Documentos de Académico
Documentos de Profesional
Documentos de Cultura
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Content
Welding
Casting
Metrology
Unconventional
Other Machine tools
Jig Fixtures
NC CNC Robotics
Material Science
Metal Cutting, Metal forming, metrology
All PPTs
respective
temperature
ranges
and
Metal
MS
High carbon steel
Grey cast iron
Alloy steel
Aluminium
Brass
Copper, Bronze
Nickel alloys
Lead
Flame
N
R
N, slightly oxidizing
N
Slightly carburizing
Slightly oxidizing
N, slightly oxidizing
Slightly carburizing
N
4/1/2015
5.
LPG
CH
2 2 O2 2CO H2
+ Heat
This reaction occurs near the tip of the torch.
In the second stage combustion of the CO and H2 and
occurs just beyond the first combustion zone.
2CO + O2 2CO2 + Heat
1
H2 + 2O2 H2O + Heat
Oxygen for secondary reactions is obtained from the
atmosphere.
IAS-2011 Main
Draw a self explanatory sketch of oxy-acetylene gas
cutting torch. Briefly explain how cutting is
effected.
[20-Marks]
4/1/2015
Fig- differences in torch tips for gas welding and gas cutting
Contd
Contd
Contd
4/1/2015
IFS-2011
IFS-2011
What is the maximum output current that can be
drawn at 100% duty cycle from a welding power source
rated at 600A at 60% duty cycle.
[3-Marks]
Duty Cycle
The percentage of time in a 5 min period that a
welding machine can be used at its rated output
without overloading.
Time is spent in setting up, metal chipping, cleaning
and inspection.
For manual welding a 60% duty cycle is suggested and
for automatic welding 100% duty cycle.
Contd
4/1/2015
IAS-2013
I
Ia
Fig.
Typical
pressure cycle
welding. The
forging and
operations.
current
and
for resistance
cycle includes
post heating
Projection welding
Limitations of spot welding.
1. Electrode
Contd
4/1/2015
Fig. Principle of
projection welding,
(a) prior to application of
current and pressure
(b) and after formation of
welds
Contd
IES 2007
What is the principle of resistance welding?
Indicate where the resistance is maximum in spot
welding operation.
[ 2 marks]
Flash Welding
It is similar to upset welding except the arc rather than
resistance heating.
One pieces is clamped with cam controlled movable
Contd
4/1/2015
Advantages
1. Butt welding is possible
2. Impurities and contaminants are squeezed out during this
operations so good quality welding
Applications
Friction Welding
IFS-2011
Discuss with figure the various steps required for
friction welding, mentioning at least two methods
of control.
[5-marks]
Contd
4/1/2015
Very efficient.
Wide variety of metals or combinations of metals can
be joined such as aluminium to steel.
Grain size is refined
Strength is same as base metal.
Only round bars or tubes of the same size, or
connecting bars or tubes to flat surfaces can join.
One of the components must be ductile.
Friction welding is a solid state welding.
A low contact pressure may be applied initially to
permit cleaning of the surfaces by a burnishing action.
Contd
IAS-2014
oxy-fuel cutting,
High velocity electrons generated by the arc impact gas
Advantage
Plasma arc has directional Stability, work to torch
distance is not critical and arc length can vary.
Lower heat input and lower filler metal needed
No edge preparation needed
Limitation
Expensive equipment
Restricted to flat and horizontal positions only
Maximum thickness limited 25 mm
Large amount of ultraviolet and infrared rays are emitted.
4/1/2015
Application
Stainless steel
Nickel based alloy
Suitable for refractory metal coating like alumina on
graphite nozzles for rockets.
Lamellar Tearing
Causes
High joint rigidity
Excessive stresses
Arc blow
Poor joint selection
Improper cleaning in multipass welding
Excessive H2, O2, N2, in the
welding atmosphere or Damp
electrodes
inclusions such as Mn Fe and S
in the base metal and/or
residual stress
1. Carbon equivalent
2. Heat input
3. Effective thickness
3. Hydrogen content in weld pool
2
Ta I T 60 160 T T 23.4375
100
Ia
2
4/1/2015
[2 Marks]
Ans.
1. Distortion
2. Cracking in the base metal
3.
Lamellar Tearing
Advantages:
1. Welding transformer and its controller is very much cheaper as compared to D.C
set.
2. No rotating parts so less of wear and tear.
3. Troublesome magnetic fields causing arc blow is eliminated.
4. Efficiency is slightly more than DC setup.
Disadvantages:
1. Covered electrodes must be used. The AC arc cannot be used satisfactorily for bare
wire or lightly coated rods as the DC arc.
2. Higher voltage is to be used , consequently risk of shock is also more as compared
to DC Welding.
3. AC welding machines have moderate penetration.
4. More diamter is required to have more AC current to get more filler material
deposit rates and faster welding speeds.
5. Welding of cast iron, bronze and aluminium cannot be done using AC set up.
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4/1/2015
DIFFUSION WELDING
It is a solid state welding process which produces
coalescence of the faying surfaces by the application
of pressure and elevated temperatures (about 50 to
80% of absolute melting point of the parent
materials) for a time ranging from a couple of minutes
to a few hours.
Produces high quality bonds with good strength with
little or no distortion.
Can join very dissimilar materials.
A solid filler metal may or may not be inserted.
Materials welded for aircraft and rocket industry:
Boron, Titanium, Aluminium, Ceramic, Composite,
Graphite, Magnesium etc.
TIG
Arc is established between a non-consumable tungsten electrode
and the workpiece.
Tungsten is alloyed with thorium or zirconium for better currentcarrying and electron-emission characteristics.
Arc length is constant, arc is stable and easy to maintain.
With or without filler.
Very clean welds.
All metals and alloys can be welded. (Al, Mg also)
Straight polarity is used.
Weld voltage 20 to 40 V and weld current 125 A for RPDC to 1000
A for SPDC.
Shielded Gas: Argon
Torch is water or air cooled
IAS-2011
11
4/1/2015
steels,
tool
steels,
aluminum,
magnesium,
Advantages
Limitations
No weld spatter.
Large-grain-size structures.
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4/1/2015
IES-2010
How do zirconium and thorium affect the tungsten
electrode in the GTAW process? What is weld decay
in Ni Cr steels ?
IES-2010
Is it possible to weld tantalum to steel, if yes, by
which method ? Explain
the term hot cracks in
welding and write four important causes.
WELD DECAY
During welding of steel ; formation of chromium carbide
along the grain boundaries may take place.
This results in the depletion of chromium percentage in
the adjoining region of grain boundary.
If this depletion of Chromium percentage is more than
12% which is needed to maintain a passive layer then the
region will be susceptible to corrosion, resulting in
intergranular attack.
Intergrannular corrosion causes loss of metal in the
region that parallels the weld deposit. This corrosion
behaviour is called as weld decay.
Explosion Welding
Done at room temperature in air, water or vacuum.
Surface contaminants tend to be blown off the surface.
Typical impact pressures are millions of psi.
Well suited to metals that is prone to brittle joints
Contd
13
4/1/2015
Contd
Advantages,
Can bond many dissimilar, normally unweldable
metals
The lack of heating preserves metal treatment
The process is compact, portable, and easy to contain
Inexpensive
No need for surface preparation
Contd
Disadvantages,
The metals must have high enough impact resistance,
and ductility (at least 5%)
The cladding plate cannot be too large.
Noise and blast can require worker protection, vacuum
chambers, buried in sand/water.
Contd
Typical applications:
Very large plates can be cladded.
Joins dissimilar metals.
Contd
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4/1/2015
IES-2010
Discuss short circuiting metal transfer in GMAW
mentioning its suitability.
Also define the term
transition current, with figure.
TRANSITION CURRENT:
At a current above the critical
value called the transition
current
transfer
higlhly
directed stream of discrete
droplets of metal in the form of
spray occurs.
Below
transition
current
transfer
mode
becomes
globular and above tansition
current it is spray transfer.
Spray Transfer is achieved by
high current and larger
diameter of electrode wire.
IES 2010
In metal casting define the terms chaplet and resin
Fig (a) shows the initiation of arc. Under the intense heat of arc
electrode tip melts away and forms a globule of molten metal at the tip.
Fig(b) As the electrode wire is fed towards the work piece, the molten
tip touches the weld metal pool and
Fig (c) when the tip touches the metal pool short circuiting takes place,
that short circuits electrode to the workpiece. This reduces Voltage
across the arc.
Fig (d) The metal tip gets pinched by the surface tension of the weld
metal pool as well as the magnetic force due to current flow. Finally the
metal is pinched away and the arc gets ignited again, and the cycle is
repeated all over again.
Casting
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4/1/2015
Merits
Good dimensions tolerance
Good surface finishing
High production rate.
IES-2010
Explain why the strength to weight ratio of die cast
parts increases with decreasing wall thickness.
Demerits
Part size limited
Expensive pattern and equipment required.
IES-2010
Density is another property engineers may considers
especially for compact, high efficiency and light weight
application. Material strength helps determine if a
design made out of die cast metal can be slimmed
down for weight saving, and hence when decrease as
thickness increase. Strength to weight ratio of die
cast part.
IAS2011
Stack moulding are high production plastic injection
16
4/1/2015
Contd
17
4/1/2015
Metallurgical defects
During solidification nucleation event produces a
18
4/1/2015
[30 Marks]
[10 Marks]
Areaof ellipseab
Circumference 3ab 3aba3b
2 a2 b2 /2 (approx.)
Modulus Method
It has been empirically established that if the modulus
D2 D2
satisfactory.
MR = 1.2 Mc
Modulus = volume/Surface area
In steel castings, it is generally preferable to choose a
Caines Method
Freezing ratio = ratio of cooling characteristics of casting to
the riser.
A
X V Casting
A
V Riser
According to Caine
Y=
X=
a c
Yb
Vriser
and a, b, c are constant.
Vcasting
19
4/1/2015
20
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Example
2T
4T
1.14
1.02
1.00
GATE-2015
The dimensions of a cylindrical side
riser(height = diameter) for a 25 cm x 15 cm x 5
cm steel casting are to be determined. For the
tabulated shape factor values given below, the
diameter of the riser (in cm)________
Shape Factor
10
12
Riser volume /
Casting Volume
1.0
0.70
Normally the risers are located at the heaviest sections and they themselves act as
feeders for thin sections. But when smaller sections are connected to thicker
sections, the riser should have larger volume to cater this appendage.
The total volume of the casting is taken as the volume of the main section plus
the effective percentage of the appendage volume, called the parasitic volume.
Example
Calculate the risering requirement for the casting
shown in fig.
GRAPH-2
21
4/1/2015
First neglect the branch and calculate shape factor for main
plate ;
Shape Factor = (25+12.5)/5 = 7.5
From graph at shape factor 7.5 (riser volume/casting volume)
is 0.575
Riser Volume(Vr ) = (riser volume/casting volume) x casting
volume
Riser Volume = 0.575 x 25 x 12.5x 5 =898.437 cm3
The branch Volume=2.5 x 2.5 x 10 =62.5cm3
This is plate feeding the bar with thickness ratio (2.5/5) of 0.5.
From the graph we get parasitic volume of 30%
Hence, riser volume = 0.3 x 62.5 + 898.437=917.185cm3
Vr = (.D3 )/4
or 917.185= (.D3 )/4
or D = 10.53 cm
22
4/1/2015
Cupola
The mis-run and cold shut defects are caused either by
a lower fluidity of the mold or when the section
thickness of the casting is very small. Fluidity can be
improved by changing the composition of the metal
and by increasing the pouring temperature of the
metal.
IES 2007
What is permeability? Permeability is more important
in the basic process of sand casting than porosity. Give
one important reason for this feature.
[2 marks]
R VH
pAT
p 5.0g / cm2
T 1min25s 1.417min
R 501.28 70.75
51.417
R 501.28
pT
.
23
4/1/2015
Contd
Purpose
24
4/1/2015
Distortion Allowance
A metal when it has just solidified is very weak and
therefore is likely to be distortion prone.
This is particularly so for weaker sections such as long
flat portions, V, U sections or in a complicated casting
which may have thin and long sections which are
connected to thick sections.
The foundry practice should be to make extra
material provision for reducing the distortion.
25
4/1/2015
Investment Casting
Investment casting process or lost wax process
Basic steps:
1. Produce expendable wax, plastic, or polystyrene patterns.
2. Assemble these patterns onto a gating system
3. Investing or covering the pattern assembly with refractory
slurry
4. Melting the pattern assembly to remove the pattern material
5. Firing the mould to remove the last traces of the pattern
material
6.Pouring molten metal
7. Knockout, cutoff and finishing.
Fig. Investment flask-casting procedure
IES 2009
2 marks
Slush Casting
Slush casting is a variation of the permanent mold process
26
4/1/2015
Errors
IES 2010
Repeatability
It is the ability of a measuring system to reproduce
output readings when the same input is applied to it
consecutively, under the same conditions, and in the
same direction.
Imperfections in mechanical systems can mean that
during a Mechanical cycle, a process does not stop at the
same location, or move through the same spot each
time. The variation range is referred to as repeatability.
Reliability of measurement
It is a quantitative characteristic which
implies
confidence in the measured results depending on
whether
or
not
the
frequency
distribution
characteristics of their deviations from the true values
of the corresponding quantities are known. It is the
probability that the results will be predicted.
27
4/1/2015
Calibration
It is the setting or correcting of a measuring device
usually by adjusting it to match or conform to a
dependably known value or act of checking.
IAS 2013
IFS 2013
IAS 2014
limit of the shaft and the lower limit of the hole knowing
fully well that still some margin is left for machining before
the part is rejected.
28
4/1/2015
Methods of Measurement
Direct method
Indirect method e.g density
3. Absolute method or Fundamental method e.g
lenghth form definition
4. Comparison method e.g comparator
5. Deflection method e.g. Dial Indicator
1.
2.
Snug fit
1/3
Tolerance = 0.0004D
and Deviation 0
Mediumforce fit :
1/3
1/3
Tolerance = 0.0006D
and Deviation 0.0005D 0.0006D
iron
29
4/1/2015
IFS 2012
measuring instruments
Resolution: It is the smallest change of the measured
IAS 2012
IFS 2011
IAS 2011
IAS 2010
30
4/1/2015
IES 2010
Why is a unilateral tolerance preferred over bilateral
tolerance ?
In surface roughness, discuss with a figure Root
Complex shapes.
A very high accuracy is desired besides the complexity of
for development of
processes
which
utilize
non-traditional
other
machining
methods
such
as
Classification of NTMM
The Non-traditional Machining Methods are classified
according to the major energy sources employed in
machining.
31
4/1/2015
Some Observations
EDM has the lowest specific power requirement and can
achieve sufficient accuracy.
ECM has the highest metal removal rate, MRR.
USM and AJM have low MRR and combined with high
tool wear, are used for non-metal cutting.
LBM and EBM have high penetration rates with low
MRR and, therefore, are commonly used for micro
drilling, sheet cutting, and welding.
CHM is used for manufacturing PCB and other shallow
components.
PAM can be used for clean, rapid cuts and profiles in
almost all plates upto 20 cm thick with 5o to 10o taper.
USM
cutting workpiece
Computer control to achieve shape
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IAS2014
193
Physical Principle
Basic process
Physical Principle
An arc jumps between two points along the path of least
resistance.
Physical Principle
Physical Principle
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4/1/2015
Physical Principle
The blast from the expanding vapors knocks some
molten particles loose, and the remaining molten metal
hardens.
Advantages
1.
2.
3.
4.
5.
6.
Disadvantages
1. Only electrically conductive materials can be machined
by EDM. Thus non - metallic, such as plastics, ceramics
or glass, cannot be machined by EDM.
2. Electrode wear and over-cut are serious problems.
3. A re-hardened, highly stressed zone is produced on the
work surface by the heat generated during machining.
This brittle layer can cause serious problems when the
part is put into service.
4. Perfectly square corners cannot be made by EDM.
5. High specific energy consumption (about 50 times that
in conventional machining)
6. MRR is quite low
IAS2011
EDM Tool
The usual choices for tool (electrode) materials are
Copper,
brass,
alloys of zinc and tin,
hardened plain carbon steel,
copper tungsten,
silver tungsten,
tungsten carbide,
copper graphite, and graphite.
Electrochemical Machining
Electrochemical machining is the reverse of electro
plating
The work-piece is made the anode, which is placed in
close proximity to an electrode (cathode), and a highamperage direct current is passed between them through
an electrolyte, such as salt water, flowing in the anodecathode gap.
Metal is removed by anodic dissolution and is carried
away in the form of a hydroxide in the electrolyte for
recycling or recovery.
MRR in ECM depends on atomic weight of work material
34
4/1/2015
Electrochemical Machining
Variation in the current density will result in work
taking the electrodes shape.
The electrode is fed with a constant velocity, and the
electrolyte is fed through the tool.
Advantages
Disadvantages
1.
3.
4.
mm3/min)
2.
5.
6.
7.
IAS2012
Refer note
35
4/1/2015
IFS2012
Tool
Tool materials: Copper, brass, bronze, Al, Stainless
IAS2011
36
4/1/2015
Advantages of AJM
Disadvantages of AJM
machined.
Application of AJM
Cutting and drilling on metal foils and thin
Low MRR
automobile windows
Cleaning, polishing and deburring the surface
IFS-2011
High-voltage
workpiece
electron
beam
directed
toward
[5-Marks]
region of workpiece
Electron beam moved by deflection coils
Similar process to EB welding
222
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4/1/2015
Advantage
There is no effect of local heat on workpiece as the
223
Disadvantage
Application
Necessity of vacuum
Safety
IFS2014 IAS2013
38
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laser welding
Successive pulses from laser gun vaporize tiny bits of
workpiece
Location of laser beam controlled by computer
Workpiece need not be conductive
Cuts are tapered
Gotta trap overshoot from laser beam
229
230
engines
231
39
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Application
IAS2014
G Ratio
Grade
The worn out grit must pull out from the bond and make
room for fresh sharp grit in order to avoid excessive rise
of grinding force and temperature.
IES2009
40
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IAS2012
41
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Centerless Grinding
IES 2010
Draw the typical configuration of Internal Centre less
grinding mentioning main advantage and use.
Centerless Grinding
Centerless Grinding
Loading
Some grinding chips get lodged into the spaces between
dressing.
42
4/1/2015
Dressing
Truing
IFS-2011
Rose Reamer
Chucking Reamer
Fluted
chucking
reamers have relief
behind the edges of the
teeth as well as beveled
ends. They can cut on
all portions of the teeth.
Their
flutes
are
relatively short and they
are intended for light
finishing cuts.
Shell Reamer
Shell reamers often are
used for sizes over 20
mm to save cutting-tool
material. The shell,
made of HSS for smaller
sizes and with carbide
edges for larger sizes or
for
mass-production
work.
43
4/1/2015
the web
44
4/1/2015
Gear Hobbing
The HSS or carbide cutter having teeth like gear milling
cutter and the gear blank apparently interact like a pair
of worm and worm wheel.
The hob (cutter) looks and behaves like a single or
multiple start worms.
Gear Hobbing
Having lesser number (only three) of tool work
IFS 2013
Applications of Hobbing
The gears produced by gear hobbing are used in
45
4/1/2015
Jig
Fixtures
IES - 2007
Fig. A
component with
six locators
46
4/1/2015
Considering 12 DOF
You must fix all the 12 degrees of freedom except the three
GATE - 2005
When 3-2-1 principle is used to support and locate a
three dimensional work-piece during machining,
the number of degrees of freedom that are
restricted is
(a) 7
(b) 8
(c) 9
(d) 10
Points to ponder
When more than one locator is placed on a surface
GATE - 2001
3-2-1 method of location in a jig or fixture would
collectively restrict the workpiece in n degrees of
freedom, where the value of n is
(a) 6
(b) 8
(c) 9
(d) 12
GATE-2013 (PI)
IES 2011
number of
47
4/1/2015
IES 1999
Assertion (A): Spherical washers are used to locate
the job in the fixtures.
Reason (R): 3-2-1 principle should be adopted to
locate the job.
(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
Clamping
To restrain the workpiece completely a clamping device
IFS 2012
IAS 2012
is required.
Holds the workpiece securely in a jig or fixture against
Cam Clamps
Provide clamping force because of the contour of the cam
surface that comes into contact with the plate used for the
clamping.
Plate is pushed down by the cam against the spring
pressure to hold the part in place.
Cam clamps are quick in operation.
Cam clamps are of three types, eccentric cam, flat spiral
cam and cylindrical cam.
The design shown in Fig. is flat spiral and is the most
commonly used clamp.
Fig. A cam clamp used
for quick and easy
clamping a part
Fig. An example of a
fixture held by a cam
clamp
48
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Duplex Fixture
IFS-2011
What are the functions of jig ? Draw a jig to machine
four holes in a plate. What are two reasons for not
having drill bushings actually touching the workpiece
? What is a duplex fixture ?
[10-marks]
49
What is NC/CNC?
NC is an acronym for Numerical Control and CNC is an
capability.
The earliest NC machines performed limited functions
and movements controlled by punched tape or punch
cards.
As the technology evolved, the machines were equiped
with increasingly powerful microprocessors (computers)
with the addition of these computers, NC machines
become CNC machines.
CNC machines have far more capability than their
predecessor.
contd..
operator/programmer
use
simple
descriptive
NC/CNC Machines-Advantages
High Repeatability and Precision e.g. Aircraft parts
Turbines
Flexibility in job change, automatic tool settings, less
scrap
More safe, higher productivity, better quality
Less paper work, faster prototype production, reduction
in lead times
NC/CNC Machines-Disadvantages
Costly setup, skilled operators
Computers, programming knowledge required
Maintenance is difficult
Stepper Motor
The stepper motor is special type of synchronous motor
IAS-2010 Main
Illustrate with the help of neat sketches the differences
between open-loop and closed-loop control in NC
system. Why is feedback not possible in open-loop
control system ?
[22- Marks]
IAS2010
IAS2013
IAS2014
(b) 320
(c) 300
(d) 280
Example
A DC servomotor is coupled directly to a leadscrew
10
2.
3.
IAS-2010 Main
In open-loop NC system the shaft of a stepping motor is
connected directly to the lead screw x-axis of the
machine table. The pitch of the lead screw is 3.0 mm.
The number of step angles on the stepping motor is 200.
Determine how closely the position of the table can be
controlled, assuming that there are no mechanical errors
in the positioning system.
Also, what is the required frequency of the pulse train
and the corresponding rotational speed of the stepping
motor in order to drive the table at a travel rate of 100
mm/min?
[8- Marks]
Q.6.(b) (ii) What is meant by Part Programming ? Discuss point to point control,
and its applications.
Part programs for simple components can be carried out manually. However, if the component has complex
features which require too many repetitive and/or tedious calculations for preparing its program for cutter
path description, then it is recommended that computer-aided part programming be resorted to.
To be a good CNC programmer, one should have a fair knowledge about the machine tools, cutting tools
and fixtures to be used and the manufacturing process. He also should have a good understanding of
geometry, algebra and trigonometry. In fact, machine shop experience is the pre-requisite for a good
11
programmer as only careful process planning can lead to efficient and practical programs.
12
Y - Y axis designation
Z - Z axis designation
R - Radius designation
F Feed rate designation
Meaning
Format
G00
Rapid Transverse
G01
G02
Linear Interpolation
Circular Interpolation,
CW
Circular Interpolation,
CCW
G04
G17
Dwell
XY Plane
N__G04P___
G18
G19
XZ Plane
G03
YZ Plane
13
Meaning
Format
G21/G71
G28
G40
G41
G42
G43
Metric Unit
Automatic Return to Reference
Point
Cutter compensation cancel
Cutter compensation left
Cutter compensation right
Tool length compensation
(plus)
N__G41D__
N__G42D__
N__G43H__
Format
G44
N__G44H__
G49
G80
G81
G90
G91
G92
N__G81 Z__R__F__
Drilling cycle
Absolute positioning
Incremental positioning
Absolute preset, change the N__G92X__Y__Z__
datum position
14
G90:
absolute
coordinates
(20,10)
(10,10)
(0,0)
Start
Y
End
100.0
Start
200.0
15
interpolation
G02
R
G17
G03X __Y __I __ J __F __;
G
02
R
G18
G03X __Z __I __ K __F __;
G02
R
G19 Y __Z __
F __;
G03
J __ K __
End
point
R=-50mm
End
Specify R with
sign before it:
180 +R
Start
>180 -R
R=50mm
16
G92:
To define working
coordinate
Or
G90:
absolute
coordinates
R50
R60
60
40
X
O
90 120 140
200
Tool-Radius Compensation
Tool-radius compensations make it possible to
program directly from the drawing, and thus eliminate
the tool-offset calculation
G41 (G42) D
D: the radius of tool to compensate is saved in a memory unit that
is named D
17
Tool-Height Compensation
G43 (G44) H
H: specified memory unit used to save height
compensation of tool.
Tool-Height Compensation
Example:
N0010 G91 G00 X12.0 Y80.0
G91:
incremental
coordinates
18
19
Tool Home
Top
View
Front
View
Top
View
Front
View
.100
20
Top
View
5.) Z Axis Feed Move to
Drill Hole
Front
View
Top
View
Front
View
21
Top
View
Front
View
Top
View
Front
View
Tool At Home
O0001
N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
N020 G01 Z-.75 F3.5
N025 G00 Z.1 M09
N030 G91 G28 X0 Y0 Z0
N035 M30
22
IAS2011
IES-2008
40
20
L2
L3
135
80
20
C1
L4
L1
C2
L5
P2
20
20
P1
X
23
Answer:
PARTNO CONTOUR
MACHIN/MILL, 1
CLPRNT
UNITS/MM
P0 = POINT/0.0, 0.0, 0.0
P1 = POINT/110.0, 20.0, 0.0
P2 = POINT/20.0, 20.0, 0.0
P3 = POINT/90.0, 110.0, 0.0
P4 = POINT/20.0, 100.0, 0.0
P5 = POINT/50.0, 130.0, 0.0
L1 = LINE/P2, ATANGL, 90, XAXIS
L2 = LINE/P4, ANTNGL, 45, XAXIS
L3 = LINE/P5, ATANGL, 135, L2
L4 = LINE/P1, PERPTO, L3
L5 = LINE/P1, PERPTO, L4
C1=CIRCLE/CENTER, P3, RADIUS, 20.0
C2=CIRCLE/CENTER, P1, RADIUS, 20.0
PL1=PLANE/P1, P2, P3
Contd.
CUTTER/25.0
TOLER/0.1
INTOL/0.05
OUTTOL/0.05
FEDRAT/200
SPINDL/500, CLW
COOLNT/ON
FROM/P0
GO/TO, L1, TO, PL1, TO, L5
GOLFT/L1, PAST, L2
GORGT/L2, PAST, L3
GORGT/L3, TANTO, C1
GOFWD/C1, PAST, L4
GOFWD/L4, PAST, C2
GORGT/C2, PAST, L5
GORGT/L5, PAST, L1
24
Contd.
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
IES-2007
R30
Q
110
120
E
R40
40
+ 40
100
P
Material : M S.
8 mm
25
Answer:
PARTNO CONTOUR
MACHIN/MILL, 2
CLPRNT
UNITS/MM
P0 = POINT/0.0, 0.0, 10.0
PTA = POINT/0.0, 0.0, 0.0
PTB = POINT/0.0, 120.0, 0.0
PTC = POINT/30.0, 150.0, 0.0
PTD = POINT/140.0, 150.0, 0.0
PTE = POINT/140.0, 40.0, 0.0
PTF = POINT/100.0, 0.0, 0.0
PTQ = POINT/30.0, 120.0, 0.0
PTP = POINT/140.0, 0.0, 0.0
LAB = LINE/PTA, PTB
LCD = LINE/PTC, PTD
LDE = LINE/PTD, PTE
LAF = LINE/PTA, PTF
CBC = CIRCLE/CENTRE, PTQ, RADIUS, 30.0
CEF = CIRCLE/CENTRE, PTP, RADIUS, 40.0
PL1=PLANE/PTA, PTB, PTC
26
Contd.
CUTTER/25.0
TOLER/0.1
INTOL/0.05
OUTTOL/0.05
FEDRAT/200
SPINDL/500, CLW
COOLNT/ON
FROM/P0
GO/TO, LAB, TO, PL1, TO, LAF
GOLFT/LAB, TANTO, CBC
GOFWD/CBC, PAST, LCD
GORGT/LCD, PAST, LDE
GORGT/LDE, PAST, CEF
GORGT/CEF, PAST, LAF
GORGT/LAF, PAST, LAB
Contd.
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
27
IES-2006
R20
100 mm
80
50
60
200 mm
Material: MS
Thickness: 8.0 mm
R30
L2
C2
P3
C1
R20
P2
L3
100 mm
80
L1
X
P1
60
50
L4
200 mm
28
P4
R30
L2
P3
C1
Answer:
C2
R20
PARTNO CONTOUR
MACHIN/MILL, 3
CLPRNT
80 L1
UNITS/MM
P0 = POINT/0.0, 0.0, 10.0
P1 = POINT/0.0, 0.0, 0.0
P2 = POINT/60.0, 80.0, 0.0
P3 = POINT/150.0, 100.0, 0.0
60
P1
P4 = POINT/200.0, 0.0, 0.0
C1 = CIRCLE/ CENTER, P2, RADIUS, 20
C2 = CIRCLE/CENTER, P3, RADIUS, 30
L1 = LINE/P1, LEFT, TANTO, C1
L2 = LINE/LEFT, TANTO, C1, LEFT, TANTO, C2
L3 = LINE/P4, RIGHT, TANTO, C2
L4 = LINE/P1, P4
PL1=PLANE/P1, P2, P3
P2
L3
100 mm
X
50
L4
200 mm
Contd.
CUTTER/25.0
TOLER/0.1
INTOL/0.05
OUTTOL/0.05
COOLNT/ON
SPINDL/500, CLW
FEDRAT/200
FROM/P0
GO/TO, L1, TO, PL1, TO, L4
GOLFT/L1, TANTO, C1
GOFWD/C1, PAST, L2
GOFWD/L2, TANTO, C2
GOFWD/C2, PAST, L3
GOFWD/L3, PAST, L4
GORGT/L4, PAST, L1
29
P4
Contd.
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
Home Work
Write a complete part program in APT for machining
the product which is given in the diagram. Thickness of
the workpiece is 6 mm. All dimensions are in mm.
[15]
30
PARTNO CONTOUR
MACHIN/MILL, 1
CLPRNT
UNITS/MM
P0 = POINT/-25.0,-25.0, 25.0
P1 = POINT/0.0, 0.0, 6.0
P2 = POINT/117.0, 32.0, 6.0
P3 = POINT/117.0, -32.0, 6.0
C1=CIRCLE/CENTER, P1, RADIUS, 10.0
C2=CIRCLE/CENTER, P2, RADIUS, 12.5
C3=CIRCLE/CENTER, P3, RADIUS, 12.5
31
32
Line (LINE)
LIN1 = LINE/ P1, P2
y
P2
P1
LIN1
x
Line (LINE)
L12 = LINE/ PT4, ATANGL, 20, XAXIS
L14 = LINE/ PT1, ATANGL, 40
L15 = LINE/ 32, -3, 2, ATANGL, -15, XAXIS
L16 = LINE/ PT3, ATANGL, 40, YAXIS
y
PT3
L14
40
L12
PT1
L16
PT4
40
L15
20
15
(32, -3, 2)
33
Line (LINE)
L2 = LINE/ PT51, RIGHT, TANTO, C11
L3 = LINE/ PT40, RIGHT, TANTO, C11
L4 = LINE/ PT40, LEFT, TANTO, C11
L3
Right
PT40
L1
Left
Left
L4
PT51
Right
L2
Line (LINE)
LN3 = LINE/ PNT6, PARLEL, LN15
LN4 = LINE/ PNT5, PERPTO, LN13
y
PNT6
PNT5
LN3
LN4
LN15
LN13
34
IAS2012
35
Advantages of Robots
36
Disadvantages of Robots
37
2.
3.
4.
5.
Q.6.(a) (iv)
Ans.6.(a) (iv) manipulator : - manipulator are built as serial chains or parallel chains
or occasionally a
combination of both. Links and joints (revolute and prismatic) that are mostly used in manipulators. In
spatial manipulators (open chains) adjacent axes are parallel or perpendicular to each other.
Wrists : - Wrists roll, yaw and pitch. There are 3 motions and 3 actuators are
IES2010
38
welding (FCAW)
operation at one
workstation
while fitter
changes parts at
the other
workstation
Ans PPT
39
IFS2013
IFS2011
Q.6.(b) (iii) In FMS define the terms : Automatic Guided Vehicle (AGV) and DNC. Explain
the
terms
chucking reamers and climb milling. What effect does the helix angle have on drill performance. Explain
the terms combined cuts and
multiple cuts.
Ans.6.(b) (iii) Automatic guided vehicle (AGV) : - It is mobile robot that follows markers or wire in the
floor or uses vision or lasers. They are most of ten used in industrial application to move material around
40
a manufacturing
facility or a warehouses. AGV system lareliable horizontal transportation when
spacels at a premium and flexibility is critical e.g Aerospace,
Automotive, clean room.
Direct numerical control (DNC) : - It is commonly manufacturing term for
networking CNC
machine tool. On some CNC machine controllers the
available memory is too small to contain the
machine programmed. So in this case the programme is stored in separate computer and sent directly to
the machine. If the computer connected to a number of machines it can
distribute
programme to different machine required. DNC networking or
DNC communication is always required
when CAM programme are th run or
some CNC machine control.
Helix angle effect : - An increase in the helix angle to more quickly remove chips
but
a
decrease in helix angle in the interest of greater strength of
cutting
edges,
in
the
drilling
performance.
IES2010
IAS2011
CAD
41
CAM
Automations
FMS
from PPTS
42
MATERIALSCIENCEQUESTIONANDANSWER (CONVENTIONALTYPE)
Q-1:
A-1:
What are coordination number of BCC, FCC and HCP crystal structure?
CN, the coordination number, which is the number of closest neighbors to which an atom is bonded.
CN of BCC structure is 8
CN of FCC structure is 12
CN of HCP structure is 12
BCC
FCC
HCP
Q-2:
A-2:
What are packing factors of BCC, FCC and HCP crystal structure?
APF, the atomic packing factor, which is the fraction of the volume of the cell actually occupied by
the hard spheres. APF = Sum of atomic volumes/Volume of cell.
APF of BCC structure is 0.68
APF of FCC structure is 0.74
APF of HCP structure is 0.74
Q-3:
A-3:
How many slip planes are there in BCC, FCC and HCP crystal structure?
Crystal
BCC
FCC
HCP
Q-4:
A-4:
[1 2 0]
Slip Planes
{110}, {112}, {123}
{111}
Basal plane, Prismatic & Pyramidal planes
Crystalographic Directions
Page 1 of 14
[1 3 3]
a/3, b, c
[1 1 0 0]
[1 2 0]
a/2, -b, 0c
Page 2 of 14
Q-5:
A-5:
[ 2 2 1]
[632]
[10 1 0]
Plane
ABCD
Page 3 of 14
Q-6:
A-6:
Q-7:
A-7:
Q-8:
A-8:
What is the type of solid solution (a) copper and nickel (b) Iron and carbon
(a) copper and nickel
Cu-Ni forms a sunstitutional solid solution. If a melt of Cu and Ni with any composition is
cooled, a solid solution begins to freeze out. This solid solution is richer in Ni than the liquid
solution. As the two phase system of solid plus melt is cooled further, the mole fractin of Ni
decreases in both the solid solution and the liquid melt.
(b) Iron and carbon
Fe-C forms an interstitial solid solution; the C atoms occupy interstices in the crystal
structure of substance Fe. The Fe-Fe3C is characterized by five individual phases. Five
phases that exist in the Fe-C diagram are: ferrite (BCC) Fe-C solid solution, -austenite
(FCC) Fe-C solid solution, -ferrite (BCC) Fe-C solid solution, Fe3C (iron carbide) or
cementite - an inter-metallic compound and liquid Fe-C solution.
Q-9:
A-9:
Following empirical curves are used to estimate mean stress effects on fatigue life
a. Soderberg (USA, 1930)
b. Goodman (England, 1899)
c. Gerber (Germany, 1874)
d. Morrow (USA, 1960s)
Q-11: Explain the difference between Soderberg line and Goodman line.
A-11:
Alternating stress ( a ) =
Mean stress ( m ) =
max min
2
max + min
2
Yield strength = y
Ultimate TensileStrength = u
1.
Goodman Line
2.
Soderberg Line
a m
+
=1
e ut
a m
+
=1
e y
Most actual test data tend to fall above the Goodman line.
The Soderberg line is very conservative and seldom used.
Q-12: What are creep resistant alloy? Give composition of Nimonic 90 and Vitallium HS 21.
A-12: Creep resistant alloy
To make creep resistance alloy we have to strengthen the solid solution by mechanisms which cause
dislocation locking and those which contribute to lattice friction hardening.
The alloy can also be hardened by precipitation. Some solute alloying elements is added in reducing
the rate of climb and cross-slip processes.
Page 5 of 14
Example: The nickel alloy (Inconol, Nimonic), ferritic steel, austenitic steel 16-25-6, etc.
Composition of Nimonic 90
Cr-20%, Co-16%, Ti-2.3% Al-1.40 %, Fe-0.5%, C-0.08%, Mn-0.06%, Si-0.017% and Ni -58%
Composition of Vitallium HS 21
C 0.25%, Cr 27%, Ni 3 %, Mo 5%, Fe 1%, Mn 1%, Si -1%, Co - bal
Q-13: Differentiate between temper embrittlement and hydrogen embrittlement.
A-13: Temper embrittlement
Tempering of some steels may result in a reduction of toughness what is known as temper
embrittlement. This may be avoided by (1) compositional control, and/or (2) tempering above 575oC
or below 375oC , followed by quenching to room temperature. The effect is greatest in Martensite
structures, less severe in bainitic structures and least severe in pearlite structures. It appears to be
associated with the segregation of solute atoms to the grain boundaries lowering the boundary
strength. Impurities responsible for temper brittleness are: P, Sn, Sb and As. Si reduces the risk of
embrittlement by carbide formation. Mo has a stabilizing effect on carbides and is also used to
minimize the risk of temper brittleness in low alloy steels.
Hydrogen embrittlement
Hydrogen embrittlement is more failure than a form of corrosion, but it is often results from the
hydrogen, produced from corrosion. Atomic hydrogen produced during corrosion diffuses
interstitially through crystal lattice, and interferes with dislocation motion, leading to failure. It is
similar to stress corrosion in the sense that ductile materials experience brittle failures as a result.
Counter measures to hydrogen embrittlement include: heat treatment to reduce strength of the
alloy; removal of source of hydrogen; baking the component to drive out any dissolved hydrogen.
Q-14: What is diffusion couple? Give two examples.
A-14: Diffusion couple is made by two metals A and
B. Two containers of two metals are joined
together by removing the barrier between
them. This couple is heated for an extended
period at a higher temperature, but certainly
lower than the melting points of A and B, and
then cooled to room temperature. It is
observed that atoms A have migrated into
atoms B and atoms B have migrated into
atoms A. There is a net flow of atoms from
higher concentration to lower concentration
regions. This type of diffusion is known as
inter-diffusion or impurity diffusion.
Example
(i)
Copper and Nickel couple
Gold and Silver couple
(ii)
Q-15: Explain how annealing and normalizing are diffusion controlled processes?
A-15: Annealing can be defined as a heat treatment process in which the material is taken to a high
temperature, kept there for some time and then cooled. Carbon atoms diffuse in BCC and FCC by
interstitial diffusion process. High temperatures allow diffusion processes to occur fast. The time at
the high temperature (soaking time) must be long enough to allow the desired transformation to
occur.
Normalizing is used to refine the grains and produce a more uniform and desirable size distribution.
It involves heating the component to attain single phase (e.g.: austenite in steels), then cooling in
open air atmosphere. In normalizing also high temperature allows diffusion process to occur fast.
Q-16: What is a Eutectic system? Explain copper/silver and lead/tin eutectics.
A-16: Many binary systems have components which have limited solid solubility, e.g.: Cu-Ag, Pb-Sn. The
regions of limited solid solubility at each end of a phase diagram are called terminal solid solutions
as they appear at ends of the diagram.
Many of the binary systems with limited solubility are of eutectic type, which consists of specific
alloy composition known as eutectic composition that solidifies at a lower temperature than all other
compositions. This low temperature which corresponds to the lowest temperature at which the liquid
can exist when cooled under equilibrium conditions is known as eutectic temperature. The
corresponding point on the phase diagram is called eutectic point. When the liquid of eutectic
composition is cooled, at or below eutectic temperature this liquid transforms simultaneously into
two solid phases (two terminal solid solutions, represented by and ). This transformation is
known as eutectic reaction and is written symbolically as:
Liquid (L) solid solution-1 () + solid solution-2 ()
This eutectic reaction is called invariant reaction as it occurs under equilibrium conditions at a
specific temperature and specific composition which can not be varied.
Thus, this reaction is represented by a thermal horizontal arrest in the cooling curve of an alloy of
eutectic composition. A typical eutectic type phase diagram is shown in figure-4 along with a cooling
curve.
Page 7 of 14
cooling
R
heating
Page 8 of 14
cooling
R
heating
Page 9 of 14
Austempering is different from martempering in the sense that it involves austenite-to bainite
transformation. Thus, the structure of austempered steel is bainite. Advantages of austempering are
improved ductility; decreased distortion and disadvantages are need for special molten bath; process
can be applied to limited number of steels.
Carbonitriding
Carbonitriding is a lower cost surface hardening process that provides a thin, high hardness case on
lower hardenability steels. Carbonitriding involves the diffusion of both carbon and nitrogen into the
base steel. The carbon provides the base metal with a high carbon surface, and the nitrogen provides
the case with an added boost of hardenability to insure full case hardness. The addition of nitrogen
makes the carbonitriding process especially suited to plain, low carbon steel that would not
otherwise respond to standard carburizing. Carbonitriding is usually carried out in a temperature
range of 820-900C in a gaseous atmosphere adding between 0.5 to 0.8% carbon and 0.2-0.4% (< 5%)
nitrogen to the surface of plain carbon steel or low alloy steel.
Q-23: What are the high-strength low-alloy steel?
A-23:
High-strength low-alloy steel (HSLA) is a type of alloy steel that provides better mechanical
properties or greater resistance to corrosion than carbon steel.
HSLA steels vary from other steels in that they are not made to meet a specific chemical composition
but rather to specific mechanical properties.
They have low carbon content between 0.050.25% to retain formability and weldability.
Other alloying elements include up to 2.0% manganese and small quantities
of copper, nickel, niobium, nitrogen, vanadium, chromium,
molybdenum, titanium, calcium, rare
earth elements, or zirconium.
Copper, titanium, vanadium, and niobium are added for strengthening purposes.
These steels are not strengthened by heat treatment due to low carbon content.
Q-24: Give composition and use of (a) Hadfield steel (b) Maraging steel (c) Spring Steel (d) Rail
Steel (e) Invar Steel
A-24:
Composition
Use
(a) Hadfield steel
C 1.1 to 1.4%, Mn 11-14%, rest Fe
Jaw crusher plate, Nuts and
bolts, Chains
(b) Maraging steel
C <0.03%, Ni-25%, Co 7-10%, Mo 3 -5%, Ti Aircraft under carriage parts,
1.75 %, Al- 0.2%, other trace, rest Fe
portable bridges and booster
motor in missile
(c) Spring Steel
C 0.55 0.65%, Si 0.1 0.35%, Mn 0.7 1.0 Spring
%, Cr 0.4 0.6%, Ni 0.4 0.7%, Mo 0.15
0.25%, rest Fe
Ni 32%, Fe-68%
Rail
Precision measuring
instrument, survey measuring
tapes
Applications of Superalloy?
Gas Turbine Engines
Blades, vanes, disks, combustors
Space Vehicles
Rocket motors
Nuclear Reactors
Submarines
Petroleum Equipment
Composition
Waspalloy
Cr-19%, Co-13%, Ti-3%, Al 1.4%, Zr 0.06 %,
C 0.08%, rest Ni
Inconel
Cr 15%, Ti 2.4%, Al 1%, Nb 1%, Ta 1%, Fe
7%, C 0.04%, rest Ni
Use
For
high
temperature
application upto 900oC
For
high
temperature
application upto 820oC
Q-27: What are PTFE, Nylon 6, Nylon 610, Perspex, where they are used?
A-27:
What is?
Use
PTFE
Fluorocarbons (PTFE or TFE) or Teflon. It Anticorrosive seals, chemical
is chemically inert in almost all pipes and valves, bearings, anti
environments,
excellent
electrical adhesive coatings, high
properties; low coefficient of friction; may be temperature electronic parts.
used to 260oC; relatively weak and poor
cold-flow properties.
Nylon 6
Synthetic fibers
Nylon 610
Polyhexamethylene sebacamide
Flexible tubes
Perspex
PMMA-polymethyle methacrylate
Domestic article
Q-28: What are conducting polymers and conducting ceramics? Give 2 examples of each.
A-28: Conducting Polymers
Due to the kind of bonding, polymers are typically electrical and thermal insulators. However,
conducting polymers can be obtained by doping, and conducting polymer-matrix composites can be
obtained by the use of conducting fillers. They decompose at moderate temperatures (100 400oC),
and are lightweight. Other properties vary greatly. . The most recent research in this has been the
development of highly conducting polymers with good stability and acceptable processing attributes.
Example: Polyacetylene, Polyphenylene, Polypyrroles
Conducting Ceramics
Conductive ceramics, advanced industrial materials that, owing to modifications in their structure,
serve as electrical conductors. Like metals, conducting ceramics have overlapping electron energy
bands and are therefore excellent electronic conductors. They constitute complex systems based on
oxide and non-oxide phases.
Examples: lead oxide (PbO), ruthenium dioxide (RuO2), bismuth ruthenate (Bi2Ru2O7)
Page 12 of 14
Q-29: What are silicon carbide and silicon nitride, what are their strength and hardness?
A-29: Silicon carbide (SiC)
It is known as one of best ceramic material for very high temperature applications. It is used as
coatings on other material for protection from extreme temperatures. It is also used as abrasive
material. It is used as reinforcement in many metallic and ceramic based composites. It is a
semiconductor and often used in high temperature electronics.
Ultimate tensile strength of SiC is 300 MPa
Hardness of SiC is 2500 VPN (Vickers Pyramid Number)
Silicon nitride (Si3N4)
It has properties similar to those of SiC but is somewhat lower, and found applications in such as
automotive and gas turbine engines.
Ultimate tensile strength of Si3N4 is 580 MPa
Hardness of Si3N4 is 2300 VPN (Vickers Pyramid Number)
Q-30: What are dispersion strengthened and particulate composites? Give two examples of
each.
A-30: Dispersion-strengthened composites
In this composite, particles are of 0.01-0.1 m in size.
Strengthening occurs as a result of dislocation motion hindrance. It is similar to that of
precipitation hardening in metals.
Matrix bears the major portion of the applied load, while dispersoids obstruct the motion of
dislocations.
Example: thoria (ThO2) dispersed Ni-alloys (TD Ni-alloys) with high-temperature strength; SAP
(sintered aluminium powder) where aluminium matrix is dispersed with extremely small flakes of
alumina (Al2O3).
Particulate composites
These composites contain large number of coarse particles.
These composites are designed to produce combination of properties rather than increase the
strength.
Mechanical properties are characterized by rule-of-mixtures.
Particulate composites are usually made of all three conventional engineering materials, namely
metals, polymers and ceramics.
Example: tungsten carbide (WC) or titanium carbide (TiC) embedded cobalt or nickel based cutting
tools. Aluminium alloy castings containing dispersed SiC particles are widely used for automotive
applications including pistons and brake applications.
Q-31: Describe the following
(a) Ceramic matrix composite
(b) Metal matrix composite
(c) Carbon Carbon Composite
A-31: (a) Ceramic matrix composites (CMCs)
They are a subgroup of composite materials as well as a subgroup of technical ceramics. They consist
of ceramic fibers embedded in a ceramic matrix, thus forming a ceramic fiber reinforced ceramic
(CFRC) material. The matrix and fibers can consist of any ceramic material,
whereby carbon and carbon fibers can also be considered a ceramic material.
(b) Metal Matrix Composites (MMC)
Metal Matrix Composites are composed of a metallic matrix (aluminium, magnesium, iron, cobalt,
copper) and a dispersed ceramic (oxides, carbides) or metallic (lead, tungsten, molybdenum) phase.
Page 13 of 14
For -2015
Rev1
Answer &Explanation
Page-2
Page-9
Page-16
Page-137
Page-141
Page-151
Page-34
Page-44
Page-55
Page-160
Page-165
Page-166
Page-60
Page-65
Page-75
Page-86
Page-99
Page-117
Page-167
Page-168
Page-171
Page-176
Page-179
Page-184
Page-127
Page-185
--
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
S d
i
Sandcasting
y Sand casting uses ordinary sand as the primary
M t lC ti
MetalCasting
B SKM d l
BySKMondal
mould material.
y The sand grains are mixed with small amounts of
other materials, such as clay and water, to improve
mouldability and cohesive strength,
strength and are then
packed around a pattern that has the shape of the
desired casting.
casting
y The pattern must be removed before pouring, the
mold
ld is
i usually
ll made
d in
i two
t or more pieces.
i
y An opening called a sprue hole is cut from the top of
the mold through the sand and connected to a
system of channels called runners.
Contd.
Sequentialstepsinmakingasandcasting
i l
i
ki
d
i
y Apatternboardisplacedbetweenthebottom(drag)
andtop(cope)halvesofaflask,withthebottomsideup.
y Sandisthenpackedintothedraghalfofthemold.
y Abottomboardispositionedontopofthepackedsand,
andthemoldisturnedover,showingthetop(cope)half
ofpatternwithsprue andriserpinsinplace.
y Thecopehalfofthemoldisthenpackedwithsand.
Th
h lf fth ldi th k d ith d
y
y
y
y
(removed),
(removed) and the runner and gate are cut into the
surface of the sand.
y The mold is reassembled with the pattern board
removed,
d and
d molten
l
metall is poured
d through
h
h the
h
sprue.
y The contents are shaken from the flask and the metal
Contd
CastingTerms
y Flask: A moulding flask is one which holds the sand
mould
ld intact.
i t t It is
i made
d up off wood
d for
f temporary
t
applications
pp
or metal for longterm
g
use.
y Drag: Lower moulding flask.
y Cope: Upper moulding flask.
y Cheek: Intermediate moulding flask used in three
For-2015 (IES, GATE & PSUs)
Page 1 of 240
piece
i
moulding.
ldi
Rev.0
Contd
p
j
y Pattern: Pattern is a replica
of the final object
to be
made with some modifications.
moulding
ld
fl k that
flasks
h makes
k up the
h sand
d mould.
ld
proportions.
y Backing sand: This is made up of used and burnt
sand.
y Core:
C
U d for
Used
f making
ki hollow
h ll cavities
i i in
i castings.
i
Threeflaskmould
Contd
Padding
y Chaplet: Chaplets are used to support cores inside the
mould cavity.
y Chill: Chills are metallic objects, which are placed in
the
h mould
ld to increase
i
the
h cooling
li rate off castings.
i
casting so that hot metal can flow back into the mould
the
h mould
ld cavity.
Contd
IES2001
is known as 'padding'.
y This will require extra material.
y If p
padding
g is not p
provided, centre line shrinkage
g or
porosity will result in the thinner section.
to solidification
y Tapering
section
T
i off thinner
thi
ti towards
t
d thicker
thi k section
ti
IES1996
Which of the following methods are used for
obtaining
bt i i directional
di ti
l solidification
lidifi ti for
f riser
i design
d i
1.
2.
3.
Employing padding
IES2007
Which one of the following is the correct
statement?
t t
t?
Gate is provided in moulds to
(a) Feed the casting at a constant rate
((b)) Give p
passage
g to g
gases
(c) Compensate for shrinkage
(d) Avoid cavities
Rev.0
GATE2009
MatchtheitemsinColumnIandColumnII.
MatchtheitemsinColumnIandColumnII
ColumnIColumnII
P MetallicChills1 Supportforthecore
P.MetallicChills1.Supportforthecore
Q.MetallicChaplets2.Reservoirofthemoltenmetal
R Riser3 Controlcoolingofcritical
R.Riser3.Controlcoolingofcritical
sections
S ExothermicPadding4 Progressivesolidification
S.ExothermicPadding4.Progressivesolidification
(a) P1,Q3,R2,S4
(b)
P1,Q4,R2,S3
(c) P3,Q4,R2,S1
P 3 Q 4 R 2 S 1
(d)
P 4 Q 1 R 2 S 3
P4,Q1,R2,S3
Pattern
A pattern is a replica of the object to be made by the
gp
process,, with some modifications.
casting
The main modifications are
y The addition of pattern allowances,
allowances
y The provision of core prints, and
y Elimination of fine details, which cannot be obtained
by casting and hence are to be obtained by further
processing
GATE1992
Inagreensandmouldingprocess,uniform
rammingleadsto
(a) Lesschanceofgasporosity
(b) Uniformflowofmoltenmetalintothemould
cavity
(c) Greaterdimensionalstabilityofthecasting
(d) Lesssandexpansiontypeofcastingdefect
PatternAllowances
1. Shrinkageorcontractionallowance
2. Draftortaperallowance
3. Machiningorfinishallowance
M hi i fi i h ll
4 Distortionorcamberallowance
4.
55. Rappingallowance
pp g
GATE2011
Green sand mould indicates that
(a) polymeric mould has been cured
(b) mould has been totally dried
((c)) mould is g
green in colour
(d) mould contains moisture
Sh i k
Shrinkageallowance
ll
y All metals shrink when cooling except perhaps
bismuth.
bismuth
y This is because of the interatomic vibrations which
Contd
Liquidshrinkageandsolidshrinkage
y Liquid
refers
to the
in
Li id shrinkage
h i k
f
h reduction
d i
i volume
l
Page 3 of 240
y Pattern Allowances
Cast Iron
Brass, Copper, Aluminium
Steell
Zinc, Lead
10 mm/m
15 mm/m
20 mm/m
25 mm/m
Rev.0
IES1995
IES1999
GATE1999
In
off metal
casting,
I solidification
lidifi ti
t l during
d i
ti
Which of the following materials requires the
l
largest
t shrinkage
hi k
allowance,
ll
while
hil making
ki
a
pattern for casting?
( ) Aluminium
(a)
l
(b) Brass
(c) Cast Iron
(d) Plain Carbon Steel
(d) Copper.
compensation
p
for solid contraction is
(a) Provided by the oversize pattern
(b) Achieved by properly placed risers
(c) Obtained
by
promoting
directional
solidification
lidifi i
(d) Made by providing chills
GATE2001
ISRO2007
Shrinkage allowance is made by
( ) Adding
(a)
dd
to externall and
d internall dimensions
d
(b) Subtracting from external and internal
dimensions
((c)) Subtracting
g from external dimensions and
adding to internal dimensions
(d) Adding to external dimensions and subtracting
from internal dimensions
GATE2011
GATE2008
While cooling, a cubical casting of side 40 mm
undergoes 3%, 4% and 5% volume shrinkage
during the liquid state, phase transition and solid
state
state,
respectively
respectively.
The
volume
of
(b) 7%
(c) 8%
(d) 9%
metal
GATE2004
Gray cast iron blocks 200 x 100 x 10 mm are to be
castt in
i sand
d moulds.
ld Shrinkage
Sh i k
allowance
ll
f
for
pattern making is 1%. The ratio of the volume of
pattern
tt
t that
to
th t off the
th casting
ti will
ill be
b
(a) 0.97
(b) 0.99
(c) 1.01
(d) 1.03
IAS1995
Assertion
(A):
A
i
(A) A pattern is
i made
d exactly
l similar
i il to
the part to be cast.
R
Reason
(R) Pattern
(R):
P
i used
is
d to make
k the
h mould
ld
cavity for pouring in molten for casting.
( ) Both
(a)
B h A and
d R are individually
i di id ll true and
d R is
i the
h
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
( ) A is
(c)
i true but
b R is
i false
f l
(d) A is false but R is true
Rev.0
D ft
Draft
IAS2003
Match
I (Material
II
M h List
Li
(M
i l to be
b cast)) with
i h List
Li
(Shrinkage Allowance in mm/m) and select the
correct answer using the codes given below the lists:
ListI
ListII
(MaterialtoCast)(ShrinkageAllowanceinmm/m)
(A) Greycastiron
1.
7 10
(B) Brass
2
2.
15
(C) Steel
3.
20
(D) Zinc
4
4.
24
Codes:A
B
C
D
A
B
C
D
(a) 1
2
3
4
(b) 3
4
1
2
(c) 1
4
3
2
(d) 3
2
1
4
y To
the
off the
off the
T reduce
d
th chances
h
th damage
d
th mould
ld
outer surfaces.
surfaces
y Draft is always provided as an extra metal.
DRAFTALLOWANCE
Sh k ll
ShakeAllowance
y At the time of pattern removal, the pattern is rapped
Thepatternmaterialshouldbe
y Lightinweight
making patterns?
y Strong,hardanddurable
1. Aluminium
y Resistanttocorrosion,andtochemicalreactions
y Availableatlowcost.
For-2015 (IES, GATE & PSUs)
y
y
GATE2000
Disposablepatternsaremadeof
2. Wax
33. Mercuryy 4
4. Lead
y Dimensionallystableandunaffectedbyvariationsin
temperatureandhumidity.
IES1994
y Easilyworked,shapedandjoined
y Resistanttowearandabrasion
y Wood
are relatively
W d patterns
tt
l ti l easy to
t make.
k Wood
W d is
i nott
prone.
therefore is likelyy to be distortion p
P
M
i l
PatternMaterials
ll
DistortionAllowance
(a) 1,3 and 4 (b) 2,3 and 4 (c) 1, 2 and 4 (d) 1, 2 and 3
Page 5 of 240
(a)
Wood
(b)
Rubber
(c)
Metal
(d)
P l
Polystyrene
Rev.0
T
f P tt
TypesofPattern
T
f P tt
TypesofPattern
Single
Pattern
Si l Piece
Pi
P tt
These are inexpensive and the simplest type of
patterns.
tt
A the
As
th name indicates,
i di t they
th are made
d off a
single piece.
Gated Pattern
TypesofPattern
y Match Plate Pattern
The
h cope and
d drag
d
patterns along
l
with
h the
h
gating and the risering are mounted on a single
matching metal or wooden plate on either side.
IES2008
TypesofPattern
y Loose Piece Pattern
T
f P tt
TypesofPattern
These
ese aaree ssimilar
a to sp
splitt patte
patterns.
s. In add
addition
t o to
splitting the pattern, the cope and drag halves of
pattern along
g with the g
gating
g and riser systems
y
the p
are attached separately to the metal or wooden
plates along
p
g with the alignment
g
pins. Theyy are
p
called the cope and drag patterns.
