Rev1
Answer &Explanation
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Page-151
Page-34
Page-44
Page-55
Page-160
Page-165
Page-166
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--
Page-188
Section-II: Metrology
Chapter-4: Limit, Tolerance & Fits
Chapter-5: Measurement of Lines & Surfaces
Chapter-6: Miscellaneous of Metrology
Page 1 of 205
Rev.1
IAS 2009 i
IAS2009main
GATE 2014
GATE2014
p
p
y Name four independent
variables and three dependent
TheoryofMetalCutting
B SKM d l
BySKMondal
[ 5 marks]
I d
IndependentVariables
d tV i bl
D
DependentVariables
d tV i bl
Startingmaterials
Startingmaterials
Forceorpowerrequirements
Forceorpowerrequirements
(tool/work)
Maximumtemperaturein
Toolgeometry
cutting
CuttingVelocity
Surfacefinish
g rake
Better surface finish is obtained with a large
angle because
(a) the area of shear plane decreases resulting in the
decrease in shear force and cutting force
(b) the tool becomes thinner and the cutting force is
reduced
( ) less
(c)
l
h
heat
i accumulated
is
l d in
i the
h cutting
i zone
(d) the friction between the chip and the tool is less
Lubrication
Lubrication
1
IES 2013
IES2013
Feed&Depth ofcut
S 200
IES2001
IES1995
Singlepointthreadcuttingtoolshouldideally
have:
a)) Zerorake
b) Positiverake
c) Negativerake
d) Normalrake
Cuttingpowerconsumptioninturningcanbe
C tti
ti i t
i
b
significantlyreducedby
g
y
y
(a)Increasingrakeangleofthetool
(b)Increasingthecuttinganglesofthetool
(c)Wideningthenoseradiusofthetool
(d)I
(d)Increasingtheclearanceangle
i h l
S 2005
200
IES
IES1993
GATE1995;2008
S 2002
IES
Assertion (A): Negative rake is usually provided on
carbide tipped tools.
Reason (R): Carbide tools are weaker
in
compression.
( ) Both
(a)
B th A and
d R are individually
i di id ll true
t
and
d R is
i the
th
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES2011
Which one of the following statement is NOT correct
with reference to the purposes and effects of rake angle
of a cutting tool?
(a) To guide the chip flow direction
(b) To reduce the friction between the tool flanks and
the machined surface
(c) To add keenness or sharpness to the cutting edges.
(d) To provide better thermal efficiency.
( )
GATE 2008(PI)
Brittle materials are machined with tools
having zero or negative rake angle because it
(a) results in lower cutting force
( ) improves surface finish
(b)
(c) provides adequate strength to cutting tool
(d) results in more accurate dimensions
10
11
12
ForIESOnly
[ 2 marks]
k ]
Considerthefollowingcharacteristics
1. Thecuttingedgeisnormaltothecuttingvelocity.
2. Thecuttingforcesoccurintwodirectionsonly.
Th tti f
i t di ti
l
3. Thecuttingedgeiswiderthanthedepthofcut.
Thecharacteristicsapplicabletoorthogonalcutting
wouldinclude
(a) 1and2
(b) 1and3
(c) 2and3
(d) 1,2and3
1 2and3
13
IES 2012
IES
14
IES2006
Duringorthogonalcutting,anincreaseincuttingspeed
causes
(a)Anincreaseinlongitudinalcuttingforce
(b)Anincreaseinradialcuttingforce
(c)Anincreaseintangentialcuttingforce
( )
(d)Cuttingforcestoremainunaffected
g
IES 2014
IES
S 1994
99
IAS
IES2007Conventionall
16
Whichofthefollowingisasinglepointcutting
tool?
(a) Hacksawblade
(b) Millingcutter
(c) Grindingwheel
(d) Partingtool
P ti t l
Page 3 of 205
15
IES 2012
IES
()
g
g
p
g
Statement(I):Negativerakeanglesarepreferredonrigidset
upsforinterruptedcuttinganddifficulttomachine
materials.
Statement(II):Negativerakeangledirectsthechipsontothe
machinedsurface
( ) Both
(a)
B h Statement
S
(I) and
d Statement
S
(II) are individually
i di id ll
true and Statement (II) is the correct explanation of
Statement (I)
(b) Both Statement (I) and Statement (II) are individually
p
of
true but Statement ((II)) is not the correct explanation
Statement (I)
(c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement (II) is true
Rev.1
18
IES2003
The angle of inclination of the rake face with
respect to the tool base measured in a plane
perpendicular to the base and parallel to the width
of the tool is called
(a) Back rake angle
(b) Side rake angle
(c) Side cutting edge angle
((d)) End cutting
g edge
g angle
g
(b) 12 Hz
(c) 100 Hz
19
20
Thrustforcewillincreasewiththeincreasein
(a) Sidecuttingedgeangle
(b)T l
(b)Toolnoseradius
di
(c) Rakeangle
(d)Endcuttingedgeangle.
22
Thetoollifeincreaseswiththe
(a) Increaseinsidecuttingedgeangle
(b) Decreaseinsiderakeangle
D
i id k
l
(c) Decreaseinnoseradius
(d) Decreaseinbackrakeangle
(d) 500 Hz
IES 2010
IES2010
S 1995
99
IAS
IES2006
S 1996
996
IAS
GATE(PI)1990
21
IES1995
The
the fface and
the flank
Th angle
l between
b t
th
d th
fl k off the
th
single point cutting tool is known as
a) Rake angle
b) Clearance angle
g
c) Lip angle
d) Point angle.
angle
23
IES 2012
IES
IES2002
Consider the following statements:
The strength of a single point cutting tool depends
upon
1. Rake angle
2. Clearance angle
3. Lip angle
Which of these statements are correct?
( ) 1 and
(a)
d3
(b) 2 and
d3
(c) 1 and 2
(d) 1, 2 and 3
Page 4 of 205
24
26
Toollifeincreasewithincreasein
(a)Cuttingspeed
(b)N di
(b)Noseradius
(c)Feed
(d)Depthofcut
Rev.1
27
28
IES 2009
IES2009
29
S 993
IES1993
In ASA System,
System if the tool nomenclature is 8655
8655
10152mm, then the side rake angle will be
( ) 5
(a)
(b) 6
( ) 8
(c)
(d) 10
34
(c) 8o
(d) 2o
32
G
20 0 ( )
GATE
2010(PI)
GATE2008
In a single point turning tool, the side rake angle
and orthogonal rake angle are equal. is the
principal cutting edge angle and its range is
0o 90o . The chip flows in the orthogonal plane.
The value of is closest to
(a) 00
(b) 450
0
(c) 60
(d) 900
ISRO2011
(a) 10o
31
IES 1994
IES1994
IES 1995
IES1995
IES2009
35
33
IAS 2009Main
Rev.1
36
GATE2001
IES1994
GATE2011
During
D i orthogonal
h
l cutting
i off mild
ild steell with
ih
a 10 rake angle tool, the chip thickness ratio
was obtained as 0.4. The shear angle (in
degrees)
g
) evaluated from this data is
(a)6.53
(b)20.22
( )
(c)22.94
( )
(d)50.00
37
38
IES 2004
(a) 0.3
0.31
(b)
0.133
0.
(c) 3.00
(d)
3.34
operation is .
The
shear
plane
angle
for
the
(b) 45
((c)) 330
43
Minimum
shear
strain
in
Mi i
h
i
i
g
turning
g with a cutting
g
orthogonal
tool of zero rake angle is
(a) 0.0
00
((b)) 0.55
(c) 1.0
(d) 2.0
41
GATE 2012
GATE2012
GATE(PI)1990
39
IES 2009
GATE2014
40
p
g to an orthogonal
g
g
Details pertaining
metal cutting
process are given below.
Chip thickness ratio
04
0.4
Undeformed thickness
0.6 mm
R k angle
Rake
l
+10
Cutting speed
2.5 m/s
Mean thickness of primary shear zone 25 microns
The shear strain rate in s1 during the process is
(a) 0.1781105
(b) 0.7754105
5
( ) 1.010410
(c)
(d) 4.397105
Page 6 of 205
44
42
IES2004
Considerthefollowingstatementswithrespectto
thereliefangleofcuttingtool:
1 Thisaffectsthedirectionofchipflow
1.Thisaffectsthedirectionofchipflow
2.Thisreducesexcessivefrictionbetweenthetool
andworkpiece
d
k i
3.Thisaffectstoollife
4.Thisallowsbetteraccessofcoolanttothetool
workpieceinterface
p
Whichofthestatementsgivenabovearecorrect?
(a) 1and2
(b) 2and3
(c) 2and4
(d) 3and4
Rev.1
45
IES2006
IES2004
Considerthefollowingstatements:
1. Alargerakeanglemeanslowerstrengthofthe
cuttingedge.
cuttingedge
2. Cuttingtorquedecreaseswithrakeangle.
Whichofthestatementsgivenaboveis/arecorrect?
((a)) Only1
y
((b)) Only2
y
(c) Both1and2
(d) Neither1nor2
46
The
angle
Th rake
k angle
l off a cutting
tti tool
t l is
i 15,
shear
h
l 45
and cutting
g velocity
y 35 m/min.
/
What is the velocity
y
of chip along the tool face?
(a) 28.5 m/min
(b)
27.3 m/min
(d)
23.5 m/min
47
48
IES 2014
IES
IES2008
Considerthefollowingstatements:
Inanorthogonalcuttingthecuttingratioisfoundtobe
0 75.Thecuttingspeedis60m/minanddepthofcut2 4
075.Thecuttingspeedis60m/minanddepthofcut24
mm.Whichofthefollowingarecorrect?
1
1.
Chipvelocitywillbe45m/min
Chipvelocitywillbe45m/min.
2. Chipvelocitywillbe80m/min.
3 Chipthicknesswillbe18mm.
3.
Chipthicknesswillbe1 8mm
4. Chipthicknesswillbe32mm.
Selectthecorrectanswerusingthecodegivenbelow:
l
h
h
d
b l
(a) 1and3
(b) 1and4
(c) 2and3
(d) 2and4
IES2001
IAS2003
52
(a)
V cos
cos( )
V cos
sin( )
(b)
(d)
V sin
cos ( )
V sin
sin( )
50
IES2003
An orthogonal cutting operation is being
carried out under the following conditions:
cutting
tti speed
d = 2 m/s,
/ depth
d th off cutt = 0.5 mm,
chip thickness = 0.6 mm. Then the chip
velocity is
(a) 2.0
2 0 m/s (b) 2.4
2 4 m/s
(c) 1.0 m/s (d) 1.66 m/s
(c)
49
IES2004,ISRO2009
Match.ListIwithListIIandselectthecorrectanswer
usingthecodesgivenbelowtheLists:
ListI
ListII
A. Planapproachangle
1.
Toolface
B Rakeangle
B.
2
2.
Toolflank
C. Clearanceangle
3.
Toolfaceandflank
D Wedgeangle
D.
W d
l
4.
C i d
Cuttingedge
5.
Toolnose
A
B
C
D
A
B
C
D
(a) 1
4
2
55
(b) 4
1
33
2
(c) 4
1
2
3
(d) 1
4
3
5
51
IAS2002
Inorthogonalcutting,shearangleistheanglebetween
Inorthogonalcutting shearangleistheanglebetween
((a)) Shearplaneandthecuttingvelocity
p
g
y
(b) Shearplaneandtherakeplane
(c) Shearplaneandtheverticaldirection
(d) Shearplaneandthedirectionofelongationofcrystalsin
thechip
Page 7 of 205
53
Rev.1
54
IAS2000
IAS1998
IAS1995
(b)
2.51
(c)
48
(d)
151
55
56
G
2009 ( ) CommonDataS1
GATE
2009(PI)
G
2009 ( ) CommonDataS2
GATE
2009(PI)
thickness
hi k
i 0.2 mm.
is
thickness
hi k
i 0.2 mm.
is
((a)) 26.8
((a)) 8
((b)) 27.8
7
((c)) 28.8
((d)) 29.8
9
((b)) 10
((c)) 12
61
GATE1995
Plainmillingofmildsteelplateproduces
(a) egu a s aped d sco t uous c ps
(a)Irregularshapeddiscontinuouschips
(b)Regularshapeddiscontinuouschip
(c)Continuouschips ithoutbuiltupedge
(c)Continuouschipswithoutbuiltupedge
(d)Joinedchips
59
IES 2007
IES2007
57
((d)) 14
4
58
Duringmachining,excessmetalisremovedintheform
ofchipasinthecaseofturningonalathe.Whichofthe
followingarecorrect?
C ti
Continuousribbonlikechipisformedwhenturning
ibb lik hi i f
d h t
i
1. Atahighercuttingspeed
2. Atalowercuttingspeed
A l
i
d
3. Abrittlematerial
4. Aductilematerial
Ad
il
i l
Selectthecorrectanswerusingthecodegivenbelow:
( ) 1and3
(a)
d
(b) 1and4
d
(c) 2and3
(d) 2and4
GATE2002
IAS1997
Considerthefollowingmachiningconditions:BUEwill
Considerthefollowingmachiningconditions BUEwill
formin
(a) Ductilematerial.
60
Abuiltupedgeisformedwhilemachining
Ab ilt
d i f
d hil
hi i
(a)Ductilematerialsathighspeed
(b)
Highcuttingspeed.
(b)Ductilematerialsatlowspeed
p
Smalluncutchipthickness.
(c)Brittlematerialsathighspeed
(d)Brittlematerialsatlowspeed
Page 8 of 205
62
Rev.1
63
Workbook
Ch1:MechanicsofBasicMachiningOperation
G
2009
GATE2009
IES1997
Friction
can be
F i ti att the
th toolchip
t l hi interface
i t f
b reduced
d
d by
b
64
65
ESE2000(Conventional)
A l i off Metal
Analysis
M t l Cutting
C tti
BySKMondal
68
LinkedAnswerQuestionsGATE2013S1
GATE2010(PI)LinkedS2
g
g of an engineering
g
g alloy,
y, it has
In orthogonal
turning
been observed that the friction force acting at the chip
tool interface is 402.5 N and the friction force is also
perpendicular to the cutting velocity vector. The feed
velocity is negligibly small with respect to the cutting
velocity.
l it The
Th ratio
ti off friction
f i ti
f
force
t normall force
to
f
associated with the chiptool interface is 1. The uncut
chip thickness is 0.2
0 2 mm and the chip thickness is 0.4
04
mm. The cutting velocity is 2 m/s.
Assume that the energy expended during machining is
completely converted to heat. The rate of heat
generation (in W) at the primary shear plane is
(a) 180.5 (b)For-2015
200.5 (IES,
(c) 302.5
(d) 402.5
GATE & PSUs)
70
Option
p
Q. No
Option
p
11
12
13
14
15
16
17
18
19
10
20
66
GATE2010(PI)LinkedS1
The
the
Th following
f ll i data
d t from
f
th orthogonal
th
l cutting
tti test
t t
is available. Rake angle = 100, chip thickness ratio =
0.35, uncutt chip
hi thickness
thi k
= 0.51 mm, width
idth off cutt =
3 mm, yield shear stress of work material = 285
2, mean friction
N/
N/mm
f i ti
coefficient
ffi i t on tool
t l face
f
=
0.65,
Determine
()
(i)
Cutting force (F
( c)
(ii) Radial force
(iii) Normal force (N) on tool and
(iv) Shear force (Fs ).
)
67
Q. No
LinkedAnswerQuestionsGATE2013S2
(a) zero
(b) 3.58
(c) 5
(d) 7.16
Page 9 of 205
(c) 20oo
(d) 2500
Rev.1
72
GATE 2014
GATE2014
Which pair of following statements is correct for
orthogonal cutting using a singlepoint cutting
tool?
P. Reduction in friction angle increases cutting force
Q Reduction in friction angle decreases cutting force
Q.
R. Reduction in friction angle increases chip thickness
S Reduction
S.
R d i in
i friction
f i i angle
l decreases
d
chip
hi thickness
hi k
(a) P and R
(b) P and S
(c) Q and R
(d) Q and S
S 1999
999
IAS
GATE1997
In
process, rake
I an orthogonal
th
l cutting
tti
k angle
l off the
th
(b)
42.25
(c) 47.75
47 75
(d)
50 5
50.5
73
Mild steel
machined
speed
t l is
i being
b i
hi d att a cutting
tti
d off
200 m/min with a tool rake angle of 10. The width of
cutt and
d uncutt thickness
thi k
are 2 mm and
d 0.2 mm
respectively. If the average value of coefficient of
f i ti between
friction
b t
th tool
the
t l and
d the
th chip
hi is
i 0.5 and
d the
th
shear stress of the work material is 400 N/mm2,
(b) 30
(c) 60
(d) 40
74
ESE2005Conventional
(a) 45
75
g
g experiment,
p
g
In an orthogonal
cutting
an HSS tool having
g
g experiment,
p
g
In an orthogonal
cutting
an HSS tool having
system (ORS)
(
) has
h been
b
used:
d 0107710751. Given
system (ORS)
(
) has
h been
b
used:
d 0107710751. Given
material = 460
N/mm2;
(i) shear
h
angle
l and
d
Sh
Shear
plane
l
angle
l (in
(i degree)
d
) for
f minimum
i i
cutting
tti force
f
Mi i
Minimum
power requirement
i
t (in
(i kW) att a cutting
tti speed
d
is
of 150 m/min is
Determine
76
IES 2010
IES2010
The relationship between the shear angle ,
the friction angle and cutting rake angle
is given as
79
(a) 20.5
(b) 24.5
(c) 28.5
(d) 32.5
77
(a) 3.15
(b) 3.25
IES2005
(d) 3.45
78
IES2003
Which
is
Whi h one off the
h following
f ll i
i the
h correct
expression for the Merchant's machinability
constant?
(a) 2 +
(b) 2 +
(c) 2
(d) +
(Where = shear angle, = friction angle
and = rake angle)
Page 10 of 205
(c) 3.35
80
(b)
969.6 N
(c) 479.4 N
(d)
69.6 N
Rev.1
81
IES 2014
IES
GATE 2007(PI)CommonData1
2007 (PI) C
D t 1
GATE
IES2000
(a)2
( b)2
( c)
( d) 2
2
82
g
g test,, the following
g
In an orthogonal
machining
observations were made
Cutting force
1200 N
Thrust force
500 N
T l rake
Tool
k angle
l
zero
Cutting speed
1 m/s
Depth of cut
0.8 mm
Chip thickness
1.5 mm
Chip speed along the tool rake face will be
( ) 0.83
(a)
8 m/s
/
(b) 0.53 m/s
/
85
(c) 1.2 m/s
(d) 1.88 m/s
IFS2012
83
GATE 2011(PI)LinkedS1
GATE
2011 (PI) Linked S1
GATE 2007(PI)CommonData2
2007 (PI) C
D t 2
GATE
88
g
g test,, the following
g
In an orthogonal
machining
observations were made
Cutting force
1200 N
Thrust force
500 N
T l rake
Tool
k angle
l
zero
Cutting speed
1 m/s
Depth of cut
0.8 mm
Chip thickness
1.5 mm
Friction angle during machining will be
( ) 22.6
(a)
6o (b) 32.8
8o
( ) 57.1o
(c)
(d) 67.4
6 o
84
GATE 2011(PI)LinkedS2
GATE
2011 (PI) Linked S2
GATE2006CommonDataQuestions(1)
GATE2006CommonDataQuestions(2)
Inanorthogonalmachiningoperation:
I th
l
hi i
ti
Uncutthickness=0.5mm
Cuttingspeed=20m/min Rakeangle=15
Widthofcut=5mm
Widthofcut
5mm
Chipthickness=0.7mm
Chipthickness
0.7mm
Thrustforce=200N
Cuttingforce=1200N
A
AssumeMerchant'stheory.
M h t' th
Thecoefficientoffrictionatthetoolchipinterfaceis
( )
(a)0.23
(b)
(b)0.46
(c)0.85
(d)0.95
Page 11 of 205
89
87
Inanorthogonalmachiningoperation:
I th
l
hi i
ti
Uncutthickness=0.5mm
Cuttingspeed=20m/min Rakeangle=15
Widthofcut=5mm
Widthofcut
5mm
Chipthickness=0.7mm
Chipthickness
0.7mm
Thrustforce=200N
Cuttingforce=1200N
A
AssumeMerchant'stheory.
M h t' th
Thepercentageoftotalenergydissipateddueto
f
frictionatthetoolchipinterfaceis
h
l h
f
(a)30%
(b)42%
(c)58%
(d)70%
Rev.1
90
IES1995
GATE2006CommonDataQuestions(3)
Inanorthogonalmachiningoperation:
I th
l
hi i
ti
Uncutthickness=0.5mm
Cuttingspeed=20m/min Rakeangle=15
Widthofcut=5mm
Widthofcut
5mm
Chipthickness=0.7mm
Chipthickness
0.7mm
Thrustforce=200N
Cuttingforce=1200N
A
AssumeMerchant'stheory.
M h t' th
Thevaluesofshearangleandshearstrain,
respectively,are
l
(a)30.3 and1.98
(b)30.3 and4.23
(c)40.2 and2.97
(d)40.2 and1.65
((b))
Tangential
g
force
(d)
Frictional force.
91
IES1997
S 2003 Conventional
C
i
l
ESE2003
97
93
GATE2014
The
Th radial
di l force
f
iin singlepoint
i l
i tooll during
d i
turning operation varies between
(a) 0.2 to 0.4 times the main cutting force
(b) 0.4
0 4 to 0.6
0 6 times the main cutting force
(c) 0.6 to 0.8 times the main cutting
g force
(d) 0.5 to 0.6 times the main cutting force
94
Power
consumption
in
is
P
i
i metall cutting
i
i
mainly due to
(a) Tangential component of the force
(b) Longitudinal component of the force
(c) Normal component
p
of the force
(d) Friction at the metaltool interface
92
IES1999
Consider
the
forces
acting
on a
C
id
h following
f ll i
f
i
finish turning tool:
1. Feed force
2 Thrust force
2.
3. Cutting
g force.
The correct sequence of the decreasing order of
the magnitudes of these forces is
(a) 1, 2, 3
(b) 2, 3, 1
(c) 3, 1, 2
(d) 3, 2, 1
IES2001
95
GATE 1995Conventional
IAS2003MainExamination
While
Whil turning
t
i a C15
C steel
t l rod
d off 160
6 mm diameter
di
t att
315 rpm, 2.5 mm depth of cut and feed of 0.16
mm/rev
/
b a tool
by
t l off geometry
t 00, 100, 80, 90,150, 750,
0(mm), the following observations were made.
Tangential component of the cutting force = 500 N
Axial component
p
of the cutting
g force = 200 N
Chip thickness = 0.48 mm
Draw schematically the Merchant
Merchantss circle diagram
for the cutting force in the present case.
Page 12 of 205
96
98
During
D i tturning
i process with
ith 7 6 6 8 30 1
(mm) ASA tool the undeformed chip thickness of
2.0 mm and
d width
idth off cutt off 2.5 mm were used.
d The
Th
side rake angle of the tool was a chosen that the
machining
hi i
operation
ti
could
ld be
b approximated
i t d to
t be
b
orthogonal cutting. The tangential cutting force and
th
thrust
t force
f
were 1177 N and
d 560
6 N respectively.
ti l
Calculate:
[30 marks]
( ) The
(i)
h side
d rake
k angle
l
(ii) Coefficient of friction at the rake face
(iii) The dynamic shear strength of the work material
Rev.1
99
GATE2007
GATE2007
(b) 1.25
1 25
(c) 0.80
0 80
100
GATE2003CommonDataQuestions(2)
A cylinder
is
li d
i tturned
d on a llathe
th with
ith orthogonal
th
l
machining principle. Spindle rotates at 200 rpm. The
axial
i l feed
f d rate
t is
i 0.25 mm per revolution.
l ti
D th off cutt is
Depth
i
0.4 mm. The rake angle is 10. In the analysis it is found
th t the
that
th shear
h
angle
l is
i 27.75
Intheaboveproblem,thecoefficientoffrictionat
thechiptoolinterfaceobtainedusingEarnestand
Merchanttheoryis
(a)0.18
(b)0.36
(c)0.71
(d)0.98
(d) 0.64
0 64
GATE2008CommonDataQuestion(1)
Orthogonal
O th
l turning
t
i is
i performed
f
d on a cylindrical
li d i l work
k
piece with shear strength of 250 MPa. The following
conditions
diti
are used:
d cutting
tti velocity
l it is
i 180
8 m/min.
/ i feed
f d
is 0.20 mm/rev. depth of cut is 3 mm. chip thickness
ratio
ti = 0.5. The
Th orthogonal
th
l rake
k angle
l is
i 7o. Apply
A l
Merchant's theory for analysis.
Theshearplaneangle(indegree)andtheshear
(
)
forcerespectivelyare
(a)52:320N
(b)52:400N
(c)28:400N
(d)28:320N
102
GATE2008CommonDataQuestion(2)
Orthogonal
O th
l turning
t
i is
i performed
f
d on a cylindrical
li d i l work
k
piece with shear strength of 250 MPa. The following
conditions
diti
are used:
d cutting
tti velocity
l it is
i 180
8 m/min.
/ i feed
f d
is 0.20 mm/rev. depth of cut is 3 mm. chip thickness
ratio
ti = 0.5. The
Th orthogonal
th
l rake
k angle
l is
i 7o. Apply
A l
Merchant's theory for analysis.
ThecuttingandThrustforces,respectively,are
(a)568N;387N (b)565N;381N
(c)440N;342N
(d)480N;356N
104
105
GATE 2013
GATE2013
A cylinder
is
li d
i tturned
d on a llathe
th with
ith orthogonal
th
l
machining principle. Spindle rotates at 200 rpm. The
axial
i l feed
f d rate
t is
i 0.25 mm per revolution.
l ti
D th off cutt is
Depth
i
0.4 mm. The rake angle is 10. In the analysis it is found
th t the
that
th shear
h
angle
l is
i 27.75
Thethicknessoftheproducedchipis
(a)0.511mm
(b)0.528mm
(c)0.818mm
(d)0.846mm
101
103
IES 2004
IES
GATE2003CommonDataQuestions(1)
106
GATE(PI)1991
Page 13 of 205
107
((b)) Milling
g
(c) Reaming
(d) Grinding
Rev.1
108
GATE2007
In
carbon
steel.
I orthogonal
th
l turning
t
i off medium
di
b
t l The
Th
specific machining energy is 2.0 J/mm3. The cutting
velocity,
l it feed
f d and
d depth
d th off cutt are 120 m/min,
/ i 0.2
mm/rev and 2 mm respectively. The main cutting
f
force
i N is
in
i
(a) 40
(b) 80
(c) 400
(d) 800
109
GATE2014
The main cutting force acting on a tool during the
turning (orthogonal cutting) operation of a metal is
400 N. The turning was performed using 2 mm
depth of cut and 0.1 mm/rev feed rate. The specific
cutting pressure is
(a) 1000
Example
Whentherakeangleiszeroduringorthogonalcutting,
showthat
s
pc
(1 r ) r
1+ r2
110
111
GATE1993
GATE1992
The
off rake
angle
h effect
ff
k angle
l on the
h mean friction
f
l in
machining can be explained by
(A) sliding (Coulomb) model of friction
(B) sticking and then sliding model of friction
(C) sticking friction
((D)) Sliding
g and then sticking
g model of friction
The
Th effect
ff t off rake
k angle
l on the
th mean friction
f i ti angle
l in
i
machining can be explained by
( ) Sliding (coulomb)
(a)
(
) model of friction
(b) sticking
g and then siding
g model of friction
(c) Sticking friction
(d) sliding and then sticking model of friction
(b) 2000
(c) 3000
(d) 4000
112
IES2000
113
IES2004
Assertion
(A):
the
A
i
(A) In
I metall cutting,
i
h normall
laws of sliding friction are not applicable.
Reason (R): Very high temperature is
produced at the tool
toolchip
chip interface.
interface
(a) Both A and R are individually true and R is
the correct explanation of A
(b) Both A and R are individually true but R is
not the correct explanation of A
( ) A is
(c)
i true but
b R is
i false
f l
For-2015 (IES, GATE & PSUs)
(d) A is false but R is true
115
114
IES2002
In
process, the
I a machining
hi i
h percentage off
heat carried away by the chips is typically
(a) 5%
(b) 25%
(c) 50%
(d) 75%
Rev.1
117
S 2003
IAS
IES1998
In
operation,
the
I metall cutting
i
i
h approximate
i
ratio of heat distributed among chip, tool
and work, in that order is
(a) 80: 10: 10 (b) 33: 33: 33
(c) 20: 60: 10 (d) 10: 10: 80
Asthecuttingspeedincreases
(a) Moreheatistransmittedtotheworkpieceandless
heatistransmittedtothetool
(b) Moreheatiscarriedawaybythechipandlessheatis
t
transmittedtothetool
itt dt th t l
(c) Moreheatistransmittedtoboththechipandthe
tool
((d)) Moreheatistransmittedtoboththeworkpieceand
p
thetool
118
Theinstrumentordeviceusedtomeasurethecutting
forcesinmachiningis:
( )T h
(a)Tachometer
t
(b)Comparator
(c)Dynamometer
(d)Lactometer
122
S 200
IAS2001
The
off a resistive
pickup
off
Th gauge factor
f
i i
i k
cutting force dynamometer is defined as the
ratio of
(a) Applied strain to the resistance of the wire
(b) The proportional change in resistance to the
applied strain
(c) The resistance to the applied strain
(d) Change in resistance to the applied strain
124
cutting
can
120
IES1996
A 'Dynamometer'
used
the
'D
' is
i a device
d i
d for
f
h
measurement of
(a) Chip thickness ratio
(b) Forces during metal cutting
(c) Wear of the cutting
g tool
(d) Deflection of the cutting tool
121
IES1998
119
IES1993
IES2011
S 2003
IAS
ForPSU&IES
In strain gauge dynamometers the use of how
many active
ti gauge makes
k the
th dynamometers
d
t
more
effective
( ) Four
(a)
(b) Three
(c) Two
(d) One
Rev.1
126
IES 2010
IES2010
ToolFailure
ToolWear,ToolLife&
ToolWear,ToolLife&Machinability
Machinability
B SKM d l
BySKMondal
IAS 2009Main
[
[4
marks]
k ]
distance
129
IES 2014
IES
y Explainsuddendeathmechanismoftoolfailure.
following?
128
127
S 2007
200
IES
from
131
Tool Wear
ToolWear
ToolWear
S 1994
99
IES
Assertion(A):Toolwearisexpressedintermsof
flankwearratherthancraterwear.
Reason(R):Measurementofflankwearissimple
andmoreaccurate.
( ) BothAandRareindividuallytrueandRisthe
(a)
B thA dR i di id ll t dRi th
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
(a)
( ) Flank
Fl k Wear
W
(b) Crater Wear
(c) Chipping
pp g off of the cutting
g edge
g
132
133
Page 16 of 205
134
Rev.1
135
G
20
GATE2014
FlankWear:(Wearland)
Reason
y Abrasion by
y hard p
particles and inclusions in the work
piece.
y Shearing off the micro welds between tool and work
material.
y Abrasion by fragments of builtupedge
built up edge ploughing
against the clearance face of the tool.
y At low
l speed
d flank
fl k wear predominates.
d i t
y If MRR increased flank wear increased.
FlankWear:(Wearland)
136
Effect
y Flank wear directly
y affect the component
p
dimensions
produced.
y Flank wear is usually the most common determinant of
tool life.
137
138
FlankWear:(Wearland)
Stages
FlankWear:(Wearland)
Primary wear
FlankWear:(Wearland)
Tertiary wear
The region
g
where the sharp
p cutting
g edge
g is q
quicklyy
broken down and a finite wear land is established.
The region
g
where wear p
progresses
g
at a g
graduallyy
increasing rate.
y In the tertiary region the wear of the cutting tool has
become sensitive to increased tool temperature due to
high wear land.
y Regrinding is recommended before they enter this
region.
region
Secondar wear
Secondary
ear
The region
g
where the wear p
progresses
g
at a uniform rate.
139
S 2004
200
IES
Consider the following statements:
During the third stage of toolwear, rapid
deterioration of tool edge takes place because
1. Flank wear is only marginal
2. Flank wear is large
33. Temperature
p
of the tool increases g
graduallyy
4. Temperature of the tool increases drastically
Which of the statements given above are correct?
(a) 1 and 3
(b) 2 and 4
(c) 1 and 4
(d) 2 and 3
For-2015 (IES, GATE & PSUs)
140
142
141
IFS2012
Explain
off flank
E l i the
th mechanism
h i
fl k wear off a cutting
tti
tool. Plot a flank wear rate curve and indicate the
region of tool failure.
[10 Marks]
For a critical wear land of 1.8 mm, the cutting tool life (in
minute) is
(a) 52.00
(b) 51.67
51.50
(d) 50.00
Page 17(c)
of 205
143
Rev.1
144
Craterwear
ToollifecriteriaISO
(Acertainwidthofflankwear(VB)isthemostcommon
criterion)
y Uniformwear:0.3mmaveragedoverallpast
Uniformwear:0 3mmaveragedoverallpast
y Localizedwear:0.5mmonanyindividualpast
CraterwearContd..
y More
common in
M
i ductile
d til materials
t i l which
hi h produce
d
continuous chip.
p
y Crater wear occurs on the rake face.
y At very high speed crater wear predominates
y For crater wear temperature is main culprit and tool
d f
defuse
i
into
the
h chip
hi material
i l & tooll temperature is
i
maximum
a
u at so
somee d
distance
sta ce from
o tthee too
tool ttip.
p.
145
S 2002
IES
146
147
S 2007
200
IAS
Craterwearontoolsalwaysstartsatsomedistance
fromthetooltipbecauseatthatpoint
(a) Cuttingfluiddoesnotpenetrate
(b) Normalstressonrakefaceismaximum
(c) Temperatureismaximum
((d)) Toolstrengthisminimum
g
148
S 1995
99
IES
S 2000
IES
Whydoescraterwearstartatsomedistancefrom
thetooltip?
(a) Toolstrengthisminimumatthatregion
(b) Cuttingfluidcannotpenetratethatregion
(c) Tooltemperatureismaximuminthatregion
((d)) Stressonrakefaceismaximumatthatregion
g
149
150
WearMechanism
IES2009Conventional
Craterwearispredominantin
(a) Carbonsteeltools
(b) Tungstencarbidetools
T
t bid t l
(c) Highspeedsteeltools
(d) Ceramictools
Craterwearstartsatsomedistancefromthetooltip
because
(a) Cuttingfluidcannotpenetratethatregion
(b) Stressonrakefaceismaximumatthatregion
(c) Toolstrengthisminimumatthatregion
((d)) Tooltemperatureismaximumatthatregion
p
g
Showcraterwearandflankwearonasinglepoint
Sh t
dfl k
i l i t
cuttingtool.Statethefactorsresponsibleforwear
onaturningtool.
t
i t l
[2marks]
1. Abrasionwear
2. Adhesionwear
3. Diffusionwear
4. Chemicaloroxidationwear
151
Page 18 of 205
152
Rev.1
153
S 2002
IAS
S 1995
99
IES
154
h hi i
ff fi
k
Whychippingofforfinecracks
developedatthecuttingedge
developed at the cutting edge
MatchListIwithListIIandselectthecorrect
answerusingthecodesgivenbelowthelists:
ListI(Weartype) ListII(Associatedmechanism)
A. Abrasivewears
1.
Galvanicaction
B. Adhesivewears
2.
Ploughing action
C. Electrolyticwear
y
33.
Moleculartransfer
D. Diffusionwears
4.
Plasticdeformation
5
5.
Metallicbond
Code:A
B
C
D
A
B
C
D
(a) 2
5
1
3
(b) 5
2
1
3
(c) 2
1
3
4
(d) 5
2
3
4155
156
S 2003
IAS
h
NotchWear
y Tool
T l material
t i l is
i too
t brittle
b ittl
y Weak
k design
d
off tool,
l such
h as high
h h positive rake
k angle
l
y As a result of crack that is already in the tool
y Excessive static or shock loading of the tool.
157
S 1996
996
IES
Notchwearattheoutsideedgeofthedepthofcutis
dueto
(a) Abrasiveactionoftheworkhardenedchipmaterial
(b) Oxidation
(c) Slipstickactionofthechip
((d)) Chipping.
pp g
S 1999
999
IAS
160
158
159
Listtheimportantpropertiesofcuttingtool
materialsandexplainwhyeachisimportant.
materials and explain why each is important
Whyareceramicsnormallyprovidedas
insertsfortools,andnotasentiretools?
inserts for tools and not as entire tools?
161
Ceramicsarebrittlematerialsandcannotprovidethe
p
structuralstrengthrequiredforatool.
Rev.1
162
S 1992
992
IES
ToolLifeCriteria
Tool
T l life
lif criteria
it i can be
b defined
d fi d as a predetermined
d t
i d
numerical value of any type of tool deterioration which
can be
b measured.
d
Some of
the ways
y Actualcuttingtimetofailure.
Toollifeisgenerallyspecifiedby
(a) Numberofpiecesmachined
(b) Volumeofmetalremoved
V l
f t l
d
(c) Actualcuttingtime
(d) Anyoftheabove
y Volumeofmetalremoved.
y Numberofpartsproduced.
Numberofpartsproduced
y Cuttingspeedforagiventime
163
S 2012Main
20 2
i
IAS
y Lengthofworkmachined.
164
ValuesofExponentn
TaylorsToolLifeEquation
Define
tool
four
methods
D fi
t l life
lif and
d list
li t down
d
f
th d for
f
quantitative measurement of tool life.
q
[Marks12]
basedonFlankWear
Causes
y Slidingofthetoolalongthemachinedsurface
y Temperaturerise
VT n = C
166
IES 2012
IES
Where,V=cuttingspeed(m/min)
T=Time(min)
n=exponentdependsontoolmaterial
C=constantbasedontoolandworkmaterialandcutting
167
condition.
S 2008
IES
InTaylor
stoollifeequationVTn =C,theconstantsn
C,theconstantsn
InTaylorstoollifeequationVT
andCdependupon
1 Workpiecematerial
1.Workpiecematerial
2.Toolmaterial
3.Coolant
( )
(a)1,2,and3
3
(b)1and2only
(c)2and3only
(d)1and3only
169
n = 0.08
8 to 0.2 for
f HSS tooll
= 0.1
0 1 to 0.15
0 15 for Cast Alloys
= 0.2 to 0.4 for carbide tool
[IAS1999; IES2006]
= 0.5 to
t 0.7 for
f ceramic
i tool
t l
[
[NTPC2003]
3]
168
S 2006
IES
InTaylor
stoollifeequationisVTn =constant.
InTaylor'stoollifeequationisVT
Whatisthevalueofnforceramictools?
( ) 0.15to0.25
(a)
t
(b) 0.4to0.55
t
(c) 0.6to0.75
(d) 0.8to0.9
Page 20 of 205
165
170
Rev.1
171
S 1999
999
IES
S 1998
998
IAS
(
g
)
MatchList I(Cuttingtoolmaterial)withList
II
(Typicalvalueoftoollifeexponent'n'intheTaylor's
equationV.Tn =C)andselectthecorrectanswerusing
th d i
thecodesgivenbelowthelists:
b l th li t
List I
List II
A HSS
A.
1.
0.18
8
B. Castalloy
2.
0.12
C Ceramic
C.
C
i
3.
0.25
D. Sinteredcarbide 4.
0.5
Codes:A
d
B
C
D
A
B
C
D
(a) 1
2
3
4
(b) 2
1
3
4
( ) 2
(c)
1
4
3
( ) 1
(d)
2
4
3
172
( )
GATE2009(PI)
In an orthogonal machining operation, the tool life
obtained is 10 min at a cutting speed of 100 m/min,
while at 75 m/min cutting speed, the tool life is 30
min The value of index (n) in the Taylor
min.
