
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| 89. |
A strip of 120mm width and 8 mm thickness is rolled between two 300 mm diameter rolls to get a strip of 120 mm width and 7.2 mm thickness The speed of the strip at the exit is 30m/mm There is no front or back tension. Assuming uniform roll pressure of 200 MPa in the roll bite and 100% mechanical efficiency, the minimum total power (in kW) required to drive the two rolls is_______9.12 |
Answer» A strip of 120mm width and 8 mm thickness is rolled between two 300 mm diameter rolls to get a strip of 120 mm width and 7.2 mm thickness The speed of the strip at the exit is 30m/mm There is no front or back tension. Assuming uniform roll pressure of 200 MPa in the roll bite and 100% mechanical efficiency, the minimum total power (in kW) required to drive the two rolls is_______
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| 90. |
A sheet metal with a stock hardness of 250 HRC has to be sheared using a punch and a die having a clearance of 1 mm between them. If the stock hardness of the sheet metal increases to 400 HRC, the clearance between the punch and the die should be (in mm)_____.1.265 |
Answer» A sheet metal with a stock hardness of 250 HRC has to be sheared using a punch and a die having a clearance of 1 mm between them. If the stock hardness of the sheet metal increases to 400 HRC, the clearance between the punch and the die should be (in mm)_____.
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| 91. |
In an orthogonal cutting test, the following observation were madeCutting force =1200NThrust force =500NTool rake angle =zeroCutting speed =1m/sDepth of cut =0.8mmChip thickness =1.5mmFriction angle during machining will be |
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Answer» In an orthogonal cutting test, the following observation were made |
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| 92. |
In a slab rolling operation, the maximum thickness reduction (Δhmax) is given by Δhmax=μ2R, where R is the radius of the roll and μ is the coefficient of friction between the roll and the sheet. If μ=0.1, the maximum angle subtended by the deformation zone at the centre of the roll (bite angle in degree) is____.5.73 |
Answer» In a slab rolling operation, the maximum thickness reduction (Δhmax) is given by Δhmax=μ2R, where R is the radius of the roll and μ is the coefficient of friction between the roll and the sheet. If μ=0.1, the maximum angle subtended by the deformation zone at the centre of the roll (bite angle in degree) is____.
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| 93. |
Find the speed range ratio for the drilling machine spindle if the minimum and maximum diameters of drills used are 5mm and 25mm respectively and if the machinability indices for the work materials are 120 (brass) and 40 (alloy steel) |
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Answer» Find the speed range ratio for the drilling machine spindle if the minimum and maximum diameters of drills used are 5mm and 25mm respectively and if the machinability indices for the work materials are 120 (brass) and 40 (alloy steel) |
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| 94. |
A cutting tool has a nose radius of 1.8mm the feed rate for a theoretical surface roughness of Rt=5 microns is |
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Answer» A cutting tool has a nose radius of 1.8mm the feed rate for a theoretical surface roughness of Rt=5 microns is |
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| 95. |
If a is the rake angle of a cutting tool, ϕ is the shear angle, then the ratio of velocity of chip to the shear velocity is given by |
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Answer» If a is the rake angle of a cutting tool, ϕ is the shear angle, then the ratio of velocity of chip to the shear velocity is given by |
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| 96. |
Minimum shear strain in orthogonal turning with a cutting tool of zero rake angle is |
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Answer» Minimum shear strain in orthogonal turning with a cutting tool of zero rake angle is |
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| 97. |
A cold roll aluminium strip of 1400 mm width from 4 mm to 3.2 mm thickness on a 4 high mill. The diameter of the roll is 450 mm. Plane strain of aluminium at inlet as used is 0.5 and corresponding plane stress is 135N/mm2. Take the value of μ as 0.05 and strain at the end of rolling as 0.8 when plane stress is 148N/mm2. The expression of roll force is given byF=ω√RΔhσm(1+μ√RΔhhb+hf)Nwhere symbols carry usual meaning.The rolling load will be_____tonne. 296.168 |
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Answer» A cold roll aluminium strip of 1400 mm width from 4 mm to 3.2 mm thickness on a 4 high mill. The diameter of the roll is 450 mm. Plane strain of aluminium at inlet as used is 0.5 and corresponding plane stress is 135N/mm2. Take the value of μ as 0.05 and strain at the end of rolling as 0.8 when plane stress is 148N/mm2. The expression of roll force is given by F=ω√RΔhσm(1+μ√RΔhhb+hf)N where symbols carry usual meaning. The rolling load will be_____tonne.
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| 98. |
In a single point turning tool, the side rake angle and orthogonal rake angle are equal. ϕ is the principal cutting edge angle and its range is 0o≤ϕ≤90o. The chip flows in the orthogonal plane. The value of ϕ is closest to |
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Answer» In a single point turning tool, the side rake angle and orthogonal rake angle are equal. ϕ is the principal cutting edge angle and its range is 0o≤ϕ≤90o. The chip flows in the orthogonal plane. The value of ϕ is closest to |
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| 99. |
Common Data:A disc of 200mm outer and 80mm inner diameter is faced at a feed of 0.1mm/rev with a depth of cut of 1mm. The facing operation is undertaken at a constant cutting speed of 90m/min in a CNC lathe The main (tangential) cutting force is 200NAssuming approach and over-travel of the cutting tool to be zero, the machining time in min is |
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Answer» Common Data: |
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| 100. |
A batch of 10 cutting tools could produce 500 components while working at 50rpm with a tool feed of 0.25mm/rev and depth of cut of 1mm. A similar batch of 10 tools of the same specification could produce 122 components while working at 80rpm with a feed of 0.25mm/rev and 1mm depth of cut. How many components can be produced with one cutting tool at 60rpm? |
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Answer» A batch of 10 cutting tools could produce 500 components while working at 50rpm with a tool feed of 0.25mm/rev and depth of cut of 1mm. A similar batch of 10 tools of the same specification could produce 122 components while working at 80rpm with a feed of 0.25mm/rev and 1mm depth of cut. How many components can be produced with one cutting tool at 60rpm? |
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