T
f P tt
TypesofPattern
y Follow Board Pattern
This type of pattern is adopted for those
castings where there are some portions,
portions which
are structurally weak and if not supported
properly are likely to break under the force of
ramming.
T
fP
TypesofPattern
y Skeleton Pattern
y Sweep Pattern
TypesofPattern
Page 6 of 240
Rev.0
CoolingCurve
Fluidity
The ability of a metal to flow and fill a mold is known
as fluidity.
Pouring Temperature
y The most important controlling factor of fluidity is the
pouring
p
g temperature
p
or the amount of superheat.
p
y Higher the pouring temperature, the higher the fluidity.
y Excessive temperatures should be avoided, however. At
high pouring temperatures, metalmold reactions are
accelerated and the fluidity may be so great as to permit
penetration.
i
y Penetration is a defect where the metal not only fills the
mold cavity
ca it but also fills the small voids
oids between
bet een the sand
particles in a sand mold.
ISRO2011
Fluidity in casting (CI) operation is greatly
i fl
influenced
d by
b
a) Melting temperature of molten metal
b) Pouring temperature of molten metal
c)) Finish of the mould
Core
y Used for making cavities and hollow projections.
y All sides of core are surrounded by the molten metal
( )
GATE2012(PI)
In sand casting, fluidity of the molten metal
i
increases
with
ith
(A) increase in degree of superheat
(B) decrease in pouring rate
((C)) increase in thermal conductivityy of the mould
(D) increase in sand grain size
Desiredcharacteristicsofacore
y Green Strength: A core made of green sand should
b strong
be
t
enough
h to
t retain
t i the
th shape
h
till it goes for
f
baking.
y Dry Strength:
h It should
h ld have
h
adequate
d
d strength
dry
h
so that when the core is placed in the mould, it
should
h ld be
b able
bl to resist the
h metall pressure acting on
it.
y Refractoriness: Since in most cases, the core is
surrounded all around it is desirable that the core
material should have higher refractoriness.
Contd
through
th
h a standard
t d d specimen
i
under
d a standard
t d d pressure is
i
termed as permeability number.
y The
Th standard
d d permeability
bili test is
i to measure time
i
y Then,, the p
permeabilityy number,, R is obtained byy
VH
R=
pAT
WhereV=volumeofair=2000cm3
H=heightofthesandspecimen=5.08cm
p=airpressure,g/cm
p
p
, g/ 2
A=crosssectionalareaofsandspecimen=20.268cm2
T timeinminutesforthecompleteairtopassthrough
T=timeinminutesforthecompleteairtopassthrough
Insertingtheabovestandardvaluesintothe
expression,weget
501.28
R=
p.T240
Page 7 of
y Calculatethepermeabilitynumberofsandifittakes1min
p = 5.0 g / cm 2
T = 1 min 25 s = 1.417
1 417 min
501.28
R=
= 70.75
5 1.417
1 417
Rev.0
IES2007
Whatispermeability?Permeabilityismoreimportant
inthebasicprocessofsandcastingthanporosity.Give
y Collapsibility:
p
y At the time of cooling,
g, casting
g shrinks,, and
oneimportantreasonforthisfeature.
i
t t
f thi f t
[2marks]
f good
for
d finish
fi i h to
t the
th casting.
ti
y Low Gas Emission
C
S d
CoreSands
y Used
silica
d clay
l free
f
l sand.
d
y Binders used are linseed oil,
oil core oil,
oil resins,
resins dextrin,
dextrin
molasses, etc.
y Core oils are mixtures of linseed, soy, fish and
C b Di id M ldi
CarbonDioxideMoulding
y Sodium silicate (water glass, SiO2:Na2O) is used as a binder.
Contd
IES2002
Assertion (A): In CO2 casting process,
process the mould or
core attains maximum strength.
Reason (R): The optimum gassing time of CO2
through the mould or core forms Silica Gel which
imparts sufficient strength to the mould or core.
core
(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
i false
f l but
b t R is
i true
t
For-2015 (IES, GATE & PSUs)
GATE 2008(PI)
GATE
2008 (PI)
g of a hollow p
y
In sand casting
part of lead,, a cylindrical
core
of diameter 120 mm and height 180 mm is placed inside
the mould cavity. The densities of core material and lead
GATE2014
An
alloy
is
A aluminium
l i i
ll (density
(d i 2600 ) casting
i
i to be
b
produced. A cylindrical
p
y
hole of 100 mm diameter and
100 mm length is made in the casting using sand core
(b) 64.5
(c) 193.7
(d) 257.6
Page 8 of 240
Rev.0
M ldi S d C
MouldingSandComposition
iti
y Sand:
silica
or olivine
S d Ordinary
O di
ili Sand
S d (SiO2),
) zircon,
i
li i
sands.
Oth Additi
OtherAdditives
y Cereal binder up to 2% increases the strength.
y Pitch
Pit h if used
d up to
t 3%
% would
ld improve
i
th hot
the
h t
sands
strength.
g
y Saw dust up to 2% may improve the collapsibility by
M ldi S d P
MouldingSandProperties
ti
y Porosity or Permeability: Permeability or porosity of
y Plasticity: Itisthemeasureofthemouldingsandtoflow
aroundandoverapatternduringrammingandtouniformly
filltheflask.
y Collapsibility:Thisistheabilityofthemouldingsandto
decreaseinvolumetosomeextentunderthecompressive
forcesdevelopedbytheshrinkageofmetalduringfreezing
p
y
g
g
g
andsubsequentcooling.
y Adhesiveness:Thisisthepropertyofsandmixtureto
p p y
adheretoanotherbody(here,themouldingflasks).The
mouldingsandshouldclingtothesidesofthemoulding
g
g
g
boxessothatitdoesnotfalloutwhentheflasksarelifted
andturnedover.Thispropertydependsonthetypeand
amountofbinderusedinthesandmix.
Oth S d
OtherSands
material sprinkled on the inner surface of the mold
give a better surface finish to the castings.
g
cavityy to g
y Backing sand: It is what constitutes most of the
refractory material found in the mould.
mould This is made
up of used and burnt sand.
y Green Sand: The molding sand that contains
moisture is termed as green sand. The green sand
should have enough strength so that the constructed
mould retains its shape.
y Dry
D sand:
d When
Wh the
th moisture
i t
i the
in
th moulding
ldi sand
d is
i
completely expelled, it is called dry sand.
Grainsizenumber
y ASTM (American
Society for Testing and Materials))
(
IES2008
IES2002
In the grain size determination using standard
charts, the relation between the given size
number n and the average number of grains 'N'
per square inch at a magnification of 100 X is
( ) N = 2n
(a)
(b) N = 2nl
(c) N = 2n + 1
(d) N = 2n + 1
Page 9 of 240
S dSli
SandSlinger
Rev.0
Gating System
GatingSystem
CastingYield
Thecastingyieldistheproportionoftheactual
g
, ,
p
castingmass,w,tothemassofmetalpouredintothe
mould,W,expressedasapercentage.
Casting yield =
w
100
W
Contd
Gating System
GatingSystem
y Ingate: Achannelthroughwhichthemoltenmetal
entersthemouldcavity.
y Vent: Smallopeninginthemouldtofacilitateescape
p
g
p
ofairandgases.
Contd
fG
TypesofGateorIngate
Top
turbulence
in
T gate: Causes
C
b l
i the
h mould
ld cavity,
i it
i is
i prone
p
gradient towards the
g
to form dross,, favourable temperature
gate, only for ferrous alloys.
Bottom gate: No mould erosion, used for very deep moulds,
higher pouring time,
time Causes unfavourable temperature
gradients.
Parting Gate: most widely used gate, easiest and most
economical in preparation.
Step Gate: Used for heavy and large castings, size of ingates
For-2015 (IES, GATE & PSUs)
are normally increased from top to bottom.
Contd
IES2011
In light metal casting,
casting runner should be so designed
that:
1. It avoids
id aspiration
i ti
2. It avoids turbulence
3. The path of runner is reduced in area so that
q
volume of flow through
g each g
gate
unequal
takes place
(a) 1 and 2 only
(b) 1 and 3 only
(c) 2 and 3 only
(d) 1, 2 and 3
Page 10 of 240
G
20 0 ( )
GATE
2010(PI)
During
the
process off a given
sand
D i
h filling
filli
i
d mould
ld cavity
i by
b
molten metal through a horizontal runner of circular cross
section the frictional head loss of the molten metal in the
runner will increase with the
(a) increase in runner diameter
(b) decrease in internal surface roughness of runner
(c) decrease in length of runner
(d) increase in average velocity of molten metal
Rev.0
IES 2011
IES2011
Match List I with List II and select the correct answer using
the code given below the lists :
ListI
ListII
A.Topgate
1.Heavyandlargecastings
B.Bottomgate
g
2.Mostwidelyusedandeconomical
y
C.Partinggate
3.Turbulence
D.Stepgate
4.Unfavourable temperaturegradient
Codes
C
d
A
( ) 3
(a)
(c) 3
B
4
2
C
2
4
D
1
1
(b)
(d)
A
1
1
B
4
2
C
2
4
D
3
3
Th
Thegoalsforthegatingsystem
l f th
ti
t
y To
to
T minimize
i i i turbulence
t b l
t avoid
id trapping
t
i gasses into
i t
the mold
y To get enough metal into the mold cavity before the
metal starts to solidify
y To avoid shrinkage
y Establish the best possible temperature gradient in the
solidifying casting so that the shrinkage if occurs must
be in the gating system not in the required cast part.
y Incorporates a system for trapping the nonmetallic
inclusions.
inclusions
T
TypesofGatingSystems
f G ti S t
Thegatingsystemsareoftwotypes:
y Pressurizedgatingsystem
y Unpressurizedgatingsystem
U
i d i
IES1998
A sand casting mould
assembly is shown in
the above figure. The
elements marked A
and B are respectively
(a) Sprue and riser
(b) Ingate
I
t and
d riser
i
(c) Drag and runner
(d) Riser and runner
GATE2002
The primary purpose of a sprue in a casting
mould
ou d iss to
(a)Feed the casting at a rate consistent with the rate
of solidification
(b)Act as a reservoir for molten metal
( ) d molten
(c)Feed
l
metall from
f
the
h pouring
i basin
b i to the
h
gate
(d)Help feed the casting until all solidification takes
place
IES 1998
IES1998
Whichofthefollowingaretherequirementsofanideal
gatingsystem?
1 Themoltenmetalshouldenterthemouldcavitywithas
1.
highavelocityaspossible.
2 Itshouldfacilitatecompletefillingofthemouldcavity.
2.
Itshouldfacilitatecompletefillingofthemouldcavity
3. Itshouldbeabletopreventtheabsorptionofairorgases
fromthesurroundingsonthemoltenmetalwhile
flowingthroughit.
Selectthecorrectanswerusingthecodesgivenbelow:
(a)1,2and3
(b)1and2 (c)2and3 (d)1and3
IES2009
Considerthefollowingstatements:
C
id th f ll i t t
t
1.Theactualentrypointthroughwhichthemolten
metalentersthemouldcavityiscalledingate.
2.Bottomgateincaseofamouldcreatesunfavourable
g
temperaturegradient.
3.Sprueincaseofamouldismadetaperedtoavoidair
inclusion.
Whichoftheabovestatementsis/arecorrect?
(a)1only (b)1and2 (c)2and3 (d)1and3
P
PressurizedGatingSystem
i d G ti S t
U P
i d G ti S t
UnPressurizedGatingSystem
mold cavity
y Back pressure is maintained by the restrictions in the
metal flow
y Flow of liquid (volume) is almost equal from all gates
y Back pressure helps in reducing the aspiration as the
sprue always runs full
y Because
B
off the
h restrictions
i i
the
h metall flows
fl
at high
hi h
velocity leading to more turbulence and chances of
mold
ld erosion.
i
Page 11 of 240
mold cavity
y Restriction only
y at the bottom of sprue
p
y Flow of liquid (volume) is different from all gates
y Aspiration in the gating system as the system never
runs full
y Less
L
turbulence.
b l
Rev.0
Sprue Design
Sincethevelocitiesareproportionaltothesquareof
p
,
thepotentialheads,ascanbederivedfrom
Bernoulli'sequation,
At = Ac
Theexacttaperingcanbeobtainedbytheequationof
continuity.DenotingthetopandchokesectionsofThesprue by
thesubscriptstand'c'respectively,weget
A t Vt = A c Vc
At = Ac
WhereH=actual
h
l
sprue height
andht=h+H
Vc
Vt
Contd
Contd
GATE2001
hc
ht
GATE 2007
GATE2007
g down sprue
p
A 200 mm long
has an area of cross
section of 650 mm2 where the pouring basin meets the
p
((i.e. at the beginning
g
g of the down sprue).
p )
down sprue
A constant head of molten metal is maintained by the
pouring
p
g basin. The Molten metal flow rate is 6.55 105
3
mm /s. Considering the end of down sprue to be open
p
and an acceleration due to g
gravityy of
to atmosphere
104mm/s2, the area of the down sprue in mm2 at its end
((avoiding
g aspiration
p
effect)) should be
(a)650.0 (b)350.0 (c)290.7 (d)190.0
Contd
G ti
Gatingratio
ti
y Gatingratioisdefinedas:Sprue area:Runnerarea:
Ingate area.
area
y Forhighqualitysteelcastings,agatingratioof1:2:2or
1:2:1.5willproducecastingsnearlyfreefromerosion,
willminimizeoxidation,andwillproduceuniform
ill i i i id i d ill d if
flow.
y Agatingratioof1:4:4mightfavour theformationof
oxidationdefects.
For-2015 (IES, GATE & PSUs)
IES2003
A gating
ratio
ti
ti off 1: 2: 4 is
i used
d to
t design
d i the
th gating
ti
system for magnesium alloy casting. This gating ratio
refers to the cross section areas of the various gating
elements as given below:
1
1.
Down sprue 2.
2
Runner bar 3.
3
Ingates
The correct sequence of the above elements in the
ratio 1: 2: 4 is
(a) 1, 2 and 3
(b) 1,3 and
d2
(c) 2, 3 and 1
(d) 3, 1 an 2
Page 12 of 240
IES2005
The gating ratio 2: 8: 1 for copper in gating system
d i refers
design
f to
t the
th ratio
ti off areas of:
f
(a) Sprue: Runner: Ingate
(b) Runner: Ingate: Sprue
((c)) Runner: Sprue:
p
Ingate
g
(d) Ingate: Runner: Sprue
Rev.0
GATE2010
Inagatingsystem,theratio1:2:4represents
(a) Sprue basearea:runnerarea:ingate area
(b) Pouringbasinarea:ingate area:runnerarea
(c) Sprue basearea:ingate area:castingarea
(d) Runnerarea:ingate
R
i
area:castingarea
IAS1999
Assertion
off metall through
A
i (A):
(A) The
Th rate off flow
fl
h
h sprue
is NOT a function of the crosssectional areas of
sprue runner and gate.
sprue,
gate
Reason (R): If respective crosssectional areas of
p
, runner and g
gate are in the ratio of 1: 2: 2,, the
sprue,
system is known as unpressurised gating system.
(a) Both A and R are individuallyy true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation
l
i off A
(c) A is true but R is false
(d) A is false
f l but
b R is true
Ri
RisersandRiserDesign
d Ri D i
y Risers are added reservoirs designed to feed liquid
TypesofRisers
Ch i
Chvorinovs
rule
l
IES 1994
IES1994
Assertion (A): In a mould, a riser is designed and placed
so that the riser will solidify after the casting has solidified.
Reason (R): A riser is a reservoir of molten metal which
will supply molten metal where a shrinkage cavity would
have occurred.
(a) Both A and R are individually true and R is the correct
explanation
p
of A
(b) Both A and R are individually true but R is not the
correct explanation
p
of A
(c) A is true but R is false
(d) A is false but R is true
IES2011
The relationship between total freezing time t,
t
volume of the casting V and its surface area A,
g to Chvorinovs rule is :
according
V
(a ) t = k
A
A
(b ) t = k
V
A
(c ) t = k
V
(d ) t = k
y Totalsolidificationtime(ts)=B(V/A) n
wheren=1.5to2.0
[Wh
[Where,B=mouldconstantandisafunctionof(mould
B
ld
di f
i f(
ld
material,castingmaterial,andconditionofcasting]
n=2 andtriser =1.25tcasting
2
or
Forcylinder
ofdiameterD
fdi
D
andheightH
V
V
= 1.25
A
riser
A casting
V = D2H / 4
2
A = DH + 2 D
)
GATE 2013 SameQuestion(PI)
GATE2013
IES 1998
IES1998
A spherical drop of molten metal of radius 2 mm
A cube
solidifies
in
The
b shaped
h
d casting
ti
lidifi
i 5 min.
i
Th
casting, will be
(b) 20 seconds
d
( ) 10
(a)
(b) 20
( ) 24
(c)
(d) 40
(c) 28.30
28 30 seconds
2
Where K is a constant
(d) 4
40 seconds
Page 13 of 240
Rev.0
GATE2014
GATE2014(PI)
GATE2003
(a) onefourth
(b) half
(c) double
IES2006
According
to
Chvorinov's
( ) 539
(a)
riser is ..
GATE 2010(PI)
equation,
the
(a) v2
(b) Directlyy p
proportional
p
to the specific
p
heat of the
radius r are equal. Both the cube and the sphere are solid
and
d off same material.
t i l They
Th are being
b i cast.
t The
Th ratio
ti off the
th
cast material
p
is:
solidification time of the cube to the same of the sphere
(c) 1/v
the
h molten
l
metall
(d) 1/v2
Where, v = volume of casting
(d)Inversely
proportional
to
the
A solid
D and
l d cylinder
l d off diameter
d
d height
h h equall to D, and
d a solid
ld
cube of side L are being sand cast by using the same material.
4 r
6 l
( b )
4 r
6 l
( c )
cube is
(a) (L/D)2
(d) 0.76
GATE2009(PI)
(c) 1.31
4 r
6 l
pouring
((b)) 0.877
(a )
temperature.
(d) 3233
Solidification
off a metallic
S lidifi ti time
ti
t lli alloy
ll casting
ti is
i
(a) Directly proportional to its surface area
(b) v
( ) 4311
(c)
GATE2007
solidification
lidifi ti time
ti
off a casting
ti is
i proportional
ti
l to:
t
((a)) 1.14
4
(b) 1078
8
(b) (2L/D)2
(c) (2D/L)2
(d) (D/L)2
Page 14 of 240
Rev.0
4 r
6 l
( d )
IES 2012
IES
Theratioofsurfaceareaofvolumeforaunitvolumeof
Th ti f f
f l
f it l
f
ConventionalQuestionESE2003
riserisminimumincaseof
cross section,
i
with
i h a major
j to minor
i
axis
i ratio
i off 2, and
d
(a)Cylindricalriser
(b)Sphericalriser
(c)Hemisphericalriser
(d)Cuboidsriser
times
i
off the
h two castings
i
?
Area of ellipse = ab
[ Marks]
[10
M k ]
Ci
Circumference
f
= 3 ( a + b )
= 2
A cylindrical
with
li d i l blind
bli d riser
i
ith diameter
di
t d and
d height
h i ht h,
h is
i
placed on the top of the mold cavity of a closed type
sand
d mold
ld as shown
h
i the
in
th figure.
fi
If the
th riser
i
i off
is
constant volume, then the rate of solidification in the
riser
i is
i the
th least
l t when
h the
th ratio
ti h : d is
i
(a) 1 : 2
(c) 1 : 4
(b) 2 : 1
(d) 4 : 1
(a
( 3a + b )( a + 3b )
+ b2 ) / 2
(approx.)
M d l M th d
ModulusMethod
GATE2014
Sprue basin
[30 Marks]
Mold cavity
D2
4
satisfactory.
f
+ D2
MR = 1.2
1 2 Mc
d
Riser
y It has
empirically
h been
b
i i ll established
t bli h d that
th t if the
th modulus
d l
Q
ConventionalQuestionIES2008
y Calculate the size of a cylindrical riser (height and diameter
C i Method
Caines
M th d
Freezingratio=ratio ofcoolingcharacteristicsofcastingto
theriser.
A
X=
( V)
( AV )
Casting
AccordingtoCaine
Riser
Th i h ld lidif l
Therisershouldsolidifylastsox>1
X=
a
+c
Yb
V
Vcasting
riser
Y=anda,b,careconstant.
Page 15 of 240
Rev.0
Table:ConstantsinCaines Method
Q
Conventional QuestionIES2007
y Calculate the size of a cylindrical riser (height and
IES1995
GATE1998,2007,2014(PI)
improved by using
(d) Smoothen
S
h metall flow
fl for
f reducing
d i splatter.
l
Chills
Chill
g
p
y, highthermal
g
y External chills are masses of highheatcapacity,
conductivity material that are placed in the mould (adjacent to
the casting) to accelerate the cooling of various regions.
Chills can effectively promote directional solidification or
increase the effective feeding distance of a riser. They can often
b used
be
d to reduce
d
the
h number
b off risers
i
required
i d for
f a casting.
i
y Internal chills are pieces of metal that are placed within the
mould cavity to absorb heat and promote more rapid
solidification. Since some of this metal will melt during the
operation,
ope
at o , itt w
will abso
absorb
b not
ot o
onlyy tthee heatcapacity
eat capac ty eenergy,
e gy, but
also some heat of fusion. Since they ultimately become part of
the final casting, internal chills must be made from the same
alloy as that being cast.
IAS1994
Chillsareusedincastingmouldsto
(a) Achievedirectionalsolidification
(b) Reducepossibilityofblowholes
(c) Reducethefreezingtime
(d) Increasethesmoothnessofcastsurface
Cupola
y Cupola has been the most widely used furnace for
IES1997
Assertion (A):
( ) Steell can be
b melted
l d in hot
h blast
bl cupola.
l
Reason (R): In hot blast cupola, the flue gases are used to
preheat the air blast to the cupola so that the temperature in
the furnace is considerably higher than that in a
conventional
i
l cupola.
l
(a) Both A and R are individually true and R is the correct
explanation
l
i off A
(b) Both A and R are individually true but R is not the
correct explanation
l
i off A
(c) A is true but R is false
(d) A is false but R is true
Page 16 of 240
IES 2012
IES
) Cupola
C p
p y
Statement ((I):
furnace is not employed
for
melting steel in foundry
) The temperatures
p
generated within a
g
Statement ((II):
cupola are not adequate for melting Steel
((a)) Both Statement ((I)) and Statement ((II)) are
individually 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
Rev.0
Induction Furnace
y The induction furnaces are used for all types of
materials, the chief advantage being that the heat
source is isolated from the charge and the slag and flux
get the necessary heat directly from the charge instead
of the heat source.
CastingCleaning(fettling)
g
g(
g)
Ladles
y Twotypesofladlesusedinthepouringofcastings.
Pouring time
Pouringtime
GATE2005
Timetakentofillthemouldwithtopgate
Where A=Areaofmould
A.H
tA =
H H i ht f
H=Heightofmould
ld
A g 2gh m
Ag =AreaofGate
Hm =Gateheight
Timetakentofillthemouldwithbottomgate
tB =
(
2g
2A
Ag
hm hm H
Impuritiesinthemoltenmetalarepreventedfromreaching
y yp
g
themouldcavitybyprovidinga
(i) Strainer
(ii) Bottomwell
(iii) Skimbob
Page 17 of 240
GATE1996
Light impurities in the molten metal are prevented
f
from
reaching
hi the
th mould
ld cavity
it by
b providing
idi a
(a) Strainer
(b) Button well
((c)) Skim bob
(d) All of the above
GATE 2006
GATE2006
tB = 2 t A
(B)
tB = 2 t A
((C))
tB =
(D)
tB = 2 2 t A
tA
2
Rev.0
GATE 2007(PI)LinkedS1
2007 (PI) Li k d S 1
GATE
GATE 2007(PI)LinkedS2
2007 (PI) Li k d S 2
GATE
Expressionforchokearea
CA =
m
mm2
ct 2gH
Wherem=massofthecasting,kg
=Densityofmetal,kg/m3
t=pouringtime
p
g
c=Efficiencyfactorandisthefunctionofgate
systemused
y
H=Effectiveheadofliquidmetal
=hfortopgate
Contd
H=h
H h
hm
2
h2
=h c
2hm
IES2009
forbottomgate
f b tt t
IAS2011Main
y 2marks
forpartinglinegate
hC
hm
hm
[
[10Marks]
]
hm
li
t t ti li t b tt t
topgatepartinglinegatebottomgate
IES2013
When an alloy solidifies over a range of
C ti D f t
CastingDefects
G D f t
GasDefects
Thefollowingarethemajordefects,whicharelikelyto
Th f ll i th j d f t hi h lik l t
occurinsandcastings:
g
y Gasdefects
y Shrinkagecavities
( ) Wholly columnar
(b)
y Moldingmaterialdefects
y Pouringmetaldefects
(d) Dendritic
y Moldshift.
M ld hift
Page 18 of 240
Rev.0
Shrinkage Cavities
ShrinkageCavities
y These are caused by liquid shrinkage occurring during the
Scab
y This defect occurs when a portion of the face of a mould
MoldingMaterialDefects
y These
appear as rough
Th
h spots
t and
d areas off excess metal,
t l and
d
y Cutsandwashes,
y Scab
y Metalpenetration,
y Fusion,and
y Swell
S ll
M t l
Metalpenetration
t ti
y When molten metal enters into the gaps between sand
Inclusions
Particles of slag, refractory materials sand or
deoxidation products are trapped in the casting during
pouring solidification.
ldf
The
h provision off choke
h k in the
h
gating system and the pouring basin at the top of the
mold
ld can preventt this
thi defect
d f t
For-2015 (IES, GATE & PSUs)
Fusion
y This is caused by the fusion of the sand grains with
th molten
the
lt metal,
t l giving
i i a brittle,
b ittl glassy
l
appearance
on the casting
g surface.
y The main reason for this is that the clay or the sand
P i M t lD f t
PouringMetalDefects
Swell
Cutandwashes
d
h
Contd
Rev.0
GATE 2014
GATE2014
Match the casting defects (Group A) with the probable
causes (Group B):
GroupA
P: Hot tears
GroupB
1: Improper fusion of two streams of liquid
metal
Q: Shrinkage 2: Low permeability of the sand mould
q
and
R: Blow holes 33: Volumetric contraction both in liquid
solid stage
S: Cold Shut 4: Differential cooling rate
P
(a) 1
(c) 3
Q
3
4
R
2
2
S
4
1
(b)
(d)
P
4
1
Q
3
2
R
2
4
S
1
3
MoldShift
ld h f
The mold shift defect occurs when cope and drag
or molding
ldi boxes
b
h
have
nott been
b
properly
l aligned.
li
d
IES2001
Scabisa
(a) Sandcastingdefect
(b) Machiningdefect
(c) Weldingdefect
(d) Forgingdefect
F i d f
For-2015 (IES, GATE & PSUs)
GATE2004
Misrun is a casting defect which occurs due to
(a) Very high pouring temperature of the metal
(b) Insufficient fluidity of the molten metal
(c) Absorption of gases by the liquid metal
(d) Improper
I
alignment
li
off the
h mould
ld flasks
fl k
GATE2009
Two streams of liquid metal which are not hot
enough
h to
t fuse
f
properly
l result
lt into
i t a casting
ti defect
d f t
known as
(a) Cold shut
(b) Swell
(c) Sand wash
(d) Scab
Metallurgical defects
Metallurgicaldefects
GATE2014
IAS2004
MatchListI(CastingDefects)withListII(Explanation)andselectthecorrect
MatchList I(CastingDefects)withList II(Explanation)andselectthecorrect
answerusingthecodesgivenbelowthelists:
ListI
ListII
(CastingDefects)
(Explanation)
A.Metallicprojections 1.Consistofroundedorroughinternalorexposedcavities
includingblowholesandpinholes
B.Cavities
2.Formedduringmelting,solidificationandmoulding.
C.Inclusions
3.Includessinglefolds,laps,scarsadheringsandlayersand
oxidescale
D.Discontinuities
4.Includecracks,coldorhottearingandcoldshuts
5.Consistoffins,flashormassiveprojectionsandrough
Consistoffins flashormassi eprojectionsandrough
surfaces
Codes:A
B
C
D
A
B
C
D
(a) 1
5
3
2
(b)
1
5
2
4
(c)
5
1
2
4
(d)
5
1
3
2
Page 20 of 240
GATE2003
Hardnessofgreensandmouldincreaseswith
(a) Increaseinmoisturecontentbeyond6percent
y
p
(b) Increaseinpermeability
(c) Decreaseinpermeability
(d) Increaseinbothmoisturecontentand
permeability
bilit
Rev.0
IES1998
Assertion(A):Stiffeningmembers,suchaswebs
A
i (A) S iff i
b
h b
andribs,usedonacastingshouldbeliberally
provided
provided.
Reason(R):Theywillprovideadditionalstrength
toacastmember.
toacastmember
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
Ai f l b tRi t
IES2009
In which one of the following furnaces most of the
nonferrous alloys are melted?
(a) Reverberatory furnace
(b) Induction furnace
(c) Crucible furnace
(d) Pot
P t furnace
f
1 Aluminium,99%ormore
, 99
2 copper
3 Silicon,withcopperand/ormagnesium
3
Silicon withcopperand/ormagnesium
4 silicon
5 magnesium
6 notused
7 zinc
8 tin
8
For-2015 (IES, GATE & PSUs)
9 otherelements
IES2005
In gating system design, which one of the
following is the correct sequence in which choke
area, pouring time, pouring basin and sprue sizes
are calculated?
(a) Chokearea Pouringtime Pouringbasin Sprue
(b) Pouringbasin
ou g bas
Sprue
Sp
ue C
Chokearea
o e a ea Pouringtime
ou g t e
(c) Chokearea Sprue Pouringbasin Pouringtime
(d) Pouringbasin
P i b i Pouringtime
P i ti Chokearea
Ch k
Sprue
S
IES1997
If the melting ratio of a cupola is 10: 1, then the
coke requirement for one ton melt will be
(a) 0.1 ton
(b) 10 tons
(c) 1 ton
(d) 11 tons
t
IAS2001
Whichofthefollowingpatternmaterialsareused
inPrecisionCasting?
1. PlasterofParis
2. Plastics
3. AnodizedAluminium Alloy
4. FrozenMercury
F
M
Selectthecorrectanswerusingthecodesgivenbelow:
(a)1and2(b) 2and4(c)3and4(d)1and3
IAS2004
Whichoneofthefollowinggatingsystemsisbest
suitedtoobtaindirectionalsolidification?
(a) Topgrating
(b) Part
Partlinegrating
linegrating
(c) Bottomgrating
(d) Steppedgrating
St
d ti
C
l i i
C d
CastAluminiumCode
Contd..
y Second two digits identify the aluminium alloy or
IES2011
In the designation of Aluminium casting A514.0
A514 0
indicates :
( ) Aluminium
(a)
Al i i
purity
it
(b) Aluminium content
(c) Percentage of alloy element
(d) Magnesium Content
A
Ans.
(d)
Rev.0
ShellMoulding
y The sand is mixed with a thermosetting resin is
SpecialCasting
BySKMondal
y A good
d surface
f
fi i h and
finish
d good
d size
i
t l
tolerance
MoldingSandinShellMolding
and
d powdered
d d bakelite.
b k li
y Cold coating and Hot coating methods are used for
Shellmouldingprocess
h ll
ldi
Ad t
Advantages
5% bakelite, 3% ethylaldehyde )
Contd
Li it ti
Limitations
y Dimensional
Di
i
l accuracy.
y Expensive pattern
y Very
y thin sections can be cast.
engines
y Automobile transmission parts.
y Piston rings
Applications
Page 22 of 240
Rev.0
IES 2010
IES2010
Considerthefollowingadvantagesofshell
mouldcasting:
1.Closedimensionaltolerance.
Cl di
i
lt l
2.Goodsurfacefinish.
3.Lowcost.
4.Easier.
E i
Whichofthesearecorrect?
(a)1,2and3only (b)2,3and4only
( )
(c)1,2and4only
( )
(d)1,2,3and4
IES2006
Shellmouldingcanbeusedfor:
(a) Producingmillingcutters
g
g
(b) Makinggoldornaments
(c) Producingheavyandthickwalledcasting
(d) Producingthincasting
IES1996
IES2005
Inshellmoulding,howcantheshellthickness
I h ll
ldi h
th h llthi k
beaccuratelymaintained?
( )
(a)Bycontrollingthetimeduringwhichthepattern
isincontactwithmould
(b)Bycontrollingthetimeduringwhichthepattern
isheated
(c)Bymaintainingthetemperatureofthepatternin
therangeof175oC
C 380oC
(d)Bythetypeofbinderused
IES2007
IAS2007
IAS1999
I
t
t C ti
InvestmentCasting
Match
Process)
M t h List
Li t I (Moulding
(M ldi
P
) with
ith List
Li t II (Binding
(Bi di
Agent) and select the correct answer using the codes
given below the lists:
g
List I
List II
A. Green sand
1. Silicate
B. Core sand
2. Organic
C. Shell moulding
3. Clay
D CO2
D.
CO process
4. Plaster
Pl
off Paris
P i
5. Plastic
Codes:A
B
C
D
A
B
C
D
(a) 3
2
5
1
(b) 3
2
4
1
(c) 2
3
5
4
(d) 2
3
4
5
For-2015 (IES, GATE & PSUs)
Page 23 of 240
Rev.0
Fig.Investmentflaskcastingprocedure
CeramicShellInvestmentCasting
IES2009
y 2marks
Advantages
Limitations
Applications
can
be
reduced
or
completely
p
y
eliminated
y Limited size
y Surgical instruments
IES2011
The proper sequence of investment casting steps is :
(a) Slurry coating pattern melt outShakeout Stucco
coating
ti
(b) Stucco coating Slurry coating Shakeout Pattern
melt out
(c) Slurryy coating
g Stucco coating
g Pattern melt out
Shakeout
(d) Stucco coating Shakeout Slurry coating Pattern
melt out
GATE2006
An expendable pattern is used in
( ) Slush
(a)
l h casting
(b) Squeeze casting
(c) Centrifugal casting
(d) Investment casting
GATE2011(PI)
Which of the following casting processes uses
expendable pattern and expendable mould?
(a) Shell mould casting
( ) Investment casting
(b)
(c) Pressure die casting
(d) Centrifugal casting
Page 24 of 240
Rev.0
ISRO2010
Investment casting is used for
(a) Shapes which are made by difficulty using complex
patterns
tt
i sand
in
d casting
ti
(b) Mass production
p
IES1992
Themostpreferredprocessforcastinggasturbine
bladesis:
(a) Diemoulding
(b) Shellmoulding
(c) Investmentmoulding
(d) Sandcasting
S d ti
20 0
JWM2010
g
Considerthefollowingmaterials:
1.Wax
2 Wood
2.Wood
3.Plastic
Whichofthesematerialscanbeusedaspatternin
investmentcastingprocess?
(a)1,2and3
(b)1and2only
(c)2and3only
(d)1and3only
IES 2010
IES2010
( ) The investment casting
g is used for
Assertion (A):
precision parts such as turbine plates, sewing
machines etc.
Reason (R): The investment castings have a good
surface finish and are exact reproductions of the
master pattern.
(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 NOT the
th
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IAS1996
Light and intricate parts with close dimensional
tolerances of the order of 0.005 mm are
produced by
(a) Investment casting
g
(b) Die casting
(c) Centrifugal casting
(d) Shell mould casting
IES 2007
IES2007
Consider the following statements in respect of
investment castings:
1. The pattern or patterns is/are not joined to a stalk or
sprue also of wax to form a tree of patterns.
2.The prepared moulds are placed in an oven and heated
gently to dry off the invest and melt out the bulk of wax.
3.The moulds are usually poured by placing the moulds in
a vacuum chamber. Which of the statements given above
are correct?
(a) 1 and 2 only
(b) 1 and 3 only
(c)2 and 3 onlyy
(d) 1, 2 and 3
IES2006
Which of the following materials are used for
making patterns in investment casting method?
1. Wax
2. Rubber 3. Wood
4. Plastic
Select the correct answer using the codes given below:
(a) Only 1 and 3
(b) Only 2 and 3
( ) Only
(c)
O l 1, 2 and
d4
(d) Only
O l 2, 3 and
d4
PermanentMouldCasting
y The process in which we use a die to make the
Advantages
y Good surface finish and dimensional accuracy
y Metal
M l mold
ld gives
i
rapid
id cooling
li
and
d finegrain
fi
i
structure
y Multipleuse molds.
Rev.0
Disadvantages
y High initial mold cost
y Shape,
Shape size
size, and complexity are limited
y Mold life is very limited with highmeltingpoint
Zinc
Magnesium alloys
Brass
Cast iron
Applications
y Pistons/cylinders/rods
y Gears
y Kitchenware
DieCasting
y Molten metal is injected into closed metal dies under
IES 2013
IES2013
Hotchambermachinesare
y Good for low temperature (approx. 400C)
y Faster than
h cold
ld chamber
h b machines
h
y Hotchamber
y Coldchamber
contamination
y Metal starts in a heated cylinder
y
y A piston forces metal into the die
y The piston retracts,
retracts and draws metal in
y Metal: Lead, Tin, Zinc
Coldchambermachines
y Castshighmeltingpointmetals(>600C)
y Highpressuresused
y Metalisheatedinaseparatecrucible
l h
d
bl
y Metalisladledintoacoldchamber
y Themetalisrapidlyforcedintothemoldbeforeit
cools
For-2015
(IES, GATE & PSUs)
HotChamber
y Copper
Copper,BrassandAluminiumcancast.
BrassandAluminiumcancast
Page 26 of 240
Rev.0
Advantages
y Extremelysmoothsurfaces(1m)
Limitations
y Excellentdimensionalaccuracy
y Highinitialdiecost
y Rapidproductionrate
y Limitedtohighfluiditynonferrousmetals
y Bettermechanicalpropertiescomparedtosand
y Partsizeislimited
y Intricatepartspossible
y Minimumfinishingoperations
y Carburettors
y Automotive
A t
ti parts
t
y Bathroom fixtures
y Toys
y Porositymaybeaproblem
P
it
b
bl
casting
Applications
y Somescrapinsprues,runners,andflash,butthiscan
p
p
,
,
,
bedirectlyrecycled
Common metals
y Alloys
All
off aluminum,
l i
zinc,
i
magnesium,
i
and
d lead
l d
y Also possible with alloys of copper and tin
y Thinsectionspossible
IES2011
Consider the following advantages of die casting over
sand casting :
1 Rapidity of the process
1.
2. Smooth surface
3 Strong dense metal structure
3.
Which of these advantages are correct ?
( ) 1, 2 and
(a)
d3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 onlyy
IES2005
Which one of the following processes produces a
casting when pressure forces the molten metal
into the mould cavity?
(a) Shell moulding
g
(b) Investment casting
g
(c) Die casting
(d) Continuous casting
IES2009
Which of the following are the most suitable
materials for die casting?
(a) Zinc and its alloys
(b) Copper and its alloys
(c) Aluminium and its alloys
(d) Lead
L d and
d its
it alloys
ll
IES2006
In which of the following are metal moulds used?
(a) Greensand mould
(b) Dry sand mould
(c) Die casting process
(d) Loam moulding
Page 27 of 240
20 0
JWM2010
( ) : In die casting
g method,, small
Assertion (A)
thickness can be filled with liquid metal.
Reason (R) : The air in die cavity trapped inside the
casting causes problems.
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot
B hA dR i di id ll
b Ri
the
h
correctexplanationofA
(c) AistruebutRisfalse
((d)) AisfalsebutRistrue
IES1995
Assertion
(A):
alloy
is
A
i
(A) An
A aluminium
l
i i
ll with
i h 11 % silicon
ili
i
used for making engine pistons by die casting
technique.
technique
Reason (R): Aluminium has low density and addition
p
its fluidity
y and therefore its
of silicon improves
castability.
(a) Both A and R are individuallyy true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation
l
i off A
(c) A is true but R is false
(d) A is false
f l but
b R is true
Rev.0
IES1995
MatchListIwithListIIandselectthecorrectanswertakingthehelp
ofcodesgivenbelowthelists:
ListI
ListII
(Products)
(Processofmanufacture)
A.
Automobilepistoninaluminium alloy
1.Pressurediecasting
B.
Enginecrankshaftinspheroidal
graphiteiron
hi i
2.Gravitydiecasting
G i di
i
C.
Carburettor housinginaluminium alloy 3.Sandcasting
D.
Casttitaniumblades
4.Precisioninvestment
casting
i
5.Shellmoulding
Code: A
B
C
D
A
B
C
D
(a) 2
3
1
5
(b)
3
2
1
5
(c) 2
1
3
4
(d)
4
1
2
3
IAS2007
Considerthefollowingstatements:
1. Zincdiecastingshavelowstrength.
g
g
2. Inthediecastingprocess,verythinsectionsor
complexshapescanbeobtainedeasily.
Whichofthestatementsgivenaboveis/arecorrect?
( ) 1only
(a)
l
(b) 2only
(c) Both1and2
((d)) Neither1nor2
IES2011
Consider the following statements :
1. Hot chamber machine is used for casting zinc, tin and
other
th low
l melting
lti alloys.
ll
2. Cold chamber machine is used for die casting of
ferrous alloys
33. Rapid
p
cooling
g rate in die casting
g p
produces high
g
strength and quality in many alloys.
Which of these statements are correct?
(a) 1, 2 and 3
(b) 1 and 2 only
( ) 2 and
(c)
d 3 only
l
(d) 1 and
d 3 only
l
( )
GATE2009(PI)
Hot chamber die casting process is NOT suited for
(a) Lead and its alloy
(b) Zinc and its alloy
( ) Tin
(c)
Ti and
d its
it alloy
ll
((d)) Aluminum and its alloyy
GATE2007
Which of the following engineering materials is
th mostt suitable
the
it bl candidate
did t for
f hot
h t chamber
h b die
di
casting?
( ) Low carbon
(a)
b steell
(b) Titanium
(c) Copper
(d) Tin
Assertion
off good
A
i (A):
(A) Die
Di casting
i yields
i ld a product
d
d
accuracy and finish.
R
Reason
(R) Low
(R):
L
melting
li
alloys
ll
used
d in
i die
di
casting.
( ) Both
(a)
B h A and
d R are individually
i di id ll true and
d R is
i the
h
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
( ) A is
(c)
i true but
b R is
i false
f l
(d) A is false but R is true
IES1995
Assertion
(A):
alloys
are cast in
A
i
(A) Aluminium
Al
i i
ll
i hot
h
chamber die casting machine.
Reason (R): Aluminium alloys require high melting
when compared to zinc alloys.
(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
Centrifugal Casting
CentrifugalCasting
g sand,
y Process: Molten metal is introduced into a rotating
metal, or graphite mould, and held against the mould
wall by centrifugal force until it is solidified
y A mold is set up and rotated along a vertical (rpm is
IAS1996
28 of 240
towards the center ofPage
rotation.
Fi T
Fig.Truecentrifugalcasting
if
l
i
Rev.0
P
Properties
ti
y The mechanical properties of centrifugally cast jobs are
l
Commonmetals
y
y
y
y
Iron
steel
stainlesssteel
t i l t l
alloysofaluminium,copper,andnickel
( )
GATE2008(PI)
In hollow cylindrical parts, made by centrifugal casting,
the density of the part is
( ) maximum
(a)
i
at the
h outer region
i
(b) maximum at the inner region
((c)) maximum at the midpoint
p
between outer and inner
surfaces
(d) uniform throughout
For-2015 (IES, GATE & PSUs)
Li it ti
Limitations
Advantages
y Fine
att the
off the
Fi grained
i d structure
t t
th outer
t surface
f
th
metallic
lli inclusions
i l i
y Inaccurate internal diameter
y Shape is limited.
y Spinning equipment can be expensive
y Poor machinability
GATE1993
GATE2002
In centrifugal casting, the impurities are
( ) Uniformly
(a)
f
l distributed
d
b d
(b) Forced towards the outer surface
(c) Trapped near the mean radius of the casting
(d) Collected at the centre of the casting
IES2008
Which of the following casting processes does not
/do not require central core for producing pipe?
1 Sand casting process
1.
2. Die casting process
3 Centrifugal casting process
3.
Select the correct answer using the code given below:
( ) 1 and
(a)
d2
(b) 2 only
(c) 2 and 3
(d) 3 onlyy
Page 29 of 240
IES2009
Which one of the following casting processes is
b t
best
suited
it d
t
to
make
k
bi
bigger
size
i
symmetrical
y
pipes?
p
p
(a) Die casting
(b) Investment casting
(c) Shell moulding
(d) Centrifugal casting
Rev.0
h ll
hollow
IES2007
Which one of the following is the correct
statement?
In a centrifugal casting method
(a) No core is used
(b) Core may be made of any metal
( ) Core
(c)
C
i made
is
d off sand
d
(d) Core is made of ferrous metal
IES2007
MatchListIwithListIIandselectthecorrectanswerusingthecodegiven
belowtheLists:
ListI
ListII
(CastingProcess)
(Principle)
A.
Diecasting
1.Themetalsolidifiesinarotatingmould
B.
Investmentcasting
2.Thepatternclusterisrepeatedlydipped
intoaceramicslurryanddustedwith
refractory
f
C.
Shellmoulding
3.Moltenmetalisforcedbypressureinto
ametallicmould
D
D.
Centrifugalcasting
4 Aftercooling theinvestisremoved
4.Aftercooling,theinvestisremoved
fromthe Castingbypressurejettingor
vibratorycleaning
Code: A
B
C
D
A
B
C
D
(a) 2
1
3
4
(b)
3
4
2
1
(c) 2
4
3
1
(c)
3
1
2
4
IES1998
Poormachinability ofcentrifugallycastironpipe
isdueto
(a) Chilling
(b) Segregation
(c) Densestructure
(d) Highmouldrotationspeed
Hi h
ld t ti
d
MatchListI(Process)withListII(Products/materials)
M t hLi tI(P
) ithLi tII(P d t / t i l )
andselectthecorrectanswerusingthecodesgiven
belowtheLists:
ListI
ListII
A. Diecasting
1.Phenolformaldehyde
B. Shellmolding
2.C.I.pipes
C. CO2 molding
3.Nonferrousalloys
D Centrifugalcasting
D.
C
if
l
i
4.Sodiumsilicate
S di ili
Codes:A
B
C
D
A
B
C
D
(a) 1
3
4
2
(b) 3
1
4
2
(c) 3
1
2
4
(d) 1
3
2
4
IAS2004
MatchListI(NameoftheProcess)withListII(Advantage)andselectthecorrect
answerusingthecodesgivenbelowthelists:
List I
ListI
List II
ListII
(NameoftheProcess)
(Advantage)
A.
SandCasting
1.Largecylindricalpartswithgoodquality
B
B.
C
Ceramicmoldcasting
i ld ti
2.Excellentdimensionalaccuracyandsurface
E ll tdi
i
l
d f
finish
C.
Diecasting
3.Intricateshapesandclosetoleranceparts
D
D.
C
Centrifugalcasting
if
l
i
4.Almostanymetaliscastandthereifnolimitto
Al
li
d h if li i
size,shapeandweight
5.Gooddimensionalaccuracy,finishandlow
porosity
Codes:A
B
C
D
A
B
C
(a)
2
3
5
1
(b)
4
1
2
D
3
(c)
(d)
IAS2003
Assertion
(A):
Semicentrifugal
process is
A
i
(A) S
i
if
l casting
i
i
similar to true centrifugal casting except that the
central core is used in it to form inner surface.
surface
Reason (R): In semicentrifugal casting process the
p is always
y vertical
axis of spin
(a) Both A and R are individually true and R is the correct
p
of A
explanation
(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
central
t l reservoir
i to
t the
th extremities
t
iti
off a rotating
t ti
symmetrical
y
mold,, which mayy be either expendable
p
or
multipleuse
y Rotational speeds are lower than for true centrifugal
casting
product.
IES2000
SemicentrifugalCasting
IES2009
Page 30 of 240
Fig. Semicentrifugalcasting
Rev.0
IES2013
Centrifuging
y Uses centrifuging action to force the metal from a central
trees.
Fig.Methodofcastingbythecentrifugingprocess
IES2000
MatchListI(Typeofcasting)withListII(Workingprinciples)
M t hLi tI(T
f ti ) ithLi tII(W ki i i l )
andselectthecorrectanswerusingthecodesgivenbelowthe
Lists:
Li tI
ListI
Li tII
ListII
A. Diecasting
1.Moltenmetalisforcedintothedie
underpressure
B. Centrifugalcasting
2.Axisofrotationdoesnotcoincidewith
axisofmould
C. Centrifuging
g g
33.Metalsolidifieswhenmouldisrotating
g
D. Continuouscasting 4.Continuouslypouringmoltenmetal
intomould
Codes: A
B
C
D
A
B
C
D
(a) 1
3
2
4
(b)
4
3
2
1
(c) 1
2
3
4
(d)
4
2
3
1
IAS2004
Which of the following are produced by slush
casting?
(a) Hollow castings with thick walls
(b) Hollow castings with thin walls
(c) Thin castings
(d) Thick
Thi k castings
ti
DrySandMolding
SlushCasting
Types:
1 Skin drying and
1.Skin
2.Complete mold drying
IES2011
The method of casting for producing ornamental pieces
are:
( ) Slush
(a)
Sl h and
d gravity
it casting
ti
(b) Pressed and slush casting
(c) Gravity and semi permanent mould casting
(d) Semi permanent mould and pressed casting
Page 31 of 240
IES 2012
IES
The process of making hollow castings of non
circular
noncircular
shape and desired thickness by permanent mould
without the use of cores is known as
(a) Die casting
(b) Slush casting
( ) Pressed
(c)
P
d casting
ti
(d) Centrifugal
C t if
l casting
ti
Rev.0
SqueezeCasting
IAS2002
Si l C
SingleCrystalCasting
lC i
Process:
1. Molten metal is p
poured into an open
p face die.
2. A punch is advanced into the die, and to the metal.
3 Pressure (less than forging) is applied to the punch
3.Pressure
and die while the part solidifies.
4.The
Th punch
h is
i retracted,
t t d and
d the
th partt is
i knocked
k
k d outt
with an ejector pin.
y Overcomes problems
bl
with
h feeding
f d
the
h die,
d
and
d
produces near net, highly detailed parts.
MatchListI(CastingProcess)withListII
M t hLi tI(C ti P
) ithLi tII
(Applications)andselectthecorrectanswerusingthe
codesgivenbelowtheLists:
g
ListI
ListII
(CastingProcess)
(Applications)
A. Centrifugalcasting
1.
Carburetor
B. Squeezecasting
2.
Pipes
C DieCasting
C.
Di C i
3.
Wh l f
Wheelsfor
automobiles
4
4.
Gearhousings
Codes:A
B
C
A
B
C
(a) 2
3
1
(b) 4
1
3
(c) 2
1
3
(d) 4
3
1
IES2009
l
i
PlasterCasting
y Process: A slurry of plaster,
plaster water,
water and various additives is
y Creepandthermalshockresistanceproperties.
2marks
PitMoulding
IES1996
Whichofthefollowingpairsarecorrectlymatched?
1. Pitmoulding
g ..................Forlargejobs.
g j
2. Investmentmoulding ...Lostwaxprocess.
3 PlastermouldingMouldpreparedin
3.
Plastermoulding
Mouldpreparedin
gypsum.
( ) 1,2and3
(a)
d
(b) 1and2
d
(c) 1and3
(d) 2and3
LoamMoulding
y Moulding
g loam is g
generallyy artificiallyy composed
p
of
Page 32 of 240
Rev.0
IES1997
Which one of the following pairs is not correctly
matched?
(a) Aluminium alloy piston Pressure die casting
(b) Jewellery.. Lost wax process
(c) Large pipes ..Centrifugal casting
(d) Large
L
b ll Loam
bells
L
moulding
ldi
GATE1998
ListI
Li tI
(A) Sandcasting
circularshapesonly
(B) Plastermouldcasting
skinsandsoftinterior
(C) Shellmouldcasting
castingprocessing
(D) Investmentcasting
ListII
Li tII
(1)
Symmetricaland
(2)
Partshavehardened
(3)
Minimumpost
(4)
Partshaveatendency
towarp
Partshavesoftskin
andhardinterior
Suitableonlyfornon
f
ferrousmetals
t l
(5)
(6)
GATE1996
IES2003
ListI
ListII
(A) Rivetsforaircraftbody
y 1.
Forging
g g
(B) Carburettor body
2.
Coldheading
(C) Crankshafts
3
3.
Aluminiumbased
alloy
(D) Nails
N il
4.
P
Pressurediecasting
di ti
5.
Investmentcasting
MatchListI(Products)withListII(CastingProcess)andselect
M t hLi tI(P d t ) ithLi tII(C ti P
) d l t
thecorrectanswerusingthecodesgivenbelowtheLists:
ListI
ListII
(Products)
(CastingProcess)
A. Hollowstatues
1.
CentrifugalCasting
B
B.
Dentures
2
2.
InvestmentCasting
C. Aluminium alloypistons
3.
SlushCasting
D. Rockerarms
4.
ShellMoulding
5.
G i Di C i
GravityDieCasting
Codes: A
B
C
D
A
B
C
D
((a)
) 33
2
4
4
5
((b)
)
1
33
4
4
5
(c) 1
2
3
4
(d)
3
2
5
4
IAS2004
GATE 2007(PI)
2007 (PI)
GATE
MatchListI(NameoftheCastingProcess)withListII(ProcessDefinition)andselect
M hLi I(N
f h C i P
) i hLi II(P
D fi i i ) d l
thecorrectanswerusingthecodesgivenbelowthelists:
ListI
ListII
(NameoftheCastin Process)
(NameoftheCastingProcess)
(ProcessDefinition)
A.
Diecasting
1.Thisprocessinvolvesuseofamouldmadeof
Driedsilicasandandphenolic resinmixture
B
B.
El t l casting
Electroslag
ti
2.Inthisprocess,moltenmetalisforcedby
I thi
lt t li f
db
Pressureintoametalmould
C.
Centrifugalcasting
3.Thisprocessemploysaconsumableelectrode
D
D.
P i i
Precisioncasting
i
4.Thisprocessinvolvesrotatingamouldwhilethe
Thi
i
l
i
ld hil h
metalsolidifies
5.Thisprocessproducesverysmooth,highly
Accuratecastingsfrombothferrousandnon
ferrousalloys
Codes:A
B
C
D
A
B
C
D
(a)
5
4
1
2
(b)
2
3
4
5
(c)
5
3
4
2
(d)
2
4
1
5
GATE1992
Matchthefollowingmoulding/castingprocesseswith
M h h f ll i
ldi /
i
i h
theproduct:
Moulding/Castingprocesses
Product
(A) Slushcasting
(P)Turbineblade
(B) Shellmoulding
(Q)Machinetoolbed
(C) Drysandmoulding
(R)Cylinderblock
(D) Centrifugalcasting
C t if
l ti
(S)H ll ti
(S)Hollowcastings
likelampshades
(T)Rainwaterpipe
(U)Castironshoe
brake
IES1993
MatchtheitemsofListI(Equipment)withtheitems
M h h i
fLi I(E i
) i h h i
ofListII(Process)andselectthecorrectanswerusing
thegivencodes.
thegivencodes
ListI(Equipment)
ListII(Process)
P HotChamberMachine 1.
1
Cleaning
Q Muller
2.
Coremaking
R DielectricBaker
3
3.
Diecasting
S SandBlaster
4.
Annealing
5
5.
Sandmixing
(a) P2,Q1,R4,S5
(b) P4,Q2,R3,S5
(c) P4,Q5,R1,S2
P 4 Q 5 R 1 S 2
(d) P3,Q5,R2,S1
P 3 Q 5 R 2 S 1
Group1
P.SandCasting
Q CentrifugalCasting
Q.CentrifugalCasting
R.InvestmentCasting
S.DieCasting
Group2
1.Turbineblades
2 ICEnginePistons
2.ICEnginePistons
3.Largebells
4.Pulleys
(a) P 4, Q 1, R 3, S 2
((c)) P 3, Q 4, R 1,, S 2
(b) P 2, Q 4, R 3, S 1
( ) P 3, Q 2,, R 1,, S 4
(d)
Page 33 of 240
BySKMondal
Rev.0
WeldingDefinition
y Welding is a process by which two materials, usually
Cl ifi ti
Classificationofweldingprocesses
f ldi
Requirementforahighqualitywelding
Resistance welding
Solid
l d state welding
ld
(f
(friction
welding,
ld
ultrasonic
l
welding,
ld
y Unique process
metallurgical
g
effects.
Thermit welding
g
Laser beam welding
Electroslag
g welding
g
Flash welding
Induction welding
IES 2012
IES
Weldability /FabricationProcesses
CaseofAluminium
y The
Th weldability
ld bilit off a material
t i l will
ill depend
d
d on the
th
y The
on aluminum
alloys
causes some
Th oxide
id coating
ti
l i
ll
y
y
y
y
CaseofCastIron
CaseofStainlessSteel
CaseofStainlessSteel
Contd..
y Welding process:
IES 2010
IES2010
( ) It is generally
g
y difficult to weld
Assertion (A):
Aluminum parts by normal arc welding process.
Reason (R): Hard and brittle Aluminum
Aluminumoxide
oxide film
is formed at the welded joints.
(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
IES2011
During plasma arc welding of aluminium,
aluminium improved
removal of the surface oxide from the base metal is
obtained with typical polarity of :
(a) DC Straight
(b) DC reverse
(c) AC potential
p
(d) Reverse polarity of phase of AC potential
IES1999
Thecorrectsequenceofthegivenmaterialsin
g
is
ascendingorderoftheirweldability
(a) MS,copper,castiron,aluminium
(b) Castiron,MS,aluminium
Castiron MS aluminium copper
(c) Copper,castiron,MS,aluminium
(d) Aluminium,copper,castiron,MS
Al i i
i
S
IES2006
Assertion(A):Aluminium
haspoorweldability.
( )
Reason(R):Aluminium hashighthermal
g
conductivityandhighaffinitytooxygen.
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
( ) AistruebutRisfalse
(c)
Ai t b tRi f l
(d) AisfalsebutRistrue
IES2011
Considerthefollowingstatements.
Considerthefollowingstatements
Castironisdifficulttoweld,becauseof
1.Lowductility
L d tilit
2.Poorfusion
3.Tendencytocrackoncooling
Whichofthesestatementsarecorrect?
(a)1,2and3
(b)1and2only
(c)2and3only
(d)1and3only
IES 2010
IES2010
Weldability of ferritic stainless steel used in
automotive exhaust system is improved by
selecting stainless steel electrode having low
content of
(a) Carbon
(b) Nitrogen
(c) Chromium
(d) Carbon and Nitrogen
Page 35 of 240
GATE2014
The major difficulty during welding of aluminium is
due to its
(a) high tendency of oxidation
(b) high thermal conductivity
(c) low melting point
(d) low
l density
d it
IES2006
Fabricationweldability testisusedtodetermine
(a) Mechanicalpropertiesrequiredforsatisfactory
ec a ca p ope t es equ ed o sat s acto y
performanceofweldedjoint
(b) Susceptibilityofweldedjointforcracking
(c) Suitabilityforjointdesign
(d) Appropriatemachiningprocess
A
i
hi i
IES 2010
IES2010
g statements regarding
g
g
Consider the following
welded joints:
1 It is a permanent type of joint.
1.
joint
2. It is reliable and economical for pressure vessel
construction.
construction
3. It is free from fabricational residual stresses.
4. Such joints are suitable for static loading only.
55. Welding
g is a versatile and flexible metal jjoining
gp
process.