Taylorss tool life
equation
(a) 0.262
(b) 0.323
174
G
200
GATE2004
(d) 0.521
173
ISRO2011
A 50 mm diameter
steell rod
d
d was turned
d at 284 rpm and
d
(c) 0.423
S 2000
IES
1
8
(b)
1
4
(c )
1
3
(d )
1
2
( a )2
( b )3
( c )4
( d ) 8
speed
d and
d tooll life,
l f the
h value
l off Taylorian
l
Exponent is
(a) 0.21
0 21
(b) 0.13
0 13
(c) 0.11
0 11
(d) 0.23
0 23
175
176
S 1999,ISRO2013
999 S O 20 3
IES
177
S 2002
IAS
S 1995
99
IAS
In
operation
off steel
I a singlepoint
i l
i t turning
t
i
ti
t l with
ith a
Using
the
equation
VTn = c, calculate
U i
th Taylor
T l
ti
l l t the
th
percentage
p
g increase in tool life when the cutting
g
increase by
(a) 300%
(b)
400%
(c) 100%
(d)
50%
( ) Two times
(a)
(b)
Four times
(d)
Sixteen times
the
h tooll life
lif will
ill become
b
(a) Half
(b) Two times
(c) Eight times
178
Page 21 of 205
Rev.1
180
IES 2013
IES2013
S 1997
99
IAS
S 2006conventional
2006
i
l
IES
In
I the
th Taylor's
T l ' tool
t l life
lif equation,
ti
VTn = C,
C the
th value
l
An
The
A HSS tool
t l is
i used
d for
f turning
t
i operation.
ti
Th tool
t l life
lif is
i
of n = 0.5.
5 The tool has a life of 180 minutes at a
( ) 200
(a)
( ) 9 m/min
(a)
(b)
18 m/min
mm diameter
di
t so that
th t tool
t l life
lif is
i 30 min.
i
(b) 180
(c) 36 m/min
(d)
72 m/min
(c) 150
(d) 100
181
GATE2009LinkedAnswerQuestions(1)
182
IFS2013
GATE2009LinkedAnswerQuestions(2)
Inamachiningexperiment,toollifewasfoundtovary
withthecuttingspeedinthefollowingmanner:
Cuttingspeed(m/min)
Toollife(minutes)
60
81
90
36
Theexponent(n)andconstant(k)oftheTaylor's
p
( )
( )
y
toollifeequationare
(a)n=0.5andk=540
(a)n
0.5andk 540
(b)n=1andk=4860
(b)n
1andk 4860
(c)n=1andk=0.74
(d)n0.5andk=1.15
183
Inamachiningexperiment,toollifewasfoundtovary
withthecuttingspeedinthefollowingmanner:
Cuttingspeed(m/min)
Toollife(minutes)
60
81
90
36
Whatisthepercentageincreaseintoollifewhen
p
g
thecuttingspeedishalved?
(a)50%
(b)200%
(c)300%
(d)400%
120
50
Derive Taylor's
y
tool life equation
q
for this operation
p
and estimate the tool life at a speed of 2.5 m/s. Also
estimate the cutting speed for a tool life of 80 min.
184
185
Example
p
GATE 2013
GATE2013
G
20 0
GATE2010
For
F tool
t l A,
A Taylors
T l tool
t l life
lif exponentt (n)
( ) is
i 0.45 and
d
constant ((K)) is 9
90. Similarly
y for tool B,, n = 0.33 and K
( ) 26.7
(a)
Wh
Where
V is
i the
h cutting
i speed
d in
i m/min
/ i and
d T is
i the
h
(b) 42.5
( ) 80.7
(c)
(d) 142.9
186
Thefollowingdatawasobtainedfromthetoollife
cuttingtest:
CuttingSpeed,m/min:49.74
d
49 4 49
49.23
23 48
48.67
6 4
45.76
6 42
42.58
8
Toollife,min
2.94 3.90 4.77 9.87 28.27
DeterminetheconstantsoftheTaylortoollifeequation
VTn =C
(a) 15.0
187
(b) 39.4
(c) 49.3
(d) 60.0
Page 22 of 205
188
Rev.1
189
GATE2003
components while working at 50 rpm with a tool
feed of 0.25
0 25 mm/rev and depth of cut of 1 mm.
mm A
similar batch of 10 tools of the same specification
p
could produce 122 components while working at 80
What
change
is
Wh t is
i approximate
i t percentage
t
h
i the
th life,
lif t,
t
of a tool with zero rake angle
g used in orthogonal
g
cutting when its clearance angle, , is changed from
10o to 7o?
(
(Hint:
Flank
l k wear rate is proportionall to cot ))
(a) 30 % increase
(b) 30%,
30% decrease
one cutting
g tool at 60 rpm?
p
(a) 29
(b) 31
(c) 37
(d) 42
190
IES 2010
IES2010
191
193
S 1994,2007
99 200
IES
Considerthefollowingelements:
C
id th f ll i l
t
without any
y constraints,, what is the right
g sequence
q
to adjust the cutting parameters?
2.
Feed
3.
Depth of cut
(b)
2 3 1
(c) 3 2 1
(d)
1 3 2
196
1
1.
Noseradius
2
2.
Cuttingspeed
33.
Depthofcut
p
4.
Feed
ThecorrectsequenceoftheseelementsinDECREASING
orderoftheirinfluenceontoollifeis
(a) 2,4,3,1
(b)
4,2,3,1
( ) 2,4,1,3
(c)
(d)
4,2,I,3
I
194
S 2008
IES
For
F increasing
i
i the
th material
t i l removall rate
t in
i turning,
t
i
192
S 1997
99
IES
((a)) Feed
Speed
ii.ee Cuttingspeedhasthegreatereffectfollowedbyfeed
anddepthofcutrespectively.
ISRO2012
1.
E t d d M difi d T l
ti
ExtendedorModifiedTaylorsequation
G
999
GATE1999
S 1995
99
IAS
Whatarethereasonsforreductionoftoollifeina
machiningoperation?
1 Temperatureriseofcuttingedge
1.
2. Chippingoftooledgeduetomechanicalimpact
3. Gradualwearsattoolpoint
4. Increaseinfeedofcutatconstantcuttingforce
4
g
Selectthecorrectanswerusingthecodegiven
below:
(a) 1,2and3
(b) 2,3and4
( ) 1,3and4
(c)
d
(d) 1,2and4
d
Page 23 of 205
195
197
198
T l Lif C
ToolLifeCurve
S 999 S 20 0 C
i
l
ESE1999;IAS2010Conventional
IFS2009
The
Th following
f ll i equation
ti for
f tool
t l life
lif was obtained
bt i d for
f HSS
tool. A 60 min tool life was obtained using
g the following
g
speed,
d feed
f d and
d depth
d th off cutt are together
t th increased
i
d by
b
25%
5 and also if theyy are increased individuallyy byy 25%;
5 ;
[
[10Marks]
]
2.Carbide
3.Ceramic
199
S 20 0 C
i
l
IES2010Conventional
y Drawtoollifecurvesforcastalloy,Highspeedsteeland
ceramictools.
[2 Marks]
Ans.
1.Highspeedsteel
2.castalloyand3.ceramictools.
202
Cuttingspeedusedfordifferent
toolmaterials
l
l
200
S 2003
IAS
IES2010
The above figure shows a typical
relationship between tool life and
cutting
g speed
p
for different
materials. Match the graphs for
HSS, Carbide and Ceramic tool
materials
i l and
d select
l
the
h correct
answer using the code given
below the lists:
Code: HSS Carbide Ceramic
(a) 1
2
3
(b) 3
2
1
(c) 1
3
2
(d) 3
1
2
ThetoollifecurvesfortwotoolsAandBareshownin
thefigureandtheyfollowthetoollifeequationVTn =C.
Considerthefollowingstatements:
g
1.
2.
3.
4.
Valueofnforboththetoolsissame.
ValueofCforboththetoolsissame.
ValueofCfortoolAwillbegreaterthanthatforthetoolB.
ValueofCfortoolBwillbegreaterthanthatforthetoolA.
a ue o C o too
be g eate t a t at o t e too .
Whichofthesestatementsis/arecorrect?
(a) 1and3
(b) 1and4
(c) 2only
(d) 4only
203
EffectofRakeangleontoollife
204
EffectofClearanceangleontoollife
If clearance angle increased it reduces flank wear but
weaken the cutting edge, so best compromise is 80 for
HSS and 50 for carbide tool.
201
tooll life.
lif
y With larger grain size tool life is better.
205
Page 24 of 205
206
Rev.1
207
IES 2013Con.Answer
IES 2013Conventional
IES
2013 Conventional
ForIESOnly
4.AsCast
207
60
40
ToollifeTests
y Conventionaltest:Usingempiricalformula
y Acceleratedtest:Estimatethetoollifequickly
A l t dt t E ti t th t llif i kl
Extrapolatingofsteadywearrate
Highspeedtestwilltakelesstime
Variablespeedtest
Multipassturning
Taperturning
p
g
Draw a figure
D
fi
showing
h i
variation
i i
off tooll life
lif with
ih
cutting speed and the effect of workpiece hardness
and
d microstructure.
i
208
IES 2014
IES
209
ChipEquivalent
ChipEquivalent(q) =
Refer:B.LJuneja+Nitin Seth
Engaged
E
d cutting
tti edge
d llength
th
Plan area of cut
edge
affecting
d without
ih
ff i the
h area off cut. As
A a result,
l the
h
chip equivalent changed.
changed When the SCEA is increased,
211
212
213
IES1996
Chip equivalent is increased by
(a) An increases in sidecutting edge angle of tool
(b) An increase in nose radius and side cutting
edge angle of tool
(c) Increasing the plant area of cut
(d) Increasing the depth of cut.
214
Page 25 of 205
215
Rev.1
216
Formula
Vo Ton = C
O ti
Optimum
tool
t l life
lif for
f minimum
i i
costt
C 1 n
To = Tc + t
if Tc , Ct & Cm given
C
m n
C 1 n
= t
if Ct & Cm given
Cm n
Optimum tool life for Maximum Productivity
(minimum production time)
1 n
To = Tc
Toolingcost(Ct)=toolregrindcost
) toolregrindcost
+tooldepreciationperservice/replacement
Machiningcost(Cm)=labour cost+overheadcostper
min
217
G
20
GATE2014
218
219
S 200 C
i
l
ESE2001Conventional
If the
th Taylors
T l tool
t l life
lif exponentt n is
i 0.2, and
d the
th
tool changing
g g time is 1.55 min,, then the tool life ((in
min) for maximum production rate is .
220
G
200
GATE2005
S 2009 C
i
l
IES2009Conventional
Units:Tc min(Toolchangingtime)
Ct Rs./servicingorreplacement(Tooling
/
i i l
(
li
cost)
Cm Rs/min(Machiningcost)
V m/min(Cuttingspeed)
/
(
g p
)
221
S 2007Contd
200
C d
IAS
223
IAS 2011Main
g
g economics with
A diagram
related to machining
various cost components is given above. Match List I
(Cost Element) with List II (Appropriate Curve) and
select the correct answer using the code given below
the Lists:
ListI
ListII
(CostElement)
(AppropriateCurve)
A. Machiningcost
1.
Curvel
2.
Curve2
B. Toolcost
C. Toolgrindingcost
3.
Curve3
D Non
D.
Nonproductivecost
productivecost 4.
4
Curve4
Curve
4
5.
Curve5
Page 26 of 205
224
222
Contd
Contd.
From previous slide
Code:A
(a) 3
(c) 3
B
2
1
C
4
4
D
5
2
(b)
(d)
A
4
4
B
1
2
Rev.1
C
3
3
D
2
5
225
MinimumCostVsProductionRate
IES2011
The optimum cutting speed is one which should
have:
1. High
Hi h metal
t l removall rate
t
2. High cutting tool life
3. Balance the metal removal rate and cutting
tool life
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
( ) 3 only
(d)
226
S 1998
998
IES
S 2000
IES
Inturning,theratiooftheoptimumcuttingspeed
forminimumcostandoptimumcuttingspeedfor
maximumrateofproductionisalways
(a) Equalto1
(b) Intherangeof0.6to1
I th
f 6t
(c) Intherangeof0.1to0.6
(d) Greaterthan1
230
S 2004
200
IES
232
228
S 1997
99
IAS
229
227
S 2002
IAS
S 1999
999
IES
g statements:
Consider the following
1. As the cutting speed increases, the cost of production
initially reduces, then after an optimum cutting speed it
increases
2. As the cutting speed increases the cost of production
also
l increases
i
and
d after
f a critical
i i l value
l it
i reduces
d
3. Higher feed rate for the same cutting speed reduces cost
of production
4. Higher feed rate for the same cutting speed increases the
cost of production
Which of the statements given above is/are correct?
(a) 1 and 3
(b) 2 and 3
(c) 1 and 4
(d) Page
3 only
27 of 205
233
231
S 2002
IES
Ineconomicsofmachining,whichoneofthe
followingcostsremainsconstant?
(a) Machiningcostperpiece
(b) Toolchangingcostperpiece
(c) Toolhandlingcostperpiece
((d)) Toolcostperpiece
p p
Rev.1
234
IES 2010
IES2010
S 2007
200
IAS
Assertion (A): The optimum cutting speed for the
minimum cost of machining may not maximize the
profit.
Reason (R): The profit also depends on rate of
production.
production
(a) Both A and R are individually true and R is the
correctt explanation
l
ti off A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
235
236
MachinabilityDefinition
Machinability can be tentatively defined as ability
ability of
being machined and more reasonably as ease of
machining.
machining.
Such ease of machining or machining characters
of any toolwork pair is to be judged by:
y Tool
237
ForIESOnly
FreeCuttingsteels
y Addition
carbon
Additi off lead
l d in
i low
l
b resulphurised
l h i d steels
t l and
d
IES 2012
IES
MachinabilityIndex
OrMachinabilityRating
O M hi bilit R ti
The machinability index KM is defined by
KM = V60/V60R
Wh
Where
V60 is
i the
th cutting
tti
speed
d for
f the
th target
t
t material
t i l
that ensures tool life of 60 min, V60R is the same for the
reference
f
material.
t i l
If KM > 1, the machinability of the target material is
better that this of the reference material, and vice versa
238
239
240
ForIESOnly
S 1996
996
IAS
MachinabilityofSteel
Assertion(A):Themachinabilityofamaterialcan
bemeasuredasanabsolutequantity.
Reason(R):Machinabilityindexindicatesthecase
withwhichamaterialcanbemachined
( ) BothAandRareindividuallytrueandRisthe
(a)
B thA dR i di id ll t dRi th
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
For-2015 (IES, GATE & PSUs)
241
ForIESOnly
MachinabilityofSteelcontd
steel.
y Resulfurized
R
lf i d steel:
t l Sulfur
S lf is
i added
dd d to
t steel
t l only
l if
there is sufficient manganese in it. Sulfur forms
manganese sulfide
lf d which
h h exists as an isolated
l d phase
h
and act as internal lubrication and chip breaker.
y If insufficient manganese is there a low melting iron
sulfide will formed around the austenite grain
boundary. Such steel is very weak and brittle.
y Tellurium and selenium is similar to sulfur.
sulfur
Page 28 of 205
242
Rev.1
243
ForIESOnly
MachinabilityofSteelcontd
y Stainless Steel: Difficult to machine due to abrasion.
abrasion
y Aluminum and Silicon in steel: Reduce machinability
ForIESOnly
IES 2011 C
ti
l
IES2011Conventional
RoleofmicrostructureonMachinability
g elements on the
y Discuss the effects of the following
machinability of steels:
(i) Aluminium and silicon
(ii) Sulphur and Selenium
(iii) Lead
L d and
d Tin
Ti
(iv) Carbon and Manganese
(v) Molybdenum and Vanadium
ForIESOnly
[5 Marks]
Coarsemicrostructureleadstolesservalueofs.
Therefore,
Th
f
s canbedesirablyreducedby
b d i bl d db
y Properheattreatmentlikeannealingofsteels
y Controlledadditionofmaterialslikesulphur (S),lead
((Pb),Tellerium
)
etcleadingtofreecuttingofsoftductile
g
g
metalsandalloys.
y Brittlematerialsarerelativelymoremachinable.
244
245
246
ForIESOnly
S 1992
992
IES
Toollifeisgenerallybetterwhen
(a) Grainsizeofthemetalislarge
(b) Grainsizeofthemetalissmall
G i i fth t li
ll
(c) Hardconstituentsarepresentinthemicrostructure
ofthetoolmaterial
((d)) Noneoftheabove
hi bili i
y Buttoomuchincreaseinrakeweakensthecuttingedge.
Buttoomuchincreaseinrakeweakensthecuttingedge
247
248
ForIESOnly
EffectsofCuttingEdgeangle(s)on
machinability
S 2000
IAS
Considerthefollowingstatements:
Thetoollifeisincreasedby
1. Builtupedgeformation
B ilt d f
ti
2. Increasingcuttingvelocity
3. Increasingbackrakeangleuptocertainvalue
Whichofthesestatementsarecorrect?
(a) 1and3
(b) 1and2
( ) 2and3
(c)
d
(d) 1,2and3
d
249
ForIESOnly
Effectsofclearanceangleonmachinability
ForIESOnly
EffectsofNoseRadiusonmachinability
Proper
tool
improves
machinability
P
t l nose radiusing
di i
i
hi bilit to
t
some extent through
y increase in tool life by increasing mechanical strength
and reducing temperature at the tool tip
y reduction of surface roughness, hmax
surface
f
fi i h sizeably
finish
i bl in
i continuous
ti
chip
hi formation
f
ti
hence Machinability.
y
Page 29 of 205
251
hmax
f2
=
8R
Rev.1
252
S 1992
992
IES
S 2007,2009
200 2009
IES
ISRO2007
Considerthefollowing:
Easeofmachiningisprimarilyjudgedby
E
f
hi i i i
il j d db
(a) Lifeofcuttingtoolbetweensharpening
1.
Toollife
Machinability depends on
(b) Rigidityofworkpiece
g y
p
2.
Cuttingforces
(c) Microstructureoftoolmaterial
3.
Surfacefinish
(d) Shapeanddimensionsofwork
253
Whichoftheaboveis/arethemachinability
( ) Cutting forces
(b)
criterion/criteria?
(a) 1,2and3
(b)
1and3only
(c) 2and3only
(d)
2only
S 2003
IES
formation during
g machining
g are
(a) Sulphur, lead and phosphorous
(b) Sulphur, lead and cobalt
(c) Aluminium, lead and copper
(d) Aluminium, titanium and copper
following
Considerthefollowingcriteriainevaluating
machinability:
1 Surfacefinish 2.
1.
2
Typeofchips
3. Toollife
4.
Powerconsumption
InmodernhighspeedCNCmachiningwithcoated
carbidetools,thecorrectsequenceofthesecriteria
inDECREASINGorderoftheirimportanceis
((a)) 1,2,4,3
4 3
((b)) 2,1,4,3
4 3
(c) 1,2,3,4
(d) 2,1,3,4
257
S 1996
996
IES
the
255
S 1998
998
IES
The
Th elements
l
t which,
hi h added
dd d to
t steel,
t l help
h l in
i chip
hi
256
of
254
S 2009
IES
) The machinability
y of steels improves
p
Assertion ((A):
by adding sulphur to obtain so called 'Free
Machining Steels.
Reason (R): Sulphur in steel forms manganese
sulphide inclusion which helps to produce thin
ribbon like continuous chip.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
Which
258
S 1996
996
IES
indicate
better
S 1995
99
IES
Small
S ll amounts
t off which
hi h one off the
th following
f ll i
Inlowcarbonsteels,presenceofsmallquantities
I l b t l
f
ll
titi
machinability?
elements/pairs
/p
of elements is added to steel to
sulphur
p
improves
p
1.
(a) Weldability
(b)
Formability
2.
(a) Nickel
(b)
(c) Machinability
(d)
Hardenability
3.
L
Longer
tooll life
lif
(c) Silicon
(d)
(b)
2 and 4
259
Page 30 of 205
260
Rev.1
261
ForIESOnly
ForIESOnly
S 1992
992
IES
MachinabilityofTitanium
y Titanium
is
Tit i
i very reactive
ti and
d the
th chips
hi tend
t d to
t weld
ld to
t
S 2013Conventional
20 3 C
i
l
IES
Machiningoftitaniumisdifficultdueto
M hi i ftit i
i diffi ltd t
(a) Highthermalconductivityoftitanium
chipping.
(b) Chemicalreactionbetweentoolandwork
causing high
h h temperature rise and
d BUE.
Why
titanium
have
poor machinability?
Wh does
d
tit i
h
hi bilit ?
(c) Lowtoolchipcontactarea
(d) Noneoftheabove
titanium.
262
263
264
IES 2002
IES
S f
h
SurfaceRoughness
IES1995
Consider
C
id the
th following
f ll i work
k materials:
t i l
1. Titanium
2.
Mild steel
3. Stainless steel
4.
Grey cast iron.
The correct sequence of these materials in terms of
increasing order of difficulty in machining is
(a) 4,
4 2,
2 3,
3 1
(b) 4,
4 2,
2 1,
1 3
(c) 2, 4, 3, 1
(d) 2, 4, 1, 3
y Ideal
( Zero
nose radius)
Id l Surface
S f
Z
di )
f
tan SCEA + cot ECEA
h
f
and (Ra) =
=
4 4 ( tan SCEA + cot ECEA )
y Practical
P ti l Surface
S f
( with
ith nose radius
di = R)
h=
f2
8R
Ra =
and
f2
18 3R
266
IAS 1996
IAS
IES 1999
IES
Given that
S = feed in mm/rev. and
R = nose radius
di in
i mm,
the maximum height of surface roughness Hmax
produced by a singlepoint turning tool is given by
((a)) S2/2R
(b) S2/4R
(c) S2/4R
(d) S2/8R
For-2015 (IES, GATE & PSUs)
267
268
GATE 1997
GATE
In
operation,
the
I turning
t
i
ti
th feed
f d could
ld be
b doubled
d bl d to
t
Acuttingtoolhasaradiusof1.8mm.Thefeedrate
A tti t lh di f 8
Th f d t
foratheoreticalsurfaceroughnessofis5mis
g
5
(a) 0.268mm/rev
should be
(b) 0.187mm/rev
( ) Halved
(a)
l d
(b)
Kept unchanged
h
d
(c) 0.036mm/rev
(c) doubled
(d)
(d) 0.0187mm/rev
Page 31 of 205
269
Rev.1
270
GATE 2007(PI)
2007 (PI)
GATE
GATE 2005
GATE
10o
(b) 0.26 mm
(c) 0.32 mm
(d) 0.48 mm
tan 8o + cot15o
tan 8o + cot 30o
tan15o + cot7o
(c )
tan 30o + cot7o
(a)
271
IES 2006
IES
IES 1993,ISRO2008
1993 ISRO 2008
IES
tan15o + cot 8o
tan 30o + cot 8o
tan7o + cot15o
(d )
tan7o + cot 30o
(b)
requirement
q
of surface finish would p
put a limit on
which of the following?
(a) The maximum feed
(b) The maximum depth of cut
( ) The
(c)
Th maximum
i
speed
d
is
(a) Depth of cut
(b)
Cutting speed
(c) Feed
(d)
273
Cutting fluid
Cuttingfluid
turning
g the most important
p
factor to be controlled
272
In
off optimal
conditions,
the
I the
th selection
l ti
ti l cutting
tti
diti
th
For
finish
F achieving
hi i a specific
ifi surface
f
fi i h in
i single
i l point
i t
277
275
276
IES 2001
IES
y Whatareextremepressurelubricants?
[3 marks]
g
pressures and rubbing
p
g action are
Where high
encountered, hydrodynamic lubrication cannot be
maintained; so Extreme Pressure (EP) additives must be
added
dd d to the
h lubricant.
l bi
EP lubrication
l b i i is
i provided
id d by
b a
number of chemical components such as boron,
phosphorus sulfur,
phosphorus,
sulfur chlorine,
chlorine or combination of these.
these
The compounds are activated by the higher temperature
resulting from extreme pressure.
pressure As the temperature
rises, EP molecules become reactive and release
derivatives such as iron chloride or iron sulfide and
forms a solid protective coating.
Page 32 of 205
278
Rev.1
279
Workbook
Ch4:EconomicsofMachiningOperation
Workbook
Ch3:CuttingTools,ToolLifeandCuttingFluid
IES 2012
IES
Themostimportantfunctionofthecuttingfluidisto
(a)Providelubrication
(b)C lth t l d
(b)Coolthetoolandworkpiece
k i
(c)Washawaythechips
(d)Improvesurfacefinish
Q. No
Q
Option
p
Q. No
Q
Option
p
Q. No
Q
Option
p
Q. No
Option
Q. No
Option
12
23
13
24
14
25
15
26
2
3
B
A
7
8
A
C
16
27
17
28
18
29
19
30
20
31
10
21
32
11
22 B
280
33
B
C
C
281
282
283
Page 33 of 205
Rev.1
Terminology
Terminology
y Nominal size: Size of a part specified in the drawing.
It
I is
i used
d for
f generall identification
id ifi i purpose.
y Basic size: Size of a part to which all limits of
Limit Tolerance&Fits
Limit,Tolerance&Fits
BySKMondal
TerminologyContd....
Terminology
Contd
Terminology
Contd....
Terminology
Terminology
Contd....
+0 10
+0.10
0.10
BilateralLimits occurwhenthemaximumlimitisabove
andtheminimumlimitisbelowthebasicsize.
e.g. 25 -0.10
-0.20
Basic
B
i Size
Si
= 25
25.00
00 mm
Upper Limit = 24.90 mm
Lower Limit = 24.80 mm
Tolerance = 0.10 mm
e.g. 25 0.04
Basic Size = 25.00 mm
Upper Limit = 25.04 mm
Lower Limit = 24.96 mm
Tolerance = 0.08 mm
Terminology
Contd
Terminology
Contd....
ForPSU
ISRO2010
Tolerancesarespecified
( ) Toobtaindesiredfits
(a)
b
d
df
(b) becauseitisnotpossibletomanufactureasize
exactly
((c)) toobtainhigheraccuracy
g
y
(d) tohaveproperallowances
y Deviation:
D i i
I the
Is
h algebraic
l b i difference
diff
b
between
a size
i
th maximum
the
i
size
i and
d the
th basic
b i size.
i
For-2015 (IES, GATE & PSUs)
Page 34 of 205
Rev.1
Terminology
Contd
Terminology
Contd....
GATE 2010,ISRO2012
2010 ISRO 2012
GATE
GATE 1992
GATE
g
y Lower deviation: Is the algebraic
difference between
0.009
and
d lower
l
d
deviations.
y Fundamental deviation: This is the deviation,
deviation either
(b) 0.025,0.016
(d) 0.009,0.016
11
GATE 2004
2004
GATE
IES 2005
IES
12
GATE 2000
GATE
p
y the designer
g
The tolerance specified
by
for the
diameter of a shaft is 20.00 0.025 mm. The shafts
produced by three different machines A, B and C
have mean diameters of 1999 mm, 2000 mm and
20.01 mm respectively, with same standard
d i ti
deviation.
Wh t will
What
ill be
b the
th percentage
t
rejection
j ti
f
for
the shafts produced by machines A, B and C?
( ) Same
(a)
S
f the
for
th machines
hi
A Band
A,
B d C since
i
th standard
the
t d d
deviation is same for the three machines
(b) Least
L t for
f machine
hi A
(c) Least for machine B
(d) Least for machine C
13
14
Clearance Fits
Fit
15
GATE 2007
GATE
0 .0 5 0
Hole
Fits:(assemblyconditionbetweenHole&Shaft)
H l Afeatureengulfing
Hole
Af t
lfi acomponent
Max C
Min C
Shaft Afeaturebeingengulfed
g g
bya
y
component
Tolerancezonesnevermeet
Shaft
TwoshaftsAandBhavetheirdiametersspecifiedas
100 0.1mmand0.1 0.0001mmrespectively.
Whichofthefollowingstatementsis/aretrue?
(a) ToleranceinthedimensionisgreaterinshaftA
(b) Therelativeerrorinthedimensionisgreaterinshaft
A
(c) ToleranceinthedimensionisgreaterinshaftB
(d) Therelativeerrorinthedimensionissameforshaft
AandshaftB
16
Theclearancefitsmaybeslidefit,easyslidingfit,running
Page 35 of 205
17
fit,slackrunningfitandlooserunningfit.
A hole is specified as 4 0 0 . 0 0 0
mm. The mating
shaft has a clearance fit with minimum clearance of
0.01 mm. The tolerance on the shaft is 0.04 mm. The
maximum clearance in mm between the hole and
the shaft is
(a) 0.04
(b) 0.05
(c) 0.10
(d) 0.11
Rev.1
18
Transition Fits
Interference Fits
Hole
Hole
M C
Max
Max I
Tolerancezonesalways
overlap
Shaft
Shaft
IES2011
Tolerancezonesnevermeet
butcrosseseachother
Interference
fit
f
f joints are provided
d d for:
f
(a) Assembling bush bearing in housing
Min I
Max I
(b) Mounting
ou t g heavy
ea y duty gea
gearss o
on sshafts
a ts
(c) Mounting pulley on shafts
Max. C = UL of hole - LL of shaft
Max. I = LL of hole - UL of shaft
Thetransitionfitsmaybetightfitandpushfit,wringing
Thetransitionfitsmaybetightfitandpushfit
wringing
fit(Gear,pulleyonshaft),pressfit.
19
IES 2013
IES2013
Theinterferencefitsmaybeshrinkfit,heavydrivefitand
h
f
f
b h kf h
d
f
d
lightdrivefit.
20
IES 2014
GATE 2005
GATE
In
interference
fit,
I order
d to
t have
h
i t f
fit it is
i essential
ti l that
th t
interference fits?
(d) Joint
J i off lathe
l h spindle
i dl and
d its
i bearing
b i
22
GATE2011
A hole is of dimension 9
+0.015
0 015
+0
corresponding
p
g shaft is of dimension
The resulting assembly has
(a) loose running fit
(b) close running fit
( ) transition
(c)
t
iti fit
(d) interference fit
9 +0.001
mm.
25++0.03
0 02
0.02
Page 36 of 205
24
25+0.04
0.01
mm.
25
23
GATE2012SameQinGATE2012(PI)
mm. The
21
26
Rev.1
27
IES 2007
IES
IES 2006
IES
ISRO2011
Which
fit?
Whi h off the
th following
f ll i is
i an interference
i t f
Ashaftandholepairisdesignatedas50H7d8.
Thisassemblyconstitutes
(b) Running
g fit
(a)Interferencefit
(b)Transitionfit
(c)Clearancefit
(d)Noneoftheabove
28
29
IES 2009
IES
IES 2008
IES
Allowance
34
32
33
GATE 2001
2001
GATE
IES 2004
IES
31
30
GATE 1998
GATE
Allowance
in
to
All
i limits
li it and
d fits
fit refers
f
t
In
and
I the
th specification
ifi ti off dimensions
di
i
d fits,
fit
hole
shaft
tolerance.
tolerance
Page 37 of 205
35
Rev.1
36
IES 2012
IES
IES 2012Conventional
2012 C
ti
l
IES
S O 20 0
ISRO2010
Clearance
in
between
Cl
i a fit is
i the
th difference
diff
b t
Explain
the
between
tolerance
and
l
h difference
d ff
b
l
d
allowance.
allowance
+0.02
Dimension of the hole is 50+0.02
mm
0.00 mm and shaft is 50 +0.00 mm.
(b) 0.00 mm
(d) 0.01
0 01 mm
37
5.BasisofFits HoleBasis
Legends:
Hole
Shaft
Tolerance
C - Clearance
T - Transition
I - Interference
38
ForIESOnly
BasisofFits ShaftBasis
H l basis
b i system: When
Wh
Hole
the hole is kept as a
constant
member
(i.e.
t t
b
(i
when the lower deviation of
th
the
h l
hole
i zero)) and
is
d
different fits are obtained
b varying
by
i
th shaft
the
h ft size
i
then the limit system is said
t be
to
b on a hole
h l basis.
b i
For hole basis system, H
stands for dimensions of
holes
whose
lower
deviation is zero.
Legends:
Hole
Shaft
Tolerance
C - Clearance
T - Transition
I - Interference
Sh f basis
b i system: When
Wh
Shaft
the shaft is kept as a
constant
member
(i.e.
t t
b
(i
when the upper deviation
off the
th shaft
h ft is
i zero)) and
d
different fits are obtained
b varying
by
i
th hole
the
h l size
i
then the limit system is said
t be
to
b on a shaft
h ft basis.
b i
For shaft basis system, h
stands for dimensions of
shafts
whose
upper
deviation is zero.
40
( ) Zero, Zero
(c)
increases cost of
production.
d i
42
IES 2005
IES
41
ISRO2008
(a) +ve, ve
39
43
IFS 2013
IFS
44
Explain,
the
E l i with
ith the
th help
h l off sketches,
k t h
th concepts
t off
hole basis and shaft basis in terms of assembly
y fit
specifications. Which of the two is preferred and
why?
[
[8Marks]
k ]
Rev.1
45
ToleranceZone
It is defined graphically
b th
by
the magnitude
it d off th
the
Tolerance Zone tolerance and by its
position in relation to the
zero line.
55
20
Basic Size
46
DiameterSteps
p
Above
(mm)
3
6
10
18
30
50
80
120
180
250
315
400
500
ValueoftheTolerance
IT01
IT0
IT1
IT3
ar2
IT4
ar3
IT5
ar4 = 7i
IT7
IT8
IT9
Upto andincluding
(mm)
3
3
6
10
10
18
30
50
80
120
120
180
250
250
315
400
10(1.6)(ITn -IT6)
= 16i
IT11
10(1.6)(ITn -IT6)
= 100i
IT15
10(1.6)(ITn -IT6)
49
= 640i
10(1.6)(ITn -IT6)
= 25i
IT12
10(1.6)
(
)(ITn -IT6)
= 160i
10(1.6)(ITn -IT6)
= 40i
IT13
10(1.6)(ITn -IT6)
= 250i
IT2
ar
r = 101/5
IT6
IT6)
10(1.6)
10(1
6)(ITn -IT6)
= 10i
IT10
10(1.6)(ITn -IT6)
= 64i
IT14
T l
Tolerance
on a shaft
h ft or a hole
h l can be
b calculated
l l t d by
b using
i
table provided.
T = K i
Where, T isthetolerance(inm)
in m
d
f l
GradesofTolerance
y It is
i an indication
i di ti off the
th level
l l off accuracy.
y IT01 to IT4
= 400i
IT16
10(1.6)(ITn -IT6)
= 1000i
ToleranceDesignation(IS)
50
work
51
FundamentalDeviations
Fundamental Deviation
is chosen to locate the tolerance zone w.r.t. the zero line
C l l ti f U
dL
D i ti
CalculationforUpperandLowerDeviation
y ForShaft
ei =es IT
es =ei
ei +IT
y ForHole
EI=ES IT
ES=EI+IT
S
52
es =upperdeviationofshaft
ei =lowerdeviationofshaft
ES
ES=upperdeviationofhole
d i ti fh l
Page 39 of 205
EI=lowerdeviationofhole
53
Rev.1
54
GATE 2014
GATE2014
de
at o refers
e e s to tthee bas
e. Thee hole
o e H for
o which
c
deviation
basicc ssize.
the lower deviation is zero is called a basic hole.
y Similarly,
y, for shafts,, h stands for a dimension whose
upper deviation refers to the basic size. The shaft h for
which the upper deviation is zero is called a basic
shaft.
y A fit is designated by its basic size followed by symbols
representing the limits of each of its two components,
the hole being quoted first.
y For example, 100 H6/g5 means basic size is 100 mm
and the tolerance grade for the hole is 6 and for the
shaft
h ft is
i 5.
Forthegivenassembly:25H7/g8,matchGroupAwith
GroupB
Basicsize
HoleToleranceZone
ShaftToleranceZone
FundamentalDeviation
IT#
55
IES 2008
IES
56
58
GATE 2009
GATE
pp
What are the upper
and lower limits of the shaft
represented by 60 f8?
Use the following data:
Diameter 60 lies in the diameter step of 5080 mm.
Fundamental tolerance unit,
i, in m= 0.45 D1/3 + 0.001D, where D is the
representative size in mm;
T l
Tolerance
value
l for
f lT8 = 25i.
i
Fundamental deviation for 'f shaft = 5.5D0.41
( ) Lower limit
(a)
l
= 59.924 mm, Upper Limit = 59.970 mm
(b) Lower limit = 59.954 mm, Upper Limit = 60.000 mm
( ) Lower limit = 59.970 mm, Upper Limit = 60.016 mm
(c)
For-2015
(IES,
GATE
& Limit
PSUs)= 60.046 mm 61
(d) Lower limit
= 60.000
mm,
Upper
GroupB
P.H
I.ShaftType
Q IT8
Q.IT8
II HoleType
II.HoleType
R.IT7
III.HoleToleranceGrade
S.g
IV.ShaftToleranceGrade
( )
(a)
(c)
P
I
II
Q
III
III
R
IV
IV
S
II
I
( )
(b)
(d)
P
I
II
Q
IV
IV
Page 40 of 205
57
60
GATE 2000
GATE
GATE 2008(PI)
2008 (PI)
GATE
S
II
I
59
R
III
III
IES 2002
IES
S 2006 C
i
l
IES2006Conventional
GroupA
62
63
GATE 2003
GATE
R
RecommendedSelectionofFits
d d S l ti
f Fit
GATE2010(PI)
65
66
ForIESOnly
GATE 1996,IES2012
1996 IES 2012
GATE
IES 2000
IES
SelectiveAssembly
67
Process capability
T l
Tolerance
desired
d i d
68
69
ForIESOnly
Interchangeability
y Interchangeability, a maintainability design factor, is
p
parts
of equivalent
q
size will be equally
q
y fit for operating
p
g in
machines and mechanisms and the mating parts will
give the required
g
q
fitting.
g
y This facilitates to select at random from a large number
off parts
t for
f an assembly
bl and
d results
lt in
i a considerable
id bl
saving in the cost of production, reduce assembly time,
replacement
l
t and
d repair
i becomes
b
very easy.
For-2015 (IES, GATE & PSUs)
70
ISRO2008
IAS2010main
(a) Standardization
(c) Simplification
(d) Better
B
product
d
planning
l
i
Page 41 of 205
[12Marks]
71
Rev.1
72
GATE 2003
2003
GATE
ToleranceSink
GATE 1997
GATE
Three blocks B1 , B2 and B3 are
to be inserted in a channel of
width S maintaining a
minimum
i i
gap off width
idth T =
0.125 mm, as shown in Figure.
For P = 18.
18 75 0.08;
0 08;
Q = 25.00 0.12;
R = 28.125
28 125 0.1
0 1 and
S = 72.35 + X, (where all
dimensions are in mm),
mm) the
tolerance X is
y A design
engineer keeps
one section off the
d
k
h part blank
bl k
(a)+0 38
(a)+0.38
73
(b) Runout
(c) Perpendicularity
(d) Flatness
0 050
b t
between
30++0.050
the plating
l ti thickness
thi k
varies
i
+0.010 mm. If th
electroplated
l t
l t d in
i a shop.
h
Thickness
Thi k
off the
th
(a) 30
+0.070
+0.030
( ) 30
(c)
+0.080
0 080
+0.030
mm
mm
+0.065
+0.020
mm
+00.070
070
+0.040
mm
(b) 30
(d) 30
77
Limit Gauges
LimitGauges
the size of the low limit of the hole while the NOT GO plug
gauge corresponds to the high limit of the hole.
y Snap, Gap or Ring gauge: used for gauging the shaft and
male components. The Go snap gauge is of a size
corresponding
di to the
h high
hi h (maximum)
(
i
) limit
li i off the
h shaft,
h f
while the NOT GO gauge corresponds to the low
(minimum limit).
limit)
Fig.Pluggauge
Fig.Ringandsnapgauges
For-2015 (IES, GATE
& PSUs)
79
75
GATE 2013
GATE2013
76
(d)0
(d)
0.05
05
GATE 2007(PI)
2007 (PI)
GATE
The g
geometric tolerance that does NOT need a datum
(a) Concentricity
(c)+0 05
(c)+0.05
74
GATE 2007(PI)
GATE
2007(PI)
for its specification is
(b) 0.38
(b)
0 38
ISRO2008
y
g
g tolerance zone lies
y Unilateral system:
gauge
Page 42 of 205
78
80
Rev.1
81
Bilateral system:
y
in this
Example
l
Size of the hole to be checked 25 00.02
02 mm
Here, Higher
g
limit of hole = 25.02 mm
Lower limit of hole = 24.98 mm
W k tolerance
Work
l
= 0.04
0 04 mm
Gauge
y Wearallowance:GOgaugeswhichconstantlyrub
T ki example
Taking
l as above:
b
Dimension
Dimension of 'GO'
GO Plug gauge = 24.98
24 98
+0.002
mm
0.002
+0.002
+
0 002
Dimension of 'NOT GO' Plug gauge = 25.02
mm
0.002
againstthesurfaceofthepartsintheinspectionare
subjectedtowearandloosetheirinitialsize.
y Thesizeofgopluggaugeisreducedwhilethatofgo
Th i f l
i d d hil h f
snapgaugeincreases.
y Toincreaseservicelifeofgaugeswearallowanceis
addedtothegogaugeinthedirectionoppositeto
wear.Wearallowanceisusuallytakenas5%ofthe
worktolerance.
y Wearallowanceisappliedtoanominaldiameter
g g
pp
beforegaugetoleranceisapplied.
83
84
Takingexampleofabove:
Wear
W
Allowance
All
= 5% off work
k ttolerance
l
= 0.002
0 002 mm
Nominal size of GO p
plugg ggauge
g = 24.98 + 0.002 mm
+0.004
Dimension of 'GO' Plug
g gauge
g g = 24.982
mm
0.000
+0.000
+
0.000
Dimension of 'NOT GO' Plug gauge = 25.02
mm
0.004
GATE 2014
GATE
GATE 2004
GATE
A GO
NOGO plug gauge is to be designed for
GONOGO
measuring a hole of nominal diameter 25 mm with a
hole tolerance of 0.015 mm. Considering 10% of
work tolerance to be the gauge tolerance and no
wear condition, the dimension (in mm) of the GO
plug gauge as per the unilateral tolerance system is
(a ) 24.985
(c) 24.985
24 985
+0.003
0 003
0.003
+0.03
0 03
0.03
(b) 25.015
+00.000
000
0.006
(d ) 24
24.985
985
85
+0.003
000
00.000
GO and NO
GO plug gages are to be designed for a
NOGO
0.05
hole 200.01 mm. Gage tolerances can be taken as 10%
of the hole tolerance.
tolerance Following ISO system of gage
design, sizes of GO and NOGO gage will be
respectively
(a) 20.010 mm and 20.050 mm
(b) 20.014 mm and 20.046 mm
((c)) 20.006 mm and 20.054
54 mm
(d) 20.014 mm and 20.054 mm
86
87
ForIESOnly
GATE 1995
GATE
Checking the diameter of a hole using GO
NO GO
GONOGO
gauges is an, example of inspection by
..(variables/attributes)
The above statement is
( ) Variables
(a)
V i bl
(b) Attributes
(c) Cant say
(d) Insufficient data
TaylorssPrinciple
Principle
Taylor
GATE 2006,VS2012
2006 VS 2012
GATE
88
This
be
Thi principle
i i l states
t t that
th t the
th GO gauge should
h ld always
l
b
so designed
g
that it will cover the maximum metal
condition (MMC) of as many dimensions as possible in
the same limit gauges, whereas a NOT GO gauges to
cover the
th minimum
i i
metal
t l condition
diti
off one dimension
di
i
only.
y
Page 43 of 205
89
Rev.1
90
ForIESOnly
ForIESOnly
Preferred Number
PreferredNumber
y Motor
power, machine
tool
M t speed,
d engine
i
hi
t l speed
d and
d
y Many
other
M
th derived
d i d series
i are formed
f
d by
b multiplying
lti l i or
10 1.58,
10
10 1.26,
20
(
R10 : 1.26 :1.0,1.25,1.6,... (
R 20 : 1.12 :1.0,1.12,1.4,... (
R5 : 1.58 :1.0,1.6, 2.5,...
)
1000,....)
10
20
10, 20 100, 20
R 40 : 1.06 :1.0,1.06,1.12,...
40
91
MeasurementofLines&Surfaces
BySKMondal
92
93
Vernier Caliper
Li
Linearmeasurements
t
Some of the instruments used for the linear
measurements are:
y Rules
y Vernier
y Micrometer
y Height
g g
gauge
g
y Bore gauge
y Dial indicator
y Slip gauges or gauge blocks
scale.
scale
y The vernier scale is that a certain number n of divisions on
94
S O 20 0
ISRO2010
96
Metric Micrometer
MetricMicrometer
ISRO2008
Vernier Caliper
95
in common use.
divisions = 0.5
0 5 mm) is
Method of Measurement
97
((a)) 0.0055 mm
((b)) 0.01 mm
StepI:
p Find the whole number of mm in the barrel
(c) 0.02 mm
(d) 0.005mm
Page 44 of 205
98
99
B
G
d for
f measuring
i
b
diff
y Bore
Gauge:
used
bores
off different
,
ISRO2009,2011
Micrometer
((a)) 2.620 mm
((b)) 2.512
5 mm
(c) 2.120 mm
(d) 5.012 mm
100
p
into a radial
displacement
movement to measure over a
g of movement for the
small range
plunger.
y The typical least count that can be
obtained with suitable gearing
dial indicators is 0.01 mm to 0.001
mm.
y It is possible to use the dial
indicator as a comparator by
mounting it on a stand at any
suitable height.
101
GATE 2008
2008
GATE
Applicationsofdialindicatorinclude:
y offsettinglathetailstocks
y aligningaviceonamillingmachine
li i i illi
hi
y checkingdimensions
GATE 2008contdfromS2
2008
td f
S2
GATE
If Rp= RQ>0, which one of the
following would be consistent with the
observation?
(A) The drill spindle rotational axis is
coincident with the drill spindle taper
hole axis
(B) The drill spindle rotational axis
intersects the drill spindle taper hole
axis at point P
(C) The drill spindle rotational axis is
parallel to the drill spindle taper hole
axis
(D) The drill spindle rotational axis
intersects the drill spindle taper hole
axis at point Q
For-2015 (IES, GATE & PSUs)
104
105
GATE 2014(PI)S1
2014(PI)
S1
GATE
GATE 2014(PI)S2
2014(PI)
S2
GATE
S1
S1
Principleofadialindicator
103
102
Page 45 of 205
107
Rev.1
108
Sli G
SlipGaugesorGaugeblocks
G
bl k
y These are small blocks of alloy steel.
steel
y Used in the manufacturing shops as length standards.
y Not
N t
t
to
b
be
used
d for
f
regular
l
and
d continuous
ti
measurement.
y Rectangular blocks with thickness representing the
dimension of the block. The crosssection of the block
is usually 32 mm x 9 mm.
y Are hardened and finished to size. The measuring
g
surfaces of the gauge blocks are finished to a very high
g
of finish, flatness and accuracy.
y
degree
p a Slip Ga
ge pile to 41
125 mm
To make up
Gauge
41.125
q
set to suit the requirements
of measurements.
y A typical set consisting of 88 pieces for metric units is
shown in.
in
y To build any given dimension, it is necessary to
identify a set of blocks, which are to be put together.
y Number of blocks used should always
y be the smallest.
y Generally the top and bottom Slip Gauges in the pile
are 2 mm wear gauges.
gauges This is so that they will be the
only ones that will wear down, and it is much cheaper
to replace two gauges than a whole set.
p Gauge p
e iss set up with
t tthe
e use o
pe
yAS
Slip
pile
of ssimple
109
case 41.125mm.
41 125mm
y Take away
y the thickness of the two wear g
gauges,
g ,
110
111
p a Slip Ga
ge pile to 41
125 mm
To make up
Gauge
41.125
41.125
-4.000
______
37.125
-1.005
_______
36.120
-1.020
_______
35.100
-1.100
_______
34 000
34.000
-4.000
_______
30.000
-30.000
_______
0.000
pg g
Slipgaugessizeor
range,mm
1 005
1.005
1.001to1.009
1 010to1 490
1.010to1.490
0.500 to9.500
10to100
112
,
Increment,mm
0.001
0 010
0.010
0.500
10 000
10.000
Numberof
Pieces
1
9
49
19
10
113
114
Comparators
ISRO2010
A master gauge is
(a) A new gauge
(b) An international reference standard
( ) A standard
(c)
t d d gauge for
f checking
h ki
accuracy off
gauges used on shop floors
(d) A gauge used by experienced technicians
ISRO2008
maths.
115
Page 46 of 205
116
117
GATE 2007(PI)
2007 (PI)
GATE
FeelerGauge
Fig. Principleofacomparator
118
119
Mechanical Comparators
MechanicalComparators
Li it G
LimitGauges
PSU
Afeelergaugeisusedtocheckthe
(a)Pitchofthescrew
(b)Surfaceroughness
Gauge
ForMeasuring
SnapGauge
ExternalDimensions
PlugGauge
InternalDimensions
T
TaperPlugGauge
Pl G
T
Taperhole
h l
g
g
RingGauge
ExternalDiameter
(c)Thicknessofclearance
GapGauge
GapsandGrooves
(d)Fl
(d)Flatnessofasurface
f f
RadiusGauge
Gaugingradius
ThreadpitchGauge
ExternalThread
121
120
greatly
magnifies
any
deviation in size so that
even
small
deviations
produce large deflections of
the pointer over the scale.
122
Si
h i lC
SigmaMechanicalComparator
123
MechanicalComparators
The
Mechanical
uses a partially
Th Sigma
Si
M h i l Comparator
C
t
ti ll
wrapped
pp band wrapped
pp about a driving
g drum to turn a
springs.
i
SigmaMechanicalComparator
124
Page 47 of 205
125
Rev.1
126
O ti l C
OpticalComparators
t
P
PneumaticComparators
ti C
t
PneumaticComparators
y Flow
Fl type:
t
y The float height is essentially proportional to the air
the scales
y The
Th
i
input
pressure
i
is
regulated
l d
to
allow
ll
magnification
ag cat o adjust
adjustment
e t
127
A
AngularMeasurement
l M
t
128
129
B lP t t
BevelProtractor
This
the
and
Thi involves
i
l
th measurementt off angles
l off tapers
t
d
y Is
I partt off the
th machinist's
hi i t' combination
bi ti square.
tools are:
y Bevel protractor
y Sine bar
d
discrimination
off one degree.
d
ABevelProtractor
130
131
132
Sine Bar
SineBar
ISRO2011
can be
b used.
d
y Basically a sine bar is a bar of known length. When gauge blocks
are placed under one end, the sine bar will tilt to a specific
angle.
g
formula.
(d) The
Th distance
di
b
between
rollers
ll and
d upper surface
f
two rollers, i.e. 100 mm, 200 mm, & 300 mm. the various part of
sine bar are hardened before grinding & lapping.
133
H
s i n48 of=205
Page
L
134
Rev.1
135
d
Disadvantages
Th d M
ThreadMeasurements
t
y 1. Sine
bars
cannott be
conveniently
Si
b
b used
d for
f
i tl for
f
Threadsarenormallyspecifiedbythemajordiameter.
y Threadsarenormallyspecifiedbythemajordiameter
GATE2012(PI)
A sine bar has a length of 250 mm. Each roller has
a diameter
di
t
off 20 mm. During
D i
t
taper
angle
l
measurement of a component,
p
, the height
g from the
(c) 23.6
engineering,themostcommonthreadencounteredis
engineering
themostcommonthreadencounteredis
themetricVthreadshowninFig.
sometimes introduce
d
considerable
d bl errors.
adjustment problems.
y Thoughtherearealargevarietyofthreadsusedin
(a) 21.1
measuring
g angles
g
more than 60o because of slip
pg
gauge
g
(d) 68.9
136
137
138
Three-Wire Method
y Theparametersthatarenormallymeasuredare:
y Majordiameter
M j di
t
y Micrometer
on one side
id and
d one on other
th side
id
y Pitchdiameter
y Screwthreadmicrometer
y Wiremethod
wires (M)
y Pitch
y Screwpitchgauge
y Pitchmeasuringmachine
y Threadform
y Opticalprojector
139
140
( )
GATE 2011(PI)
W = D p + d 1 + cosec cot
2 2
2
W = D + 3d 11.5156
5156 p
sec
2
2
For ISO metric thread, = 60
d = 0.5774 p
d=
D p = pitch
it h di
diameter
t or Eff
Effective
ti di
diameter
t
For-2015
(IES,
GATE
& PSUs)
p = pitch
of thread
, and
= thread
angle
142
Page 49 of 205
141
143
Rev.1
144
GATE 2013
GATE2013
( )
GATE 2011(PI)
A metric
t i thread
th d off pitch
it h 2 mm and
d thread
th d angle
l 60
6
inspected
p
for its p
pitch diameter using
g 33wire
method. The diameter of the best size wire in mm is
(a) 0.866
(b) 1.000
(c) 1.154
(d) 2.000
145
S f
Surfaces
146
y Surfacegeometrycanbequantifiedafewdifferent
y No
is
N surface
f
i perfectly
f tl smooth,
th but
b t the
th better
b tt the
th
can
be
difficult
to
analyse
quantitatively.
l
y Realsurfacesarerarelysoflat,orsmooth,butmost
y
commonlyacombinationofthetwo.
147
ways.
surface q
quality,
y, the longer
g a p
product g
generallyy lasts,,
y Surface
Measurement of Surfaces
MeasurementofSurfaces
149
150
p
g than that of roughness
g
greater spacing
width.
ag
y Determined by the height of the waviness and its
width.
y The greater the width, the smoother is the surface and
thus is more desirable.
desirable
y Lay direction: is the direction of the predominant
surface
f
pattern
tt
produced
d d on the
th workpiece
k i
b the
by
th tool
t l
marks.
y Flaw:
l
are surface
f
irregularities
l
that
h are present which
h h are
random and therefore will not be considered.
For-2015 (IES, GATE & PSUs)
151
Page 50 of 205
152
Rev.1
153
Lay
Di
Diagram
S b l
Symbol
LayContd..
D
i i
Description
Di
Diagram
S b l
Symbol
y Layy parallel
p
Parallel lay:
to
the Surface. Surface is
produced
p
byy
shaping,
p g,
planning etc.
y Layy
Multidirectional lay:
multidirectional. Surface is
produced byy g
p
grinding,
g,
lapping, super finishing.
Circular lay:
Approximately
circular
relative to the center.
center
Surface is produced by
facing.
facing
Radiallay:Approximately
radialrelativetothecenter
ofthenominalsurface. 155
RepresentationofSurfaceRoughness
i
f
f
h
157
IES 2012
IES2012
D
i i
Description
Roughness
Ra (m)
50
RoughnessGrade
Number
RoughnessSymbol
N12
255
12.5
N11
N10
63
6.3
N9
3.2
N8
1.6
N7
0.8
N6
0.4
N5
0.2
N4
0.1
N3
0.05
N
N2
0.025
N1
Which grade
broaching?
(a) N12 (b)
(c) N4 (d)
158
159
l i
fS f
h
EvaluationofSurfaceRoughness
What
Wh t is
i meantt by
b interchangeable
i t h
bl manufacture?
f t ?
160
156
IFS2011
[2marks]
IES 1992
IES
valleys
y Roughness
R
h
width
idth cutoff
t ff a value
l greater
t than
th the
th
maximum roughness width that is the largest
separation
ti
off surface
f
i
irregularities
l iti included
i l d d in
i the
th
measurements. Typical values are (0.003, 0.010,
0.030, 0.100, 0.300))
y Lay the direction the roughness pattern should
f ll
follow
y Stylus travel is perpendicular to the lay specified.
g
What are theyy ? Define the terms 'roughness
[
[10marks]
k ]
Page 51 of 205
161
162
i i
f
i
DeterminationofMeanLine
i i
f
i
DeterminationofMeanLine
y MSystem:
After
MS t
Aft
plotting
the
l tti
th characteristic
h
t i ti off any
surface a horizontal line is drawn by joining two points.
Thi line
This
li is
i shifts
hift up and
d down
d
i such
in
h a way that
th t 50%
%
area is above the line and 50% area is below the line
Arithmetical Average:
y ESystem:
(Envelop
System)
off 25 mm
ES t
(E
l
S t ) A sphere
h
1
1
Ra = y ( x) dx
L0
N
163
RRMS =
1
N
165
IES 2006
IES
ISRO2011
The
in
are related
Th M and
d Esystem
E
t
i metrology
t l
l t d to
t
CLAvalueandRMSvaluesareusedformeasurement
measurement of:
of
2
i
164
y Theotherparameterthatisusedsometimesistheroot
meansquarevalueofthedeviationinplaceofthe
arithmeticaverage,Thisinexpressionformis
(a)Metalhardness
(b)
Flatness
(c) Angularity
(d)
Surface finish
(b)Sharpnessoftooledge
(c)Surfacedimensions
(d)Surfaceroughness
Fig.Surfaceroughnessparameters
166
167
IES 2007
IES
IES 2008
IES
IES2010
What
Wh t is
i the
th dominant
d
i
t direction
di ti off the
th tool
t l marks
k or
What
is
off the
Wh t term
t
i used
d to
t designate
d i
t the
th direction
di ti
th
predominant
p
quality, called?
machining operation?
surface
pattern
p
produced
p
Secondary texture
(a) Roughness
(b)
Lay
(c) Lay
Flaw
(c) Waviness
(d)
Cut off
(d)
168
169
Page 52 of 205
by
y
170
(a)
(c)
A
4
4
B
2
1
C
1
2
D
3
3
(b)
(d)
A
B
3
2
3 Rev.1
1
C
1
2
D
4
4 171
IES 2008
2008
IES
ISRO2010
Surface
roughness
on a drawing
is represented
f
h
d
d by
b
IAS 2013Main
For a machined surface, show macro and micro
(a) Triangles
(b) C
Circles
c es
(c) Squares
E l i any three
Explain
th
off them.
th
(d) Rectangles
172
173
Ob
ObservationMethods
ti M th d
St l E i
StylusEquipment
t
y Human
perception
H
ti is
i highly
hi hl relative.
l ti
y To give the human tester a reference for what they are
perceptive to surface
f
roughness
h
should
be
made
against
matched
identical processes.
y Interferometry
y uses light
g wave interference p
patterns
(discussed later)
174
y One
O method
h d off note is
i the
h finger
fi
nail
il assessment off
roughness
oug ess aand
d touc
touch method.
et od.
175
176
177
P fil
Profilometer
t
y Measuring instrument used to measure a surface's
178
Page 53 of 205
179
Rev.1
180
GATE 1997
1997
GATE
C t t
Contactprofilometers
fil
t
y Adiamondstylusismovedverticallyincontactwitha
sampleandthenmovedlaterallyacrossthesamplefor
aspecifieddistanceandspecifiedcontactforce.
y Aprofilometer canmeasuresmallsurfacevariationsin
verticalstylusdisplacementasafunctionofposition.
verticalstylusdisplacementasafunctionofposition
y Theradiusofdiamondstylusrangesfrom20
nanometresto25m.
t t
181
AdvantagesofopticalProfilometers
d
f
i l
fil
y Because
the
nott touch
B
th noncontact
t t profilometer
fil
t does
d
t
h
N
NoncontactProfilometers
t t P fil
t
List I
List II
(A) Surface profilometer
1.
Calibration
(B) Light Section Microscope 2.
2 Form tester
(C) Microkater
3.
Film thickness
measurement
(D) Interferometer 4.
Centre line average
5
5.
Comparator
6.
Surface lay measurement
C d A B
Codes:A
C
D
A
B
C
D
(a) 4
1
2
3
(b) 4
3
5
1
(c) 4
2
1
3
(d) 3
1
2
4
providing
idi
much
h off the
th same information
i f
ti
as a stylus
t l
based profilometer.
p
y There are many different techniques which are
182
183
O ti l Fl t
OpticalFlats
g
y Op
Opticalgrade
clear fused q
quartz or g
glass structures
lapped and polished to be extremely flat on one or
both sides.
y Used with a monochromatic light to determine the
flatness of other optical surfaces by interference.
y When a flat surface of another optic is placed on the
optical flat, interference fringes are seen due to
interference in the tiny gap between the two surfaces.
y The spacing between the fringes is smaller where the
gap is changing more rapidly, indicating a departure
from flatness in one of the two surfaces, in a similar
way to
t the
th contour
t
li
lines
on a map.
184
185
186
187
Page 54 of 205
188
Rev.1
189
ForIESOnly
ForIESOnly
ForIESOnly
IES 2012Conventional
2012 C
ti
l
IES
IAS 2012Main
2012 M i
IAS
Explainhowflatnessofasurfaceismeasuredwithanoptical
l i h fl
f f i
d i h i l
Write
about
optical
Two
fringe
patterns
W i in
i short
h
b
i l flat.
fl
T
f i
flat.
pp
for two completely
p
y different surfaces using
g
are supplied
[12marks]
191
h =
of surfaces.
GATE 2003
GATE
n l
2
(a)2
(c)8
193
192
(b)6
(d)13
194
195
T l
Talysurf
f
Clinometer
horizontal.
y Compass clinometers are fundamentally just magnetic
compasses held with their plane vertical so that a
plummet or its equivalent can point to the elevation of
the sight line.
y The
Th clinometer
li
t can read
d easily
il and
d accurately
t l angles
l off
elevation that would be very difficult to measure in any
other
th simple
i l and
d inexpensive
i
i way.
y A fairly common use of a clinometer is to measure the
height of trees.
196
MiscellaneousofMetrology
Page 55 of 205
BySKMondal
197
Rev.1
198
Autocollimator
Clinometer
l
small
ll angles
l or small
ll angular
l tilts
il off a reflecting
fl i surface.
f
y Used to align components and measure deflections in
optical or mechanical systems.
y An autocollimator works by
yp
projecting
j
g an image
g onto a
target mirror, and measuring the deflection of the
g against
g
a scale,, either visuallyy or byy
returned image
means of an electronic detector.
y A visual autocollimator can measure angles as small as
0.5 arcsecond, while an electronic autocollimator can be
up to 100 times more accurate.
accurate
199
200
201
GATE 1998
1998
GATE
Autocollimator
ll
( )
GATE 2009(PI)
An autocollimator is used to
(a) measure small angular displacements on flat
surface
( ) compare known and unknown dimensions
(b)
(c) measure the flatness error
(d) measure roundness error between centers
202
203
OpticalSquare
GATE 2014
p
q
y
y An Optical
square
consists of a small cylindrical
metal box,,
( ) Auto collimator
(b)
(c) Height gauge
204
205
AnOpticalSquare
Rev.1
207
S O 20 0
ISRO2010
LaserScanningMicrometer
Optical square is
(a) Engineer's square having stock and blade set at 90o
(b) A constant
t t deviation
d i ti
prism
i
h i
having
th angle
the
l off
deviation between the incident ray and reflected ray,
equall to
t 90o
(c) A constant deviation prism having the angle of
deviation between the incident ray and reflected ray,
equal to 45o
(d) Used to produce interference fringes
208
IES 1998
IES
Match ListI with ListII and select the correct answer using the
codes
below
the
d given
i
b l
h lists:
li
ListI
ListII
((Measuring
g Device))
((Parameter Measured))
A. Diffraction grating
1.
Small angular deviations on long
flat surfaces
B
B.
Optical flat
2
2.
Online measurement of moving
parts
C. Auto collimators
3.
Measurement of gear pitch
D
D.
L
Laser
scan micrometer4.
i
t
S f
Surface
t t
texture
using
i interferometer
i t f
t
5.
Measurement of very small
displacements
Code: A
B
C
D
A
B
C
D
(a) 5
4
2
1
(b)
3
5
1
2
(c) 3
5
4
1
(d)
5
4
1
2
209
McLeodgauge
d
GATE2014
Which one of the following instruments is widely
used to check and calibrate geometric features of
machine tools during their assembly?
(a) Ultrasonic probe
(b) Coordinate Measuring Machine (CMM)
(c) Laser interferometer
(d) Vernier calipers
211
surfacebytracingtheboundaryofthearea.
Page 57 of 205
213
LVDT
y Adeviceusedformeasuringtheareaofanyplane
214
212
Planimeter
l
210
215
GATE 1992
GATE
LVDT
ToolMakersMicroscope
l
k
y
q
y
Match the instruments with the p
physical
quantities they
measure:
Instrument
Measurement
(A) Pilottube
(1)
R.P.M. of a shaft
g
(2)
Displacement
p
(B) McLeod Gauge
(C) Planimeter
(3)
Flow velocity
(4)
4
Vacuum
(D) LVDT
(5)
Surface finish
((6)) Area
Codes:A
B
C
D
A
B
C
D
((a)) 4
1
2
3
((b)) 3
4
6
2
(c) 4
2
1
3
(d) 3
1
2
4
217
218
List I
(Measuring instruments)
(A) Talysurf
T l
f
1.
(B) Telescopic gauge
2.
(C) Transfer callipers
3.
(D) Autocollimator
4.
Codes:A B
C
D
( ) 4
(a)
1
2
3
(b)
(c) 4
2
1
3
(d)
List II
(Application)
T l t
Tslots
Flatness
Internal diameter
Roughness
A
B
C
D
4
3
1
2
3
1
2
4
223
219
Telescopic Gauges
TelescopicGauges
GATE 2004
GATE
GATE 1995
GATE
internal
i
l dimension
di
i to a remote measuring
i tool.
l
y They are a direct equivalent of inside callipers and
221
Advantages,
y Aninstrumentthatlocatespointcoordinatesonthree
dimensionalstructuresmainlyusedforqualitycontrol
applications.
y Thehighlysensitivemachinemeasurespartsdownto
Th hi hl
ii
hi
d
thefractionofaninch.
y Specifically,aCMMcontainsmanyhighlysensitiveair
bearingsonwhichthemeasuringarmfloats.
Page 58 of 205
222
224
y canautomateinspectionprocess
y lesspronetocarelesserrors
p
y allowsdirectfeedbackintocomputersystem
Disadvantages,
Disadvantages
y Costly
y fixturing
fi
i iscritical
i ii l
y requiresaverygoodtolerancemodel
Rev.1
225
GATE 2010
GATE
A taper hole is inspected using a CMM, with a probe
of 2 mm diameter. At a height, Z = 10 mm from the
bottom, 5 points are touched and a diameter of
circle (not compensated for probe size) is obtained
as 20 mm. Similarly, a 40 mm diameter is obtained
at a height Z = 40 mm. the smaller diameter (in mm)
of hole at Z = 0 is
(a) 13.334
(b) 15.334
(c) 15.442
(d) 15.542
226
GATE 2014
GATE2014
The diameter of a recessed ring was measured by using two
spherical balls of diameter d2 = 60 mm and d1 = 40 mm as
shown in the figure.
The distance
H2 = 35.55
mm
and
H1 = 20.55
mm.
The
diameter (D,
(D
in mm) of the
ring
g g
gauge
g is
.
H1
H2
d1 Diameter
H
A
227
228
WorkbookCh13:Metrology
gy
ISRO2007
Q.No
Option
Q.No
Option
Which
Whi h off the
h following
f ll i errors are inevitable
i
i bl in
i the
h
10
measuring
g system
y
and it would be vain full
11
12
13
14
(b) Random
R d
errors
15
16
17
Recessed Ring
D
d2 Diameter
229
232
230
Page 59 of 205
231
Rev.1
Terminology
y
y
MetalForming
y
y
Semifinished product
Ingot: is the first solid form of steel.
Bloom: is the product of first breakdown of ingot has square
cross section 6 x 6 in.
in or larger
Billet: is hot rolled from a bloom and is square, 1.5 in. on a
side or larger.
larger
Slab: is the hot rolled ingot or bloom rectangular cross
section 10 in.
in or more wide and 1.5
1 5 in.
in or more thick.
thick
y Drawing:
D
i
The diameter of a wire or bar is reduced by
B SKM d l
BySKMondal
i l
Terminology
PlasticDeformation
y Plate
Pl t is
i the
th product
d t with
ith thickness
thi k
> 5 mm
Billet
slab
y These
processes involve
amountt off plastic
Th
i
l large
l
l ti
deformation.
y Duetoslip,grainfragmentation,movementof
D t li i f
t ti
t f
Bloom
BulkDeformationProcesses
y Deformationbeyondelasticlimits.
Mill product
Ingot
atomsandlatticedistortion.
g
volume change.
y The ratio crosssection area/volume is small.
600 mm
< 600 mm
Sh
SheetFormingProcesses
F
i P
StrainHardeningg
section of
y In sheet metal working operations, the cross
crosssection
workpiece does not changethe material is only
subjected to shape changes.
GATE1995
grain
i distortion
di t ti
or fragmentation
f
t ti
d
does
nott take
t k
(a) Decreases
p
place.
( ) Increases
(b)
strength i.e.
i e strain hardening.
hardening
Page 60 of 205
Rev.1
IES2013
Statement (I): At higher strain rate and lower
temperature structural steel tends to become brittle.
Statement (II): At higher strain rate and lower
temperature the yield strength of structural steel tends
to increase.
increase
(a) Both Statement (I) and Statement (II) are individually
true and
d Statement
S
(II) is
i the
h correct explanation
l
i
off
Statement (I)
(b) Both Statement (I) and Statement (II) are individually
true but Statement (II) is not the correct explanation of
Statement (I)
((c)) Statement ((I)) is true but Statement ((II)) is false
(d) Statement (I) is false but Statement (II) is true
Recrystallisation Temperature(Rxtemp.)
The minimum temperature at which the completed
y The
recrystallisation of a cold worked metal occurs within a
specified period of approximately one hour
hour..
y Rx temp. decreases strength and increases ductility.
whereas working
g below are coldworking
gp
process.
y It involves replacement of coldworked structure by a
11
G i
th
Graingrowth
M ll bilit
Malleability
y Graingrowthfollowscompletecrystallizationifthematerials
y Malleability
M ll bilit is
i the
th property
t off a material
t i l whereby
h b it can
leftatelevatedtemperatures.
12
be shaped
p when cold byy hammering
g or rolling.
g
y Graingrowthdoesnotneedtobeprecededbyrecoveryand
hd
d b
d db
d
y Incontrarytorecoveryandrecrystallization,drivingforce
forthisprocessisreductioningrainboundaryenergy.
has already received. The higher the cold work, the lower
would be the Rx temp.
temp
(
(Kelvin).
)
10
recrystallization;itmayoccurinallpolycrystallinematerials.
y Rx temp.
temp depends on the amount of cold work a material
ColdWorking
y Inpracticalapplications,graingrowthisnotdesirable.
particlesareeffectiveinretardinggraingrowth.
Workingbelowrecrystalization temp.
temp
essential to be so strong.
strong
y Incorporationofimpurityatomsandinsolublesecondphase
y Lead,
ead, so
softt stee
steel,, wrought
oug t iron,
o , coppe
copper aand
d aaluminium
u
u aaree
y Graingrowthisverystronglydependentontemperature.
13
Ad t
f C ld W ki
AdvantagesofColdWorking
14
15
Di d t
f C ld W ki
DisadvantagesofColdWorking
Equipmentofhigherforcesandpowerrequired
1. Better
tolerances
B tt accuracy, closer
l
t l
1.
1
2. Surfacesofstartingworkpiecemustbefreeofscaleand
dirt
3. Strain hardening
g increases strength
g and hardness
3. Ductilityandstrainhardeninglimittheamountofforming
l d
h d
l
h
ff
thatcanbedone
4. Insomeoperations,metalmustbeannealedtoallow
furtherdeformation
5 Somemetalsaresimplynotductileenoughtobecold
5.
16
worked.
Page 61 of 205
17
Rev.1
18
HotWorking
W ki b
Workingaboverecrystalization
li i temp.
AdvantagesofHotWorking
DisadvantagesofHotWorking
1.
1 The porosity of the metal is largely eliminated.
eliminated
2. The grain structure of the metal is refined.
3. The impurities like slag are squeezed into fibers and
distributed throughout the metal.
4. The mechanical properties such as toughness,
percentage
p
g elongation,
g
percentage
p
g reduction in area, and
resistance to shock and vibration are improved due to
g
the refinement of grains.
1.
1 It requires expensive tools.
tools
2. It produces poor surface finish, due to the rapid
oxidation
id ti and
d scale
l formation
f
ti on the
th metal
t l surface.
f
3. Due to the poor surface finish, close tolerance
cannot be maintained.
19
20
Annealing
Annealing relieves the stresses from cold working three
g recovery,
y recrystallization
y
and g
grain g
growth.
stages:
During recovery, physical properties of the coldworked
g in
material are restored without anyy observable change
microstructure.
21
W
F
i
WarmForming
y Deformation
intermediate
D f
ti produced
d d att temperatures
t
t
i t
di t to
t
material ductility.
y Compared to hot forming, it produce less scaling and
I th
lF
i
IsothermalForming
interior, and the variations in strength can result in non
uniform deformation and cracking of the surface.
y For temp.sensitive
temp sensitive materials deformation is performed
t
temperature,
t
sacrificing
ifi i die
di life
lif for
f product
d t quality.
lit
y Close tolerances,, low residual stresses and uniform metal
25
24
G
2003
GATE2003
IES2011
flow.
23
26
Rev.1
27
ISRO 2010
ISRO2010
G
2002 S O 20 2
GATE2002,ISRO2012
S 2006
IES
(b) Tempering
(c) Normalizing
(d) Annealing
28
S 2004
200
IES
29
S 2009
IES
S 2008
IES
34
32
S 2004
200
IES
S 2008
IES
31
30
S 2003
IES
33
35
Rev.1
36
S 2000
IES
Assertion (A): To obtain large deformations by cold
working intermediate annealing is not required.
Reason (R): Cold working is performed below the
recrystallisation temperature of the work material.
( ) Both
(a)
B th A and
d R are individually
i di id ll true
t
and
d R is
i the
th
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
37
S 1996
996
IES
S 1997
99
IES
ISRO2009
38
S 2006
IES
40
S 1996
996
IAS
S 2004
200
IAS
Assertion(A):Hotworkingdoesnotproducestrain
hardening.
Reason(R):Hotworkingisdoneabovethere
Reason(R):Hotworkingisdoneabovethere
crystallizationtemperature.
( ) BothAandRareindividuallytrueandRisthe
(a)
B thA dR i di id ll t dRi th
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
43
41
39
S 1992
992
IES
Considerthefollowingstatements:
Whenametaloralloyiscoldworked
1. Itisworkedbelowroomtemperature.
Iti
k db l
t
t
2. Itisworkedbelowrecrystallisation temperature.
3. Itshardnessandstrengthincrease.
4. Itshardnessincreasesbutstrengthdoesnot
increase.
Ofthesecorrectstatementsare
(a) 1and4
(b) 1and3
(c) 2and3
(d) 2and4
Inmetalssubjectedtocoldworking,strain
hardeningeffectisdueto
(a) Slipmechanism
(b) Twiningmechanism
(c) Dislocationmechanism
((d)) Fracturemechanism
Page 64 of 205
42
S 2002
IAS2002
44
45
S 2008
IES2008
Rolling
y Definition:
The
D fi iti
Th process off plastically
l ti ll deforming
d f
i metal
t l
Which
Whi h one off the
th following
f ll i is
i correct?
t?
Malleability is the property by which a metal or
alloy can be plastically deformed by applying
(a) Tensile stress
(b)
Bending stress
(d)
Compressive stress
byy p
passing
g it between rolls.
Rolling
B SKM d l
BySKMondal
46
47
48
50
51
GATE 2013
GATE2013
In
process, the
off the
I a rolling
lli
th state
t t off stress
t
th
material undergoing
g
g deformation is
(a) pure compression
(b) pure shear
(c) compression and shear
(d) tension and shear
49
ChangeingrainsstructureinHot rolling
ChangeingrainsstructureinHotrolling
HotRolling
y Done above the recrystallization temp.
temp
y Results fine g
grained structure.
y Surface quality and final dimensions are less accurate.
y Breakdown of ingots into blooms and billets is done by
h
hotrolling.
lli
Thi is
This
i followed
f ll
d by
b further
f h hotrolling
h
lli
i
into
plate,, sheet,, rod,, bar,, p
p
pipe,
p , rail.
y Hot rolling is terminated when the temp. falls to about
52
53
S 2001
200
IAS
Consider the following characteristics of rolling
process:
1 Shows work hardening effect
1.
2. Surface finish is not good
3. Heavy reduction in areas can be obtained
Which of these characteristics are associated with hot
rolling?
(a) 1 and 2
(b) 1 and 3
(c) 2 and 3
(d) 1, 2 and 3
Rev.1
54
ColdRolling
RingRolling
ISRO2006
y Done
below
D
b l the
th recrystallization
t lli ti temp..
t
y Products are sheet,
sheet strip,
strip foil etc.
etc with good surface
product dimensions.
y Ring
ring
Ri rolls
ll are used
d for
f tube
t b rolling,
lli
i rolling.
lli
( ) Extrusion
(b)
crosssection profiles.
y Ring
Ri rolls
ll are made
d off spheroidized
h idi d graphite
hi bainitic
b i i i and
d
pearlitic
pea
t c matrix
at o
or aalloy
oy cast stee
steel base.
(d) Forging
55
56
Sheetrolling
ISRO2009
y In
we are only
to
the
I sheet
h t rolling
lli
l attempting
tt
ti
t reduce
d
th
58
57
59
RollForming
60
RollBending
y A continuous form of threepoint bending is roll
b di
bending,
where
h
plates,
l t sheets,
h t and
d rolled
ll d shapes
h
can
be bent to a desired curvature on forming
g rolls.
y Upper roll being adjustable to control the degree of
curvature.
61
Page 66 of 205
62
Rev.1
63
S 2006
IES
Packrolling
Shaperolling
y Pack
involves
hot
multiple
P k rolling
lli
i
l
h t rolling
lli
lti l sheets
h t off
Which
bending
Whi h one off the
th following
f ll i is
i a continuous
ti
b di
process in which opposing
p
pp
g rolls are used to p
produce
y Improved productivity
stock?
( ) Stretch
(a)
h forming
f
(b)
Roll
ll forming
f
(d)
Spinning
65
Threadrolling
66
Threadrollingcontd.
y Used
threads
U d to
t produce
d
th d in
i substantial
b t ti l quantities.
titi
y Major
greater
M j diameter
di
t is
i always
l
t than
th the
th diameter
di
t off the
th
y This is a cold
coldforming
forming process in which the threads are
blank.
y Blank diameter is little larger (0.002 inch) than the pitch
y No metal is removed,
removed greater strength,
strength smoother,
smoother harder,
harder
68
S 1992,GATE1992(PI)
992 G
992( )
IES
70
69
S 1993,GATE1989(PI)
993 G
989( )
IES
Threadrollingisrestrictedto
Th d lli i t i t dt
The
Th blank
bl k diameter
di
t used
d in
i thread
th d rolling
lli will
ill be
b
(a) Ferrousmaterials
(b) Ductilematerials
(b) Equal
q
to p
pitch diameter of the thread
(c) Hardmaterials
(d) Noneoftheabove
Page 67 of 205
71
Rev.1
72
S 2013Conventional
20 3 C
i
l
IES
Manufactureofgearsbyrolling
Writetwoadvantagesofthreadrollingandexplain
W it t d
t
fth d lli d
l i
y The
external
Th straight
t i ht and
d helical
h li l teeth
t th off disc
di or rod
d type
t
t
l
withfiguretwodiecylindricalmachine.
g
y
steel g
gears of small to medium diameter and module are
[5Marks]
machine)
y Larger
a ge ssizee gea
gearss aaree formed
o ed by hot
ot rolling
o g aand
d tthen
e
73
R ll i i
Rollpiercing
finished by machining.