Which of the above statements are correct?
(a) 1,
1 2 and 3 only
(b) 2,
2 3 and 4 only
Rev.0
(c) 1, 2, 3, 4 and 5
(d) 1, 2 and 5 only
IES 2012
IES
Whichofthefollowingfactorsimproveweldabilityof
steel?
1 Lowcarboncontent
1.Lowcarboncontent
2.Highcarboncontent
3.Goodaffinitycontent
4
4.Pooraffinitytooxygen
y
yg
(a)1and3
(b)2and3
(c)1and4
(d)2and4
IES 2013
IES2013
Weldability dependson
GasFlameProcesses:
Welding Cutting and Straightening
Welding,CuttingandStraightening
y Oxyfuel gas Welding (OFW): Heat source is the
1.Thermalconductivityy
flame produced
fl
d d by
b the
h combustion
b i off a fuel
f l gas and
d
oxygen.
2.Surfacecondition
3.Changeinmicrostructure
(a)1and2only
(b)1and3only
(c)2and3only
(d)1,2and3
y Combustionofoxygenandacetylene(C2H2)ina
weldingtorchproducesatemp.inatwostagereaction.
y Inthefirststage
C2 H2 + O2 2CO + H2
+Heat
H t
Thisreactionoccursnearthetipofthetorch.
y InthesecondstagecombustionoftheCOandH2 and
occursjustbeyondthefirstcombustionzone.
2CO+O2 2CO2+Heat
1
H2 +O
2 2 H2O+Heat
Oxygenforsecondaryreactionsisobtainedfromthe
atmosphere
atmosphere.
Oxyacetylenegasweldingneutralflame
flame,
flame hotter than the neutral flame (about 3300oC)
but similar in appearance.
y Used when
hen welding
elding copper and copper alloys
allo s but
harmful when welding steel because the excess oxygen
reacts with the carbon,
carbon decarburizing the region
around the weld.
OxyacetylenegasweldingOxidisingflame
For-2015 (IES, GATE & PSUs)
Page 36 of 240
OxyacetylenegasweldingCarburizingflame
Metal
MS
High carbon steel
Grey cast iron
Alloy steel
Aluminium
Brass
Copper, Bronze
Nickel alloys
y
Lead
Flame
N
R
N, slightly oxidizing
N
Slightly carburizing
Slightly oxidizing
N, slightly oxidizing
Slightly
g y carburizing
g
N
Rev.0
U
Uses,Advantages,andLimitations
Ad t
d Li it ti
y OFW is fusion welding.
welding
Diagram
y No pressure is involved.
y Filler
Fill metal
t l can be
b added
dd d in
i the
th form
f
off a wire
i or rod.
d
prevent contamination.
contamination
Contd
Oxyacetyleneweldingequipment
y Oxygen is stored in a cylinder at a pressure ranging
PressureGasWeldingg
y Pressure gas welding (PGW) or Oxyacetylene
IES 2010
IES2010
The ratio between Oxygen and Acetylene
gases for neutral flame in gas welding is
( )2:1
(a)
(b) 1 : 2
((c)) 1 : 1
((d)) 4 : 1
CaC2 + 2 H 2O C2 H 2 + Ca (OH ) 2
GATE1994
The ratio of
acetylene to
oxygen
is
approximately
approximately.
for a neutral flames used in
gas welding.
( ) 1:1
(a)
(b) 1 : 2
(c) 1 : 3
(d) 1.5
15:1
GATE2003
InOxyacetylenegaswelding,temperatureatthe
innerconeoftheflameisaround
(a) 3500C
(b) 3200
3200C
C
(c) 2900C
(d) 2550C
C
Page 37 of 240
IES 2010
IES2010
) Oxidizing
g flame is used in gas
g
Assertion ((A):
welding to join medium carbon steels having high
gp
point.
melting
Reason (R): In gas welding, oxidizing flame
produces the maximum temperature compared to
neutral and reducing flame.
(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 NOT the
th
correct explanation of A
(c) A is true but R is false
Rev.0
(d) A is false but R is true
IES2009
GATE2002
The temperature of a carburising flame in gas
welding is that of a neutral or an oxidising flame.
(a) Lowerthan
(b) Higherthan
(c) Equalto
(d) Unrelatedto
U l t dt
IAS1994
IES1998
IES 2012
IES
IAS1995
OxygenTorchCutting(GasCutting)
y Iron and steel oxidize (burn)
(
) when heated to a
Assertion (A):
( ) If neutral flame is used in oxy
acetylene welding, both oxygen and acetylene
cylinders of same capacity will be emptied at the same
time.
Reason (R): Neutral flame uses equal amounts of
oxygen and
d acetylene.
l
(a) BothAandRareindividuallytrueandRisthecorrect
explanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
Contd
) In g
g the metal to be jjoined g
Statement ((I):
gas welding
gets
oxidized or carburized
) The neutral flame affects no chemical
Statement ((II):
change on the molten metal.
((a)) Both Statement ((I)) and Statement ((II)) are
individually 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
oxygen consumed.
y At kindling temperature (about 870oC), iron form iron
oxide.
oxide
y Reaction:
3Fe + 2O2 Fe3O4 +6.67
+6 67 MJ/kg of iron
The other reactions:
2Fe + O2 2FeO + 3.18 MJ/kg
k off iron
4Fe + 3O2 2Fe2O3 + 4.9 MJ/kg of iron
y All exothermic reactions preheat the steel.
Fig differencesintorchtipsforgasweldingandgascutting
Page 38 of 240
Contd
Rev.0
Contd
required
i d
y Due to unoxidized metal blown away the actual
requirement is much less.
y Torch tip
p held verticallyy or slightly
g y inclined in the
direction of travel.
y Torch position is about 1.5
1 5 to 3 mm vertical from plate.
plate
y Drag
g is the amount byy which the lower edge
g of the drag
g
Contd
Contd
Application
IAS2011Main
and
d the
th oxides
id have
h
l
lower
melting
lti
points
i t than
th
th
the
metals.
y Widely used for ferrous materials.
y Cannot be used for aluminum, bronze, stainless steel
Difficulties
y Metal
y Steels
St l with
ith less
l
th 0.3 % carbon
than
b
cause no problem.
bl
IES1992
The edge of a steel plate cut by oxygen cutting will
get hardened when the carbon content is
g
(a) Less than 0.1 percent
(b) Less than 0.3
0 3 percent
(c) More than 0.3 percent
(d) Anywhere
A
h
b
between
0.1 to 1.0 percent
Contd
Page 39 of 240
Rev.0
IES2007
Considerthefollowingstatementsinrespectofoxy
acetylenewelding:
1
1.
Thejointisnotheatedtoastateoffusion
Thejointisnotheatedtoastateoffusion.
2. Nopressureisused.
3 Oxygenisstoredinsteelcylinderatapressureof14
3.
MPa.
4. Whenthereisanexcessofacetyleneused,thereisa
d id d h
decidedchangeintheappearance
i h
offlame.
Whichofthestatementsgivenabovearecorrect?
(a)1,2and3
(b) 2,3and4
(c) 1,3and4
1 3and4
(d) 1,2and4
1 2and4
IES2005
Considerthefollowingstatements:
Ingaswelding,thetorchshouldbeheldatanangleof
30 to45 fromthehorizontalplane.
f
h h
l l
2. Ingaswelding,theSizeofthetorchdependsuponthe
thi k
thicknessofmetaltobeformed.
f t lt b f
d
3. Dragingascuttingisthetimedifferencebetween
heatingoftheplateandstartingtheoxygengasfor
cutting.
1.
Whichofthestatementsgivenabovearecorrect?
(a) 1,2and3 (b) 1and2
(c) 2and3
(d) 1and3
IES2001
Oxyacetylenereducingflameisusedwhile
g
g
carryingouttheweldingon
(a) Mildsteel
(b) Highcarbonsteel
(c) Greycastiron
(d) Alloysteels
IES1992
Thick steel plate cut with oxygen normally shows
g of cracking.
g This tendency for cracking
g can
signs
be minimised by
((a)) Slow speed
p
cutting
g
(b) Cutting in two or more stages
(c) Preheating the plate
(d) Using oxyacetylene flame
d C i
PowderCutting
( )
GATE2009(PI)
El t i A W ldi
ElectricArcWelding
Pl
C tti
PlasmaCutting
p
y Uses ionized g
gas jjet (plasma)
to cut materials resistant to
y
y
y
y
y
oxyfuel cutting,
High
g velocityy electrons g
generated byy the arc impact
p
gas
g
molecules, and ionize them.
The ionized g
gas is forced through
g nozzle ((upto
p 5500 m/s),
/ ), and
the jet heats the metal, and blasts the molten metal away.
More economical,, more versatile and much faster (5 to 8
times) than oxyfuel cutting, produces narrow kerfs and
smooth surfaces.
HAZ is 1/3 to th than oxyfuel cutting.
Maximum plate thickness = 200 mm
For-2015 (IES, GATE & PSUs)
ElectricArcWelding
Fi B i i
Fig.Basiccircuitforarcwelding
i f ldi
Page 40 of 240
Rev.0
PrincipleofArc
ISRO2011
th are touched
they
t
h d to
t establish
t bli h the
th flow
fl
off currentt and
d
then separated
p
byy a small distance.
polarity (RPDC).
Inarcwelding,penetrationisminimumfor
g p
(b)DCRP
(a)DCSP
(c)AC
(d)DCEN
(SPDC).
(SPDC)
Contd
Contd
Threemodesofmetaltransferduringarcwelding
electrodes
MajorForcestakepartinMetalTransfer
(i)gravityforce
(i)
it f
(ii)Surfacetension
machines
machines.
y Non consumable electrodes (e.g tungsten) is not
consumed
d by
b the
h arc and
d a separate metall wire is used
d
as filler.
y There are three modes of metal transfer (globular,
spray and shortcircuit).
20 0
JWM2010
Assertion
(A) : Bead
A
ti
B d is
i the
th metal
t l added
dd d during
d i
single pass of welding.
Reason (R)
( ) : Bead material is same as base metal.
(a) Both A and R are individuallyy 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
For-2015 (IES, GATE & PSUs)
(iii)electromagneticinteraction
g
(iv)hydrodynamicactionofplasma
GATE1993
Ind.c.welding,thestraightpolarity(electrode
(
negative)resultsin
(a) Lowerpenetration
(b) Lowerdepositionrate
(c) Lessheatingofworkpiece
(d) Smallerweldpool
S ll ld
l
Page 41 of 240
Arcweldingequipments
1. Droopers: Constant current welding machines
Good for manual welding
g
Rev.0
Contd
Formula
q
g current ((150
5 to 1000 A),
), voltage
g is
y Requires
a large
between 30 and 40 V, actual voltage across the arc
varying from 12 to 30 V.
y To initiate a weld,
ld the
h operator strike
k the
h electrode
l
d and
d
Fig.Machinewithdifferentsettings
start arc.
V
I
+
=1
OCV SCC
Fig.Characteristiccurveofaconstantvoltagearcweldingmachine
IES 2010
IES2010
In arc welding, the arc length should be equal to
(a) 4.5 times the rod diameter
(b) 3 times
ti
th rod
the
d diameter
di
t
(c) 1.5 times the rod diameter
(d) Rod diameter
IES2001
Inarcwelding,d.c.reversepolarityisusedtobear
g
greateradvantagein
g
(a) Overheadwelding
(b) Flatweldingoflapjoints
(c) Edgewelding
(d) Flatweldingofbuttjoints
l ldi fb j i
IES2005
Considerthefollowingstatements:
IES2001
Inarcwelding,65%to75%heatisgeneratedatthe
anode.
2. Dutycycleincaseofarcweldingisthecycleof
completeweldingofworkpiecefromthe
beginning.
3 ArcblowismorecommonwithDCwelding.
3.
ArcblowismorecommonwithDCwelding
Inmanualarcwelding,theequipmentshould
Whichofthestatementsgivenaboveare
correct?
(a) 1,2and3 (b) 1and2
(c) 2and3 (d) 1and3
(c) Temperatureintheareconstant
1.
IES1998
The voltagecurrent characteristics of a dc
generator for arc welding
g
g is a straight
g
line
between an opencircuit voltage of 80 V and short
circuit current of 300 A. The generator settings for
maximum arc power will be
((a)) 0 V and 150
5 A
((b)) 4
40 V and 3300 A
(c) 40 V and 150 A
(d) 80 V and 300 A
Page 42 of 240
havedroopingcharacteristicsinordertomaintain
(a) Voltageconstantwhenarclengthchanges
(b) Currentconstantwhenarclengthchanges
(d) Weldpoolredhot
IAS1999
Opencircuit voltage of 60 V and current of 160A
were the welding
g conditions for arc welding
g of a
certain class of steel strip of thickness 10 mm. For
arc welding of 5mm thick strip of the same steel,
the welding voltage and current would be
((a)) 60 V and 80 A
(b) 120 V and 160 A
(c) 60 V and 40 A
(d) 120 V and 40 A
Rev.0
IAS1998
AssumingastraightlineVIcharacteristicsfora
gg
dcweldinggenerator,shortcircuitcurrentas400A
andopencircuitvoltageas400whichoneofthe
followingisthecorrectvoltageandcurrentsetting
formaximumarcpower?
((a)) 4
400Aand100V
((b)) 200Aand200V
(c) 400Aand50V
(d) 200Aand50V
GATE1992
A low carbon steel plate is to be welded by the manual
metal arc welding process using a linear V I
characteristic DC Power source. The following data are
available :
OCV of Power source = 62 V
Short
S
o t ccircuit
cu t cu
current
e t = 130
30 A
Arc length, L = 4 mm
T
Traverse
speed
d off welding
ldi = 15 cm/s
/
Efficiency of heat input = 85%
Voltage is given as V = 20 + 1.5 L
Calculate the heat input into the workprice
GATE2012SameQinGATE2012(PI)
In
operation,
the
I a DC arc welding
ldi
ti
th voltagearc
lt
length characteristic was obtained as Varc = 20 + 5L
where
h
th arc length
the
l
th L was varied
i d between
b t
5 mm
and 7 mm. Here Varc denotes the arc voltage in Volts.
Th arc currentt was varied
The
i d from
f
400 A to
t 500 A.
A
Assuming linear power source characteristic, the
open circuit
i
it voltage
lt
and
d the
th short
h t circuit
i
it currentt for
f
the welding operation are
( ) 45 V, 450 A
(a)
(b) 75 V, 750 A
(c) 95 V, 950 A
(d) 150 V, 1500 A
DutyCycle
y The percentage of time in a 5 min period that a
of tthe
o
ee
electrode
ect ode iss 4 mm/s,
/s, tthe
e ccrosssectional
oss sect o a a
area,
ea,
in mm2, of the weld joint is _______
Where,T=rateddutycycle
I=ratedcurrentattherateddutycycle
Io =Maximumcurrentattherateddutycycle
3. If the
to melt
l the
h electrode
l
d is
i 20 J/mm
J/
h travell speed
d
IFS2011
I
Requireddutycycle,Ta = T
Ia
GATE 2007(PI)
2007 (PI)
GATE
Page 43 of 240
Contd
Electrode
1. NonconsumableElectrodes
2. ConsumableElectrodes
NonconsumableElectrodes
Madeofcarbon,GraphiteorTungsten.
CarbonandGraphiteareusedforD.C.
b
d
h
df
Electrodeisnotconsumed,thearclengthremains
constant,arcisstableandeasytomaintain.
Rev.0
Contd
ConsumableElectrodes
Provides
P id filler
fill materials.
t i l
Same composition.
This requires that the electrode be moved toward or
away from the work to maintain the arc and
satisfactory welding conditions.
Electrodecoatingcharacteristic
1. Provide a protective atmosphere.
2. Stabilize the arc.
3. Provide a protective slag coating to accumulate
4
4.
5.
6.
7.
8.
Contd
Electrodecoatings
GATE1994
Theelectrodesusedinarcweldingarecoated.
Thiscoatingisnotexpectedto
(a) Provideprotectiveatmospheretoweld
(b) Stabilizetheare
(c) Addalloyingelements
(d) Preventselectrodefromcontamination
P
t l t d f
t i ti
3.DeoxidizingIngredients. Cellulose,Calcium
carbonate,dolo
carbonate,dolo mite,starch,dextrin,woodflour,
graphite,aluminium,ferromanganese.
4.BindingMaterials Sodiumsilicate,potassiumsilicate,
asbestos.
5.AlloyingConstituentstoImproveStrengthofWeld
6.TiO2 andpotassiumcompoundsincreasethemelting
p
p
g
rateofthebasemetalforbetterpenetration.
7.Ironpowderprovideshigherdepositionrate.
Contd
Contd
i d
Binders
y AC arc welding
used
binders.
ld
d potassium silicate
l
b d
y Coatings are designed to melt more slowly than the
f ll wire.
filler
with sodium.
Contd
Page 44 of 240
Rev.0
IES2007
The coating material of an arc welding electrode
g
contains which of the following?
1. Deoxidising agent
2 Arc stabilizing agent
2.
3. Slag forming agent
S l
Select
the
h correct answer using
i the
h code
d given
i
b l
below:
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only
WeldingFlux
Availableinthreeforms
y Granular
y Electrodewirecoating
y Electrodecore
Welding Positions
WeldingPositions
IES1997
Assertion (A):
( ) The electrodes of ac arc welding are
coated with sodium silicate, whereas electrodes used
for dc arc welding are coated with potassium silicate
binders.
Reason (R): Potassium has a lower ionization
potential
i l than
h sodium.
di
(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
Fig.Positioningofelectrodeforweldinginverticallyupwardposition
MatchListIwithListIIandselectthecorrectanswer:
ListI(Ingredients)
ListII(Welding
f
functions)
i
)
A. Silica
1.
Arc stabilizer
B. Potassium
i
oxalate
l
2.
Deoxidizer
idi
C. Ferrosilicon
3.
Fluxingagent
D. Cellulose
4.
Gasformingmaterial
Codes:A
B
C
D
A
B
C
D
(a) 3
4
2
1
(b) 2
1
3
4
(c) 3
1
2
4
(d) 2
4
3
1
y g
LowHydrogenElectrode
y The basic coatings contain large amount of
IFS2011
Whatismeantbylowhydrogenelectrode?
calcium
l i
carbonate
b
t (limestone)
(li
t
) and
d calcium
l i
fluoride (fluorspar) and produce low hydrogen.
y But it can absorb
b b moisture therefore
h f
coated
d low
l
hydrogen electrodes are backed before use to a
temperature off 200oC to 3000C and
d stored
d in an
oven at 110oC to 150oC
y Other types of electrode release large amount of
hydrogen, which can dissolve in the weld metal
and lead to embrittlement or cracking.
[
[2marks]
k ]
W ldi C
WeldingCurrent
t
y Weldingcurrentdependsupon:thethicknessofthe
Fig.Thepositionofelectrodeforhorizontalwelding
IES2002
weldedmetal,typeofjoint,weldingspeed,positionof
theweld,thethicknessandtypeofthecoatingonthe
electrodeanditsworkinglength.
y Weldingcurrent,I=k.d,amperes;disdia.(mm)
Page 45 of 240
WeldingVoltage
y Thearcvoltagedependsonlyuponthearclength
V=k1 +k2l
Volts
ArcLength
y For good welds, a short arc length is necessary,
because:
1. Heat is concentrated.
2. More stable
3. More protective atmosphere.
Fig.ArcPowerVsArcLength
Contd
Arclengthshouldbeequaltothediameteroftheelectrodesize
G
2002 C
i
l
GATE2002,Conventional
The
characteristic
off a DC arc is given
h arc lengthvoltage
l
h l
h
by the equation: V = 24 + 4L,
4L where V is voltage in volts
and L is arc length in mm. The static voltampere
characteristic of the power source is approximated by a
Beadwidthshouldbeequaltothreediameteroftheelectrodesize
straight
h line
l
with
h a no load
l d voltage
l
off 80 V and
d a short
h
circuit current of 600A. Determine the optimum arc
length for maximum power.
GATE2008
In arc welding of a butt joint, the welding speed is
to be selected such that highest cooling rate is
achieved. Melting efficiency and heat transfer
efficiency are 0.5 and 0.7, respectively. The area of
the
h weld
ld cross section is 5 mm2 and
d the
h unit
energy required to melt the metal is 10 J/mm3. If
the
h welding
ld
power is 2 kW,
k
the
h welding
ld
speed
d in
mm/s is closest to
(a) 4
(b) 14
(c) 24
(d) 34
For-2015 (IES, GATE & PSUs)
( )
GATE2010(PI)
g a steadyy g
g with direct
During
gas metal arc welding
current electrode positive polarity, the welding current,
voltage and weld speed are 150 A, 30 V and 6 m/min,
respectively. A metallic wire electrode of diameter 1.2
mm is being fed at a constant rate of 12 m/min. The
d it specific
density,
ifi heat
h t and
d melting
lti
t
temperature
t
off the
th
wire electrode are 7000 kg/m3, 500 J/kgoC and 1530oC,
respectively Assume the ambient temperature to be 30oC
respectively.
and neglect the latent heat of melting. Further, consider
that two
twothird
third of the total electrical power is available for
melting of the wire electrode. The melting efficiency (in
percentage)
p
g of the wire electrode is
(a) 39.58
(b) 45.25
(c) 49.38 (d) 54.98
GATE2006
In an arc welding process, the voltage and current
are 25 V and 300 A respectively. The arc heat
transfer efficiency is 0.85 and welding speed is 8
mm/sec. The net heat input (in J/mm) is
(a) 64
(b) 797
(c) 1103
(d) 79700
Page 46 of 240
( )
GATE2009(PI)
Autogenous gas tungsten arc welding of a steel
plate is carried out with welding current of 500 A,
voltage of 20 V, and weld speed of 20 mm/sec.
Consider the heat transfer efficiency from the arc
to the weld pool as 90%. The heat input per unit
length (in KJ/mm) is
(a) 0.25
(b) 0.35
(c) 0.45
(d) 0.55
Rev.0
Example
ArcblowinDCarcwelding
g the welding
g of magnetic
g
y Arc blow occurs during
Effectofarcblow
y Low heat penetration.
y Excessive weld spatter.
p
y Pinch effect in welding is the result of electromagnetic
forces
y Weld spatter occurs due to
High
Hi h welding
ldi currentt
Too small an electrode arc
Contd
IES2001
Arcblowismorecommonin
(a) A.C.welding
.C. e d g
(b) D.C.weldingwithstraightpolarity
(c) D.C.weldingwithbareelectrodes
D C elding ithbareelectrodes
(d) A.C.weldingwithbareelectrodes
Contd
IES 2013
IES2013
Statement (I): The deflection of Arc from its intended
path is called Arc
Arc blow.
blow
Statement (II): The chances of Arc blow is common in
A C Arc
A.C.
A welding.
ldi
(a) Both Statement (I) and Statement (II) are individually
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
GATE & PSUs)
(d) Statement For-2015
(I) is false(IES,
but Statement
(II) is true
IES2001
Pincheffectinweldingistheresultof
(a) Expansionofgasesinthearc
pa s o o gases t e a c
(b) Electromagneticforces
(c) Electricforce
(d) Surfacetensionofthemoltenmetal
Page 47 of 240
ISRO2006
Too
T high
hi h welding
ldi currentt in
i arc welding
ldi would
ld result
lt in
i
(a) Excessive spatter, under cutting along edges, irregular
deposits, wasted electrodes
(b) Excessive p
piling
g up
p of weld metal, p
poor p
penetration,
wasted electrodes
(c) Too small bead, weak weld and wasted electrodes
(d) Excessive piling up of weld metal, overlapping
without penetration of edges,
edges wasted electrodes
Rev.0
Gasshields
CarbonArcwelding
other
th atmospheric
t
h i gases.
y Gases are argon,
argon helium,
helium nitrogen,
nitrogen carbon dioxide and
work.
k
very well.
ll
IES 2010
IES2010
)
g
p
y is always
y
Assertion ((A):
Straight
polarity
recommended for Carbonelectrode welding.
Reason (R): Carbon arc is stable in straight polarity.
(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
l
i off A
(c) A is true but R is false
(d) A is false but R is true
TungstenInertGaswelding(TIG)
y Arc
Contd
GATE2011
Whichoneamongthefollowingweldingprocesses
usednon consumableelectrode?
( )G t l ldi
(a)Gasmetalarcwelding
(b)Submergedarcwelding
(c)Gastungstenarcwelding
(d)Fluxcoatedarcwelding
Fig.TIG
For-2015 (IES,
GATE & PSUs)
Page 48 of 240
IES 2010
IES2010
gp
y used
In an inert g
gas welding
process,, the commonly
gas is
(a) Hydrogen
(b) Oxygen
( ) Helium
(c)
H li
or Argon
A
(d) Krypton
Rev.0
ISRO2009
Following gases are used in tungsten inert
gas welding
ldi
(a) CO2 and H2
(b) Argon and neon
(c) Argon and helium
(d) Helium and neon
GATE2002
Whichofthefollowingarcweldingprocessesdoes
notuseconsumableelectrodes?
(a) GMAW
(b) GTAW
(c) SubmergedArcWelding
(d) Noneofthese
N
fth
IES1994
Whichoneofthefollowingweldingprocesses
usesnon consumableelectrodes?
(a) TIGwelding
(b) MIGwelding
(c) Manualarcwelding
(d) Submergedarcwelding.
S b
d ldi
IES2013
IES2000
Whichoneofthefollowingstatementsiscorrect?
(a) Nofluxisusedingasweldingofmildsteel
o u s used gas e d g o
d stee
(b) Boraxisthecommonlyusedfluxcoatingon
weldingelectrodes
(c) Laserbeamweldingemploysavacuumchamber
andthusavoidsuseofashieldingmethod
(d) ACcanbeusedforGTAWprocess
Statement ((I):
) Non consumable electrodes,, used in arc
welding are made of high melting point temperature
g of electrode g
goes on
materials,, even then the length
decreasing with passage of time.
Statement (II): The electrode material gets oxidized
and melts on the weld material to form a strong flux.
(a) Both Statement (I) and Statement (II) are individually
true and Statement (II) is the correct explanation of
Statement (I)
(b) Both Statement (I) and Statement (II) are individually
true but
b Statement
S
(II) is
i not the
h correct explanation
l
i off
Statement (I)
(c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement (II) is true
GasMetalArcWelding(GMAW)orMIG
y A consumable electrode in a gas shield.
y Arc is between workpiece
p
and an automaticallyy fed
barewire electrode.
y Argon, helium, and mixtures of the two can be used.
y Any metal can be welded but are used primarily with
the nonferrous metals.
metals
y When welding steel, some O2 or CO2 is usually added
t improve
to
i
th arc stability
the
t bilit and
d reduce
d
weld
ld spatter.
tt
Contd
IES2007
InMIGwelding,themetalistransferredintothe
g
formofwhichoneofthefollowing?
(a) Afinesprayofmetal
(b) Moltendrops
(c) Weldpool
(d) Molecules
l
l
Page 49 of 240
Fig.MIG
Rev.0
IES1997
Considerthefollowingstatements:
MIGweldingprocessuses
gp
1.Consumableelectrode2. nonconsumableelectrode
3.D.C.powersupply
4.A.C.powersupply
Ofthesestatements
(a) 2and4arecorrect
(b) 2and3arecorrect
( ) 1and4arecorrect
(c)
d
(d) 1and3arecorrect
IES 2012
IES
() C
p
y
G
Statement(I):DCwithreversepolarityisusedinMIG
welding
( )
p
y
Statement(II):UseofDCwithreversepolarityenables
deeperpenetrationandacleanSurface
((a)) Both Statement ((I)) and Statement ((II)) are
individually 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
IES 2013
IES2013
IES 2010
IES2010
g statements:
Consider the following
In metal are welding
1. Utilizes a consumable electrode
2. A welding torch used is connected to acetylene gas
supply
3. The
Th electrode
l t d and
d workpiece
k i
are connected
t d to
t the
th
welding power supply
Which of these statements are correct?
(a) 1,
1 2 and 3
( )
g
Assertion(A):Inertgasandbareelectrodeinstead
offluxcoatedelectrodeisusedinthecaseof
gp
automaticTIGandMIGweldingprocesses.
Reason(R):Betterprotectionisprovidedbyacloud
ofinertgasthanthecovercreatedbytheflux.
(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
SubmergedArcwelding(SAW)
y A thick layer of granular flux is deposited just ahead of
a bare
b
wire
i consumable
bl electrode,
l t d and
d an arc is
i
maintained beneath the blanket of flux with onlyy a few
y Most suitable
or fillet
bl for
f flat
fl butt
b
f ll welds
ld in low
l
steels,
tool
steels,
aluminum,
magnesium,
Advantages
Characteristicofsubmergedarcwelding
y Highspeeds,
y Wireelectrodesareinexpensive.
y Highdepositionrates,
y Noweldspatter.
y Deeppenetration,
Deeppenetration
y Nearly100%depositionefficiency.
Nearly100%depositionefficiency
y Highcleanliness(duetothefluxaction).
y Lesserelectrodeconsumption.
Page 50 of 240
Rev.0
IES2011
Limitations
IES2005
IES2008
Whichofthefollowingarethemajor
characteristicsofsubmergedarcwelding?
1. Highweldingspeeds.
2. Highdepositionrates.
3. Lowpenetration.
4. Lowcleanliness.
4
Selectthecorrectanswerusingthecodegivenbelow:
(a) 2and3
(b) 1,2and3
1 2and3
(c) 3and4
(d) 1and2
AtomicHydrogenwelding(AHW)
y An
two tungsten electrodes
A a.c. arc is
i formed
f
d between
b
l
d
Assertion (A):
( ) Submerged arc welding is not
recommended for high carbon steels, tool steels,
aluminium, magnesium etc.
Reason (R): This is because of unavailability of
suitable fluxes, reactivity at high temperatures and
l
low
sublimation
bli
i temperatures.
(a) Both A and R are true and R is the correct explanation
of A
(b) Both A and R are 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
p
y Temperature
of about 37
3700oC.
y Hydrogen acts as shielding also.
y Used for very thin sheets or small diameter wires.
y Lower thermal efficiency than Arc welding.
y Ceramics may be arc welded.
IES2006
Inwhichofthefollowingweldingprocesses,flux
g
isusedintheformofgranules?
(a) ACarcwelding
(b) Submergedarcwelding
(c) Argonarcwelding
(d) DCarcwelding
C ldi
GATE1999
For butt welding 40 mm thick steel plates, when
the expected quantity of such jobs is 5000 per
month over a period of 10 year, choose the best
suitable welding process out of the following
available
l bl alternatives.
l
(a) Submerged
g arc welding
g
(b) Oxyacetylene welding
(c) Electron beam welding
(d) MIG welding
IES2005
Inatomichydrogenwelding,hydrogenactsas
(a) Aheatingagent
eat g age t
(b) Oneofthegasestogeneratetheflame
(c) Aneffectiveshieldinggasprotectingtheweld
Aneffecti eshieldinggasprotectingthe eld
(d) Alubricanttoincreasetheflowcharacteristicsof
weldmetal
ld
l
y AC used.
used
Page 51 of 240
Rev.0
ResistanceWelding
ResistanceWelding
Principle
y Both heat and pressure are used.
y Heat is generated by the electrical resistance of the
work pieces and the interface between them.
y Pressure is supplied externally and is varied
g
the weld cycle.
y
throughout
y Due to pressure, a lower temperature needed than
oxyfuel
oxy
fuel or arc welding.
BySKMondal
Contd
Contd
Fig.
g
Typical
yp
pressure cycle
welding. The
forging and
operations.
current
and
for resistance
cycle includes
post heating
FIG.Thefundamentalresistanceweldingcircuit
Advantages
IES2007
What is the principle of resistance welding?
Indicate where the resistance is maximum in spot
welding operation.
[
[2marks]
k ]
Limitations
1. Very rapid.
flux is required.
q
Rev.0
Application
Differenttypes
Resistancespotwelding
y The process description given so far is called resistance
4. Upset welding
5. Flash welding
6. Percussion welding
HeatinputandEfficiencyCalculations
IES2003
Inresistancewelding,heatisgeneratedduetothe
resistancebetween
(a) Electrodeandworkpiece
(b) Asperitiesbetweentouchingplates
(c) Twodissimilarmetalsbeingincontact
(d) Interatomicforces
i f
Contd
IES2001
Themaximumheatinresistanceweldingisatthe
(a) Tipofthepositiveelectrode
p o t e pos t e e ect ode
(b) Tipofthenegativeelectrode
(c) Topsurfaceoftheplateatthetimeofelectric
contactwiththeelectrode
(d) InterfacebetweenthetwoplatesbeingJoined
f b
h
l
b i i d
GATE2007
p jjoint
Two metallic sheets,, each of 2.0 mm thickness,, are welded in a lap
configuration by resistance spot welding at a welding current of 10 kA
and welding time of 10 millisecond. A spherical fusion zone extending
up to the full thickness of each sheet is formed. The properties of the
metallic sheets are given as:
ambient temperature = 293 K
melting temperature = 1793 K
l t t heat
latent
h t off fusion
f i = 300 kJ/kg
kJ/k
density = 7000 kg/m3
specific heat = 800 J/kg K
Assume:
(i) Contact resistance along sheetsheet interface is 500 microohm and
along electrodesheet interface is zero;
( ) No conductive heat loss through the bulk sheet materials; and
(ii)
(iii) The complete weld fusion zone is at the melting temperature.
g efficiencyy (in %) of the p
process is
The melting
(a) 50.37 (b)
60.37 (c)
70.37 (d)
80.37
Page 53 of 240
GATE2009(PI)LinkedS1
Resistance spot welding of two steel sheets is carried out in
lap joint configuration by using a welding current of 3 kA and
a weld time of 0.2 S. A molten weld nugget
gg of volume 20 mm3
is obtained. The effective contact resistance is 200
(microohms). The material properties of steel are given as:
(i) latent heat of melting: 1400 kJ/kg, (ii) density: 8000
kg/m3, (iii) melting temperature: 1520oC, (iv) specific heat:
0.5 kJ/kg
kJ/k oC.
C The
Th ambient
bi
temperature is
i 20oC.
C
Heat (in Joules) used for producing weld nugget will be
(
(assuming
100%
% heat
h
transfer
f efficiency)
ff
)
(a) 324
(b) 334
(c) 344
(d) 354
Rev.0
GATE2009(PI)LinkedS2
Resistance spot welding of two steel sheets is carried out in
lap joint configuration by using a welding current of 3 kA and
a weld time of 0.2 S. A molten weld nugget
gg of volume 20 mm3
is obtained. The effective contact resistance is 200
(microohms). The material properties of steel are given as:
(i) latent heat of melting: 1400 kJ/kg, (ii) density: 8000
kg/m3, (iii) melting temperature: 1520oC, (iv) specific heat:
0.5 kJ/kg
kJ/k oC.
C The
Th ambient
bi
temperature is
i 20oC.
C
Heat (in Joules) dissipated to the base metal will be
(
(neglecting
l
all
ll other
h heat
h
l
losses)
)
(a) 10
(b) 16
(c) 22
(d) 32
GATE2004
Two 1 mm thick steel sheets are to be spot welded
at a current of 5000 A. Assuming effective
resistance to be 200 microohms and current flow
time of 0.2 second, heat generated during the
process will
ll be
b
(a) 0.2 Joule (b) 1 Joule
(c) 5 Joule
(d) 1000 Joules
GATE2014
For
metal)
F spott welding
ldi off two
t steel
t l sheets
h t (base
(b
t l) each
h off
3 mm thickness,, welding
g current of 10000 A is applied
pp
for 0.2 s. The heat dissipated to the base metal is 1000 J.
Assuming that the heat required for melting 1 mm3
volume
l
off steel
t l is
i 20 J and
d interfacial
i t f i l contact
t t resistance
i t
between sheets is 0.0002,, the volume ((in mm3) of weld
GATE2005
Spot welding of two 1 mm thick sheets of steel
(density = 8000 kg/m3) is carried out successfully
by passing a certain amount of current for 0.1
second through the electrodes. The resultant weld
nugget formed
f
d is 5 mm in diameter
d
and
d 1.5 mm
thick. If the latent heat of fusion of steel is 1400
k k and
kJ/kg
d the
h effective
ff
resistance in the
h welding
ld
operation in 200 , the current passing through
the
h electrodes
l
d is approximately
l
(a) 1480A
(b) 3300 A
(c) 4060 A
(d) 9400 A
GATE1992
For resistance spot welding of 1.5 mm thick steel
sheets, the current required is of the order of
(a) 10 A
(b) 100 A
(c) 1000 A
(d) 10,000 A
GATE2010
Two pipes of inner diameter 100 mm and outer
diameter 110 mm each joined by flash butt
welding using 30 V power supply. At the interface,
1 mm of material melts from each pipe which has
a resistance off 42.4 . Iff the
h unit melt
l energy is
64.4 MJm3, then time required for welding in
seconds
d is
(a) 1
(b) 5
(c) 10
(d) 20
IES 2007 C
ti
l
IES2007Conventional
Two steel sheets of thickness one mm are welded
by resistance projection welding technique. A
current of 30,000 A for 0005 second is made to
flow. The effective resistance of joint can be taken
as 100 micro ohms. The joint can be considered as
a cylinder of diameter 5 mm and height 15 mm.
The density of steel is 000786 gm/mm3. The heat
needed for welding steel is 10 J/mm3. Calculate the
efficiency of welding.
[20]
nugget is .
For-2015 (IES, GATE & PSUs)
GATE2001
GATE 2008(PI)
Aluminum strips of 2 mm thickness are joined together
by resistance spot welding process by applying an
electric current of 6000 A for 0.15 sec. The heat required
for melting
g aluminum is 2.9
9 J/
J/mm3. The diameter and
the thickness of weld nugget are found to be 5 mm and
2 5 mm,
2.5
mm respectively.
respectively Assuming the electrical resistance
to be 75 (micro ohms), the percentage of total
energy utilized in forming the weld nugget is
(a) 28
Page 54 of 240
(b) 35
(c) 65
(d) 72
Rev.0
IAS2003
Resistanceseamwelding
Assertion (A):
( ) Spot welding is adopted to weld two
overlapped metal pieces between two electrode
points.
Reason (R): In this process when current is switched
on, the lapped pieces of metal are heated in a
restricted
i d area.
(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
Th seam is
The
i a series
i off overlapping
l
i spott welds.
ld
welds.
welds
Contd
( )
GATE 2012(PI)
In resistance seam welding, the electrode is in the
f
form
off a
(a) cylinder
(b) flat plate
((c)) coil of wire
(d) circular disc
Contd
Projectionwelding
y Limitations of spot welding.
1. Electrode
Fig.Resistanceseamwelding
Contd
g
placed between largearea
locations and then p
electrodes, and pressure and current applied like spot
welding.
g
y Current flows through the dimples and heats them
and pressure causes the dimples to flatten and form a
weld.
Fig.Principleof
projectionwelding,
j ti ldi
(a)priortoapplicationof
currentandpressure
( )
(b)andafterformationof
&welds
PSUs)
Contd
Upsetwelding
name.
y Useful for joining rods or similar pieces.
Page 55 of 240
Rev.0
Contd
FlashWelding
resistance
i t
h ti
heating.
y One pieces is clamped with cam controlled movable
Contd
Contd
PercussionWelding
p
pieces are separated
switched on. Momentarilyy the two p
to create the arc to melt the ends of the two pieces.
g
the p
pieces are brought
g together
g
and the
Then again
power switched off while the two ends are fused under
force. Most of the metal melted would flash out
through the joint and forms like a fin around the joint.
y Faster than upset welding.
highly concentrated.
y Small weld metal is produced, little or no upsetting, and
low HAZ.
HAZ
y Application: Butt welding of bar or tube where heat
Contd
Thermit Welding
OtherWelding
Technique
h i
metal
t l obtained
bt i d from
f
a chemical
h i l reaction
ti
b t
between
a
metal oxide and a metallic reducing
g agent.
g
y Used mixture one part aluminum and three parts iron
metal.
metal
y Runners and risers are provided like casting.
Contd
Rev.0
IES2000
ElectroSlagWelding
Considerthefollowingprocesses:
1. Gaswelding
2. Thermit welding
33. Arcwelding
g
4. Resistancewelding
Thecorrectsequenceoftheseprocessesinincreasing
orderoftheirweldingtemperaturesis
(a) 1,3,4,2
1 3 4 2
(b) 1,2,3,4
1 2 3 4
(c) 4,3,1,2
(d)4,1,3,2
y Watercooled
W
l d copper molding
ldi
plates
l
confined
fi d the
h
supply of filler.
Contd
Contd
IAS2003
Whichoneofthefollowingisnotanelectric
g
resistancemethodofwelding?
(a) Electroslagwelding
(b) Percussionwelding
(c) Seamwelding
(d) Flashwelding
l h ldi
Contd
IAS2000
Considerthefollowingweldingprocesses:
1.. TIGwelding
G ed g
2.. Sub
Submergedarcwelding
e ged a c e d g
3. Electroslagwelding4. Thermit welding
Whichofthese eldingprocessesareusedfor elding
Whichoftheseweldingprocessesareusedforwelding
thickpiecesofmetals?
( ) 1,2and3
(a)
d (b) 1,2and4
d
(c) 1,3and4 (d) 2,3and4
ElectronBeamWelding
y A beam of electrons is magnetically focused on the
work
k piece
i
i a vacuum chamber.
in
h b
y Heat of fusion is produced by electrons decelerate.
decelerate
y Allows
precise
p
beam
control
and
deep
p
weld
penetration.
y No shield gas (vacuum chamber used)
Page 57 of 240
Rev.0
IES2004
IES2002
IAS2004
IES1993
Inwhichoneofthefollowingweldingtechniques
isvacuumenvironmentrequired?
(a) Ultrasonicwelding
(b) Laserbeamwelding
(c) Plasmaarcwelding
(d) Electronbeamwelding
l
b
ldi
LaserBeamWelding
Whichoneofthefollowingweldingprocesses
consistsofsmallerHeatAffectedZone(HAZ)?
(a) Arcwelding
(b) Electronbeamwelding
(c) MIGwelding
(d) Thermit welding
Electronbeamweldingcanbecarriedoutin
(a) Ope
Openair
a
(b) Ashieldinggasenvironment
(c) Apressurizedinertgaschamber
Apressuri edinertgaschamber
(d) Vacuum
y Filler metal and inert gas shield may or may not used.
y Deep penetration.
y The high
highintensity
intensity beam produces a very thin column
y No
N vacuum needed.
d d
y No direct contact needed.
needed
Contd
IES2007
to weld
the
polyurethane insulation.
insulation
Contd
Considerthefollowingstatementsinrespectofthe
laserbeamwelding:
1. Itcanbeusedforweldinganymetalortheir
I b df ldi
l h i
combinationsbecauseofveryhightemperatureofthe
focalpoints.
focalpoints
2. Heataffectedzoneisverylargebecauseofquick
heating.
3. Highvacuumisrequiredtocarrytheprocess.
Whichofthestatementsgivenaboveis/arecorrect?
(a) 1and2only (b) 2and3only
(c) 1only
(d) 1,2and3
Page 58 of 240
Contd
IES2006
Whichoneofthefollowingweldingprocesses
consistsofminimumheataffectedzone(HAZ)?
(a) ShieldedMetalArcWelding(SMAW)
(b) LaserBeamWelding(LBW)
(c) UltrasonicWelding(USW)
(d) MetalInertGasWelding(MIG)
l
G ldi ( G)
Rev.0
GATE2012(PI)
IAS2007
ForgeWelding
IAS1999
FrictionWelding
y Blacksmith do this.
th two
the
t parts
t to
t be
b joined.
j i d
h d
hardness
off the
h metals
l being
b
joined.
d
y Pressure 40 MPa for lowcarbon
low carbon steels to as high as 450
used
d by
b industry.
i d
Contd
Contd
GATE2007
y Very efficient.
y Wide variety of metals or combinations of metals can
Contd
Whichoneofthefollowingisasolidstatejoining
process??
(a) Gastungstenarcwelding
(b) Resistancespotwelding
p
g
(c) Frictionwelding
(d) submergedarcwelding
Page
59 of 240
Fig
frictionweldingprocess
Rev.0
GATE2013
pairs
Match the CORRECT pairs.
GATE2014
In solidstate welding, the contamination layers
b t
between
th surfaces
the
f
t be
to
b welded
ld d are removed
d by
b
(a) alcohol
(b) p
plastic deformation
(c) water jet
(d) sand blasting
Characteristics/Applications
1.Nonconsumableelectrode
Q.GasMetalArc
Q
GasMetalArc
Welding
R T
R.TungstenInertGas
t I tG
Welding
2 Joiningofthickplates
2.Joiningofthickplates
friction welded,
welded end to end,
end at an axial pressure of 200
S.Electroslag Welding
4.Joiningofcylindrical
dissimilarmaterials
( ) 4 Q3
(a)P4,Q3,R1,S2
(c)P2,Q3,R4,S1
( ) 4 Q
(b)P4,Q2,R3,S1
3
(d)P2,Q4,R1,S3
(d) 24.66
Discusswithfigurethevariousstepsrequiredfor
Highfrequency
g
q
y (10 to 200, KHz) is applied.
pp
frictionwelding,mentioningatleasttwomethods
[
[5marks]
k ]
(c) 18.50
ofcontrol.
UltrasonicWelding(USW)
IFS2011
G
20 0 ( )
GATE2010(PI)
Processes
P.FrictionWelding
pressure.
Temp. do not exceed onehalf of the melting point.
The
Th ultrasonic
lt
i transducer
t
d
i same as ultrasonic
is
lt
i
machining.
Contd
pp
Applications
y Joiningthedissimilarmetalsinbimetallics
y Makingmicrocircuitelectricalcontacts.
Contd
ExplosionWelding
y Done at room temperature in air, water or vacuum.
y Surface contaminants tend to be blown off the surface.
y Weldingrefractoryorreactivemetals
W ldi f
i
l
y Bondingultrathinmetal.
g
y Titanium on steel
Page 60 of 240
Contd
Rev.0
Contd
Contd
Disadvantages,
y The metals must have high enough impact resistance,
and ductilityy ((at least 55%))
y The cladding plate cannot be too large.
y Noise and blast can require worker protection,
protection vacuum
chambers, buried in sand/water.
g ,
Advantages,
y Can bond many dissimilar, normally unweldable
metals
y The lack of heating preserves metal treatment
y The
Th process is
i compact, portable,
bl and
d easy to contain
i
y Inexpensive
y No need for surface preparation
Contd
Contd
yp
pp
Typicalapplications:
y Verylargeplatescanbecladded.
y Joinsdissimilarmetals.
(titaniumtosteel,Altosteel,AltoCuetc.)
y Jointubetotubesheetsoflargeheatexchangers.
Contd
Contd
IES2011S1Contd
GATE1992
Inanexplosiveweldingprocess,the..
(maximum/minimum)velocityofimpactisfixed
bythevelocityofsoundinthe
(flyer/target)platematerial
(a) Maximum;target
(b) M
Minimum;target
u ; ta get
(c) Maximum;flyer
(d) Minimum;flyer
Mi i
fl
For-2015 (IES, GATE & PSUs)
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowthelists:
ListI
A.Laserbeam
welding
B.Electron
beamwelding
ListII
1.Canbeappliedforweldingorrefractorymetals
likeniobium,tantalum,molybdenumandtungsten.
2.Asoundandcleanweldedjointiscreateddueto
rubbingoftwopartsagainsteachotherwith
adequatespeedandpressureproducingintenseheat
raisingtemperatureabovemeltingpoint.
raisingtemperatureabovemeltingpoint
C.Ultrasonic 3.Cleanheatsourcecreatedmuchawayfromjob,a
welding
narrowspotisheated workchamberoperatesina
narrowspotisheated,workchamberoperatesina
highvacuum.
D.Friction
D
Friction
welding
4.Cleanheatsourceveryquickheating,verysmall
4
Cleanheatsourceveryquickheating,verysmall
focalspot,novacuumchamberisrequired.
Page 61 of 240
IES2011FromS1
Codes:
A
(a) 4
((c)) 4
B
3
1
C
1
3
D
2
4
(b)
( )
(d)
A
2
2
B
3
1
Rev.0
C
1
3
D
4
4
IES2009
IAS2002
MatchListIwithListIIandselectthecorrectanswerusingthecodegiven
belowtheLists:
ListI
ListII
(WeldingProcess)
(Application)
A. Laserwelding
1.
Unitinglargeareasheets
B. Frictionwelding
2.
Repairinglargeparts
C Ultrasonicwelding
C.
3
3.
Weldingarodtoaflatsurface
D. Explosivewelding
4.
Fabricationofnuclearreactor
components
55.
Weldingverythinmaterials
g
y
Code:
(a)
A
B
C
D
(b)
A
B
C
D
5
4
3
2
1
4
2
5
(c)
A
1
B
3
C
4
D
2
(d)
A
5
B
3
C
4
D
1
MatchListI,(Welding)withListII(Application)andselectthecorrect
(
)
(
)
answerusingthecodesgivenbelowtheLists:
ListI
ListII
(
(Welding)
)
(
(Application)
)
A.
Explosive
1.
Joiningthicksheets
g
B.
Ultrasonic
2.
Manufactureofheatexchanges
C.
Thermit
3.
Joiningthinsheetsorwiresof
similar/dissimilar metals
D.
Projection
4.
Joininghydraulicpistonrodsfor
agricultural
l
l machinery
h
5.
Joiningrails,pipesandthicksteel
sections
Codes:A
d
B
C
D
A
B
C
D
(a) 2
5
1
3
(b)
4
5
1
3
(c) 2
3
5
1
(d)
4
3
5
1
Autogeneous Welding
MicroPlasmaArcWeld(PAW)
material in an inert g
gas shield without the use
of filler metals.
i constricted
is
t i t d by
b a watercooled
t
l d orifice
ifi
y Capable of high welding speeds where size permits
y Argon
g is used as the shielding
gg
gas.
IFS 2009
Two plates of aluminium and stainless steel are to
be welded back to back to create a single plate of
thickness equal to the sum of the thicknesses of
the two plates.
plates Suggest the suitable process and
explain it in brief.
[10 marks]
DiffusionWelding
g p
y It is a solid state welding
process which p
produces
coalescence of the faying surfaces by the application of
pressure and elevated temperatures (about 50 to 80%
of absolute melting point of the parent materials) for a
time ranging from a couple of minutes to a few hours.
y Produces high quality bonds with good strength with
little or no distortion.
y Can join very dissimilar materials.
y A solid filler metal may or may not be inserted.
y Materials welded for aircraft and rocket industry:
Boron, Titanium, Aluminium, Ceramic, Composite,
Graphite, Magnesium etc.
JWM2010
GATE 2008(PI)
Which
solid
h h pair among the
h following
f ll
l d state welding
ld
processes uses heat from an external source?
P Diffusion welding;
Q Friction welding
R Ultrasonic welding
S Forge welding
(a) P and R
(b) R and S
(c) Q and S
(d) P and S
For-2015 (IES, GATE & PSUs)
IAS2001
MatchListI(Weldingprocesses)withListII(Features)and
(
)
(
)
selectthecorrectanswerusingthecodesgivenbelowtheLists:
ListI
A. Ultrasonicwelding
1.
B.
Electronbeamwelding2.
C
C.
Plasmaarcwelding
3
3.
4.
Codes:A
C
d A
(a) 1
(c) 2
B
2
1
C
4
4
(b)
(d)
ListII
Gasheatedtoionizedcondition
forconductionofelectriccurrent
Highfrequencyandhigh
intensityvibrations
Concentratedstreamofhigh
Concentratedstreamofhigh
energyelectrons
Exothermalchemicalreaction
A
B
C
4
3
1
2
3
1
Page 62 of 240
M hLi I i hLi II d l h
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowthelists:
ListI
ListII
A.Atomic
1.Twopiecesarebroughttogetherand
h d
hydrogenwelding
ldi powersupplyisswitchedon
l i i h d
B.Plasmaarc
B
Plasma arc
welding
22.Nuggetisformedattheinterfaceof
Nuggetisformedattheinterfaceof
twoplates
C Spotwelding
C.Spotwelding
3 Gasisionized
3.Gasisionized
D.Flashwelding
4.Inertgasshieldedarcwelding
Code:A
(a) 4
(c) 4
B
3
2
C
2
3
D
1
1
(b)
(d)
A
B
1
3
Rev.0
1
2
C
2
3
D
4
4
BrazingandSoldering
y Brazing
is
off metals
B i
i the
th joining
j i i
t l through
th
h the
th use off heat
h t
BrazingandSoldering
g
g
Brazingprocesshasseveraldistinct
Brazing
process has several distinct
advantages:
g
1. All metals can be joined.
2. Suited for dissimilar metals.
3. Quick and economical.
4. Less defects.
d f
5 Corrosion prone
5.
Brazingmetalsaretypicallyalloyssuchas,
y Brazingbrass(60%Cu,40%Zn)
g
y Manganesebronze
y Nickelsilver
y Coppersilicon
y Silveralloys(with/withoutphosphorous)
l
ll
( h
h
h
h
)
y Copperphosphorous
Contd
acid.
chlorides fluorides,
chlorides,
fluorides tetraborates
tetra borates and other wetting
y Sodium
S di
cyanide
id is
i used
d in
i brazing
b i tungsten to copper.
agents.
g
Contd
Contd
Page 63 of 240
Rev.0
S O 20 0
ISRO2010
IES2006
GATE2005
Thestrengthofabrazedjoint
(a) Decreaseswithincreaseingapbetweenthetwo
g p
joiningsurfaces
(b) Increaseswithincreaseingapbetweenthetwo
joiningsurfaces
(c) Decreasesuptocertaingapbetweenthetwo
joiningsurfacesbeyondwhichitincreases
(d) Increasesuptocertaingapbetweenthetwo
I
t t i b t
th t
joiningsurfacesbeyondwhichitdecreases
BrazeWelding
Whichoneofthefollowingisnotafusionwelding
process?
(a) Gaswelding
(b) Arcwelding
(c) Brazing
(d) Resistancewelding
i
ldi
Soldering
where
h
th filler
the
fill metal
t l has
h
a melting
lti
t
temperature
t
below 450C.
45
y Strength of the filler metal is low.
y Soldering is used for a neat leakproof joint or a low
Fig.BrazeWelding
Contd
S ld M t l
SolderMetals
S ld
l
SolderFlux
y Ammonium
chloride
A
i
hl id or rosin
i for
f soldering
ld i tin
ti
galvanized iron
use
Page 64 of 240
Contd
Rev.0
g
p
y Silver solders uses for highertemperature
service,,
Electrical and Electronic purpose.
GATE2014(PI)
BrazingandSolderingare
d ld
(a)plasticjoiningmethods
(b) o oge eous jo
(b)homogeneousjoiningmethods
g et ods
y
DifficultieswithGreyCastIron
Soldering and brazing are difficult of grey cast Iron due
to surface contamination with graphite having a very low
surface energy.
(c)autogenous joiningmethods
(d)heterogeneousjoiningmethods
IES1994
MatchList IwithList IIandselectthecorrect
answerusingthecodesgivenbelowtheLists:
List I(Filler)
List
List II(Joiningprocess)
List
A. Cu,Zn,Agalloy
1.
Brazewelding.
B Cu,Sn,alloy
B.
Cu Sn alloy
2
2.
Brazing
C. Pb,Sb,alloy
3.
Soldering
D.Iron oxideandaluminium p
powder4.
4
TIGweldingof
g
aluminium
Codes:A B
C
D
A
B
C
D
( ) 2
(a)
1
3
(b) 1
2
4
(c) 2
1
3
4
(d) 2
3
4
IES2004
MatchListI(Weldingproblems)withListII(Causes)andselect
(
)
(
)
thecorrectanswerusingthecodesgivenbelowtheLists:
ListI
ListII
A. Crackingofweldmetal
1.
Excessivestresses
B. Crackingofbasemetal
2.
Highjointrigidity
C
C.
Porosity
3
3.
Failuretoremoveslag
frompreviousdeposit
D. Inclusions
4.
Oxidation
5.
E
ExcessiveH
i H2,O
O2,N
N2,in
i
theweldingatmosphere
Codes:A
B
C
D
A
B
C
D
(a) 2
1
5
3
(b)
3
4
2
1
(c) 2
4
5
3
(d)
3
1
4
2
W ldi d i
Weldingdesignanddefect
dd f
IAS1996
MatchListIwithListIIandselectthecorrectanswerusing
thecodesgivenbelowthelists
ListII
List
ListII
List
II
(Fillerrodmaterial) (Joiningprocess)
A. Mildsteel
1.
MIGwelding
B. Bronze
2.
Soldering
C. Brass
3.
Brazing
D Leadandtinalloy
D.
L d dti ll 4.
Th
Thermit
it welding
ldi
5.
Brazewelding
Codes:A
B
C
D
A
B
C
D
(a) 1
5
3
2
(b)
4
3
2
5
(c) 4
3
5
2
(d) 1
3
5
4
IES2003,ISRO2011
MatchListI(WeldingDefects)withListII(Causes)and
(
)
(
)
selectthecorrectanswerusingthecodesgivenbelowthe
Lists:
ListI
ListII
(WeldingDefects)
(Causes)
A Spatter
A.
S
1.
D
Dampelectrodes
l
d
B. Distortion
2.
Arcblow
C Slaginclusion
C.
3
3.
Impropercleaningin
multipasswelding
D. Porosity
4.
Poorjointselection
Codes:A B
C
D
A
B
C
D
(a) 4
2
3
1
(b) 4
2
1
3
(c) 2
4
1
3
(d) 2
4
3
1
Page 65 of 240
Welding
Problem
W ldi
P
bl
Cracking of weld metal
Cracking of base metal
Spatter
Distortion
Slag inclusion
Porosity
LamellarTearing
Causes
C
High joint rigidity
Excessive stresses
Arc blow
Poor joint selection
Improper cleaning in multipass welding
Excessive H2, O2, N2, in the
welding atmosphere or Damp
electrodes
inclusionssuchasMn FeandS
inthebasemetaland/or
h b
l d
residualstress
C k
Cracks
HAZ Cracking
HAZCracking
g
y
y
y Crackinginheataffectedzonemaybecausedby:
(i)Hydrogeninweldingatmosphere
(ii)hotcracking
(iii)lowductility
(iv)highresidualstresses
(v)brittlephaseinthemicrostructure
Fig.VariousTypesofCracksinWelds
f
k
ld
hydrogenmayentertheweldpoolandgetdissolvedin
h d
h ld
l d di l di
theweldmetal.
y DuringcoolinghydrogendiffusestotheHAZ.
y Crackingmaydevelopduetoresidualstressesassistedby
g
y
p
y
hydrogencoalesence.
y Thefactorsthatdeterminetheprobabilityofhydrogen
inducedembrittlementandcrackingofweldare:
(a)Hydrogencontent
(b)fracturetoughnessofweldandHAZ
(c)stresstowhichthejointisexposedasaresultof
theweldthermalcycle.