74
Fig.Gearrollingbetweenthreegearrolltools
75
i a variation
i ti off rolling
lli called
ll d roll
ll piercing.
i i
y It is
y The billet or round stock is rolled between two rolls,
both
rotating
direction
b h off them
h
i iin the
h same di
i with
i h their
h i
axes at an angle of 4.5 to 6.5 degree.
y These
Th
rolls
ll have
h
a centrall cylindrical
li d i l portion
i with
i h the
h
sides tapering slightly. There are two small side rolls,
which help in guiding the metal.
metal
y Because of the angle at which the roll meets the metal,
it gets
t in
i addition
dditi
t a rotary
to
t
motion,
ti
an additional
dditi
l
axial advance, which brings the metal into the rolls.
y This
Thi crossrolling
lli action
ti makes
k the
th metal
t l friable
f i bl att the
th
centre which is then easily pierced and given a
cylindrical shape by the centralpiercing
central piercing mandrel.
mandrel
76
77
S 2007
200
IAS
g
Match List I with List II and select the correct answer using
the code given below the Lists:
List I
List II
(
(Type
of Rolling Mill))
(
(Characteristic)
)
A. Two high nonreversing mills 1. Middle roll rotates by friction
B
B.
Th
Three
hi h mills
high
ill
2. By
B small
ll working
ki
roll,
ll power
for rolling is reduced
C Four high mills
C.
3 Rolls of equal size are
3.
rotated only in one direction
D. Cluster mills
4. Diameter of working
g roll is
very small
Code:A
B
C
D
A
B
C
D
( ) 3
(a)
4
2
1
(b)
2
1
3
4
(c) 2
4 For-2015
3
1
(d) &3 PSUs)
1
2
4 79
(IES,
GATE
S 2003
IAS
78
S 2000
IAS
In
off rolls
mill,
I one setting
tti
ll in
i a 3high
hi h rolling
lli
ill one
Rollingverythinstripsofmildsteelrequires
R lli
thi t i f ild t l
i
g
gets
(a) Largediameterrolls
(b) Smalldiameterrolls
(c) Highspeedrolling
(d) Rollingwithoutalubricant
80
Rev.1
81
b
Camber
Planetarymill
g rolls surrounded byy a large
g
y Consist of a p
pair of heavyy backing
number of planetary rolls.
82
S 1993
993
IES
83
In
thickness
off the
I order
d to
t gett uniform
if
thi k
th plate
l t by
b
y Hot
metals
without
H t rolling
lli off ferrous
f
t l is
i done
d
ith t a lubricant.
l bi
t
rolling
gp
process,, one p
provides
85
84
S 2004
200
IAS
LubricationforRolling
86
87
DefectsinRolling
Defects
Whatis
Cause
Surface
Defects
Scale,
Scale
rust Inclusions and
rust,
impurities in the
scratches,
pits cracks
pits,
materials
Wavyy edges
g
Strip
p
is
thinner along
g than
its edges
at its centre.
Due
to
roll
bending edges
elongates
g
more
and buckle.
Ed breaks
Edge
b k
Nonuniform
N
if
deformation
Alli
Alligatoring
i
88
GeometryofRollingProcess
( )
GATE 2009(PI)
Anisotropy in rolled components is caused by
(a) changes in dimensions
(b) scale formation
(c) closure of defects
(d) grain
i orientation
i
i
Page 69 of 205
89
Rev.1
90
Draft
S 20 2
i
IAS2012Main
Angle of bite:
What
off (1)
Wh t is
i the
th significance
i ifi
( ) angle
l off nip,
i and
d (2)
( )
Angle
A l off nip:
i
angle
g of bite during
g rolling
g operation?
p
How are they
y
[10marks]
91
G
200
GATE2007
92
93
G
998
GATE1998
The
off a metallic
an
Th thickness
thi k
t lli sheet
h t is
i reduced
d
d from
f
A strip
150 mm x 4.5 mm is
t i with
ith a crosssection
ti
i
being
g rolled with 20% reduction of area using
g 45
450
i degree
in
d
will
ill be
b
(a) 0.006
(b) 0.031
( ) 0.01 (b)
(a)
0.02
(c) 0.062
0 062
(d) 0.600
0 600
(c) 0.03
0 03 (d)
0 06
0.06
(a) 5.936
5 936
(b)
7 936
7.936
(c) 8.936
(d)
9.936
94
95
G
200
GATE2004
ForUnaidedentry
y Rollstripcontactlength
In
process, sheet
is
I a rolling
lli
h t off 25 mm thickness
thi k
i
L=R
[ mustbeinradian]
96
tan
length will be
97
( ) 5 mm
(a)
(b)
39 mm
(c) 78 mm
(d)
120 mm
Page 70 of 205
98
Rev.1
99
MaximumDraftPossible
GATE 2014
GATE2014
GATE2011
The
off
h maximum possible
bl draft
d f in cold
ld rolling
ll
( h )max
= R
100
101
G
2006
GATE2006
A 4 mm thick
thi k sheet
h t is
i rolled
ll d with
ith 300 mm diameter
di
t
ho h f min = 2 R
103
(a) 1.0
1 0 mm
(b)
1 5 mm
1.5
(c) 2.5 mm
(d)
3.7 mm
104
105
GATE 2011(PI)
GATE
2011 (PI)
Numberofpassneeded
hrequired
hmax
S 2001
200
IES
A strip
a thickness
off 30 mm to
t i is
i to
t be
b rolled
ll d from
f
thi k
t
155 mm using
g a twohigh
g mill having
g rolls of
change
h
i width.
in
id h If the
h coefficient
ffi i
off friction
f i i
102
MinimumPossibleThickness (h f min )
S 1999
999
IES
Assertion (A): In a two high rolling mill there is a
limit to the possible reduction in thickness in one
pass.
Reason (R): The reduction possible in the second
pass is less than that in the first pass.
pass
(a) Both A and R are individually true and R is the
correctt explanation
l
ti off A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
n=
106
(b) 4
(c) 6
( ) 0.35
(a)
(b)
0.5
(c) 0.25
0 25
(d)
0 07
0.07
(d) 7
Page 71 of 205
107
Rev.1
108
NeutralPointandNeutralPlane
G
20 ( )
GATE2014(PI)
A 80 mm thick steel plate with 400 mm width is
rolled to 40 mm thickness in 4 passes with equal
reduction in each pass, by using rolls of 800 mm
diameter. Assuming the planestrain deformation,
what is the minimum coefficient of friction
required for unaided rolling to be possible?
(a) 0.111
0 111 (b) 0.158
0 158 (c) 0.223
0 223 (d) 0.316
0 316
Backward slip =
Forward slip =
109
IES 2014
IES
Vr Vo
100%
Vr
V f Vr
Vr
100%
R=rollradius
ho =backheight
b kh i h
hf =outputorfinal
thickness
hi k
=angleofbite
NN=neutralpointorno
slippoint
TotheleftoftheNeutralPoint:
Velocityofthestrip<Velocityoftheroll
y
p
y
TotherightoftheNeutralPoint:
110
Velocityofthestrip>Velocityoftheroll
S 2002
IES
GATE2008(PI)
In
process, thickness
off a strip
I a rolling
lli
thi k
t i is
i reduced
d
d
In
a strip
two
rolls,
off
I rolling
lli
t i between
b t
t
ll the
th position
iti
from 4 mm to 3 mm using
g 3300 mm diameter rolls
the neutral p
point in the arc of contact does not
depend on
(b)
(d)
( ) 1.57
(a)
(b) 3.14
( ) 47.10
(c)
(d) 94.20
112
113
114
Continuity Equation
ContinuityEquation
S l
dQ
i
SelectedQuestions
GATE2014
The
Th effect
ff t off friction
f i ti on the
th rolling
lli mill
ill is
i
(a) always bad since it retards exit of reduced metal
(b) always
y g
good since it drags
g metal into the g
gap
p between
the rolls
A mild
has
ld steell plate
l
h to be
b rolled
ll d in one pass such
h
hobovo = hf bfvf
is
where
h
vo and
d vf are the
th entering
t i
and exiting velocities of the
work.
work
( )
GATE1990(PI)
115
Page 72 of 205
116
Rev.1
117
Force,TorqueandPower
El
i F
El
i C ffi i
ElongationFactororElongationCoefficient
A
L
E= 1 = o
Lo A1
for single
g pass
p
L
A
En = n = o
Lo An
for n pass
( )
GATE1992(PI)
Iff the
factor
during
rolling
off an
h elongation
l
f
d
ll
ingot is 1.22. The minimum number of passes
needed to produce a section 250 mm x 250 mm
from an ingot of 750 mm x 750 mm are
(a) 8
(b) 9
( ) 10
(c)
(d) 17
118
Will
be
discussed
in class
119
120
G
2008
GATE2008
RollSeparating Force ( F ) = o Lp b , N
[ o in N / mm 2 i.e. MPa ]
S 2000,GATE2010(PI)
2000 G
20 0( )
IES
121
decreased by
y
(a) Reducing the roll diameter
(b) Increasing the roll diameter
(c) Providing backup rolls
(d) Increasing the friction between the rolls and the
metal
122
S 2007
200
IAS
123
AssumptionsinRolling
In
process, roll
force
can be
I the
th rolling
lli
ll separating
ti
f
b
124
1.
1 Rolls are straight, rigid cylinders.
cylinders
2. Strip is wide compared with its thickness, so that no
[F IESC
[ForIESConventionalOnly]
i
lO l ]
Page 73 of 205
125
the radius
th
di off the
th roll.
ll
4. The material is rigid perfectly plastic (constant yield
strength).
55. The coefficient of friction is constant over the tool
work interface.
Rev.1
126
StressEquilibriumofanElementinRolling
S 2001
200
IES
g assumptions
p
Which of the following
are correct for
cold rolling?
1. The material is plastic.
p
2. The arc of contact is circular with a radius greater than
the radius of the roll.
3. Coefficient of friction is constant over the arc of
g
the arc of
contact and acts in one direction throughout
contact.
g the codes g
given below:
Select the correct answer using
Codes:
(a) 1 and 2
(b) 1 and 3
(c) 2 and 3
(d) 1, 2 and 3
127
( p / )
II =
2R
( ) d
h f + R 2
2 R d
l ( p / ) =
ln
h f + R 2
2 R
h f + R 2 d = I II (say)
2d
h/R
h
= ln
R
R
.tan 1
hf
R
. + ln C
hf
R
.tan 1
hf
R
.
hf
R
.tan 1
.
hf
hf
h0
1
1
H0 ln
2
hf
132
If bac
back tension
te s o b iss tthere
e e at Entry,
t y,
p = ( o b )
ho
H 2H
= e ( 0 n)
hf
h
H H
. e ( 0 )
h0
R
.
hf
h f Hn
hf
.tan
.
n =
R 2
R
and h n = h f + 2R
(1 74cos
Page
of
205
n)
From H = 2
129
h
p = C '0 e H
R
where
h
H =2
2
d
/ R + 2
or Hn =
133
h
ln p / '0 = ln 2
R
131
or
h
p = '0 .eH
hf
At the neutral po int above equations
d ( x h )
= 2 pR ( )
d
2
p x =
0 = 0'
3
d
h ( p 0' ) = 2 pR ( )
d ' p
0 h ' 1 = 2 pR ( )
d
0
d
d p p
0' h
( 0' h ) = 2 pRR ( )
' + ' 1
d 0 0
d
hn
h
H H
. e ( 0 n ) = n . e Hn
h0
hf
hf
+ 2
R
130
h
H H
. e ( 0 )
h0
will give
same results
For-2015 (IES, GATE & PSUs)
2Rd
=
h
2R
d
2
f + R
= 2
h
In the entry zone, p = C. '0 o e Ho
R
R Ho
and C =
.e
e
ho
p = '0
d h
= 2 \
d R
2Rd
=
2
f + R
or
h = h f + 2 R (1 cos ) h f + R 2
=
128
Now h / R =
d
( p / 0' ) 2R
d
=
( )
p / 0'
h
'
0
+ 2 x R d cos = 0
I=
th 0' h nearly
thus
l a constant
t t andd itsderivative
it d i ti zero.
d ( p / 0' )
p = ( o f )
R
.tan
tan 1
hf
134
h
. e H
hf
Rev.1
135
IAS 2012 M i
IAS2012Main
S 1998
998
IAS
IFS 2010
Whatis"frictionhill"?
136
137
Workbook:Rolling Ch14
Q.No
Option
1
2
3
C
B
D
6
7
A
B
8
9
D
C
10
11
C
B
12
Forging
y Forging process is a metal working process by which
Forging
BySKMondal
139
142
141
140
IES2013
ClosedDieforging
O
d Cl d di f i
OpenandCloseddieforging
y Depending upon complexity of the part forging is
blows by a mechanical
manipulated manually.
hammer and
shape is
Rev.1
144
Ad t
fF i
AdvantagesofForging
Di d t
fF i
DisadvantagesofForging
S 1996
996
IES
y Costly
Which
is
off
Whi h one off the
th following
f ll i
i an advantage
d
t
forging?
g g
146
IES 2005
IES
IES 2013
IES2013
IES 2012
IES
Intheforgingprocess:
1.Themetalstructureisrefined
2.Originalunidirectionalfibers aredistorted.
3.Poorreliability,asflawsarealwaysthereduetointense
2. Forged
d components can be
b provided
d d with
h thin
h
working
4 Partareshapedbyplasticdeformationofmaterial
4.Partareshapedbyplasticdeformationofmaterial
(a)1,2and3
(b)1,3and4
(c)1,2and4
(d)2,3and4
148
(a) Only 1
(b)
Only 2
(d)
Neither 1 nor 2
ISRO 2013
ISRO2013
149
F
bilit
Forgeability
(c) Swaging
forgeability.
(d) Turning
151
Page 76 of 205
IES 2012
IES
(b) Forging
147
152
153
D ft
Draft
Fl h
Flash
S 2006
IES
forging.
y Adequate draft should be providedat least 3o for
154
Fl h
Flash
155
156
IES 2014
IES
Contd
flash thickness.
thickness
S 2002
IAS
157
G tt
Gutter
158
G tt
Gutter
die for additional space so that any excess metal can flow
and help in the complete closing of the die. This is called
gutter.
Considerthefollowingstatementsrelatedto
forging:
1 Flashisexcessmaterialaddedtostockwhichflows
1.
aroundpartingline.
2. Flashhelpsinfillingofthinribsandbossesinupper
Fl hh l i filli fthi ib db
i
die.
3. Amountofflashdependsuponforgingforce.
Whichoftheabovestatementsarecorrect?
(a) 1,2and3 (b) 1and2
(c) 1and3
(d) 2and3
159
S 1993,GATE1994(PI)
993 G
99 ( )
IES
Contd.
y Without
excessively
With t a gutter,
tt a flash
fl h may become
b
i l thick,
thi k
not allowing
g the dies to close completely.
p
y
Which
Whi h
one
off
the
th
following
f ll i
manufacturing
f t i
processes requires
p
q
the p
provision of gutters?
g
160
Page 77 of 205
161
Rev.1
162
Sequentialstepsinvolvedincloseddieforging
S 1997
99
IES
) In drop
p forging
g g besides the p
Assertion ((A):
provision
for flash, provision is also to be made in the forging
die for additional space called gutter.
Reason (R): The gutter helps to restrict the outward
flow of metal thereby helping to fill thin ribs and
bases in the upper die.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
( )
GATE1989(PI)
Atthelasthammerstroketheexcessmaterialfrom
F ll i
Fulleringor
swaging
Edgingorrolling
R d i
ti d ki itl
Reducingcrosssectionandmakingitlonger.
Bending
Requiredforthosepartswhichhaveabent
shape
thefinishingcavityofaforgingdieispushed
into..
163
164
E
l
Example
Preformshape.Gathersthematerialas
Preformshape Gathersthematerialas
requiredinthefinalforging.
Drawingorcogging Likefulleringbutc/sofonlyoneend is
reduced
Flattening
Flattenthestocksothatitfitsproperlyinto
thefinishingimpression.
Blocking
g
Semifinishingimpression,Impartstothe
g p
, p
forgingitsgeneralbutnotexactorfinalshape.
Finishing
g
Finalimpression,FlashlandandGutter
p
,
provided tothedie.
Trimmingorcutoff Removalofflashpresent aroundforging 165
S 1998
998
IES
S 2001
200
IES
Which
processes is
Whi h one off the
th following
f ll i
i mostt
Intheforgingoperation,fulleringisdoneto
I th f
i
ti
f ll i i d
t
commonly
y used for the forging
g g of bolt heads of
(a) Drawoutthematerial
hexagonal shape?
(b) Bendthematerial
(c) Upsetthematerial
(d) Extrudingthematerial
( ) Close
(c)
Cl
di press forging
die
f i
(d) Open die progressive forging
166
S 2003
IES
and in the p
process making
g it longer
g is termed as
(b)
Punching
Extruding
168
S 2005
200
IES
IES2011
A forging
f
i method
th d for
f reducing
d i the
th diameter
di
t off a bar
b
(a) Fullering
167
169
170
The
the
or flash
a
Th process off removing
i
th burrs
b
fl h from
f
forged
g component
p
in drop
p forging
g g is called:
(a) Swaging
(b)
Perforating
Fettling
Rev.1
171
S 2002
IES
S 2003
IES
172
IES 2012 C
ti
l
IES2012Conventional
S 2001
200
IAS
Match List I (Forging operations) with List II (Descriptions)
and
the
d select
l
h correct answer using the
h codes
d given below
b l
the Lists:
List I
List II
A. Flattening
1.
Thickness is reduced continuously at
different sections along length
B
B.
D
Drawing
i
2.
M l is
Metal
i displaced
di l d away from
f
centre,
reducing thickness in middle and
increasing length
C. Fullering
3.
Rod is pulled through a die
D. Wire drawing 4.
Pressure a workpiece between two flat
dies
Codes:A
B
C
D
A
B
C
D
((a)) 3
2
1
4
((b))
4
1
2
3
(c) 3
1
2
4
(d)
4
2
1
3
173
174
D
F i
DropForging
y The
forging
halves.
The
Th drop
d
f i die
di consists
i t off two
t
h l
Th lower
l
S 1994,ISRO2010
99 S O 20 0
IES
178
p
p
g closing
g of
press and component
is p
produced in a single
die, hence the dimensional accuracy is much better than
p forging.
g g
drop
Page 79 of 205
177
PressForging
S 2000
IAS
176
179
Rev.1
180
IES 2011
IES2011
AdvantagesofPressForgingoverDropForging
y Press
forging
forging
P
f i is
i faster
f t than
th drop
d
f i
y Alignment of the two die halves can be more easily
forging.
y With
Wi h ejectors
j
i the
in
h top and
d bottom
b
di it
dies,
i is
i possible
ibl to
handle
a d e reduced
educed d
diee d
drafts.
a ts.
181
IFS2011
What advantages does press forging have over drop
forging ? Why are pure metals more easily cold worked
th alloys
than
ll
?
[5 marks]
[5marks]
182
183
M hi F i
MachineForging
U tF i
UpsetForging
R ll F i
RollForging
y Unlike
or press forging
where
the
U lik the
th drop
d
f i
h
th material
t i l is
i
y Increasing
I
i the
th diameter
di
t off a material
t i l by
b compressing
i its
it
y When
the
Wh the
th rolls
ll are in
i the
th open position,
iti
th heated
h t d stock
t k
length.
g
is advanced up
p to a stop.
p As the rolls rotate,, theyy g
grip
p and
cavities.
piece
i
i finished.
is
fi i h d
184
185
R ll F i
RollForging
Contd.
y A rapid process.
process
186
S ith F i
SmithForging
k
ll
SkewRolling
metal ball
operator.
y Round
stock is fed
continuouslyy to two
specially
designed
pp
g rolls.
opposing
187
off the
h grooves in
i the
h rolls
ll
and emerges from the
end
d as a metall ball.
b ll
Page 80 of 205
188
Rev.1
189
ForIESOnly
IES 2008
S 2005
200
IES
yp of Forging)
g g) with List II (Operation)
( p
)
Match List I ((Type
and select the correct answer using the code given
below the Lists:
List I
List II
A. Drop Forging 1. Metal is gripped in the dies and
pressure is
i applied
li d on the
h heated
h
d end
d
B. Press Forging 2. Squeezing action
C Upset
C.
U
F i
Forging
3. Metal
M l is
i placed
l d between
b
rollers
ll
and
d
pushed
D Roll Forging 4.
D.
4 Repeated hammer blows
blo s
A
B
C
D
A
B
C
D
( ) 4
(a)
1
2
3
(b) 3
2
1
4
(c) 4
2
1
3
(d) 3
1
2
4190
Match ListI with ListII and select the correct answer using
the code given below the lists:
ListI (Forging Technique)
ListII (Process)
A.SmithForging
1. Materialisonlyupsettogetthe
desiredshape
B.DropForging
p
g g
2.Carriedoutmanuallyopendies
y p
C.PressForging
3. Done in closed impression dies by
hammers in blows
D.MachineForging 4. Done in closed impression dies by
continuous squeezing force
Code: A
(a) 2
(c) 2
B
3
1
C
4
4
D
1
3
(b)
(d)
A
4
4
B
3
1
C
2
2
D
1
3 191
provided
id d on the
h movements off rams and
d dies.
di
y As K.E
K E V2, high energy is delivered to the metal with
IES2013
S
(I) In
I high
hi h velocity
l i forming
f
i
hi h
Statement
(I):
process, high
energy can be transferred to metal with relatively small
weight.
i ht
Statement (II): The kinetic energy is the function of
mass and velocity.
((a)) Both Statement ((I)) and Statement ((II)) are individuallyy
true and Statement (II) is the correct explanation of
()
Statement (I)
(b) Both Statement (I) and Statement (II) are individually
true but Statement (II) is not the correct explanation of
Statement (I)
(c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement (II) is true
193
IFS2011
IAS2011Main
Writefouradvantagesofhighvelocityformingprocess.
[
[2marks]
k ]
194
195
ForIESOnly
Flashless forging
y The work material is completely surrounded by the die
196
L b i ti f F i
LubricationforForging
S 2008
IES
The balls of the ball bearings are manufactured
from steel rods. The operations involved are:
1 Ground
1.
2. Hot forged on hammers
3. Heat treated
4. Polished
4
What is the correct sequence of the above
operations from start?
(a) 3241
(b) 3214
( ) 2314
(c)
(d) 2341
Page 81 of 205
197
y Lubricants
friction,
wear, deforming
forces
L bi
t influence:
i fl
f i ti
d f
i
f
glass.
l
y For cold forging: mineral oil and soaps.
soaps
y In hot
ot forging,
o g g, tthee lubricant
ub ca t iss app
applied
ed to tthee d
dies,
es, but in
198
F i D f t
ForgingDefects
F i D f t
ForgingDefects
Contd.
y Unfilled
Die
U fill d Sections:
S ti
Di cavity
it is
i nott
completely
p
y filled,, due to improper
p p
design of die
y Cold Shut or fold: A small crack at
the
h corners off the
h forging.
f
Cause:
improper design of the die
199
S 1998
998
IAS
The forging defect due to hindrance to smooth flow
of metal in the component called 'Lap' occurs
because
(a) The corner radius provided is too large
(b) The
Th corner radius
di provided
id d is
i too
t small
ll
(c) Draft is not provided
(d) The shrinkage allowance is inadequate
F i D f t
ForgingDefects
Contd.
y Forging
Laps:
These
are folds
F
i
L
Th
f ld off metal
t l squeezed
d
together
g
during
g forging.
g g Theyy have irregular
g
contours
and occur at right angles to the direction of metal flow.
y Hot tears and thermal cracking: These are surface
cracks
k occurring due
d to nonuniform
f
cooling
l
f
from
the
h
forging stage or during heat treatment.
treatment
200
IES2011
Assertion (A) : Hot tears occur during forging
because of inclusions in the blank material
Reason (R) : Bonding between the inclusions
and the parent material is through physical
g
and chemical bonding.
(a) Both A and R are individually true and R is the
p
of A
correct explanation
(b) Both A and R are individually true but R is NOT
p
of A
the correct explanation
(c) A is true but R is false
(d) A is false but R is true
202
201
( )
GATE2008(PI)
Matchthefollowing
Group1
P. Wrinkling
Q.Centreburst
R.Barrelling
g
S.Coldshut
Group2
1.Upsetting
2.Deepdrawing
33.Extrusion
4.Closeddieforging
203
204
IES2013
Barrelling
IES 2007
Sometimes the parting plane between two forging
dies is not a horizontal plane, give the main reason
for this design aspect, why is parting plane
provided in closed die forging?
provided,
[
[2marks]
]
205
Inhomogeneousdeformationwithbarreling oftheworkpiece
Page 82 of 205
206
ForIESOnly
Di M t i l Sh ld h
DieMaterialsShouldhave
G
20 0 ( )
GATE2010(PI)
,
g
y
y Goodhardness,toughnessandductilityatlowand
Hot
solid
forging,
H t die
di steel,
t l used
d for
f large
l
lid dies
di in
i drop
d
f i
elevatedtemperatures
y Adequatefatigueresistance
y Sufficienthardenability
y Lowthermalconductivity
y Amenabilitytoweldrepair
y Goodmachinability
Material:CrMoValloyedsteelandCrNiMoalloyed
steel.
208
209
210
ForIESOnly
IES2013
Statement (I): In power forging energy is provided by
compressed air or oil pressure or gravity.
Statement (II): The capacity of the hammer is given by
the total weight,
weight which the falling pans weigh.
weigh
(a) Both Statement (I) and Statement (II) are individually
t
true
and
d Statement
St t
t (II) is
i the
th correctt explanation
l
ti
off
Statement (I)
(b) Both
h Statement (I)
( ) and
d Statement (II)
( ) are individually
d d ll
true but Statement (II) is not the correct explanation of
Statement (I)
()
(c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement (II) is true
211
G
20
GATE2014
engineering
g
g strain ((E ) in a uniaxial tension test is
(a)E =ln(1+T )
(b)E =ln(1 T )
(c) T =ln(1+E )
(d)T =ln(1 E )
214
True stress ( T ) = (1 + )
L
True strain ( T ) = ln(1 + ) = ln
Lo
Ao
= ln
A
212
GATE1992,ISRO2012,VS2013
The
true
strain
Th relationship
l ti
hi between
b t
t
t i (
( T ) and
d
S
&
S i
TrueStress&TrueStrain
Thetruestrainforalowcarbonsteelbarwhichis
doubledinlengthbyforgingis
(a) 0.307
(b) 0.5
(c) 0.693
(d) 1.0
Page 83 of 205
215
do
= 2 ln d
213
G
200
GATE2007
In open
die forging, a disc of diameter 200 mm and
opendie
height 60 mm is compressed without any barreling
effect. The final diameter of the disc is 400 mm. The
true strain is
(a) 1.986
1 986
(b) 1.686
1 686
(c) 1.386
(d) 0.602
Rev.1
216
StrainHardening&FlowStress
y In the p
plastic region,
g , the material behaviour is expressed
p
= K
A
AverageFlowStress
Fl
S
y Average
(mean)
stress
is
A
(
) flow
fl
t
i nott on the
th basis
b i off
A erage flow
Average
flo stress ( o ) =
K nf
y Strainrateeffect(hotWorking)
o = C m
1 dh v
Platen Velocity
= =
h dt h Instantaneous height
1+ n
218
219
ForIESOnly
GATE 2006
GATE2006
G
20 2 SameQGATE2012(PI)
GATE2012
g of a material is 400
4
The ultimate tensile strength
MPa and the elongation up to maximum load is
35%. If the material obeys
35
y p
power law of hardening,
g,
then the true stresstrue strain relation (stress in
plastic deformation range
g is:
MPa)) in the p
(a) = 540 0.30 (b) = 775 0.30
0 35 (d) = 775 0.35
0 35
( ) = 540 0.35
(c)
Asolidcylinderofdiameter100mmandheight50mm
A lid li d fdi
t
dh i ht
isforgedbetweentwofrictionlessflatdiestoaheightof
g
g
25mm.Thepercentagechangeindiameteris
(a)0
(b)2.07
(c)20.7
(d)41.4
220
221
ForIESOnly
Assumption
IESConventionalOnly
ForIESOnly
IES 2012
IES
dies (platens).
(platens)
y Thickness of the workpiece is small compared with other
type.
222
ForIESOnly
R t
l B F i
RectangularBarForging
process.
223
Page 84 of 205
224
Rev.1
225
ForIESOnly
ForIESOnly
IES 2007Conventional
2007 C
ti
l
IES
S 2005Conventional
200 C
i
l
IES
A strip
24 mm x 24
t i off lead
l d with
ith initial
i iti l dimensions
di
i
mm x 150
5 mm is forged
g between two flat dies to a
final size of 6 mm x 96 mm x 150 mm. If the
coefficient of friction is 0.25, determine the
maximum
i
f i force.
forging
f
Th average yield
The
i ld stress
t
off
lead in tension is 7 N/mm2
ForIESOnly
IES 2006
2006 Conventional
C
ti
l
IES
[10]
226
227
228
ForIESOnly
P ti P bl
1
PracticeProblem1
GATE2014(PI)
GATE1987
Inforgingoperationthestickingfrictioncondition
occursnearthe(Centre/ends)
p
g g, a circular disc is g
y
In an open
die forging,
gradually
compressed between two flat platens. The
exponential decay of normal stress on the flat face
of the disc, from the center of the disc towards its
periphery, indicates that
(a) there is no sticking friction anywhere on the flat face
of the disc
(b) sticking friction and sliding friction coexist on the
flat face of the disc
(c) the flat face of the disc is frictionless
(d) there is only sticking friction on the flat face of the
disc
229
230
ForIESOnly
231
ForIESOnly
ForIESOnly
P ti P bl
2
PracticeProblem2
P ti P bl
3
PracticeProblem3
P ti P bl
4
PracticeProblem4
f = 1030
. Determine maximum
the equation
232
is given by
forging force.
equation is
0.17
f = 1030
0.17
=y
Page 85 of 205
233
f = 200(0.01 + ) 0.41 = y
]
Rev.1
234
ForIESOnly
Practice Problem 5
{GATE2010
(PI)}
PracticeProblem
5{GATE
2010(PI)}
ForIESOnly
ForIESOnly
Contd.
IFS 2012
IFS2012
PracticeProblem5{GATE2010(PI)}
During open die forging process using two flat and parallel dies,
a solid
lid circular
i l steel
t l disc
di off initial
i iti l radius
di (R IN ) 200 mm andd initial
i iti l
height (H IN ) 50 mm attains a height (H FN ) of 30 mm and radius of R FN .
friction, is
(a) 241.76
R
IN
ii iin the
ii.
h region
i R ss r RFN ,sliding
lidi friction
f i i prevails,
il and
d
(b) 254.55
(c) 265.45
(d) 278.20
[ M k ]
[10Marks]
2
( RFN r )
H FN
p = 3Ke
K
and
d = p,
where p and are the normal and shear stresses, respectively;
K is the shear yield strength of steel and r is the radial distance
of any point
235
(contd ........)
Option
Q. No
Option
2
3
A
A
7
8
C
C
237
Extrusion&Drawing
WorkbookCh15:Forging
Q. No
236
E t i
Extrusion
q
g toothpaste
p
y The extrusion p
process is like squeezing
out of
a tube.
B SKM d l
BySKMondal
238
difficult
diffi l to extrude.
d (high
(hi h yield
i ld strengths,
h welding
ldi with
ih
suitablyy shaped
p die to form a p
product with reduced but
wall).
a ). Use p
phosphatebased
osp ate based a
and
d molten
o te
glass
g
ass
lubricants .
metals
eta s aaree co
commonly
o y eextruded.
t uded.
For-2015 (IES, GATE & PSUs)
241
240
239
Page 86 of 205
242
S 2007
200
IES
g is the correct
Which one of the following
statement?
((a)) Extrusion is used for the manufacture of seamless
tubes.
((b)) Extrusion is used for reducing
g the diameter of round
bars and tubes by rotating dies which open and close
rapidly on the work?
(c) Extrusion is used to improve fatigue resistance of the
metal by setting up compressive stresses on its surface
(d) Extrusion comprises pressing the metal inside a
chamber to force it out by high pressure through an
orifice which is shaped to provide the desired from of the
finished part.
Rev.1
243
E t i R ti
ExtrusionRatio
Ad t
fE t i
AdvantagesofExtrusion
IES 2012
IES
y Ratio
R ti off the
th crosssectional
ti
l area off the
th billet
bill t to
t the
th cross
y Any
An crosssectional
cross sectional shape can be extruded
e truded from the
nonferrous metals.
y No draft
y Huge
H
reduction
d i in
i cross section.
i
S 2009
IES
Which one of the following statements is correct?
(a) In extrusion process, thicker walls can be obtained
by increasing the forming pressure
(b) Extrusion is an ideal process for obtaining rods from
metal
t l having
h i poor density
d it
(c) As compared to roll forming, extruding speed is high
(d) Impact extrusion is quite similar to Hooker's process
g the flow of metal being
g in the same direction
including
245
Li it ti
fE t i
LimitationofExtrusion
A li ti
Application
y Cross
section
mustt be
for
C
ti
b uniform
if
f the
th entire
ti length
l
th off
y Working
off poorly
metals
W ki
l plastic
l ti and
d non ferrous
f
t l and
d
the product.
p
alloys.
y
y Manufacture
of
sections
and
of
complex
248
249
G
99
GATE1994
Extrusion
Hot
Direct
Cold
Indirect
Forward
Hydrostatic
pipes
configuration.
247
S 1994
99
IES
246
250
Page 87 of 205
251
Backward
C ld
Cold
Extrusion
Forging
g g
Rev.1
Impact
Extrusion
252
IAS 2012main
2012
i
IAS
S 1999
999
IES
Which one of the following is the correct
temperature range for hot extrusion of aluminium?
(a) 300340
300 340C
C (b) 350400
350 400C
C
(c) 430480C (d) 550650C
H tE t i P
HotExtrusionProcess
Classify
with
Cl if the
th process off extrusion
t i
ith the
th help
h l off
sketches.
y The
range for
is
Th temperature
t
t
f hot
h t extrusion
t i off aluminum
l i
i
43 4
430480C
y Used to produce curtain rods made of aluminum.
y Design of die is a problem.
y Either direct or indirect method used.
253
254
255
Di t E t i
DirectExtrusion
S 2009
IES
S 1993
993
IES
256
257
S 2000
IES
I di t E t i
IndirectExtrusion
g statements:
Consider the following
In forward extrusion process
1. The ram and the extruded p
product travel in the same
direction.
2. The ram and the extruded p
product travel in the opposite
pp
direction.
3. The speed of travel of the extruded product is same as that
off the
h ram.
4. The speed of travel of the extruded product is greater than
that of the ram.
ram
Which of these Statements are correct?
( ) 1 and
(a)
d3
(b) 2 and
d3
(c) 1 and 4 For-2015
(d) (IES,
2 andGATE
4
& PSUs)
259
258
I di t E t i
IndirectExtrusion
Contd
confined billet.
y Required
is
(25
R
i d force
f
i lower
l
( to
t 30%
% less)
l )
y Low process waste.
waste
th chamber
the
h b is
i eliminated.
li i t d
Page 88 of 205
260
Rev.1
261
IES 2012
IES
S 2007
200
IES
S 2004
200
IAS
262
263
C ld E t i
ColdExtrusion
B k
d ld t i
Backwardcoldextrusion
y Used
U d with
ith lowstrength
l
t
th metals
t l such
h as lead,
l d tin,
ti zinc,
i
y The
the
Th metal
t l is
i extruded
t d d through
th
h the
th gap between
b t
th
and aluminum to p
produce collapsible
p
tubes for
264
I
tE t i
ImpactExtrusion
f d and
food
d beverages.
b
similar articles.
y Now
Nowadays
a days also been used for forming mild steel parts.
parts
y The
h extruded
d d parts are stripped
d by
b the
h use off a stripper
265
S 2008,GATE1989(PI)
2008 G
989( )
IES
manufacture of collapsible
p
toothpaste
p
tubes?
(b)
Direct extrusion
(d)
Piercing
268
267
IES 2014
IES
S 2003
IES
Which
Whi h one off the
th following
f ll i methods
th d is
i used
d for
f the
th
266
269
Rev.1
270
H k M th d
HookerMethod
IAS2010Main
How
are
metal
toothpaste
tubes
H k M th d
HookerMethod
/p
y The ram/punch
has a shoulder and acts as a mandrel.
y A flat blank of specified diameter and thickness is placed in a
made
y
y
y
271
H d t ti E t i
HydrostaticExtrusion
272
H d t ti E t i
HydrostaticExtrusion
Contd.
y High
Highpressure
pressure fluid applies the force to the workpiece
through a die.
is forward extrusion, but the fluid pressure
fi i
friction
i
is
eliminated,
li i
d
and
d
the
h
pressurized
p
essu ed fluid
u d acts as a lubricant
ub ca t bet
between
ee tthee b
billet
et
and the die.
274
275
S 2000
IAS
pp
Application
y Claddingofmetals
y Makingwiresforlessductilematerials
277
Page 90 of 205
S 2006
IES
y Extrusionofnuclearreactorfuelrod
273
H d t ti E t i
HydrostaticExtrusion
Contd.
y Another
off cold
A th type
t
ld extrusion
t i process.
y It
suitable die and is forced through the opening of the die with
the punch
when the punch starts downward movement. Pressure is
exerted
d by
b the
h shoulder
h ld off the
h punch,
h the
h metall being
b i forced
f
d
to flow through the restricted annular space between the
punch and the opening in the bottom of the die.
die
In place of a flat solid blank, a hollow slug can also be used.
If the tube sticks to the punch on its upward stroke,
stroke a
stripper will strip it from the punch.
Small copper tubes and cartridge cases are extruded by this
method.
278
Rev.1
279
( )
GATE1990(PI)
Semi brittle materials can be extruded by
(a) Impact extrusion
(b) Closed cavity extrusion
(c) Hydrostatic extrusion
(d) Backward
B k
d extrusion
i
280
S 2001
200
IES
L b i ti f E t i
LubricationforExtrusion
282
ForIESOnly
IES 2014
IES2009Conventional
ProcessvariablesinExtrusion
Explain
below.
E l i the
th processes off extrusion
t i given
i
b l
Indicate one typical product made through each of these
processes:
(i) Direct Extrusion
(ii) Indirect Extrusion
(iii) Hydrostatic Extrusion
(i ) Impact
(iv)
I
t Extrusion
E t i
283
285
ForIESOnly
Extrusion Defects
ExtrusionDefects
y Surface crack due to high temperature, high speed,
286
IAS 2012main
2012
i
IAS
20 0
JWM2010
p
p
Assertion ((A)) : Extrusion speed
depends
on work
material.
Reason (R) : High extrusion speed causes cracks in
the material.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both
B h A and
d R are individually
i di id ll true but
b R is
i not the
h
correct explanation of A
(c) A is true but R is false
((d)) A is false but R is true
Page 91 of 205
287
Enumeratetheconditionsunderwhichcentralburst
E
t th
diti
d hi h t lb t
mayoccur.Wheredoesa'pipe'occur?
y
pp
Rev.1
288
GATE2014
P
II
III
Q
III
I
R
VI
IV
S
V
VI
(b)
(d)
P
III
I
Q
I
II
R
VI
V
S
V
VI
289
Wi D
i
WireDrawing
Wi D
i
WireDrawing
Contd.
y A cold
process to
from
rods
ld working
ki
t obtain
bt i wires
i
f
d off
bigger
gg diameters through
g a die.
y Same process as bar drawing except that it involves
smallerdiameter material.
y At the start of wire drawing, the end of the rod or wire to
Wi D
i
WireDrawing
Contd.
291
S 2007
200
IES
y Wire
Wi getting
tti continuously
ti
l wound
d on the
th reel.
l
y For fine wire,
wire the material may be passed through a
S 2009
IES
is
used
for
292
293
S 2005
200
IES
Which of the following types of stresses is/are
involved in the wiredrawing operation?