Residualstress
Porosity
Solid Inclusion
SolidInclusion
y Solid inclusions may be in the form of slag or any other
Fig DifferentFormsofPorosities
Fig.DifferentFormsofPorosities
For-2015 (IES, GATE & PSUs)
Fig SlagInclusioninWeldments
Fig.SlagInclusioninWeldments
Rev.0
Lack of Fusion
LackofFusion
y Lack of fusion is the failure to fuse together either the
base
metall and
beads
b
d weld
ld metall or subsequent
b
b d in
i
multipass welding because of failure to raise the
temperature off base
b
metall or previously
i
l deposited
d
i d weld
ld
layer to melting point during welding.
y Lack of fusion can be avoided by properly cleaning of
surfaces to be welded, selecting proper current, proper
welding technique and correct size of electrode.
I
l t P
t ti
IncompletePenetration
y Incomplete penetration means that the weld depth is not
ImperfectShape,Distortions
p
p
y Imperfect shape means the variation from the desired shape and
IES 2011 C
ti
l
IES2011Conventional
y Enumeratefourdefectscausedduetoresidualstressesin
weldedjoints.
[2Marks]
Ans.
1 Distortion
1.
2. Crackinginthebasemetal
g
3.
LamellarTearing
4. Reductionoffatiguestrength
IES2004
Consider the following statements:
The magnitude of residual stresses in welding
d
depends
d upon
1. Designofweldment
2. Supportandclampingofcomponents
S
d l
i f
3. weldingprocessused
4. Amountofmetalmelted/deposited
Whichofthestatementsgivenabovearecorrect?
(a) 1,2and4
(b)1,2and3
(c) 1and3
(d)2and3
For-2015 (IES, GATE & PSUs)
GATE2003
Matchthefollowing
M h h f ll i
Workmaterial
P Aluminium
P.Aluminium
Q.DieSteel
R.CopperWire
S.Titaniumsheet
(a)P 2
(a)P
(b)P 6
(c)P 4
(d)P 5
Q 5
Q
Q 3
Q 1
Q 4
R 1
R
R 4
R 6
R 2
Typeofjoining
1
1.
SubmergedArcWelding
2.
Soldering
3.
Thermit Welding
4.
AtomicHydrogenWelding
5.
GasTungstenArcWelding
6
6.
L
LaserBeamWelding
B
W ldi
7.
Brazing
S 3
S
S 4
S 2
S 6
Page 67 of 240
IES2004
Considerthefollowingstatements:
Thesizeoftheheataffectedzone(HAZ)willincreasewith
1. Increasedstartingtemperature
2. Increasedweldingspeed
3. Increasedthermalconductivityofthebasemetal
4 Increaseinbasemetalthickness
4.
Whichofthestatementsgivenabovearecorrect?
( ) 1,2and3
(a)
d
(b) 1and3
d
(c) 1and4
(d) 2and3
Rev.0
IES1992
Weld spatter occurs due to any of the following
except
(a) High welding current
(b) Too small an electrode
(c) Arc
(d) Wrong polarity
l i
IES2004
Assertion (A): A sound welded joint should not only
be strong enough but should also exhibits a good
amount of ductility
Reason (R): Welding process is used for fabricating
mild steel components only
(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
p
of A
correct explanation
(c) A is true but R is false
((d)) A is false but R is true
IES2011
Coldcrackinginsteelweldments
Cold crackinginsteelweldments dependson
1.Carbonequivalent
2.Heatinput
3
3.Effectivethickness
3.Hydrogencontentinweldpool
(a)1 2and3only
(a)1,2and3only
(b)1,2and4only
( )
(c)2,3and4only
3
(d)1,2,3and4
For-2015 (IES, GATE & PSUs)
20 0
JWM2010
p
g defects.
Assertion ((A)) : Spatter
is one of the welding
Reason (R) : In submerged arc welding process,
there is no spatter of molten metal.
(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
l
i off A
(c) A is true but R is false
(d) A is false but R is true
IES1998
An arc welded joint is shown in the above figure.
g
is known as
The part labelled 'B' in the figure
(a) Weld preparation
(b) Penetration
(c) Reinforcement
(d) Slag
Sl
IAS2003
GATE1996
Toolmaterialnotsuitedtoresistanceweldingis
Preheatingbeforeweldingisdoneto
(a) Makethesteelsofter
(b) Bumawayoil,grease,etc,fromtheplatesurface
(c) Preventcoldcracks
(d) Preventplatedistortion
(b)
(d)
Stellite
Masonite
GATE2001
Two plates of the same metal having equal
thickness are to be butt welded with electric arc.
When the plate thickness changes, welding is
achieved by
(a) Adjusting the current
(b) Adjusting
djust g tthee du
duration
at o o
of cu
current
e t
(c) Changing the electrode size
(d) Changing
Ch
i the
th electrode
l t d coating
ti
Page 68 of 240
IES 2012
IES
Brittle welds are mainly obtained due to
(a) Wrong electrode, faulty preheating and metal
hardened by air
(b) Faulty welds, faulty sequence and rigid joints
(c) Wrong speed, current improperly adjusted and faulty
preparation
(d) Uneven heat, improper sequence and deposited
metal shrinks
Rev.0
IES 2012
IES
Which of the following are associated with Heat
Affected Zone?
1 Coldcracking
1.Coldcracking
2.Notchtoughness
3.Hydrogenembrittlement
4
4.Stresscorrosioncracking
g
(a)1,2and3only
(b)1 3and4only
(b)1,3and4only
(c)2,3and4only
(d)1,2,3and4
GATE 2014
GATE2014
Within the Heat Affected Zone (HAZ) in a fusion
welding process, the work material undergoes
(a) microstructural changes but does not melt
(b) neither melting nor microstructural changes
(c) both melting and microstructural changes after
solidification
(d) melting and retains the original microstructure after
solidification
Page 69 of 240
IES 2012
IES
) Hydrogen
y
g induced cracking
g occurs in the
Statement ((I):
heat effected zone adjacent to fusion zone and
classified as solid state cracking
Statement (II):Hydrogen from burning of flux coating
penetrates martensitic micro cracks preventing healing
as well as enlarging them.
them
(a) Both Statement (I) and Statement (II) are individually
true and Statement (II) is the correct explanation of
Statement (I)
((b)) Both Statement ((I)) and Statement ((II)) are individuallyy
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
Rev.0
Lathe
h
B SKM d l
BySKMondal
L th
Lathe
L th
Lathe
NumberofSpindleSpeed
y Number of spindle speed is in a geometric progression.
progression
y If n number of spindle speed is required with N1 is the
y carriage this part of the lathe carries the cutting tool and
moves based on the rotation of the lead screw or rod.
y Lead
L d screw A large
l
screw with
ith a few
f threads
th d per inch
i h used
d
Generalclassificationsusedwhendescribinglathes
y Swing the largest diameter of work that can be rotated.
rotated
y Distance Between Centres the longest length of
workpiece
y Length of Bed Related to the Distance Between
C t
Centres
y Power The range of speeds and feeds, and the
horsepower available
IES 2001
IES
IES 1992
IES
Thespindlespeedrangeinageneralpurposelathe
isdividedintostepswhichapproximatelyfollow
(a) Arithmeticprogression
(b) Geometricprogression
(c) Harmonicprogression
((d)) Logarithmicprogression
g
p g
Feedgearboxforascrewcuttinglatheisdesigned
onthebasisof
(a) Geometricprogression
(b) Arithmeticprogression
(c) Harmonicprogression
((d)) None.
N n1
Therefore, Step Ratio ( r ) = max
N min
y The values of step ratios are 1.06, 1.12, 1.26, 1.41, 1.58 and 2
For-2015 (IES, GATE & PSUs)
Page 70 of 240
Rev.0
Threading
T i
Turning
y Turning
Turning producesasmoothandstraightoutsideradius
onapart.
y Threading
Threading Thecuttingtoolismovedquicklycutting
threads.
IES 1998
IES
h di
Threading
y Inonerevolutionofthespindle,carriagemusttravel
thepitchofthescrewthreadtobecut.
N s Pz s = N L Lz L
P = Pitch of the screw thread to be cut
L = Pitch of the lead screw
z s = Number of start of the screw thread to be cut
z L = Number of start of the lead screw
icg = gear ratio
ti off spindle
i dl ( N s ) to
t carriage
i ( N L ) gear train
t i
Facing
y Facing The end of the part is turned to be square.
square
Tapering
y Tapering
Tapering thetoolismovessoastocutataper(cone
shape).
IES 1993,ISRO2009
1993 ISRO 2009
IES
It is required to cut screw threads of 2 mm pitch on
a lathe. The lead screw has a pitch of 6 mm. If the
spindle speed is 60 rpm, then the speed of the lead
screw will be
(a) 10 rpm
(b) 20 rpm
(c) 120 rpm
(d) 180 rpm
P ti /Sl tti /G
i
Parting/Slotting/Grooving
y A tool is moved in/out of the work.
work shallow cut will leave
Page 71 of 240
Rev.0
D illi /B i
Drilling/Boring
K li
Knurling
S i i
Spinning
ISRO2007
Spinning operation is carried out on
(a) Hydraulic press
(b) Mechanical press
Reaming
y A reamer enters the workpiece axially through the end
Tapping
y A tap enters the workpiece axially through the end and
(c) Lathe
(d) Milling
Milli machine
hi
W k h ldi D i
f L th
WorkholdingDevicesforLathes
y Held between centers
y 3 jaw self centering chuck (Disc type jobs being held
in chucks )
y 4 jaw independently adjusted chuck
y Held in a collet (Slender rod like jobs being held in
collets )
y Mounted on a face plate (Odd shape jobs, being held
p
)
in face plate)
y Mounted on the carriage
y Mandrels
(IES,
GATE
y MagneticFor-2015
chuck for
thin
job & PSUs)
L th h k
Lathechucks
pp
y Lathe chucks are used to support
a wider varietyy of
workpiece shapes and to permit more operations to be
performed than can be accomplished when the work is
held between centers.
y Threejaw, selfcentering chucks are used for work that
has a round or hexagonal cross section.
y Each jaw in a fourjaw independent chuck can be moved
inward and outward independent of the others by means
of a chuck wrench. Thus they can be used to support a
wide
id variety
i t off work
k shapes.
h
y Combination fourjaw chucks are available in which each
j
jaw
can be
b moved
d independently
i d
d tl or can be
b moved
d
Page of
72 aofspiral
240 cam.
simultaneously by means
3JawChuck
4JawChuck
Rev.0
T i
Turning
F
l f T i
FormulaforTurning
y Depth of cut,
cut d = DOC =
Collets
D1 D2
mm
2
Magnetic Chuck
MagneticChuck
Davgg =
D1 + D2
mm
2
y Cutting Time,
Time CT = L + A + O
fN
M RR =
y Cutting Speed, V =
Face Plate
FacePlate
Example
How much
time will
h machining
h
ll be
b required
d to reduce
d
the diameter of a cast iron rod from 120 mm to 116 mm
over a length of 100 mm by turning using a carbide
insert. Cutting velocity is 100 m/min and feed rate = 0.2
mm/rev.
IES 2010
IES2010
In turning a solid round bar, if the travel
of the cutting tool in the direction of
f d motion
feed
i
i 1000 mm, rotational
is
i
l
speed
p
of the workpiece
p
is 5500 rpm,
p , and
rate of feed is 0.2 mm/revolution, then
th machining
the
hi i time
ti
will
ill be
b
(a) 10 seconds
(b) 100 seconds
(c) 5 minutes
(d) 10 minutes
IAS 2002
IAS
A 150 mm long, 12 mm diameter 304 stainless steel
rod is being reduced in diameter to 115 mm by
turning on a lathe. The spindle rotates at N = 400
rpm and the tool is travelling at an axial speed of
200 mm/min. The time taken for cutting is given by
(a) 30 s
(b) 36 s
( ) 1 minute
(c)
i t
(d) 45 s
Page 73 of 240
(D
2
1
D 22
4 / fN
)=
D a v g d fN
D1N
,m / min
1000
IES 2003
IES
The time taken to face a workpiece of 72 mm
diameter, if the spindle speed is 80 r.p.m. and cross
feed is 0.3 mm/rev, is
(a) 1.5 minutes (b) 3.0 minutes
( ) 5.4 minutes
(c)
i t (d) 8.5
8 minutes
i t
IES 2004
IES
A medium carbon steel workpiece is turned on a
lathe at 50 m/min. cutting speed 0.8 mm/rev feed
and 1.5 mm depth of cut. What is the rate of metal
removal?
(a) 1000 mm3/min
(b) 60,000 mm3/min
(c) 20,000 mm3/min
((d)) Can not be calculated with the g
given data
Rev.0
T i T
L th
TurningTapersonLathes
y Usingacompoundslide,
d ld
y Usingformtools,
y Offsettingthetailstock,and
y Usingtaperturningattachment.
IES 2006
IES
For taper turning on centre lathes, the method of
swiveling the compound rest is preferred for:
(a) Long jobs with small taper angles
(b) Long jobs with steep taper angles
(c) Short jobs with small taper angles
((d)) Short jjobs with steep
p taper
p angles
g
h=
L(D d )
or h = L tan
2l
E
l
Example
Find the angle at which the compound rest should
be set up to turn taper on the workpiece having a
length of 200 mm, larger diameter 45 mm and the
smaller 30 mm.
IES 1992
IES
Tailstocksetovermethodoftaperturningis
preferredfor
(a) Internaltapers
(b) Smalltapers
(c) Longslendertapers
((d)) Steeptapers
p p
Page 74 of 240
UsingaCompoundSlidecontd..
y The angle is determined by
tan =
= Half taper angle
Dd
2l
D = Diameter of stock
d = smaller diameter
l = length of the taper
Off tti th t il t k
Offsettingthetailstock
y It is necessary to measure the tailstock offset when using
this method.
y This method is limited to small tapers (Not exceeding 8o
) over long lengths.
y By
B offsetting
ff tti the
th tailstock,
t il t k the
th axis
i off rotation
t ti off the
th job
j b
is inclined by the half angle of taper.
IAS 2002
IAS
The amount of offset of tail stock for turning taper
on full length of a job 300 mm long which is to have
its two diameters at 50 mm and 38 mm respectively
is
(a) 6 mm
(b) 12 mm
(c) 25 mm
(d) 44 mm
Rev.0
IES 1998
IES
A 400 mm long shaft has a 100 mm tapered step at
the middle with 4 included angle. The tailstock
offset required to produce this taper on a lathe
would be
(a) 400 sin 4
4 (b) 400 sin 22
(c) 100 sin 4 (d) 100 sin 2
F
t l
Formtool
E
i t l tti
Errorsintoolsettings
y Setting the tool below the centre decrease actual rake angle,
T
t L th
TurretLathe
TurretLathe
IES 2010
IES2010
The effect of centering error
when the tool is set above the
center line as shown in the figure
results
lt effectively
ff ti l in
i
1. Increase in rake angle.
2. Reduction
R d ti in
i rake
k angle.
l
3. Increase in clearance angle.
4. Reduction
R d i in
i clearance
l
angle.
l
Which of these statements is/are
correct?
t?
(a) 1 only
(b) 1 and 4 only
( ) 2 and
(c)
d 4 only
l
(d) 1, 2, 3 and
d4
CapstanLathe
p
Page 75 of 240
Rev.0
Capstan lathe
Turret lathe
A t
ti L th
AutomaticLathe
y The term automatic is somewhat loosely applied, but is
l i S i dl
i
h
MultiSpindleAutomaticLathe
IES 2012
IES
Lathe machine with turret can turn a work piece of
limited length only because,
(a) Cross slide motion is obstructed by turret
(b) Turret cannot work on a long job
(c) Chuck cannot be replaced by a face plate
((d)) Turret replaces
p
the loose centre
i d i
h i
Turretindexingmechanism
y The
indexing)
h hexagonal
h
l turret is rotated
d (for
(f
d
) by
b a
N t t
T bl
i k h
G
b
NortontypeTumblergearquickchangeGearbox
p
y It comprises
a cone of g
gears 1 to 8 mounted on shaft S2.
y The tumbler gear can slide on shaft S1. It can mesh with any
located
ocated o
on a sswinging
g g aand
d ssliding
d g lever
e e so tthat
at itt ca
can eengage
gage
y The lever can be fixed in any desired ratio position with the
Page 76 of 240
shaft S2.
Rev.0
GATE 2002
GATE
A leadscrew
with
to
l d
ith half
h lf nuts
t in
i a lathe,
l th free
f
t rotate
t t
in both directions has
(a) Vthreads
(b) Whitworth threads
(c) Buttress threads
GATE 2008
2008
GATE
GATE 2008
GATE2008
Contd.
IES 2004
IES
Match List I (Cutting tools) with List II (Features)
and select the correct answer using the codes given
below the Lists:
List I
List II
A Turning
A.
T i tool
t l
1.
Chi l edge
Chisel
d
B. Reamer
2.
Flutes
C. Milling cutter
3.
Axial relief
4.
Side relief
Codes: A
B
C
A
B
C
( ) 1
(a)
2
3
(b) 4
3
2
(c) 4
2
3
(d) 1
3
2
IES 2009
IES
Whatisthenumberofjawsinself
centred chuck?
Whatisthenumberofjawsinselfcentred
(a) Eight
(b) Six
Si
(c) Four
(d) Three
G
99
GATE1994
To get good surface finish on a turned job,
job
one should use a sharp tool with a ..feed
and
d
speed
d off rotation
t ti off the
th job.
j b
((a)) Minimum, minimum
(b) Minimum, maximum
( ) Maximum,
(c)
M i
maximum
i
((d)) Maximum,, minimum
IES 1999
IES
Which one of the following sets of forces are
encountered by a lathe parting tool while groove
cutting?
(a) Tangential, radial and axial
(b) Tangential
T
ti l and
d radial
di l
(c) Tangential and axial
(d) Radial and axial
Page 77 of 240
ThecorrectconnectionsandthecorrectplacementofUsare
givenby
((a)) Q
QandEareconnected. Us,,isplacedbetweenPandQ.
p
Q
(b) SandEareconnected.Us isplacedbetweenRandS.
((c)) Q
QandEareconnected.Us,,isplacedbetweenQandE.
p
Q
(d) SandEareconnected.Us,isplacedbetweenSandE.
IES 1996
IES
Inturningofslenderrods,itisnecessarytokeep
thetransverseforceminimummainlyto
(a) Improvethesurfacefinish
(b) Increaseproductivity
(c) Improvecuttingefficiency
((d)) Reducevibrationsandchatter.
IES 2009
IES
Whichoneofthefollowingmethodsshouldbeused
forturninginternaltaperonly?
(a) Tailstockoffset
(b) Taperattachment
(c) Formtool
((d)) Compoundrest
p
Rev.0
IES 1992
IES
Whichofthefollowingstatementisincorrectwith
referenceoflathecuttingtools?
(a) Theflankofthetoolisthesurfacebelowand
adjacenttothecuttingedges
(b) Thenoseisthecorner,orchamferjoiningtheside
Th
i th
h f j i i th id
cuttingandtheendcuttingedges
(c) Theheelisthatpartofthewhichisshapedto
producethecuttingedgesandface
(d) Thebaseisthatsurfaceoftheshankwhichagainst
pp
g
thesupportandtakestangent
IES 2006
IES
It is required to cut screw threads with double start
and 2 mm pitch on a lathe having lead screw pitch
of 6 mm. What is the speed ratio between lathe
spindle and lead screw?
(a) 1 : 3 (b) 3: 1
(c) 2 : 3 (d) 3: 2
IES 2009
IES
A capstan lathe is used to mass
produce, in batches
massproduce,
of 200, a particular component. The direct material
cost is Rs 4 per piece, the direct labour cost is Rs 3
per piece and the overhead costs are 400% of the
labour costs. What is the production cost per piece?
(a) Rs 19 (b) Rs 23
( ) Rs
(c)
R 16
6 (d) Rs
R 15
IES 1995
IES
C
g characteristics:
Consider the following
1. Multiple operations can be performed
2 Operator
2.
Operator'ss fatigue is greatly reduced.
reduced
3. Ideally suited for batch production
4 A breakdown
4.
break down in one machine does not affect the
flow of products.
5 Can accommodate modifications in design of
5.
components, within certain limits.
The characteristics which can be attributed to special
purpose machines would include
(a) 1,
1 3 and 4 (b) 1,
1 2 and 4
GATE
(c) 2, 3 and For-2015
5 (d) (IES,
1, 2 and
5 & PSUs)
IES 1996
IES
Assertion (A): Special purpose machine tools and
automatic machine tools are quite useful for job
shops
Reason (R): Special purpose machine tools can do
special types of machining work automatically
(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 isPage
true78 of 240
IES 1997
IES
Consider the following operations:
1. Under cutting
2.
Plain turning
3. Taper
T
t
turning
i
4.
Th d cutting
Thread
tti
The correct sequence of these operations in machining a
product is
((a)) 2, 33, 4
4, 1
((b)) 33, 2, 4
4, 1
(c) 2, 3, 1, 4
(d) 3, 2, 1, 4
IES 2007
IES
Assertion (A): In a multi
spindle automatic lathe, the
multispindle
turret tool holder is indexed to engage the cutting tools
one by
y one for successive machining
g operations.
p
Reason (R): Turret is a multiple tool holder so that for
successive machining
g operation,
p
, the tools need not be
changed.
((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
IES 2003
IES
Which one of the following mechanisms is
employed for indexing of turret in an automatic
lathe?
(a) Whitworth
(b) Rack and pinion
( ) Ratchet
(c)
R t h t and
d pawll
(d) Geneva
G
wheel
h l
Rev.0
IES 2009
IES
For the manufacture of screw fasteners on a mass
scale, which is the most suitable machine tool?
(a) Capstan lathe
(b) Singlespindle automatic lathe
(c) CNC turning centre (lathe)
((d)) CNC machining
g centre
IES 1992
IES
Maximum production of small and slender parts is
done by
(a) Watch maker
maker'ss lathe
(b) Sliding head stock automatic lathe
(c) Multispindle automatic lathe
((d)) Capstan
p
lathe
IAS 1996
IAS
Apart from hexagonal turret, the elements (s) in a
turret lathe include (s)
(a) Crossslide
Cross slide tool post
(b) Crossslide tool post and rear tool post
(c) Crossslide tool post and tail stock
((d)) Teal tool p
post and tail stock
IES 2001
IES
The indexing of the turret in a single
spindle
singlespindle
automatic lathe is done using
(a) Geneva mechanism
(b) Ratchet and Pawl mechanism
(c) Rack and pinion mechanism
((d)) Whitworth mechanism
IAS 2007
IAS
Which one of the following is the characteristic for
capstan lathe?
(a) Rate of production is low
(b) Labour cost is high
(c) Used for handling jobs of varying shapes and sizes
((d)) Capstan
p
head is mounted on a slide
IAS 2004
IAS
Swiss type screw machines have
(a) Turrets
(b) Radial slides
( ) Spindle
(c)
S i dl carriers
i
(d) Tool
T l posts
t
Page 79 of 240
IES 1995
IES
) In a Swiss type
yp automatic lathe,, the
Assertion ((A):
turret is given longitudinal feed for each tool in a
specific order with suitable indexing.
Reason (R): A turret is a multiple tool holder to
facilitate machining with each tool by indexing
without the need to change the tools.
(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
IAS 2002
IAS
Consider the following statements related to Turret
lathe:
1 Turret is mounted directly on the saddle.
1.
saddle
2. Turret is mounted on an auxiliary slide.
3. Much heavier and larger jobs than Capstan lathe can
be produced.
Which of the above statements is/are correct?
(a) 1 and 3
(b) 2 and 3
(c) 1 only
(d) 2 only
IAS 2001
IAS
Consider the following operations and time
required on a multi spindle automatic machine to
produce a particular job
1. Turning
1.2 minutes
2. Drilling
D illi
1.6
6 minutes
i t
3. Forming
0.2 minute
4. Parting
0.6 minute
The time required to make one piece (cycle time) will be
(a) 0.6 minutes
(b) 1.6 minutes
( ) 3.6
(c)
6 minutes
i t
(d) 0.9 minute
i t
Rev.0
IAS 1995
IAS
) In a multispindle
p
Assertion ((A):
automat,, the turret
is indexed to engage each of the cutting tool
mounted on it.
Reason(R): Turret is a multiple tool holder so that
the machining can be continued with each tool
without the need to change the tool.
(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
IAS 1994
IAS
A multi
spindle automat performs four operations
multispindle
with times 50, 60, 65 and 75 seconds at each of its
work centers. The cycle time (time required to
manufacture one work piece) in seconds will be
(a) 50 + 60 + 65 + 75
(b) (50 + 60 + 65 + 75) /4
(c) 75/4
((d)) 75
IAS 1998
IAS
IES2011
IAS 2000
IAS
IAS 1998
IAS
Drilling
D illi
Drilling
y Drilling is a operation that cuts cylindrical holes.
holes
BySKMondal
Page 80 of 240
Rev.0
D illi O
ti
DrillingOperations
Chip formation
of a drill
y Verticalorpillartype
V ti l ill t
y RadialArmtype
y Gangdrill
g
y MultiSpindledrill
y NumericalControldrill
Drill
y The twist drill does most of the cutting with the tip of
D ill
Drill
the bit.
There are flutes
to carry the chips
up
from
the
cutting edges to
the top of the
hole where they
are cast off.
IES 2004
IES
Consider the following statements:
The helical flute in a twist drill provides the necessary
1. Clearance
Cl
angle
l for
f the
th cutting
tti edge
d
2. Rake angle for the cutting edge
3. Space for the chip to come out during drilling
4. Guidance for the drill to enter into the workpiece
Which of the statements given above are correct?
( ) 1 and
(a)
d2
(b) 2 and
d3
(c) 3 and 4
(d) 1 and 4
IES 2003
IES
D ill
Drill
D ill
Drill
y Axial rake angle is the angle between the face and the line
y Drill sizes
si es are typically
t picall measured across the drill points with
ith
a micrometer
y Most widely used material is High Speed Steel
y The drill blanks are made by forging and then are twisted to
Rev.0
GATE 1996
GATE
The rake angle in a drill
(a) Increases from centre to periphery
(b) decreases
d
f
from
centre
t to
t periphery
i h
(c) Remains constant
(d) Is irrelevant to the drilling operation
H li A l ()
HelixAngle()
y Helix angle is the angle between the leading edge of the
IES 1992
IES
Low helix angle drills are preferred for drilling
holes in
(a) Plastics
(b) Copper
(c) Cast steel
(d) Carbon steel
IES 1997
IES
P i t A l (2)
PointAngle(2)
y
y
y
y
y
y
IES 1992
IES
A drill for drilling deep
have
(a) High helix angle
(c) Small point angle
GATE 1997
GATE
Taper shank
No lip
IFS2011
y Thecuttingspeedindrillingisthesurfacespeedofthe
twistdrill.
V=
DN
1000
m / min
i
[5marks]
Page 82 of 240
Rev.0
D illi Ti
DrillingTime
y Time for drilling the hole
T=
L
, min
i
fN
MRR i D illi
MRRinDrilling
D2
3
MRR =
fN , mm / min
4
E
l
Example
A hole
h l with
ith 40mm diameter
di
t and
d 50mm depth
d th is
i to
t
be drilled in mild steel component.
p
The cutting
g
speed can be taken as 65 m/min and the feed rate as
0.25 mm/rev. Calculate the machining time and the
material
t i l removall rate.
t
f
sin
i
2
D
2sin
GATE 2002
GATE
The time taken to drill a hole through a 25 mm thick
plate with the drill rotating at 300 r.p.m. and
moving at a feed rate of 0.25 mm/revolution is
(a) 10 sec
(b) 20 sec
( ) 60
(c)
6 sec
(d) 100 sec
t
( 2r / D ) tan
Orthogonal rake angle ( ) = tan 1
sin
GATE 2012
GATE
In
a through
I a single
i l pass drilling
d illi operation,
ti
th
h hole
h l off
155 mm diameter is to be drilled in a steel p
plate of 550
mm thickness. Drill spindle speed is 500 rpm, feed
is 0.2 mm/rev and drill point angle is 118. Assuming
2 mm clearance
l
att approach
h and
d exit,
it the
th total
t t l drill
d ill
time ((in seconds)) is
(a) 35.1
(c) 31.2
IES 2002
IES
The arm of a radial drilling machine is being raised
at a speed of 3.9 m/min by single start square
threads of 6 mm pitch and 30 mm diameter. The
speed of the screw
(a) Is 650 rpm
(b) Is 180 rpm
(c) Is 130 rpm
((d)) Cannot be determined as the data is insufficient
GATE 2004
GATE
Through holes of 10 mm diameter are to be drilled
in a steel plate of 20 mm thickness. Drill spindle
speed is 300 rpm, feed 0.2 mm/ rev and drill point
angle is 120. Assuming drill over travel of 2 mm, the
time for producing a hole will be
(a) 4 seconds
(b) 25 seconds
( ) 100 seconds
(c)
d
(d) 110 seconds
d
IES 1994
IES
The ratio between two consecutive spindle speeds
for a sixspeed drilling machine using drills of
diameter 6.25 to 25 mm size and at a cutting velocity
of 18 m/min is
(a) 1.02
1 02 (b) 1.32
1 32
(c) 1.62 (d) 1.82
(b) 32.4
For-2015 (IES,
GATE & PSUs)
(d) 30.1
Page 83 of 240
Rev.0
IES 2009
IES
What is the drilling time for producing a hole in an
MS sheet of 25 mm thickness using an HSS drill of
20 mm diameter? The cutting speed and feed for
drill are 20 m/min and 0.25 mm/revolution
respectively, Neglect time taken for setting up,
approaching and travelling of tools.
(a) 0.314
0 314 min (b) 0.236
0 236 min
(c) 0.438 min (d) 0.443 min
IES 2002
IES
A 31.8 mm H.S.S. drill is used to drill a hole in a cast
iron block 100 mm thick at a cutting speed 20
m/min and feed 0.3 mm/rev. If the over travel of
drill is 4 mm and approach 9 mm, the time required
to drill the hole is
(a) 1 min 40 s (b) 1 min 44 s
( ) 1 min
(c)
i 49 s (d) 1 min
i 53 s
GATE 2014
GATE
A hole
h l off 20 mm diameter
di
t is
i to
t be
b drilled
d ill d in
i a steel
t l block
bl k
of 4
40 mm thickness. The drilling
g is p
performed at
rotational speed of 400 rpm and feed rate of 0.1 mm/rev.
The required approach and over run of the drill together
i equall to
is
t the
th radius
di
off drill.
d ill The
Th drilling
d illi
ti
time
(i
(in
minute)) is
(a) 1.00
IAS 1999
IAS
GATE2014(PI)
An HSS drill of 20 mm diameter with 5 mm cone
height is used to drill a through hole in a steel work
work
piece of 50 mm thickness. Cutting speed of 10
m/min and feed rate of 0.3 mm/rev are used. The
(b) 1.25
(c) 1.50
(d) 1.75
GATE 2007(PI)LinkedS1
2007 (PI) Li k d S 1
GATE
Blind holes 10 mm diameter, 50 mm deep are
being drilled in steel block. Drilling spindle
speed is 600 rpm,
rpm feed 0.2
0 2 mm/rev,
mm/rev point angle of
drill is 120o.
Machining time (in minutes) per hole will be
(a) 0.08
0 08
(b) 0.31
0 31 (c) 0.44
0 44 (d) 0.86
0 86
GATE 2007(PI)LinkedS2
2007 (PI) Li k d S 2
GATE
Blind holes 10 mm diameter, 50 mm deep are
being drilled in steel block. Drilling spindle
speed is 600 rpm,
rpm feed 0.2
0 2 mm/rev,
mm/rev point angle of
drill is 120o.
During the above operation, the drill wears out
after p
producing
g 200 holes. Taylors
y
tool life
equation is of the form VT0.3 = C, where V =
cutting speed in m/minute and T = tool life in
minutes. Taylors constant C will be
( ) 15
(a)
( ) 72
(b)
( ) 93
(c)
( ) 490
(d)
For-2015 (IES, GATE & PSUs)
IAS 1994
IAS
The time (in minutes) for drilling a hole is given by
t=
Page 84 of 240
IES 1999
IES
pp
Match ListI (Drill bits) with ListII (Applications)
and select the correct
answer using the codes given below the Lists:
ListI
ListII
A Core
A.
C
d ill
drill
1.
T enlarge
To
l
a hole
h l to
t a certain
t i depth
d th so as to
t
accommodate the bolt head of a screw
g an alreadyy existing
g hole in a
B.
Reamer 2.
To drill and enlarge
casting
C.
Counter bore drill 3.
To drill a hole before making internal
thread
h d
D.
Tap drill
4.
To improve the surface finish and dimensional
accuracy of the already drilled hole
Code:A
B
C
D
A
B
C
D
(a) 1
3
2
4
(b)
2
3
1
4
(c) 2
4
1
3
(d)
3
2
4
1
Rev.0
R
i
Reaming
Reamer
Reaming,Boring,Broaching
straight
i h or in
i a helix
h li are used.
d
y No special machines are built for reaming. The same
B SKM d l
BySKMondal
machine that was employed for drilling the hole can be used
for reaming by changing the cutting tool.
y Only a minimum amount of materials should be left for
removal by reaming. As little as 0.1 mm is desirable, and in
no case should the amount exceed 0.4 mm.
y A properly reamed hole will be within 0.025 mm of the
correct size and have a fine finish.
Reamer Flutes
ReamerFlutes
y The reamer flutes are either straight or helical.
y The helical flutes promote smoother cutting and should be
y
y
R
i
Reaming
R
i
Reaming
accuracy (tolerances on
diameter,
roundness,
straightness, and absence of bell
bellmouth
mouth at ends of
holes). Reamers must have adequate support for the
cutting edges, and reamer deflection must be minimal.
y Reaming speed is usually twothirds the speed for
drilling the same materials.
materials However,
However for close tolerances
and fine finish, speeds should be slower.
y Feeds
F d are usually
ll much
h higher
hi h than
th
th
those
f drilling
for
d illi
and depend upon material.
y Recommended cutting fluids are the same as those for
For-2015 (IES, GATE & PSUs)
drilling.
T
fR
TypesofReamers
Theprincipaltypesofreamersare:
1. Handreamers
a.
St i ht
Straight
b.
Taper
2. Machineorchuckingreamers
a.
Rose
b.
Fluted
3. Shellreamers
Sh ll
4. Expansionreamers
5. Adjustablereamers
RoseReamer
Rose chucking reamers
are ground
d cylindrical
li d i l
and have no relief
b hi d the
behind
th outer
t edges
d
of the teeth. All cutting
is done on the beveled
be eled
ends of the teeth
Rev.0
g
ChuckingReamer
Fluted
chucking
reamers have
h
relief
li f
behind the edges of the
t th as well
teeth
ll as beveled
b l d
ends. They can cut on
all portions of the teeth.
teeth
Their
flutes
are
relatively short and they
are intended for light
finishing cuts.
cuts
Trepanning
y Trepanning is a annular groove producing operation
ShellReamer
Shell reamers often are
used
d for
f sizes
i
over 20
mm to save cuttingtool
material.
t i l
Th
The
shell,
h ll
made of HSS for smaller
si es and with
sizes
ith carbide
edges for larger sizes or
for
mass production
massproduction
work.
IES 1999
IES
Which one of the following processes results in the
best accuracy of the hole made?
(a) Drilling
(b) Reaming
(c) Broaching (d) Boring
IFS2011
What is the main difference between rose reamer
and chucking reamer ? Write in short about shell
reamer.
[
[5marks]
k ]
IES 1999
IES
Consider the following statements regarding
reaming process:
1 Reaming generally produces a hole larger than its
1.
own diameter
2. Generally
G
ll rake
k angles
l are nott provided
id d on reamers.
3. Even numbers of teeth are preferred in reamer
design.
Which of these statements are correct?
(a) 1 and 2
(b) 2 and 3
(c) 1 and 3
(d) 1,
1 2 and 3
TrepanningTool
IES 1998
1998
IES
Match List
II and select the correct answer
ListII with List
ListII
using the codes given below the lists:
ListII
List
ListII
List
II
A. Reaming
1. Smoothing and squaring surface
around the hole for proper seating
B. Counterboring 2.Sizing and finishing the hole
C Countersinking
C.
Counter sinking 3.
3 Enlarging the end of the hole
D. Spot facing
4. Making a conical enlargement at the
end of the hole
Code:A
B
C
D
A
B
C
D
( ) 3
(a)
2
4
1
( ) 2
(b)
3
1
4
For-2015 (IES, GATE & PSUs)
(c) 3
2
1
4
(d) 2
3
4
1
IES 1994
IES
In reaming process
(a) Metal removal rate is high
(b) High
Hi h surface
f
fi i h is
finish
i obtained.
bt i d
(c) High form accuracy is obtained
(d) High dimensional accuracy is obtained.
Page 86 of 240
GATE 2007(PI)
2007 (PI)
GATE
Reaming is primarily used for achieving
(a) Higher MRR
(b) Improved
I
d dimensional
di
i
l tolerance
t l
(c) Fine surface finish
(d) Improved positional tolerance
Rev.0
GATE 2014(PI)
2014 (PI)
GATE
Reamingisaprocessusedfor
R
i i
df
(a)creatingacircularholeinmetals
(b)cuttingaslotontheexistingholesurface
g
g
(c)finishinganexistingholesurface
(d)makingnoncircularholesinmetals
IES 1993
IES
A hole of 30 mm diameter is to be produced by reaming.
The minimum diameter permissible is 30.00 mm while
the maximum diameter p
permissible is 330.055 mm. In this
regard, consider the following statements about the
reamer size:
1. The minimum diameter of the reamer can be less than 30 mm.
2. The minimum diameter of the reamer cannot be less than 30 mm.
3. The maximum diameter of the reamer can be more than 30.05 mm.
4.The maximum diameter of the reamer must be less than 30.05 mm.
Of these statements
(a)
1 and 4 are correct
(c)
2 and 3 are correct
IAS 1999
IAS
For reaming operation of blind hole, the type of
reamer required is
(a) Straight flute reamer
(b) Right hand spiral fluted reamer
(c) Left hand spiral fluted reamer
((d)) None of the above
Boring
(b)
(d)
IAS 2003
IAS
p
) with List II ((Application)
pp
) and select
Match List I ((Operation)
the correct answer using the codes given below the lists:
ListI
ListII
(
(Operation)
)
(
(Application)
)
(A) Reaming 1. Used for enlarging the end of a hole to give it a
conical
i l shape
h
f a short
for
h distance
di
(B) Boring
2. Used for enlarging only a limited portion of the
hole
(C) Counter boring
3.
Used for finishing a hole
(D) Counter sinking
4
4.
Used for enlarging a hole
Codes:A
B
C
D
A
B
C
D
(a) 3
2
4
1
(b)
1
4
2
3
(c) 3
4
2
1
(d)
1
2
4
3
IES 1998
IES
A component requires a hole which must be within
the two limits of 25.03 and 25.04 mm diameter.
Which of the following statements about the
reamer size are correct?
1 Reamer size cannot be below 25.03
1.
25 03 mm.
mm
2. Reamer size cannot be above 25.04 mm.
3. Reamer size can be 25.04 mm.
4. Reamer size can be 25.03
4
5 3 mm.
Select the correct answer using the codes given below:
(a) 1 and 3
(b) 1 and 2
(c) 3 and 4
(d) 2 and 4
IES 1992
IES
Shell reamers are mounted on
(a) Tool holders
(b) Amour plates
( ) Arbor
(c)
Ab
(d) Shanks
Sh k
Boring
y Boring always involves the enlarging of an existing hole,
Rev.0
B i
Boring
B i
Boring
axis of rotation.
rotation Slightly larger end clearance angles
sometimes have to be used to prevent the heel of the tool
from rubbing on the inner surface of the hole.
hole
F
l f B i
FormulaforBoring
y Average diameter of workpiece
Davg =
IES 1993
IES
D1 + D2
mm
2
y Cutting Time,
Time CT = L + A + O
fN
IES2009
IES 1994,ISRO2008
1994 ISRO 2008
IES
Enlarging an existing circular hole with a rotating
single point tool is called
(a) Boring
(b) Drilling
(c) Reaming (d) Internal turning.
(D
2
1
D 22
4 / fN
)=
D a v g d fN
IES 1992,ISRO2010
1992 ISRO 2010
IES
Which of the machine tools can be used for boring
1. Lathe
2. Drilling
D illi machine
hi
3. Vertical milling machine
4. Horizontal milling machine
(a) 1, 2, 3
(b) 1, 3, 4
(c) 2 and 4
(d) 1, 2, 3, 4
IES 2000
IES
Which one of the following sets of tools or tools and
processes are normally employed for making large
diameter holes?
(a) Boring tool
(b) BTA tools
t l (Boring
(B i and
d trepanning
t
i association)
i ti ) and
d
gun drill
(c) Gun drill and boring tool
((d)) Boring
g tools and trepanning
p
g
Page 88 of 240
IES 1996
IES
Which of the following statements are correct?
1. A boring machine is suitable for a job shop.
2. A jig
ji boring
b i machine
hi is
i designed
d i
d specially
i ll for
f doing
d i
more accurate work when compared to a vertical
milling
illi machine.
hi
3. A vertical precision boring machine is suitable for
boring holes in cylinder blocks and liners.
((a)) 1, 2 and 3 ((b)) 1 and 2
(c) 2 and 3
(d) 1 and 3.
Rev.0
IES 1995
IES
The effects of setting a boring tool above centre
height leads to a/an.
(a) Increase in the effective rake angle and a decrease in
the effective clearance angle.
(b) Increase
I
i both
in
b th effective
ff ti rake
k angle
l and
d effective
ff ti
clearance angle.
(c) Decrease in the effective rake angle and an increase
in the effective clearance angle.
(d) Decrease in both effective rank angle and effective
g
clearance angle.
JWM2010
Considerthefollowingoperationsregardingboring
machines:
1.Counterboring
C
t b i
2.Countersinking
3.Trepanning
Whichoftheaboveoperationsis/arecorrect?
(a)1,2and3
(b)1and2only
( ) d l (d)1only
(c)2and3only
(d) l
Broaching
B
hi
Broaching
g is a multipletooth
p
g operation
p
y Broaching
cutting
with the
tool reciprocating.
y Since in broaching
g the machining
g operation
p
is
completed in a singlestroke as the teeth on the cutting
tool, called broach, are at gradually increasing height
corresponding to the feed per tooth of a milling cutter.
y The shape of the broach determines the shape of the
machined part.
y Broaching was originally developed for machining
internal keyways, but looking at the advantages, it has
been extensively used in the mass production of
automobile
t
bil componentt manufacture
f t
f various
for
i
other
th
surfaces as well.
Broaching
B
h C t ti
BroachConstruction
B
h C t ti
BroachConstruction
B
h C t ti
BroachConstruction
B
h C t ti
BroachConstruction
Rev.0
B
h C t ti
BroachConstruction
B
h C t ti
BroachConstruction
Li it ti
fb
hi
Limitationsofbroaching
p
1. C
Custom made broaches are veryy expensive
and can
therefore be justified only for very large volume
production.
2. A broach has to be designed for a specific application
and can be used only for that application. Hence, the
lead time for manufacture is more for custom designed
broaches.
3. Broaching, being a very heavy metal removal
operation, requires that the workpiece is rigid and
capable
bl off withstanding
ith t di the
th large
l
f
forces.
4. Broaching can only be carried out on the workpiece
whose
h
geometry
t is
i such
h that
th t there
th
i no interference
is
i t f
f
for
the broach movement for the cutting.
IES 1993,2001
1993 2001
IES
Assertion (A): No separate feed motion is required
during broaching.
Reason (R): The broaching machines are generally
hydraulically operated.
( ) 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)
mm.
y In the normal speed BUE may be a problem. To avoid
this a copious supply of the cutting fluid is provided.
IES 2007
IES
Among the following machining processes, which
can be used for machining flat surfaces?
1 Shaping
1.
2
2.
Milling
3
3.
Broaching
Select the correct answer using the code given below:
(a) 1 and 2 only
(b) 1 and 3 only
((c)) 2 and 3 onlyy
((d)) 1, 2 and 3
IES 2001
IES
The screw and nut in a broaching machine are
changed from square thread to ACME thread. The
power requirement of the machine at the same
r.p.m. will
(a) Remain same
(b) Decrease
(c) Increase
((d)) Depend
p
on the operator
p
Page 90 of 240
Ad t
fb
hi
Advantagesofbroaching
g an operation
p
g
1. It is the fastest wayy of finishing
with a single
stroke.
2. Since all the machining parameters are built into the
broach very little skill is required from the operator.
broach,
operator
3. Broaching machine is simple since only a single
reciprocating
p
g motion is required
q
for cutting.
g
4. Final cost of the machining operation is one of the lowest
for mass production.
5. Any
A type off surface,
f
i
internal
l or external,
l can be
b generated
d
with broaching.
6 Many surfaces,
6.
surfaces which are very difficult or impossible by
other means, can be done by broaching. For example, square
hole and internal splines.
7. Good surface finish and fine dimensional tolerances can be
achieved by broaching, often better than boring or reaming
IES 1993
IES
Assertion (A): Soluble oils are employed with
broaching machine.
Reason (R): Soluble oils have excellent cooling
effect.
( ) 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
IAS 2004
IAS
Which one of the following is true for the last few
teeth of a broach which are meant for fine
finishing?
(a) They have equal diameter
(b) They
Th have
h
i
increasing
i diameter
di
t
(c) They have decreasing diameter
(d) They have alternately increasing and decreasing
diameter.
Rev.0
IES 2005
2005
IES
IES 2002
IES
(
) with List II (Element
(
Match List I (Tool)
of Tool)) and
select the correct answer using the code given below the
Lists:
List I
List II
A Broach
1.
Tang
B. Reamer
2.
Pilot
C. Drill
3.
Front taper
D. Carbide insert face mill 4.
Bond
5.
Sweeper tooth
Codes:A
B
C
D
A
B
C
D
(a) 2
5
1
3
(b) 1
3
4
5
(c) 2
3
1
5
(d) 1
5
4
3
Milli
Milling
Milli
Milling
y 2D
clutches
D contouring
t i like
lik cam profiles,
fil
l t h etc
t and
d 3D
D
U
illi
dd
illi
Upmillinganddownmilling
Ad t
fD
Milli
AdvantagesofDownMilling
Milling
B SKM d l
BySKMondal
U
illi
dd
illi
Upmillinganddownmilling
contouring
g like die or mould cavities
y Cutting teeth in piece or batch production of spur gears,
1.
to hold parts since
1 Suited to machine thin and hard
hardtohold
the workpiece is forced against the table or holding
device by the cutter.
2. Work need not be clamped as tightly.
3. Consistent
C
i t t parallelism
ll li
and
d size
i may be
b maintained,
i t i d
particularly on thin parts.
4. It may be used where breakout at the edge of the
workpiece could not be tolerated.
5. It requires upto 20% less power to cut by this method.
6. It may be used when cutting off stock or when milling
deep, thin slots.
Page 91 of 240
Di d t
fD
Milli
DisadvantagesofDownMilling
1. It cannot be used unless the machine has a backlash
eliminator and the table jibs have been tightened.
2. It cannot be used for machining castings or hot rolled
steel, since the hard outer scale will damage the cutter.
Rev.0
IES 2007
IES
What is the process of removing metal by a milling
cutter which is rotated against the direction of
travel of the work piece, called?
(a) Down milling
(b) Up milling
( ) End
(c)
E d milling
illi
(d) Face
F
milling
illi
IES 1997
IES
g statements:
Consider the following
In Up milling process,
1. The cutter starts the cut from the machined surface and
proceeds upwards.
p surface and
2. The cutter starts the cut from the top
proceeds downwards.
3. The job is fed in a direction opposite to that of cutter
rotation.
i
4. The job is fed in the same direction as that of cutter
rotation.
rotation
Of these statements correct are:
( ) 1 and
(a)
d3
(b) 1 and
d4
(c) 2 and 3
(d) 2 and 4
IES 2010
IES2010
Assertion (A): Climb or down milling operation ensures
smoother operation of the machine tool and longer tool life
as compared to the conventional up milling operation.
Reason (R):
( ) In climb or down milling operation, the
rotational motion of the cutter as well as the feed motion of
the workpiece
work piece are in the same direction,
direction and the depth of
cut is maximum at the entry point as the cutter engages the
workpiece.
p
(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
Cl ifi ti
f illi
hi
Classificationofmillingmachines
Cl ifi ti
f illi
hi
Classificationofmillingmachines
((c)) According
g to the orientation of the spindle(s).
p
( )
y Plain horizontal knee type
y Horizontal axis ((spindle)
p
) and swiveling
g bed type
yp
y Vertical spindle type
y Universal head milling machine
(d) According to mechanization / automation and
production rate
p
y Hand mill (milling machine)
y Planer and rotary
y table type
yp vertical axis milling
g machines
y Tracer controlled copy milling machine,
y Milling
g machines for short thread milling
g
y Computer Numerical Controlled (CNC) milling machine
Cl ifi ti
f illi
tt
Classificationsofmillingcutters
Cl ifi ti
f illi
tt
Classificationsofmillingcutters
Sl b Pl i
illi
tt
SlaborPlainmillingcutters
Page 92 of 240
IAS2009main
Definethetermfeedinmilling
Definetheterm
feedinmilling.[2Marks]
[2Marks]
Rev.0
Sid
d l t illi
tt
Sideandslotmillingcutters
Slitti
ti t l
Slittingsaworpartingtool
E d illi
tt
E d ill
EndmillingcuttersorEndmills
F
illi
tt
Facemillingcutters
U
ff
li d
( illi )
Useofformrelievedcutters(milling)
Toolformcutters
T slotcutter
l t tt
T
G
t th illi
tt
Gearteethmillingcutters
S li shaftcutters
h ft tt
Spline
Page 93 of 240
Rev.0
St ddl
illi
Straddlemilling
IES 1995,ISRO2010
1995 ISRO 2010
IES
G
illi
Gangmilling
IES 2006
IES
IAS2009Main
With a sketch, explain the principle of working
and variations of bedtype milling machine.
[9marks]
T i b
l ( illi
)
Turningbyrotarytools(millingcutters)
Gang milling is a
(a) Milling process for generating hexagonal surfaces
(b) Process
P
off cutting
tti gears
(c) Process in which two or more cutters are used
simultaneously
((d)) Milling
g operation
p
combined with turning
g
I d i
Indexing
IES 2009
IES
For machining, which one of the following gang
milling operations is employed?
(a) Threads
(b) Bores
(c) Grooves
((d)) Steps
p on p
prismatic p
parts
Si l
Pl i I d i
SimpleorPlainIndexing
y Plain indexing is the name given to the indexing method
Page 94 of 240
Rev.0
IES 2004,ISRO2011
2004 ISRO 2011
IES
One brand of milling machine has the following two
index plates supplied along with the indexing head:
Plate 1: 15, 16, 17, 18, 19, 20 hole circles
Plate 2: 21, 23, 27, 29, 31, 33 hole circles
It is proposed to mill a spur gear of 28 teeth using simple
indexing method. Which one of the following combinations
of index plate and number of revolutions is correct?
(a) Plate 1: 1 revolution and 9 holes in 18 hole circles
(b) Plate 2:
2 1 revolution
re olution and 9 holes in 21 hole circles
(c) Plate 2: 1 revolution and 9 holes In 33 hole circles
( ) Plate 1: 1 revolution and 9 holes In 15 hole circles
(d)
Milli V l it
MillingVelocity
IES 2000
IES
One of the index plates of a milling machine
dividing head has the following hole circles: 15; 16;
17; 18; 19; 20
A gear wheel of 34 teeth has to be milled by simple
indexing method.
method To machine each tooth,
tooth the index
crank has to be rotated through
( ) 17 holes
(a)
h l in
i the
th 20hole
h l circle
i l
(b) 18 holes in the 20hole circle
(c) 1 revolution and 3 holes in 17hole circle
(d) 1 revolution and 2 holes in 18
18hole
hole circle
V=
DN
DN
1000
MRR i Milli
MRRinMilling
Consideringtheparametersdefinedinthediscussionof
speedsandfeeds,etc,theMRRisgivenbelow,
Where,
Where
y Approach distance,
d=depthofcut
p
AC50steelflatsurfaceofdimensions100mm 250
mmistobeproducedonahorizontalaxismilling
machine.AnHSSslabmillwitha100mmdiameter
and150mmwidthistobeusedforthepurpose.The
millingcutterhas8teeth.
Calculatethemachiningtimeassumingthatentire
stockcanberemovedinonedepthof2mm.
stockcanberemovedinonedepthof2mm
Given,
Feed,f=0.13mm/tooth,
Cuttingspeed,V=20m/min.
g p
L + 2 A minutes
fZN
2
D D
A = d = d (D d )
2 2
2f
NZ
f
Average uncut chip thickness (t a vg ) =
NZ
wd F
MRR =
where,w=widthofcut,
d
D
d
D
f2
Peak to valley surface roughness (h max ) =
4DN 2 Z 2
Page 95 of 240
Example
Milli Ti
MillingTime
milling cutter.
IAS 1994
IAS
GATE 2014
GATE
Two
separate
operations,
1 and
T
t slab
l b milling
illi
ti
d 2, are
performed with identical milling
p
g cutters. The depth
p of
cut in operation 2 is twice that in operation 1. The other
cutting parameters are identical. The ratio of maximum
uncutt chip
hi thicknesses
thi k
i operations
in
ti
1 and
d 2 is
i
Rev.0
GATE 1995
GATE
List
ListII
(Manufacturing Processes)
(A) Finish
Fi i h turning
t
i
1.
(B) Forming
2.
(C) Thread cutting
3.
(D) Down milling
4.
Codes:A B
C
D
( ) 2
(a)
3
4
1
(b)
(c) 1
2
3
4
(d)
List
List II
(Condition)
B kl h eliminator
Backlash
li i t
Zero rake
Nose radius
Low speed
A
B
C
D
3
4
1
2
4
1
2
3
IES 2009
IES
The arbor of a milling machine is used to hold
which one of the following?
(a) Spindle
(b) Overarm
Over arm
(c) Cutting tool
(d) Mandrel
GATE 1992
GATE
In horizontal milling process. (up/down)
milling provides better surface finish and..
(updown)
(up
down) milling provides longer tool life.
GATE 1993
GATE
A milling cutter having 8 teeth is rotating at 150
rpm. If the feed per tooth is 0.1 mm, the table speed
in mm per minute is
(a) 120 (b) 187
( ) 125 (d) 70
(c)
IES 1994
IES
Consider the following operations:
1. Cutting key ways on shafts
2. Cutting
C tti external
t
l screw threads.
th d
3. Cutting teeth of spur gears
4. Cutting external splines.
Those which can be performed with milling cutters
would include
(a) 1 and 2
(b) 2,3
2 3 and 4
(c) 1 and 3
(d) 1,2,3 and 4 .
IES 1995
IES
Assertion (A): Up milling or climb milling is
commonly used for machining castings and
forgings.
Reason (R): Up milling can be done on universal
milling machines.
machines
(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 isPage
true96 of 240
IES 2003
IES
In milling machine, the cutting tool is held in
position by
(a) Chuck
(b) Spindle
(c) Arbor
(d) Tool holder
IES 1992
IES
A set of eight form relieved milling cutters for each
module is provided to enable cutting of gears of
different
(a) Materials
(b) Types
T
e.g. spur, helical,
h li l etc.
t
(c) Number of teeth
(d) Width of gears
IES 2005
IES
Which one of the following statements is correct?
In upmilling operation, the undeformed chip thickness,
a)) Is
I zero att the
th start
t t off the
th cutt and
d increases
i
t a
to
maximum value just before the tooth disengages the
workpiece.
k i
b) Increases to the maximum value at the centre of the
travel and decreases towards the end of tooth
engagement.
c) Has a maximum value just after the cut is started and
p to zero at the end of the cut.
drops
d) Remains unchanged.
Rev.0
IES 1993
IES
Climb milling is chosen while machining because
(a) The chip thickness increases gradually
(b) It enables
bl the
th cutter
tt to
t dig
di in
i and
d depth
d th off cutt
(c) The specific power consumption is reduced
(d) Better surface finish can be obtained
IES 1999
IES
A straight teeth slab milling cutter of 100 mm
diameter and 10 teeth rotating at 200 r.p.m. is used
to remove a layer of 3 mm thickness from a steel bar.
If the table feed is 400 mm/minute, the feed per
tooth in this operation will be
(a) 0.2 mm
(b) 0.4 mm
( ) 0.5 mm
(c)
(d) 0.6
6 mm
GATE 2012(PI)CommonDataS2
Data for a plain milling operation are given below.
below
Length of workpiece
200 mm
Cutter diameter
100 mm
No. of teeth
4
Cutter speed
100 rpm
Feed
200 mm/min
Depth of cut
2 mm
Total clearance (entry
(
and exit)) 5 mm
g
g p
Machiningtimeforasinglepass(inseconds)is
(a)60 (b)66
(c)126
For-2015 (IES,
GATE &(d)150
PSUs)
IES 2002
IES
) Virtually
y all modern milling
g machines
Assertion ((A):
are capable of doing downmilling.
Reason (R): In downmilling the cutter tends to push
the work along and lift it upward from the table. This
action tends to eliminate any effect in looseness in the
feed screw and nut of the milling machine table and
results in smooth cut.
(a) Both A and R are individually 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
IES 2002
IES
A side and face cutter 125 mm diameter has 10 teeth.
It operates at a cutting speed of 14 m/min with a
table traverse 100 mm/min. The feed per tooth of
the cutter is
(a) 10 mm
(b) 2.86
2 86 mm
(c) 0.286 mm (d) 0.8 mm
IES 2004
IES
(
g p
Match List I (Milling
problem)) with List II ((Probable
causes) and select the correct answer using the codes
given below the Lists:
List I
List II
A. Chatter
1.
Too high feed
B. Poor surface finish 2.
Lack of rigidity in machine
fixtures, bar or workpiece
C Loss
C.
L
off accuracy 3.
Hi h cutting
High
i load
l d
D. Cutter burrs
4.
Radial relief too great
5.
Not enough
h lubricant
l b
Codes:A
B
C
D
A
B
C
D
( ) 2
(a)
1
5
3
( ) 2
(b)
1
3
5
of 2404
(c) 4
5
2 Page
3 97(d)
2
3
5
IES 2004
IES
The cutting speed of a milling cutter while cutting
brass is:
(a) 45 to 60 m/min
(b) 30 to 40 m/min
(c) 25 to 35 m/min
(d) 15 to 20 m/min
GATE 2012(PI)CommonDataS1
Data for a plain milling operation are given below.
below
Length of workpiece
200 mm
Cutter diameter
100 mm
No. of teeth
4
Cutter speed
100 rpm
Feed
200 mm/min
Depth of cut
2 mm
Total clearance (entry
(
and exit)) 5 mm
Mean undeformed chip
p thickness (in microns) is
(a) 142
(b) 100
(c) 71
(d) 50
IAS 2001
IAS
Which one of the following statements are correct in respect of
upmilling
illi and
d downmilling?
d
illi ?
1.
In upmilling the cutter rotates in a direction opposite to that of
workpiece travel whereas in downmilling the cutter rotates in a
di
direction
i similar
i il to that
h off workpiece
k i
travel.
l
2.
In downmilling chip will be thin at the beginning and increase to a
maximum at the end of the cut and reverse will be the case for a chip
p
f
formed
d by
b upmilling.
ll
3.
Downmilling is desirable with milling cutters having a high radial
g when compared
p
to upmilling.
p
g
rake angle
4.
Downmilling forces the workpiece against the milling table to
exert more pressure while upmilling tends to lift the workpiece from the
table.
Select the correct answer using the codes given below:
Codes:
(a) 1,
1 2 and 3
(b)
1 2 and 4
1,
(c) 3 and 4
(d)
1, 3 and 4
Rev.0
IAS 1998
IAS
IAS 2001
IAS
IAS 2003
IAS
S 99
IES1994
IES 2011
IES2011
MatchListIwithListIIandselectthecorrectanswerusing
thecodegivenbelowthelists:
ListI
ListII
A.Lathe
1.Flute
B.Shaper
2.Universalindexing
C D illi
C.Drillingmachine
hi
3.Leadscrew
L d
D.Millingmachine
g
C d
Codes
4.Rockerarm
4
A
((a)) 2
(c) 2
B
C
D
A
B
4
1
3
(b) 3
4
(IES,
GATE
1 For-2015
4
3
(d) &3PSUs)
1
C
1
4
D
2
2
Whichoneofthefollowingoperationsiscarriedout
attheminimumcuttingvelocityifthemachinesare
equallyrigidandthetoolworkmaterialsarethe
same?
(a) Turning
(b) Grinding
(c) Boring
((d)) Milling
g
IAS 2000
IAS
Consider the following mechanisms:
1. Geneva gearing
2. Rack
R k and
d pinion
i i
3. Ratchet and pawl
Which of these mechanisms are used to index the work
table on a transfer machine?
(a) 1 and 2
(b) 2 and 3
(c) 1 and 3
(d) 1,
1 2 and 3
IES 2012
IES
) Vibrations in milling
g are induced due to
Statement ((I):
interrupted cutting operation.
Statement (II):Vibrations can be suppressed to a large extent
by using equal spacing of teeth along the periphery of the
cutters.
( ) 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
IES 2002
IES
Match List I with List
answer:
List I (Machine tools)
A. Lathe
B. Milling machine
C. Shaper
p
D. Drilling machine
Codes:A B
C
D
(a) 4
2
3
1
(c) 4
3
2
1
Page 98 of 240
GearManufacturing
G M
f t i
BySKMondal
Rev.0
M
f t
fG
ManufactureofGears
Manufacture of gears needs several processing operations in
sequentiall stages depending
upon the
d
d
h materiall and
d type off the
h
gears and quality desired. Those stages generally are:
y Preforming the blank without or with teeth
y Annealing of the blank, if required, as in case of forged or
cast steels
y Preparation of the gear blank to the required dimensions
by machining
y Producing teeth or finishing the preformed teeth by
b
machining
y Full or surface hardening of the machined gear (teeth), if
required
y Finishing teeth, if required, by shaving, grinding etc
y Inspection of the finished gears
F
i
dG
ti
FormingandGeneration
Gear teeth are produced by machining based on
Forming
g where the p
profile of the teeth are obtained as
the replica of the form of the cutting tool (edge); e.g.,
milling, broaching etc.
Sunderlandmethodusingracktypecutter
y The rack type HSS cutter (having rake and
Sunderlandmethodusingracktypecutter
G
h i
Gearshaping
G
h i
Gearshaping
y Applicationsofthismethod(andmachine)include:
A li ti
fthi th d( d
hi )i l d
y automatic indexing
g
y Generation method is characterised by
y Moderatesizestraightandhelicaltoothedexternal
spurgearswithhighaccuracyandfinish
y Cuttingtheteethofdoublehelicalorherringbone
gearswithacentralrecess(groove)
y Cuttingteethofstraightorhelicalflutedclustergears
C i
h f
i h h li lfl d l
y Howeverthismethodneeds,thoughautomatic,few
Howeverthismethodneeds thoughautomatic few
indexingoperations.
G
H bbi
GearHobbing
g teeth like g
g
y The HSS or carbide cutter having
gear milling
G
H bbi
GearHobbing
y Having
lesser
number
(only
H i
l
b
( l three)
th ) off tool
t l work
k
motions,, hobbing
g machines are much more rigid,
g , strong
g
and productive than gear shaping machine.
y But hobbing provides lesser accuracy and finish and is
used
d only
l for
f cutting straight
h or helical
h l l teeth
h (single)
(
l ) off
external spur gears and worm wheels.
wheels
(a)Straight(b)helicaltoothand(c)wormwheel
For-2015 (IES, GATE & PSUs)
Page 99 of 240
Ad t
fG
H bbi
AdvantagesofGearHobbing
(a) The method is versatile and can generate spur,
helical, worm and worm wheels.
(b) Since gear hobbing is a continuous process,
process it is
rapid; economical and highly productive.
( ) The
(c)
Th method
th d produces
d
accurate
t gears and
d is
i suitable
it bl
for medium and large batch production.
(d) The cutter is universal, because it can cut all gears of
same module, irrespective of number of teeth on the
gear.
Rev.0
Di d t
f
H bbi
DisadvantagesofgearHobbing
(a) Gear hobbing cannot generate internal gears and
bevel gears.
(b) Enough
h space has
h
to be
b there
h
in component
configuration for hob approach.
Milli
Milling
Milli
Milling
yp
y Gear teeth can be p
produced byy both disc and end mill type
g
g are characterised
Production of gear
teeth byy form milling
by:
y Use of HSS form milling cutters
y Use of ordinary milling machines
y Low p
production rate for
ApplicationsofHobbing
pp
g
Fig.
Sh i
Pl
i
d Sl tti
Shaping,PlanningandSlotting
module.
F
d i
f
h f
Fastproductionofteethofspurgears
machine.
y Both productivity and product quality are very low in
this process which therefore, is used, if at all, for making
one or few teeth on one or two pieces of gears as and
when required for repair and maintenance purpose.
y Planning
Pl
i
and
d slotting
l tti
machines
hi
work
k on the
th same
principle. Planning machine is used for making teeth of
l
large
gears whereas
h
slotting
l tti for
f internal
i t
l gears.
Fig gearteethcuttinginordinaryshapingmachine
F
d i
f
h f
Fastproductionofteethofspurgears
M
f t
f
b
lli
Manufactureofgearsbyrolling
Broaching
y Teeth of small internal and external spur gears; straight
or single helical,
helical of relatively softer materials are
produced in large quantity by broaching.
y This
Thi method
th d leads
l d to
t very high
hi h productivity
d ti it and
d quality
lit
but cost of machine and broach are very high.
Rev.0
Powder Metallurgy
PowderMetallurgy
Wire EDM
WireEDM
y Sandcasting
y Metalmouldcasting
y Diecasting
Di ti
y Investmentcasting
y Shellmouldcasting
y Centrifugalcasting
G
fi i hi
Gearfinishingprocess
gp
yO
One of the g
goals of the g
gear finishing
process in g
gears is
Casting
G
h i
Gearshaving
y A micro finishing film is affixed to the mold and the
g is a g
g operation
p
g
yG
Gear shaving
gear finishing
with high
efficiency and high precision.
y When a work g
gear has been shaved byy a shaving
g cutter
G
b i hi
Gearburnishing
G
L
i
GearLapping
IES 1992
IES
y It is designed
gear tooth
d
d to remove or reduce
d
h nicks
k and
d
Gear lapping
(a) An operation after heat treatment
(b) An
A operation
ti prior
i to
t heat
h t treatment
t t
t
(c) An independent operation for gear reconditioning
(d) None of the above
running
i together
t th with
ith mating
ti gears, and
d castt iron
i
toothed laps,
p , under a flow of fine oil mixed with
an abrasive compound.
y Both internalFor-2015
and external
possible to burnish.
(IES, gears
GATEare
& PSUs)
Rev.0
IES 1999
IES
Consider the following processes for the
manufacture of gears:
1 Casting
1.
2. Powder metallurgy
3. Machining from bar stock
4. Closed die forging
4
g g
The correct sequence in increasing order of bending
strength of gear teeth is
(a) 1, 2, 3, 4
(b) 1, 2, 4, 3
( ) 2, 1, 4, 3
(c)
(d) 2, 1, 3, 4
IES 2010
IES2010
Match List I with List II and select the correct answer using
the code given below the lists:
List I
List II
(Type of work)
(Manufacturing)
A. High rate production of worm Gears and 1. Gear shaving
worm wheel
B. Generating internal gears and Cluster gears 2. Gear milling
C. Finishing of gear tooth profiles
3. Gear hobbing
D. Repair and piece production of gears
4. Gear shaping
A
B
C
D
A
B
C
D
4
3
(b)
3
1
4
2
(a)
2
1
(c)
2
4
1
3
(d)
3
4
1
2
IES 2009
IES
) Gears p
y employing
p y g form
Assertion ((A):
produced by
cutting principle using gearmilling cutter on a milling
machine are not very accurate.
Reason (R): Production of the correct gear tooth profile
employing formcutting principle would require a
separate cutter for cutting different numbers of teeth
even for the same module and also errors are associated
p
of indexing
g mechanism.
with inaccurate operation
(a) Both A and R are true and R is the correct explanation of
A
(b) Both A and R are true but R is NOT the correct
explanation of A
(c) A is true but R is false
For-2015 (IES, GATE & PSUs)
(d) A is false but R is true
IES 2006
IES
Which of the following is/are used for cutting
internal gears?
1 Gear hobber
1.
2
2.
Gear shaper
3. Rack cutter
4.
Jig borer
Select the correct answer using the codes given below:
((a)) Onlyy 1 and 2
((b)) Onlyy 2 and 3
(c) Only 1 and 4
(d) Only 2
IES 1996
IES
Gear cutting on a milling machine using an involute
profile cutter is a
(a) Gear forming process
(b) Gear generating process.
(c) Gear shaping process
((d)) Highly
g y accurate g
gear p
producing
gp
process.
IES 1996
IES
Consider the following processes of gear
manufacture:
1 Milling with form cutter
1.
2. Rack type gear shaper (gear planer)
3. Rotary gear shaper (gear shaper)
4. Gear hobbing
4
g
The correct sequence of these processes in increasing
order of accuracy of involute profile of the gear
(a) 3, 2, 4, 1
(b) 2, 3, 4, 1
( ) 3, 2, 1, 4
(c)
(d) 2, 3, 1, 4
Page 102 of 240
IES 2005
IES
In helical milling, the ratio of the circumference of
the gear blank to the lead of the helix determines
the:
(a) Proper speed to use
(b) Proper
P
f d and
feed
d depth
d th off cutt required
i d
(c) Angle setting of the machine table
(d) Gear ratio for table screw and dividing head
IES 2000
2000
IES
Which one of the following processes of gear
manufacture results in best accuracy of the involute
gear tooth profile?
(a) Milling
(b) Hobbing
H bbi
(c) Rotary gear shaper
(d) Rack type gear shaper
IES 2009
IES
By which one of the following machines the teeth of
an internal spur gear can be cut accurately?
(a) Milling machine
(b) Slotting machine
(c) Hobbing machine
((d)) Gearshaping
p g machine
Rev.0
IES 2004
IES
Gear shaping is a process of manufacturing gears.
Which one of the following principles is employed by it?
( ) Form
(a)
F
cutting
tti with
ith cutter
tt
(b) Generating tooth form with a reciprocating cutter
(c) Generating tooth form by a rotating cutter
(d) Generating form with a reciprocating and revolving
cutter
IES 2008
IES
Which machining processes are used for gear
manufacture?
1 Form milling
1.
2
2.
Broaching
3. Roll forming
4.
Hobbing
Select the correct answer using the code given below:
((a)) 1, 2 and 3
((b)) 1, 3 and 4
(c) 1, 2 and 4
(d) 2, 3 and 4
IES 2007
IES
Which of the following methods are gear generating
processes?
1 Gear shaping
1.
2. Gear hobbing
3. Gear milling
Select the correct answer using
g the code g
given below:
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only
IES 1992
IES
In gear hobbing
(a) Only hob rotates
(b) Only
O l gear blank
bl k rotates
t t
(c) Both hob and gear blank rotate
(d) Neither hob nor gear blank rotates
IES 1999
IES
A 60
teeth gear when hobbed on a differential
60teeth
hobber with a twostart hob, the index change gear
ratio is governed by which one of the following
kinematic balance equations?
(a) 1 revolution of gear blank = 1/60 of hob revolutions
(b) 1 revolution of gear blank = 2/60 of hob revolutions
(c) 1 revolution of hob = 2/60 of blank revolutions
((d)) 1 revolution of hob = 1/60 of blank revolutions
GATE 2007(PI)
2007 (PI)
GATE
Which one of the following gear manufacturing
processes is NOT based on generation principle?
( ) Gear
(a)
G
H bbi
Hobbing
(b) Gear
G
Sh i
Shaping
((c)) Gear Milling
g
((d)) Gear Shaving
g
IES 2003
IES
A spur gear of 40 teeth is machined in a gear
hobbing machine using a double start hob cutter.
The speed ratio between the hob and the blank is
(a) 1:20 (b) 1:40
( ) 40: 1 (d) 20: 1
(c)
IES 1997
IES
Which of the following motions are not needed for
spur gear cutting with a hob?
1 Rotary motion of hob
1.
2. Linear axial reciprocator motion of hob
3. Rotary motion of gear blank
4. Radial advancement of hob.
4
Select the correct answer using the codes given below:
(a) 1,
1 2 and 3 (b) 1,
1 3 and 4
(c) 1, 2 and 4 (d) 2, 3 and 4
IES 1993
1993
IES
Internal gear cutting operation can be performed by
(a) Milling
(b) Shaping
Sh i with
ith rack
k cutter
tt
(c) Shaping with pinion cutter
(d) Hobbing
Rev.0
IAS 1998
IAS
Assertion (A): Internal gears are cut on a gear
shaper.
Reason (R): Hobbing is not suitable for cutting
internal gear.
( ) 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
IES 1995
IES
While cutting helical gears on a non
differential
nondifferential
gear hobber, the feed change gear ratio is
(a) Independent of index change gear ratio
(b) dependent on speed change gear ratio
(c) Interrelated to index change gear ratio
((d)) Independent
p
of speed
p
and index change
g g
gear ratio.
IAS 2001
IAS
Consider the following motions and setting in a
hobbing machine:
1 Hob rotation
1.
2. Job rotation
3. Axial reciprocating hob rotation
4. Tilting
4
g of hob to its helix angle
g
Which of these motions and setting in a hobbing
machine are required to machine a spur gear?
(a) 1, 2 and 3 (b) 2, 3 and 4
( ) 1, 2 and
(c)
d 4 (d) 1, 3 and
d4
For-2015 (IES, GATE & PSUs)
IES 2006
IES
Which of the following cannot be cut by hobbing
process?
(a) Helical gears
(b) Bevel gears
(c) Worm gears
(d) Spur gears
IES 1992
IES
Gear burnishing process for
(a) Removing residual stresses from teeth roots
(b) Surface
S f
fi i hi
finishing
(c) Undercut gears
(d) Cycloidal gears
IES 1996
IES
For the manufacture of full depth spur gear by
hobbing process, the number of teeth to be cut = 30,
module = 3 mm and pressure angle = 20
20.. The radial
depth of cut to be employed should be equal to
(a) 3.75
3 75 mm
(b) 4.50
4 50 mm
(c) 6.00 mm
(d) 6.75 mm
IAS 2003
IAS
Which one of the following is not a feature of gear
hobbing process?
(a) High rate of production
(b) Generation of helical gears
(c) Very accurate tooth profile
((d)) Generation of internal g
gears
IES 1994
IES
Consider the following machine tools:
1. Hobbing machine
2. Gear
G
shaping
h i machine
hi
3. Broaching machine.
The teeth of internal spur gears can be cut in
(a) 1, 2 and 3 (b) 1 and 2
(c) 1and 3
(d) 2 and 3
ScrewThread
S
Th d
Manufacturing
f
i
Rev.0
BySKMondal
Processes,MachinesandTools
UsedForProducingScrewThreads
(a)Machining
(b)Rolling
( )G i di
(c)Grinding
Thread Cutting
ThreadCutting
Internal
Threading on a lathe
g on a NC lathe
Threading
With a die held in a stock
((manual))
With an automatic die
((turret lathe or screw
machine) or NC lathe
y milling
g
By
By Grinding
Internal thread
y Thread cutting
g is a form
cutting operation an
p tool is
accuratelyy shaped
used (with zero rake)
y The lead screw and the
split nut, which provide
positive motion of the
carriage relative to the
rotation of the spindle.
spindle
C i
h d ih i
CuttingThreadswithDies
Th d T i
ThreadTapping
g and tapered
p
y Straight
external threads can be cut q
quicklyy
(a)Solidthreadingdie;(b)solidadjustablethreadingdie
y Grinding
Th d G i di
ThreadGrinding
can produce
very accurate threads,
h d and
d
it also permits threads to
be produced in hardened
materials.
y A singleribbed
single ribbed grinding
wheel is employed, but
multipleribbed
multiple
ribbed
wheels
are used occasionally.
y Centerless
thread
grinding is used for
g headless sets
making
screws.
External
The
Th flutes
fl t on tap
t create
t cutting
tti
edges on the thread profile and
provide
d space for
f the
h chips
h
and
d
the passage of cutting fluid.
Taps are made of either carbon
g p
steel and coated
or highspeed
with TiN.
Th d R lli
ThreadRolling
g is used to p
y Thread rolling
produce threads in substantial
quantities.
y Cold
Coldforming
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.
y Chip less process,
process
fast and economical.
y Mechanical properties
are good.
g
Page 105 of 240
Thread Milling
ThreadMilling
y Highly accurate threads,
particularly in larger
sizes, are often form
milled Either a single or
milled.
a multipleform Cutter
may be used.
used
y The milling cutter is
tilted
il d at an angle
l equall
to the helix angle of the
thread
h d and
d is
i fed
f d inward
i
d
radially to full depth
while
hil
the
h
work
k is
i
stationary.
GATE 2003
GATE
Qualityscrewthreadsareproducedby
(a) Threadmilling
(b) Threadchasing
Th d h i
(c) Threadcuttingwithsinglepointtool
(d) Threadcasting
Rev.0
IES2011
External threads can be produced by :
1. Rolling
2. Grinding
33. Milling
g
(a) 1 and 3 only
(b) 1 and 2 only
(c) 2 and 3only
( ) 1, 2 and 3
(d)
IES 2010
IES2010
For producing both internal and external
screw threads, the method used is
( ) Thread
(a)
Th d chasing
h i with
ith multiplerib
lti l ib chasers
h
((b)) Thread milling
g and multiplethread
p
cutters
(c) Thread tapping with taps
(d) Die
Di threading
h di with
i h selfopening
lf
i die
di heads
h d
ISRO2011
ISRO2010
Whichofthefollowingscrewthreadisadaptedfor
powertransmissioninonedirection
(a)Acmethreads
( )
(b)Buttressthreads
(b) Plano
l
miller
ll
(c)Squarethreads
(d)Multiplethreads
(d) lathe
IES 2012
IES
Multistart threads are used to get
(a) Smaller linear displacement
(b) Larger
L
li
linear
di l
displacement
t with
ith assured
d self
lf locking
l ki
(c) Larger linear displacement with no guarantee of self
locking
((d)) None of the above
IES 2007
IES
Screw threads are produced on solid rods by using
which of the following?
(a) Dies
(b) Punch
(c) Mandrel (d) Boring bar
IES 2012
IES
The differential screw is used in a
(a) Turnbuckle
(b) Micrometer
Mi
t
(c) Vernier Caliper
(d) Coupler
IES 2012
IES
Which of the following screw threads is adopted for
power transmission in either direction
(a) ACME threads
(b) Square threads
(c) Buttress threads
((d)) Multiple
p threads
Shaper,Planner,Slotter
B SKM d l
BySKMondal
Rev.0
Sh
Shaper
RamDrive
FeedMechanism
y Themechanicalramdriveisaslottedarmquickreturn
Sh
Shaper
y The relative motions between the tool and the workpiece,
Q i k t
ti M h i
QuickreturnmotionMechanism
y In shaping, the cutting tool is held in the tool post
motionmechanism,
motionmechanism
Cl ifi ti
f Sh
M hi
ClassificationofShaperMachine
Shapers,asmachinetoolsusuallyareclassified
accordingtotheirgeneraldesignfeaturesasfollows,
1 Horizontal
1.
a.
Pushcut
b.
Pullcutordrawcutshaper
2. Vertical
a.
Regularorslotters
b
b.
Keyseaters
3. Specialpurpose
For-2015 (IES, GATE & PSUs)
F
l
Formula
HydraulicShaper
NL(1 + m)
1000
w
y Numberofstrokes, N s =
f
y Cuttingspeed, V =
y Timeofonestroke, t =
y Totaltime,T =
L(1 + m)
min
1000V
L(1 + m)
Lw(1 + m)
Ns =
min
1000v
1000vf
Rev.0
Advantagesofhydraulicshaping
y 1. Cutting speed remains constant throughout most of the cutting
stroke, unlike the crank shaper where the speed changes continuously.
to utilise the full capacity of the cutting tool during the cutting stroke.
y 3. The ram reverses quickly without any shock due the hydraulic
y 4. The range and number of cutting strokes possible are relatively large
in hydraulic shaper.
y 5. More strokes per minute can be achieved by consuming less time for
Planer
Slotter
Sl tt
Slotter
Sl tt
Slotter
IAS 1994
IAS
Stroke of a shaping machine is 250 mm. It makes 30
double strokes per minute. Overall average speed of
operation is
(a) 3.75 m/min
(b) 5.0 m/min
( ) 7.5 m/min
(c)
/ i
(d) 15 m/min
/ i
In
I a shaping
h i process, the
th number
b off double
d bl strokes
t k per
minute is 330 and the q
quick return ratio is 0.6. If the
length of the stroke is 250 mm, the average cutting
velocity in m/min is
( ) 3.0
(a)
GATE 2005
GATE
(b) 4.5
( ) 7.5
(c)
(d) 12.0
IES 1994,ISRO2008
1994 ISRO 2008
IES
Given that, average cutting speed = 9 m/min, the
return time to cutting time ratio is = 1 : 2, the feed
rate = 0.3 mm/stroke, the clearance at each end of
cut = 25 mm and that the plate is fixed with 700 mm
side along the direction of tool travel, the time
required for finishing one flat surface of a plate of
size 700 x 30 mm in a shaper, will be
(a) 10 min
(b) 12.5 min
( ) 15 min
(c)
i
(d) 20 min
i
GATE 2014
GATE2014
A castt iron
block
i
bl k off 200 mm length
l
th is
i being
b i shaped
h
d in
i a
shaping
p g machine with a depth
p of cut of 4 mm,, feed of
0.25 mm/stroke and the tool principal cutting edge angle
of 30o. Number of cutting strokes per minute is 60.
Ui
Using
specific
ifi energy for
f cutting
tti
as 1.49 J/
J/mm3 the
th
average
g p
power consumption
p
((in watt)) is .
IES 2001
IES
In
machine,
the
for
I a shaper
h
hi
th mechanism
h i
f tool
t l feed
f d is
i
(a) Geneva mechanism
(b) Whitworth mechanism
(c) Ratchet and Pawl mechanism
(d) Ward Leonard system
IES 2010
IES2010
IES 1997
IES
) Longitudinal
g
g motion of the
Assertion ((A):
cutting
tool and crosswise feed motion of the job generates
planning
gp
process.
flat surfaces in p
Reason (R): Jobs used in planning machines are
generally long and heavy compared to shaping.
(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
IES 1995
IES
In a mechanical shaper, the length of stroke is
increased by
(a) Increasing the centre distance of bull gear and crank
pin
(b) Decreasing
D
i
th centre
the
t distance
di t
off bull
b ll gear and
d
crank pin
(c) Increasing the length of the ram
((d)) Decreasing
g the length
g of the slot in the slotted lever
IES 2004
IES
IAS 1995
IAS
ISRO2010
Size
is
by
Si off a shaper
h
i given
i
b
(a) Stroke length
(b)
Motor power
(c) Weight
g of the machine
(d)
Table size.
Rev.0
AbrasiveMachiningProcesses
GATE2014 (PI)
GATE2014(PI)
Matchthefollowing
GroupI(Mechanism)
PQuickreturn
QApron
RIntermittentindexing
SDifferentialmechanism
S
e e t a ec a s
(a)P1 Q2 R4 S3
(a)P1Q2R4S3
(c)P4Q1R2S3
GroupII(Machines)
1Lathe
2Shaping
3Gearhobbing
4Milling
4
g
Grinding&Finishing
(b)P2 Q1 R4 S3
(b)P2Q1R4S3
(d)P2Q3R1S4
BySKMondal
Process
Features
Grinding
Useswheels,accuratesizing,finishing,lowMRR;
canbedoneathighspeeds.
Creepfeed
grinding
d
Useswheelswithlongcuttingarc,veryslowfeed
rateandlargedepthofcut
dl
d h f
Abrasive
machining
Abrasivewater
jetMachining
Honing
HighMRR,toobtaindesiredshapesand
approximatesizes
Waterjetswithvelocitiesupto1000m/seccarry
abrasiveparticles(silicaandgarnet)
"Stones"containingfineabrasives;primarilya
h l finishingprocess
hole
fi i hi
Fineparticlesembeddedinsoftmetalorcloth;
primarilyasurfacefinishingprocess
i
il f
fi i hi
Lapping
Grinding
Whyishighvelocitydesiredingrinding?
machining.
y It is a material cutting
gp
process which engages
g g an abrasive
Advantages of Grinding
AdvantagesofGrinding
Applications of Grinding
ApplicationsofGrinding
y Dimensionalaccuracy
Di
i
l
y Surfacefinishing
S f fi i hi
y Goodsurfacefinish
y Slittingandparting
y Goodformandlocational accuracy
y
y Descaling,deburring
g
g
y Applicabletobothhardenedandunhardenedmaterial
y Stockremoval(abrasivemilling)
Onwhichfactorsdoesthetransverseroughness
p
p
gg
g
ofworkpiecedependduringgrinding?
y It mainly depends on the shape of the grits and overlap
y Finishingofflataswellascylindricalsurface
y Grindingoftoolsandcuttersandresharpening ofthe
For-2015 (IES, GATE & PSUs)
same
Rev.0
G i di
Grinding
y If each abrasive grain is viewed as a cutting tool then in
grinding operation.
High
y Rake angle can be positive, zero, or negative ranging from
Interactionofthegritwiththeworkpiece
Interactionofthegritwiththeworkpiece
y However,
However grits having large negative rake angle or
+45o to 60
60o, dull,
dull rounded grits has large negative rake angle
y Cutting speed is very high
y Very
V
hi h specific
high
ifi energy off cutting
i
mode.
rounded cutting edge do not form chips but may rub or
make a groove by ploughing leading to lateral flow of the
workpiece material.
Low
y Low shear angle
y Low feed rate
Howischipaccommodationvolumeis
relatedtomaterialremovalrate?
related to material removal rate?
Specificenergyconsumptioningrinding
Howmaythespecificgrindingenergyvary
withmaterialremovalrateingrinding?
with material removal rate in grinding?
GRatio
( )
GATE2011(PI)
to 80: 1.
1
y The G ratio is a measure of grinding production and
Grindingratioisdefinedas
volume of wheel wear
volume of work material removed
volume of work material removed
(b)
volume of wheel wear
cutting speed
(c)
feed
longitudinal feed
(d)
transverse feed
(a)
Parametersforspecifyagrindingwheel
1) The type of grit material
2) The grit size
3)) The
Th bond
b d strength
t
th off the
th wheel,
h l commonly
l known
k
as wheel hardness
4) The structure of the wheel denoting the porosity i.e.
the amount of inter grit spacing
5) The type of bond material
6) Other than these parameters, the wheel
manufacturer may add their own identification code
prefixing or suffixing (or both) the standard code.
Rev.0
Abrasive
Material
CommentsandUses
Aluminium oxide
Siliconcarbide
Used
for
brass,,
bronze,,
aluminum, stainless steel and
cast iron
For grinding hard, tough tool
steels, stainless steel, cobalt and
nickel based superalloys, and
hard coatings
Used
to
grind
nonferrous
materials tungsten carbide and
materials,
ceramics
cBN (cubicboron
nitride))
Diamond
Whyisaluminium oxidepreferredto
siliconcarbideingrindingsteel?
silicon carbide in grinding steel?
y Al2O3 is tougher than SiC.
SiC Therefore it is
Grit size
Gritsize
y The grain size affects material removal rate and the
Grade
Structure / concentration
Structure/concentration
y The worn out grit must pull out from the bond and make
IES2009
y 2marks
Whydoessinglelayergrindingwheelshowprogressive
riseofforceduringgrindingofhighspeedsteel?
y The geometry of grit undergoes irreversible change in
Whyiscoarsegrainandopenstructuredwheel
ispreferredforstockremovalgrinding?
is preferred for stock removal grinding?
y Coarse grit allows large grit protrusion and open
Rev.0
B di M
i l f G i di
h l
BondingMaterialsforGrindingwheels
Type of Bond
Attributes
Attributes
Rubber bond
Oxychloride
b d
bond
Metal bond
Electroplated
bond
B di M
i l f G i di
h l
BondingMaterialsforGrindingwheels
Vitrified bonds
y They are composed of clays and other ceramic
substances.
y Vitrified wheels are p
porous,, strong,
g, rigid,
g , and unaffected
by oils, water, or temperature over the ranges usually
g
encountered in metal cutting.
y The operating speed range in most cases is 1500 to 5000
m/min.
Shellac bond
Shellacbond
y At one time this bond was used for flexible cut off
wheels.
y At present use of shellac bond is limited to grinding
wheels engaged in fine finish of rolls.
Rubber bond
Rubberbond
Oxychloride bond
Metal bond
Metalbond
off
y Its principal use is in thin wheels for wet cut
cutoff
y Itislesscommontypebond,butstillcanbeusedindisc
Whatisthemainshortcomingofvitrified
bond?
Vitrified bond is brittle and can not with stand high
impact loads. This bond can not be used for high wheel
speed due to risk of wheel breakage under centrifugal
force.
operation.
y Rubber bond was once popular for finish grinding on
bearings and cutting tools.
grindingoperation.Itisusedunderdrycondition.
Rev.0
Electroplated bond
Electroplatedbond
Brazed bond
Brazedbond
Gl i
Glazing
y This
large
(3040%)
Thi bond
b d allows
ll
l
(
%) crystal
t l exposure above
b
y This
crystal
Thi is
i relatively
l ti l a recentt development,
d l
t allows
ll
t l
y With continuous
use a grinding
dull
ti
i di wheel
h l becomes
b
d ll with
ith
exposure
p
as high
g 6080%. In addition g
grit spacing
p
g can be
th only
the
l bond
b d for
f making
ki wheels
h l for
f abrasive
b i milling
illi and
d
wheel.
h l The
Th bond
b d strength
t
th is
i much
h greater
t than
th provided
id d
ultra high
g speed
p
grinding.
g
g
byy electroplated
p
bond. This bond is expected
p
to replace
p
the sharp
p abrasive g
grains becoming
g rounded.
y This condition of a dull grinding wheel with worn out
L di
Loading
Dressing
y Some
grinding
S
i di chips
hi gett lodged
l d d into
i t the
th spaces between
b t
the g
grits resulting
g in a condition known as loaded wheel.
y Loading is generally caused during the grinding of soft
dressing.
dressing
G
20
GATE2014
Match the Machine Tools (Group A) with the probable
Operations (Group B):
Group A
G
P:CenterLathe
Q:Milling
R:Grinding
S:Drilling
P
( ) 1
(a)
(c) 3
CanaresinbondedcBN wheelbe
electrochemicallydressed?
electrochemically dressed?
Isdressingnecessaryforsinglelayer
wheel?
Q
2
1
R
4
4
GroupB
G
B
1:Slotting
2:Counterboring
3:Knurling
4:Dressing
S
3
2
( )
(b)
(d)
P
2
3
Q
1
4
R
4
2
S
3
1
Truing
y Truing is the act of regenerating the required geometry
Rev.0
BalancingGrindingWheels
y Because of the high rotation speeds involved,
involved grinding
IES2011Conventional
What is creep feed grinding? Discuss its salient
f t
features,
advantages,
d
t
and
d application.
li ti
[10 marks]
Whatarethecharacteristicfeaturesofa
universalcylindricalgrinder?
universal cylindrical grinder?
y Characteristicfeaturesofauniversalcylindricalgrinder
notpossessedbyplaincylindricalgrinderare:
Swivelling wheelhead
Swivelling wheelheadslide
Swivelling headstock
withalargerdownfeedbutslowertablespeedthanthat
adoptedformulti passconventionalsurfacegrinding.
adoptedformultipassconventionalsurfacegrinding.
y Increepfeedgrinding,theentiredepthofcutis
completedinonepassonlyusingverysmallin feed
completedinonepassonlyusingverysmallinfeed
rates.
Statethebasicadvantageofacreepfeed
grinderoveraconventionalsurface
grinder over a conventional surface
y Productivityisenhancedandlifeofthegrindingwheelis
extended.
C li d i l G i di
CylindricalGrinding
type cylindrical grinding is commonly used far
y Center
Centertype
producing external cylindrical surfaces.
y The grinding wheel revolves at an ordinary cutting
speed, and the workpiece rotates on centers at a much
slower speed.
speed
y Grinding machines are available in which the workpiece
i held
is
h ld in
i a chuck
h k for
f grinding
i di both
b th external
t
l and
d internal
i t
l
cylindrical surfaces.
C t l
G i di
Centerless
Grinding
y Centerless grinding makes it possible to grind both
C t l
G i di
Centerless
Grinding
y The regulating
Rev.0
Centerless Grinding
C t l
G i di
Centerless
Grinding
The axial feed is calculated by the equation
F = dN sin
where
F = feed (mm/min)
d = diameter of the regulating wheel (mm)
N = revolutions per minute of the regulating wheel
C t l
i t
l G i di
Centreless
internalGrinding
y This machine is used for grinding cylindrical and
= angle
g of inclination of the regulating
g
g wheel
Statethedisadvantagesofcentreless
cylindricalgrindingmachine?
cylindrical grinding machine?
Itdoesnotgrindconcentricallywithcentres.
Largediametershortworkpiecearedifficultto
controlintheprocess
Itmaynotimproveworkpieceperpendicularity.
Istransversefeedprovidedinvertical
spindlereciprocatingtablesurfacegrinder?
spindle reciprocating table surface grinder?
y Usually no transverse feed is provided in such machine.
S f
G i di
hi
SurfaceGrindingMachines
y Surface grinding machines are used primarily to
L
i
Lapping
Ch
t i ti
fl
i
Characteristicsoflappingprocess
y Lappingisbasicallyanabrasiveprocessinwhichloose
y Useoflooseabrasivebetweenlapandtheworkpiece
abrasivesfunctionascuttingpointsfindingmomentary
supportfromthelaps.
y Materialremovalinlappingusuallyrangesfrom.003to
.03mmbutmanyreach0.08to0.1mmincertaincases.
03mmbutmanyreach0 08to0 1mmincertaincases
y Usuallylapandworkpiecearenotpositivelydrivenbut
areguidedincontactwitheachother
y Relativemotionbetweenthelapandtheworkshould
changecontinuouslysothatpathoftheabrasivegrains
h
ti
l th t th fth b i i
ofthelapisnotrepeatedontheworkpiece.
y Castironisthemostlyusedlapmaterial.However,soft
steel,copper,brass,hardwoodaswellashardenedsteel
andglassarealsoused.
Rev.0
Ab i
fl
i
Abrasivesoflapping
V hi l
t i l f l
i
Vehiclematerialsforlapping
Technicalparametersaffectinglappingprocessesare
y Al2O3 andSiC,grainsize5~100m
dSiC i i
y Machineoil
M hi il
y unitpressure
it
y Cr2O3,grainsize1
grainsize1~2m
2m
y Rapeside oil
y thegrainsizeofabrasive
y B4C3,grainsize5
g
5 60m
y grease
g
y concentrationofabrasiveinthevehicle
y Diamond,grainsize0.5~5m
y lappingspeed
H i
Honing
y Honing is a finishing process, in which a tool called hone
H i
Honing
y It is desired that
Fig.Honingtool
Fig.Laypatternproducedbycombinationofrotaryand
oscillatorymotion
ill
Buffing
Th
iti l
t
Thecriticalprocessparametersare
g is a p
g operation
p
p
y Buffing
polishing
in which the workpiece
y 1.rotationspeed
t ti
d
y 2.oscillationspeed
2 oscillationspeed
y 3.lengthandpositionofthestroke
3
g
p
y 4.honingstickpressure
H i
Honing
SuperFinishing
S
Fi i hi
SuperFinishing
Statethespecificapplicationofaplanetary
internalgrinder.
internal grinder
y Planetary internal grinders find application for grinding
GATE 1995
GATE
Among the conventional machining processes,
maximum specific energy is consumed in
(a) Turning
(b) Drilling
(c) Planning (d) Grinding
GATE 2000
GATE
Abrasive material used in grinding wheel selected
for grinding ferrous alloys is
(a) Silicon carbide
(b) Diamond
(c) Aluminium oxide
(d) Boron carbide
IIn this
hi case the
h abrasive
b i stone covers the
h section
i
off the
h
workpiece requiring super finish. The abrasive stone is
slowly
l l fed
f d in
i radial
di l direction
di
i
while
hil its
i oscillation
ill i
i
is
imparted in the axial direction. It reduce surface
roughness
h
and
d increase
i
b i load
bearing
l d capacity.
it
GATE 1998
GATE
Ideal surface roughness, as measured by the
maximum height of unevenness, is best achieved
when, the material is removed by
(a) An end mill
(b) A grinding
i di wheel
h l
(c) A tool with zero nose radius
(d) A ball mill.
GATE 2002
GATE
The hardness of a grinding wheel is determined by
the
(a) Hardness of abrasive grains
(b) Ability of the bond to retain abrasives
(c) Hardness of the bond
((d)) Abilityy of the g
grinding
g wheel to p
penetrate the work
piece
GATE 1998
GATE
In machining using abrasive material, increasing
abrasive grain size
(a) Increases the material removal rate
(b) Decreases the material removal rate
(c) First decreases and then increases the material
removal rate
(d) First increases and then decreases the material
removal rate
GATE 2006
GATE
If each abrasive grain is viewed as a cutting tool,
then which of the following represents the cutting
parameters in common grinding operations?
(a) Large negative rake angle, low shear angle and high
cutting speed
(b) Large positive rake angle, low shear angle and high
cutting
tti speed
d
(c) Large negative rake angle, high shear angle and low
cutting speed
(d) Zero rake angle,
g high
g shear angle
g and high
g cutting
g
speed
Rev.0
GATE 1997
GATE
List I
(A) Grinding
(B) Honing
H i
(C) Superfinishing
D)) Burnishing
g
1.
2.
3.
4.
4
5.
6
6.
List II
Surface for oil retention
S f
Surface
f max. load
for
l d
capacity
Surface of limiting friction
Surface of matte finish
Surface for pressure sealing
Surface for interference fit.
fit
IES 1997
IES
Which one of the following materials is used as the
bonding material for grinding wheels?
(a) Silicon carbide
(b) Sodium silicate
(c) Boron carbide
((d)) Aluminum oxide
IES 1996
IES
Specific energy requirements in a grinding process
are more than those in turning for the same metal
removal rate because of the
(a) Specific pressures between wheel and work being
high.
high
(b) Size effect of the larger contact areas between wheel
and
d work.
k
(c) High cutting velocities
(d) High heat produced during grinding.
For-2015 (IES, GATE & PSUs)
IES 2005
IES
Consider the following statements in respect of
grinding?
1 The pitch of the grit cutting edges is larger than the
1.
pitch of the milling cutter.
2. The
Th cutting
tti
angles
l
off the
th grits
it have
h
a random
d
geometry.
3. The size of the chip cuts is very small for grinding.
Which of the statements g
given above are correct?
(a) 1 and 2
(b) 2 and 3
(c) 1 and 3
(d) 1,
1 2 and 3
IES 1996
IES
Grinding wheel is said to be loaded when the
(a) Metal particles get embedded in the wheel surface
blocking the interspaces between cutting grains.
grains
(b) Bonding material comes on the surface and the
wheel
h l becomes
b
bl t
blunt.
(c) Work piece being ground comes to a stop in
cylindrical grinding.
((d)) Grinding
g wheel stops
p because of veryy large
g depth
p of
cut
IES 1994
IES
The ratio of thrust force to cutting force is nearly 2.5
in
(a) Turning
(b) Broaching
(c) Grinding (d) Plain milling
IES 2009
IES
Which one of the following is NOT used as abrasive
material in grinding wheels?
(a) Aluminium oxide
(b) Silicon carbide
(c) Cubic boron nitride
((d)) Manganese
g
oxide
IES 2001
IES
Specific cutting energy is more in grinding process
compared to turning because
(a) Grinding (cutting) speed is higher
(b) The wheel has multiple cutting edges (grains)
(c) Plaguing force is significant due to small chip size
((d)) Grinding
g wheel undergoes
g
continuous wear
IES 1992
IES
Assertion (A): Vitrified bond is preferred for thin
grinding wheels.
Reason (R): Vitrified bond is hard brittle.
brittle
(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
Rev.0
IES 2000
IES
) The ratio of cutting
g force to thrust force is
Assertion ((A):
very high in grinding process as compared to other
machining processes.
Reason (R): Random orientation and effective negative
rake angles of abrasive grains increase the cutting force
and adversely affect the cutting action and promote
rubbing action.
(a) Both A and R are individually 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
IES 2009
IES
Given that the peripheral speed of the grinding
wheel of 100 mm diameter for cylindrical grinding
of a steel work piece is 30 m/s, what will be the
estimated rotational speed of the grinding wheel in
revolution per minute (r.p.m.)?
(a) 11460
(b) 5730
( ) 2865
(c)
86
(d) 95
IES 2000
IES
The sequence of markings "S
S 14 K 14 S
S" on a grinding
wheel represents respectively
(a) Bond type,
type structure,
structure grade,
grade grain size and abrasive
type
(b) Abrasive
Ab i type,
t
grain
i size,
i
grade,
d structure
t t
and
d bond
b d
type
(c) Bond type, grade, structure, grain size and abrasive
type
(d) Abrasive type, structure, grade, grain size and bond
yp
type
For-2015 (IES, GATE & PSUs)
IES 1995
IES
IES 2010
IES2010
IES 2002
IES
IES 2001,ISRO2009
2001 ISRO 2009
IES
IES 1995
IES
IES 1993
IES
Rev.0
IES 2001
IES
Assertion (A): Hard wheels are chosen for grinding
hard metals.
Reason (R): In hard wheels only the abrasive grains
are retained for long time.
( ) 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
IES 2001
IES
Dry and compressed air is used as cutting fluid for
machining
(a) Steel
(b) Aluminium
(c) Cast iron (d) Brass
IES 1996
IES
A grinding wheel of 150 mm diameter is rotating at
3000 rpm. The grinding speed is
IES 1994
IES
Consider the following statements regarding
grinding of high carbon steel:
1 Grinding at high speed results in the reduction of
1.
chip thickness and cutting forces per grit.
2. Aluminium
Al i i
oxide
id wheels
h l are employed.
l d
3. The grinding wheel has to be of open structure.
Of these statements
(a) 1, 2 and 3 are correct
(b) 1 and 2 are correct
(c) 1 and 3 are correct
(d) 2 and 3 are correct
IES 1993
IES
In centre less grinding, the work piece centre will be
(a) Above the line joining the two wheel centres
(b) Below
B l the
th line
li joining
j i i the
th two
t wheel
h l centres
t
(c) On the line joining the two wheel centres
(d) At the intersection of the line joining the wheel
plate p
plane.
centres with the work p
IES 1993
IES
Consider the following parameters:
1. Grinding wheel diameter.
2. Regulating
R
l ti wheel
h l diameter.
di
t
3. Speed of the grinding wheel.
4. Speed of the regulating wheel.
5. Angle between the axes of grinding and regulating
wheels.
Among these parameters,
parameters those which influence the
axial feed rate in centreless grinding would include
( ) 2, 4 and
(a)
d 5 (b) 1, 2 and
d3
(c) 1, 4 and 5 (d) Page
3, 4121
andof5 240
IES 1999
IES
Consider the following reasons:
1. Grinding wheel is soft
2. RPM off grinding
i di wheel
h l is
i too
t low
l
3. Cut is very fine
4. An improper cutting fluid is used
A grinding wheel may become loaded due to reasons
stated at
(a) 1 and 4
(b) 1 and 3
(c) 2 and 4
(d) 2 and 3
IES 2000
IES
Consider the following advantages:
1. Rapid process
2. Work
W k with
ith keyways
k
can be
b ground
d
3. No work holding device is required.
Which of these are the advantages of centre less
g
grinding?
g
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3
(d) 1 and 3
IES 2007
IES
Honing Process gives surface finish of what order?
(a) 10 m (CLA)
(b) 1.0 m (CLA)
( ) 0.1 m (CLA)
(c)
(d) 0.01 m (CLA)
Rev.0
IES 1992
IES
CLA value for Honing process is
(a) 6
(b) 0.05 3.0
( ) 0.05 1.0 (d) 0.025 0.1
(c)
IES 1992
IES
A surface finish of 0.025 0.1 micrometer CLA values
is to by produced. Which machining process would
you recommend?
(a) Grinding (b) Rough turning
( ) Lapping
(c)
L
i
(d) Honing
H i
IAS 2000
IAS
Consider the following statements in respect of a
grinding wheel of specification, 51A 36L7R23,
using the standard alphanumeric codification:
1. Abrasive used in the wheel is aluminum oxide
2. The
Th grain
i size
i off abrasive
b i is
i medium
di
3. The wheel grade is medium hard
4. It has an open structure
5. It has resinoid as bonding agent
Which (If these statements are correct?
( ) 1, 2 and
(a)
d 3 (b) 1, 3 and
d4
GATE & PSUs)
(c) 2, 3 and For-2015
5 (d) (IES,
1, 4 and
5
IES 2012
IES
()
g
gp
Statement(I):Honingisanabradingprocesstoremove
stockfrommetallicsurfaces.
( )
g
y
Statement(II):Honingiscommonlydoneoninternal
surfaces.
((a)) Both Statement ((I)) and Statement ((II)) are
individually 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
IES 1992
IES
Buffing wheels are mode of
(a) Softer metals
(b) Cotton fabric
( ) Carbon
(c)
C b
(d) Graphite
G hit
IAS 1999
IAS
Assertion (A): The grade of a grinding wheel is a
measure of hardness of the abrasive used for the
wheel.
Reason (R): Grading is necessary for making right
selection of the wheel for a particular work.
work
(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
true122 of 240
Page
IES 2001
IES
(
g Tools)) with ListII ((Applications)
pp
)
Match ListI (Cutting
and select the correct answer using the codes given
below the lists:
List I
List II
A. Trepanning tool 1.
For surface finishing by
h i
honing
B. Side milling cutter 2.
For machining gears
C Hob
C.
H b cutter
3.
F cutting
For
i keyways
k
i shafts
in
h f
D. Abrasive sticks
4.
For drilling large diameter
holes
Codes:A
B
C
D
A
B
C
D
( ) 1
(a)
3
2
4
(b) 4
3
2
1
(c) 1
2
3
4
(d) 4
2
3
1
IAS 2004
IAS
The size effect refers to the increase in specific
cutting energy at low values of under formed chip
thickness. It is due to which one of the following?
(a) Existence of ploughing force
(b) Work
W k hardening
h d i
(c) High strain rate
(d) Presence of high friction at chiptool interface.
IAS 2001
IAS
Consider the following statements:
The setup for internal centreless grinding consists of a
regulating wheel, a pressure roll and a support roll, between
which the tubular workpiece is supported with the grinding
wheel within the tube, wherein
1.The grinding wheel, workpiece and regulating wheel centers
must lie on one line
2.The directions of rotation of workpiece and grinding wheel are
same
3.The directions of rotation of pressure roll, support roll and
regulating wheel are same
4 The directions of rotation of grinding wheel and regulating
4.The
wheel are same
Which of these statements are correct?
(a) 1, 2 and 3
(b)
1, 3 and 4
Rev.0
(c) 2 and 3
(d)
3 and 4
IAS 1997
IAS
IAS 2007
2007
IAS
IAS 2001
IAS
IAS 1999
IAS
Which one of the following processing sequences
will give the best accuracy as well as surface finish?
(a) Drilling,
Drilling reaming and grinding
(b) Drilling, boring and grinding
(c) Drilling, reaming and lapping
((d)) Drilling,
g reaming
g and electroplating
p
g
NC,CNC&Robotics
Wh t i NC/CNC?
WhatisNC/CNC?
y NC is
i an acronym for
f Numerical
N
i l Control
C t l and
d CNC is
i an
acronym
y for Computer
p
Numerical Control.
B SKM d l
BySKMondal
WhatisthedifferencebetweenNCandCNC?
WhatisthedifferencebetweenNCandCNC?
Wh
did CNC t t t d?
WheredidCNCgetstarted?
y Some
off the
with
S
th enhancements
h
t that
th t came along
l
ith CNC
y 1940 Jhon
Parson
developed
Jh
P
d l
d first
fi t machine
hi able
bl to
t drill
d ill
holes at specific
p
coordinates p
programmed
g
on p
punch
cards.
capability.
y The earliest NC machines performed limited functions
and movements controlled by punched tape or punch
cards.
cards
y As the technology evolved, the machines were equiped
with
ith increasingly
i
i l powerful
f l microprocessors
i
(
(computers)
t )
with the addition of these computers, NC machines
b
become
CNC machines.
hi
y CNC machines have far more capability than their
predecessor.
contd..
For-2015 (IES, GATE & PSUs)
spline
li interpolation.
i t
l ti
Rev.0
IAS 1996
IAS
Assertion (A): The temperature control of an
electric iron is an example of servomechanism.
Reason (R): It is an automatic control system.
system
(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
y CNC machine
tool
offer
what
hi
t l builders
b ild
ff an option
ti
h t is
i
Wh t i C
ti
l C t l
WhatisaConversationalControl
the
operator/programmer
use
simple
descriptive
command
d for
f rapid
id travel.
l Some
S
older
ld machines
hi
d not
do
di l d a graphical
displayed
hi l representation
t ti off the
th instructions
i t ti
so the operator/programmer
p
p g
can verifyy the tool p
path.
C C
hi
f
h
AreCNCmachinesfasterthan
conventionalmachines?
conventional machines?
C C
hi
AreCNCmachinesmoreaccurate
thanconventionalmachines?
than conventional machines?
who
h is
i running
i the
th machine,
hi
h
how
well
ll the
th machines
hi
h
has
been maintained,, q
qualityy of setup
p and so on.
GATE 1994
GATE
CNC machines are more accurate than conventional
machines because they have a high resolution
encoder and digital read
readouts
outs for positioning.
T
True
or false?
f l ?
conventional machines.
NC/CNCMachinesAdvantages
y High
Hi h Repeatability
R
t bilit and
d Precision
P i i e.g. Aircraft
Ai
ft parts
t
y Volume of production is very high
NC/CNCMachinesDisadvantages
y Costlysetup,skilledoperators
y Computers,programmingknowledgerequired
C
t
i k
l d
i d
Turbines
y Flexibility in job change, automatic tool settings, less
scrap
y More safe, higher productivity, better quality
y Less
L
paper work,
k faster
f t prototype
t t
production,
d ti
reduction
d ti
in lead times
y Maintenanceisdifficult
IES 1999
IES
Consider the following statements
numerically controlled machine tools:
1 They reduce nonproductive
1.
non productive time
2. They reduce fixturing
3. They reduce maintenance cost
Which of these statements are correct?
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3
(d) 1 and 3
Rev.0
regarding
IES 1995
IES
Consider
the
following
characteristics
of
production jobs:
1 Processing of parts frequently in small lots
1.
2. Need to accommodate design changes of products.
3. Low rate of metal removal
4. Need for holding
4
g close tolerances
The characteristics which favour the choice of
numerically controlled machines would include
(a) 1, 2 and 3
(b) 2, 3 and 4
( ) 1, 3 and
(c)
d 4 (d) 1, 2 and
d4
NC/CNC/DNC
y Direct Numerical Control is a system that uses a
Directnumericalcontrol
IES 2009
IES
DNC
498
GATE 1993
GATE
With reference to NC machine, which of the
following statement is wrong?
(a) Both closedloop
closed loop and openloop
open loop control systems are
used
(b) Paper
P
t
tapes,
fl
floppy
t
tapes
and
d cassettes
tt are used
d for
f
data storage
(c) Digitizers may be used as interactive input devices
((d)) Post p
processor is an item of hardware
499
IES 2007
IES
What are the main components of an NC machine?
1. Part program
2. Machine
M hi Control
C t l Unit
U it
3. Servo motor
Select the correct answer using the code given below:
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only
20 0
JWM2010
g components
p
g
g numerical
Consider the following
regarding
control system :
1 Programme of instructions
1.
2. Machine control unit
3. Processing
P
i equipment
i
Which of these are correct ?
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only (d) 1 and 3 only
IES 2009
IES
What is the purpose of satellite computers in
Distributed Numerical Control machines?
(a) To act as standby
stand by systems
(b) To share the processing of largesize NC programs
(c) To serve a group of NC machines
((d)) To network with another DNC setup
p
Rev.0
IES 1999
IES
Consider the following components:
1. A dedicated computer
2. Bulk
B lk memory
3. Telecommunication lines
Which of these components are required for a DNC
y
system?
(a) 2 and 3
(b) 1 and 2
(c) 1,
1 2 and 3 (d) 1 and 3
IES 2002Contd..FromS1
2002 C td F
S1
IES
C.
y
DNC system
33.
D. Machining centre 4.
Codes:A
( ) 4
(a)
(c) 4
B
2
3
C
3
2
D
1
1
IES 2002S1
2002
S1
IES
20 0
JWM2010
g
g
y
ConsiderthefollowingadvantagesofDNCsystems:
1.Timesharing
2 Greatercomputationalcapability
2.Greatercomputationalcapability
3.Remotecomputerlocation
Whichoftheaboveis/arecorrect?
(a)1and2only
(b)2and3only
(c)2only
(d)1 2and3
(d)1,2and3
St
M t
StepperMotor
IAS2011main
y The
motor
off synchronous
motor
Th stepper
t
t is
i special
i l type
t
h
t
which is designed
g
to rotate through
g a specific
p
angle
g
control unit.
BasicCNCPrinciples
IAS2010Main
IAS2009main
Illustratewiththehelpofneatsketchesthedifferences
system.Whyisfeedbacknotpossibleinopenloop
controlsystem?
[22 Marks]
Rev.0
GATE 2007
GATE
WhichtypeofmotorisNOTusedinaxisorspindle
drivesofCNCmachinetools?
(a) Inductionmotor
(b) DCservomotor
(c) Steppermotor
(d) Linearservomotor
IES 1994
IES
IES 2002
IES
B i L
th U it (BLU)
BasicLengthUnit(BLU)
GATE 1997
GATE
( a ) 1 m
(c ) 50 m
GATE 2007(PI)
2007 (PI)
GATE
In a CNC machine feed drive, a stepper motor
with step angle of 1.8o drives a lead screw with
pitch of 2 mm.
mm The Basic Length Unit (BLU) for
this drive is
(a) 10 microns
(b) 20 microns
(c) 40 microns
(d) 100 microns
GATE 2008(PI)
A stepper
motor
The
t
t has
h 150 steps.
t
Th output
t t shaft
h ft off the
th
motor is directlyy coupled
p
to a lead screw of p
pitch 4 mm,,
which drives a table. If the frequency of pulse supply to
the motor is 200 Hz, the speed of the table (in mm/min)
is
(a) 400
(b) 320
(c) 300
(d) 280
(b) 10 m
(d ) 100 m
l
Example
y A DC servomotor is coupled directly to a leadscrew
GATE 2014(PI)
IES 2011 C
ti
l
IES2011Conventional
G
20 0 ( )
GATE
2010(PI)
2
2.
3.
For a 3 axes
axes CNC table, the slide along the vertical axis
of the table is driven by a DC servo motor via a lead
screw nut mechanism. The lead screw has a pitch of 5
screw
mm. This lead screw is fitted with a relative
(incremental) circular encoder. The basic length unit
(BLU) of the slide along the vertical axis of the table is
0.005 mm. When the table moves along the vertical axis
by 9 mm, the corresponding number of pulses generated
by the encoder is
(a) 1400
(b) 1800
(c) 4200
(d) 9000
[5 Marks]
StatementforLinkedAnswersquestions:S1
In the feed drive of a Point
to Point open loop CNC
PointtoPoint
drive, a stepper motor rotating at 200 steps/rev drives a
table through a gear box and lead screw
screwnut
nut mechanism
(pitch = 4 mm, number of starts = 1).
Output rotational speed
The gear ratio = Input rotational speed is given by U = 14
The stepper motor (driven by voltage pulses from a pulse
generator)
t ) executes
t 1 step/pulse
t / l off the
th pulse
l generator.
t
The frequency of the pulse train from the pulse
generator
t is
i f = 10,000 pulses
l
per minute.
i t
GATE 2009(PI)
with a pitch of 5.0
5 0 mm to drive the work
worktable
table by a
distance of 200 mm in a NC machine is
(a) 14400
(b) 28800
(c) 57600
(d) 72000
((a)) become
b
d bl off previous
double
i
value
l
(b) become half of previous value
(c) remain the same
(d) become zero
GATE 2008Q1
2008 Q 1 (StatementinS2)
(St t
t i S 2)
GATE
GATE 2008Q2
2008 Q 2 (StatementinS3)
(St t
t i S 3)
GATE
GATE2014(PI)
The
h totall angular
l movement (in
( degrees)
d
) off a leadscrew
l d
loop pointtopoint
point to point controlled CNC drilling
In an open loop,
machine, a stepper motor, producing 200 angular steps per
revolution,
revolution drives the table of a drilling machine by one
angular step per each pulse generated by a pulse generator
(shown in figure).
figure) Each angular step moves the table by
one Basic Length Unit (BLU) along X axis with a lead screw
having a pitch of 4 mm. If the frequency of pulse generator
is doubled, the BLU will
Each
driven
by a stepper
motor
E h axis
i off NC machine
hi iis d
i
b
t
t
drive with a lead screw. The pitch of lead screw is p mm.