(a) Tensile only
(b) Compressive only
(c) A combination of tensile and compressive stresses
((d)) A combination of tensile, compressive
p
and shear
stresses
CleaningandLubricationinwireDrawing
GATE1987
g
y
p
g
y Cleaningisdonetoremovescaleandrustbyacidpickling.
Forwiredrawingoperation,theworkmaterial
shouldessentiallybe
(a)Ductile
(b)Tough
( )
(c)Hard
( )
(d)Malleable
294
295
Page 92 of 205
296
Rev.1
297
IES 2010
IES2010
S 2000
IES
) Pickling
g and washing
g of rolled rods
Assertion ((A):
is carried out before wire drawing.
Reason (R): They lubricate the surface to reduce
friction while drawing wires.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both
B h A and
d R are individually
i di id ll true but
b R is
i NOT the
h
correct explanation of A
(c) A is true but R is false
((d)) A is false but R is true
S 1995
99
IAS
298
299
300
ForIESOnly
IES 2014
S 1996
996
IES
In wire drawing process, the bright shining surface
on the wire is obtained if one
(a) does not use a lubricant
(b) uses solid powdery lubricant.
(c) uses thick paste lubricant
((d)) uses thin film lubricant
BundleDrawingg
In this process, many wires (as much as several
thousand) are drawn simultaneously as a bundle. To
preventt sticking,
ti ki
th wires
the
i
are separated
t d from
f
each
h
other byy a suitable material. The crosssection of the
wires is somewhat polygonal.
301
Wi D
i Di
WireDrawingDie
303
R d dT b D
i
RodandTubeDrawing
y Rod drawing is similar to wire drawing except for the fact
y Die
i materials:
i l tooll steels
l or tungsten carbides
bd
or
For-2015
(IES,
GATE
& PSUs)
polycrystalline
diamond
(for
fine wire)
304
that the dies are bigger because of the rod size being
larger than the wire.
y The tubes are also first pointed and then entered
through the die where the point is gripped in a similar
way as the bar drawing and pulled through in the form
desired along a straight line.
line
y When the final size is obtained, the tube may be
annealed
l d and
d straightened.
t i ht
d
y The practice of drawing tubes without the help of an
internal mandrel is called tube sinking.
Page 93 of 205
305
Back
Rev.1
306
R d dT b D
i
RodandTubeDrawing
Contd
S
i
k
di
Swagingorkneading
;
( ),
( )
IES1993;GATE1994(PI),2014(PI)
y The
its
Th hammering
h
i off a rod
d or tube
t b to
t reduce
d
it diameter
di
t
TubeSinking
FixedPlugDrawing
(d) Forging
MovingMandrel
307
308
S
i
k
di Contd
Swagingorkneading
S 1993
993
IES
310
311
S 1999
999
IES
p
Match List I (C
(Components
of a table fan)) with List II
(Manufacturing processes) and select the correct
answer using the codes given below the Lists:
List I
List II
A. Base with stand
1.
Stamping
p g and
pressing
g
B. Blade
2.
Wire drawing
C. Armature coil wire
3.
Turning
D Armature shaft
D.
4
4.
Casting
Codes:A B
C
D
A
B
C
D
(a) 4
3
2
1
(b) 2
1
4
3
(c) 2
3
4
1
(d) 4
1
2
3312
S 1996
996
IES
S 1994
99
IES
A. Wire drawing
A
B. Extrusion
C. Blanking
D. Bending
g
Codes:A B
C
(a) 4
2
1
(c) 2
3
1
11.
2.
3.
4.
4
D
3
4
(b)
(d)
Shear force
Tensile force
Compressive force
Spring
p g back force
A
B
C
D
2
1
3
4
4
3
2
1
Page 94 of 205
309
S 2000
IES
314
MatchListIwithListIIandselectthecorrectanswer
usingthecodesgivenbelowtheLists:
ListI(Metalfarmingprocess)ListII(Asimilarprocess)
A.
B
B.
C.
D.
Blanking
Coining
C
i i
Extrusion
Cupdrawing
Codes:A
( ) 2
(a)
(c) 3
B
3
2
C
4
1
1.
2.
3.
4.
5.
D
1
5
(b)
(d)
Wiredrawing
Pi i
Piercing
Embossing
Rolling
Bending
A
B
C
2
3
1
2 Rev.1
3
1
D
4
5315
S 1993,ISRO2010
993 S O 20 0
IES
S 2002
IES
S 2001
200
IAS
A. Seamless tubes
1. Roll forming
B Accurate
B.
A
and
d smooth
h tubes
b
2.
Sh peening
Shot
i
C. Surfaces having higher
3.
Forging
hardness and fatigue strength4.
Cold forming
Codes:
A
B
C
A
B
C
(a) 1
4
2
(b) 2
3
1
( ) 1
(c)
3
2
(d) 2
4
1
316
IES 2011
IES2011
S 2002
IAS
) In wiredrawing
g process,
p
, the rod
Assertion ((A):
crosssection is reduced gradually by drawing it
several times in successively reduced diameter dies.
Reason (R): Since each drawing reduces ductility of
the wire, so after final drawing the wire is
normalized.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
319
MatchListIwithListIIandselectthecorrectanswerusing
thecodegivenbelowthelists:
ListI
ListII
322
SeamlesstubeManufacturingg
1.Rolling
A.Connectingrods
1.Welding
2Extrusion
B.Pressurevessels
2.Extrusion
3.TubeDrawing
C Machinetoolbeds
C.Machinetoolbeds
3 Forming
3.Forming
4.Spinning
S i i
D.Collapsibletubes
p
4.Casting
g
Codes
C
d
A
( ) 2
(a)
(c)
2
B
1
4
C
4
1
D
3
3
(b)
(d)
A
3
3
B
1
4
C
4
1
D
2
2320
IAS 1994
IAS1994
( )
GATE1991(PI)
317
323
IES2012Conventional
Howaretheseamlesstubesproduced?
Rev.1
324
ExtrusionLoad
y Approximate
method (Uniform
friction) work formula
A
P = Ao o ln o
Af
d
d2
= 2 o o ln o
4
df
deformation,
no
y Approximate
method (Uniform
friction) work formula
d o2
o ln ( R )
=
4
A
P = KAo ln o
A
f
F
i d i Wi
T b d
i
ForcerequiredinWireorTubedrawing
ExtrusionStress
E =
A
P
= o ln o
A0
Af
deformation,
d
= 2 o ln o
df
no
= o ln ( R )
d
d o2
=
K ln o
2
d
4
E =
K = extrusion constant.
A
P
= K ln o
A
A0
f
d
= 2 K ln o
df
y Approximate
method (Uniform
friction) work formula
A
P = Af o ln o
A
f
Drawing
g Stress
d =
deformation,
d
d 2f
=
2
o ln o
d
4
A
P
= o ln o
A
Af
f
d
= 2 o ln o
df
no
K = extrusion constant.
325
326
G
2003
GATE2003
327
G
2006
GATE2006
GATE 2009(PI)
A brass
billet
its
b
bill t is
i to
t be
b extruded
t d d from
f
it initial
i iti l
Using
U i direct
di t extrusion
t
i process, a round
d billet
bill t off 100
In
diameter
I a wire
i drawing
d
i operation,
ti
di
t off a steel
t l wire
i
mm length
g
and 550 mm diameter is extruded.
required
f extrusion
for
t
i is
i
and
d average flow
fl
stress
t
off material
t i l 300 MPa,
MP the
th
redundant
d d t work)
k) is
i
(a) 4.48
4 48 kN
(b)
8 97 kN
8.97
(c) 20.11 kN
(d)
31.41 kN
(a) 5.44
5 44 MN
(b)
2 72 MN
2.72
(c) 1.36 MN
(d)
0.36 MN
(a) 416
(b) 624
(c) 700
(d) 832
328
GATE 2008
(PI) Linked S2
GATE
2008(PI)LinkedS
2
800 MPa.
MPa
800 MPa.
MPa
g
g friction and strain hardening,
g, the stress
Neglecting
power required
q
for the drawing
gp
process ((in kW))
The p
is
(a) 8.97
(d) 2575.0
331
drawing
(ignoring
friction
329
GATE 2008
(PI) Linked S1
GATE
2008(PI)LinkedS
1
(c) 1287.5
for
and
330
G
200 G
200 ( )
GATE2001,GATE2007(PI)
For
F rigid
i id perfectlyplastic
f tl l ti work
k material,
t i l negligible
li ibl
interface friction and no redundant work,, the
theoretically maximum possible reduction in the
wire drawing operation is
(b) 14.0
(c) 17.95
(d) 28.0
Page 96 of 205
332
( ) 0.36
(a)
(b)
0.63
(c) 1.00
1 00
(d)
2 72
2.72
Rev.1
333
IES 2014
IES
Wire Drawing
WireDrawing
G
996
GATE1996
In wire
drawing
operation, the maximum
wiredrawing
reduction per pass for perfectly plastic material in
ideal condition is
(a) 68 %
(b) 63 %
( ) 58
(c)
8%
(d) 50%
%
334
MaximumReductionperpass
o =
o (1 + B )
B
2B
2B
o =
o (1 + B )
B
2B
rf
1
ro
337
GATE 2011(PI)CommonDataS2
GATE
2011 (PI) Common Data S2
In a multipass drawing operation, a round bar of 10 mm
diameter and 100 mm length is reduced in crosssection
by drawing it successively through a series of seven dies
of decreasing exit diameter. During each of these
drawing operations, the reduction in crosssectional area
is 35%. The yield strength of the material is 200 MPa.
Ignore strain hardening.
Neglectingfrictionandredundantwork,theforce(in
) q
g
g
,
kN)requiredfordrawingthebarthroughthefirstdie,is
(a)15.71
(b)10.21
(c)6 77
(c)6.77
(d)4 39
(d)4.39
For-2015 (IES, GATE & PSUs)
340
f
336
GATE 2011(PI)CommonDataS1
GATE
2011 (PI) Common Data S1
A 12.5
12 5 mm diameter rod is to be reduced to 10 mm
diameter by drawing in a single pass at a speed of 100
/
Assuming
g a semi die angle
g of 5o and coefficient
m/min.
of friction between the die and steel rod as 0.15,
calculate:
(i) The power required in drawing
((ii)) Maximum p
possible reduction in diameter of the rod
(iii) If the rod is subjected to a back pressure of 50
2 , what would be the draw stress and maximum
/
N/mm
possible reduction ?
2.
400 N/mm
/
Take stress of the work material as 4
[15Marks]
r r
1 f + f . b
ro ro
2B
2B
rf rf
1 + . b
ro ro
335
IES 2011Conventional
d =
o (1 + B )
338
G
20
GATE
2014
A metal
t l rod
d off initial
i iti l length
l
th
339
S 1997
99
IAS
is
i subjected
bj t d to
t a
drawing
g p
process. The length
g
of the rod at any
y
instant is given by the expression, L(t) = Lo(1 + t2)
where t is the time in minutes. The true strain rate
att the
th end
d off one minute
i t is
i ..
Page 97 of 205
341
Rev.1
342
S 2012
20 2
IES
Write the process variables in wire drawing.
Ans.
1. Reduction
R d ti in
i cross sectional
ti
l area
2. Die angle
3. Friction
( x + d x ) ( r + dr )
d x 2 o 2 ( o x )
+
+
cot = 0
dr
r
r
Let cot = B
or B x (1 + B ) o = ( rC )
344
IFS 2013
IFS2013
or x =
r
1
ro
Drawing stress ( d ) =
2B
r 2 B
+ . b
ro
o (1 + B )
r r
1 f + f . b
ro ro
2B
346
2B
347
at r = ro
B x (1 + B ) o = ( rC
C)
B.C s at r = rf , x = 0
xo =
o (1 + B )
B
2B
Extrusion ratio, R =
(1 + B ) o 2 B
C =
rf
or x =
r
1 o
rf
2B
1 r
B For-2015
rf GATE
(IES,
& PSUs)
xo =
o (1 + B )
349
o (1 + B )
B
345
B b (1 + B ) o 2 B
C =
ro
o (1 + B )
and x = Px = ( o x )
2B
B.C s at r = ro , x = b
d x 2
= B x (1 + B ) o
dr
r
d x
2
or
= dr
B x (1 + B ) o r
1
ln B x (1 + B ) o = 2 ln ( rC )
B
{Cis integration cont.}
dx
x r 2 + x cos 2 r
cos
dx
+ Px sin 2 r
=0
cos
Th equilibrium
The
ilib i equation
ti iin x-direction
di ti will
ill bbe
2
2B
h
= o
h
f
A
P
= o ln o
A
Af
f
x = Px = ( o x )
at Exit = P = ( o d ) = 0
348
Ao ro
=
Af rf
r
= 2 o ln o
rf
For Tangential Stress i.e. Shear Stress
d =
p f . r0 2 = 2 r0 i L or p f =
2 i L
ro
1 R 2 B
Page 98 of 205
350
Rev.1
351
WorkbookCh17:Extrusion
Q. No
Option
Q. No
Option
2
3
C
D
9
10
B
A
11
12
6
7
C
B
13
WorkbookCh16:Drawing
Q. No
Option
2
3
4
C
C
B
5
6
C
D
SheetMetalOperation
p
BySKMondal
352
353
354
Piercing(Punching)andBlanking
Pi i (P hi ) d Bl ki
Piercing(Punching)andBlanking
SheetMetal
y Product has light weight and
versatile shape as
compared to forging/casting
y Most commonly used
g formability)
y
strength,
office furniture
y Piercing
Pi i and
d blanking
bl ki are shearing
h i operations.
ti
y Both
ot do
donee o
on so
somee form
o o
of mechanical
ec a ca p
press.
ess.
355
356
357
Clearance(VIMP)
(
)
y Die opening must be larger than punch and known as
clearance.
y Punching
y Blanking
Punching
358
In Blanking clearance
on punch
Page 99 is
of provided
205
359
Blanking
Rev.1
360
ClearanceContd.
y The
clearance
is
determined
with
following
equation
E
l
Example
Clearancein%
y If the allowance for the material is a = 0.075 given then
C = 0.0032
0 0032t
y Total
T l clearance
l
b
between
punch
h and
d die
di size
i will
ill be
b
ttwice
ce tthese
ese C
C i.e.
.e. 2C
C
361
G
2003
GATE2003
A metal
t l disc
di off 20 mm diameter
di
t is
i to
t be
b punched
h d
from a sheet of 2 mm thickness. The p
punch and the
die clearance is 3%. The required punch diameter is
(a) 19.88 mm (b)
19.94 mm
20.12 mm
362
363
P hi F
d Bl ki F
PunchingForceandBlankingForce
CapacityofPressforPunchingandBlanking
Fm ax = Lt
dt
3
364
E
l
Example
Estimate
to
E ti t the
th blanking
bl ki force
f
t cutt a blank
bl k 25 mm wide
id
and 330 mm long
g from a 1.55 mm thick metal strip,
p, if the
ultimate shear strength of the material is 450 N/mm2.
Also determine the work done if the percentage
penetration
t ti is
i 25 percentt off material
t i l thickness.
thi k
367
Fmax C
[WhereCisaconstantandequalto1.1to1.75depending
upontheprofile]
Thepunchingforceforholeswhicharesmallerthanthestock
thicknessmaybeestimatedasfollows:
Fmax =
P
Presscapacitywillbe=
it illb
d
t
365
GATE2014
IAS2011Main
366
368
Rev.1
369
Mi i
Di
t
f Pi i
MinimumDiameterofPiercing
IES 2014
IES
S 1999
999
IES
A hole
h l is
i to
t be
b punched
h d in
i a 15 mm thick
thi k plate
l t
having
g ultimate shear strength
g of 33Nmm2. If the
s d.t
dt
Piercingpressure,=Strengthofpunch,
Pi
i
St
th f
h c 4 d2
(b)
30 mm
(c) 60 mm
(d)
120 mm
370
371
IES 2013
IES2013
S O 2008 20
ISRO2008,2011
372
EnergyandPowerforPunchingandBlanking
With a punch
which
crushing
h for
f
hi h the
th maximum
i
hi
EN
60
[Where N = actual number of stroke per minute]
Ideal power in press ( P inW ) =
be equal to:
Where C is a constant and equal to 1.1 to 1.75 depending upon the profile
(a)
1
4
(c) 1
EN
60
Wh E iis actuall energy and
WhereE
d iis efficiency
ffi i
off the
h press
(b) 2
(d) 2
373
374
Sh
P h
ShearonPunch
375
ForcerequiredwithshearonPunch
d
h h
h
y To
shearing
shear
is
off
T reduce
d
h i force,
f
h
i ground
d on the
th face
f
F=
Fmax pt
S
Wherep=penetrationofpunchasafraction
S=shearonthepunchordie,mm
376
377
Rev.1
378
E
l
Example
Example
y A hole, 100 mm diameter, is to be punched in steel plate
5.6
6 mm thick.
thi k The
Th ultimate
lti t shear
h
stress
t
i 550 N/
is
N/mm2 .
With normal clearance on the tools,, cutting
g is complete
p
at 40 per cent penetration of the punch. Give suitable
shear angle for the punch to bring the work within the
capacity
it off a 30T
T press.
G
20 0 S
i k d
GATE2010StatementLinked1
379
380
Fi Bl ki
FineBlanking
G
20 0 S
i k d2
GATE2010StatementLinked2
Q
Statement for Linked Answer Questions:
In a shear cutting operation, a sheet of 5mm thickness
is cut along a length of 200 mm. The cutting blade is 400
mm long and zeroshear
zero shear (S = 0) is provided on the edge.
edge
The ultimate shear strength of the sheet is 100 MPa and
penetration to thickness ratio is 0.2. Neglect friction.
close together
g
are cut in flat work material.
400
strip or blank.
S
383
384
y Shaving
g Accurate dimensions of the p
part are obtained byy
scrap.
y Sq
Squeezing
g Metal is caused to flow to all p
portions of a die
385
386
Rev.1
387
y Steel
St l Rules
R l soft
ft materials
t i l are cutt with
ith a steel
t l strip
ti
shaped
p so that the edge
g is the p
pattern to be cut.
y Nibbling a single punch is moved up and down rapidly,
Di ki
Dinking
El ti
i b k
Elasticrecoveryorspringback
y Total
= elastic
+ plastic
T t l deformation
d f
ti
l ti deformation
d f
ti
l ti
deformation.
allows
ll
a simple
l die
d to cut complex
l slots.
l
El ti
i b k Contd..
Elasticrecoveryorspringback
y More important in cold working.
working
389
390
S 2003
IAS
S 0 2013
20 3
ISR0
The 'spring
spring back
back' effect in press working is
(a) Elastic recovery of the sheet metal after removal of
the load
(b) Regaining the original shape of the sheet metal
(c) Release of stored energy in the sheet metal
((d)) Partial recoveryy of the sheet metal
Spring
S i back
b k in
i metal
t l forming
f
i depends
d
d on
(a) Modulus of Elasticity
(b) Load Applied
pp
(c) Strain Rate
(d) None of these
y To compensate this,
this the cold deformation be carried
P hi P
PunchingPress
PunchandDiematerial
y
Commonlyused toolsteel
Forhighproduction carbides
392
394
393
B lt
l t
Bolsterplate
395
Rev.1
396
B lt
l t
Bolsterplate
Contd....
P h l t
Punchplate
y When
Wh many dies
di are to
t run in
i the
th same press att different
diff
t
St i
Stripper
y Used
U d to
t locate
l t and
d hold
h ld the
th
punch in p
p
position.
y This is a useful way of
mounting,
small
ll punches.
h
especially
for
attached to it.
it
397
St i
Stripper
Contd....
pp removes the stock from the p
y The stripper
punch after a
piercing or blanking operation.
398
K k t
Knockout
Pit
Pitman
y It is
i a connecting
ti rod
d which
hi h is
i used
d to
t transmit
t
it motion
ti
Ps = KLt
399
Where Ps =strippingforce,kN
L i t f t
L=perimeterofcut,mm
t=stockthickness,mm
K=strippingconstant,
K
strippingconstant
=0.0103forlow carbonsteelsthinnerthan1.5mmwith
thecutattheedgeornearaprecedingcut
=0.0145forsamematerialsbutforothercuts
=0.0207forlow
7
carbonsteelsabove1.5mmthickness
5
=0.0241forhardermaterials
400
D
l i
Dowelpin
401
402
GATE2011
The shear strength of a sheet metal is 300 MPa.
MPa The
blanking force required to produce a blank of 100
mm diameter from a 1.5
1 5 mm thick sheet is close to
(a) 45 kN
(b) 70 kN
(c) 141
4 kN
(d) 3500 kN
( )
GATE 2009(PI)
A disk of 200 mm diameter is blanked from a strip
of an aluminum alloy of thickness 3.2 mm. The
material shear strength to fracture is 150 MPa. The
blanking force (in kN) is
((a)) 291
9
403
404
((b)) 3301
((c)) 3311
((d)) 3321
Rev.1
405
S O 2009
ISRO2009
G
200
GATE2007
minimum
i i
punching
hi force
f
required
i d in
i kN is
i
(a) 2.57
2 57
(b) 3.29
(c) 5.03
(d) 6.33
406
G
200
GATE2004
10 mm diameter holes are to be punched in a steel
sheet of 3 mm thickness. Shear strength of the
material is 400 N / mm2 and penetration is 40%.
Shear provided on the punch is 2 mm. The blanking
force during the operation will be
(a) 22.6 kN
(b) 37.7 kN
( ) 61.6
(c)
6 6 kN
(d) 94.3 kN
407
G
2002
GATE2002
412
(b) 50.00
50 00 and 50.15
50 15
410
G
200
GATE2001
( )
GATE2008(PI)
GATE 2012
409
408
G
996
GATE1996
411
413
Rev.1
414
S 1994
99
IES
S 2002
IES
415
S 2006
IES
S 2004
200
IES
421
417
419
GATE 2007(PI)
2007 (PI)
GATE
S 2000
IAS
S 1997
99
IES
418
S 1995
99
IAS
S 1994
99
IAS
420
422
Rev.1
423
S 2002
IAS
S 2007
200
IAS
424
S 2002
IES
S 1995
99
IAS
Assertion (A): A flywheel is attached to a punching
press so as to reduce its speed fluctuations.
Reason(R): The flywheel stores energy when its
speed increase.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both
B th A and
d R are individually
i di id ll true
t
b t R is
but
i nott the
th
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
425
426
S 2003
IAS
S 2000
IES
427
428
429
D
i
Drawing
S 1999
999
IES
Assertion (A): In sheet metal blanking operation,
clearance must be given to the die.
Reason (R): The blank should be of required
dimensions.
( ) Both
(a)
B th A and
d R are individually
i di id ll true
t
and
d R is
i the
th
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
For-2015 (IES, GATE & PSUs)
430
y Drawing
D
i is
i a plastic
l ti deformation
d f
ti process in
i which
hi h a flat
fl t
sheet or p
plate is formed into a threedimensional p
part
with a depth more than several times the thickness of
the metal.
y As a punch
h descends
d
d into a mating die,
d
the
h metall
Drawing
Page 107 of 205
431
Rev.1
432
Blank Size
BlankSize
D
i
Drawing
y Hot
is
H t drawing
d
i
i used
d for
f thickwalled
thi k
ll d parts
t off simple
i l
geometries,, thinning
g
g takes p
place.
D = d 2 + 4dh
Whend>20r
D=
( d 2r )
+ 4d ( h r ) + 2 r ( d 00.7
7r )
wide
d variety off shapes.
h
433
434
S 1994
99
IES
G
2003
GATE2003
For
F obtaining
bt i i a cup off diameter
di
t 25 mm and
d height
h i ht 15
A shell
h ll off 100 mm diameter
di
t and
d 100 mm height
h i ht with
ith
mm by
y drawing,
g, the size of the round blank should
be approximately
(a) 42 mm
(b)
44 mm
(a) 118 mm
(b)
161 mm
(c) 46 mm
(d)
48 mm
(c) 224 mm
(d)
312 mm
435
ISRO2011
The initial blank diameter required to form
a cylindrical
li d i l cup off outside
id diameter
di
'd and
d
total height
g 'h' having
g a corner radius 'r' is
obtained using the formula
(a ) Do = d 2 + 4dh 0.5
0 5r
(b) Do = d + 2h + 2r
(c) Do = d 2 + 2h 2 + 2r
436
437
438
S 2013Main
20 3
i
IAS
y Drawing Force
P = dt C
d
(d ) Do = d 2 + 4dh 0.5r
439
440
Rev.1
441
D
d
i
Deepdrawing
S 20 3
IFS2013
A symmetrical
with
t i l cup off circular
i
l cross section
ti
ith
diameter 4
40 mm and height
g 60 mm with a corner
radius of 2 mm is to be obtained in C20 steel of 0.6
mm thickness. Calculate the blank size for the
d
drawn
cup. Will it be
b possible
ibl to
t draw
d
th cup in
the
i
S 2008
IES
single
g step?
p
[10Marks]
442
D
D
bilit
DeepDrawability
p
g
StressesonDeepDrawing
uniaxial
present etc.
present,
etc
S 1997
99
IES
Fi draw:Reduction
First
d
R d i = 50 %
Second draw:Reduction = 30 %
446
447
S 1998
998
IES
Thumb rule:
Third draw:Reduction = 25 %
Fourth draw:Reduction = 16 %
Fifth draw:Reduction = 13 %
y Limiting
t g d
drawing
a
g ratio
at o ((LDR)) iss 1.6
.6 to 2.3
.3
445
y Theaveragereductionindeepdrawing
d
= 0.5
D
Biaxial
Bi
i l tension
t i and
d
compression
444
LimitingDrawingRatio(LDR)
y The
blank
to
Th ratio
ti off the
th maximum
i
bl k diameter
di
t
t the
th
y In flange of blank:
simple
tension
443
448
IFS 2009
y What is deep drawing process for sheet metal
Rev.1
450
ForIESOnly
Di D i
DieDesign
ForIESOnly
P
i dies
di
Progressive
Perform two or more operations simultaneously in a single
stroke of a punch press,
press so that a complete component is
obtained for each stroke.
y Progressivedies
P
i di
ForIESOnly
Progressivepiercingandblankingdiefor
makingasimplewasher.
making a simple washer.
Compound dies
All the necessary operations are carried out at a single
station, in a single
g stroke of the ram. To do more than one set
of operations, a compound die consists of the necessary sets
of punches and dies.
y Compounddies
C
ddi
y Combinationdies
C
bi ti di
Combination dies
A combination die is same as that of a compound die with
the main difference that here noncutting operations such as
bending and forming are also included as part of the
operation.
operation
451
Back
453
452
ForIESOnly
ForIESOnly
IFS 2013
IFS2013
M th d f
ki
i l
h i
d i i
d
Methodformakingasimplewasherinacompoundpiercingand
blankingdie.Partisblanked(a)andsubsequentlypierced
(b)Theblankingpunchcontainsthedieforpiercing.
(b) The blanking punch contains the die for piercing
y Differentiate
Diff
ti t
among
the
th
simple,
i l
L b i ti
Lubrication
compound
d
and
d
progressive
p
g
dies.
y Indrawingoperation,properlubricationisessentialfor
d
l b
lf
1. Toimprovedielife.
T i
di lif
[6 Marks]
2 Toreducedrawingforces.
2.
Toreducedrawingforces
3 Toreducetemperature.
3.
Toreducetemperature
4 Toimprovesurfacefinish.
4.
Toimprovesurfacefinish
Back
454
S 2007
200
IAS
In drawing operation, proper lubrication
essential for which of the following reasons?
1 To improve die life
1.
2. To reduce drawing forces
3. To reduce temperature
4. To improve
4
p
surface finish
Select the correct answer using the code given below:
(a) 1 and 2 only
(b) 1,
1 3 and 4 only
(c) 3 and 4 only
(d) 1, 2, 3 and 4
For-2015 (IES, GATE & PSUs)
is
457
455
456
D f t i D
i
i kl
DefectsinDrawing
wrinkle
D f t i D
i
F t
DefectsinDrawing
Fracture
458
Rev.1
459
D f t i D
i
i
DefectsinDrawingearing
D f t i D
i
i t ik
DefectsinDrawing
missstrike
D f t i D
i
O
l
DefectsinDrawing
Orangepeel
460
461
G
2008
GATE2008
Surfacescratches
y Dieorpunchnothavingasmoothsurface,insufficient
yielding.
y These lines can crisscross the surface of the workpiece and
lubrication
strains.
463
S 1997
99
IAS
466
464
G
999
GATE1999
462
G
2006
GATE2006
465
467
S 1999
999
IES
Spinning
S 1994
99
IAS
471
S i i
Spinning
S i i
Spinning
y Spinning is a coldforming operation in which a
1.
1 A mandrel (or die for internal pieces) is placed on a
rotating axis (like a turning center).
2 A blank or tube is held to the face of the mandrel.
2.
mandrel
3. A roller is pushed against the material near the
center
t off rotation,
t ti
and
d slowly
l l moved
d outwards,
t
d pushing
hi
the blank against the mandrel.
4. The part conforms to the shape of the mandrel (with
some springback).
5. The process is stopped, and the part is removed and
trimmed.
472
473
474
G
992
GATE1992
tc = tb sin
S 1994
99
IES
Thethicknessoftheblankneededtoproduce,by
Th thi k
fth bl k
d dt
d
b
The
off the
Th mode
d off deformation
d f
ti
th metal
t l during
d i
p
powerspinningamissileconeofthickness1.5mm
p
g
5
spinning
p
g is
andhalfconeangle30,is
(a) Bending
(a) 3.0mm
(b)
2.5mm
(b) Stretching
(c) 2.0mm
(d)
1.5mm
475
476
Rev.1
477
ForIESOnly
ForIESOnly
HERF
IFS2011
y High Energy
Energ Rate Forming,
Forming also known
kno n as HERF or explosive
e plosi e
Comparemetalspinningwithpresswork.
[
[2marks]
k ]
HighEnergyRateForming(HERF)
479
ForIESOnly
Underwater
explosions.
480
ForIESOnly
ForIESOnly
Underwater explosions
Underwaterexplosions
Underwater Explosions
UnderwaterExplosions
y A shock
(normally
h k wave in
i the
th fluid
fl id medium
di
(
ll water
t ) is
i
Electromagnetic
(th f
(theuseof
rapidlyformed
g
)
magneticfields).
HERF
Underwaterspark
discharge(electro
hydraulic)
hydraulic).
y TNT and dynamite for higher energy and gun powder for
y Employed
E l d
Pneumatic
mechanical
means
i
in
A
Aerospace,
aircraft
i
f
i d
industries
i
and
d
automobile
auto
ob e related
e ated co
components.
po e ts.
481
482
ForIESOnly
483
ForIESOnly
ForIESOnly
El t h d li F
i
ElectrohydraulicForming
ElectromagneticorMagneticPulseForming
y A large
l
capacitor
it bank
b k is
i discharged,
di h
d producing
d i a currentt
484
485
ForIESOnly
ForIESOnly
IES2011
ElectromagneticorMagneticPulseForming
y The
Th process is
i very rapid
id and
d is
i used
d primarily
i
il to
t expand
d
High
process used
h energy rate forming
f
d for
f
or contract tubing,
g, or to p
permanentlyy assemble
component parts.
(
(0.25
to 1.25 mm thick).
h k)
(a) Petroforming
(b) Magnetic pulse forming
(c) Explosive forming
(d) electrohydraulic
electro hydraulic forming
487
488
489
IES 2010
IES2010
20 0
JWM2010
( ) : In magnetic
g
p
g method,,
Assertion (A)
pulseforming
magnetic field produced by eddy currents is used to
p
create force between coil and workpiece.
Reason (R) : It is necessary for the workpiece
material to have magnetic properties.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is NOT the
correctt explanation
l
ti off A
(c) A is true but R is false
(d) A is false but R is true
490
S 2007
200
IES
g energy
gy rate forming
g
Assertion ((A)) : In the high
method, the explosive forming has proved to be an
g energy
g at high
g rate and
excellent method of utilizing
utilizes both the high explosives and low explosives.
Reason ((R):
) The g
gas p
pressure and rate of detonation
can be controlled for both types of explosives.
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is NOT the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
491
S 2009
IES
S 2005
200
IES
Which
Whi h
one off
the
following
th
f ll i
metal
t l
forming
f
i
492
IES2013Conventional
Which
is
Whi h one off the
th following
f ll i
i a high
hi h energy rate
t
Magnetic
M
ti forming
f
i is
i an example
l of:
f
forming
gp
process?
(b)
Hot forming
(c) High
g energy
gy rate forming
g
(d)
Roll forming
g
[5marks]
493
494
Rev.1
495
St t h F
i
StretchForming
St t h F
i
StretchForming
Contd......
g sheet metal p
y Produce large
parts in low or limited
quantities.
y A sheet of metal is g
gripped
pp byy two or more sets of jjaws
that stretch it and wrap it around a single form block.
y Because most of the deformation is induced by
y the
tensile stretching, the forces on the form block are far
less than those normally encountered in bending or
forming.
y There is very little springback, and the workpiece
conforms very closely to the shape of the tool.
y Because the forces are so low, the form blocks can often
be made of wood, lowmeltingpoint metal, or even
plastic.
496
St t h F
i
StretchForming
Contd......
St t h F
i
StretchForming
Contd......
y Popular
P
l in
i the
th aircraft
i
ft industry
i d t and
d is
i frequently
f
tl used
d to
t
497
498
I i
Ironing
G
2000
GATE2000
A 1.5 mm thick sheet is subject to unequal biaxial
stretching and the true strains in the directions of
stretching are 0.05 and 0.09. The final thickness of
the sheet in mm is
(a) 1.414
1 414
(b) 1.304
1 304
(c) 1.362
(d) 289
y The
cylinder
Th process off thinning
thi i the
th walls
ll off a drawn
d
li d by
b
passing
p
g it between a p
punch and die whose separation
p
is
less than the original wall thickness.
y The walls are thinned and lengthened, while the
thickness
h k
off the
h base
b
remains unchanged.
h
d
y Examples of ironed products include brass cartridge
500
501
ForIESOnly
I i
Ironing
Contd....
I i F
IroningForce
E b i
Embossing
y It is
the
i a very shallow
h ll drawing
d
i operation
ti where
h
th depth
d th off
t
F = dt tt av ln o
tt
For-2015 (IES, GATE & PSUs)
502
unchanged.
503
Rev.1
504
C i i
Coining
di
Bending
y Coining
C i i is
i essentially
ti ll a coldforging
ld f i operation
ti exceptt for
f
articles.
l
Bendallowance,
Bendallowance
Lb =(R+kt)
the fact that the flow of the metal occurs onlyy at the top
p
layers and not the entire volume.
di
Bending
=
where
R=bendradius
k=constant(stretchfactor)
For R > 2t
k = 0.5
05
For R < 2t
1
2R
+1
t
k = 0.33
t=thicknessofmaterial
=bendangle(inradian)
505
506
507
ForIESOnly
BendingForce
Bending
Force
Kl ut t 2
F=
IES 1998
IES1998
G
200
GATE2005
of
t = blank
bl k thickness,
thi k
mm
w = width of die-opening, mm
(a) 1 : 2 : 0.5
(b) 2: 1 : 0.5
( ) 1: 2 : 1
(c)
( ) 1: 1 : 1
(d)
K = die
die-opening
opening factor , (can be used followin table)
Condition
V-Bending
U-Bending
Edge-Bending
W < 16t
1 33
1.33
2 67
2.67
0 67
0.67
W > = 16t
1.20
2.40
0.6
1 radian
ForUorchannelbendingforcerequiredisdoublethanV bending
ForUorchannelbendingforcerequiredisdoublethanV
ForedgebendingitwillbeaboutonehalfthatforV bending
508
509
510
ForIESOnly
S
ki
Spanking
y During
the
D i bending,
b di
th area off the
th sheet
h t under
d the
th punch
h
so that
h when
h the
h punch
h and
d die
d are completely
l l closed
l d on
the blank,
blank any bulging developed earlier will be
completely presses or spanked out.
For-2015 (IES, GATE & PSUs)
511
512
Rev.1
513
G
200
GATE2007
g metal
Match the correct combination for following
working processes.
Associated state of stress
Processes
P. Blanking
1.
Tension
Q Stretch Forming 2.
Q.
2
Compression
R. Coining
3.
Shear
S Deep Drawing
S.
4
4.
Tension and Compression
5.
Tension and Shear
C d P Q
Codes:P
R
S
P
Q
R
S
(a) 2
1
3
4
(b) 3
4
1
5
(c) 5
4
3
1
(d) 3
1
2
4
G
200
GATE2004
GATE2012SameQinGATE2012(PI)
Match the following metal forming processes with their
associated stresses in the workpiece.
Metalformingprocess
lf
i
1.Coining
2.WireDrawing
3 Blanking
3.Blanking
4.DeepDrawing
D D
i
(a) 1S, 2P, 3Q, 4R
(c) 1P, 2Q, 3S, 4R
Typeofstress
f
P.Tensile
Q.Shear
R Tensileand
R.Tensileand
compressive
S C
S.Compressive
i
(b) 1S, 2P, 3R, 4Q
(d) 1P, 2R, 3Q, 4S
514
515
S 1999
999
IAS
S 1997
99
IAS
(
) with List II ((Production of p
Match List I (Process)
parts))
and select the correct answer using the codes given
below the lists:
ListI
ListII
A. Rolling
1.
Discrete parts
B. Forging
2.
Rod and Wire
C. Extrusion 3.
Wide variety of shapes with thin
walls
ll
D. Drawing
4.
Flat plates and sheets
5.
Solid
l d and
d hollow
h ll parts
Codes:A
B
C
D
A
B
C
D
( ) 2
(a)
5
3
4
( ) 1
(b)
2
5
4
(c) 4
1
3
2
(d) 4
1
5
2517
Match List
II
ListII (metal forming process) with List
ListII
(Associated feature) and select the correct answer
using the codes given below the Lists:
Listl
List II
A Blanking
A.
Bl ki
1.
Sh
Shear
angle
l
B. Flow forming
2.
Coiled stock
C. Roll forming
3.
Mandrel
D. Embossing
4.
Closed matching dies
Codes:A B
C
D
A
B
C
D
( ) 1
(a)
3
4
2
(b) 3
1
4
2
(c) 1
3
2
4
(d) 3
1
2
4518
WorkbookCh18:SheetMetalForming
Q. No
Option
Q. No
IES 2010
IES2010
g statements:
Consider the following
The material properties which principally
determine how well a metal may be drawn are
1. Ratio of yield stress to ultimate stress.
2.Rate of increase of yield stress relative to
progressive
p
g
amounts of cold work.
3. Rate of work hardening.
Whi h off the
Which
th above
b
statements
t t
t is/are
i /
correct?
t?
(a) 1 and 2 only
(b) 2 and 3 only
(c) 1 only
(d) 1, 2 and 3
519
gy
PowderMetallurgy
Option
1
2
C
B
10
11
C
C
12
13
14
15
16
8
9
A
A
17
PowderMetallurgy
gy
pressed
d
i t
into
d i d
desired
shape
h
((compacted),
p
) and then heated ((sintered)) in a
properties.
520
Rev.1
522
ManufacturingofPowder
g
S 2003
IAS
Atomizationusingagasstream
S 2007
200
IAS
Molten metal is
forced through a
small orifice and
is disintegrated by
a
jet
of
compressed air,
inert g
gas or water
jet,. It is used for
low melting point
materials, brass,
bronze, Zn, Tn,
Al Pb etc.
Al,
etc
523
) Mechanical disintegration
g
Assertion ((A):
of a
molten metal stream into fine particles by means of
a jet of compressed air is known as atomization.
Reason (R): In atomization process inertgas or
water cannot be used as a substitute for compressed
air.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
524
525
Manufacturing of Powder
ManufacturingofPowder
S 1999
999
IES
Assertion (A): In atomization process of manufacture of
metal powder, the molten metal is forced through a
small orifice and broken up
p by
y a stream of compressed
p
air.
Reason ((R):
) The metallic p
powder obtained by
y
atomization process is quite resistant to oxidation.