Th step
The
t angle
l off stepper
t
motor
t per pulse
l input
i
t is
i
degrees/pulse. The ratio of gear drive in stepper motor
d i is
drive
i g(number
(
b off turns
t
off the
th motor
t for
f each
h single
i l
turn of the lead screw). The number of pulses required
t achieve
to
hi
a linear
li
movementt off x mm is
i
g
360 g
g
360 g
x
x
x
x
(a)
(b)
(c )
(d )
360 p
p
360 p
p
Page 128 of 240
IAS2010
Main
IAS
2010Main
In openloop NC system the shaft of a stepping motor is
connected directly to the lead screw xaxis
x axis of the
machine table. The pitch of the lead screw is 3.0 mm.
The number of step angles on the stepping motor is 200.
200
Determine how closelyy the p
position of the table can be
controlled, assuming that there are no mechanical errors
positioning
g system.
y
in the p
Also, what is the required frequency of the pulse train
and
d the
h corresponding
d
rotationall speed
d off the
h stepping
motor in order to drive the table at a travel rate of 100
mm/min?
[ Marks]
[8
k ]
Rev.0
ControlSystemspossibleinCNCMachine
y Point to point mode:
GATE 1992
GATE
P i tt
i t t i ht li
d
Pointtopointstraightlinemode
In a point
to point type of NC system
pointtopoint
(a) Control of position and velocity of the tool is
essential
(b) Control of only position of the tool is sufficient
(c) Control of only velocity of the tool is sufficient
((d)) Neither p
position nor velocityy need be controlled
GATE 2006
GATE
NC contouring is an example of
(a) Continuous path positioning
(b) Pointtopoint
P i tt
i t positioning
iti i
(c) Absolute positioning
(d) Incremental positioning
GATE2005
WhichamongtheNCoperationsgivenbeloware
continuouspathoperations?
ArcWelding(AW)
Milling(M)
Drilling(D)
g
PunchingisSheetMetal(P)
g
LaserCuttingofSheetMetal(LC)SpotWelding(SW)
(a) AW,LCandM
(c) D,LC,PandSW
C
di t
t
Coordinatesystem
ordinate system.
y All the machine tool use Cartesian Co
Coordinate
system
y The first axis to be identified is the Z axis, This is
(b)AW,D,LCandM
(d)D,LC,andSW
Righthandcoordinatesystems
Page 129 of 240
Rev.0
IES 2000
IES
Assertion (A): The axis of an NC drilling machine
spindle is denoted as zaxis.
Reason (R): In NC machine tool,
tool the axis
perpendicular to both x and yaxis is designated as
z axis
zaxis
(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
IES 1996
IES
Assertion (A): Numerically controlled machines
having more than three axes do not exist.
Reason (R): There are only three Cartesian
coordinates namely xyz.
( ) 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
5axesCNCverticalaxismachiningcentreconfiguration
Rev.0
IES 2003S1
2003
S1
IES
While part programming
in CNC machines, the
input
of
dimensional
information for the tool
path can be given in the
absolute
coordinate
system or in incremental
coordinate system. The
above figure shows the
route to be followed by the
tool from O to C, i.e., O A
B C.
IES 2003Contd..FromS1
2003 C td F
S1
IES
Q
( )
GATE2012SameQinGATE2012(PI)
If incremental co
ordinates system is used, the co
coordinates
co
ordinates of each point A, B and C are
(a) A: X 5.0,
5 0 Y 10.0
10 0
(b) A: X 5.0,
5 0 Y 10.0
10 0
B: X 20.0, Y5.0
B: X 25, Y 15.0
C: X 10.0, Y 10.0
C: X 35, Y 5.0
((c)) A: X 10.0, Y 55.0
((d)) A: X 10.0, Y 55.0
B: X 15.0, Y 25.0
B: X 5.0, Y 20.0
C: X 15.0,
15 0 Y 35.0
35 0
C: X 10.0,
10 0 Y 10
10.0
0
P tP
i
PartProgramming
Th f ll i
th t
t b f ll
d
Thefollowingarethestepstobefollowed
whiledevelopingtheCNCpartprograms.
y FANUCCONTROLL
y Processplanning
y SIEMENSCONTROLL
y Axesselection
y Toolselection
y Cuttingprocessparametersplanning
y Jobandtoolsetupplanning
J
pp
g
y Machiningpathplanning
y Partprogramwriting
y Partprogramproving
CNC programming
CNCprogramming
Importantthingstoknow:
speed, feed,
speed
feed depth of cut,
cut tool selection , coolant on off
and tool paths. The MCU issues commands in form of
numeric data to motors that position slides and tool
accordingly.
TableofImportantGcodes
ProgrammingKeyLetters
y O Programnumber(Usedforprogramidentification)
CoordinateSystem
Units,incrementalorabsolutepositioning
G01
LinearInterpolation
N__G01X___Y___Z___F___
G02
CircularInterpolation,
CircularInterpolation
CW
N G02X Y Z
N__G02X__Y__Z___R___F___
R
F
G
G03
CircularInterpolation,
C
l
l
CCW
N G X___Y___Z__R__F___
N__G03
X
Y
Z R F
G04
G17
Dwell
XY Plane
N__G04P___
G18
G19
9
XZPlane
y X Xaxisdesignation
y Z Zaxisdesignation
y F Feedratedesignation
y S Spindlespeeddesignation
CoolantControl:On/Off,Flood,Mist
C l C
l O /Off Fl d Mi
ToolControl:Toolandtoolparameters
T lC
l T l d l
For-2015 (IES, GATE & PSUs)
Format
N__G00X___Y___Z___
N G00X
Y Z
y G
G Preparatoryfunction
y R Radiusdesignation
Feedrateandspindlespeed
F d
d i dl
d
Meaning
RapidTransverse
y N Sequencenumber(Usedforlineidentification)
y Y Yaxisdesignation
g
Coordinates:X,Y,Z,RX,RY,RZ
Code
G00
y H
H Toollengthoffsetdesignation
y D Toolradiusoffsetdesignation
y T ToolDesignation
g
y M Miscellaneousfunction
N__G02X___Y__Z__I___J__K__F__
N__G03 X__Y__Z__I__J__K__F__
YZPlane
Rev.0
TableofImportantGcodes
Code
Meaning
G20/G70 InchUnit
G21/G71 MetricUnit
TableofImportantGcodes
Rapidtraverse:G00
G28
AutomaticReturntoReference
Point
Code Meaning
Format
G44 Toollengthcompensation N__G44H__
N G44H
(minus)
G49 Toollengthcompensation
cancel
G40
Cuttercompensationcancel
G80
Cancelcannedcycles
Ca
ce ca ed cyc es
G41
G
G42
Cuttercompensationleft
C tt
Cuttercompensationright
ti i ht
G81
Drillingcycle
G90
G91
Absolutepositioning
Incrementalpositioning
G92
Absolutepreset,changethe
Absolutepreset
changethe N__G92X__Y__Z__
N G92X Y Z
datumposition
G43
Format
N__G41D__
N G D
N__G42D__
Toollengthcompensation
(plus)
N G43H
N__G43H__
Linearinterpolation:G01
y Itisusedforpositioningmotion.
G90G00X20 0Y10 0
G90G00X20.0Y10.0
N__G81Z__R__F__
End
G90:
9
absolute
coordinates
Start
Circularinterpolation:G02,G03
y Forcircularinterpolation,thetooldestinationandthecircle
y linearinterpolationatfeedspeed.
p
p
centerareprogrammedinoneblock
y G02isclockwiseinterpolation,G03iscounterclockwise
interpolation
G91G0lX200.0Y100.0F200.0
Y
End
100.0
200 0
200.0
Start
p
,
Circularinterpolation:G02,G03
Y
y tomakethemachinemoveatmaximumspeed.
t k th
hi
t
i
(
(20,10)
)
(10,10)
(0,0)
Circularinterpolation:G02,G03
y G02,G03:
y G01:
G91:
incremental
coordinates
y G00:
y I,J,Karetheincremental
distancefromthestartof
thearc;
h
X
Start
j
Center
y Viewingthestartofarcas
theorigin,I,J,Khave
th
i i I J Kh
positiveornegativesigns.
F __;
J __
F __;
K __
G 02
R
G19
Y __ Z __
G 03
J __
F __;
K __
End
point
Start
N0010G92X200.0Y40.0Z0;
N0020G90G03X140.0Y100.0I60.0F300
N0030G02X120.0Y60.0I 50.0
N0010G92X200.0Y40.0Z0
N0010G92X200
0Y40 0Z0
N0020G90G03X140.0Y100.0R60.0F300
N0030G02X120.0Y60.0R50.0
Y
100
60
40
SpecifyRwith
signbeforeit:
>180
R
R=50mm
Circularinterpolation:G02,G03
AnnotationforCircularInterpolation
G92:
Todefineworking
coordinate
G90:
absolute
coordinates
di t
End
G91G02X60.0Y20.0R50.0 F300.0
9
5
F300.0
3
G91G02X60.0Y20.0R50.0
Circlecenter radius
Circlecenter,radius
Or
R=-50mm
180 +R
Circularinterpolation:G02,G03
y SpecifyCenterwithI,J,K
End
G 02
R
G17
X __ Y __
G 03
I __
G 02
R
G18
X __ Z __
G 03
I __
y I0.0,J0.0,andK0.0canbeomitted.
I
J
dK b itt d
y IfX,Y,Zareallomittedintheprogram,thatmeans
startandendofarcaresamepoints
startandendofarcaresamepoints.
N0020G02I20.0(afullcircle)
y IfI,J,K,andRallappearsincircularinterpolation
IfI J K andRallappearsincircularinterpolation
instruction,RisvalidandI,J,andKareinvalid
R50
R60
X
90 120 140
200
Rev.0
GATE 2014
GATE2014
FortheCNCpartprogramming,matchGroupAwith
GroupB:
GroupA
Group B
P:circularinterpolation,counter
clockwise
Q:dwell
R:circularinterpolation clockwise
R:circularinterpolation,clockwise
S:pointtopointcountering
P
( ) II
(a)
(c) I
Q
III
IV
R
I
II
S
IV
III
( )
(b)
(d)
P
I
II
I:G02
GATE 2007(PI)
2007 (PI)
GATE
The interpolator in a CNC machine controls
(a) Spindle Speed
(b) Coolant flow
(c) Feed rate
(d) Tool change
II:G03
III:G04
IV:G00
Q
III
I
R
II
III
S
IV
IV
GATE 2010
GATE
In a CNC program block, N002 G02 G91 X40 Z40,
G02 and G91 refer to
(a) Circular interpolation in counterclockwise direction
and incremental dimension
(b) Circular
Ci l interpolation
i t
l ti in
i counterclockwise
t l k i direction
di ti
and absolute dimension
(c) Circular interpolation in clockwise direction and
incremental dimension
(d) Circular interpolation in clockwise direction and
absolute dimension
GATE 2005
GATE
The tool of an NC machine has to move along a
circular arc from (5, 5) to (10,10) while performing an
operation. The centre of the arc is at (10, 5). Which
one of the following NC tool path commands
performs the above mentioned operation?
(a) N010G02 X10 Y10 X5 Y5 R5
(b) N010G03
N G X10
X Y10
Y X5
X Y5
Y R5
R
(c) N010G01 X5 Y5 X10 Y10 R5
(d) N010G02 X5 Y5 X10 Y10 R5
For-2015 (IES, GATE & PSUs)
GATE 2004
GATE
IES 2009
IES
Interpolation
in
to
I t
l ti
i the
th controller
t ll refers
f
t control
t l off
which one of the following
g in a CNC machine?
(a) Loading/unloading of jobs on machine
(b) Loading/unloading of tools from the tool changer
(c) Axes of machine for contouring
(d) Coolant and miscellaneous functions on machine
GATE2014(PI)
A CNC instruction G91G01X30Y40F100 commands the
GATE 2001
GATE
In an NC machining operation, the tool has to be
moved from point (5, 4) to point (7, 2) along a
circular path with centre at (5, 2). Before starting the
operation, the tool is at (5, 4). The correct G and M
code for this motion is
(a) N010 G03 X7.0 Y2.0 I5.0 J2.0
(b) N010
N
G X7.0
G02
X
Y
Y2.0
I
I5.0
J
J2.0
(c) N010 G01 X7.0 Y2.0 I5.0 J2.0
(d) N010 G00 X7.0 Y2.0 I5.0 J2.0
ToolCompensation
y ToolRadiusCompensation
y LefthandG41
L fth dG
y RighthandG42
y CanceltoolradiuscompensationG40
C
l l di
i G
y ToolHeightCompensation
y PositiveG43
y NegativeG44
y CanceltoolheightcompensationG49
Rev.0
ToolRadiusCompensation
y Toolradiuscompensationsmakeitpossibleto
programdirectlyfromthedrawing,andthuseliminate
thetooloffsetcalculation
th
t l ff t l l ti
G41(G42)D
CancelToolCompensation:G40
y Notethedifferencebetweentwoways
N0060G40G01 X2.000Y1.700M02
y D:theradiusoftooltocompensateissavedinamemoryunitthat
D th di ft lt
t i
di
itth t
N0060G01 X2.000Y1.700
N0070G40
7
4 M02
isnamedD
y G41/G42isdirectlyrelatedwithdirectionoftoolmovementand
whichsideofpartiscut
whichsideofpartiscut.
rampoffblock
GATE 2014
GATE
For machining a rectangular island represented by
coordinates P(0, 0), Q(100, 0), R(100, 50) and S(0, 50) on
a casting using CNC milling machine, an end mill with a
diameter of 16 mm is used. The trajectory of the cutter
center to machine the island PQRS is
(a) (8, 8), (108, 8), (108, 58), (8, 58), (8, 8)
(b) (8,
(8 8),
8) (94,
(94 8),
8) (94,
(94 44),
44) (8,
(8 44),
44) (8,
(8 8)
(c) (8, 8), (94, 0), (94, 44), (8, 44), (8, 8)
(d) (0,
( 0),
) (100,
(
0),
) (100,
(
50),
) (50,
(
0),
) (0,
( 0))
TableofImportantMcodes
effectivetotheendpoint
ToolHeightCompensation
G43(G44)H
y H:specifiedmemoryunitusedtosaveheight
compensationoftool.
y Positivecompensation(G43):
realposition=specifiedposition+valuesavedinH
y Negativecompensation(G44):
realposition=specifiedposition
l iti
ifi d iti valuesavedinH
l
di H
g
p
ToolHeightCompensation
y Example:
y N0010G91G00X12.0Y80.0
G G
y N0020G44Z32.0H02
G91:
incremental
coordinates
y Ifweput0.5mmintoH02,
y realposition=32.0 0.5=32.5
y Canceltoolheightcompensation:G49
p g
g
Rulesforprogramming
Block Format
y M01Optionalprogramstop
y M03Spindleonclockwise
S i dl l k i
y M04Spindleoncounterclockwise
Sample Block
Restrictions on CNC blocks
Each may contain only one tool move
Each may contain any number of non-tool move G-codes
Each may contain only one feed rate
Each may contain only one specified tool or spindle speed
The block numbers should be sequential
Both the program start flag and the program number must be
independent of all other commands (on separate lines)
The data within a block should follow the sequence shown
in the above sample
p block
y M05Spindlestop
y M06Toolchange
y M08Coolanton
y M09Coolantoff
y M10Clampson
y M11Clampsoff
GATE 2009
2009
GATE
y M00Programstop
M P
y M02orM30Programstop,resettostart
GATE 2000
GATE
Rev.0
IES 1993
1993
IES
A 'block'
block of information in N.C. machine program
means
(a) One row on tape
(b) A word comprising several rows on tape
(c) One complete instruction
((d)) One complete
p
program
p
g
for a jjob
ToolHome
IES 1996
IES
In manual programming and tape preparation for a
NC drilling machine, the spindle speed was coded
as S 684 (using the magic
magicthree
three code). The spindle
speed in rpm will be
(a) 684
(b) 68.4
(c) 840
((d)) 6840
4
Top
p
View
Top
View
2.)ZAxisRapidMove
JustAboveHole
3.)TurnOnCoolant
)
ExampleofCNCProgramming
Example of CNC Programming
y WhatMustBeDoneToDrillAHoleOnACNC
VerticalMillingMachine
g
Top
View
55.)ZAxisFeedMoveto
DrillHole
4.)TurnOnSpindle
)
O S i dl
1 )X&YRapidToHolePosition
1.)X&YRapidToHolePosition
Front
View
.100
Front
View
Front
View
HeresTheCNCProgram!
Top
View
6.)RapidZAxisMove
6
)RapidZAxisMove
OutOfHole
Front
View
Top
View
Top
View
8.)TurnOffCoolant
Front
View
For-2015 (IES, GATE & PSUs)
7.)TurnOffSpindle
9.)X&YAxisRapid
MoveHome
Front
View
ToolAtHome
O0001
O
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
N025G00Z 1M09
N025G00Z.1M09
N030G91G28X0Y0Z0
N035M30
Rev.0
ToolAtHome
Top
View
O0001
O
O0001
N
NumberAssignedtothisprogram
b A i
d hi
Front
View
Top
View
Front
View
Top
View
Front
View
ToolAtHome
Top
View
O0001
O
N005G54G90S600M03
N005
G54
G90
S600
M03
SequenceNumber
FixtureOffset
AbsoluteProgrammingMode
SpindleSpeedsetto600RPM
SpindleoninaClockwiseDirection
Front
View
O0001
O
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
G43
H01
Z.1
M08
ToolLengthCompensation
SpecifiesToollengthcompensation
ZCoordinate.1in.fromZero
FloodCoolantOn
O0001
N005G54G90S600M03
N
G G S6 M
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
75 3 5
N025G00Z.1M09
N030G91G28X0Y0Z0
G91
IncrementalProgrammingMode
G28
ZeroReturnCommand
X0,Y0,Z0
X,Y,&ZCoordinatesatZero
Top
View
Front
View
p
Top
View
Front
F
View
Top
View
O0001
O
N005G54G90S600M03
N010G00X1.0Y1.0
G
G00
X1.0
Y1.0
R idM i
RapidMotion
XCoordinate1.0in.fromZero
YCoordinate1.0in.fromZero
Front
View
O0001
O
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
G01
Z.75
35
F3.5
StraightLineCuttingMotion
ZCoordinate.75 in.fromZero
FeedRatesetto3.5in/min.
35 /
O0001
N005G54G90S600M03
N
G G S6 M
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
N020G01Z
.75F3.5
N025G00Z.1M09
N030G91G28X0Y0Z0
N035M30
M30
EndofProgram
Top
View
Front
View
O0001
O
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
N025G00Z 1M09
N025G00Z.1M09
G00
Z
Z.1
M09
RapidMotion
ZCoordinate.1in.fromZero
ZC
di
i f
Z
CoolantOff
IES 1995
1995
IES
Match List I with List II and select the correct answer
using the codes given below the lists:
List I
List II
(A function
f
i connected
d
(A
(Associated
i d parameter))
with NC m/c tool)
A Interpolation
A.
1 Tape preparation
1.
B. Parity check
2. Canned cycle
C Preparatory function
C.
3 Drilling
3.
D. Point to point control
4. Contouring
5. Turning
Code:A
B
C
D
A
B
C
D
(a) 4
1
2
3
(b) 4
1
2
5
(c) 5
1
3
2
(d) 1
4
3
2
Rev.0
IAS 2011 M i
IAS2011Main
g operation,
p
, the tool tip
p is at location (
(
In an NC drilling
100, 0, 100). The datum (0, 0, 0) is left hand lower corner
p surface of the workpiece,
p
, which is rectangular
g
on top
(300 mm x 300 mm x 1.5 mm thick). A thru' hole of 10
mm diameter is t o be drilled in the centre of the
workpiece. Using only rapid positioning and linear
p
functions,, write the p
program
g
blocks,, in
interpolation
absolute mode.
Assume permitted cutting speed = 32 m/min and feed
rate = 150 mm/min.
[10Marks]
IFS2011
IES 1998
IES
Which of the following are the rules of
programming NC machine tools in APT language?
1 Only capital letters are used
1.
2. A period is placed at the end of each statement
3. Insertion of space does not affect the APT word
Select the correct answer using
g the codes g
given below:
(a) 1 and 2
(b) 2 and 3
(c) 1 and 3
(d) 1 alone
OtherPartProgrammingLanguages
programming system for smaller computers
d l
developed
d by
b IBM and
d first
fi t introduced
i t d d in
i 1962
6
Th
l t APT
t
it f
ThecompleteAPTpartprogramconsistsof
thefollowingfourtypesofstatements
y Geometry
y Motion
y Postprocessor
y Compilationcontrol
MACHIN/DRILL,
MACHIN/DRILL 2
COOLNT/
COOLNT/FLOOD
OthercapabilitiesofAPT,themacrofacility,withusevariableargumentasina
FORTRANsubroutine,forexample:
FORTRAN b
i f
l
Additionalstatements:
Forexample: COOLNT/MIST
APTLanguage
g g
APTLanguage
D
((ADaptation
Daptat o APT)) was tthee first
st atte
pt to adapt APT
y ADAPT
attempt
y AUTOSPOT (AUTOmatic Sytem for POsitioning Tools) was
Words
y The
Th words
d to
t be
b used
d in
i the
th statements
t t
t are built
b ilt up from
f
APT L
APTLanguage
COOLNT/OFF
FEDRAT/
whenthedefinitionofthemacroDRILLis:
SPINDL/
Forexample:
l SPINDL/ON
/
TOOLNO/
TURRET/
END
SPINDL/1250,
/
CCLW
62
Rev.0
63
Point (POINT)
Point (POINT)
(
)
PTA = POINT/ 33,4,5
45
Point (POINT)
PTC
(3, 4, 5)
LIN2
PTA
z
LIN3
PTB
C1
LIN1
PTD
Point (POINT)
PTE = POINT/ YLARGE,
YLARGE INTOF,
INTOF C1,
C1 C2
PTE = POINT/ XLARGE, INTOF, C1, C2
PTF = POINT/ YSMALL,, INTOF,, C1,, C2
PTF = POINT/ XSMALL, INTOF, C1, C2
Point (POINT)
(
)
Line (LINE)
(
)
y
y
C1
y
C6
PTE
P2
PT7
PTF
P1
C2
LIN1
Line (LINE)
Line (LINE)
(
)
Line (LINE)
LINE2
PT6
PT3
L
L14
P1
40
L4
L12
PT1
L16
30
PT4
LINE1
LINE
(15,30,3)
L15
20
15
Rev.0
Line (LINE)
Line (LINE)
Line (LINE)
N = LINE/
N / ATANGL,
NG , DEGREES,
G
S, INTERC,
N
C, MODIFIER,
O
,d
LIN
The modifier options are [XAXIS, YAXIS], and d is the
corresponding
p
g intercept
p value on the selected axis ((i.e., modifier).
)
LINE1
L1
LINE1
C11
LINE1=LINE/ATANGL 30 INTERC d
LINE1=LINE/ATANGL,30,INTERC,d
PT51
=30
x
(6 )P i t fX I t
(6,0)PointofXIntercept
t
Line (LINE)
Line (LINE)
Line (LINE)
L6
Left
L3
C3
Right
L6
Right
Right
PT40
L1
L8
L9
Left
f
Left
Left
PT51
Right
C3
L7
L4
L
L2
Line (LINE)
L8
L9
L77
Plane (PLANE)
Line
LN5 = LINE/ INTOF,
INTOF PLAN1,
PLAN1 PLAN2
LN5
PLAN10
PT15
y
PNT6
PNT5
LN3
PT6
LN15
LN13
3.0
PLAN1
PT4
PLAN2
PT12
LN4
4
z
PLAN14
Rev.0
C4
Plane (PLANE)
Circle (CIRCLE)
(
)
Circle (CIRCLE)
(
)
C3 = CIRCLE/ CENTER, PT6, TANTO, LN4
C7 = CIRCLE/ CENTER
CENTER, PT8,
PT8 PT5
C1 = CIRCLE/ 3, 6, 5, 4.3
C1 = CIRCLE/
C C / CENTER,
C
PT3,
3 RADIUS,
A
S 4.3
43
PLAN10
PT15
C1
y
PT6
LN4
PT12
PT5
43
4.3
3.0
PT3
PT4
PT6
PT8
(3,6,5)
C7
C3
z
PLAN14
x
The Machining
g Plan
Contouring:
CS
CS
CS
tool is riding.
y Drive surface: the surface against which the edge of
Checksurface
Drivesurface
cutter
Directionof
cuttermotion
DS
DS
DS
motion
i is
i to stop.
GOUP
The Machining
g Plan
Motion
i commands:
GOLFT/
GORGT/
GOUP/
GOBACK
ON
PAST
FROM/PTARG
GO/TO,L1,TO,PL2,TOL3
GORGT/L3,PAST,L4
GORGT/L3 PAST L4
GOLFT
TO
Partsurface
GOFWD
Present tool
position
GORGT
GODOWN
Previous
Page 140 of 240
tool position
Rev.0
M hi i Specifications
S ifi i
Machining
Postprocessor
commands
P
d for
f a particular
i l machine
hi tooll are:
MACHIN/ : used to specify the machine tool and call the
postprocessor for that tool:
MACHIN/ DRILL,, 3
COOLNT/ : allows the coolant fluid to be turned on or off:
Machining Specifications
FEDRAT/ : specifies the feed rate for moving the tool along the
part surface in inches per minute:
FEDRAT/ 4.5
SPINDL/ : gives the spindle rotation speed in revolutions per
minute:
COOLNT/ MIST
SPINDL/ 850
COOLNT/ FLOOD
COOLNT/ OFF
Machining Specifications
TOLERANCE SETTING:
motion
is
SETTING Nonlinear
N li
i
i accomplished
li h d in
i
straight-line segments, and INTOL/ and OUTTOL/ statements
di
dictate
the
h number
b off straight-line
i h li segments to be
b generated.
d
INTOL/ 0.0015
OUTTOL/ 0.001
TURRET/ 11
M hi i Specifications
S ifi i
Machining
Machining Specifications
PARTNO:
PARTNO identifies
id ifi the
h part program andd is
i inserted
i
d at the
h start off
the program.
FINI:
FINI specifies
ifi the
h endd off the
h program.
g g
APTLanguage
OtherMotionstatements:
GO/{TO}, Drive surface, {TO} Part surface, {TO},
Ch k surface
Check
f
Or
GO/{TO}, Drive surface, {TO} Part surface, {TANTO},
Check surface
AndthesamewithPASTorONinsteadofTO
GOLFT/
GORGT/
GOUP/
GODOWN/
GOFWD/
/
GOBACK/
Forexample:
GO/TO, L1, TO, PS, TANTO, C1
GO/PAST, L1, TO, PS, TANTO, C1
96
IES 2008
IES2008
Name the four types of statements in a complete APT
part program.
program Prepare part program for geometry
description of the contour shown in the figure below:
Y
[15Marks]
[15
Marks]
40
30
20
L2
L3
135
80
20
C1
L4
L1
C2
L5
P2
20
20
P1
Answer:
Contd.
PARTNO CONTOUR
MACHIN/MILL, 1
CLPRNT
UNITS/MM
P0 = POINT/0.0, 0.0, 0.0
P1 = POINT/110.0,
POINT/110 0 20.0,
20 0 0.0
00
P2 = POINT/20.0, 20.0, 0.0
P3 = POINT/90.0, 110.0, 0.0
P4 = POINT/20.0, 100.0, 0.0
P5 = POINT/50.0, 130.0, 0.0
L1 = LINE/P2, ATANGL, 90, XAXIS
L2 = LINE/P4, ANTNGL, 45, XAXIS
L3 = LINE/P5, ATANGL, 135, L2
L4 = LINE/P1,, PERPTO,, L3
L5 = LINE/P1, PERPTO, L4
C1=CIRCLE/CENTER, P3, RADIUS, 20.0
C2=CIRCLE/CENTER,
C2
CIRCLE/CENTER, P1, RADIUS, 20.0
PL1=PLANE/P1, P2, P3
CUTTER/25.0
TOLER/0.1
INTOL/0.05
INTOL/0 05
OUTTOL/0.05
FEDRAT/200
SPINDL/500, CLW
COOLNT/ON
FROM/P0
GO/TO, L1, TO, PL1, TO, L5
GOLFT/L1, PAST, L2
GORGT/L2 PAST,
GORGT/L2,
PAST L3
GORGT/L3, TANTO, C1
GOFWD/C1, PAST, L4
GOFWD/L4, PAST, C2
GORGT/C2, PAST, L5
GORGT/L5 PAST,
GORGT/L5,
PAST L1
Rev.0
Contd.
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
IES 2007
IES2007
R30
Q
110
120
E
R40
40
+ 40
P
Material : M S.
100
8 mm
Answer:
Contd.
Contd.
CUTTER/25.0
TOLER/0.1
INTOL/0.05
INTOL/0 05
OUTTOL/0.05
FEDRAT/200
SPINDL/500, CLW
COOLNT/ON
FROM/P0
GO/TO, LAB, TO, PL1, TO, LAF
GOLFT/LAB, TANTO, CBC
GOFWD/CBC PAST
GOFWD/CBC,
PAST, LCD
GORGT/LCD, PAST, LDE
GORGT/LDE, PAST, CEF
GORGT/CEF, PAST, LAF
GORGT/LAF, PAST, LAB
PARTNO CONTOUR
MACHIN/MILL, 2
CLPRNT
UNITS/MM
P0 = POINT/0.0, 0.0, 10.0
PTA = POINT/0.0, 0.0, 0.0
PTB = POINT/0.0, 120.0, 0.0
PTC = POINT/30.0, 150.0, 0.0
PTD = POINT/140.0, 150.0, 0.0
PTE = POINT/140.0, 40.0, 0.0
PTF = POINT/100.0, 0.0, 0.0
PTQ = POINT/30.0, 120.0, 0.0
PTP = POINT/140.0, 0.0, 0.0
LAB = LINE/PTA, PTB
LCD
C = LINE/PTC,
/ C, PTD
LDE = LINE/PTD, PTE
LAF = LINE/PTA, PTF
CBC = CIRCLE/CENTRE,, PTQ,
Q, RADIUS,, 30.0
CEF = CIRCLE/CENTRE, PTP, RADIUS, 40.0
PL1=PLANE/PTA, PTB, PTC
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
R30
L2
Y
C1
IES 2006
IES2006
Prepare part program to machine the contour shown in
C2
Answer:
P2
L3
100 mm
80
L1
R20
X
100 mm
P1
60
80
50
60
200 mm
Material: MS
Thickness: 8.0 mm
L4
200 mm
50
P4
C2
P3
C1
R20
R30
L2
P3
R20
P2
PARTNO CONTOUR
MACHIN/MILL, 3
CLPRNT
80 L1
UNITS/MM
P0 = POINT/0.0, 0.0, 10.0
P1 = POINT/0.0, 0.0, 0.0
P2 = POINT/60.0, 80.0, 0.0
P3 = POINT/150.0, 100.0, 0.0
60
P1
P4 = POINT/200.0,
POINT/200 0 0.0,
0 0 0.0
00
C1 = CIRCLE/ CENTER, P2, RADIUS, 20
C2 = CIRCLE/CENTER, P3, RADIUS, 30
L1 = LINE/P1, LEFT, TANTO, C1
L2 = LINE/LEFT, TANTO, C1, LEFT, TANTO, C2
L3 = LINE/P4
LINE/P4, RIGHT,
RIGHT TANTO
TANTO, C2
L4 = LINE/P1, P4
PL1=PLANE/P1, P2, P3
L3
100 mm
X
L4
200 mm
Rev.0
50
P4
Contd.
CUTTER/25.0
TOLER/0.1
INTOL/0.05
INTOL/0 05
OUTTOL/0.05
COOLNT/ON
SPINDL/500, CLW
FEDRAT/200
FROM/P0
GO/TO, L1, TO, PL1, TO, L4
GOLFT/L1, TANTO, C1
GOFWD/C1 PAST,
GOFWD/C1,
PAST L2
GOFWD/L2, TANTO, C2
GOFWD/C2, PAST, L3
GOFWD/L3, PAST, L4
GORGT/L4, PAST, L1
IES 2011 C
ti
l
IES2011Conventional
State the method of defining line segment of
cutter motion using APT program format.
[5 Marks]
H
W k
HomeWork
p
p
p g
g
Write a complete
part
program
in APT for machining
the product which is given in the diagram. Thickness of
the workpiece is 6 mm. All dimensions are in mm.
[15]
PARTNOCONTOUR
MACHIN/MILL,1
CLPRNT
UNITS/MM
P0=POINT/25.0,25.0,25.0
P1=POINT/0.0,0.0,6.0
/ ,
,
P2=POINT/117.0,32.0,6.0
P3=POINT/117 0 32 0 6 0
P3=POINT/117.0,32.0,6.0
C1=CIRCLE/CENTER,P1,RADIUS,10.0
C CIRCLE/CENTER P RADIUS
C2=CIRCLE/CENTER,P2,RADIUS,12.5
C3=CIRCLE/CENTER,P3,RADIUS,12.5
Contd.
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
IES 1997
IES
Which of the following are valid statements for
point to point motion of the tool in APT language?
1 GO/TO/............
1.
GO/TO/
2. GO DLTA/............
3. GO/TO, .
Select the correct answer using
g the codes g
given below:
(a) 1 and 2
(b) 2 and 3
(c) 1 and 3
(d) 1,
1 2 and 3
REMARKMOTIONSTATEMENTFOLLOW
FROM/P0
GO/TO,L1,TO,PL1,TANTO,C1
GORGT/L1,TANTO,C3
GOFWD/C3,TANTO,C4
GOFWD/C4 TANTO C2
GOFWD/C4,TANTO,C2
GOFWD/C2,PAST,L2
GOFWD/L2 TANTO C1
GOFWD/L2,TANTO,C1
GOFWD/C1,PAST,L1
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
IES 1995
IES
In APT language, the cutter motion in incremental
coordinate mode is addressed as
(a) GO/TO/.....
GO/TO/
(b) GO/TO.....
(c) GO DLTA/....
((d)) GO FWD/...
Rev.0
Robotics
Advantages of Robots
AdvantagesofRobots
p
y, safety,
y, efficiency,
y, q
y, and consistencyy of
productivity,
quality,
products
Robots can work in hazardous environments
R b t need
Robots
d no environmental
i
t l comfort
f t
Robots work continuously without any humanity needs and
illnesses
Robots have repetable precision at all times
Robots can be much more accurate than humans, they may have
mili or micro inch accuracy.
accuracy
Robots and their sensors can have capabilities beyond that of
humans
Robots can process multiple stimuli or tasks simultaneously,
humans can only one.
Robots replace human workers who can create economic
problems
Disadvantages of Robots
DisadvantagesofRobots
2.
3.
4.
5.
"arm,"
the
the robot.
"
" that
th t does
d
th actual
t l work
k off th
b t It iis
composed of mechanical linkages and joints with actuators
to drive the mechanism directly or indirectly through gears,
chains, or ball screws.
Feedback devices: transducers that sense the p
positions of
various linkages and joints and transmit this information to
the controllers in either digital or analog Form.
End effectors: the "hand" or "gripper" portion of the
robot, which attaches the end of the arm and perform the
operations of the robot.
robot
Controller: the brains of the system that direct the
movements of the manipulator.
manipulator
Power supply
Page 144 of 240
Wh t i
Whatisanindustrialrobot?
i d t i l b t?
A robot is a reprogrammable,
reprogrammable multifunctional
manipulator designed to handle material, parts, tools or
specialized devices through variable programmed
motions for the performance of a variety of tasks.
WhatCanRobotsDo?
IndustrialRobots
d
l b
Material
Material handling
Material transfer
Machine loading and/or unloading
Spot welding
Continuous arc welding
Spray
p y coating
g
Assembly
Inspection
MaterialHandling
Manipulator
A
Assembly
bl
Manipulator
SpotWelding
Manipulator
WristConfigurations
y Wristassemblyisattachedtoendofarm
y Endeffector
E d ff
i
isattachedtowristassembly
h d i
bl
y Functionofwristassemblyistoorientendeffector
y Bodyandarmdeterminesglobalpositionofend
effector
y Twoorthreedegreesoffreedom:
h
d
ff d
y Roll
y Pitch
y Yaw
Rev.0
End Effectors
EndEffectors
y Thespecialtoolingforarobotthatenablesitto
DegreesofFreedom
g
pp
GrippersandTools
performaspecifictask
y Twotypes:
y For
F each
h degree
d
off freedom
f d
a joint
j i is
i required.
i d
y Grippers tograspandmanipulateobjects(e.g.,
parts)duringworkcycle
y Tools toperformaprocess,e.g.,spotwelding,spray
configuration.
painting
robot
robotss hand at any point in its work space.
space
y Although six degrees of freedom are needed for
maximum flexibility,
flexibility most robot employee only three to
five degrees of freedom.
y The more the degrees of freedom,
freedom the greater is the
complexity of motions encountered.
y The three degrees of freedom located in the arm of
a robotic system are:
The
Th rotational
t ti
l reverse: is
i the
th movementt off the
th arm
assembly about a rotary axis, such as leftandright
swivel
i l off the
th robots
b t arm about
b t a base.
b
T
fR b t
TypesofRobot
y Cartesian
or
y
Gantry
robot:
y It's a robot whose arm
has
three
prismatic
joints, whose axes are
coincident
with
a
Cartesian coordinator.
y Used for pick and place
work, application of
sealant,
assembly
operations,
handling
machine tools and arc
welding.
welding
For-2015 (IES, GATE & PSUs)
T
fR b t
TypesofRobot
T
fR b t
TypesofRobot
y Cylindrical robot:
p
y Spherical
or
Polar robot:
y It
It'ss a robot whose axes
form a polar coordinate
y
system.
y Used for handling at
p
machine tools,, spot
welding,
diecasting,
fettling machines, gas
welding
and
arc
welding.
form a cylindrical
coordinate system.
y Used
U d for
f
assembly
bl
operations, handling at
machine
hi
t l
tools,
spott
welding, and handling
att
di
die
casting
ti
machines.
Page 145 of 240
Rev.0
Types of Robot
TypesofRobot
T
fR b t
TypesofRobot
y SCARA robot
y Articulated
or
Revolute Robot:
y It
It'ss a robot whose arm
has at least three rotary
joints.
joints
y Used for assembly
operations,
ti
di casting,
die
ti
fettling machines, gas
welding,
ldi
arc welding
ldi
and spray painting.
y The
SCARA
acronym
stands
for Selective Compliant Assembly
Robot Arm or Selective Compliant
Articulated Robot Arm.
y It's a robot which has two parallel
provide compliance
p
rotaryy jjoints to p
in a plane
y Used for pick and place work,
work
application of sealant, assembly
operations and handling machine
tools
Theconfigurationofarobotusingatelescopingarmthat
canberaisedorloweredonahorizontalpivotmounted
onarotatingbaseiscalled
(a)Polar
(b)C li d i l
(b)Cylindrical
(c)Cartesiancoordinate
(d)Jointedarm
y
JointDriveSystems
y Electric
y Useselectricmotorstoactuateindividualjoints
y Preferreddrivesystemintoday'srobots
y Hydraulic
y Useshydraulicpistonsandrotaryvaneactuators
y Notedfortheirhighpowerandliftcapacity
y Pneumatic
y Typicallylimitedtosmallerrobotsandsimplematerial
T i ll li it dt
ll b t d i l t i l
transferapplications
Working Envelope
WorkingEnvelope
y
RobotControlSystem
Joint2
Level2
Controller
&Program
Level1
Joint4
Joint5
Joint6
Sensors
y Limitedsequencecontrol pickandplace
operationsusingmechanicalstopstosetpositions
i
i
h i l
ii
y Playbackwithpointtopointcontrol records
workcycleasasequenceofpoints,thenplaysback
thesequenceduringprogramexecution
y Playbackwithcontinuouspathcontrol
greatermemorycapacityand/orinterpolation
capabilitytoexecutepaths(inadditiontopoints)
y Intelligentcontrol exhibitsbehaviorthatmakes
itseemintelligent,e.g.,respondstosensorinputs,
makesdecisions,communicateswithhumans
Cell
C
ll
Supervisor
Joint3
y Parallel robot
IES 2012
IES
Joint1
T
fR b t
TypesofRobot
fluxcoredarc
welding(FCAW)
operationatone
workstation
k
i
whilefitter
changespartsat
theother
workstation
Level0
Rev.0
Robot Programming
RobotProgramming
Leadthrough Programming
y Leadthrough programming
y Work cycle is taught to robot by moving the
IES2011
Trajectoryofarobotmean:
(a)Pathtracedbytheendeffectors
(b)KinematicsofRobot
( )
(c)Robotjoints
j
(d)Robotprogramming
1. Poweredleadthrough
y Commonforpointto
pointrobots
y Usesteachpendant
2. Manualleadthrough
y Convenientfor
continuouspath
controlrobots
y Humanprogrammer
physicalmoves
manipulator
y Easilylearnedbyshoppersonnel
y Logicalwaytoteacharobot
y Nocomputerprogramming
y Disadvantages:
y Downtimeduringprogramming
y Limitedprogramminglogiccapability
Li i d
i l i
bili
y Notcompatiblewithsupervisorycontrol
IES 2010
IES2010
g statements:
Consider the following
Good dynamic performance is usually difficult to achieve
in robots which contain a rotary base because
1. Position, speed and acceleration of the other joints cause
variations in the reflected torque and moment of inertia.
2. The moment of inertia reflected at the base depends upon the
weight of the object being carried.
3. The moment of inertia reflected at the base also depends upon
the distance between the base axis and the manipulated object.
Which of the above statements is/are correct?
(a) 1, 2 and 3
(b) 2 and 3 only
(c) 1 only
(d) 1 and 3 only
IES 2000
IES
Consider the following characteristics of a robot:
1. The tip of the robot arm moves from one point to
another with its in
inbetween
between path not being defined.
2. It can be used for drilling holes at difference points in a
workpiece.
workpiece
3. It can be used for V butt joint welding between two
points.
points
4. The memory capacity required for its control unit is low.
Which of these are the characteristics associated with
ith a point
to point robot?
( ) 1 and
(a)
d2
(b) 1, 3 and
d4
GATE
(c) 1, 2 and 4For-2015
(d) (IES,
2, 3 and
4 & PSUs)
L dh
h ProgrammingAdvantages
P
i Ad
Leadthrough
g
y Advantages:
IES 2006
IES
Which one of the following is the third basic
component of robots besides power supply and
control (memory) console?
(a) Software
(b) Coaxial cable
( ) Mechanical
(c)
M h i l unit
it arm (d) Microcomputer
Mi
t
GATE 2013
GATE2013
CAD
Computer Aided
d d Design (CAD):
(
) Used
d for
f creating the
h
In
mirror
image
off a 2D
I a CAD package,
k
i
i
D point
i t
product database
P(5,10)
(5, ) is to be obtained about a line which p
passes
Geometric Modeling
Engineering Analysis
Automated Drafting
Page 147 of 240
(b) (10,
(10 5)
(c) (7.5,
(7 5 5)
5)
Rev.0
(d) (10,
(10 5)
5)
GATE 2014
GATE2014
ArobotarmPQwithendcoordinatesP(0,0)andQ(2,5)
A b t
PQ ith d
di t P( ) dQ( )
rotatescounterclockwiseaboutPintheXYplaneby90
p
y 9 o.
ThenewcoordinatepairoftheendpointQis
(a)(2,5)
(b)(5,2)
(c)(5,2)
(d)(2,5)
CAM
ComputerAidedManufacturing(CAM):
y ComputerAidedProcessPlanning(CAPP)
y ComputerizedmaterialResourcePlanning(MRP)
IES 2006
IES
Which item best describes a CAM technology?
(a) Geometric modeling (b) Documentation
( ) Drafting
(c)
D fti
(d) Numerical
N
i l control
t l
y NCpartprogramming
y RobotProgramming
R b P
i
y ComputerizedScheduling
y Computerizedprocesscontrol
y ComputerizedManufacturingControlbyFMS
y Shopfloorcontrol
y ComputerAidedQualityControl(CAQC)
p
Q
y
( Q )
y ComputerAidedInspection
Automation
ISRO2011
In CAM, " Part programming" refers to
(a) Generation of cutter location data
(b) Online Inspection
(c) Machine Selection
(d) Tool
T l Selection
S l i
Automation
Automation
Programmable Automation
Flexible Automation
Automation
Fixed Automation
y It
as hard
I is
i also
l known
k
h d automation.
i
y Used to produce a standardized product.
product
y Used for very large quantity production of one or few
IES 2012
IES
Programmableautomationissuitablefor
P
bl t
ti i it bl f
(a)Lowproductionvolumeandlargevarietiesofparts
(b)Lowproductionvolumeandsmallvarietiesofparts
p
p
any order
d or mix.
i
(c)Highproductionvolumeandsmallvarietiesofparts
different components.
p
(d)Highproductionvolumeandlargevarietiesofparts
Rev.0
Wh t i
FMS?
WhatisanFMS?
f
g system
y
((FMS)) is a
y A fflexible manufacturing
manufacturing system in which there is some
amount of flexibilityy that allows the system
y
to
react in the case of changes.
y Two categories of flexibility
y Machine flexibility, covers the system's ability to be
FMSComponents
y
FMS G l
FMSGoals
f
AdvantagesofFMS
Di d t
f FMS
DisadvantagesofFMS
IES 1996
IES
g from one p
y Faster,, lower cost changes
part to another
Whichofthefollowingpairsarecorrectlymatched?
1. CNCmachinePostprocessor
2. Machiningcentre.Toolmagazine
M hi i t
T l
i
3. DNC.FMS
(a) 1,2and3 (b) 1and2
(c) 1and3
(d)2and3
IES 2006
2006
IES
Flexible manufacturing allows for:
(a) Tool design and production
(b) Automated
A t
t d design
d i
(c) Quick and inexpensive product change
(d) Quality control
IES 2004
IES
Consider the following characteristics:
1. Single machine tool
2. Manual
M
l materials
t i l handling
h dli system
t
3. Computer control
4. Random sequencing of parts to machines
Which of the above characteristics are associated with
flexible manufacturing system?
(a) 1,
1 2 and 3 (b) 1 and 2
(c) 3 and 4
(d) 2, 3 and 4
Page 149 of 240
IES 2012
IES
Rankorderclusteringasappliedtomanufacturing
automationis
(a)Atechniqueofidentifyingprocesssequencein
productionofacomponent
(b)Aj ti ti (JIT) th d
(b)Ajustintime(JIT)method
(c)Anapproachofgroupingthemachinesintocellsin
anFMSsystem
( )
(d)Atooltogeneratebillofmaterials
g
Rev.0
ReferenceBook
IFS2011
y CAD/CAM:ComputerAidedDesignand
ManufacturingByGroover
y CNCMachines ByB.S.Pabla,M.Adithan
ByB S Pabla M Adithan
y Machinetooldesignandnumericalcontrol By
Mehta
y ComputerControlOfManu.Systems ByKoren
N df U
ti
lP
NeedforUnconventionalProcesses
y New materials having high strength and hardness,
hardness such as
process.
[
[10marks]
k ]
f
for
d l
development
t off
processes
which
utilize
nontraditional
t diti
l
other
machining
hi i
methods
such
as
N df U
ti
lP
NeedforUnconventionalProcesses
y Complex
C
l shapes.
h
y A very high accuracy is desired besides the complexity of
1 Th
lE
M th d
1.ThermalEnergyMethods
I U
ti
l M hi i
InUnconventionalMachining
y Different forms of energy directly applied to the
2 El
Ch i l E
M h d
2.Electro
ChemicalEnergyMethod
y Electricaldischargemachining(EDM)
El t i ldi h
hi i (EDM)
y ElectroChemicalMachining(ECM)
El
Ch i lM hi i (ECM)
y LaserbeamMachining(LBM)
y ElectroChemicalgrinding(ECG)
El t Ch i l i di (ECG)
y PlasmaArcMachining(PAM)
g
y ElectronBeamMachining(EBM)
y IonBeamMachining(IBM)
Cl ifi ti
f NTMM
ClassificationofNTMM
The Non
traditional Machining Methods are classified
Nontraditional
according to the major energy sources employed in
machining.
1.ThermalEnergyMethods
2.Electro ChemicalEnergyMethod
3.ChemicalEnergyMethods
4.MechanicalEnergyMethods
3 ChemicalEnergyMethods
Ch i l E
M th d
3.
These methods involve controlled etching of the
workpiece material in contact with a chemical solution.
y Chemical Machining Method (CHM).
y ElectroChemicalHoning(ECH)
El t Ch i lH i (ECH)
y ElectroChemicalDeburring
Electro ChemicalDeburring (ECD)
Rev.0
GATE 2014
GATE2014
4 MechanicalEnergyMethods
M h i lE
M th d
4.
S
Ob
ti
SomeObservations
y UltraSonicMachining(USM)
Ult S i M hi i (USM)
p
p
q
y EDM has the lowest specific
power requirement
and can
y AbrasiveJetMachining(AJM)
removing material is
y WaterJetMachining(WJM)
g
Sh
C tti C
bilit
ShapesCuttingCapability
The various NTMM have some special shape cutting
capability as given below:
1. Micromachining and Drilling : LBM and EBM
2 Cavity sinking and standard Hole Drilling: EDM and
2.
USM
GATE2014
IES 2012
IES
Whichofthefollowingprocesseshasveryhighmaterial
removalrateefficiency?
(a)Electronbeammachining
(b)Electrochemicalmachining
(c)Electrodischargemachining
( )
(d)Plasmaarcmachining
g
g
tool wear,, are used for nonmetal cutting.
MRR and,, therefore,, are commonlyy used for micro
drilling, sheet cutting, and welding.
y CHM is used for manufacturing
g PCB and other shallow
components.
y PAM can be used for clean,, rapid
p cuts and p
profiles in
almost all plates upto 20 cm thick with 5o to 10o taper.
Li it ti
f NTMM
LimitationsofNTMM
The
unconventional
Th following
f ll i four
f
ti
l machining
hi i processes
y Expensive
required.
E
i sett up, low
l MRR and
d skilled
kill d labour
l b
i d
25 mm deep is
( ) Abrasive
(a)
b
Jet Machining
h
((c)) Laser
ase Beam
ea Machining
ac
g
(d) Electro Discharge Machining
GATE 2006
GATE
g the p
g order of
Arrange
processes in the increasing
their maximum material removal rate.
g ((ECM))
Electrochemical Machining
Ultrasonic Machining (USM)
Electron Beam Machining (EBM)
Laser Beam Machining (LBM) and
Electric Discharge Machining (EDM)
(a) USM, LBM, EBM, EDM, ECM
(b) EBM,
EBM LBM,
LBM USM,
USM ECM,
ECM EDM
(c) LBM, EBM, USM, ECM, EDM
(d) LBM, EBM, USM, EDM, ECM
Page 151 of 240
IES 2007
IES
Consider the following statements in relation to the
unconventional machining processes:
1 Different forms of energy directly applied to the
1.
piece to have shape transformation or material removal
from work surface.
surface
2. Relative motion between the work and the tool is
essential.
ti l
3. Cutting tool is not in physical contact with work
piece.
(b) 1, 2 and 3 onlyy
(a) 1 and 2 onlyy
(c) 2 and 3 only
(d) 1 and 3 only
Rev.0
IES 2009
2009
IES
IAS 2002
IAS
(
) with List II (Tolerances
(
Match List I (Processes)
obtained) and select the correct answer using the codes
given below the Lists:
List I
List II
(Processes)
(Tolerances obtained)
A. Plasma Arc machining 1.
75 microns
B. Laser Beam machining 2.
25 microns
C. Abrasive Jet machining 3.
50 microns
D. Ultrasonic machining
4.
125 microns
Codes:A
B
C
D
A
B
C
D
(a) 4
1
3
2
(b) 3
2
4
1
(c) 4
2
3
1
(d) 3
1
4
2
ECM
B SKM d l
BySKMondal
El t h i l M hi i
ElectrochemicalMachining
El t h i l M hi i
ElectrochemicalMachining
plating
y The workpiece
work piece is made the anode,
anode which is placed in
close proximity to an electrode (cathode), and a high
amperage direct current is passed between them through
an electrolyte, such as salt water, flowing in the anode
cathode gap.
gap
y Metal is removed by anodic dissolution and is carried
away in
i the
th form
f
off a hydroxide
h d id in
i the
th electrolyte
l t l t for
f
recycling or recovery.
y MRR in ECM depends on atomic weight of work material
ECM E i
t
ECMEquipment
ECM E i
t
ECMEquipment
ECM E i
t
ECMEquipment
Rev.0
Tool
El t l t
Electrolyte
y is so chosen that the anode (workpiece)
(
p
)
The electrolyte
is dissolved but no deposition takes place on the cathode
(tool).
Properties electrolyte should be
1. High
g electrical conductivityy
2. Low viscosity
3 High specific heat
3.
4. Chemical stability
5 Resistance to formation of passivating film on
5.
workpiece surface
6 Noncorrosive
6.
Non corrosive and nontoxic
non toxic
7. Inexpensive and readily available
p
The p
properties
of tool materials should be:
ForECMofsteelNaCl isusedastheelectrolyte.
ISRO2009
The machining process in which the work picce is
di l d into
dissolved
i t an electrolyte
l t l t solution
l ti is
i called
ll d
(a) Electro
Electrochemical
chemical machining
(b) Ultrasonic machining
g
2.
Easy machinability
3.
Good shiffness
4.
d
Advantages
1.
1 Complex threedimensional
three dimensional surfaces can be machined
1.
i d
Disadvantages
1.
2.
3.
4.
5.
6
6.
7
7.
y
Use of corrosive media as electrolytes
makes it difficult to
handle.
Sharp interior edges and corners (< 0.2 mm radius) are
difficult to produce.
Very expensive machine.
Forces are large with this method because of fluid pumping
forces.
V
Very
hi h specific
high
ifi energy consumption
i
( b
(about
150 times
i
that required for conventional processes),
Not applicable with
ith electrically
electricall nonconducting
non conducting materials
and jobs with very small dimensions
Lower fatigue strength
PSU
ECMcannotbeundertakenfor
ECM
tb d t k f
(a)steel
(b)Nickelbasedsuperalloy
(c)Al2O3
(d)Titaniumalloy
A li ti
Applications
y Any electrically conductive work material irrespective
i
inaccessible.
ibl
y Shape application blind complex cavities, curved
y
y
y
y
y
y
y
PSU
Commercial ECM is carried out at a combination
off
(a) low voltage high current
(b) low current low voltage
((c)) high
g current high
g voltage
g
(d) low current low voltage
Rev.0
IAS2011Main
What is the principle of electrochemical
machining
hi i (ECM)?
What are the advantages and disadvantages of
ECM over conventionall drilling?
d ll
Comment on the surface finish and the accuracy of
the ECM.
[
[20Marks]
]
ECM C l l ti
ECMCalculations
y laws state that,,
Faradays
m=
It E
F
Where
m
I
t
E
F
ECM C l l ti
ECMCalculations
yMRR =
=weight(g)ofamaterial
=current(A)
=time(sec)
=gramequivalentweightofthe
gramequivalentweightofthe
material
co sta t o p opo t o a ty
=constantofproportionality
Faraday(96,500coulombs)
Eeq I cm
eq F sec
100
x
= i
eq
i i
Atomicweightofiron56,density7.8g/cm3 valency,2
g/s
IfyouputE=equivalentweightinCGSi.e.g/mole
IfyouputE=equivalentweightinCGSi
e g/mole
IinAmpere(A)
F=96500columb/molei.e.As/mole
l b
l
l
TheMRRwillbeing/s
GATE 2014
GATE2014
chemical machining is
(a)Ficks law
and
( )Ki hh ff l
(c)Kirchhoffslaws
(d)Ohm slaw
(d)Ohmslaw
100
x v
= i i
Eeq
i Ai
GATE 2011(PI)
2011 (PI)
GATE
GATE2008(PI)
In an electro chemical machining (ECM) operation,
operation a
square hole of dimensions 5 mm x 5 mm is drilled in a
block of copper. The current used is 5000 A. Atomic
weight
g of cupper
pp is 633 and valencyy of dissolution is 1.
Faradays constant is 96500 coulomb. The material
removal rate (in g/s) is
(a) 0.326
AI
F V
F.
(b)Faradayslaws
3
E
l
Example
g/s =
p
The p
principle
of material removal in Electro
AI cm3 EI cm3
vF sec F sec
whatcurrentisrequired?
q
EI
F
ECM C l l ti
ECMCalculations
y MRR for pure metal
UsingECMremove5cm
U i ECM
3/minfromanironworkpiece,
/ i f
i
k i
ECM C l l ti
ECMCalculations
(b) 3.260
Rev.0
E
l
Example
Calculate the material removal rate and the
electrode feed rate in the electrochemical
machining of an iron surface that is 25 mm 25 mm
in crosssection using NaCl in water as electrolyte.
The gap between the tool and the workpiece is 0.25
mm. The supply voltage is 12 V DC. The specific
resistance of the electrolyte is 3 c m
For iron, Valency, Z = 2
At
Atomic
i weight,
i ht A = 55.85
8
Density, = 7860 kg / m3
E
l (GATE 2009)
Example(GATE2009)
Electrochemicalmachiningisperformedtoremove
materialfromanironsurfaceof20mmx20mmunder
thefollowingconditions:
Interelectrodegap
=
0.2mm
S
SupplyVoltage(DC)
l V lt (DC) =
12V
V
Specificresistanceofelectrolyte
=2cm
AtomicweightofIron =
55.85
ValencyofIron =
2
Faraday'sconstant
=
96540Coulombs
Th t i l
Thematerialremovalrate(ing/s)is
l t (i / )i
E
l
Example
p
p
y is as follows:
Composition
of a Nickel superalloy
Ni = 70.0%, Cr = 20.0%, Fe = 5.0% and rest Titanium
Calculate rate of dissolution if the area of the tool is 1500
mm2 and a current of 1000 A is being passed through the
cell Assume dissolution to take place at lowest valancy
cell.
of the elements.
GATE 2013
GATE2013
During the electrochemical machining (ECM) of
iron (atomic weight = 56, valency = 2) at current of
1000 A with 90% current efficiency, the material
removal rate was observed to be 0.26 gm/s. If
Titanium (atomic weight = 48, valency = 3) is
machined by the ECM process at the current of 2000
A with 90% current efficiency, the expected material
removal rate in gm/s will be
(a) 0.1
0 1 1 (b) 0.23
0 23
(c) 0.30
0 30
(d) 0.52
0 52
GATE 2008
GATE
Fl
l i
Flowanalysis
A researcher
h conducts
d t electrochemical
l t
h i l machining
hi i
((ECM)) on a binary
y alloy
y ((density
y 6000 kg/m
g/ 3) of iron
(b) 25
E
l
Example
The electrochemical machining of an iron surface that is
25 mm 25 mm in crosssection using NaCl in water as
electrolyte. The gap between the tool and the workpiece
is 0.25 mm. The supply voltage is 12 V DC. The specific
resistance of the electrolyte is 3 cm.