((a)) Both A and R are individuallyy true and R is the correct
explanation of A
((b)) Both A and R are individuallyy true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
526
Reduction
( )
GATE2011(PI)
exposed
d to
t below
b l
melting
lti
point
i t gases results
lt in
i a
product of cake of sponge
p
p g metal.
y The irregular spongelike particles are soft, readily
Which of
((green)
green ) strength
Cobalt.
(d) Pulverization
527
528
OnlyforIES
Manufacturing of Powder
ManufacturingofPowder
Manufacturing of Powder
ManufacturingofPowder
Comminution
Grinding
IES 2013 C
ti
l
IES2013Conventional
Explain the terms comminution and reduction used in
powder metallurgy.
metallurgy
[
[2marks]
]
529
Rev.1
531
ManufacturingofPowder
g
IES 2012
IES
Electrolytic Deposition
M
f t i
fP d
ManufacturingofPowder
In electrolysis
(a) For making copper powder, copper plate is made
cathode in electrolyte tank
(b) For making aluminum powder, aluminum plate is
made
d anode
d
(c) High amperage produces powdery deposit of cathode
metal on anode
((d)) Atomization p
process is more suitable for low melting
g
point metals
y Used
copper, silver
U d for
f iron,
i
il
y Process is similar to electroplating.
y For making copper powder, copper plates are placed as
533
G
20 ( )
GATE2014(PI)
IES 2010
IES2010
S 2000
IAS
535
534
536
537
ConventionalQuestions
Characteristics of metal powder:
y Fineness: refers to particle size of powder, can be
determined either by pouring the powder through a sieve or
by microscopic testing. A standard sieves with mesh size
varies between (100) and (325) are used to determine
particle size and particle size distribution of powder in a
certain range.
range
y Particle size distribution: refers to amount of each particle
size
i in
i the
th powder
d andd have
h
a greatt effect
ff t in
i determining
d t
i i
flowability, apparent density and final porosity of product.
For-2015 (IES, GATE & PSUs)
538
539
Rev.1
540
Bl di
Blending
S 1999
999
IES
g or mixing
g operations
p
y Blending
can be done either dryy or wet.
produce
the
reverse
effect
of
lubricants.
IES 2013 C
ti
l
IES2013Conventional
542
Compacting
Compacting
543
[
[2marks]
k ]
y 40 to
t 1650
6 MPa
MP pressure (Depends
(D
d on materials,
t i l
product complexity)
p
p
y)
y Still very porous, ~70% density
y May be done cold or warm (higher density)
544
Sintering
545
S 2002
IES
( )
GATE2010(PI)
y Controlledatmosphere:nooxygen
y Heatto0.75
Heatto0 75*Tmelt
Tmelt
y Particlesbindtogether,diffusion,recrystalization
andgraingrowthtakesplace.
y Partshrinksinsize
546
y Densityincreases,upto95%
(d) Reduces
R d
porosity
i and
d increases
i
bi l
brittleness
y Strengthincreases,Brittlenessreduces,Porosity
decreases Toughnessincreases
decreases.Toughnessincreases.
For-2015 (IES, GATE & PSUs)
547
548
Rev.1
549
C ld I t ti Pressing(CIP)
P
i (CIP)
ColdIsostatic
IES 2007Conventional
y The
Th powder
d is
i contained
t i d in
i a flexible
fl ibl mould
ld made
d off
ColdIsostatic Pressing
[
[2Marks]
]
d
directions)
)
y No lubricant is needed
y High
g aand
du
uniform
o de
density
s ty ca
can be ac
achieved
e ed
550
551
552
S 1997
99
IAS
) C
Assertion ((A):
Close dimensional tolerances are
NOT possible with isostatic pressing of metal
powder in powder metallurgy technique.
Reason (R): In the process of isostatic pressing, the
pressure is equal in all directions which permits
uniform density of the metal powder.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
temperature)
p
y Compaction
and
sintering
are
completed
simultaneously.
y Used
U d in
i the
th production
d ti off billets
bill t off superalloys,
ll
hi h
high
speed
p
steels, titanium, ceramics, etc, where the integrity
g y
of the materials is a prime consideration
553
554
555
ForIESOnly
Spray Deposition
SprayDeposition
IES 2011Conventional
g
y Fine metal p
powders are blended with an organic
binder such
generation process.
y Spray deposition is a shape
shapegeneration
y Whatisisostatic pressingofmetalpowders?
y Whatareitsadvantage?
[2Marks]
y The powderpolymer
powder polymer mixture is then injected into split dies,
dies
(a) Atomiser
(b) Spray chamber with inert atmosphere
(c) Mould for producing preforms.
y After
Af the
h metall is
i atomised,
i d it
i is
i deposited
d
i d into
i
a cooler
l
preformed mould.
compaction.
y Good
G d dimensional
di
i
l accuracy.
ForIESOnly
557
y High
g p
production rate.
y Good mechanical properties.
Rev.1
558
ForIESOnly
ForIESOnly
Roll Compaction
RollCompaction
E l i C
ExplosiveCompaction
ti
g Energy
gy Rate Forming
g ((HERF)) or Explosive
p
g
y High
Forming
y Higher
Hi h green densities
d iti
y Higher
g e ssintered
te ed st
strength
e gt
elevated temperature.
559
560
561
ForIESOnly
ISRO 2013
ISRO2013
LiquidPhaseSintering
y During sintering a liquid phase,
phase from the lower MP
Following
powder
F ll i is
i a process used
d to
t form
f
d metal
t l to
t
shape
p
(a) Sintering
(b) Explosive Compacting
(c) Isostatic Molding
(d) All of these
562
P d ti
f
t
Productionofmagnets
Ad t
Advantages
y Goodtolerancesandsurfacefinish
y AlNiFeisusedforpermanentmagnets
y Highlycomplexshapesmadequickly
y Sinteringisdoneinawirecoiltoalignthemagnetic
Si t i i d
i i ilt li th
ti
y Canproduceporouspartsandhardtomanufacture
C d
t dh dt
f t
polesofthematerial
y H2 isusedtorapidlycoolthepart(tomaintainmagnetic
alignment)
y Totalshrinkageisapproximately37%(foraccurateparts
anextrasinteringstepmaybeaddedbeforemagnetic
g p
y
g
alignment)
y Thesinteringtemperatureis600
Thesinteringtemperatureis600CinH
CinH2
materials(e.g.cementedoxides)
y Poresinthemetalcanbefilledwithother
materials/metals
y Surfacescanhavehighwearresistance
y Porositycanbecontrolled
y Lowwaste
y Automationiseasy
A t
ti i
565
563
50:50Fe Alalloysisusedformagneticparts
y 50:50FeAlalloysisusedformagneticparts
F t
f PM
d t
FeaturesofPMproducts
564
Ad t
Advantages
Contd.
y Physicalpropertiescanbecontrolled
y Variationfromparttopartislow
p
p
y Hardtomachinemetalscanbeusedeasily
y Nomoltenmetals
y Noneedformany/anyfinishingoperations
y Permitshighvolumeproductionofcomplexshapes
y Allowsnontraditionalalloycombinations
y
566
y Goodcontroloffinaldensity
Rev.1
567
Di d t
Disadvantages
S 2007
200
IES
( )
GATE 2009(PI)
Which of the following process is used to
manufacture products with controlled porosity?
(a) Casting
( ) welding
(b)
y Metalpowdersdeterioratequicklywhenstored
improperly
y Fixedandsetupcostsarehigh
y Partsizeislimitedbythepress,andcompressionofthe
powderused.
d d
y Sharpcornersandvaryingthicknesscanbehardto
produce
y Nonmoldablefeaturesareimpossibletoproduce.
p
p
(c) formation
(d) Powder metallurgy
568
IES 2012
IES
569
S 2006
IES
S 2004
200
IES
571
Applications
IES 2010
IES2010
Consider the following parts:
1. Grinding wheel
2. Brake lining
3 Self
3.
Selflubricating
lubricating bearings
Which of these parts are made by powder
metallurgy
ll
technique?
h i
?
((a)) 1,, 2 and 3
((b)) 2 onlyy
(c) 2 and 3 only
(d) 1 and 2 only
574
572
570
573
S 1998
998
IAS
575
Throwaway tungsten
manufactured by
(a) Forging
(c) Powder metallurgy
carbide
(b)
(d)
tip
tools
are
Brazing
Extrusion
Rev.1
576
S 2009
IES
Which
Whi h off the
th following
f ll i cutting
tti tool
t l bits
bit are made
d by
b
powder metallurgy
p
gy p
process?
(a) Carbon steel tool bits
(b)
(d)
S 2003
IAS
( )
GATE 2011(PI)
577
S 1997
99
IES
578
579
P
Si t i
Pre
Sintering
S 2001
200
IES
Carbide
tipped cutting tools are manufactured by
Carbidetipped
powder metal technology process and have a
composition of
(a) ZirconiumTungsten (35% 65%)
(b) Tungsten
T
t carbideCobalt
bid C b lt (90%
( % 10%)
%)
(c) Aluminium oxide Silica (70% 30%)
(d) NickelChromium Tungsten (30% 15% 55%)
580
S 2003
IAS
In parts produced by powder metallurgy process,
presintering is done to
(a) Increase the toughness of the component
(b) Increase the density of the component
(c) Facilitate bonding of nonmetallic particles
((d)) Facilitate machining
g of the p
part
y If a partt made
it will
d by
b PM needs
d some machining,
hi i
ill be
b
581
582
R
i
Repressing
I filt ti
Infiltration
y Repressing
is
the
R
i
i performed
f
d to
t increase
i
th density
d it and
d
y Component
meltingtemperature
C
t is
i dipped
di
d into
i t a low
l
lti t
t
alloyy liquid
q
improve
p
the mechanical p
properties.
p
y Further improvement is achieved by resintering.
583
584
I
ti
Impregnation
Oil i
dP
B
B i
OilimpregnatedPorousBronzeBearings
GATE2011
The
h operation in which
h h oill is permeated
d into the
h
as
(a) mixing
(b) sintering
(c) impregnation
(d) Infiltration
586
S 1996
996
IAS
587
589
S 2007
200
IAS
592
590
S 2004
200
IAS
IES 2014
IES
S 1998
998
IES
588
591
S 2001
200
IES
Match
List
(Components)
with
List
II
ListII
ListII
(Manufacturing Processes) and select the correct
answer using the codes given below the lists:
List I
List II
A Car
A.
C body
b d (metal)
( t l) 1.
M hi i
Machining
B. Clutch lining
2.
Casting
C. Gears
3.
Sheet metal pressing
D. Engine block
4.
Powder metallurgy
Codes:A B
C
D
A
B
C
D
( ) 3
(a)
4
2
1
(b) 4
3
1
2
(c) 4
3
2
1
(d) 3 Rev.1
4
1
2594
ConventionalQuestions
Matchthefollowing
Group 1
P Mulling
P.Mulling
Q.Impregnation
R.Flashtrimming
l h
S.Curing
g
Group2
1 Powdermetallurgy
1.Powdermetallurgy
2.Injection moulding
3.ProcessingofFRPcomposites
f
4.Sandcasting
g
( )
(a)P
4,Q
4,
Q 3,
3,R 2,S
,
1
(c)P 2,Q 1,R 4,S 3
ConventionalQuestions
y Explain
are blended.
E l i why
h metal
t l powders
d
bl d d Describe
D
ib
what happens
pp
during
g sintering.
g [[IES2010,, 2 Marks]]
( )
(b)P
2,Q
, Q 4,
4,R 3,
3,S 1
(d)P 4,Q 1,R 2,S 3
595
596
598
599
597
WorkbookCh12:PowderMetallurgy
gy
Q. No
1
Option
D
Q. No
5
Option
C
2
3
B
C
6
7
B
D
Rev.1
Introduction
y Cementedcarbides,
CuttingToolMaterials
BySKMondal
y Castcarbides,
Castcarbides
y Coatedcarbides,
y Coatedhighspeedsteels,
dh h
d
l
y Ceramics,
y Cermets,
y Whiskerreinforcedceramics,
Whiskerreinforcedceramics
y Sialons,
y Sinteredpolycrystallinecubicboronnitride(CBN),
d l
ll
b b
d (
)
y Sinteredpolycrystallinediamond,andsinglecrystal
naturaldiamond.
2
Contd
Carbon Steels
CarbonSteels
y Limited tool life. Therefore, not suited to mass
production.
production
y Can be formed into complex shapes for small production
runs
y Low cost
y Suited
S i d to hand
h d tools,
l and
d wood
d working
ki
y Carbon content about 0.9 to 1.35% with a hardness
FIGURE:Improvementsincuttingtoolmaterialshavereduced
machiningtime.
ABOUT 62
6 C Rockwell
R k ll
y Maximum cutting speeds about 8 m/min. dry and used
upto 250oC
y The hot hardness value is low. This is the major factor in
tooll life.
lif
4
S 1997
99
IAS
Highspeedsteel
Fig.Productivityraisedbycuttingtoolmaterials
y These
steels
metals
Th
t l are used
d for
f cutting
tti
t l att a much
h
Rev.1
9
Contd
IES 2013
IES2013
y WithtimetheeffectivenessandefficiencyofHSS
10
1841Highspeedsteel
chromium and 1 per cent vanadium.
y It is considered to be one of the best of all purpose tool
steels.
y It is widely used for drills, lathe, planer and shaper
g cutters, reamers, broaches, threading
g
tools, milling
dies, punches, etc.
Thebladeofapowersawismadeof
Th bl d f
i d f
(a) Boronsteel
(b) Highspeedsteel
(c) Stainlesssteel
(d) Malleablecastiron
16
12
IES2007
Thecorrectsequenceofelementsof1841HSS
Th
t
f l
t f 8
HSS
toolis
( ) W,Cr,V
(a)
(b) Mo,Cr,V
(c) Cr,Ni,C
(d) Cu,Zn,Sn
Cu Zn Sn
13
IES1993
Whichofthefollowingprocessescanbeusedfor
productionthin,hard,heatresistantcoatingatTiN,
onHSS?
1. Physicalvapour deposition.
Sinteringunderreducingatmosphere.
te g u de educ g at osp e e.
2.. S
3. Chemicalvapour depositionwithposttreatment
4. Plasmaspraying.
Selectthecorrectanswerusingthecodesgivenbelow:
Codes:
(a) 1and3
(b) 2and3
(c) 2and4
(d) 1and4
11
IES2003
y This
4 per centt
Thi steel
t l contains
t i 18
8 per centt tungsten,
t
t
IAS1997
Cuttingtoolmaterial1841HSShaswhichoneof
C tti t l t i l 8
HSSh hi h
f
thefollowingcompositions?
( ) 18%W,4%Cr,1%V
(a)
( ) 18%Cr,4%W,1%V
(b)
(c) 18%W,4%Ni,1%V
(d) 18%Cr,4%Ni,1%V
14
15
Molybdenumhighspeedsteel
Superhighspeedsteel
y This
6 per centt
Thi steel
t l contains
t i 6 per centt tungsten,
t
t
y This
called
Thi steel
t l is
i also
l
ll d cobalt
b lt high
hi h speed
d steel
t l
17
Rev.1
18
IES1995
IES2000
Thecompositionsofsomeofthealloysteelsareas
under:
1 18W4Cr1V
1.
2. 12Mo1W4Cr1V
3. 6Mo6W4Cr1V
6M 6W C V
4. 18W8Cr1V
Thecompositionsofcommonlyusedhighspeedsteels
wouldinclude
(a) 1and2
(b) 2and3
(c) 1and4
(d) 1and3
Percentageofvariousalloyingelementspresent
P
t
f i
ll i l
t
t
indifferentsteelmaterialsaregivenbelow:
1. 18%W;4%Cr;1%V;5%Co;0.7%C
2. 8%Mo;4%Cr;2%V;6%W;0.7%C
3. 27%Cr;3%Ni;5%Mo;0.25%C
4 18%Cr;8%Ni;0.15%C
4.
18%Cr;8%Ni;0 15%C
Whichoftheserelatetothatofhighspeedsteel?
( ) 1and3
(a)
d
(b) 1and2
d
(c) 2and3
(d) 2and4
19
IAS2001
Assertion(A):ThecharacteristicfeatureofHigh
speedSteelisitsredhardness.
Reason(R):ChromiumandcobaltinHighSpeed
promotemartensite formationwhenthetooliscold
worked.
(a) BothAandRareindividuallytrueandRisthecorrect
explanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
( ) AistruebutRisfalse
(c)
Ai
b Ri f l
(d) AisfalsebutRistrue
22
Castcobaltalloys/Stellite
y Cast
cobalt
are cobaltrich,
carbon
C
b l alloys
ll
b l i h chromiumtungsten
h
i
b
y
y
y
25
Contd
ThemainalloyingelementsinhighspeedSteelin
Th i ll i l
t i hi h
dSt li
orderofincreasingproportionare
( ) Vanadium,chromium,tungsten
(a)
(b) Tungsten,titanium,vanadium
g
(c) Chromium,titanium,vanadium
(d) Tungsten,chromium,titanium
Tungsten chromium titanium
20
IAS1994
Assertion(A):Forhighspeedturningofmagnesium
Assertion(A):Forhigh speedturningofmagnesium
alloys,thecoolantorcuttingfluidpreferrediswater
misciblemineralfattyoil.
Reason(R):Asarule,waterbasedoilsarerecommended
forhighspeedoperationsinwhichhightemperaturesare
generatedduetohighfrictionalheat Waterbeingagood
generatedduetohighfrictionalheat.Waterbeingagood
coolant,theheatdissipationisefficient.
((a)) BothAandRareindividuallytrueandRisthecorrect
y
explanationofA
(b) BothAandRareindividuallytruebutRisnot thecorrect
explanationofA
l
i fA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
IES1992
21
IAS 2013Main
CompareHSSandceramictoolswithregardtotheir
applicationinhighspeedmachining.
23
finished
f
h d to size by
b grinding.
d
y They are available only in simple shapes, such as single
point
i t tools
t l and
d saw blades,
bl d
b
because
off limitations
li it ti
i the
in
th
casting process and expense involved in the final shaping
(grinding). The high cost of fabrication is due primarily to
the high hardness of the material in the ascast condition.
y Materials machinable with this tool material include plain
p
carbon steels, alloy steels, nonferrous alloys, and cast iron.
y Cast cobalt alloys are currently being phased out for
cuttingtool applications because of increasing costs,
shortages of strategic raw materials (Co, W, and Cr), and
the development of other,
other superior tool materials at lower
cost.
Page 129 of 205
26
24
IES2011
Stellite is a nonferrous
non ferrous cast alloy composed of:
(a) Cobalt, chromium and tungsten
(b) Tungsten, vanadium and chromium
((c)) Molybdenum,
y
tungsten
g
and chromium
(d)Tungsten, molybdenum, chromium and vanadium
Rev.1
27
CementedCarbide
IAS 2013Main
y Carbides,
which
alloys,
are also
called,
C bid
hi h are nonferrous
f
ll
l
ll d
Whatarethedesirablepropertieswhileselectingatool
materialformetalcuttingapplications?
y
y
28
30
Contd
IES1995
Thestraightgradesofcementedcarbidecutting
toolmaterialscontain
(a) Tungstencarbideonly
(b) Tungstencarbideandtitaniumcarbide
(c) Tungstencarbideandcobalt
(d) Tungstencarbideandcobaltcarbide
T
t bid d b lt bid
31
Contd
S 1994
99
IAS
Assertion (A): Cemented carbide tool tips are
produced by powder metallurgy.
Reason (R): Carbides cannot be melted and cast.
cast
(a) Both A and R are individually true and R is the
correctt explanation
l
ti off A
(b) Both A and R are individually true but R is not the
correct explanation of A
((c)) A is true but R is false
(d) A is false but R is true
For-2015 (IES, GATE & PSUs)
bee
e oped, p
a y for
o
auto industry
dust y
been de
developed,
primarily
applications using predominantly Ni and Mo as a
binder. These are used for higherspeed (> 1000
ft/min) finish machining of steels and some malleable
cast irons.
y Cemented carbide tools are available in insert form in
many different shapes; squares, triangles, diamonds,
and
d rounds.
d
y Compressive strength is high compared to tensile
strength,
t
th therefore
th f
th bits
the
bit are often
ft brazed
b
d to
t steel
t l
shanks, or used as inserts in holders.
y These
Th
i
inserts
t may often
ft have
h
negative
ti rake
k angles.
l
34
32
Tablebelowshowsdetailgroupingofcementedcarbidetools
ThestandardsdevelopedbyISOforgroupingofcarbidetools
andtheirapplicationrangesaregiveninTablebelow.
ISO Code
Colour Code
ISO
Application
group
Application
33
35
Material
Process
P01
P10
P20
P30
P40
Turning planning
Turning,
planning, low cutting speed
speed, large chip
section
P50
Rev.1
36
K01
K10
K20
K30
K40
M10
M20
M30
M40
IES1999
Ceramics
MatchListI(ISOclassificationofcarbidetools)withList
M hLi I(ISO l ifi i f bid
l ) i hLi
II(Applications)andselectthecorrectanswerusingthe
codesgivenbelowtheLists:
g
ListI
ListII
A. P10
1.
Nonferrous,roughingcut
g g
B. P50
2.
Nonferrous,finishingcut
C. K10
3.
Ferrousmaterial,roughingcut
D. K50
4.
Ferrousmaterial,finishingcut
Code: A
B
C
D
A
B
C
D
( ) 4
(a)
3
1
2
( )
(b)
3
4
2
1
(c) 4
3
2
1
(d)
3
4
1
2
y Ceramics
C
i are essentially
i ll alumina
l i ( Al2O3 ) based
b d high
hi h
ceramic
i turning.
i
y The main problems of ceramic tools are their low
strength, poor thermal characteristics, and the
tendency to chipping.
y They are not suitable for intermittent cutting or for low
g speeds.
p
cutting
y Very high hot hardness properties
y Often used as inserts in special holders.
holders
Comparisonofimportantpropertiesofceramicandtungstencarbidetools 40
y
y
y
43
Contd
39
Contd
38
41
Contd
44
42
Contd
HighPerformanceceramics(HPC)
SiliconNitride
(i)Plain
(ii)SIALON
(iii)Whiskertoughened
Aluminatoughned by
(i)Zirconia
(ii)SiC whiskers
(iii)Metal(Sil eretc)
(iii)Metal(Silveretc)
Rev.1
45
IES 2013
IES2013
IES 2010
IES2010
Constituents of ceramics are oxides of
different materials, which are
( ) Cold
(a)
C ld mixed
i d to
t make
k ceramic
i pallets
ll t
((b)) Ground,, sintered and p
palleted to make readyy
ceramics
(c) Ground,
Ground washed with acid,
acid heated and cooled
(d) Ground, sintered, palleted and after calcining
cooled in oxygen
Sialon ceramicisusedas:
((a)Cutting
)
g tool material
(b)Creep resistant
(c)Furnacelinens
(d)Highstrength
46
IES1997
Considerthefollowingcuttingtoolmaterialsusedfor
C
id h f ll i
i
l
i l
df
metalcuttingoperationat
highspeed:
1. Tungstencarbide
2 Cementedtitaniumcarbide
2.
3. Highspeedsteel
4. Ceramic
C
i
Thecorrectsequenceinincreasingorderoftherangeof
cuttingspeedsforoptimumuseofthesematerialsis
(a) 3,1,4,2
(b) 1,3,2,4
(c) 3,1,2,4
3124
(d) 1,3,4,2
1342
For-2015 (IES, GATE & PSUs)
52
48
IES2007
Amachinistdesirestoturnaroundsteelstockof
outsidediameter100mmat1000rpm.The
materialhastensilestrengthof75kg/mm2.The
depthofcutchosenis3mmatafeedrateof0.3
mm/rev.Whichoneofthefollowingtool
h h
f h f ll
l
materialswillbesuitableformachiningthe
componentunderthespecifiedcutting
d
h
f d
conditions?
(a) Sinteredcarbides
(b) Ceramic
((c)) HSS
((d)) Diamond
49
IAS2000
MatchListIwithListIIandselectthecorrectanswer
usingthecodesgivenbelowthelists:
ListI(Cuttingtools)
(
g
)
ListII(Majorconstituent)
( j
)
A. Stellite
l.
Tungsten
B. H.S.S.
2.
Cobalt
C. Ceramic
3.
Alumina
D. DCON
4.
Columbium
5.
Ti i
Titanium
Codes:A B
C
D
A
B
C
D
(a) 5
1
3
4
(b)
2
1
4
3
(c) 2
1
3
4
(d) 2
5
3
4
47
IES1996
Assertion(A):Ceramictoolsareusedonlyforlight,
A
i (A) C
i
l
d l f li h
smoothandcontinuouscutsathighspeeds.
Reason(R):Ceramicshaveahighwearresistanceand
hightemperatureresistance.
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
((c)) AistruebutRisfalse
(d) AisfalsebutRistrue
IAS1996
Whichoneofthefollowingisnotaceramic?
(a) Alumina
(b) Porcelain
(c) Whisker
(d) Pyrosil
50
51
IAS2003
CoatedCarbideTools
Atroomtemperature,whichoneofthefollowing
isthecorrectsequenceofincreasinghardnessof
thetoolmaterials?
(a) CastalloyHSSCeramicCarbide
y
(b) HHCastalloyCeramicCarbide
(c) HSSCastalloyCarbideCeramic
(d) CastalloyHSSCarbideCeramic
y Coated
the
d tools
l are becoming
b
h norm in the
h metalworking
l
k
53
Contd
and porosity.
porosity
y Naturally, the coatings must be metallurgically bonded
to the
h substrate.
b
y Interface coatings are graded to match the properties
of the coating and the substrate.
y The coatings
g must be thick enough
g to p
prolong
g tool life
but thin enough to prevent brittleness.
y Coatings should have a low coefficient of friction so
that the chips do not adhere to the rake face.
y Multiple coatings are used,
used with each layer imparting
its own characteristic to the tool.
55
Contd
IAS1999
y The
most
successful
combinations
are
TiN/TiC/TiCN/TiN and TiN/TiC/ Al2O3 .
y Chemical vapour
p
deposition
p
((CVD)) is the technique
q
used to coat carbides.
56
Contd
TiNCoatedHighSpeedSteel
provide as dramatic improvements in cutting speeds as
do coated carbides, with increases of 10 to 20% being
typical.
y In addition to hobs, gearshaper cutters, and drills,
g coated by TiN now includes reamers, taps,
HSS tooling
chasers, spadedrill blades, broaches, bandsaw and
circular saw blades, insert tooling, form tools, end
mills, and an assortment of other milling cutters.
Cermets
y These sintered hard inserts are made by combining cer from
y
y
y
y
y
ceramics
metall (binder)
i like
lik TiC,
TiC TiN or TiCN and
d met
from
f
(bi d )
like Ni, NiCo, Fe etc.
H d more chemically
Harder,
h i ll stable
t bl and
d hence
h
more wear resistant
i t t
More brittle and less thermal shock resistant
Wt% off binder
bi d metal
t l varies
i from
f
10 to
t 20%.
%
Cutting edge sharpness is retained unlike in coated carbide
inserts
Can machine steels at higher cutting velocity than that used for
tungsten carbide,
carbide even coated carbides in case of light cuts.
cuts
Modern cermets with rounded cutting edges are suitable for
finishing and semi
semifinishing
finishing of steels at higher speeds, stainless
steels but are not suitable for jerky interrupted machining and
GATEmaterials.
& PSUs)
61
machining ofFor-2015
aluminium(IES,
and similar
59
Contd
58
Thecoatingmaterialsforcoatedcarbidetools,
includes
(a) TiC,TiN andNaCN
(b) TiC andTiN
(c) TiN andNaCN
(d) TiC andNaCN
57
IES 2010
IES2010
The cutting tool material required to
sustain high temperature is
(a) High carbon steel alloys
(b) Composite of lead and steel
(c) Cermet
(d) Alloy of steel, zinc and tungsten
62
60
IES2000
Cermetsare
(a) Metalsforhightemperatureusewithceramiclike
g
p
properties
(b) Ceramicswithmetallicstrengthandluster
(c) Coatedtoolmaterials
(d) Metalceramiccomposites
M t l
i
it
Rev.1
63
Diamonds
S 2003
IES
The correct sequence of cutting tools in the
ascending order of their wear resistance is
(a) HSSCast
HSS Cast nonferrous
non ferrous alloy (Stellite)Carbide
(Stellite) Carbide
Nitride
(b) Cast
C t nonferrous
f
alloy
ll
(St llit ) HSS C bid
(Stellite)HSSCarbide
Nitride
(c) HSSCast nonferrous alloy (Stellite)Nitride
Carbide
(d) Cast nonferrous alloy (Stellite)CarbideNitride
HSS
64
( )
GATE 2009(PI)
y low
l thermal
h
l expansion,
are desired.
d i d
y Diamondtoolsofferdramaticperformance
g tools,, milling
g cutters,, reamers,, g
g wheels,, honing
g
boring
grinding
tools, lapping powder and for grinding wheel dressing.
y Due to their brittle nature, the diamond tools have poor
resistance to shock and so, should be loaded lightly.
y Polycrystalline diamond (PCD) tools consist of a thin layer (0.5
to 1.5 mm) of'fine grain size diamond particles sintered
together and metallurgically bonded to a cemented carbide
substrate.
substrate
y The main advantages of sintered polycrystalline tools over
natural single
singlecrystal
crystal tools are better quality,
quality greater toughness,
toughness
and improved wear resistance, resulting from the random
orientation of the diamond g
grains and the lack of large
g cleavage
g
planes.
improvementsovercarbides.Toollifeisoftengreatly
improvementsovercarbides Toollifeisoftengreatly
improved,asiscontroloverpartsize,finish,and
surfaceintegrity.
surfaceintegrity
y Positiveraketoolingisrecommendedforthevast
majorityofdiamondtoolingapplications.
majorityofdiamondtoolingapplications
y IfBUEisaproblem,increasingcuttingspeedandthe
useofmorepositiverakeanglesmayeliminateit.
f
ii k
l
li i
i
y Oxidationofdiamondstartsatabout450oCand
thereafteritcanevencrack.Forthisreasonthe
diamondtooliskeptfloodedbythecoolantduring
cutting,andlightfeedsareused.
67
Contd
70
Assertion(A):Nonferrousmaterialsarebest
A
i (A) N
f
i l b
machinedwithdiamondtools.
Reason(R):Diamondtoolsaresuitableforhighspeed
machining.
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
((c)) AistruebutRisfalse
(d) AisfalsebutRistrue
68
S 1999
999
IES
Assertion(A):Diamondtoolscanbeusedathigh
A
i (A) Di
d
l
b
d hi h
speeds.
Reason(R):Diamondtoolshaveverylowcoefficient
offriction.
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
((c)) AistruebutRisfalse
(d) AisfalsebutRistrue
IES1995
IES2001
Considerthefollowingstatements:
Forprecisionmachiningofnonferrousalloys,diamond
ispreferredbecauseithas
1. Lowcoefficientofthermalexpansion
2. Highwearresistance
33. Highcompressionstrength
g
p
g
4. Lowfracturetoughness
Whichofthesestatementsarecorrect?
(a) 1and2
(b) 1and4
(c) 2and3
(d) 3and4
Page 134 of 205
71
69
IES1992
Whichofthefollowinggiventhecorrectorderof
increasinghothardnessofcuttingtoolmaterial?
(a) Diamond,Carbide,HSS
(b) Carbide,Diamond,HSS
(c) HSS,carbide,Diamond
(d) HSS,Diamond,Carbide
HSS Di
d C bid
Rev.1
72
S 1999
999
IAS
Assertion(A):Duringcutting,thediamondtoolis
keptfloodedwithcoolant.
Reason(R):Theoxidationofdiamondstartsat
about4500C
( ) BothAandRareindividuallytrueandRisthe
(a)
B thA dR i di id ll t dRi th
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
Cubicboronnitride/Borazon
y Next to diamond, cubic boron nitride is the hardest
steels,hardchillcastiron,andnickel andcobalt
basedsuperalloys.
y CBNcanbeusedefficientlyandeconomicallyto
y
y
machinethesedifficulttomachinematerialsathigher
g
speeds(fivefold)andwithahigherremovalrate
(fivefold)thancementedcarbide,andwithsuperior
accuracy,finish,andsurfaceintegrity.
IES2002
Considerthefollowingtoolmaterials:
1. Carbide
2.
Cermet
3. Ceramic
4.
Borazon.
Correctsequenceofthesetoolmaterialsinincreasing
orderoftheirabilitytoretaintheirhothardnessis
( ) 1,2,3,4
(a)
(b) 1,2,4,3
(c) 2,1,3,4
(d) 2,1,4,3
Whichoneofthefollowingisthehardestcutting
toolmaterialnextonlytodiamond?
(a) Cementedcarbides
(b) Ceramics
(c) Silicon
(d) Cubicboronnitride
C bi b
it id
77
IES1994
Cubicboronnitride
(a) Hasaveryhighhardnesswhichiscomparableto
y g
p
thatofdiamond.
(b) Hasahardnesswhichisslightlymorethanthatof
HSS
(c) Isusedformakingcylinderblocksofaircraft
engines
(d) Isusedformakingopticalglasses.
I df ki ti l l
79
75
Contd
IES1994
76
IES1996
74
Contd
73
y CBNislessreactivewithsuchmaterialsashardened
IAS1998
Cubicboronnitrideisused
(a) Asliningmaterialininductionfurnace
g
(b) Formakingopticalqualityglass.
(c) Forheattreatment
(d) Fornoneoftheabove.
78
Whichofthefollowingtoolmaterialshavecobalt
asaconstituentelement?
1. Cementedcarbide
2.
CBN
3. Stellite
4.
UCON
Selectthecorrectanswerusingthecodesgivenbelow:
C d
Codes:
(a) 1and2
(b) 1and3
(c) 1and4
(d) 2and3
80
Rev.1
81
Coronite
y Coronite is made basically by combining HSS for strength and
toughness
and
and
h
d tungsten carbides
bid for
f heat
h
d wear resistance.
i
y Microfine TiCN particles are uniformly dispersed into the matrix.
y Unlikeasolidcarbide,thecoronite
lk
ld
bd h
b d
basedtoolismadeofthree
l
d f h
layers;
y thecentralHSSorspringsteelcore
th t lHSS i t l
y alayerofcoronite ofthicknessaround15%ofthetool
diameter
y athin(2to5m)PVDcoatingofTiCN
y The coronite tools made by
b hot extrusion
e trusion followed
follo ed by
b PVD
PVD
coating of TiN or TiCN outperformed HSS tools in respect of
cutting forces,
forces tool life and surface finish.
IES1993
83
84
Considerthefollowingtoolmaterials:
1. HSS
2.
Cementedcarbide
3. Ceramics
4.
Diamond
Thecorrectsequenceofthesematerialsindecreasing
orderoftheircuttingspeedis
( ) 4,3,1,2
(a)
(b) 4,3,2,1
(c) 3,4,2,1
(d) 3,4,1,2
MatchListIwithListIIandselectthecorrectanswer
M t hLi t I ithLi t II d l tth
t
usingthecodesgivenbelowtheLists:
ListI
ListII
(Materials)
(Applications)
A. Tungstencarbide
1.
Abrasivewheels
B
B.
Sili
Siliconnitride
i id
2.
H i l
Heatingelements
C. Aluminium oxide
3.
Pipesforconveying
liquidmetals
q
D. Siliconcarbide
4.
Drawingdies
Code: A
B
C
D
A
B
C
D
(a) 3
4
1
2
(b) 4
3
2
1
(c) 3
4
2
1
(d) 4
3
1
2
Match.ListI(Cuttingtoolmaterials)withListII
M t h Li tI(C tti t l t i l ) ithLi tII
(Manufacturingmethods)andselectthecorrectanswer
usingthecodesgivenbelowtheLists:
ListI
ListII
A. HSS
1.
Casting
B
B.
Stellite
2
2.
Forging
C. Cementedcarbide
3.
Rolling
D. UCO
UCON
4.
4
Extrusion
5.
Powdermetallurgy
Codes:A
B
C
D
A
B
C
D
(a) 3
1
5
2
(b) 2
5
4
3
(c) 3
5
4
2
(d) 2
1
5
3
85
86
87
IES1999
Attritionwear
IES1996
y The
bonding
the
Th strong
t
b di between
b t
th chip
hi and
d tool
t l material
t i l att
Thelimittothemaximumhardnessofawork
Th li itt th
i
h d
f
k
materialwhichcanbemachinedwithHSStools
evenatlowspeedsissetbywhichoneofthe
tl
d i tb hi h
fth
followingtoolfailuremechanisms?
( ) Attrition
(a)
(b) Abrasion
(c) Diffusion
(d) Plasticdeformationundercompression.
Plasticdeformationundercompression
y
y
Whichoneofthefollowingisnotasynthetic
abrasivematerial?
(a) SiliconCarbide
(b) Aluminium Oxide
(c) TitaniumNitride
(d) CubicBoronNitride
82
IES2000
IES2003
MatchListIwithListITandselectthecorrectanswerusingthe
M t hLi tI ithLi tIT d l tth
t
i th
codesgivenbelowthelists:
List I(CuttingtoolMaterial) List II(Major
characteristicconstituent)
h
t i ti
tit
t)
A. Highspeedsteel
1.
Carbon
B. Stellite
2.
Molybdenum
y
C. Diamond
3.
Nitride
D. Coatedcarbidetool
4.
Columbium
5
5.
Cobalt
Codes: A
B
C
D
A
B
C
D
(a) 2
1
3
5
(b)
2
5
1
3
(c) 5
2
4
3
(d)
5
4
2
3
IAS2001
IES2005
Considerthefollowingstatements:Anincreasein
thecobaltcontentinthestraightcarbidegrades
ofcarbidetools
1. Increasesthehardness.
2 Decreasesthehardness.
2.
Decreasesthehardness
3. Increasesthetransverserupturestrength
4. Lowersthetransverserupturestrength.
L
h
h
Whichofthestatementsgivenabovearecorrect?
(a) 1and3
(b) 2and4
(d) 2and3
(c) 1and4
89
Rev.1
90
Page No.2
Slide No.3
Ans. (a)
IES-2013
Page No.2
SlideNo.4
Ans.(c)
Speed V
IES-2001
DN
1000
Page No.2
degree.
m / min
30 1000
Slide No.5
1000
IES-1995
Page No.2
Slide No.6
Ans. (a) It is true form-cutting procedure, no rake should be
ground on the tool, and the top of the tool must be horizontal and be set exactly in line with the axis of
rotation of the work; otherwise, the resulting thread profile will not be correct. An obvious disadvantage
of this method is that the absence of side and back rake results in poor cutting (except on cast iron or
brass). The surface finish on steel usually will be poor.
GATE-1995;2008
Page No.2
Slide No.7
Ans. (a) Increasing rake angle reduces the cutting force
on the tool and thus power consumption is reduced.
IES-1993
Page No.2
Slide No.8
Ans. (d) Negative rake angle increases the cutting force i.e.
Cutting force
feeddepth of cut
IES-2005
Page No.2
Slide No.9
Ans.(b)Carbide tips are generally given negative rake angle it is
very hard and very brittle material. Negative rake is used as carbides are brittle not due to hardness.
Hardness and brittleness is different property.
IES-2002
Page No. 3
Slide No.10
Page No.3
Slide No.14
Ans. (d)
IES-2014
Page No.3
Slide No.15
Ans. (c)
Page No.3
Slide No.17
Page No.4
Slide No.19
Ans. (b)
Page 137 of 205
Rev.1
GATE(PI)-1990
Page No.4
Slide No.20 Ans. (c)
No of chattering per cycle 360/30 = 12
No of cycle per second = 500 /60
Therefore chattering frequency is 12 x 500/60 = 100 Hz
IAS-1996
Page No.4
Slide No.21
Ans. (a)
IAS-1995
Page No.4
Slide No.22
IES-2010
Page No.4
Slide No.23
Ans. (c)
Fy Ft cos Ft sin CS
(radial
force)
Fx Ft sin Ft cos CS (axial force)and SCEA has no influence on cutting force i.e. tangential force. But
this question is not for Orthogonal Cutting it should be turning.