Estimate the electrolyte flow rate. Specific heat of the
electrolyte is given as 0.997
0 997 cal/g
cal/gC
C. The ambient
temperature is 35C and the electrolyte boiling
temperature is 95
temperature,
95C
C.
Density, = 7860 kg/m3
For-2015 (IES, GATE & PSUs)
(c) 15
l2R = q e ce (B o )
(d) 79
g
Overvoltage
DynamicsofElectrochemicalMachining
V V
R
Rev.0
E
l
Example
In
an equilibrium
gap off 2
I ECM operation
ti off pure iron
i
ilib i
mm is to be kept.
p Determine supply
pp y voltage,
g , if the total
overvoltage is 2.5 V. The resistivity of the electrolyte is 50
mm and the set feed rate is 0.25 mm/min.
GATE 2012(PI)LinkedS2
In an EDM process using RC relaxation circuit,
circuit a 12 mm
diameter through hole is made in a steel plate of 50 mm
thickness using a graphite tool and kerosene as
dielectric. Assume discharge time to be negligible.
Machining is carried out under the following conditions:
Resistance
40
Capacitance
20 F
Supply
pp y voltage
g
220 V
Discharge voltage
110 V
Averagepowerinput(inkW)is
(a)0.373
(b)0.137
(c)0.218 (d)0.500
El t h i l G i di (ECG)
ElectrochemicalGrinding(ECG)
p g and sharpening
p
g
y The p
process is used for shaping
carbide cutting tools, which cause high wear rates on
expensive diamond wheels in normal grinding.
Electrochemical grinding greatly reduces this wheel
wear.
y Fragile parts (honeycomb structures), surgical needles,
and tips of assembled turbine blades have been ECG
processed
d successfully.
f ll
y The lack of heat damage, burrs, and residual stresses is
very beneficial,
b
f
l particularly
l l when
h coupled
l d with
h MRRs
that are competitive with conventional grinding but
with
ith far
f less
l wheel
h l wear.
For-2015 (IES, GATE & PSUs)
GATE 2007(PI)
2007 (PI)
GATE
Which one of the following process conditions
leads to higher MRR in ECM process?
( ) higher
(a)
hi h current,
t larger
l
atomic
t i weight
i ht
((b)) higher
g
valency,
y, lower current
(c) lower atomic weight, lower valency
(d) higher
hi h valency,
l
l
lower
atomic
i weight
i h
GATE 2012(PI)LinkedS1
In an EDM process using RC relaxation circuit,
circuit a 12 mm
diameter through hole is made in a steel plate of 50 mm
thickness using a graphite tool and kerosene as
dielectric. Assume discharge time to be negligible.
Machining is carried out under the following conditions:
Resistance
40
Capacitance
20 F
Supply
pp y voltage
g
220 V
Discharge voltage
110 V
The time for one cycle,
cycle in milliseconds,
milliseconds is
(a) 0.55 (b) 0.32
(c) 0.89
(d) 0.24
l
h i l G i di ( CG)
ElectrochemicalGrinding(ECG)
g, metal bonded,,
y In ECG,, the tool electrode is a rotating,
diamond grit grinding wheel.
y As the electric current flows between the workpiece and the
IES 2000
IES
C
g statements:
Consider the following
In electrochemical grinding,
1 A rubber bonded alumina grinding wheel acts as the
1.
cathode and the workplace as the anode.
2 A copper bonded alumina grinding wheel acts as the
2.
cathode and the work piece as the anode.
3 Metal removal takes place due to the pressure
3.
applied by the grinding wheel.
4 Metal removal takes place due to electrolysis.
4.
electrolysis
Which of these statements are correct?
(a) 1 and 3
(b) 2 and 4
156 of 240
(c) 2 and 3
(d) Page
1 and3
Equipmentsetupandelectricalcircuitforelectrochemicalgrinding.
p
OtherElectrochemicalprocesses
y Electrochemicalpolishing
p
g
y Electrochemicalholedrilling
g
y ElectrochemicalDeburring
g
Rev.0
GATE 2001
GATE
In ECM, the material removal is due to
(a) Corrosion
(b) Erosion
E i
(c) Fusion
(d) Ion displacement
GATE 1997
GATE
Selection electrolyte for ECM is as follows:
(a) Nonpassivating electrolyte for stock removal and
passivating electrolyte for finish control
(b) Passivating electrolyte for stock removal and non
passivating
i ti electrolyte
l t l t for
f finish
fi i h control
t l
(c) Selection of electrolyte is dependent on current
density
((d)) Electrolyte
y
selection is based on tool work
electrodes
GATE 1997
GATE
Inter electrode gap in ECG is controlled by
(a) Controlling the pressure of electrolyte flow
(b) Controlling
C t lli the
th applied
li d static
t ti load
l d
(c) Controlling the size of diamond particle in the wheel
(d) Controlling the texture of the work piece
GATE 1992
GATE
The two main criteria for selecting the electrolyte in
Electrochemical Machining (ECM) is that the
electrolyte should
(a) Be chemically stable
(b) Not
N t allow
ll dissolution
di l ti off cathode
th d material
t i l
(c) Not allow dissolution of anode material
(d) Have high electrical conductivity
IES 2002
IES
Assertion (A): In ECM, the shape of the cavity is the
mirror image of the tool, but unlike EDM, the tool
wear in ECM is less.
Reason (R): The tool in ECM is a cathode.
( ) 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
IES 1997
IES
Which one of the following processes does not
cause tool wear?
(a) Ultrasonic machining
(b) Electrochemical machining
(c) Electric discharge machining
((d)) Anode mechanical machining
g
Ph i l P i i l
PhysicalPrinciple
y Basic process
Ph i l P i i l
PhysicalPrinciple
y An arc jumps between two points along the path of least
resistance.
Rev.0
Ph i l P i i l
PhysicalPrinciple
Ph i l P i i l
PhysicalPrinciple
Ph i l P i i l
PhysicalPrinciple
Ch
t i ti
f EDM
CharacteristicsofEDM
Ch
t i ti
f EDM
CharacteristicsofEDM
EDMTool
W
R ti
WearRatio
S
M h i
ServoMechanism
y The
the
a critical
Th gap between
b t
th tool
t l and
d work
k has
h
iti l
Theusualchoicesfortool(electrode)materialsare
y Copper,
y brass,
b
y alloysofzincandtin,
y hardenedplaincarbonsteel,
y coppertungsten,
y silvertungsten,
y tungstencarbide,
t
t bid
y coppergraphite,andgraphite.
For-2015 (IES, GATE & PSUs)
4: 1.
metallic electrodes, it is about 33: 1 or 4
y With graphite (with the highest melting point, 3500C),
the wear ratio may range from 5: 1 up to 50: 1.
Page 158 of 240
EDM T l
EDMTool
Prime requirements EDM tool Material
1. It should be electrically conductive.
2. It should
h ld have
h
good
d machinability,
hi bilit thus
th
allowing
ll i
easy manufacture of complex shapes.
3. It should have low erosion rate or good work to tool
wear ratio.
4. It should have low electrical resistance.
5. It should have high melting point.
6. It should have high electron emission.
importance.
p
As the workpiece
p
is machined,, this g
gap
p
tends to increase. For optimum machining efficiency,
this gap should be maintained constant. This is done by
servo mechanism
h i
which
hi h controls
t l the
th movementt off the
th
electrode.
Rev.0
Di l t i Fl id
DielectricFluid
p carryy awayy
y Fluid is used to act as a dielectric,, and to help
Discuss
the
Di
th effects
ff t off insufficient
i
ffi i t dielectric
di l t i and
d
debris.
y If the fluid is p
pumped
p through
g and out the end of the
electrode, particles will push out, and mainly collect at
the edges. They will lower the dielectric resistance,
resulting in more arcs. As a result the holes will be
conical.
y If fluid is vacuum pumped into the electrode tip, straight
holes will result.
y Quite often kerosenebased oil.
y The dielectric fluid is circulated through the tool at a
pressure of 0.35 N/m2 or less. To free it from eroded
metal particles, it is circulated through a filter.
electrolyte
y circulation in the interelectrode g
gap
p on the
Electric Discharge machining and Electro Chemical
Machining process respectively.
2.
3.
4.
5.
6.
g
Hardness,, toughness
or brittleness of the material p
poses no
problems. Due to this EDM can be used for machining
materials that are too hard or brittle to be machined by
conventional
ti
l methods.
th d
The method does not leave any chips or burrs on the work
piece.
piece
Cutting forces are virtually zero, so very delicate and fine
work can be done.
done
The process dimension repeatability and surface finish
g are extremelyy g
good.
obtained in finishing
The characteristic surface obtained, which is made up of
p in better oil retention. This improves
p
die life.
craters, helps
Because the forces between the tool and the workpiece and
virtually zero, very delicate work can be done.
1. O
Onlyy electricallyy conductive materials can be machined
2.
33.
4.
5.
6.
A li ti
Applications
A li ti
Applications
y EDM is
with
i particularly
ti l l useful
f l when
h dealing
d li
ith internal
i t
l
A li ti
Applications
y EDM can be
any material
b used
d for
f machining
hi i
t i l that
th t is
i
shapes,
h
narrow slots
l
and
d blind
bl d cavities etc., for
f example,
l
sinking of dies for moulding,
moulding die casting,
casting plastic
moulding, wire drawing, compacting, cold heading,
forging, extrusion and press tools.
IES2009Conventional
What is the principle of metal removal in EDM
process??
ii. Describe the process with the help of sketch.
iii. List advantages and limitations of the system.
i.
generated
d on a workpiece
k
iff a suitable
bl tooll can be
b
Fig Relaxation circuit used for generating the pulses in EDM process
Fig-Relaxation
[5 Marks]
Disadvantages
Ad t
Advantages
1.
R l ti
i it
Relaxationcircuit
S 20 C
i
l
IES2011Conventional
[ 5
[15marks]
]
Rev.0
GATE 1994
GATE
Electric discharge machining is more efficient
process than Electrochemical machining for
producing large non
noncircular
circular holes.
The above statement is
( ) True
(a)
T
(b) False
(c) Cant say
(d) Insufficient data
Wi EDM
WireEDM
y Wire EDM is a special form of EDM wherein the
electrode.
y The electrode wire is typically made with a 0.05 to 0.25
mm diameter,
diameter which is wire electrode wound between
the two spools.
y Deionized water is used as the dielectric.
Wi EDM
WireEDM
y This
Thi process is
i much
h faster
f t than
th electrode
l t d EDM.
EDM
y This process is widely used for the manufacture of
El t i Di h
G i di (EDG)
ElectricDischargeGrinding(EDG)
El t i Di h
G i di (EDG)
ElectricDischargeGrinding(EDG)
The method
Th
th d can be
b used
d for
f
1. External cylindrical grinding, internal grinding and
surface grinding.
2. Grinding
g carbide and steel at the same time without
wheel loading.
3. Grinding thin sections where abrasive wheel pressures
might cause distortion.
4 Grinding brittle materials or fragile parts where
4.
abrasive materials might cause fracturing.
Rev.0
IES 2012
IES
Statement (I): In Electro Discharge Machining (EDM)
process, tool is made cathode and work piece anode
Statement (II): In this process if both electrodes are made of
same material, greatest erosion takes place upon anode
(a) Both Statement (I) and Statement (II) are individually
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
p
of
Statement (I)
(c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement (II) is true
GATE 1999
GATE
In Electro
Discharge Machining (EDM), the tool is
ElectroDischarge
made of
(a) Copper
(b) High Speed Steel
(c) Cast Iron
(d) Plain Carbon Steel
GATE 2004
GATE
The mechanism of material removal in EDM
process is
(a) Melting and Evaporation
(b) Melting and Corrosion
(c) Erosion and Cavitation
((d)) Cavitation and Evaporation
p
G
20 0 ( )
GATE2010(PI)
Keeping all other parameters unchanged,
unchanged the tool
wear in electrical discharge machining (EDM) would
be less if the tool material has
(a) high thermal conductivity and high specific heat
( ) high thermal conductivity and low specific heat
(b)
GATE 2003
GATE
As tool and work are not in contact in EDM process
(a) No relative motion occurs between them
(b) No
N wear off tool
t l occurs
(c) No power is consumed during metal cutting
(d) No force between tool and work occurs
GATE 2007
GATE
In electro discharge machining (EDM), if the
thermal conductivity of tool is high and the specific
heat of work piece is low, then the tool wear rate
and material removal rate are expected to be
respectively
(a) High and high
(b) Low and low
( ) High
(c)
Hi h and
d low
l
(d) Low
L and
d high
hi h
GATE 2005
GATE
A zigzag cavity in a block of
high strength alloy is to be
finish machined. This can be
carried out by using
(a) Electricdischargemachining
(b) Electrochemicalmachining
(c) Laserbeammachining
((d)) Abrasiveflowmachining
g
IES 2005
IES
Which of the following is/are used as low wearing
tool material(s) in electric discharge machining?
(a) Copper and brass
(b) Aluminium and graphite
(c) Silver tungsten and copper tungsten
((d)) Cast iron
GATE 2000
GATE
Deep hole drilling of small diameter, say 0.2 mm is
done with EDM by selecting the tool material as
(a) Copper wire
(b) Tungsten wire
(c) Brass wire
(d) Tungsten carbide
Rev.0
GATE 2009(PI)
Ult
i M hi i
UltrasonicMachining
UltrasonicMachining
((b)) 200
((c)) 3300
((d)) 4
400
BySKMondal
Ult
i M hi i
UltrasonicMachining
Ult
i M hi i
UltrasonicMachining
Ult
i M hi i
UltrasonicMachining
P
P
t
ProcessParameters
y MRRw
EffectofmachiningparametersonMRR
2
( w db )3/2 nf
3
Ult
i M hi
UltrasonicMachine
Feedforce(F)
Amplitudeofvibration(ao)
averagegritdiameter,dg
Frequencyofvibration(f)
Volumeconcentrationofabrasive
inwaterslurry C
Rev.0
Ult
i M hi
UltrasonicMachine
Ult
i M hi
UltrasonicMachine
to a drill press.
SubsystemsofUSM
Subsystemsof
USM
y The transducer,
transducer which generates the ultrasonic vibration
work material.
y The
Th workpiece
k i
i mounted
is
t d on a vice,
i
which
hi h can be
b
located at the desired position under the tool using a 2
axis
i table.
t bl
y The table can further be lowered or raised to
accommodate work of different thickness.
y Slurry
y deliveryy and return system
y
T
d
Transducer
GATE2010(PI)
y The
the vibration
th
ib ti to
t the
th required
i d amplitude
lit d off 15 50 m and
d
accommodates the tool at its tip.
Ultrasonic
used
l
i machines,
hi
d in
i material
i l removall processes,
q
ultrasonic transducers. The transducers works on
require
different working principles. One of the working principles
of such ultrasonic transducers is based on
(a) eddy current effect
(c) p
piezoresistive effect
(d) p
piezoelectric effect
T l h ld
H
ToolholderorHorn
y Its
is
the
amplitude
It function
f
ti
i to
t increase
i
th tool
t l vibration
ib ti
lit d
Limitations
T l
Tool
y Tools
relatively
T l should
h ld be
b constructed
t t d from
f
l ti l ductile
d til
materials.
y LowMRR
y Ratherhightoolwear
y Lowdepthofhole
L d th fh l
y The harder the tool material, the faster its wear rate will
be.
A li ti
Applications
Rev.0
Note
y The following material is generally machined by USM
(i)
Glass
(ii)
Sili
Silicon
(iii)
Germanium
y Tool in USM is generally made of Steel
GATE 1993
GATE
In ultrasonic machining process, the material
removal rate will be higher for materials with
(a) Higher toughness
(b) Higher ductility
(c) Lower toughness
(d) Higher fracture strain
IES 2006
IES
During ultrasonic machining, the metal removal is
achieved by
(a) High frequency eddy currents
(b) high frequency sound waves
(c) Hammering action of abrasive particles
((d)) Rubbing
g action between tool and workpiece
p
GATE 1994
GATE
Ultrasonic machining is about the best process for
making holes in glass which are comparable in size
with the thickness of the sheet.
The above statement is
( ) True
(a)
T
(b) False
(c) Cant say
(d) Insufficient data
IES2011
USM has good machining performance for :
(a) Al
(b) Steel
((c)) Super
p alloys
y
(d) Refractory material
GATE 1992
1992
GATE
In Ultrasonic Machining (USM) the material
removal rate would
(a) Increase
(b) Decrease
(c) Increase and then decrease
((d)) decrease and then increase
with increasing mean grain diameter of the abrasive
material.
IES 2009
IES
By which one of the following processes the
metering holes in injector nozzles of diesel engines
can be suitably made?
(a) Ultrasonic machining
(b) Abrasive
Ab i jet
j t machining
hi i
(c) Electron beam machining
(d) Chemical machining
Chemical Machining
ChemicalMachining
IAS 1996
IAS
During ultrasonic machining, the metal removal is
affected by the
(a) Hammering action of abrasive particles
(b) Rubbing action between tool and workpiece
(c) High frequency sound waves
((d)) High
g frequency
q
y eddyy currents
y Chemicals
Ch i l are used
d to
t dissolve
di l material
t i l
y Masks are used to control attack
y Most common use is circuit boards and p
plates for
printing.
y Cutting speed of 0.00250.1 mm/minute very slow
Rev.0
Chemical Machining
ChemicalMachining
L
B
M hi i
LaserBeamMachining
L
B
M hi i
LaserBeamMachining
LaserBeamMachining
y Produceslargeremelt zone
laser welding
y Canproduceholesassmallas0.0005mmdiameter
C d h l
ll
di
y Canproducedeepholes
workpiece
k i
y Usedtoproducecoolingholesinblades/vanesforjet
engines
y Workpiece
p
need not be conductive
y Cuts are tapered
y Gotta trap overshoot from laser beam
310
l
h
ElectronBeamMachining
311
ElectronBeamMachining
IFS2011
electron
beam
directed
312
Writetheadvantages,limitationsandapplicationsof
toward
electronbeammachining.Whatisthesafetyproblem
workpiece
connectedwithEBM?
t d ithEBM?
[5 Marks]
[5Marks]
region of workpiece
y Electron beam moved by
y deflection coils
y Similar process to EB welding
313
314
Rev.0
l
PlasmaArcCutting
h
WaterJetMachining
WaterJetMachining
y Narrowjetofwaterdirected,athighpressureand
j f
di
d hi h
d
velocity,againstsurfaceofworkpiece
y, g
p
y Jetofwatererodessurfaceofworkpiece,thereby
cuttingworkpiece
y Computercontroltoachieveshape
C
t
t lt hi h
316
317
y
y
y
y
y
y
y
g
g
gas and abrasive p
particles achieves localized cutting.
It removes material through the eroding action of a high
velocity stream of abrasiveladen gas.
The gas is first compressed and mixed with the abrasive
powder in a mixing chamber and passed through outlet
nozzle.
l
Computer is used to position the jet.
G Pressure
Gas
P
about
b t 7 atm
t
Velocity of jet about 300 m/s
Jet Diameter 0.12
0 12 mm to 1.25
1 25 mm
Abrasive used: Al2O3 , SiC with particle size 10 to 50 m
Tool (nozzle) material tungsten carbide or sapphire
Tool(nozzle)Life about30hours
318
AbrasiveJetMachining
In
jet
the
jet
I water
t
j t machining,
hi i
th water
t
j t is
i issued
i
d
through
g a 0.33 mm diameter orifice at a p
pressure of
400 MPa. The density of water is 1000 kg/m3. The
coefficient of discharge is 1.0. Neglecting all losses
d i
during
water
t jet
j t formation
f
ti
th
through
h the
th orifice,
ifi
th
the
power of the water jjet in KW is
p
(a) 25.3
(b) 50.6
(c) 75.9
(d) 101.2
319
AdvantagesofAJM
y Can be used in any material, conductive, non
321
DisadvantagesofAJM
y LowMRR
y Possibilityofstraycutting
P ibilit f t tti
y Embeddingofabrasiveparticlesinsoftworkpiece
y Dustcontrolneeded
automobile windows
y Due to negligible
g g
force delicate workpiece
p
can be
ApplicationofAJM
Rev.0
Q
( )
GATE2012SameQinGATE2012(PI)
In abrasive jet machining, as the distance between
th nozzle
the
l tip
ti and
d the
th work
k surface
f
i
increases,
th
the
material removal rate
( ) increases continuously.
(a)
l
(b) decreases continuously.
(c) decreases, becomes stable and then increases.
(d) increases,
increases becomes stable and then decreases.
decreases
GATE2014(PI)
A hard
h d ceramic
i marble,
bl having
h i density
d it ()
( ) off 3000 kg/m
k / 3
and diameter (d) of 0.025 m, is dropped accidentally
f
from
a static
t ti weather
th balloon
b ll
att a height
h i ht off 1 km
k above
b
the roof of a greenhouse. The flow stress of roof material
( ) is
()
i 2.5 GPa.
GP
Th marble
The
bl hits
hit and
d creates
t
an
indentation on the roof. Assume that the principle of
creation
ti
off indentation
i d t ti
i the
is
th same as that
th t in
i case off
abrasive jet machining (AJM). The acceleration due to
gravity
it (g)
( ) is
i 10 m/s
/ 2. If V is
i the
th velocity,
l it in
i m/s,
/ off the
th
marble at the time it hits the greenhouse, the
indentation
d
d h = 1000 d V , in mm, is.........
depth
Whatarethedisadvantagesofabrasivejetmachining?
Writesomeofitsapplications.
[5Marks]
g
do the cutting
y 80mesh garnet (sandpaper) is typically used though 50
and
d 120mesh
h is also
l used
d
y Standoff distance between mixing
g tube and workpart
p
is
GATE 1992
GATE
g components
p
pp p
Match the following
with the appropriate
machining processes:
p
Process
Component
(A) Square hole in a high strength alloy
(1)
Milling
((B)) Square
q
hole in a ceramic component
p
((2))
Drilling
g
(C) Blind holes in a die
(3)
ECM
((D)) Turbine blade p
profile on high
g strength
g alloy(4)
y(4) JJig
g boring
g
(5)
EDM
(6)
USM
Codes:A
B
C
D
A
B
C
D
(a) 4
1
2
3
(b)
5
6
1
3
(c) 4
2 For-2015
1
3
(d) &3 PSUs)
1
2
4
(IES,
GATE
GATE 2011
GATE2011
Mechanismofmaterialremoval
f
P.Chemicalmachining
1.Erosion
Q.Electro
Q
Electro chemical
machining
R Electro discharge
R.Electro
machining
2 Corrosivereaction
2.Corrosivereaction
S.Ultrasonicmachining
4.Fusionandvaporization
3 Iondisplacement
3.Iondisplacement
Statethemechanismofcuttingbyabrasivejet.
Whataretheadvantagesanddisadvantagesof
AJM?Mentiontwoapplications.
[
[10Marks]
]
b
AbrasiveWJCutting
IFS2011
IAS2011Main
AbrasiveWJCutting
y Evolution
of mixing tube
technology
y Standard Tungsten Carbide
lasts 46
4 6 hours (not used much
anymore)
y Premium Composite Carbide
lasts 100150 hours
y Consumables
C
bl
i l d
include
water,
t
abrasive, orifice and mixing
tube
GATE 2007
GATE
gp
Matchthemostsuitablemanufacturingprocessesfor
thefollowingparts.
g
Parts
ManufacturingProcesses
P. Computerchip 1.
ElectrochemicalMachining
Q Metalformingdiesandmoulds
Q.
2.
UltrasonicMachining
R Turbineblade
R.
3
3.
Electro discharge
Electrodischarge
Machining
S Glass
S.
4
4.
PhotochemicalMachining
Codes:P Q
R
S
P
Q
R
S
( ) 4
(a)
3
1
2
(b) 4
3
2
1
(c) 3
1
4
2
(d) 1 Rev.0
2
4
3
GATE 1998
1998
GATE
IES 2008
IES
IES 1998,ISRO2009
1998 ISRO 2009
IES
Match List
II and select the correct answer
ListII with List
ListII
using the code given below the lists:
ListII
List
ListII
List
II
(Unconventional machining process) (Basic process)
A Electro polishing
A.
1
1.
Thermal
B. Electrochemical machining
2.
Mechanical
C Abrasive
C.
Ab i jet
j machining
hi i
3.
El
Electrochemical
h i l
D. Electrical discharge machining 4.
Chemical
Code:A
B
C
D
A
B
C
D
(a) 4
3
2
1
(b) 2
1
4
3
(c) 4
1
2
3
(d) 2
3
4
1
Match List
II
ListII (Machining process) with List
ListII
(Associated medium) and select the correct answer
using the codes given below the lists:
ListI
ListII
A Ultrasonic
A.
Ult
i machining
hi i
1.
K
Kerosene
B. EDM
2.
Abrasive slurry
C. ECM
3.
Vacuum
D. EBM
4.
Salt solution
Code:A
B
C
D
A
B
C
D
( ) 2
(a)
3
4
1
(b) 2
1
4
3
(c) 4
1
2
3
(d) 4
3
2
1
IES 2005
2005
IES
IES 2003
IES
IES 2003
IES
(
) with List II ((Machining)
g) and
Match List I (Materials)
select the correct answer using the codes given below
the Lists:
List I
List II
(Materials)
(Machining)
A. Machining of conducting materials
1.
ECM
B. Ruby rod
2.
EDM
C. Electrolyte
3.
USM
D. Abrasive slurry
4.
LBM
Codes:A
B
C
D
A
B
C
D
(a) 4
2
1
3
(b) 4
2
3
1
(c) 2
4
3
1
(d) 2
4
1
3
IAS 2002
IAS
IAS 1999
IAS
IES 2004
IES
(
g p
Match List I (Machining
processes)) with List II
(Operating media) and select the correct answer using
the codes given below the Lists:
List I
List II
A. Abrasive jet machining
1.
Dielectric
B. Electron beam machining
2.
Electrolyte
C. Electrochemical machining
3.
Abrasive slurry
D. Electrodischarge machining 4.
Vacuum
5.
Air
Codes:A
B
C
D
A
B
C
D
(a) 5
4
2
1
(b) 4
5
2
1
(c) 4
2
3
5
(d) 2
5
3
4
Rev.0
List I
(A) ECM
(B) EDM
(C) USM
(D) LBM
Codes:A
C
d A
(a) 4
(c) 4
B
1
2
(1)
( )
(2)
(3)
(4)
(5)
(6)
C
2
1
List II
Plastic shear
E i /B ittl fracture
Erosion/Brittle
f t
Corrosive reaction
Melting and vaporization
Ion displacement
Plastic shear and ion displacement
D
A
B
C
D
3
(b) 5
4
2
4
3
(d) 3
1
2
4
) Water jet
j
g uses high
g
Assertion ((A):
machining
pressure and high velocity water stream which acts
like a saw and cuts a narrow groove in the material.
Reason (R): The force required for cutting is
generated from sudden change in the momentum
of the water stream.
(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
IES 1999
IES
Match ListI with ListII and select the correct answer
using the codes given below the Lists:
ListI
ListII
A. Die sinking
1. Abrasive jet machining
g
2. Laser beam machining
g
B. Debarring
C. Fine hole drilling (thin materials) 3. EDM
D. Cutting/sharpening
g
p
g hard materials
4. Ultrasonic machining
55. Electrochemical g
grinding
g
Code:A
B
C
D
A
B
C
D
((a)) 3
5
4
1
((b)) 2
4
1
3
(c) 3
1
2
5
(d) 4
5
1
3
GATE 2004
GATE
yp
g operations
p
Typical
machining
are to be p
performed on hard
tomachine materials by using the processes listed below.
Choose the best set of OperationProcess combinations
O
Operation
ti
P
Process
P. Debarring (internal surface) 1.
Plasma Arc Machining
Q Die sinking
Q.
2
2.
Abrasive Flow Machining
R. Fine hole drilling in thin sheets 3. Electric Discharge
Machining
g
S. Tool sharpening
4.
Ultrasonic Machining
5.
Laser beam Machining
g
6.
Electrochemical Grinding
(a) P1 Q5 R3 S4
(b)
P1 Q4 R1 S2
(c) P5 Q1 R2 S6
(d)
P2 Q3 R5 S6
Rev.0
C t l St t
f
t i l
CrystalStructureofmaterials
y FCC: Ni,Cu,Ag,Pt,Au,Pb,Al(soft)
y BCC: V,Mo,Ta,W(hardmaterial)
y HCP: Mg,Zn
g
y CobaltHCP<4200C,FCC>4200C
oC
y ChromiumHCP<20oC,BCC>20
,
GATE 2011
GATE2011
Thecrystalstructureofausteniteis
(a)bodycenteredcubic
(b)facecenteredcubic
(c)hexagonalclosedpacked
( )
(d)bodycenteredtetragonal
y
g
y Glass Amorphous
y BCC
BCCFerriteor
Ferriteor iron
ironferriteoriron
& ferriteor iron
y FCC Austeniteoriron
IES 2011
IES2011
Match List I with List II and select the correct answer using
the code given below the lists :
ListI
ListII
A.Alphairon
p
1.FCC
B.Zinc
2.BCC
C Glass
C.Glass
3 HCP
3.HCP
D.Copper
4.Amorphous
Codes
A
(a) 1
(c) 1
B
4
3
C
3
4
D
2
2
(b)
(d)
A
2
2
B
4
3
C
3
4
D
1
1
IES2003
MatchList
I(CrystalStructure)withList II(Example)and
MatchListI(CrystalStructure)withListII(Example)and
selectthecorrectanswerusingthecodesgivenbelowthe
Lists:
ListII
List
ListII
List
II
(CrystalStructure)
(Example)
A. SimpleCubic
1.Zinc
B
B.
B d
BodycenteredCubic
t dC bi
2.Copper
C
C. FacecenteredCubic
3.Alphaironatroom
temperature
D HexagonalClosePacked
D.
H
lCl P k d
4.Manganese
M
Codes:A
B
C
D
A
B
C
D
((a)
) 4
3
1
2
((b)
)
4
3
2
1
(c) 3
4
2
1
(d) 3
4
1
2
IES2001
IES2006
MatchListI(NameoftheElement)withListII
(CrystalStructure)andselectthecorrectanswerusing
thecodesgivenbelowthelists:
ListI
ListII
A. Fluorspar
1.Bodycenteredcubic
p
2.Hexagonalclosedpacked
g
p
B. AlphaIron
C. Silver
3.Simplecubic
D. Zinc
4.Facecenteredcubic
Codes A
Codes:A
B
C
D
A
B
C
D
(a) 3
2
4
1
(b) 4
1
3
2
((c)
) 4
4
2
33
1
((d)
) 33
1
4
4
2
MatchListI(Element)withListII(CrystalStructure)
andselectthecorrectanswerusingthecodegiven
belowtheLists:
List I
List
List II
List
A. AlphaIron
1.Hexagonalclosedpacked
pp
2.Bodycentredcubic
y
B. Copper
C. Zinc
3.Amorphous
D. Glass
4.Facecentredcubic
Codes A
Codes:A
B
C
D
A
B
C
D
(a) 2
3
1
4
(b) 1
4
2
3
((c)
) 2
4
4
1
33
((d)
) 1
33
2
4
IES 1998
IES1998
MatchListIwithListIIandselectthecorrectanswer
usingthecodesgivenbelowthelists:
h
d
b l
h l
ListI
ListII
(Material)
(Structure)
A. Charcoal
1.
F.C.C
B. Graphite
2.
H.C.P
C. Chromium
3.
Amorphous
D. Copper
4.
B.C.C
Code:A
B
C
D
A
B
C
D
(a) 3
2
1
4
(b) 3
2
4
1
( ) 2
(c)
3
4
1
( ) 2
(d)
3
1
4
Pl ti d f
ti
Plasticdeformation
Following the elastic deformation, material undergoes
plastic deformation.
y Also characterized by relation between stress and
strain at constant strain rate and
d temperature.
y Microscopically, it involves breaking atomic bonds,
moving
i atoms, then
h restoration
i off bonds.
b d
y StressStrain relation here is complex because of
atomic
t i plane
l
movement,
t dislocation
di l ti
movement,
t and
d
the obstacles they encounter.
y Crystalline solids deform by processes slip and
twinning in particular directions.
Contd
Rev.0
Slip
y Slip is the prominent mechanism of plastic deformation in
metals.
y It involves sliding of blocks of crystal over one other along
.m
= K( 0 + )n
= 0 + K n
value.
y During slip each atom usually moves same integral
number
b off atomic distances
d
along
l
the
h slip
l plane
l
producing
d
a step, but the orientation of the crystal remains the same.
y Steps observable under microscope as straight lines are
called slip lines.
Contd
Twinning
y The second important mechanism of plastic deformation
y
is twinning.
It results when a portion of crystal takes up an orientation
that is related to the orientation of the rest of the untwined
l tti in
lattice
i a definite,
d fi it symmetrical
t i l way.
The twinned portion of the crystal is a mirror image of the
parent crystal.
p
y
The p
plane of symmetry
y
y is called twinning
g
plane.
Each atom in the twinned region moves by a homogeneous
shear
h
a distance
di t
proportional
ti
l to
t its
it distance
di t
f
from
th twin
the
t i
plane.
The lattice strains involved in twinning
g are small,, usuallyy
in order of fraction of interatomic distance, thus resulting
in very small gross plastic deformation.
y
y
y
IES2007
Whatisthemovementofblockofatomsalong
Wh ti th
t fbl k f t
l
certaincrystallographicplanesanddirections,
termedas?
(a) Glide
(b) Twinning
(c) Slip
(d) Jog
Contd
IES2005
TheB.C.C.andH.C.P.metalsundergoplastic
Th B C C dH C P t l d
l ti
deformationby:
(a) Slip
(b) Twinning
( ) Edgedislocation
(c)
Ed di l ti
(d) Twinningincombinationwithslip
IES1998
Assertion(A):Plasticdeformationinmetalsand
alloysisapermanentdeformationunderload.This
propertyisusefulinobtainingproductsbycold
rolling.
rolling
Reason(R):Plasticorpermanentdeformationin
metaloralloyiscausedbymovementordislocations.
( ) BothAandRareindividuallytrueandRisthecorrect
(a)
B thA dR i di id ll t dRi th
t
explanationofA
(b) BothAandRareindividuallytruebutRisnotthe
correctexplanationofA
l
f
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
At i St t
AtomicStructure
y Atoms consist of a relatively dense nucleus composed of
Rev.0
Contd
At i B d
AtomicBonds
y
y
Contd
p
positive ions can move within the structure without
the breaking of discrete bonds. Materials bonded by
metallic bonds can therefore be deformed by atom
movement mechanisms and produce a deformed
material that is every bit as strong as the original.
y This
h phenomenon
h
is the
h basis
b
off metall plasticity,
l
ductility, and many of the shaping processes used in
the fabrication of metal products.
products
IES 2011
IES2011
Solid material chemical bonds are :
(a) Ionic, molecular and fusion
(b) Covalent, fusion and fission
(c) Ionic, covalent and molecular
((d)) Fission,, molecular and ionic
IES2008
Contd
IES2003
Assertion(A):Elementsareclassifiedintometalsand
nonmetalsonthebasisoftheiratomicweights.
Reason(R):Thevalenceelectronstructures
contributetotheprimarybondingbetweentheatoms
toformaggregates.
(a) BothAandRaretrueandRisthecorrectexplanation
ofA
(b) BothAandRaretruebutRisNOTthecorrect
explanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
Ai f l b tRi t
Assertion(A):Unlikeinthecaseofionicbonds,the
Assertion(A):Unlikeinthecaseofionicbonds the
coordinationnumbersforcovalentlybondedatoms
arenotcontrolledbytheradiiratio.
Reason(R):Acovalentbondhasaspecificdirectionof
bondinginspace.
(a) BothAandRareindividuallytrueandRisthecorrect
explanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
Ai f l b tRi t
D l
f
i
Developmentofagrainstructure
from
the
characteristic
f
th liquid
li id with
ith a lattice
l tti structure
t t
h
t i ti off the
th
given material.
y This p
particle then acts like a seed or nucleus and g
grows as
other atoms in the vicinity attach themselves. The basic
crystalline unit is repeated throughout space.
y In actual solidification,
solidification many nuclei form independently at
various locations throughout the liquid and have random
orientations with respect to one another. Each then grows
untill it begins
b
to interfere
f
with
h its neighbours.
hb
y Since adjacent lattice structures have different alignments
or orientations,
orientations growth cannot produce a single continuous
structure.
Contd
Rev.0
Contd
Th number
b and
d size
i off the
h grains
i in
i a metall vary with
i h the
h
y The
Fracture of metals
Fractureofmetals
IES2002
Chemicalsattackatomswithingrainboundaries
Ch i l tt k t
ithi i b
d i
preferentiallybecausetheyhave
(a) Lowerenergythanthoseinthegrains
(b) Higherenergythanthoseinthegrains
( ) Highernumberofatomsthaninthegrains
(c)
Hi h
b f t
th i th i
(d) Lowernumberofatomsthaninthegrains
GATE2010
Thematerialpropertywhichdependsonlyonthe
Th t i l
t hi hd
d l th
basiccrystalstructureis
(a) Fatiguestrength
(b) Workhardening
(c) Fracturestrength
(d)
Elasticconstant
IES1992
Whichofthefollowingstatementistrueabout
Whi h fth f ll i t t
ti t
b t
brittlefracture?
(a) Hightemperatureandlowstrainratesfavour
brittlefracture
(b) ManymetalwithHCPcrystalstructurecommonly
showbrittlefracture
(c) Brittlefractureisalwaysprecededbynoise
(d) Cupandconeformationischaracteristicforbrittle
materials
noting that the initial response to the applied load was one
plastic deformation.
of p
y Another possibility, however, is where fracture precedes
plastic deformation, occuring in a sudden, catastrophic
manner and propagating rapidly through the material.
manner,
material
These fractures, known as, brittle fractures, are most
common with metals having the bcc or hcp crystal
structures.
y Whether the fracture is ductile or brittle, however, often
depends on the specific conditions of material,
temperature state of stress,
temperature,state
stress and rate of loading.
loading
y Fracture strength depends only on the basic crystal
structure .
becomesstoredwithinthematerialintheformofadditional
dislocationsandincreasedgrainboundarysurfacearea.Ifa
deformedpolycrystallinemetalissubsequentlyheatedtoa
high enoughtemperature,thematerialwillseektolowerits
highenoughtemperature,thematerialwillseektolowerits
energy.New,equiaxed (sphericalshaped)crystalswillnucleate
andgrowoutoftheoriginalstructure.Thisprocessofreducing
theinternalenergythroughtheformationofnewcrystalsis
knownasrecrysrallization.
y The temperatureatwhichrecrystallization
p
y
takesplaceis
p
differentforeachmetalandalsovarieswiththeamountofprior
deformation.
Contd
Contd
y Ifmetalsaredeformedattemperaturessufficiently
abovetherecrystallization,theprocessisknownas
hotworking.
y Deformationandrecrystallization cantakeplace
simultaneously,and
i l
l
d largedeformationsarepossible.
l
d f
i
ibl
y Sincearecrystallized grainstructureisconstantly
f
forming,thefinalproductwillnotexhibitstrain
i th fi l d t ill t hibit t i
hardening.
Rev.0
Contd
Plastic deformation in
Plasticdeformationin
polycrystallinemetals
g
movement and (re)arrangement
of dislocations.
y The second important mechanism of plastic
deformation is twinning. It results when a portion of
crystal takes up an orientation that is related to the
orientation of the rest of the untwined lattice in a
d fi it symmetrical
definite,
t i l way.
y The twinned portion of the crystal is a mirror image of
the parent crystal.
crystal The plane of symmetry is called
twinning plane.
Contd
U i ll
Unitcell
Itischaracterizedby:
Mostcommonunitcells Facecenteredcubic,
g
BodycenteredcubicandHexagonal.
y Typeofatomandtheirradii,R
y Celldimensions(Latticespacinga,bandc)intermsof
Celldimensions(Latticespacinga bandc)intermsof
Randanglebetweentheaxis
ya
a*,b*,c*
,b ,c latticedistancesinreciprocallattice,
latticedistancesinreciprocallattice,*,*,
, ,
* anglesinreciprocallattice
y Numberofatomsperunitcell,n
p
,
y Coordinationnumber(CN) closestneighborstoan
atom
y Atomicpackingfactor,APF
Contd
For-2015 (IES, GATE & PSUs)
C
lS
CrystalStructures
/
,
y All solid materials are made of atoms/molecules,
which are arranged in specific order in some materials,
called crystalline solids. Otherwise noncrystalline or
amorphous solids.
solids
y Groups of atoms/molecules specifically arranged
crystal.
y Lattice is used to represent a threedimensional
periodic array of points coinciding with atom
positions.
y Unit cell is smallest repeatable entity that can be used
to completely represent a crystal structure.
structure It is the
building block of crystal structure
N
1
CN
6
a/R
2
APF
0.52
4/3
0.68
12
4/2
0.74
12
0.74
Rev.0
C t l St t
f
t i l
CrystalStructureofmaterials
y FCC: Ni,Cu,Ag,Pt,Au,Pb,Al(soft)
IAS2009main
y BCC: V,Mo,Ta,W(hardmaterial)
y HCP: Mg,Zn
g
y CobaltHCP<4200C,FCC>4200C
oC
y ChromiumHCP<20oC,BCC>20
,
y Glass Amorphous
y BCC
BCCFerriteor
Ferriteor iron
ironferriteoriron
& ferriteor iron
y FCC Austeniteoriron
Fig.DifferentUnitCell
IES 2010
IES2010
Assertion(A):Mostofthematerialsexistinsingle
crystal.
crystal
Reason(R):Sugarisasinglecrystalmaterial.
( ) 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
GATE2009
The
Th effective
ff ti number
b off lattice
l tti points
i t in
i the
th unit
it
cell of simple cubic, body centered cubic, and face
cantered cubic space lattices, respectively, are
(a) 1, 2, 2
(b) 1,
1 2,
2 4
(c) 2, 3, 4
(d) 2,
2 4,
4 4
IES2008
In
model
I the
th atomic
t i hardsphere
h d h
d l off the
th crystal
t l
structure of Copper, what is the edge length of unit
cell?
IES2004
Assuming
to
what
A
i atoms
t
t be
b perfect
f t spheres,
h
h t is
i the
th
value of the highest possible atomic packing
factor (APF) in metals?
(a) 0.95
(b) 0.74
0 74
(c) 0.66
(d) 0.5
05
IES2003
The
coordination
Th
di ti
structure is
(a) 4
(b) 8
( ) 12
(c)
(d) 16
number
b
for
f
FCC
crystal
t l
IES2000
Atomicpackingfactor(APF)inthecaseofcopper
At
i
ki f t (APF)i th
f
crystalis
(a) 0.52
0 52
(b) 0.68
( ) 0.74
(c)
(d) 1.633
Rev.0
IES1999
MatchList
I(Crystalstructure)withList II(Atomic
MatchListI(Crystalstructure)withListII(Atomic
packingfactor)andselectthecorrectanswerusingthe
codesgivenbelowtheLists:
ListII
List
ListII
List
II
A. Simplecubic
1.
74%
B. Bodycenteredcubic
2.
74%
C Facecenteredcubic
C.
F
t d bi
3.
52%
%
D. Hexagonalclosepacked
4.
68%
Codes:
A
B
C
D
A
B
C
D
(a) 3
4
2
1
(b)
4
3
2
1
(c) 3
4
1
2
(d)
4
3
1
2
IES2007
Which one of the following is the correct ascending
order of packing density for the given crystal
structures of metals?
(a) Simple cubic Face centred cubic Body centred
cubic
(b) Body centred cubic Simple cubic Face centred cubic
(c) Simple cubic Body centred cubic Face centred cubic
(d) Body centred cubic Face centred cubic Simple cubic
F
l f
l i
Formulaforalatticeconstant
nM
a=
B i L i
d i ll
BravisLatticeandunitcell
IES2004
AmetalhasFCCstructure.Supposeitsatomic
A t lh FCC t
t
S
it t
i
weightandatomicradiusisAandrrespectively.
LetNdenotesAvogadro snumber.Whatisthe
LetNdenotesAvogadro'snumber.Whatisthe
densityofthematerial?
(a)
[Wheren=noofatomspercell,M=Atomicweight,
[Wheren
noofatomspercell M Atomicweight
N=Avogadrosnumber, =DensityofMetal]
IES2005
(c)
(b)
2 2r3 N
A
(d)
8 2r3 N
c>
A
4 2r3 N
a>
>
y Therearesevenlatticesystems
16 2r 3 N
1 C bi
1.Cubic
2 T
l
2.Tetragonal
b c
y a
a=b=c
b c
y a
a=b
y . = = = 90
y = =
IES2001
1 SimpleCubic(SC)=1atom
1.
Whichoneofthefollowingpairsofaxislengths(a,b,
Whi h
fth f ll i i f i l
th ( b
c)andinteraxialangles(,,)representsthe
tetragonalcrystalsystem?
1.Simpletetragonal(ST)
2. Bodycenteredcubic(BCC)=2atom
c
2.Bodycenteredtetragonal(BCT)
3. Facecenteredcubic(FCC)=4atom
F t d bi (FCC) t
(a)
(b)
(c)
(d)
a = b = c; = = = 900
a = b c; = = = 900
a b c; = = = 900
a = b = c; = = 900
Rev.0
3 O h h bi
3.Orthorhombic
IES2006
In
each
is
I Zinc
Zi Blende
Bl d structure,
t
t
h atom
t
i surrounded
d d
by four atoms of the opposite kind which are
located at the corners of which one of the
following?
(a) Tetrahedron
(b) Hexahedron
(c) Cube
(d) Orthorhombic
4 Rh b h d l
4.Rhombohedral
y abc
b c
y a
a=b=c
y = = =900
y = = 90o
1.Simpleorthorhombic(SO)
a
b
(i)SimpleRhombohedral (Sr)
2.Bodycenteredorthorhombic(BCO)
3
3.Facecenteredorthorhombic(FCO)
(
)
4.Endcenteredorthorhombic(ECO)
5 H
l
5.Hexagonal
IES2007
ForaRhombohedral
F Rh b h d l spacelattice,whichoneofthe
l tti hi h
fth
followingiscorrect?
6 M
li i
6.Monoclinic
bc
y a
a=bc
y abc
y = =900
y = =900
y =1200
1. SimpleMonoclinic(Sm)
()
(i)SimpleHexagonal(Sh)
p
g
( )
c
2. Endcenteredmonoclinic(ECM)
7 T i li i
7.Triclinic
IES 2011
IES2011
y abc
Inatriclinicunitcell:
(d ) 90o
1.SimpleTriclinic(Stri)
c
a
IES2006
Whichoneofthefollowingpairsisnotcorrectly
Whi h
fth f ll i i i t
tl
matched?
SpaceLatticeRelationbetweenAtomicradiusr and
Edgeelementa
(a) Simplecubicstructure:
a2 =4r2
(b) Bodycentred cubicstructure:3a2 =16r2
(c) Triclinic:
2a2 =3r
3r2
2
(d) Facecentred cubicstructure: a =8r2
Rev.0
Mill i di
Millerindices
Mill i di
Di
i
Millerindices
Direction
Mill i di
Pl
Millerindices
Plane
required direction
y The length
g of the vector p
projection
j
on each of three
axes are measured in terms of unit cell dimensions
y These three numbers are made to smallest integer
g
values, known as indices, by multiplying or dividing by
a common factor
y The three indices are enclosed in square brackets,
[uvw]
y A family of directions is represented by <uvw>
Millerindices UsefulConventions
y If a plane is parallel to an axis, its intercept is at infinity
(
)
MillerIndices(hkl)
StepI:Findtheinterceptsofaplanealongthecrystalaxesa,
Step I:Findtheinterceptsofaplanealongthecrystalaxesa
b,candexpresstheinterceptsinunitsofcrystalparameter
a,b,crespectively.
StepII:Findthereciprocaloftheintercepts.
StepIII:Reduce thereciprocalstothethreesmallestinteger
(h k l)keepingtheratiossame
(h,k,l)keepingtheratiossame.
StepIV:Enclosetheseintegerintosameparameters(h,k,l)
b
b
a
For-2015 (IES, GATE & PSUs)
Contd
Contd
Intercepts
Take reciprocals
Reduce to reciprocals
IAS2009Main
Rev.0
IES 2010
IES2010
Miller indices (x, y,
z) for the hatched
plane in the above
abo e
unit
cell
are
represented as
(a) (100)
(b) (110)
(c) (111)
(d) (101)
IES1998
Aunitcellofacrystalisshowninthegivenfigure.
A it ll f
t li h
i th i
fi
TheMillerindicesofthedirection(arrow)shown
inthefigureis
(a) [012]
(b) [021]
(c) [210]
(d) [201]
IES2006
IES1999
Whatistheplanardensityof(100)planeinFCC(face
Whatistheplanardensityof(100)planeinFCC(face
centred cubic)crystalwithunitcellsideaequalto?
(a) 1.484
a2
(b)
a2
((c)
)
a2
((d)
)
ThesetofMillerindicesoftheplaneshowninthe
Th t fMill i di fth l
h
i th
givenfigureis
(a) (00)
(b) (100)
1
(c) (101)
(d) (110)
1
2
a2
E.g.:(111) [111]
y [uvw] is parallel to (hkl) if hu + kv + lw = 0
y Two planes (h1k1l1) and (h2k2l2) are normal if
h1h2+k1k2+l1l2 = 0
y Two directions (u1v1w1) and (u2v2w2) are normal
u1u2+v1v2+w1w2 = 0
I
Pl
di
b
f il f l
{hkl}
InterPlanardistancebetweenfamilyofplanes{hkl}
d( hkl ) =
a
h2 + k 2 + l 2
Anglesbetweentwoplanesisgivenby
cos =
h1h2 + k1 k2 + l1l2
h12 + k12 + l12 h22 + k22 + l22
Contd
CrystalDefects
y The assumption of perfectly arranged atoms in a
P i d f
Pointdefects
y Pointdefectsareofzerodimensionali.e.atomicdisorderis
restrictedtopointlikeregions.
y Thermodynamicallystablecomparedwithotherkindof
defects.
y Fractionofvacancysitescanbegivenasfollows:
act o o vaca cy s tes ca be g ve as o ows:
Q
n
= e kT
N
[WherenisthenumberofvacantsitesinNlatticepositions,k
isgasorBoltzmannsconstant
isgasorBoltzmann
sconstant,Tisabsolutetemperaturein
Tisabsolutetemperaturein
kelvin,andQistheenergyrequiredtomoveanatomfromthe
interiorofacrystaltoitssurface.]
Contd
Rev.0
IES1998;1999
IES1992
Assertion(A):Carbonformsinterstitialsolid
solutionwhenaddedtoiron.
Reason(R):Theatomicradiusofcarbonatomis
muchsmallerthanthatofiron.
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
Li d f
Linedefects
Whichofthefollowingisapointimperfection?
Whi h fth f ll i i i ti
f ti ?
1.Vacancy
2.Interstitialcy
3.Frenkelimperfection
F k li
f i
4.Schottkyimperfection
S h k i
f i
( ) 1and2only
(a)
( )
(b)
2and3only
( ) 2,3and4only
(c)
d l
(d)
1,2,3and4
d
Burgersvector
p change
g in atomic
y Line defects or Dislocations are abrupt
y
IES2009
Whichoneofthefollowingdefectsis
Schottky
Whi h
fth f ll i d f t i 'S
h ttk
defect?
(a) Vacancydefect
(b) Compositionaldefect
( ) Interstitialdefects
(c)
I t titi ld f t
(d) Surfacedefect
Li d f
Ed di l
i
Linedefects
Edgedislocation
Orowan dislocation.
y ItisalsocalledasTaylor
ItisalsocalledasTaylorOrowan
y Itwillhaveregionsofcompressiveandtensilestresses
direction of close p
pack lattice direction. It is also the
slip direction of a dislocation.
y It represents
p
the magnitude
g
and direction of distortion
associated with that particular dislocation.
y Two limiting cases of dislocations, edge and screw,
are characterized by Burgers vector perpendicular to
the dislocation line (t) and Burgers vector parallel to
th dislocation
the
di l ti line
li respectively.
ti l Ordinary
O di
di l ti
dislocation
is of mixed character of edge and screw type.
oneithersideoftheplanecontainingdislocation.
p
g
Contd
Contd
Rev.0
Contd
IES2009
Whichoneofthefollowingiscorrectfor
Climb
Whi h
fth f ll i i
tf 'Cli
b'??
(a) Dislocationmovesparalleltotheslipplane
(b) Dislocationmovesperpendiculartotheslipplane
Di l
i
di l h li l
(c) Slidingofoneplaneofatomsovertheotherplane
( ) Dislocationmovesfromaslipplanetoanotherslip
(d)
plane
Li d f
S
di l
i
Linedefects
Screwdislocation
y It is also called as Burger
Burgerss dislocation.
y It will have regions of shear stress around the
dislocation line
positive screw dislocation, dislocation line
direction is p
parallel to Burgers
g
vector, and vice versa.
y For
Contd
Li d f
Di l
i
i
Linedefects
Dislocationmotion
pp
y Dislocations move under applied
stresses,, and thus
causes plastic deformation in solids.
y Dislocations can move in three ways glide/slip, cross
slip
li and
d climb
li b depending
d
di on their
h i character.
h
Sli is
Slip
i
conservative in nature, while the climb is non
conservative, and is diffusion
diffusioncontrolled.
controlled.
y Any dislocation can slip, but in the direction of its
burgers vector.
y Edge dislocation moves by slip or climb.
y Screw dislocation moves by slip / crossslip. Possibility
f crossslip
for
li arises
i
as screw dislocation
di l
i does
d
not have
h
a preferred slip plane as edge dislocation have.
Contd
Linedefects Dislocationcharacteristics
y Dislocationshavedistortionalenergyassociatedwith
them.
y Storedelasticenergyperunitlengthofthedislocation
Gb 2
E=
2
[WhereG shearmodulusandb Burgersvector]
g
IES2003
Ascrewdislocation
1. LiesparalleltoitsBurger'svector
2. LiesperpendiculartoitsBurger
LiesperpendiculartoitsBurger'svector
svector
3. MovesinaperpendiculardirectiontotheBurger's
vector
4. MovesinaninclineddirectiontotheBurger'svector
Selectthecorrectanswerusingthecodesgivenbelow:
Codes:
(a) 1and4
(b) 1and3
(c) 2and3
(d) 2and4
IES2009
Whichoneofthefollowingiscorrectfor"Burger's
vector inscrewdislocation?
vector"inscrewdislocation?
(a) Perpendiculartothedislocationline
(b) Inclinedtothedislocationline
I li dt th di l ti li
(c) Paralleltothedislocationline
(d) Oppositetothedislocationline
O
i h di l
i li
Rev.0
IES2008
I
f i ld f
Interfacialdefect
IES2007
Whatistheapproximatestrainenergyexpression
Wh ti th
i t t i
i
foradislocationofunitlength,irrespectiveofits
edgeorscrewcharacter?
(a)
G 2b
2
(b)
(c)
G 2b
4
(d)
Gb2
2
Gb2
4
D imperfection in
y An interfacial defect is a 2
2D
crystalline solids and have different crystallographic
orientations on either side of it.
y They usually arise from clustering of line defects into a
plane..
y E.g.: External surface, Grain boundaries, Stacking
faults, Twin boundaries, Dislocations and Phase
b
boundaries.
d i
Contd
IES 2010
IES2010
Surface imperfections which separate two
orientations
that
image
off one
i
i
h are mirror
i
i
another is called
(a) Stacking fault
((b)) Grain boundaryy
(c) Tilt boundary
(d) Twinned boundary
IES2008
Whatisasurfaceimperfection,whichseparates
Wh ti
f
i
f ti
hi h
t
crystalsofdifferentorientationsinapoly
crystallineaggregate,called?
(a) Edgedislocation
(b) Stackingfault
(c) Grainboundary
(d) Screwdislocation
Stackingfaults
Th planner
l
i
f i produced
d d by
b the
h passage off a
y The
imperfection
partial dislocation is called stacking fault.
y They
planes.
Th are faults
f lt in
i stacking
t ki sequence off atom
t
l
y Stacking sequence in an FCC crystal is ABC ABC ABC
, and the sequence for HCP crystals is AB AB AB.
AB
y Two kinds of stacking faults in FCC crystals are:
y (a)
( ) ABC AC ABCwhere
ABC h
CA CA representt thin
thi HCP
region which is nothing but stacking fault in FCC,
y (b) ABC ACB CABC is called extrinsic
e trinsic or twin
t in stacking
fault. Three layers ACB constitute the twin. Thus
stacking faults in FCC crystal can also be considered as
submicroscopic twins.
Contd
For-2015 (IES, GATE & PSUs)
y
g faults is energetically
g
y
crystals
as formation of stacking
favorable.
y The total energy
gy of a p
perfect lattice is lower than one
with a stacking fault. This difference is stacking fault
energy, and varies in range 0.010.1 J/m2.
y Lower the stacking fault energy, wider the stacking
fault, metal strain hardens rapidly and twin easily.
Oh
Otherwise,
i
metals
l off high
hi h stacking
ki
f l energy i.e.
fault
i
narrower stacking faults show a deformation structure
of banded,
banded linear arrays of dislocations.
dislocations
B lk aVolumedefects
V l
d f
Bulkor
y Volume defects are threedimensional in nature.
y These defects are introduced, usually, during
IES 2011
IES2011
Assertion (A): Excess defects are created by
hammering the crystalline materials.
Reason (R) : The thermal fluctuations create
the
h point defects
d f
in crystalline
ll
materials.
l
(a) Both A and R are individually true and R is the
correct explanation
l
i off A
(b) Both A and R are individually true but R is NOT
th correctt explanation
the
l
ti off A
(c) A is true but R is false
(d) A is
i false
f l but
b R is
i true
IES 2010
IES2010
Assertion (A): Natural crystals always contain
defects.
defects
Reason (R): The defects may affect colour and can
make a crystal a valuable gem.
gem
(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
IES2003
Whichoneofthefollowingpairsisnot
Whi h
fth f ll i i i t correctly
tl
matched?
(a) Pointdefectincrystallattice :Selfinterstitials
(b) Lineardefectincrystallattice:Grainboundary
( ) Planardefectincrystallattice:Externalsurface
(c)
Pl
d f ti
t ll tti E t
l f
(d) Volumedefectincrystallattice:otherphases
IES1997
Whichofthefollowingpropertiesofasolidare
dependentoncrystalimperfections?
1. Yieldstress
2.
Meltingpoint
3. Semiconductivity
4.
Ductility
Selectthecorrectanswerusingthecodesgivenbelow:
g
g
(a) 1and3
(b) 1,3and4
3
(c) 2,3and4
(d) 2and4
Rev.0
H tT t
t
HeatTreatment
y Heating
working
cooling
(for
example
ki or non uniform
if
li
(f
l welding):
ldi )
Annealing
a metal or alloy),
alloy) but also the grain size.
size
IES 1992
IES1992
y Annealing
gg
y
Whichofthefollowinggenerallydecreasesinthe
steelafterquenchhardening?