IES-1995 Page No.4
Slide No.24
Ans. (c)
Slide No.25
Slide No.27
Ans. (b)
Page No.5
Slide No.29
IES-1994
Page No.5
Slide No.30
Ans. (b)
IES-2009
Page No.5
Slide No.31
Ans. (b)
Slide No.32
Slide No.33
Ans. (b)
Slide No.34
angle = 90 -
CS . When, principal cutting edge angle =90;then S . Dont confuse with side cutting
edge angle. Side cutting edge angle is not principal cutting edge angle.
GATE-2010 (PI) Page No.5
Slide No.35
GATE-2001Page No.6
Slide No.37
Ans.(c)
tan 1
r cos
0.4cos10
tan 1
22.944
1 r sin
1 0.4sin10
GATE-2011Page No. 6
tan 1
IES-1994 Page No.6
Slide No.38
Ans. (b) r
t 0.81
0.45
tc 1.8
r cos
0.45cos12o
tan 1
25.90o
1 r sin
1 0.45sin12o
Slide No.39
Ans. (b)
Rev.1
Slide No.40
t
f sin
0.2 sin 90o
(for turning) =
0.4
tc
tc
0.5
r cos
r cos 0
tan 1
tan 1 r tan 1 0.4
1 r sin
1 r sin 0
21.80o
tan 1
Slide No.41
Ans.(d)
r = 0.3, 10
tan 1
r cos
0.3cos10
tan 1
17.31o
1 r sin
1 0.3sin10
Slide No.42
GATE-1990(PI)Page No.6
Slide No.43
Ans. (a)
cot tan 12
d
cos ec 2 sec2 12 0 gives 51o
d
GATE-2012 Page No. 6
Slide No.44
Ans. (c)
r 0.4; 10
r cos
0.4 cos10
tan 1
22.94
1 r sin
1 0.4sin10
from the velocity triangle;
tan 1
VS
V
sin 90 sin 90
VS
2.5
VS 2.526 m / s
1.0104 105 / s
tS 25 106 m
Slide No.45
Ans. (b) actually 2,3 and 4 are correct.But best choice is (b)
Slide No.46
Slide No.47
Ans. (c)
Slide No.48
Ans. (a)
VC
V
sin sin 90
VC
35 sin 45
28.577m / min
sin 90 15 45
Slide No.49
Ans. (b)
Page 139 of 205
Rev.1
t
2.4
tC
3.2 mm
tC
0.75
VC
sin
r 0.75
V sin(90 )
VC 0.75 60 45 m / min
Slide No.50Ans. (c)f = f sin = 0.2 sin 90 = 0.2 mm ; tc= 0.32 mm; cutting
ratio = chip thickness ratio = t / tc = 0.2/0.32 = 0.625 But examiner has given reciprocal value = 1.6
IES-2001 Page No.7
Slide No.51 Ans. (a) Most of the students get confused in this question.
Velocity of chip sliding along the shear plane is shear velocity (Vs) and velocity of chip along rake
face is chip velocity (Vc ).
IES-2003 Page No.7
Slide No.52
Ans. (d)
VC
t 0.5
r
V
tc 0.6
2 0.5
1.66 m / s
0.6
Slide No.53
Ans. (a)
Slide No.54
Ans. (a)
Slide No.55
Ans. (d)
IAS-1998Page No.8
Slide No.56
Ans. (b)
DN
1000 60
m/ s
100 480
1000 60
m / s 2.51m / s
Slide No.58
Ans.(c)
t
r cos
0.5cos15
0.5; tan 1
tan 1
29.02
tc
1 r sin
1 0.5sin15
Nearest option is c
V 20 m / min;
Slide No.59
Ans. (b)
VC
r 0.5 orVC 10 m / min
V
Slide No.61
Ans. (b)
IAS-1997Page No.8
Slide No.62
Ans. (a)
Rev.1
Slide No.68Ans.
y 285 N / mm 2 , 0.65
r cos
0.35 cos10
0.3669
1 r sin 1 0.35sin10
tan 1 0.3669 20.152
tan
bt
3 mm 0.51 mm
285 N / mm 2
1265.7 N
sin
sin 20.152
tan , tan 1 tan 1 0.65 33.023
FS y
FS
1735.6 N
cos
r cos
r cos 0
r 0.5.......( = 0)
1 r sin 1 r sin 0
or tan 1 r tan 1 0.5 26.565
tan
tan 1; 45
From merchant circle:
F R sin or R 402.5 N
sin 45
569.22 N
In FS and FC triangle:
Rev.1
Slide No.70
Ans.
VS
V
sin 90 sin 90
V
2
S
sin 90 26.565 sin 90
VS 2.2361 m
s
Heat generation at the primary shear zone
will be because of shear velocity and shear force
Heat =FS VS 180.0 N 2.2361 m / s 402.5W
GATE-2013 linked queS-1 Page No.9
Slide No.71
Ans. (a)
From Merchant Circle if cutting force ( FC ) is perpendicular to the friction force ( F ) then the rake
angle will be zero
Page No.9
Slide No.72
Ans. (b)
=45 +
Page No.10
Page No.10
45
20 25.5
42.25
2
2
GATE-1997
Page No.10
Using Merchant Analysis:
= 45 +
2
10
20 45
2
2
ESE-2005(conventional)
60
Page No.10
Slide No.76
Ans.
Rev.1
= 45 +
26.565
36.717
2
bt
2 mm 0.2 mm
FS y
400 N / mm 2
267.61 N
sin
sin 36.717
From merchant circle:
or 45 5
Fs R cos -
or 267.61 N R cos(36.717 26.565 10 )
or R 447.6 N
and Fc R cos -
FC 447.6 cos(26.565 10 ) 429.02 N
Ft 447.6sin(26.565 10 ) 127.61N
GATE-2008 (PI) Linked S-1 Page No.10
45
2 2
10 34.99
45
32.5
2
2
GATE-2008 (PI) Linked S-2 Page No.10
b 3.6 mm
IES-2014
Ans. (b)
Rev.1
N Fc cos Ft sin
0;
. so F=F 500 N
t
N Fc 1000 N
F
500
1
N 1000 2
GATE-2007 (PI) Linked S-1 Page No.11
FC 1200 N ; Ft 500 N ; 0
N 1200
500
tan 1
22.6
1200
GATE-2007 (PI) Linked S-2 Page No.11
Orthogonal machining, t = depth of cut = 0.8 mm,
t c =1.5 mm, V =1m/s
tan
t 0.8 Vc Vc
tc 1.5 V
1
Vc 0.53 m / s
GATE-2011 (PI) linked S-1
Page No.11
Slide No.86 Ans. (b)
t 0.25 mm; tc 0.75 mm; 0; b 2.5 mm; N 950 N ; Ft 475 N
t 0.25
0.33333
tc 0.75
r cos
r cos 0
r 0.33333
1 r sin 1 r sin 0
18.435
tan
Rev.1
0.62
N 457.67
To calculate shear strength;
r=
t 0.1 mm
0.5
tc 0.2 mm
r cos
0.5cos10
tan 1
28.334
1 r sin
1 0.5sin10
Using relation;
tan 1
sin
bt
5 0.1
Fs y
345.18 y
sin
sin 28.334
y 327.65 N / mm 2
Slide No.89
Ans. (b)
t 0.5
0.7142
tc 0.7
r cos
0.7142 cos15
tan 1
40.24
1 r sin
1 0.7142sin15
F Fc sin Ft cos 1200sin15 200 cos15 503.77 N
tan 1
0.455 0.46
N 1107.3
Alternatively
45
2 2
15
45
40.24 24.5
2
tan tan 24.5 0.456 0.46
GATE-2006 common data Q-2
Page No.11
Slide No.90
Ans.(a)
Rev.1
or
Vc
0.5
20 m / min 0.7
F VC
119.95
100%
100% 29.988% 30%
Fc V
400
GATE-2006 common data Q-3
Page No.12
Slide No.91
Ans. (d)
IES-2001
Page No.12
Slide No.93
Ans. (a)
Slide No.94
Slide No.95
Slide No.96
Ans. (c)
Ans. (a)
Ans. 0.08 to 0.12
90 CS 90 60 30
t 0.2sin 30 0.1 mm
Rev.1
828.22 N
sin sin 75
(i) Using the force relations
Ft
4.1411 mm,
sin sin 75
t 0.3091 mm
Now , r
0.38638
tc
0.8 mm
r cos
r cos 0
tan 1
tan 1 r tan 1 0.38638 21.13
1 r sin
1 r sin 0
Fs Fc cos Ft sin 1200 cos 21.13 828.22sin 21.13 820.76 N
tan 1
bt
sin
F
820.76
or y s
230.93 N / mm 2
bt
4.1411 0.3091
sin
sin 21.13
DN 0.160 400
(iii ) V
3.351 m / s
60
60
Power consumption(P)=Fc V 1200 3.351W 4.021kW
Fs y
GATE-1995(conventional)
Given : =10
750
Page No.12
Slide No.98
Ans.
t f sin 0.15455mm
r
t
0.32197
tc
r cos
0.33586
1 r sin
f = 0.16 mm/rev or =18.5650
t c 0.48mm
tan =
Fc 500N
Fx
200
207N
sin sin75
F = Fc sin Ft cos 500sin10 207 cos10 290.68N
Ft
0.63667
N 456.56
tan 1 32.484 o
IAS-2003(main exam)
Page No.12
Slide No.99
Ans.
Rev.1
Given :
b 7; CS 30; 90 30 60
t 2mm; b 2.5mm; Fc 1177 N ; Ft 560 N
Using relations:
tan tan s sin tan b cos
or tan tan s sin 60 tan 7 cos 60...........(i)
tan b tan cos sin tan i
or tan 7 tan cos 60 sin 60 tan 0
or 13.79
From (i ) s 12
Using force relations
F = FC sin Ft cos
1177 sin13.79 560 cos13.79 824.44 N
N FC cos Ft sin
1177 cos13.79 560sin13.79 1009.6 N
F 824.44
0.816
N 1009.6
tan 1 tan 1 0.816 39.214
= 45+
45
2 2
Using force relation:
13.79 39.214
32.288
2
2
Fs Fc cos Ft sin
1177 cos 32.288 560sin 32.288 695.87 N
Shear strength ( y )
Fs
bt
sin
695.87
74.34 N / mm 2
2 2.5
sin 32.288
GATE-2007
Page No.13
90 ; 0
t f sin f sin 90 0.24 mm
tc 0.48 mm
r
Slide No.100
Ans. (b)
t 0.24 mm
0.5
tc 0.48 mm
tan 1
GATE-2007
r cos
r cos 0
tan 1
tan 1 r tan 1 0.5 26.56
1 r sin
1 r sin 0
Page No.13
Slide No.101
Ans.(c)
Rev.1
90 ; 0 ; 25 ; Fc 1000 N
Fx
800
800 N
sin sin 90
Using relations:
We know; Ft
F 800
0.8
N 1000
GATE-2003(common data)S-1
Page No.13
f 0.25 mm / rev, d 0.4 mm, 10, 27.75
t f sin 0.25sin 90 0.25 mm
r cos
r cos10
tan
1 r sin 1 r sin10
r cos10
tan 27.75
1 r sin10
t 0.25
r 0.4888
tc
tc
Slide No.102
Ans. (a)
tc 0.51138 mm
=45+
Slide No.103
Ans. (d)
10
44.5
2
2
tan tan 44.5 0.9826
27.75 45
GATE-2008(common data)S-1
y 250MPa;V 180 m / min;
Page No.13
Slide No.104
Ans. (d)
Slide No.105
Ans. (b)
tan 1
d b sin
.........( 90); d b & t f
t f sin
bt
0.20 3
Fs y
250
321.09 N 320 N
sin
sin 27.85
GATE-2008(common data)S-2
Page No.
Rev.1
45
Fs R cos
320 R cos(28 41 7) R 681.62 N
Fc R cos 681.62 cos(41 7) 565.09 N
Ft R sin 681.62sin(41 7) 381.16 N
IES-2004
Page No.13
MRR Vfd
Slide No.106
Ans.(b)
GATE-2013
Page No.13
Slide No.107
Ans.(d)
DN
200 160
MRR fdV fd
mm / s 0.25mm 4 mm
mm / s 1675.5mm3 / s
60
60
GATE(PI)-1991
Page No.13
Slide No.108
Ans. (d)
GATE-2007
Page No.14
Slide No.109
Ans. (d)
The energy consumption per unit volume of material removal, commonly known as specific energy.
e
or 2.0
Fc
Power (W )
3
MRR mm / s 1000 fd
Fc
Fc 800 N
1000 0.2 2
Page No.14
Slide No.112
F
F
400
Specific pressure C C
2000 N / mm2
bt
fd 2 0.1
GATE-1992
Page No.14
Slide No.113
GATE-1993
Page No.14
Slide No.114
IES-2000
Page No.14
Slide No.115
IES-2004
Page No.14
Slide No.116
IES-2002
Page No.14
Slide No.117
chip : work piece : tool = 80 : 10 : 10
IES-1998
Page No.15
Slide No.118
IAS-2003
Page No.15
Slide No.119
IAS-2003
Page No.15
Slide No.120
IES-2011
Page No.15
Slide No.121
IES-1993
Page No.15
Slide No.122
IES- 1996
Page No.15
Slide No.123
Ans. (b)
IES- 1998
Page No.15
Slide No.124
Ans. (b)
IAS- 2001
Page No.15
Slide No.125
Ans. (c)
Ans. (b)
Ans. (b)
Ans. (b)
Ans. (a)
Ans. (b)
Ans. (d)
Ans. (a)
Ans. (b)
Ans. (c)
Ans. (c)
Ans. (b)
Ans. (b)
R
G
R
Rev.1
Slide No.126
gauges are used for tensile strain, while two others are for compressive strain, total of which adds up to four
gauges.
All the four gauges in each bridge are active gauges, and the bridge fully compensates for temperature changes.
For 3-D lathe dynamometer total 12 strain gauge is needed, 4 for main cutting force, 4 for Radial force and 4 for
feed force.
Page No.16
IES-2007
Page No.16
IES-2014
Page No.16
stress on tool material.
Slide No.132 Ans. (b) Think only the parameters which can produce cyclic
IES-1994
Page No.16 Slide No.135 Ans.(c) Flank wear directly affect the component dimensions.
GATE-2014 Page No.17 Slide No.137 Ans.(c)
IES-2004
Page No.17 Slide No.142 Ans.(b)
GATE-2008(PI)
Page No.17 Slide No.143 Ans.(b)
Solving using straight line equation:
y y1
y2 y1
x x1
x2 x1
1.8 0.8
2 0.8
x 10
60 10
x 51.666
IES-2002
Page No.18 Slide No.148 Ans.(c)For crater wear temperature is main culprit and tool
defuse into the chip material & tool temperature is maximum at some distance from the tool tip that so why
crater wear start at some distance from tip.
IAS-2007
Page No.18 Slide No.149 Ans.(c)
IES-2000
Page No.18 Slide No.150 Ans.(d)
IES-1995
Page No.18 Slide No.151 Ans.(a)Crater wear occurs due to temperature mainly. And high
carbon tool steel withstands least temperature 200oC.
IAS-2002
Page No.19 Slide No.154 Ans.(c)
IES-1995
Page No.19 Slide No.155 Ans.(a)
IAS-1999
Page No.19 Slide No.156 Ans.(c)Chemical reaction between abrasive and workpiece
material at elevated temperature and in the presence of grinding fluid.
IAS-2003
Page No.19 Slide No.158 Ans.(b)
IES-1996
Page No.19 Slide No.160 Ans.(b)
IES-1992
Page No.20 Slide No.165 Ans.(d)
IES-2012
Page No.20 Slide No.169 Ans.(a)
IES-2008
Page No.20 Slide No.170 Ans. (c)
In Taylors tool life equation is
n = 0.08 0.20 for H.S.S.
n = 0.20 0.60 for Carbides.
n = 0.60 0.80 for Ceramics.
IES-2006
Page No.20 Slide No.171 Ans.(b)
IES-1999
Page No.21 Slide No.172 Ans.(c)
IAS-1998
Page No.21 Slide No.173 Ans.(d)
GATE-2009(PI)
Page No.21 Slide No.174 Ans.(a)
V1T1n V2T2 n
or 100 10n 75 30n
or n 0.2616 can be solved using solve function on calculator
For-2015 (IES, GATE & PSUs)
Rev.1
ISRO-2011
Page No.21
D 50mm;
N1 284rpm; T1 10 min;V1
D 284
m / min
1000
D 232
N 2 232rpm; T2 60 min;V2
m / min
1000
Using Taylor's Tool Life Equation, VT n C
V1T1n V2T2 n
or
D 284
10n
D 232
1000
or n 0.1128
GATE-2004
1000
Page No.21
60n
1
T
or V T 2V or 8n 2 or n
3
8
n
IES-2000
Page No.21
IES-1999,ISRO-2013
V
or V1T10.25 1 T2 0.25
2
or T2 2
IAS-2002
1
0.25
T1 16T1
Page No.21
V1
Where, n 0.5;V2 2
V
or V1T10.5 1 T20.5
2
or T2 20.5 T1 4T1
%change
IAS-1995
T2 T1
4T T
100% 1 1 100% 300%
T1
T1
Page No.21
or V1 T10.25
IES-2013
or n 0.25;V2
V1
2
V1
T 0.25 or T2 16T1
2 2
Page No.22
Page No.22
Rev.1
Page No.22
V1 T1n V2 T2n
n
T1
V2
T2
V1
taking log on both side we get
or
T
V
n ln 1 ln 2
T2
V1
V
2V
ln 2 ln 1
V1 V1 0.204
or n =
T
60
ln
In 1
2
T2
Now for = T3 30min, V3 ?
Here
V1 T1n V3 T3n
n
T
V1 T1n
60
V1 x 1 30
T
T3n
30
3
V3 = dN
or V3
or N =
0.204
34.55 m/min
V3 34.55
=
=36.66 rpm
d 0.3
Page No.22
V1 T1n V2 T2n
60 81n 90 36n
n
90
81
or
1.5
60
36
In1.5
n=
n = 0.5
81
In
36
C =60 810.5 90 360.5 540 K
Page No.22
Rev.1
V1 60
30m / min;
2
2
1/n
C
T1
V1
1/n
C
T2
V2
T2 T1 V1
T1
V2
1/n
IFS-2013
1 2
1/0.5
Page No.22
1 300%
0.45
and xTB
90
=90 TA =
x
0.3
0.45
60
= 60 TB =
x
0.30
for TA >TB
1
90 0.45 60 0.30
x
x
Solve for x using calculator, x = 26.7 m/min
GATE-2013
Page No.22
Rev.1
for A
n1 0.45, K1 3000
xT
3000
=3000 Tc =
and xTH
0.6
1
1.6
200
= 200 TH =
0.6
for Tc >TH
1
Rev.1
L
min
fN
L
min
f 50
L
min
fN
L
min
f 80
Using Taylor's Tool Life Equation:VT n C V1T1n V2T2 n
L
L
or D 50 50
D 80 12.2
0.25 50
0.25 80
or n 0.2499 0.25
L
min
fN
L
min
f 60
or D 50 50
0.25
50
0.25
D 60 x
0.25
60
0.25
0.25
x
or 50 60
60
or x 28.926 29components
GATE-1999
Page No.23
tan 2 tan 1
tan 7 tan10
100%
100% 30%
tan 1
tan10
Rev.1
C 36.49
When speed, feed & depth of cut are together increased by 25%; tool life will be
Page No.24
Page No.24
Page No.25
Page No.25
IES-2009(conventional)
Slide No.203
Slide No.204
Slide No.211
Slide No.214
Ans.(a)
Ans.(a)
Ans.
Ans.(b)
Page No.26
Rev.1
To Tc t
Cm n
Ct Cm Tr Depriciation cost
Ct Rs.0.50 / min 3min Rs.5.0 Rs.6.5 / regrind
Putting in equation:
6.5 1 0.2
To 3
64 min
0.50
0.2
Using Taylor's Tool Life Equation:VoTon C
Vo 64
GATE-2014
0.2
Page No.26
6 min
n
0.2
ESE-2001(conventional)
Page No.26
Slide No.221
Page No.26
9 min
n
0.5
Using Taylor's Tool Life Equation:VoTon C , Vo 90.5 100 orVo 33.33 m / min
GATE-2005 Page No.26 Slide No.223 Ans.(a)
IAS-2007
Page No.26 Slide No.224,225
Ans.(b)
IES-2011
Page No.27 Slide No.226 Ans.(d)
IES-1999
Page No.27 Slide No.228 Ans.(c)
IES-1998
Page No.27 Slide No.229 Ans.(c)
IAS-2002
Page No.27 Slide No.230 Ans.(c)
The minimum cost criterion will give a lower cutting speed i.e. lower prodeuction rate, while the
maximum production rate criteria will result higher cutting speed i.e. higher cost per piece as it reduces
tool life.
IAS-1997
Page No.27 Slide No.231 Ans.(b) it is less than one but very close to each other so 0.1 is not
possible.
IES-2000
Page No.27 Slide No.232 Ans.(a)
IES-2004
Page No.27 Slide No.233 Ans.(a) To improve MRR = fdv i.e. productivity we can increase
velocity or feed. but increase in velocity will reduce the tool drastically so will increase cost more than
feed.
IES-2002
Page No.27 Slide No.234 Ans.(c)
Rev.1
IAS-2007
Page No.28 Slide No.235 Ans.(a)At optimum cutting speed for the minimum cost of
machining gives low production rate.
IES-2010
Page No.28 Slide No.236 Ans.(d) After some time cutting speed will be so that tool
changing time will be significant.
IES-2012
Page No.28 Slide No.240 Ans.(d)
IAS-1996
Page No.28 Slide No.241 Ans.(d)Machinability is a comparative measure not absolute.
IES-2011(conventional)
Page No.29 Slide No.245 Ans.
Effect of elements on machinability of steels:
S.NO ELEMENTS
Cause
MACHINABILITY
1.
Aluminium& silicon
Hard oxide former
Decrease
2.
Sulphur& selenium
Internal lubrication, chip Increases
breaker
3.
Lead & Tin
Internal Lubrication, chip Increases
breaker
4.
Carbon
Carbide former
Decreases
5.
Molybedenum, vanadium
Strong carbide former
Decreases
IES-1992
Page No.29 Slide No.247 Ans.(a) large grain means soft workpiece material.
IAS-2000
Page No.29 Slide No.249 Ans.(a)Built up edge protects the cutting edge of the tool from
wear, So tool life increased but it changes the geometry of the cutting.
IES-1992
Page No.30 Slide No.253 Ans.(a)
IES-2007,2009 Page No.30 Slide No.254 Ans.(a)Machinability: Machinability can be tentatively defined as
ability of being machined and more reasonably as ease of machining.
Such ease of machining or machining characters of any tool-work pair is to be judged by:
Magnitude of the cutting forces
Tool wear or tool life
Surface finish
Magnitude of cutting temperature
Chip forms
ISRO-2007
Page No.30 Slide No.255 Ans.(a)But All of the above are machinability criteria. We have to
select best option that so why chosen (a)
IES-2003
Page No.30 Slide No.256 Ans.(c)Free-machining steels are basically carbon steels that
have been modified by an alloy addition to enhance machinability. Sulfur, lead, bismuth, selenium,
tellurium, and phosphorus have all been added to enhance machinability. Sulfur (0.08 to 0.33%)
combines with manganese (0.7 to 1.6%) to form soft manganese sulfide inclusions. These act as
discontinuities in the structure which serve as sites to form broken chips. The inclusions also provide a
built-in lubricant that prevents formation of a built-up edge on the cutting tool and imparts an altered
cutting geometry.
IES-2009
Page No.30 Slide No.257 Ans.(a) Sulphur, Lead and Phosphorous are added to steel which
when added to Manganese forms Manganese sulphide etc. which has low shear strength.
IES-1998
Page No.30 Slide No.258 Ans.(c) It is CNC machine, dimensional accuracy and surface
finish is prime factor.
IES-1996
Page No.30 Slide No.259 Ans.(d) smaller shear angle means higher force.
IES-1996
Page No.30 Slide No.260 Ans.(b)
IES-1995
Page No.30 Slide No.261 Ans.(c)
IES-1992
Page No.31 Slide No.263 Ans. (b) Titanium is very reactive and the chips tend to weld to
the tool tip leading to premature tool failure due to edge chipping. Almost all tool materials tend to react
chemically with titanium.
Titaniums work-hardening characteristics are such that titanium alloys demonstrate a complete absence
of built-up edge. Because of the lack of a stationary mass of metal (BUE) ahead of the cutting tool, a
high shearing angle is formed. This causes a thin chip to contact a relatively small area on the cutting
tool face and results in high loads per unit area. These high forces, coupled with the friction developed by
the chip as it passes over the cutting area, result in a great increase in heat on a very localized portion of
the cutting tool. All this heat (which the titanium is slow to conduct away), and pressure, means that tool
life can be short, especially as titanium has a tendency to gall and weld to the tool surface.
IES-1995
Page No.31 Slide No.265 Ans. (a) Titanium high cost and need 10 times much energy than
steel to produce.Light weight, strong, corrosion resistant, properties between steel and aluminium.
IES-2002
Page No.31 Slide No.267 Ans. (b)
IAS-1996
Page No.31 Slide No.268 Ans. (d)
IES-1999
Page No.31 Slide No.269 Ans. (d)
Rev.1
we know : hc
f2
8R
Page No.31
f2
f2
f 2 4f
1 or
R1 4 R
8R 8R1
8R 8R1
GATE-2007(PI)
f2
f2
or 5 106
or f 2.68 104 m / rev 0.268mm / rev
8R
8 1.8 103
Page No.32
Using formula: h
GATE-2005
Page No.32
f
1
0.16mm
tan SCEA cot ECEA tan 30 cot10
f
tan SCEA cot ECEA
f
f
hP
and hQ
tan 30 cot 8
tan15 cot 8
tan15 cot 8
h
P
hQ tan 30 cot 8
Using formula:h
IES-1993,ISRO-2008 Page No.32 Slide No.273 Ans. (c) Surface roughness is directly dependent on
square of feed. Slow cutting results in formation of built-up edge, but after certain speed the finish
remains same.Rake angle has noticeable effect at slow speeds, but its effect is small at speeds, used for
finish machining. So f has maximum effect.
IES-2006
Page No.
Slide No.274 Ans. (a) refer previous question
GATE-2014(PI)
Page No.32 Slide No.275 Ans.
GATE-2010(PI)
Page No.32 Slide No.276 Ans. (b)
For increasing surface finish means reduce roughness we have to increase nose radius and reduce feed.
Here MRR remains same therefore feed remains same only nose radius can be changed.
IES-2001
Page No.32 Slide No.279 Ans. (c)
IES-2012
Page No.33 Slide No.280 Ans. (b)
Slide No.7
Slide No.8
Page No.35
Ans.(b)
Ans.(b)
Slide No.11 Ans.(d)
Page No.35
Slide No.12
Ans.(a)
Rev.1
max clearance = upper limit of hole - lower limit of shaft = 40.50-39.95= 0.1 mm
IES-2011
IES-2013
GATE-2005
Page No.36
Page No.36
Page No.36
Slide No.21
Slide No.22
Slide No.23
Ans.(a)
Ans.(a)
Ans.(a)
IES-2014
GATE-2011
Page No.36
Page No.36
Slide No.24
Slide No.25
Ans. (c)
Ans.(c)
Rev.1
Rev.1
D D1 D2 18 30 23.23 mm
1
Page No.41
Slide No.64
Ans.(b)
diametric steps are not given we take given dia as the basic diameter only.
i 0.45 3 D 0.001D 1.34 m 1.34 103 mm
For IT 7 16i 16 1.34 103 0.021 mm
it is a shaft base system:
Upper limit = basic size=25.00 mm
Lower limit = Upper limit tolerance = 25.00 -0.021=24.978 mm
GATE-2010(PI)
Page No.41 Slide No.65 Ans.(d)
Fundamental deviation of all the bore is zero.
For IT7, Tolerance = 16i = 0.021 mm
For IT8, Tolerance = 25i = 0.033 mm
For IT6, Tolerance = 10i = 16i 6i = 0.021 mm (0.033-0.021)x(6/9) mm =0.013 mm
Therefore Upper Limit = 25.013 mm for IT6
GATE-1996,IES-2012 Page No.41
For-2015 (IES, GATE & PSUs)
Slide No.67
Ans.(d)
Rev.1
Remember
H7 with p6, s6: Interference fit
H7 with k6, n6: Transition fit
All other fits are clearance fit.
IES-2000
Page No.41 Slide No.68
ISRO-2008
Page No.41 Slide No.71
IAS-2010(main)Page No.41 Slide No.72
GATE-2003 Page No.42 Slide No. 74
P 35+0.08mm
Ans.(b)
Ans.(a)
Ans. Refer Slide
Ans.(b)
Q 12.00+0.02mm
R 13.00.04
0.02 13.01 0.03
Now all have same bilateral tolerance, so
P QWR
Considering dimension
35 12 W 13.01
w 9.99mm
Tolerance are probabilities and not the absolute value on any part, at
least one section must be there that treated as sink, and tolerance of
sink will be cumulative sum of all tolerances.
GATE-1997
Page No.42
S P Q R T
GATE-2007(PI)
GATE-2007(PI)
Slide No. 75
Ans.(d)
Page No.42
Page No.42
Slide No.76
Slide No.77
Page No.42
Slide No.78
Ans(c)
Page No.42
Page No.43
Slide No.80
Slide No.86
Ans.(c)
Ans.(d)
Rev.1
Pitch
reading
No.of div in thimble
Page No.45
ISRO-2010
Page No.46 Slide No.115 Ans.(c)
A measuring device of a standard size that is used to calibrate other measuring instruments.
ISRO-2008
Page No.46 Slide No.116 Ans.(d)
Primary standards are used for calibration only. In workshop it has no use.
GATE-2007(PI)
Page No.47 Slide No.119 Ans.(d)
During the measurement, a comparator is able to give the deviation of the dimension from the set
dimension. Cannot measure absolute dimension but can only compare two dimensions. (Rest all the
options will give reading of the dimension measured it will not compare)
PSU
Page No.47 Slide No.121 Ans.(c)A feeler gauge is used to check theThickness of clearance
IAS-2011(main)
Page No.
Slide No.
Ans. Refer slides for theory
ISRO-2011
Page No.48 Slide No.135 Ans.(c)
A sine bar is specified by the distance between the centre of the two rollers
GATE-2012(PI)
Page No.49 Slide No.136 Ans.(a)
sin 1
90
1
o
sin 250 21.1
GATE-2011(PI)
Page No.49
Page No.50
p
2.5 60
sec
sec 1.443 mm
2
2
2
2
Slide No.145 Ans.(c)
p
2 60
Best Wire Size: d sec sec 1.1547 mm
2
2 2
2
GATE-2011(PI)
Page No.50 Slide No.146 Ans.(c)
Difference between the readings of micrometers= 16.532-15.398=1.134mm
Diameter of cylindrical standard = 30.5mm
Effective diameter= 30.5-1.134=29.366mm
IES-2012
Page No.51 Slide No.156 Ans.Refer slides for theory
For-2015 (IES, GATE & PSUs)
Rev.1
IES-1992
Page No.51 Slide No.159 Ans.(b)
IFS-2011
Page No.51 Slide No.161 Ans.Refer slides for theory
ISRO-2011
Page No.52 Slide No.167 Ans.(d)
IES-2006
Page No.52 Slide No.168 Ans.(d)
IES-2007
Page No.52 Slide No.169 Ans.(c)Lay direction: is the direction of the predominant surface
pattern produced on the workpiece by the tool marks.
IES-2008
Page No.52 Slide No.170 Ans.(b)Lay directional of predominant surface texture produced
by machining operation is called Lay.
IES-2010
Page No.52 Slide No.171 Ans.(b)
IES-2008
Page No.53 Slide No.172 Ans.(c)
ISRO-2010
Page No.53 Slide No.173 Ans.(a)
IAS-2013(main)
Page No.53 Slide No.174 Ans.Refersildes for theory
GATE-1997
Page No.54 Slide No.182 Ans.(b)
IAS-2012(main)
Page No.55 SlideNo.191 Ans.Refer sildes for theory
IES-2012(conventional)
Page No.55 SlideNo.192 Ans.Refer sildes for theory
GATE_2003
Page No.55 Slide No.195 Ans.(a)
nl
2
n 0.678 / cm
So for both fringes=2 n 1.357 2 fringes
Rev.1
10
30
18.434
tan
Also,
tan
x
10
tan18.434
x
10
x 3.334
diameter at z 0 is (20 2 x)
diameter (20 2 3.334) 13.336
GATE-2008(PI)
Page No.
C2 A
3
tan
2 5 15.54 8 28.54
6.006
12.001
GATE-2014
Page No.59
Slide No.229Ans.
H1 20.55; H 2 35.55
H=35.55+60=95.55mm
H1 20(radius) 40.55
H 40.55 95.55 40.55 55
55 30(radius) 25 CB
CB
25
tan
(30 20) 50
30
R
cos 30
50
R 43.30
D bigger radius+43.30+smaller radius
D 30 43.30 20 93.30mm
Rev.1
Rev.1
IES-2006
Page No.67 Slide No.64 Ans.(c) A continuous form of three-point bending is roll bending,
where plates, sheets, and rolled shapes can be bent to a desired curvature on forming rolls.
IES 1992, GATE-1992(PI) Page No.67 Slide No.71 Ans.(b)Since brittle materials cannot handle
plastic deformation.
IES 1993, GATE-1989(PI) Page No.67 Slide No.72 Ans.(d)
Thread rolling is used to produce threads in substantial quantities. This is a cold-forming process
operation in which the threads are formed by rolling a thread blank between hardened dies that cause
the metal to flow radially into the desired shape. Because no metal is removed in the form of chips, less
material is required, resulting in substantial savings. In addition, because of cold working, the threads
have greater strength than cut threads, and a smoother, harder, and more wear-resistant surface is
obtained.
One obvious characteristic of a rolled thread is that its major diameter always is greater than the
diameter of the blank. When an accurate class of fit is desired, the diameter of the blank is made about
0.002 inch larger than the thread-pitch diameter. If it is desired to have the body of a bolt larger than the
outside diameter of the rolled thread, the blank for the thread is made smaller than the body.
IES-2013(conventional)
Page No.68 Slide No.73 Ans. Refer slides
IAS-2007
Page No.68 Slide No.79 Ans.(d)
IAS -2003
Page No.68 Slide No.80 Ans.(b)
IAS-2000
Page No.68 Slide No.81 Ans.(b)Rolling with smaller diagram rolls requires lower force.
IES-1993
Page No.69 Slide No.85 Ans.(a)In order to get uniform thickness of the plate by rolling
process, one provides camber on the rolls to take care of unavoidable tool bending. Cylindrical rollers
would result in production of plate with convex surface. Because of the limitations in the equipment and
workability of the metal, rolling is accomplished progressively in many steps. Plate, sheet and strip are
rolled between rolls having a smooth, cylindrical, slightly cambered (convex) or concave working surface.
IAS-2004
Page No.69 Slide No.87 Ans.(c) Rolling means hot rolling where no lubricant is used.
GATE -2009(PI)
Page No.69 Slide No.89 Ans.(d) Due to directional granule deformation.
GATE -2007 Page No.70 Slide No.94 Ans.(d)
Slide No.95
Ans.(c)
180
GATE -1998 Page No.70 Slide No.96 Ans.(d) For strip rolling sheet rolling width remains same.
Initial thickness (h1) = 4.5 mm.
As width constant therefore 20% reduction in area means 20% reduction in thickness also.
Final thickness (h2 = 0.8 x 4.5 = 3.6 mm
h D 1 cos or 4.5 3.6 450 1 cos or 3.62 0.063radian
GATE -2004 Page No.70 Slide No.98 Ans.(b)
Roll strip contact length, L = R
Page No.71
GATE -2014
Page No.71
2R
2R
IES-1999
Page No.71 Slide No.103 Ans.(b) Actually metal will get hardened in every pass due to
strain hardening. Therefore in actual practice the reduction in second pass is less than in the first pass.
GATE-2006 Page No.71 Slide No.105 Ans.(c) h max ho h f ,min 2 R 0.12 150 mm 1.5 mm
Page No.71
Rev.1
h max 2 R 0.1
300 mm 3 mm
Page No.71
20
7
3
0.3something
R
150
10 3.something
In IESobjective exam calculators are not allowed, we have to use above apporx.calculation
h 2 R or
GATE-2014(PI)
GATE-1990(PI)
IES-2014
GATE-2008(PI)
Page No.72
Page No.72
Page No.72
Page No.72
Slide No.109
Slide No.111
Slide No.112
Slide No.113
The velocity at neutral point is equal to the velocity of roller, as there is no slip occur
V=
DN
60
0.300m 100rpm
60
IES-2002
Page No.72
Selected Questions Page No.72
GATE-2014
Page No.72
1.57 m / s
The inlet and outlet volume rates of material flow must be the same, that is,
h o bo vo h f b f v f
2
h ; b 1.02bo ; v o 10m / min
3 o f
2
h o bo 10 h o 1.02bo v f v f 14.706 m / min
3
hf
GATE-1992(PI)
Page No.73
Elongation factor = E =
En
Ao
1.22...........( given)
A1
Ao
750 750
or 1.22n
or 11.04 close to (c)
An
250 250
GATE-2008
Page No.73 Slide No.122 Ans.(a)
h 20mm 18mm 2mm 0.002m
R 250mm 0.250m
Pr ojected Length (L p ) Rh 0.250 0.002 0.02236m
Arm length (a) Rh 0.5 0.250 0.002 0.01118m
Rev.1
IFS-2010
IAS-1998
Page No.75
Page No.75
Rev.1
Parts can be upset forged both hot and cold on special high-speed machines where the workpiece
is rapidly moved from station to station.
Upset forging generally employs split dies that contain multiple positions or cavities.
Drop Forging
The drop forging die consists of two halves. The lower half of the die is fixed to the anvil of the
machine, while the upper half is fixed to the ram. The heated stock is kept in the lower die while
the ram delivers four to five blows on the metal, in quick succession so that the metal spreads
and completely fills the die cavity. When the two die halves close, the complete cavity is formed.
Drop forging is used to produce small components.
Press Forging
Metal is squeezed gradually by a hydraulic or mechanical press and component is produced in a
single closing of die, hence the dimensional accuracy is much better than drop forging.
Similar to drop forging, press forging is also done in closed impression dies with the exception
that the force is a continuous squeezing type applied by the hydraulic presses.
Most commonly used for the forging of bolt heads of hexagonal shape is close die press forging.
IES-2008
Page No.81 Slide No. 197 Ans.(None) Correct sequence is 2 1 3 - 4
IAS-1998
Page No.82 Slide No. 202 Ans.(b)
IES-2011
Page No.82 Slide No. 203 Ans.(c) Bonding between the inclusions and the parent material is
through physical bonding no chemical bonding possible.
GATE-2008(PI)
Page No.82 Slide No. 204 Ans.(c)
IES-2007
Page No.82 Slide No.205 Ans.
The mating surfaces of the two halves of the die define a parting line around the edges of the forging as
they come together.It can be located such that the line will surround the largest projected area of the
piece. The angle of the surface at the parting line from the primary parting plane should not exceed 75o,
in general, much shallower angles are preferred.Select the parting line so that no undercut are in either
die impression at the time of ejection of workpiece.
IES-2013
Page No.82 Slide No. 207 Ans.(b)
GATE-2010(PI)
Page No.83 Slide No. 209 Ans.(c)Low thermal conductivity because low heat loss
from workpiece.
IES-2013
Page No.83 Slide No. 212 Ans.(b)
GATE-2014 Page No.83 Slide No. 214 Ans.(c)
elongation
original length
elongation
instantaneous length
If suppose x is the length; dx is the elongation which is infinitely small
True Strain( T )
Lo
as
dx
L
ln
x
Lo
L Lo L
L
1
1 E
Lo
Lo
Lo
T ln 1 E
Lo
A / 4 d 2
ln
A
d
L
ln o 2 ln o
Lo
A
d
Page No.83
L
2 L0
ln
ln 2 0.693
Lo
Lo
T ln
GATE-2007
Page No.83
L
True strain T
Lo
Rev.1
Page No.84
d12
4
h1
d 2 d1
d 22
4
h2
h1
50
100
141.42 mm
h2
25
d 2 d1
100% 41.42%
d1
IES-2012
Page No.84 Slide No.224 Ans.(c)Forging force attains maximum value at the end of the
operation.
IES 2005 Conventional
Page No.85 Slide No.226 Ans.
Solution: h = 6 mm, 2L = 96 mm, 0.25
xs L
h
6
1
1
ln 48
ln
39.68 mm
2
2 0.25 2 0.25
2
xS
2
(L x )
2K
( x s x ) B. dx 2 2K e h
B . dx
h
xS
Ftotal = 2 Ps
0
or
4.04 N / mm2
3
K
Ps
16.16 N / mm2
39.68
or
48
2 0.25
0
39.68
510 kN 29.10 kN 539kN(Von Mises)
F 2
150 . dx
o
K
3.5
3.5 N / mm2 ; Ps
14 N / mm2
2
0.25
39.68
48
2 3.5
0
39.68
442 kN 25 kN 467kN (Tresca ' s)
IES 2007 Conventional
Page No.85 Slide No. 227 Ans.
Solution: Given, h1 = 60 mm, d1 = 100 mm, h = 30 mm
0 120 N/ mm2 and 0.05
F 2
20.25
(48 x )
6
or
d12
h1 R2 h
4
or
or
1002
60 R2 30
4
R = 70.7 mm
20.25
(48 x )
6
150 dx
2
.R
R
1
eh
2.04 MN
F 2 0
2
2
2
2
2
h
h h
IES 2006 Conventional
Page No.85 Slide No. 228 Ans.
Rev.1
R12h1 R2 h
R = 212.1 mm
y 4 N/ mm2 (Shear yield stress) = K
By Tresca Theory;
Rs 212.1
25
1
ln
= 177.4 mm
2 0.25
2 0.25
0 mm to 177.4 mm sticking
177.4 mm to 212.1mm sliding
Ps
K
4
16 N / mm2
0.25
0 2K 2 4 8 N / mm2
20.25
(212.1 r )
25
177.4
212.1
24
16
(177.4
r
)
.
2
r
dr
(8) e
0 25
177.4
(Trescas Theory)
3.93 MN
Ftotal
. 2 r dr
25
1
ln
= 170.25 mm
2 0.25 3 0.25
0 mm to 170.25mm sticking
170.25mm to 212.1mm sliding
Ps
K
4
16 N / mm2
0.25
0 K 3 4 3 N / mm2
Ftotal
RS
2
(R r )
2K
(Rs r ) 2 r dr 0 e h
2 r dr
h
RS
170.25
212.1
24
0 16 25 (170.25 r) 2 r dr 170.25
4 3. e
= 3.6 MN (Von Misces)
GATE-1987 Page No.85 Slide No. 229 Ans. Center
GATE-2014(PI) Page No.85 Slide No. 230 Ans. (a)
Practice Problem -1
Page No.85 Slide No. 231 Ans.
Ftotal
20.25
(212.1 r )
25
2 r dr
Since
K = 4.04 N/mm2
xs came negative so there will be no sticking only sliding will take place.
L
F 4 KB e h
(L x )
dx
48
4 4.04 150
20.05
(48 x )
6
dx 177.98 kN
Practice Problem -2
Page No.85
Rev.1
ln
141.21
ln
297.1 mm
2 3
2 0.1 3 0.1
According to Tresca
Rs R
h 1
50
1
ln
141.21
ln
261.1 mm
2 2
2 0.1 3 0.1
Rs came out to be negative so only sliding friction takes place.
Rs R
The formula for pressure we get after the slab method of analysis of forging;
2
P oe h
R r
at r 0; P Pmax
Pmax 230 e
20.1
(141.21)
50
Practice Problem -3
404.94 MPa
Page No.85
d12 h1 R 2 h or
By Tresca Theory;
Rs 106.66
50
1
ln
=-7.87mm
2 0.2
2 0.2
Page No.85
2002 70 R 2 40 R 132.28 mm
4
h
40
True strain ln ln
0.5596
h1
70
4
d12 h1 R 2 h or
f 200(0.01 )0.41
f 200(0.01 0.5596)0.41 158.78 o
Rev.1
Von-Mses Theory
Practice Problem -5 {GATE-2010 (PI)}
Page No.86
Ans.
R H IN R H FN
2
IN
or
2
FN
2
2002 50 RFN
30 RFN 258.2 mm
200
Now at Rss
or K = 3Ke
2
RFN Rss
H FN
1 2
or ln
RFN Rss
3 H FN
or
H FN 1
ln
RFN Rss
2 3
or Rss RFN
IFS-2012
H FN 1
30
1
ln
ln
254.55 mm
258.2
2 3
2 0.51 3 0.51
Page No.86
Rev.1
IES-2003
Page No.89 Slide No. 269 Ans. (d)
IES-2014
Page No.89 Slide No.270 Ans. (c)
IAS-2010(main)
Page No. 90 Slide No. 271 Ans. Refer slides
IAS-2000
Page No.90 Slide No. 278 Ans. (d)Hydrostatic extrusion suppresses crack formation by
pressure induced ductility. Relative brittle materials can be plastically deformed without fracture. And materials
with limited ductility become highly plastic.
IES-2006
Page No.90 Slide No.279 Ans. (a) It is pressure induced ductility.
GATE-1990(PI)
Page No.91 Slide No. 280 Ans.(c)
IES-2001
Page No.91 Slide No.281 Ans. (d)
IES-2009(conventional)
Page No. 91 Slide No. 283 Ans.
For sketches refer slides.
(i)Direct Extrusion-curtain rods
(ii) Indirect Extrusion(iii) Hydrostatic Extrusion-Cladding of metals, Extrusion of nuclear fuel reactor fuel rod
(iv) Impact Extrusion-Collapsible tubes for toothpastes, creams etc.
IES-2014
Page No.91 Slide No.285 Ans. (d) For high extrusion pressure, the initial temperature of
billet should be low.
JWM-2010
Page No.91 Slide No. 287 Ans. (a)
IAS-2012(main)
Page No.91 Slide No.288 Ans. Refer slide
GATE-2014 Page No.92
Slide No. 289 Ans. (b)
IES-2007
Page No.92 Slide No. 293 Ans.(c)
IES-2009
Page No.92 Slide No. 294 Ans. (b)The wire is subjected to tension only. But when it is in
contact with dies then a combination of tensile, compressive and shear stresses will be there in that portion only.
IES-2005
Page No.92 Slide No. 295 Ans. (a)
GATE-1987
Page No.92 Slide No. 296 Ans. (a)
IES-2010
Page No.93 Slide No. 298 Ans.(c)
Cleaning is done to remove scale and rust by acid pickling.
Lubrication boxes precede the individual dies to help reduce friction drag and prevent wear of the dies.
It is done by sulling, phosphating, electroplating.
IES-2000
Page No.93 Slide No.299 Ans.(c)
IAS-1995
Page No.93 Slide No. 300 Ans. (d)The correct sequence for preparing a billet for extrusion
process is pickling, alkaline cleaning, phosphate coating, and lubricating with reactive soap.
IES-1996
Page No.93 Slide No. 301 Ans. (d)
IES-2014
Page No. 93 Slide No.303 Ans. (b)
IES-1993; GATE-1994(PI)
Page No. 94 Slide No. 308 Ans. (b)
IES-1993
Page No.94 Slide No. 311 Ans. (a)Tandem drawing of wires and tubes is necessary because
it is not possible to reduce at one stage.
IES-2000
Page No.94 Slide No. 312 Ans. (d)
IES-1999
Page No.94 Slide No. 313 Ans. (d)
IES-1996
Page No.94 Slide No. 314 Ans.(c)
IES-1994
Page No.94 Slide No. 315 Ans. (d)
IES-1993, ISRO-2010
Page No. 95 Slide No. 316 Ans. (b)since malleability is related to cold
rolling, hardness to indentation, resilience to impact loads, and isotropy to direction.
IES-2002
Page No.95 Slide No. 317 Ans. (a)
IAS-2001
Page No.95 Slide No. 318 Ans. (a)
IAS-2002
Page No.95 Slide No. 319 Ans. (b)
IES-2011
Page No.95 Slide No. 320 Ans. (b)
GATE-1991(PI)
Page No.95 Slide No. 322 Ans. Extrusion
IAS-1994
Page No.95 Slide No.323 Ans. (b) Extrusion and skew rolling produce seamless metallic
tubes.
IES-2012(conventional)
Page No. 95 Slide No. 324 Ans. Refer slide
GATE-2003
Page No.96 Slide No. 328 Ans. (b)
do 2
df 2
4
/ 4 0.12
2
2.72219MN
250 0.1 ln
2
4
/
4
0.05
Page No.96
Rev.1
A
Pressure ( ) o ln o
A
f
GATE-2006
Page No.96 Slide No. 330 Ans. (b)
Given : Do 10mm;Df 8mm; 0 400 MPa;Ignore friction and redundant work means
r
Ideal Force 2 0 A f ln o
rf
GATE -2008 (PI) Linked S-1
82 5
ln 8.97 kN
2 400
4
4
d
2 o ln o
df
10
2 800 ln 357 MPa
8
Page No.96
82
4
0.5W 8.97 KW
Af
IES-2014
Page No.97 Slide No.334 Ans. (b)
GATE-1996
Page No.97 Slide No. 335 Ans. (b)
Case(a) : 3 stage reduction final dia =15 1 0.8 1 0.8 1 0.8 0.12 mm error 0.02mm
(b) 4 stage reduction final dia =15 1 0.8 1 0.8 1 0.8 1 0.2 0.096mm error 0.004mm
(c)5 stage reduction final dia
=15 1 0.8 1 0.8 1 0.4 1 0.4 1 0.2 0.1728mm error 0.0728mm
IES-2011(conventional)
o 1 B
B
2B
rf
1
ro
21.7145
400(1 1.7145) 5
d
1
338.653MPa
1.7145
6.25
100
Power P V 338.653 102
m / s 44.329 kW
4
60
Maximum possible reduction; o d
o 1 B
2B
21.7145
rf min
400(1 1.7145) rf min
1
or 400
1
or rf min 4.67 mm
o
B
1.7145
ro
ro
do d f min
ro rf min
Max possible reduction in dia =
100%
100% 25.3%
do
ro
Rev.1
o 1 B
2B
2B
rf rf
1 . b
ro ro
400(1 1.7145) 5
d
1
1.7145
6.25
6.25
For maximum possible reduction; o d
21.7145
21.7145
50 361.26 MPa
o 1 B
2B
2B
rf min rf min
1
. b
ro ro
1.7145
6.25
21.7145
Initial area A o
2
o
10
21.7145
rf min
6.25
50 rf min 4.78 mm
d o d f min
do
Ao Af min
Ao
100% 23.5%
100% 41.5%
mm 2 78.54 mm 2
4
4
After first pass area A1 1 0.35 Ao 1 0.35 78.54 mm 2 51 mm 2
After second pass area A 2 1 0.35 Ao and then ........
2
L
A
78.54
True strain ln ln o ln
3.02
3.85
A
Lo
and Ao Lo A7 L7 or 78.54 100 3.85 L7 L7 2040 mm
GATE 2011 (PI) Common Data-S-2
A
P o Af ln o
A
f
GATE-2014
A
78.54
o A1 ln o 200 51 ln
N 4.40 KN
51
A1
Page No.97
dL
dL
2tdt
ln 1 t 2
2
2
L
L0 1 t
0 1 t
as, L L0 1 t 2 , dL L0 2tdt
T
IAS-1997
IES-2012
IFS-2013
dT
2t
2 1
1.0
2
dt
1 12
1 t
Page No.97
Page No.98
Page No.98
Rev.1
GATE-2014
Punching Force(F) Lt
ii Die size
ii Die size
correct size
IES-2014
fs
3
4 20 30 mm
fc
6
Ans.(c) dt c
d2
4
or d
4t
4t
t
4
Rev.1
Fmax pt
968 0.40 5.6
or 294
s 7.36 mm
s
s
Total cutting force when both punches act at the same time and no shear is
applied to either the die or punch;
F d1t d 2t 25.4 1.5 280 12.7 1.5 280 50.271 kN
The cutting force if the punches are staggered, so that only one punch acts at a time:
Fmax d outsidet 25.4 1.5 280 33.515kN
Taking 60% penetration and shear on punch of 1 mm,
The cutting force if both punches act together;
F
d1t d 2t pt 25.4 1.5 280 12.7 1.5 280 0.6 1.5 45.225kN
S
p
0.2
t
Fmax ( pt )
S
100
F
10kN
10
F
IAS-2003
ISRO-2013
back.
GATE-2011
GATE-2009(PI)
GATE-2013(PI)
ISRO-2009
GATE-2007
Blanking Force(F) Lt dt
F1 5 dt
F1
dt
5
1
or
or F2 3
F2 1.5d 0.4t
F2 1.5 0.4
GATE-2004
GATE_2012
22.6 kN
S
2
Rev.1
Punch size without allowance = Die size 2 x radial clearance = 25 2 x 0.06 = 24.88 mm
We need another gap (die allowance ) i.e. final punch size will be = 24.88 0.05 = 24.83 mm
GATE-2008(PI)
Page No.105 Slide No. 411 Ans.(c)
C = 6% of t = 0.062.5mm = 0.15mm
Punch size = diesize - 2C = 50 - 20.15mm = 49.70 mm
Diesize = 50.00 mm
GATE-2002 Page No.105 Slide No.412 Ans.(c)
GATE-2001 Page No.105 Slide No. 413 Ans.(b)
GATE-1996 Page No.105 Slide No. 414 Ans.(d) Clearance only on punch for Blanking operation. Due to
insufficient data we cant calculate.
IES-1994
Page No.106 Slide No. 415 Ans.(a)
IES-2002
Page No.106 Slide No.416 Ans.(b)
IAS-1995
Page No.106 Slide No. 417 Ans.(c)
IES-2006
Page No.106 Slide No. 418 Ans.(c)
IES-2004
Page No.106 Slide No. 419 Ans.(a)
IES-1997
Page No.106 Slide No. 420 Ans.(a)
IAS-2000
Page No.106 Slide No. 421 Ans.(d)
It is blanking operation so clearance must be provided on punch.
Therefore, Die size = blank size = 30 mm
Punch size = blank size 2C = 30 -2 x 0.06 x t = 30 2 x 0.06 x 10 = 28.8 mm
GATE-2007(PI)
Page No.106 Slide No. 422 Ans.(c)
Ans.(c)
d 2 4dh 1002 4 100 100 224mm
Ans.(a)
Slide No. 441 Ans.
d
d
; 1st Reduction; 0.4 1
d 90 mm
D
150
So, it can't be draw in a single draw.
Reduction 1
IFS-2013
d 40 mm; h 60 mm; r 2 mm
Rev.1
IES-1997
D = d 4dh = 15 cm
First draw 50% reduction, d1 = 7.5 cm
Second draw 30% reduction, d2 = 5.25 cm
Third draw 25% reduction, d3 = 3.94 cm possible
IES-1998
Page No.109 Slide No. 449 Ans.(d)
2
d
d
0.5;
Reduction 1 100% 50%
D
D
Thumb rule:
First draw:Reduction 50 %
Second draw:Reduction 30 %
Third draw:Reduction 25%
Fourth draw:Reduction 16 %
Fifth draw:Reduction 13%
IFS-2009
Page No.109 Slide No. 450 Ans.. Refer slides for theory
IFS-2013
Page No.110 Slide No. 455 Ans..Refer slides for theory
IAS-2007
Page No.110 Slide No. 457 Ans.(d) In drawing operation, proper lubrication is essential for
1. To improve die life.
2. To reduce drawing forces.
3. To reduce temperature.
4. To improve surface finish.
GATE-2008 Page No.111 Slide No. 465 Ans.(a)An insufficient blank holder pressure causes wrinkles to
develop on the flange, which may also extend to the wall of the cup.
IAS-1997
Page No.111 Slide No. 466 Ans.(c)
GATE-1999 Page No.111 Slide No. 467 Ans.(b)It is without a blank holder, so no stress.
GATE-2006 Page No.111 Slide No. 468 Ans.(d)
IES-1999
Page No.112 Slide No. 469 Ans.(b)
IAS-1994
Page No.112 Slide No. 470 Ans.(d)
GATE-1992 Page No.112 Slide No. 476 Ans.(a)
tc 1.5mm; 30
now tc tb sin ;
or 1.5 tb sin 30 tb 3 mm
IES-1994
Page No.112 Slide No. 477 Ans.(d)Mode of deformation of metal during spinning is bending
and stretching.
IFS-2011
Page No.113 Slide No. 478 Ans. Refer slides
IES-2011
Page No.114 Slide No. 489 Ans.(b)
Option (b) Magnetic pulse forming and (d) Eletro-hydraulic formingboth are High Energy Rate Forming (HERF).
But Question is "usedfor forming components form thin metal sheets or deform thin tubes"it is done by Magnetic
pulse forming only.
JWM-2010
Page No.114 Slide No. 490 Ans.(c)
IES-2010
Page No.114 Slide No. 491 Ans.(c)
IES-2007
Page No.114 Slide No. 492 Ans.(b)
High-Energy-Rate-Forming is metal forming through the application of large amount of energy in a very sort
time interval.
High energy-release rate can be obtained by five distinct methods:
(i) Underwater explosions.
(ii) Underwater spark discharge (electro-hydraulic).
(iii)Pneumatic-mechanical means.
(iv)Internal combustion of gaseous mixtures.
(v) Electro-magnetic (the use of rapidly formed magnetic fields)
IES-2009
Page No.114 Slide No. 493 Ans.(b)
IES-2005
Page No.114 Slide No. 494 Ans.(c)
IES-2013(conventional)
Page No.114 Slide No. 495 Ans. Refer slides for theory
GATE-2000 Page No.115 Slide No. 500 Ans.(b)
Rev.1
li1
l
and 2 ln i 2
lo1
lo 2
initial thickness(t )
e1 e 2
1.5
1.304 mm
e e0.09
0.05
Ans.(d)
Page No.117 Slide No.515 Ans.(a)
Ans.(b)
Ans.(d)
Ans.(c)
Ans.(d)
Rev.1
GATE-2008(PI)
Page No.126 Slide No.595 Ans. (d)
Conventional Question,IES-2010 Page No.126 Slide No.596 Ans. Refer slide
Conventional Question,IES-2005 Page No.126 Slide No.597 Ans. Refer slide
IES-2007
Ans.(a)
IES-1993
IES-1995
Ans.(d)
18-4-1 High speed steel- contains 18 per cent tungsten, 4 per cent chromium and 1 per cent vanadium
Molybdenum high speed steel contains 6 per cent tungsten, 6 per cent molybdenum, 4 per cent
chromium and 2 per cent vanadium.
IES-2000
Ans.(b)
IES-1992
Ans.(a)
IAS-2001
Ans.(a)
IAS-1994
Ans.(b)
IES-2011
Ans.(a)
IES-1995
Ans.(c)
IES-1994
Ans.(a)
IES-1999
Ans.(c)
IES-2013
Ans.(a)
IES-2010
Page No.131 Slide No.47 Ans.(b)Constituents of ceramics are oxides of different materials,
which areGround, sintered and palleted to make ready ceramics
IES-1996
Ans.(c)
IAS-1997
Page No.132 Slide No.49 Ans.(b)Ceramic tools are used only for light, smooth and
continuous cuts at high speeds.This is because of low strength of ceramics
IES-1996
D(mm) N
1000
m / min
100 1000
1000
Ans.(b)
314.15m / min
Rev.1
IES-2007
Ans.(d)
IAS-2000
Ans.(c)
H.S.S < Cast alloy < Carbide < Cemented carbide < Cermets < ceramics
IAS-2003
Ans.(c)
IAS-1999
Ans.(b)
IES-2010
Ans.(c)
IES-2000
IES-2003
Ans.(a)
GATE-2009(PI)
Page No.134 Slide No.66 Ans.(d)On ferrous materials, diamonds are not suitable
because of the diffusion of carbon atoms from diamond to the work-piece material.
IES-1995
Page No.134 Slide No.69 Ans.(b)Nonferrous materials are best to work with diamond
because ferrous materials have affinity towards diamond and diffusion of carbon atoms takes place.
IES-2001
Ans.(b)
IES-1999
Ans.(a)
IES-1992
Ans.(d)
IAS-1999
Page No.134 Slide No.73 Ans.(a)Oxidation of diamond starts at about 450oC and
thereafter it can even crack. For this reason the diamond tool is kept flooded by the coolant during cutting, and
light feeds are used. - Book B L Juneja and Nitin seth page 88
IES-1994
Ans.(a)
IES-2002
Ans.(d)
IES-1996
IES-1994
IAS-1998
Ans.(b)
IES-1993
Ans.(b)
High speed steel, in addition to W, Cr & V, has Mo as the most influencing constituent. Thus A matches with 2.
Non ferrous alloys (stellites) are high in cobalt. Thus B matches with 5.
The major constituent of diamond is carbon. Thus C matches with 1.
Coated carbide tools are treated by nitriding. Thus D matches with 3
IES-2003
Page No.136 Slide No.84 Ans.(b)This is one of the natural abrasives found, and is also
called corundum and emery. However, the natural abrasives generally have impurities and, as a result, their
performance is inconsistent. Hence the abrasive used in grinding wheels is generally manufactured from the
aluminium ore, bauxite,
Silicon carbide (SiC) Silicon carbide is made from silica sand and coke with small amounts of common salt.
IES-2000
Page No.136 Slide No.85 Ans.(b)Cutting speed of diamond is very high but small feed rate
with low depth of cut. Degarmo and Kalpakjian both book written this.
For-2015 (IES, GATE & PSUs)
Rev.1
IES-1999
Page No.136 Slide No.86 Ans.(d)WC is used for drawing dies, silicone nitride for pipes to
carry liquid metal, Al2O3 for abrasive wheels, and silicon carbide for heating elements.
IAS-2001
Ans.(d)
IES-1996
Ans.(a)
IES-2005
Ans.(d)
Rev.1
Anal
A lysis
s off Forrgin
ng
ue stre
ess an
nd Tru
ue Strrain
Tru
The tru
ue stress is defineed as the
e ratio of the load
d to the cross
c
secttion area at any
instantt. (T ) =
Where
loa
ad
= (1 + )
Instantane
eous area
a
True sttrain
L
L
A
d
Elong
gation
dx
x
=
= ln = ln (1 + ) = ln o = 2ln o
(T ) =
A
Lo
d
Instantane
eouslenght L x
o
or engineering strain
s
( ) = e T -1
The volume
v
off the specimen is a
assumed to
t be consstant durring plastic deform
mation.
[ Ao Lo = AL ] It is valid till the neck form
mation.
Flow Strress
Whenamaterialdeformsplasticallystrainhardeningocccurs.
Forgin
ngoccursiinplasticzonei.einb
between y and ultt
y Y
YieldStresss
o For
F forgingg, we need
d flow stress and flow stress is not constant and
d dependss on stress of the
workp
piece.
ult Ultimatetensilestre
esshereneeckformationstarts.
wCurve
EquationofFlow
hardening
(a)Withstrainh
o = K(T )n
Rev.1
o = y
Wewillanalyzeonlyopen
ndieforgin
ngusingsllabmethodofanalyysisfor
(1)RectangularBarforgingg,and
(2)Axisymmetrricforging
1. Rectan
R
ngula
ar Bar Forgiing
oreforging
Befo
B
h
h1
2
2L
2L1
dx
x
(x+d
d x)
x =0
2L
L
point at which
w
the material does not move in any direcction.
x = 0 , is the p
Take an elemeent dx at a distancce of x (en
nlarged viiew):
Rev.1
( x + d x ) Bh
As mettal is mo
oving outtwards so
o friction
n force wiill act in
n oppositee directio
on, this
friction
n force iss shear fforce and
d will cau
use shearr stress on the ssurface eq
qual to
( x B dxx ) in lower and upp
per surface.
Fx = 0;
0 Gives
( x + d x ) B h x . B h 2x . B dx = 0
or
or
d x B h 2x B dx = 0
d x . h 2x dx = 0
d x 2 x
=0
h
dxx
(1)
x , x and
d x so we
v
e reduce iit into tw
wo variab
bles by ap
pplying
Here there arre three variables
condiition.
material there
t
are two the
eories of plasticitty.
For a ductile m
1. Vo
on-Mises Theory:: ( 1 2 )2 + ( 2 3 )2 + ( 3 1 )2 = 2 20
2. Trescas Th
heory: 1 3 = 0
Rev.1
( Plane strain co
ondition)
2 = 0
As
3
2
1
=0
E
E
E
2 = ( 1 + 3 )
or
2 = ( x P)
1
2
2 =
There
efore,
From
m Von-Mises theo
ory:
1
( P )
2 x
2
2
x ( x P) + ( x P) + P + ( P x ) = 20
2
( x + P)2 ( x + P)2
+
+ ( x + P)2 = 220
4
4
3
2
( x + P) = 2 20
2
4
( x + P)2 = 20
3
2
( x + P) =
0
3
x + P = 2 K
ear stresss]
.(2)) [where K = 0 = flow she
3
or
or
or
or
or
m Tresca
as theor
ry :
From
1 3 = 0
or
or
x + P = 0
x + P = 2K
K .(2)) [where K =
0
= flow shear stress]]
2
g equatio
on (2)
Differrentiating
Rev.1
d x d P
+
=0
dx
d
dx
dx d P
=
d
dx
dx
or
....(3)
Condition-1
1:
ng slidin
ng friction all over th
he surfa
ace ( x
Considerin
= P )
PB
Bdx
Bdxx
F = N
orr dF = d
dN
x B dx = . PB dx
x = P
m equation
n (1) and (3)
From
or
or
or
d x 2 x
=0
h
dx
d P 2 P
=0
dx
h
dP
2
P = h dx
2
ln P =
x +C
h
.
......(4)
ndary con
nditions, at x = L
L, x = 0 (because
(
no force is applied so noo stress on that
Boun
surface) and x + P = 2K
K gives P = 2 K
or
or
2
L+C
h
2
.L
C = ln ( 2K ) +
h
ln ( 2K ) =
ng the va
alues of C in equattion (4)
Puttin
2
2
x + ln ( 2 K ) +
.L
h
h
P 2
(L x )
ln
=
2K h
ln P =
or
or
P 2
(L x )
ln
=
2K h
Rev.1
P = 2K
2 . e
or
2
(L x )
h
2
(L)
h
At
x = 0,
Pmax
= 2K e
m
At
x = L,
Pmin
= 2K e h
m
(0)
= 2K
dF = 2 K e h
L
(L x )
Integ
grating, F = 2 (2 K . e h
. B.dx
. (L x )
F = 4 KB
B . e h
(L x )
L
L
or 2L we use
u 2
. B . dx ) givess half porttion F so fo
0
0
. dx
Condition-2
2:
Considerin
ng stick
king fric
ction all over the
t surfface ( x
= y = K
Shearr failure w
will occurr at each and every point.
From
m equation
n (1) and (3)
or
or
or
d x
2 x =0
h
dx
dP 2K
=0
dx
h
2K
d P = h dx
2K
K
P=
x +C
h
......(6)
Rev.1
Boun
ndary con
nditions, at x = L
L, x = 0 (because
(
no force is applied so noo stress on
o that
surface) and x + P = 2K
K gives P = 2 K
2K L
+C
h
2K
C = 2K +
.L
h
So,
2K =
or
ng in equ
uation (6)
Puttin
P=
2K
K
2K
. x + 2K
K+
.L
h
h
P = 2K
2 +
At
2K
(L x )
h
x = 0,
Pmax
= 2K +
m
x = L,
Pmin
= 2K
m
.....
(7) {P
Pressure distributi
d
ion equattion}
2K
.L
h
2k + 2k .L
h
2h
2kk
Elemental forcce,
dF
F = P . B . dx
or
dF
F = 2K +
x=0
x=L
2K
(L x ) B . dx
h
2K
F = 2 2 K +
(L
L x ) B . dx
d
h
Condition-3
3:
Considerin
ng stick
king and
d slidin
ng both model of fricttion
( Temperat
T
ture is same throu
ughout boody)
For Sliding
S
Reegion:
dx 2x
=0
d
dx
h
Rev.1
or
or
or
d P 2 P
=0
dx
h
dP
2
P = h dx
2
ln P =
x +C
h
......(4)
2
L+C
h
2
C = ln ( 2 K ) +
.L
h
ln ( 2 K ) =
ln P =
or
or
or
P 2
ln
(L x )
=
2K h
P = 2K . e
2
(L x )
h
d x
2 x =0
dx
h
dP 2K
=0
dx
h
2 K
d P = h dx
2K
P=
x +C
h
.... (5)
......(6)
x = x s ; P = Ps
2K
xs + C
h
2K
C = Ps +
. xs
h
Ps =
2K
2K
x + Ps +
xs
h
h
2K
P = Ps +
( xs x )
...............(8)
h
P=
Rev.1
Xs
PSticking . B . dx + 2
0
Sliding
. B dx
Xs
2
s
(L
L x)
2K
K
= 2 Ps +
( x s x ) B . dx + 2 2K e h
x
B . dx
h
0
xs
nd x s
To find Ps an
ame for bo
oth stickin
ng and slliding
At x = x s , Sheear stressses are sa
x = K
x = Ps
x = K = Ps
Ps =
At
....(9)
x = xs ;
P = Ps
2
Ps = 2K e h
( xs )
(L
2
((L x s )
K
= 2K e h
or
2
(L x s )
1
=eh
2
or
1 2
ln
n =
(L x s )
2 h
or
h
1
. ln = L x s
2
2
xs = L
h
1
ln
2
2
Using
g this equ
uation we
e can deciide the condition of friction..
mple 1: L = 50 mm
m, h = 10 mm & = 0.25
Exam
xs = L
1
10
h
1
ln
ln = 50
mm
= 36.13m
2
0.25
0.25
2
2
0 to 36.13
3
mm
m sticking and 36.1
13 mm to 50 mm slliding willl take pla
ace.
Exam
mple 2: L = 50 mm
m, h = 10 mm & = 0.08
Rev.1
xs = L
h
10
1
1
ln = 50
ln
= 64.53 mm ( absurd value )
2
2
2
0.08
2
0.08
h
10
1
1
ln = 50
ln
= 52.01 mm
2
2 0.65
2 0.65
2
h
6
1
1
ln = 48
ln
= 39.68 mm
2
2
0.25
2
0.25
xS
Ftotal = 2 Ps +
0
2
(L x )
2K
( x s x ) B. dx + 2 2 K e h
B . dx
h
xS
= 4.04 N / mm2
3
K
Ps =
= 16.16 N / mm2
or
39.68
or
48
2 0.25
0
39.68
= 510 kN + 29.10 kN = 539 kN (Von Mises)
F = 2
150 . dx
o
K
3.5
= 3.5 N / mm2 ; Ps =
=
= 14 N / mm2
2
0.25
39.68
48
2 3.5
0
39.68
442 kN + 25 kN = 467kN (Tresca ' s)
F = 2
20.25
(48 x )
6
20.25
(48 x )
6
150 dx
Practice Problem-1
A strip of metal with initial dimensions 24 mm x 24 mm x 150 mm is forged between two
flat dies to a final size of 6 mm x 96 mm x 150 mm. If the coefficient of friction is 0.05,
determine the maximum forging force. Take the average yield strength in tension is 7
N/mm2
Given: 2L = 96 mm; L = 48 mm; h = 6 mm; B = 150 mm; = 0.05
h
1
ln
2 2
x s = 90.155 mm
xs = L
K = 4.04 N/mm2
Since xs came negative so there will be no sticking only sliding will take place.
L
F = 4 KB e h
(L x )
dx
Rev.1
48
= 4 4.04 150
20.05
(48 x )
dx = 177.98 kN
h1
At the start
of forging
At end of forging
dr
+ d
r
r
Rev.1
Net resultant
r
force in radially
r
outward direction
d
i 0.
is
( r + d r ) (r + dr
d ) d . h ( r . r d . h ) 2 r . r d . dr 2 dr h . sin
d
=0
2
dr.h cos d
2
d
2
dr
dr.h
h cos d
2
drh
dr.h sin d
2
d
2
dr.h
h sin d
2
d
d
gets can
ncelled they
t
are op
pposite
cos
For Axi-Symm
A
metry fo
orging
r =
r =
i.e.
m above eq
quation,
From
( r + d r ) (r + drr ) d . h ( r . r d . h ) 2 r . r d . dr 2 r dr h .
or
d
=0
2
d d
U sin g : = r ; sin
2
2
( r + d r ) (r + drr ) . h ( r . rh) 2r . r dr r . dr . h = 0
Rev.1
or
( r . r . h + dr . rh
h + dr . drh
d + r drr . h) r . rh 2r . r dr r dr
d .h =0
or
d r . r h = 2r . r dr
or
d r 2 r
=0
h
dr
...(1)
For ductile
d
ma
aterial there are tw
wo theoriies of plassticity
1. Trescas Th
heory:
1 3 = 0
...(2)
+P=
r
0
or
2. Vo
on Miscs Theory::
(1 2 )2 + ( 2 3 )2 + ( 3 1 )2 = 2 20
or
( r r )2 + ( r + P)2 + ( P r )2 = 2 20
or
2 ( r + P)
P 2 = 2 02
...(2)
+P=
r
0
or
ating;
On diifferentia
d r d P
+
=0
dr
drr
d r
dP
=
dr
d
dr
...(3)
Con
ndition
n 1:
Con
nsidering slid
ding friiction all ove
er the ssurface
e
r = P
or
d P 2r
=0
dr
h
dP
P
2.
=0
dr
h
or
d P 2 P
=
d
dr
h
From
m (1) and ((3);
dP
2
=
. dr
P
h
2
ln
nP=
.r +C
h
or
At
or
r = R; r = 0
....(4)
(because
(
on this su
urface the
ere will b
be no force
e) and r + P = 0 ; P = 0
ln
n 0 =
2 . R
+C
h
Rev.1
C = ln 0 +
or
2r
2 R
+ ln 0 +
h
h
P 2
ln
n
=
(R
( r)
h
0
m equation
n (4)
From
ln
nP=
or
P = 0 . e h
or
At
At
Here
2 R
h
(R
R r)
.. (5
5) Pressurre distribution
.R
r = 0; Pmax = 0 e h
r = R; Pmin = 0
r=0m
means a po
oint
For finding
f
fforce
Elemental forcce (dF)
dr
dA = 2
r dr
dF
F = d F = P . 2r . drr
2
d F = 0 . e h
R
or
F = 20 r.e h
(R r )
. (R r )
. 2r . dr
dr
or
(R r )
r . e h
F = 20
1 .
2
dr
2
h 0
2
(R r )
h
or
or
2
2
(R r )
(R r )
r.eh
eh
F = 20
2
2
2
h
h 0
2
R
h
R
1
e
F = 2 0
0+
2
2
2
h h
h
Rev.1
IES2007Conventional
A cylinder of height 60 mm and diameter 100 mm is forged at room temperature between
two flat dies. Find the die load at the end of compression to a height 30 mm, using slab
method of analysis. The yield strength of the work material is given as 120 N/mm2 and the
coefficient of friction is 0.05. Assume that volume is constant after deformation. There is no
sticking. Also find mean die pressure.
[20-Marks]
Solution: Given, h1 = 60 mm, d1 = 100 mm, h = 30 mm
0 = 120 N/ mm 2 and = 0.05
d12
h1 = R 2 h
4
or
1002
60 = R 2 30
4
or
or
R = 70.7 mm
R
1
F = 2 0
0+
2
2
2
h h
= 2.04 MN
2
2
h
2
eh
.R
GATE2014(PI)
In an open die forging, a circular disc is gradually compressed between two
flat platens. The exponential decay of normal stress on the flat face of the
disc, from the center of the disc towards its periphery, indicates that
(a) there is no sticking friction anywhere on the flat face of the disc
(b) sticking friction and sliding friction co-exist on the flat face of the disc
(c) the flat face of the disc is frictionless
(d) there is only sticking friction on the flat face of the disc
Answer: (a)
Condition -2: Considering sticking friction all over the surface
r = K
or
d r 2 r
=0
dr
h
d P 2K
=0
dr
h
or
dP =
or
P=
At
r = R; r = 0
2K
. dr
h
2K
.r +C
h
...(6)
2K
.R+C
h
2K
C = 0 +
R
h
0 =
or
From (6)
P=
2K
2K
. r + 0 +
R
h
h
Rev.1
P = 0 +
or
At
r = 0; Pmax = 0 +
2K
K
. (R r )
h
2K
.R
h
r = R; Pmin = 0
f
fforce:
For finding
r
R
2rdr
d F = P . 2 r dr
or
F = P . 2 r dr
R
or
2K
F = 0 +
R r ) 2 r dr
. (R
h
Con
ndition
n 3:
Whe
en ther
re is stticking
g and slliding both fr
friction
ns occu
ur
St
ic
ki
ng
d
Sli
i ng
Ps
r = Rs
Sliiding
Stickiing
Rev.1
For sliding region pressure distribution is same as we derived in previous condition same
boundary condition same differential equation.
2
P = 0 . e h
(R r )
2K
.r +C
h
Boundary condition at r = R;
or
P = Ps
2K
. Rs + C
h
2K
C = Ps +
. Rs
h
Ps =
or
Putting in equation (6)
2K
2K
(r ) + Ps +
Rs
h
h
2K
P = Ps +
. (R s r )
h
P=
or
...(8)
Rs
sticking
Ftotal =
Rs
2 r dr +
sliding
2 r dr
Rs
2K
Ps + h (R s r ) 2 r dr +
2
0
.eh
(R r )
. 2 r dr
Rs
To find Ps and Rs
r = Ps = K
or
At
Ps =
r = Rs ;
......(9)
P = Ps
2
Ps = 0 e h
or
(R Rs )
2
(R R s )
K
= 0 e h
K
ln
0
2
(R R s )
=
h
h
K
Rs = R
ln
2
0
or
According to Trescas theory
K=
0
2
Rs = R
K 1
=
0 2
or
h
1
ln
2
2
...(10)
0
3
Rs = R
or
K
1
=
0
3
h
1
ln
2
3
...(11)
IES2006Conventional
Rev.1
R = 212.1 mm
y = 4 N/ mm2 (Shear yield stress) = K
By Tresca Theory;
R s = 212.1
25
1
ln
= 177.4 mm
2 0.25
2 0.25
0 mm to 177.4 mm sticking
177.4 mm to 212.1mm sliding
Ps =
K
4
=
= 16 N / mm2
0.25
0 = 2 K = 2 4 = 8 N / mm2
20.25
(212.1 r )
25
177.4
212.1
24
Ftotal = 16 +
(177.4 r ) . 2 r dr + (8) e
25
0
177.4
= 3.93 MN
(Trescas Theory)
. 2 r dr
25
1
ln
= 170.25 mm
2 0.25
3 0.25
0 mm to 170.25 mm sticking
170.25 mm to 212.1mm sliding
Ps =
K
4
=
= 16 N / mm2
0.25
0 = K 3 = 4 3 N / mm2
Ftotal =
RS
2K
(R s r ) 2 r dr +
Ps +
h
0 e h
(R r )
2 r dr
RS
170.25
212.1
20.25
(212.1 r )
24
25
16
+
(170.25
+
4
3.
2 r dr
r
r
dr
e
25
170.25
= 3.6 MN (Von Misces)
Ftotal =
Rev.1