1. Brittleness
2. Percentageelongation
33. Impactstrength
p
g
(a) 1and2only
(b) 2and3only
((c)) 1and3only
3
y
((d)) 1,2and3
,
3
y Stress
Relieving
S
R li i
y Quench Hardening
g
y Tempering
etc.
y Carburizing
y Carbon Nitriding
y Age Hardening
Contd...
y Ion Nitriding
Contd...
Fig.TTTdiagramforeutectoidtransformationinFeC
Fig.TransformationsinvolvingausteniteforFeCsystem
Rev.0
CCT di
f F C t
CCTdiagramforFeCsystem
g
y TTT diagram
is less practical since an alloy has to be cooled
GATE 2003
GATE2003
Duringheattreatmentofsteel,thehardnessof
variousstructuresinincreasingorderis
(a) Martensite,finepearlite,coarsepearlite,
spherodite
(b) Finepearlite,coarsepearlite,spherodite,
martensite
(c) Martensite,coarsepearlite,finepearlite,
spherodite
(d) Spherodite,coarsepearlite,finepearlite,
martensite
IES 1998
IES1998
g curves A and B for a eutectoid iron
Two cooling
carbon alloy are superimposed on a continuous
cooling transformation diagram as shown in the
given
i
fi
figure.
Fine
i
pearlite
li
microstructure
i
i
is
represented by the points labelled
( ) I and
(a)
d III
(b) II
( ) IV
(c)
(d) I
GATE 1996
GATE1996
g
The ironcarbon diagram
and the TTT curves are
determined under
(a) Equilibrium and nonequilibrium conditions
respectively
(b) Nonequilibrium and equilibrium conditions
respectively
(c) Equilibrium conditions for both
(d) Nonequilibrium conditions for both
IAS2002
Two plain carbon steel specimens having 08%
carbon content are welded. If we observe the
weldment under Metallurgical Microscope from
centre towards either side, the following
structures are observed at different zones:
1. Fine Pearlite
2. Coarse Pearlite
3. Martensite
Select the correct sequence using the codes given
b l
below:
Codes:
( ) 1, 2, 3
(a)
(b) 1, 3, 2
(c) 2, 1, 3
(d) 3, 1, 2
Page 185 of 240
IES 2002
IES2002
g
p
TTTdiagramindicatestimeandtemperature
transformationof
(a) Cementite
(b) Pearlite
(c) Ferrite
(d) Austenite
GATE 1997
GATE1997
p
,
g
Oncompletionofheattreatment,theresulting
structurewillhaveretainedAusteniteif
(a) Rateofcoolingisgreaterthanthecriticalcooling
rate
(b) Rateofcoolingislessthanthecriticalcoolingrate
(c) Martensite formationstartingtemperatureis
abovetheroomtemperature
(d) Martensite formationfinishtemperatureisbelow
theroomtemperature
Rev.0
A
li
Annealingprocesses
F ll
li
Fullannealing
relieve stresses
IES 2010
IES2010
Consider the following statements regarding annealing
process:
1. All structural imperfections are removed
2 The hypoeutectoid steel is heated to about 50 70
2.
70 C below
upper critical temperature.
33. Cooling
g can be done in heat treating
g furnace,, byy heating
g it,,
keeping the metal in it and turning off furnace till it cools to
room temperature.
4. Uniform
f
grain structure is resulted.
l d
Which of these statements are correct?
( ) 1, 2 and
(a)
d 3 only
l
(b) 2, 3 and
d 4 only
l
(c) 1, 3 and 4 only
(d) 1, 2, 3 and 4
IES 1992
IES1992
p
q
g
yp
Temperaturerequiredforfullannealinginhyper
eutectoidsteelis
(a) 50Caboveuppercriticaltemperature(AC3)
(b) 50Cbelowuppercriticaltemperate(AC3)
((c)) 550Cabovelowercriticaltemperature(AC
p
( 1)
(d) 50Cbelowlowercriticaltemperature(AC1)
IES 1999
IES1999
g the hypoeutectoid
yp
Heating
steels to 330oC above
the upper critical temperature line, soaking at
that temperature and then cooling slowly to room
temperature to form
f
a pearlite
li
and
d ferrite
f i
structure, is known as
( ) Hardening
(a)
H d i
(b) Normalizing
N
li i
(c) Tempering
(d) Annealing
IES 1993
IES1993
Whichofthefollowingstatementsaretrueof
annealingofsteels?
1. Steelsareheatedto500to700C.
2. Coolingisdoneslowlyandsteadily.
C li i d
l l d
dil
3. Internalstressesarerelieved.
4. Ductilityofsteelisincreased.
D tilit f t li i
d
Selectthecorrectanswerusingthecodesgivenbelow:
Codes:
Codes
(a) 2,3and4
(b) 1,3and4
(c) 1,2and4
1 2and4
(d) 1,2and3
1 2and3
IES 2003
IES
Primaryobjectoffullannealingisto
(a) Increasetoughnessandyieldpoint
(b) Reduceductilityandresilience
(c) Removeforeignimpuritiesandimprovesurface
finish
(d) Increaseductilityandmachinability
P
li
Processannealing
y After cold working the metal can be softened by
Rev.0
Contd...
Isothermalannealingg
IES 2005
IES2005
IES 2010
IES2010
y Heat above the upper critical point and held for some
(b)
Normalizing
(c) Spheroidizing
(d)
Austenising
Isothermalannealingismainlyusedinalloy
steelstoimprove
l i
(a)Machinability
(b)Toughness
(c)Ductility
(d)Weldability
Contd...
Stressreliefannealingg
y Stress relief annealing process consists of three steps.
p is heating
g the cold worked steel to a
y The ffirst step
5000
550oC
temperature between
C and
C i.e. below its
recrystallization temperature.
y The
h second
d step involves
l
h ld
holding
the
h steell component at this
h
temperature for 12 hours.
y The final step is to cool the steel component to room
temperature in air.
y It partly relieves the internal stress in cold worked steels
without loss of strength and hardness i.e. without change in
the microstructure. Since only low carbon steels can be cold
worked,
k d the
h process is
i applicable
li bl to hypoeutectoid
h
id steels
l
containing less than 0.4% carbon.
GATE 2014
GATE2014
The process of reheating the reduce its brittleness
without any significant loss in its hardness is
(a) normalizing
(b) annealing
(c) quenching
(d) tempering
GATE2014(PI)
( )
IES 2011
IES2011
Which one of the following statements is NOT
correct for normalizing?
(a) It is often applied to casting to relieve stresses
(b) It increases strength of medium carbon steel to
some extent
(c) Better surface finish can be obtained in
machining
(d) It increases grain size
Normalizing
M i objective
bj ti
Main
1. Refine grain, improve machinability, tensile strength and
structure of weld.
weld
2. Remove cold worked stess.
3. Remove
R
di l ti
dislocations
d to
due
t hot
h t working.
ki
Process
y Heat the
h steell from
f
30C to 50C above
b
its upper criticall
IES 2000
IES2000
Assertion (A): Normalized steel will have lower
hardness than annealed steel.
Reason (R): The pearlite of normalized steel is
finer and has lower intermolecular space.
space
(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
Rev.0
S h idi i
Spheroidizing
y Heat them to slightly above the critical temperature,
temperature
GATE 2006
GATE2006
Themainpurposeofspheroidising treatmentisto
improve
(a)Hardenabilityoflowcarbonsteel
( )
(b)Machinabilityoflowcarbonsteels
(c)Hardenabilityofhighcarbonsteels
(d)Machinabilityofhighcarbonsteels
carbide.
IES 2003
IES2003
Globular form of cementite in the structure of
steel is obtained through
(a) Normalizing
(b) Malleabilising
((c)) Spheroidizing
p
g
(d) Carbonizing
Quenching
Tempering
y Quenching isheattreatmentprocesswherematerialis
cooledatarapidratefromelevatedtemperatureto
l d t id t f
l t dt
t t
p
g is the p
g martensitic steel at
y Tempering
process of heating
a temperature below the eutectoid transformation
produceMartensitephase.
temperature to make
k it
i softer
f and
d more ductile.
d il
Comparative coolingratesofQuenchMedia
Brine
Water
Water + NaOH
or KOH
Oil
Forced air
Still air
1.20 to 1.30
1
<1
0.40 to 0.50
0.03
0.02
y During
g the tempering
p
gp
process,, Martensite transforms to
y Brinehasfastestcoolingrateofsteelquenchingandis
B i h f
li
f
l
hi di
alsousedassecondaryrefrigerant.
IES 2010
IES2010
Match List I with List II and select the correct
answer using the code given below the lists:
List I
List II
(Q
(Quenching
hi media)
di )
(St
(Structure
t
produced)
d
d)
A. Water
1. Coarse pearlite
B Oil
B.
2. Martensite
M
i
C. Air
3. Very fine pearlite
D. Furnace cools
4. Fine pearlite
A
B
C
D
A
B
C
D
(a) 1
3
4
2
(b) 2
3
4
1
(c) 1
4For-2015
3
2
(d) 2& PSUs)
4
3
1
(IES,
GATE
IES 2001
IES2001
gq
g
Considerthefollowingquenchingmedia:
1. Oil
2.Water
33. Water+NaOH 4
4.Brine
Thecorrectsequenceofthesemediainorderof
increasinghardnessofsteelundergoingheat
g
g g
treatmentis
(a) 1,3,2,4
(b) 2,1,3,4
(c) 1,2,3,4
(d) 4,3,2,1
IES 2009
IES2009
g
Whichoneofthefollowingmediumsisusedfor
thefastestcoolingrateofsteelquenching?
(a) Air
(b) Oil
(c) Water
(d) Brine
Rev.0
IES 2006
IES2006
MatchListI(EffectofCooling)withListII(Cooling
Medium)andselectthecorrectanswerusingthecode
d
) d l
h
h
d
givenbelow:
ListI
List
I
List II
List
A. Martensite
1.
Waterquenched
B. Veryfinepearlite
y
p
2.
Aircooled
C. Finepearlite
3.
Furnacecooled
D. Coarsepearlite
4.
Oilquenched
A
B
C
D
A
B
C
D
(a) 1
4
2
3
(b) 2
3
1
4
( ) 2
(c)
3
4
1
(d) 1
2
3
4
M t
i
Martempering
y Quench steel from the austenizing temperature to a
austenite
transforms
to
A t
i
Austempering
GATE 2004
GATE2004
Fromthelistsgivenbelow,choosethemostappropriatesetof
heattreatmentprocessandthecorrespondingprocess
characteristics
Process
Characteristics
P
P.
Tempering
1
1.
Austeniteisconvertedinto
bainite
Q. Austempering
2.
Austeniteisconvertedinto
martensite
R. Martempering
3.
Cementite isconvertedinto
globularstructure
4.
Bothhardnessandbrittlenessare
reduced
d d
5.
Carbonisabsorbedintothemetal
(a) P3Q1R5
(b)
P4Q3R2
( ) P4Q1R2
(c)
P Q R
(d)
P Q R
P1Q5R4
IES 1994
IES1994
g
Considerthefollowingtreatments:
1. Normalizing
2.
Hardening
33. Martempering
p
g
4.
4
Coldworking
g
Hardnessandtensilestrengthinausteniticstainless
steelcanbeincreasedbyy
(a) 1,2and3
(b) 1and3
((c)) 2and4
4
((d)) 4
4alone
martensite
IES 2006
IES2006
p
g
p
g
Temperingisaprocessofannealing
(a) Martensite atlowtemperatures
((b)) Martensite athighertemperatures
g
p
(c) Bainite atlowtemperatures
(d) Bainite athighertemperatures
IES 2005
IES2005
p
g isemployedtoobtain:
p y
Austempering
(a) 100%martensitic structure
((b)) 100%bainitic structure
(c) 50%martensitic and50%bainitic structure
(d) 100%pearlitic structure
Rev.0
IES 2004
IES2004
IES 2001
IES2001
gp
Considerthefollowingpairs:
Heattreatment
Effectonmediumcarbonsteel
g
:Grainrefinement
1. Normalizing
2. Fullannealing
:Uniformgrainstructure
3. Martempering
:Decreasedductility
4. Spheroidizing
:Maximumsoftness
Whichofthepairsgivenabovearecorrectlymatched?
(a) 1and2
(b) 2and3
(c) 3and4
(d) 1,2,3and4
1 2 3and4
GATE2014
G
0
P
III
III
Q
IV
II
R
II
IV
S
I
I
(b)
(d)
P
II
II
Q
III
III
R
IV
I
p
g
q
'Tempering'ofquenchedmartensitic
steelis
necessarytoimprovethe
(a) Hardnessofthemetal
(b) Surfacetextureorthemetal
((c)) Corrosionresistanceofthemetal
(d) Ductilityorthemetal
A i
Aging
g g finelyy dispersed
p
p
p
p
y Aging
precipitate
particle will form.
solidus
lid temperatures and
d kept
k
there
h
till
ill a uniform
if
solid
lid
aging,
i
whereas
h
at elevated
l
d temperatures is
i called
ll d
Induction hardening
Inductionhardening
y Alternating current of high frequency passes for few
p
ThepatternknownasWidmanstatten
structureis
encounteredin:
(a) Tempering
(b) Normalizing
(c) Spheroidizing
(d) Annealing
Solutionizing
S
I
IV
C
H d i
CaseHardening
IES 2006
IES2006
GATE 2000
GATE2000
y
Caststeelcrankshaftsurfaceishardenedby
(a) Nitriding
(b) Normalising
((c)) Carburising
g
((d)) Inductionheating
g
Rev.0
IES 1992
IES1992
g
y
Inductionhardeningisbasicallya
(a) Carburising process
((b)) Surfacehardeningprocess
gp
(c) Corehardeningprocess
(d) Noneoftheabove
Laser hardening
Laserhardening
y Laser beams are of high intensity, a lens is used to
Fl
h d i
Flamehardening
surface quenched.
quenched
y oflathebedsarehardenedby
y
Guideways
(a) Carburising
((b)) Cyaniding
y
g
(c) Nitriding
(d) Flamehardening
C b ii
Carburizing
y Carburizing is the most widely used method of surface
hardening.
y Here,
Here the surface layers of low carbon steel are
enriched with carbon up to 0.81.0%. The source of
carbon mayy be a solid medium, a liquid
q
or a g
gas.
y In all cases, the carbon enters the steel at the surface
and diffuses into the steel as a function of time at an
elevated temperature.
y Carburizing is done at 920950oC.
Contd...
IES 2011
IES2011
Assertion (A): Carburizing is used for machine
elements
which
to have
a wear resistant
l
hi h have
h
h
i
working surface.
Reason (R) : The composition of surface layers
are changed in carburizing.
( )
(a)BothAandRareindividuallytrueandRisthe
y
correctexplanationofA
(b)BothAandRareindividuallytruebutRisNOT
thecorrectexplanationofA
h
l
i fA
(c)AistruebutRisfalse
(d)Ai f l b tRi t
(d)AisfalsebutRistrue
GATE 1992
GATE1992
p
g
Carburized machine components
have high
endurance limit because carburization
(a) Raises the yield point of the material
(b) Produces a better surface finish
((c)) Introduces a compressive
p
layer
y on the surface
(d) Suppresses any stresss, concentration produced in
the component.
IES 1992
IES1992
g Carbon is introduced to form a
In case carburising
high carbon layer at the surface. The carbon is
introduce in the form of
(a) Graphite flakes
(b) Pearlite
(c) Cementite
(d) Free carbon
Rev.0
IES 2005
IES2005
p
y stressed
If the surface of a component
is heavily
while the stresses in the core are of comparative
small magnitude, which one of the following heat
treatment methods
h d is
i employed?
l
d
(a) Annealing
(b) Tempering
(c) Quenching
(d) Case hardening
C aniding
Cyaniding
GATE 2003
GATE2003
g
y p
Hardnessofsteelgreatlyimproveswith
(a) Annealing
(b) Cyaniding
((c)) Normalising
g
((d)) Tempering
p
g
of 0.25 mm or less.
Nitriding
IES 1992
IES1992
IES 1995
IES1995
Q
g
y
g
Quenchinginnotnecessarywhenhardeningis
doneby
(a) Casecarburizing
(b) Flamehardening
((c)) Nitriding
g
(d) Anyoftheaboveprocesses
MatchListIwithListIIandselectthecorrectanswer
usingthecodesgivenbelowthelists:
i th d i
b l th li t
ListI(Heattreatment)
ListII(Effectonthe
properties)
A. Annealing
1.
Refinedgrainstructure
B. Nitriding
2.
Improvesthehardnessof
thewholemass
C. Martempering
3.
Increasessurfacehardness
D. Normalising
4.
Improvesductility
Codes:A
d
B
C
D
A
B
C
D
(a) 4
3
2
1
(b) 1
3
4
2
c) 4
2
1
3
(d) 2
1
3
4
IES 2004
IES2004
Match List I (Name of treatment) with List II (Media
used)
the
d) and
d select
l t the
th correctt answer using
i
th codes
d
given below the Lists
List I
List II
A. Pack carburizing
1.
Ammonia gas
B. Gas carburizing
2.
Sodium cyanide
C Cyaniding
C.
3
3.
Carburizing
compound
D. Nitriding
4.
Ethane
Codes:A
d
B
C
D
A
B
C
D
(a) 3
4
2
1
(b) 2
1
3
4
(c) 3
1
2
4
(d) 2
4
3
1
IAS2009Main
y
y
y
Rev.0
Contd...
IES 2009
IES2009
Grain gro th
Graingrowth
y Grain growth follows complete crystallization if the
material
t i l is
i left
l ft att elevated
l t d temperatures.
t
t
y Grain growth does not need to be preceded by recovery
y
y
y
y
y
y
; it mayy occur in all p
polycrystalline
y y
and recrystallization;
materials.
In contrary to recovery and recrystallization, driving force
for this process is reduction in grain boundary energy.
energy
Tendency for larger grains to grow at the expense of smaller
grains is based on p
g
physics.
y
In practical applications, grain growth is not desirable.
Incorporation of impurity atoms and insoluble second
phase
h
particles
i l are effective
ff i in
i retarding
di grain
i growth.
h
Grain growth is very strongly dependent on temperature.
y Optimumstrengtheningoccursduringagingoncetheright
g materials can be
Which one of the following
subjected to an age hardening process?
(a) HSS
(b) Aluminium
((c)) Pure iron
(d) Stellite
iinterspacingofparticlesisachieved.
t
i f ti l i hi d
y Smallertheparticles,dislocationscancutthroughthemat
y lowerstresses
y largertheparticlestheywillbedistributedatwider
distances.
IES 2007
IES2007
g the following
g is the most
Which one among
effective strengthening mechanism of non
ferrous metal?
(a) Solid solution hardening
(b) Strain hardening
(c) Grain size refinement
(d) Precipitation hardening
S
ki
t
i
Seasoncrackingorstresscorrosion
g
cracking.
y Brasses with more than 15% zinc often experience
IES 2001
IES2001
Whichoneofthefollowingpairsiscorrectly
matched?
h d
(a) SolidsolutionstrengtheningIncreasingdensity
ofdislocations
(b) Dispersionhardening..Creatingstrained
regioninthecrystal
(c) Strainhardening....Creatingparticlesto
resistthemovement
ofdislocations
(d) Precipitationhardening..Creatingparticlesby
decreasingsolubilityofone
phaseinanother
h i
h
IES 2007
IES2007
g elements/ alloy
y
Which one of the following
exhibits season cracking?
(a) Iron
(b) Brass
(c) Aluminium
(d) Steel
Rev.0
IAS 1994
IAS1994
IES 2011
IES2011
j
p
Majoroperationsinthemanufactureofsteelballs
usedforBallbearingsaregivenbelow
1. Oillapping
2.
Coldheading
3. Annealing
4.
Hardening
55. Roughgrinding
g g
g
Thecorrectsequenceoftheseoperationsis
(a) 3,2,4,1,5
((c)) 2,3,4,5,1
,3,4,5,
(b)
( )
(d)
3,2,1,4,5
2,3,5,4,1
,3,5,4,
Strengthening mechanisms in
Strengtheningmechanismsin
Metals
y Ability of a metal to deform plastically depends on ease of
IES1998
y Thisstrengtheningmechanismisbasedonthefact
thatcrystallographicorientationchangesabruptlyin
passingfromonegraintothenextacrossthegrain
boundary.
y Thusitisdifficultforadislocationmovingona
commonslipplaneinonecrystaltopassovertoa
similarslipplaneinanothergrain,especiallyifthe
orientationisverymisaligned.
i t ti i
i li
d
y Inaddition,thecrystalsareseparatedbyathinnon
crystallineregion whichisthecharacteristicstructure
crystallineregion,whichisthecharacteristicstructure
ofalargeanglegrainboundary.
y Withdecreaseingrainsize,themeandistanceofa
dislocationcantraveldecreases,andsoonstartspile
upofdislocationsatgrainboundaries.Thisleadsto
increaseinyieldstrengthofthematerial.
y Grainsizereductionimprovesnotonlystrength,but
alsothetoughnessofmanyalloys.
y Grainsizecanbecontrolledbyrateofcooling,andalso
b l i d f
byplasticdeformationfollowedbyappropriateheat
i f ll
db
i h
treatment.
Assertion(A):Refiningthegrainsizeofa
polycrystallinematerialrendersitharderand
stronger.
Reason(R):Grainboundariesprovideeasypathsto
dislocationmotion.
(a) BothAandRareindividuallytrueandRisthecorrect
explanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
Ai f l b tRi t
Contd
GATE1998
Decreasing
D
i grain
i size
i in
i a polycrystalline
l
t lli material
t i l
(a) Increases yield strength and corrosion resistance.
(b) Decreases
D
yield
i ld strength
h and
d corrosion
i resistance
i
(c) Decreases yield strength but increases corrosion
resistance
i t
(d) Increases yield strength but decreases corrosion
resistance.
resistance
IES 2010
IES2010
Assertion(A):Polycrystallinematerialisstronger
thanordinaryone.
thanordinaryone
Reason(R):Crystalsinpolycrystallinematerial
havedifferentorientationswithrespecttoeach
other.
(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
Page 194 of 240
Solid Solution
SolidSolution
y A solid solution is formed when two metals are
1 Substitutional SolidSolutions
Solid Solutions
1.Substitutional
y Solidsolutionsareoftwotypes.
y Theyare:
in
metall then
i the
h crystall lattice
l i by
b atoms off the
h solute
l
h
the solid solution is known as substitutional solid
solution.
solution
y For example, copper atoms may substitute for nickel
atoms without disturbing the F.C.C.
F C C structure of
nickel.
y In the substitutional solid solutions, the substitution
can be either disordered or ordered.
y HumeRothery
y formulatedcertainruleswhichgovern
g
theformationofsubstitutional solidsolutions.
(a)Substitutional solidsolutions.
(b)Interstitialsolidsolutions.
displace
a solvent
atom, but
di l
l
b rather
h it
i enters one off the
h
holes or interstices between the solvent atoms.
y An
A excellent
ll t example
l is
i ironcarbon
i
b
system
t
which
hi h is
i
shown in Fig.
S lid l bili
Solidsolubility
y in a two element system
y
y Extent of solid solubility
can be
predicted based on HumeRuthery conditions.
p
solubilityy can be expected.
HumeRuthery conditions:
y Crystal structure of each element of solid solution must be
the same.
same
y Size of atoms of each two elements must not differ by more
than 15%.
y Elements
l
should
h ld not form
f
compounds
d with
h each
h other
h i.e.
there should be no appreciable difference in the electro
negativities of the two elements.
y Elements should have the same valence.
IES 2011
IES2011
Assertion (A) : Solid solutions of metal are
crystall whose
properties
to those
off
h
i are close
l
h
the solvent.
Reason (R) : They retain the same crystal lattice
and type of bond.
((a)) Both A and R are individuallyy true and R is the
correct explanation of A
(b) Both A and R are individually true but R is NOT
the
h correct explanation
l
i off A
(c) A is true but R is false
(d) A is
i false
f l but
b t R is
i true
t
Contd
INTERMETALLIC COMPOUNDS
INTERMETALLICCOMPOUNDS
y Intermetallic compounds are generally formed when
IES2001
Whichofthefollowingfactorsgovernsolubilityof
twononferrousmetalsbothinliquidstate,as
wellasinsolidstate?
1.Crystalstructure
2.Relativesizefactor
3.Chemicalaffinityfactor
4.Relativevalence
factor
Selectthecorrectanswerusingthecodesgivenbelow:
C d
Codes:
(a) 1,2and3
(b) 2,3and4
( ) 1and4
(c)
d
(d) 1,2,3and4
d
IES 2010
IES2010
Consider the following:
1. Crystal structure 2. Relative size
33. Chemical affinityy 4
4. Valencyy
Which of these factors govern relative
solubility of two metals in each other in the
solid state?
(a) 1,
1 2 and 3 only
(b) 2, 3 and 4 only
(c) 1, 2 and 4 only
(d) 1, 2, 3 and 4
Rev.0
IES2006
Which
factors
is
Whi h one off the
th following
f ll i
f t
i more
relevant to represent complete solubility of two
metals in each other?
(a) Chemical affinity
(b) Valency factor
(c) Crystal structure factor (d) Relative size factor
Allotropictransformation
y When metals solidify,
solidify they assume a crystalline structure; that
exist
i t in
i the
th solid
lid state
t t in
i two
t or more lattice
l tti forms,
f
th particular
the
ti l
form depending on the conditions of temperature and pressure.
Such metals are said to be allotropic or polymorphic, and the
change
h
f
from
one lattice
l i form
f
to another
h is
i called
ll d an allotropic
ll
i
transformation.
y The most notable example
p of such a metal is iron, where the
allotropic change makes it possible for heattreating procedures
to produce a wide range of final properties.
y It is largely because of its allotropy that iron has become the
basis of our most important alloys.
IES 2010
IES2010
An allotropic material has
(a) Fixed structure at all temperatures
((b)) Atoms distributed in random p
pattern
(c)Different crystal structures at different
temperatures
(d) Fixed structure but random atom distribution
isnotused.
i d
y Mostimportantalloyselementiscarbon.
y Maximumamountofcarbonthatcanbealloyedwith
ironis6.67%.
y Alloycontainingupto
All
i i
2%carbonissteelandabove2%
% b i
l d b %
arecausedcostIron.
BH
N
Hardness
Strength
0.02
MediumcarbonsteelorMildsteel(0.3%to0.8%carbon)
hightoughness&ductility
Mostwidelyusedsteel
y
Heattreatable(austenitizing,quenchingandtempering).
Hardenability isincreasedbyaddingNi,Cr,Mo.
Usedinvarioustemperedconditions
Usedinvarioustemperedconditions.
Typicalapplications:gears,railwaytracks,machineparts.
Highcarbonsteel(morethe0.8%C)
Hardness&wearresistancearehighbutToughness&
formabilityisverylow
Note purestformofIroni.e.wroughtironhasleastcarbon
content.
%Carbon
1.4
Reduction area
IES 2005
IES2005
Considerthefollowingstatements:
1. Strengthofsteelincreaseswithcarboncontent.
2 Young
2.
Young'sModulusofsteelincreaseswithcarbon
sModulusofsteelincreaseswithcarbon
content.
3. Young
Young'sModulusofsteelremainsunchangedwith
sModulusofsteelremainsunchangedwith
variationofcarboncontent.
Whichofthestatementsgivenaboveis/arecorrect?
g
/
(a) 1only
(b) 2only
(c) 1and2
(d) 1and3
0.02 %Carbon
IES 2005
IES2005
IES 1995
IES1995
g
Considerthefollowingstatementsaboutmedium
carbonsteel:
1. Itcanbequenchhardenedbutnotcasehardened.
2. Itcannotbequenchhardenedbutcasehardening
canbedone.
3. Itexhibitsdistinctyieldpointundertensiontest.
It hibit di ti t i ld i t d t i t t
Whichofthefollowingstatementsgivenaboveare
correct?
(a) 1and2
(b) 2and3
(c) 1and3
(d) 1,2and3
MatchListIwithListIIandselectthecorrectanswer
usingthecodesgivenbelowthelists:
ListI(Alloy)
ListII(Use)
A Lowcarbonsteel
A.
L b
l
1.
B i
Bearing
B. Hadfieldmanganesesteel
2.
Thermocouple
C Constantan
C.
3
3.
Wirenails
Wirenails.
D. Babbittalloy
4.
Bulldozer
blades.
Code:A
B
C
D
A
B
C
D
(a) 1
2
3
4
(b) 3
4
1
2
( ) 3
(c)
2
1
4
(d) 3
4
2
1
Rev.0
IES 2005
IES2005
(
)
( pp
)
MatchListI(Steel)withListII(Application)and
selectthecorrectanswerusingthecodegivenbelow
theLists:
ListI
ListII
A. MildSteel
1.
Ballbearing
B. ToolSteel
2.
Coldchisels
C. HighCarbonSteel
3.
Shaftandaxles
D. MediumCarbonSteel 4.
Rolledsteelsections
Codes:A
B
C
D
A
B
C
D
(a) 2
1
4
3
(b) 4
3
2
1
( ) 2
(c)
3
4
1
(d) 4
(d)
1
2
3
IES 2007
IES2007
Whichofthefollowingfactorsinfluenceinaplain
carbonsteel?
g
1. Percentagecarbon
2. Quenchingmedia
3. Worksize
Selectthecorrectanswerusingthecodegivenbelow
(a) 1and2only
(b) 2and3only
(c) 1and3only
(d) 1,2and3
IAS 2002
IAS2002
MatchListI(Percentageofcarboncontentinplaincarbonsteel)with
ListII(Application)andselectthecorrectanswerusingthecodes
givenbelowthelists:
ListI
ListII
((Percentageofcarboncontent
g
((Application)
pp
)
inplaincarbonsteel)
A.010 020
1.Drophammers
B.030 040
2.Razors
C.060 070
3.Structures
D.110 140
4.Cranehooks
Codes:A
B
C
D
A
B
C
D
( ) 3
(a)
4
2
1
(b)
4
3
1
2
(c) 3
4
1
2
(d)
4
3
2
1
GATE 1992
GATE1992
Thetruestrainforalowcarbonsteelbarwhichis
doubledinlengthbyforgingis
((a)) 0.307
3 7
(b) 0.5
(c) 0.693
(d) 1.0
FigIronCarbonEquilibriumDiagram
Fe C equilibrium diagram
FeCequilibriumdiagram
y The structural form of pure iron at room temperature
is
i called
ll d ferrite
f i or iron.
i
OrthorhombicFe
Page3C.Ironatomsareblue.
197 of 240
Rev.0
Contd
I addition
dditi
t carbon,
b
t i amountt off silicon,
ili
y In
to
a certain
manganese and phosphorous may be found in ferrite.
y The face
centred modification of iron is called
facecentred
austenite or iron. It is the stable form of pure iron at
temperatures between 910C and 1400C. At its stable
temperature austenite
i
i soft
is
f and
d ductile
d il and
d
consequently, is well suited for manufacturing
processes.
y The facecentred cubic structure of iron has larger
interatomic spacing than in ferrite. Even so, in FCC
structure the interstices are barely large enough to
accommodate carbon atoms, and lattice strains are
produced As a result,
produced.
result not all the interstitial sites can
be filled at any one time.
30C.
y Above 1400C, austenite is no longer the most stable
form of iron, and the crystal structure changes back to
a bodycentred
b d
d cubic
bi phase
h
called
ll d delta
d l iron.
i
Thi is
This
i
iron except for its
the same phase as the
temperature range.
range
y The solubility of carbon in ferrite is small, but it is
appreciably larger than In ferrite
ferrite, because of higher
temperature. The maximum solubility of carbon in
&iron is 0.1% at 1490C.
49
Contd
y Thealloycontaining0.80%ofcarboniscalledthe
eutectoidsteel.
y Uponcoolingtheeutectoidsteelbelow723C,allof
theausteniteistransformedintopearlite.
y Alloyswithlessthan0.80%Carecalledhypo
All i hl h 8 %C ll dh
eutectoidsteelsandthosewithhighercompositionare
calledhyper eutectoidsteels
calledhypereutectoidsteels.
Contd
y FeFe3Cphasediagramischaracterizedbyfiveindividual
phases,:ferrite(BCC)FeCsolidsolution,austenite(FCC)
FeCsolidsolution,ferrite(BCC)FeCsolidsolution,Fe
F C lid l ti f it (BCC)F C lid l ti F 3C
(ironcarbide)orcementite anintermetalliccompoundand
liquidFeCsolutionandfourinvariantreactions:
y peritectic reaction at1495oC and0.16%C,ferrite+L
i (
iron(austenite)
i )
y monotectic reaction 1495oC and0.51%C,L L+iron
(austenite)
y eutecticreaction at1147oC and4.3%C,L iron+Fe3C
(cementite)[ledeburite]
y eutectoidreaction at723oC and0.8%C,iron ferrite+
Contd
IES2004
Contd
Contd
Three
Three phasereactions
y Suffix ic denotesatleastoneliquidphaseisthere
y Suffix
Suffix oid allphasesinvolvearesolid
I ironcarbon
i
b
ll
b
i excess off the
th solubility
l bilit
y In
alloys,
carbon
in
Considerthefollowingtemperatureranges:
C
id th f ll i t
t
1.Roomtemperature
2.0to910C
oC
oCtobelowmelting
3.910Cto1400
C
4.1400
C b l l i
point
I hi h fth b t
Inwhichoftheabovetemperaturerangesferritewith
t
f it ith
bodycenteredcubicstructureisindicatedin,theFe
Fe3Cphasediagram?
(a)1,2and4(b)2,3and4(c)1and3
(d)2and3
Fe3C(cementite)[pearlite]
Contd
IES1992
Themicrostructurecompositionofpearlite fora
Fe3Cdiagramconsistsof
(a) Carbondissolvedinalphaironhavingabody
canteredcubicstructure.
(b) Carbondissolvedingama ironhavingaface
canteredcubicstructure.
(c) Amixtureofbodycanteredalphaironandface
enteredgammairon
(d) Carbondissolvedinbodycanteredalphaironand
anFe,Fe3C.
Rev.0
IES 2011
IES2011
Liquid + solid (1) on cooling converting solid (2)
reaction is known as:
(a) Eutectoid reaction
(b) Eutectic reaction
(c) Peritectic reaction
(d) Peritectioid reaction
IES 2010
IES2010
Ironcarbon equilibrium diagram
(a) Correlates the microstructure and properties of
steel and cast iron
(b) Indicates the phase changes occurring during
g and cooling
g
heating
(c) Is made by plotting carbon percentage along X
axis and temperature along Yaxis.
Yaxis
(d) All of the above
IES 1995
IES1995
IES 2004
IES2004
y
y
5
y
g
Anironcarbonbinaryalloyhas0.5%Cbyweight.
Whatisthisalloycalled?
(a) Eutectoidalloy
(b) Eutecticalloy
((c)) Hypoeutectoidalloy
yp
y
(d) Hypereutectoidalloy
IES 2005
IES2005
The eutectoid of carbon in iron,, above lower
critical temperature, when cooled, results in:
(a) Ferrite and austenite
(b) Ferrite and cementite
((c)) Cementite and austenite
(d) Ferrite, cementite and austenite
IES 2010
IES2010
Pearlite phase in an ironcarbide phase
diagram
is
di
i
(a) Eutectic phase
(b) Hypoeutectic mixture
(c) Eutectoidal mixture
(d) Hypereutectic phase
IES 1995
IES1995
Eutectoidreactionoccursat
(a) 600C
((b)) 7723C
3
(c) 1147C
(d) 1493
1493C
C
GATE 1992
GATE1992
IES 2006
IES2006
Matchthetermsusedinconnectionwithheattreatmentofsteelwith
themicrostructural/physicalcharacteristics:
Terms
Characteristics
(A) Pearlite
(P)Extremelyhardandbrittlephase
(B) Martensite
(Q)Cementite isfinelydispersedinferrite
(C) Austenite
(R)Alternatelayersofcementite andferrite
(D) Eutectoid
(S)Canexistonlyabove723C
( )
(T)Pertainingtostateofequilibriumbetweenthree
g
q
solidphases
(U)Pertainingtostateofequilibriumbetweenone
liquidandtwosolidphase
Codes: A
B
C
D
A
B
C
D
(a) R
P
S
T
(b)
R
S
P
T
(c) T
R
P
S
(d)
T
R
S
P
Rev.0
IES 2002
IES2002
IES 1999
IES1999
IES 1993
IES1993
Inaeutecticsystem,twoelementsarecompletely
(a) Insolubleinsolidandliquidstates
(b) Solubleinliquidstate
(c) Solubleinsolidstate
(d) Insolubleinliquidstate
Eutecticreactionforiron
carbonsystemoccursat
Eutecticreactionforironcarbonsystemoccursat
(a) 600C
(b) 723
723C
C
(c) 1147C
(d) 1493
1493C
C
IES 2000
IES2000
IES 2007
IES2007
IES 2005
IES2005
Duringperitectic solidification,oneliquid
(a) Combineswithonesolidtoformasecondnew
solid
(b) Solidifiesintotwodifferentsolids
(c) Formsonesolid
(d) Formsonesolidandanotherliquid
IES 2005
IES2005
A60C
plaincarbonsteelhas,approximately:
A60Cplaincarbonsteelhas,approximately:
(a) 75%ofpearlite and25%offerrite
(b) 25%ofpearlite and75%offerrite
(c) 75%ofcementite and25%offerrite
(d) 75%ofpearlite and25%ofcementite
g is the correct
Which one of the following
statement?
Pearlite in ironcarbon system is a
(a) Phase consisting of ferrite and cementite at room
temperature
(b) Mechanical
M h i l mixture
i t
off ferrite
f it and
d cementite
tit att
room temperature
(c) Eutectic mixture ferrite and cementite at room
temperature
((d)) All the above three are correct
IES 2000
IES2000
Pearlite consistsof
(a) 6.67%Cand93.33%ferrite
(b) 13%Feand87%cementite
(c) 13%Cand87%ferrite
(d) 13%cementite and87%ferrite
Increaseofferritephaseinsteelincreases:
(a) Strength
(b) Hardness
(c) Ductility
(d) Brittleness
IES 1997
IES1997
A given steel test specimen is studied under
metallurgical microscope. Magnification used is
100 X. In that different phases are observed. One
of them is Fe3C. The observed phase Fe3C is also
known as
(a) Ferrite
(b) Cementite
(c) Austenite
(d) Martensite
Rev.0
IES 1995
IES1995
IES 2001
IES2001
1 E
i ( F C)
1.Eutectic(FeC)
Martensite is a super
saturated solution of carbon
supersaturated
in
((a)) Alpha
p iron
(b) Beta iron
(c) Gamma iron
(d) Delta iron
2 P i
i (FeC)
( F C)
2.Peritectic
3 M
i FeO
F O2SiO
SiO2
3.Monotectic
y (L+S1S2)
y (L1S1+L2)
y (L1S1+S2)
y Two materials are completely soluble in liquid state
and completely
p
y insoluble in solid state.
+ L
+L
4 S
i NaZn
N Z
4.Syntectic
y (L1+L2S1)
solid.
L
L+
+L
L
+
L1
L1
L 1+L 2
L2
L2
+ L2
L1
L2
L1 L 2
L+
L1+ L2+
5 E
id F C
5.EutectoidFeC
y (S1S2+S3)
6 P i
id CuAl
C Al
6.Peritectoid
y S1 +S2S3
+r
+
r
+
I
h system: In
I a binary
bi
h there
h
i
y Isomorphus
system when
is
L
+L
+L
+p
A
B
CompositionBw/o
Rev.0
IES 2007
IES2007
IES 2004
IES2004
MatchListIwithListIIandselectthecorrectanswerusingthe
codegivenbelowtheLists:
d i
b l th Li t
ListI
ListII
(NameoftheInvariant
(InvariantReactionduring
Reaction)
cooling)
A. Monotectic
1.LIQUID.SOLID1+SOLID2
B. Eutectic
2.LIQUID1..LIQUID2+SOLID
C
C.
E t t id
Eutectoid
3.SOLID1..SOLID1+SOLID2
SOLID
SOLID SOLID
D. Peritectic
4.LIQUID+SOLID1..SOLID2
Code: A
(a) 3
(c) 3
B
1
4
C
2
2
D
4
1
(b)
(d)
A
2
2
B
4
1
C
3
3
D
1
4
IES 2008
IES2008
Assertion (A): Lever Rule can be applied to determine
relative
amounts off phases
present at any
l
h
temperature.
Reason (R): Lever Rule is restricted to estimate
relative phases, only if they are solid phases.
(a) Both A and R are true and R is the correct explanation
off A
(b) Both A and R are 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
)
g
p
(
)
p
method)alongwithrelativefractionofphases(leverrule)canbecomputed.
y Relativeamountofliquidandsolidphasesisgivenrespectivelyby:
CL =
cV
UV
CS =
Uc
UV
CL + CS = 1
y Thereforeitisnotrestrictedtosolidphasesonly.
Example
a pe
y In a binary system of A and B, if a liquid of 35% A (65%
CL =
75 40
= 0.875
75 35
F C ll
l ifi i
FeCalloyclassification
IES 2003
IES2003
Calloysareclassifiedaccordingtowt.%Cpresent
y Fe
FeCalloysareclassifiedaccordingtowt.%Cpresent
According to Gibbs
Gibbs' phase rule, the number of
degrees of freedom of an eutectic point in a binary
system is
(a) 1
((b)) 2
(c) 0
((d)) 3
inthealloyfortechnologicalconvenienceasfollows:
y Commercialpureirons
p
%C<0.008
y Lowcarbon/mildsteels
0.008 %C 0.3
y Mediumcarbonsteels
0.3 %C
0.3
%C 0.8
y Highcarbonsteels
0.8 %C 2.11
y Castirons
2 11<%C
2.11<%C
L
R l
LeverRule
y Atapointinaphasediagram,phasespresentandtheircomposition(tieline
Rev.0
Cast Iron
CastIron
y remelting
gp
g iron with
y The cast iron is obtained by
pig
coke and limestone in a furnace known as cupola.
y It is primarily an alloy of iron and carbon.
casting
g
characteristics,
high
g
compressive
p
Contd
IES 2010
IES2010
Assertion (A): A cast iron specimen shall fail due to
shear when subjected to a compressive load.
load
Reason (R): Shear strength of cast iron in
compression is more than half its compressive
strength.
(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
IES 1998
IES1998
g
y
Assertion(A):Castironisgenerallyhard,brittleand
wearresistant.
Reason(R):Castironcontainsmorethan2%carbon
andassuchthepercentagecementite
d
h h
i initishigher.
i i i hi h
(a) BothAandRareindividuallytrueandRisthecorrect
explanationofA
(b) BothAandRareindividuallytruebutRisnot the
p
correctexplanationofA
(c) AistruebutRisfalse
((d)) AisfalsebutRistrue
IES 2005
IES2005
g
Considerthefollowingstatements:
1. CastIronhaspoorabilitytodampvibrations.
g
p
g
2. CastIronhashighercompressivestrength
comparedtothatofsteel.
33. CastIronpartsaresuitablewherepermanent
p
p
deformationispreferredoverfracture.
Whichofthestatementsgivenaboveis/arecorrect?
(a) 1,2and3
(b) 1and3
((c)) 33only
y
((d)) 2onlyy
IES 1997
IES1997
( )
y
Assertion(A):Thenotchsensitivityofcastiron
componentiszero.
Reason(R):Castirondoesnothaveayieldpoint.
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
IES 1999
IES1999
Castironisusedformachinebedsbecauseofits
high
(a) Tensilestrength
(b) Endurancestrength
((c)) Dampingcapacity
p g p
y
(d) Compressivestrength
IAS 2003
IAS2003
Considerthefollowingstatements:
1. Fromdesignconsiderations,itisalways
advantageoustoplacecastironribsonthetension
sideratherthanonthecompressionside.
sideratherthanonthecompressionside
2. Castironisanexcellentchoiceformachinetool
guidesandframes.
3. Castironpartshavelownotchsensitivity.
Whichofthesestatementsarecorrect?
(a) 1,2and3
(b) 2and3
((c)) 1and3
3
((d)) 1and2
Rev.0
IES 1992
IES1992
g
Whichofthefollowingmetalshrinksmostfrom
moltenstatetosolidstate?
(a) Castiron
(b) Caststeel
(c) Brass
(d) Admiraltymetal
y Cast
5 ;
y Carbon = 3 to 33.5%;
y The grey colour is due to the fact that the carbon is
Contd
y The grey iron castings are widely used for machine tool
bodies,
bodies automotive cylinder blocks,
blocks heads,
heads housings,
housings
flywheels, pipes and pipe fittings and agricultural
implements.
y The grey cast iron is designated by the alphabets FG
followed byy a figure
g
indicating
g the minimum tensile
strength in MPa or N/mm2. For example, FG 150
means grey cast iron with 150 MPa or N/mm2 as
minimum tensile strength.
GATE 2004
GATE2004
p
g
g y
Thepercentageofcarboningraycastironisinthe
rangeof
(a) 0.25to0.75percent
(b) 1.25to1.75percent
((c)) 33to4percent
4p
(d) 8to10percent
IES 1994
IES1994
Assertion(A):Machinetoolbedsaregenerally
madeofgreycastiron.
Reason(R):Castironpossessesgoodself
lubricatingproperties.
lubricatingproperties
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
IES 2007
IES2007
p g
y
Vibrationdampinginmachineryisbestachieved
bymeansofbasestructuresmadeofwhichoneof
thefollowingmaterials?
(a) Lowcarbonsteel
(b) Nodulariron
(c) Greycastiron
(d) Whitecastiron
Contd
IES 2005
IES2005
Whichofthefollowingpairsarecorrectlymatched?
(DesignationofSteel/CastIron)
(Description)
(D i
ti fSt l/C tI
)
(D
i ti )
1.
FeE250
:Minimumtensile
strengthof250
N/mm2
2.
40C8
:Percentageof
Manganeseis0.7%
0.9%
3.
FG200
:Greycastironwith
ultimatetensilestrength
of200N/mm2
S l tth
Selectthecorrectanswerusingthecodegivenbelow:
t
i th d i b l
(a) 1and2
(b)
2and3
(c) 1and3
(d)
1,2and3
IES 2003
IES2003
Machinetoolmanufacturersprefergreycastiron
grade40forproducingmachinecolumnsand
tablesbecausegreycastironis
1 Heavy
1.
2
2.
Easilycastable
3. Easilyweldable
4.
Havinggood
dampingcapacity
Selectthecorrectanswerusingthecodesgivenbelow:
C
Codes:
(a) 1and2
(b) 2and4
((c)) 1and33
((d)) 33and4
4
Rev.0
IES 1993
IES1993
Assertion(A):Fracturesurfaceofgreycastironis
dark.
Reason(R):Failuretakesplacealongtheweak
cementite plates.
plates
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
IES 2005
IES2005
75 to 2.3%.
3
y Carbon = 1.75
g
Whichofthefollowingmaterialsisusedinthe
manufactureofextrusionnozzles?
(a) Greycastiron
(b) Malleablecastiron
((c)) Whitecastiron
(d) Nodularcastiron
g of
y It is a white cast iron p
produced byy q
quick cooling
y It is a p
product in between g
greyy and white cast iron in
y which
y The malleable iron is a cast ironcarbon alloy
molten iron.
y The quick cooling is generally called chilling and the
Contd
1 Blackheart process
1.Blackheartprocess
2 Whiteheart process
2.Whiteheartprocess
g g
ore.
with iron oxide in the form of highgrade
y They are then heated to about 1000 deg C for between 70
y
y
Rev.0
IES 1992
IES1992
g
p yp p
Whichofthefollowingdisplaypropertiessimilar
tothatofsteel
1. Blackheartcastiron
2. Whiteheartcastiron
33. Graycastiron
y
4. Pigiron
((a)) 1and2onlyy
((b)
) 33and4only
4
y
(c) 2and4only
(d) 1and3only
IES 1992
IES1992
Forthepipefittinglikeelbow,tee,unionetc.
whichofthefollowingispreferred?
((a)) Pigiron
g
(b) Malleableiron
(c) Spheroidal graphitecastiron
(d) Highcarbonsteel
IES 2001
IES2001
IES 2009
IES2009
g
, wear resistance,, p
g
,
toughness,
pressure tightness,
weldability and machinability.
y It is g
generallyy used for castings
g requiring
q
g shock and
impact resistance along with good machinability, such
as hydraulic cylinders, cylinder heads, rolls for rolling
mill
ll and
d centrifugally
f
ll cast products.
d
y SG 400/15 means spheroidal graphite cast iron with
400 MPa
MP as minimum
i i
tensile
il strength
h and
d 15 percent
elongation.
g y
g y
Nodulargreycastironisobtainedfromthegrey
castironbyaddingasmallamountof
(a) Manganese
(b) Phosphorus
((c)) Magnesium
g
(d) Chromium
g
Whichoneofthefollowingcastironsconsistsof
carboninrosetteform?
(a) Whitecastiron
(b) Graycastiron
((c)) Malleablecastiron
(d) Nodularcastiron
IES 1995
IES1995
g
Additionofmagnesiumtocastironincreasesits
(a) Hardness
((b)) Ductilityandstrengthintension
y
g
(c) Corrosionresistance
(d) Creepstrength.
5 iron
y It is the p
purest iron which contains at least 99
99.5%
p 4
1. Silicon. It mayy be p
present in cast iron upto
4%. It
provides the formation of free graphite which makes
the iron soft and easily machinable. It also produces
sound
d castings
i
f
free
f
from
bl
blowholes,
h l
b
because
off its
i
high affinity for oxygen.
Rev.0
Contd
IES 1995
IES1995
g
Considerthefollowingworkmaterials:
1. Titanium
2.
Mildsteel
33. Stainlesssteel 4
4.
Greycastiron.
y
Thecorrectsequenceofthesematerialsintermsof
increasingorderofdifficultyinmachiningis
g
y
g
(a) 4,2,3,1
(b) 4,2,1,3
((c)) 2,4,3,1
,4,3,
((d)) 2,4,1,3.
, 4, , 3
IES 1995
IES1995
IES 2007
IES2007
g
Considerthefollowingstatements:
Additionofsilicontocastiron
g p
1. Promotesgraphitemoduleformation.
2. Promotesgraphiteflakeformation.
3. Increasesthefluidityofthemoltenmetal.
4. Improvestheductilityofcastiron.
Selectthecorrectanswerusingthecodesgivenbelow:
(a) 1and4
(b) 2and3
(c) 1and3
(d) 3and4
p
g
Pistoncompressionringsaremadeofwhichone
ofthefollowing
(a) Castiron
(b) Bronze
(c) Aluminium
(d) Whitemetal
IES 1994
IES1994
Whichofthefollowingpairsarecorrectly
matched?
1. LeadscrewnutPhosphorbronze
2. Piston..Castiron.
i
C i
3. Cam..EN31steel
4. Leadscrew..Wroughtiron.
L d
W
hti
Selectthecorrectanswerusingthecodesgivenbelow:
Codes:
Codes
(a) 2,3and4
(b) 1,3and4
(c) 1,2and4
1 2and4
(d) 1,2and3
1 2and3
IAS 2002
IAS2002
p
g
Acastironspecimeninatorsiontestgivesa
(a) Cupandconefracture
((b)) Fracturealongaplanenormaltotheaxisofthe
g p
specimen
((c)) Fracturealongahelixofapproximately45
g
pp
y 45
(d) Fracturealongaplaneinclinedat60 totheaxis
Rev.0
All St l
AlloySteel
y Definition:
A steell to which
f
h h one or more alloying
ll
1 Ni k l
1.Nickel
g and toughness
g
y It increases the strength
of the steel.
y These steels contain 2 to 5% nickel and from 0.1 to
0.5% carbon.
y In this range, nickel contributes great strength and
hardness with high elastic limit, good ductility and
good resistance to corrosion.
y An alloy containing 25% nickel possesses maximum
toughness
h
and
d offers
ff
the
h greatest resistance to rusting,
corrosion and burning at high temperature.
p
boiler tubes,, valves for use with superheated
steam,,
valves for I.C. engines and spark plugs for petrol
engines.
y A nickel steel alloy containing 36% of nickel is known
as invar. It has nearly zero coefficient of expansion. So
it is in great demand
d
d for
f measuring instruments and
d
standards of lengths for everyday use.
Contd
IES 1992
IES1992
g p p
y
Invarisusedormeasuringtapesprimarilytheto
its
(a) Nonmagneticproperties
(b) Highnickelcontent
((c)) Lowcoefficientofthermalexpansion
p
(d) Hardenability
IES 2008
IES2008
p
p
y
CoefficientofExpansionispracticallynilina
particularalloy.Whatisthisalloy?
(a) HadfieldManganeseSteel
(b) Invar
((c)) Vitallium
(d) Stellite
2 Ch
i
2.Chromium
3 T
t
3.Tungsten
p
y It p
prohibits g
grain g
growth,, increases the depth
of
bearings.
y A nickel chrome steel containing
g 33.25%
5% nickel,, 1.5%
5%
IES 2011
IES2011
Which one of the following is the major alloying element
in Invar?
(a) Aluminium
(b) Nickel
(c) Vanadium
(d) Copper
IES 2004
IES2004
p
g
g
Forimprovingthestrengthofsteelatelevated
temperatures,whichoneofthefollowingalloying
elementisused?
(a) Copper
(b) Tungsten
(c) Aluminium
(d) Zinc
Rev.0
4 V di
4.Vanadium
g a fine g
y It aids in obtaining
grain structure in tool steel.
y The addition of a very small amount of vanadium (less
5 M
5.Manganese
p
g of the steel in both the hot
y It improves
the strength
rolled and heat treated condition.
y The manganese alloy steels containing over 1.5%
7 C b lt
7.Cobalt
y It g
gives red hardness byy retention of hard carbides at
high temperatures.
y It tends to decarburise steel during heattreatment.
y It increases hardness and strength and also residual
GATE 1997
GATE1997
y g
y
p
Thealloyingelementmainlyusedtoimprovethe
endurancestrengthofsteelmaterialsis
(a) Nickel
(b) Vanadium
((c)) Molybdenum
y
(d) Tungsten
IES
y
Alloysteelwhichisworkhardenable
andwhichis
usedtomakethebladesofbulldozers,bucket
wheelexcavatorsandotherearthmoving
equipmentcontainiron,carbonand
i
i i
b d
(a) Chromium
(b) Silicon
(c) Manganese
(d) Magnesium.
IES 2010
IES2010
Some high speed steels have cobalt (Co)
added
in
from
2%
dd d to them
h
i amounts ranging
i
f
%
to 15%, since this element improves the
(a)Cutting efficiency, especially at high
temperature
(b) Depth hardening ability of the HSS tool
(c) Red hardness of the HSS tool
(d) Grain structure of the HSS tool
Page 209 of 240
IES 2000
IES2000
Additionofvanadiumtosteelresultsin
improvementof
(a) Heattreatabilitybyquenching
(b) Hardenability
((c)) Fatiguestrength
g
g
(d) Resistancetooxidationatelevatedtemperature
6 Sili
6.Silicon
y The silicon steels behave like nickel steels.
y These steels have a high elastic limit as compared to
8 M l bd
8.Molybdenum
y small q
3 ) of molybdenum
y
y A very
quantityy ((0.155 to 0.30%)
is generally used with chromium and manganese (0.5
to 0.8%) to make molybdenum steel.
y These steels possess extra tensile strength and are used
for airplane fuselage and automobile parts. It can
replace
l
t
tungsten
t in
i high
hi h speed
d steels.
t l
Rev.0
9 B
9.Boron
y Boron (not exceeding 0.003%) is a very powerful
hardenability
agent, being
from
250 to 750 times as
h d
bl
b
f
effective as nickel, 75 to 125 times as effective as
y
, and about 100 times as p
powerful as
molybdenum,
chromium.
y Only a few thousandths of a percent are sufficient to
produce the desired effect in lowcarbon
low carbon steels,
steels but the
results diminish rapidly with increasing carbon content.
y Since no carbide formation or ferrite strengthening
g
g is
produced, improved machinability and coldforming
capability often result from the use of boron in place of
other hardenability additions.
additions
y It has no effect on tensile strength of steel.
IES 1992
IES1992
p
y
y Itisanundesirableimpurityinsteelbecauseitsforms
p
g
Smallpercentageofboronisaddedtosteelto
(a) Increaseshardenability
((b)) Reducemachinabilityy
(c) Increaseswearresistance
(d) Increaseendurancestrength
ironsulphide,whichcanresultincracking.
y However,inthepresenceofproperamountofMn,it
formsMn Swhichimprovesthemachinability of
steels.
y Itscontentmayveryfrom0.06 0.30%.
All St l t l
AlloySteelataglance
11.Copper
y Copper has been known
kno n to resist atmospheric corrosion
10 l h
10.sulphur
(4)
,
,
Donotformcarbide: nickel,Silicon,Aluminium
Carbideformingorder:Manganese,chromium,
Tungsten,Molybdenum,vanadium,titanium,
niobium.
(1) Manganese:
Toughness&ductility
Machinability withsulphur
(2) Chromium:
Corrosionresistance
Wearresistance
(3) Nickel:
toughness
g
(5)
(6)
(7)
(8)
(9)
Tungsten,Molybdenum,Vanadium: hothardness
Tungsten
wearresistance,
Vanadium:
endurancelimit
V di
d
li i
Molybdenum
creepproperty
Si&Al deoxidizer,restrictgraingrowth
deoxidizer restrictgraingrowth
Si Magneticpermissibility
Cobalt:
hardenability
Impactstrength
Phosphorus:
reducestrengthtoimpact
conductivityofcopper
Copper:
Raisesyieldpoint
Magnesium:
becauselightweightitisused
whereweightisimportant.
Contd
IES 2011
IES2011
Superalloy: Isforhightemperatureuse[jetengine,
gasturbinebladeetc]
Ex: Hastelloy X
C 0.1%
Mn 1%
Cr 21.8%
Si
Si
1%
%
Ni balance
C 2.5%
Co
%
Mo 9%
W 0.6%
W
0 6%
Fe 18.5%
For-2015 (IES, GATE & PSUs)
Match List I with List II and select the correct answer using
the code given below the lists :
ListI
ListII
A.Copper
pp
1.Corrosion
B.Nickel
2.Demagnetization
C M
C.Manganese
3.NonSparking
N S ki
D.Vanadium
4.Deformationrestriction
Codes
A
(a) 1
(c) 1
B
2
3
C
3
2
D
4
4
(b)
(d)
A
4
4
B
3
2
C
2
3
D
1
1
IES 1996
IES
Whichofthefollowingpairsregardingtheeffectof
alloyingelementsinsteelarecorrectlymatched?
ll i l
t i t l
tl t h d?
1. Molybdenum:Formsabrasionresistingparticles.
2 Phosphorus:Improvesmachinability infreecutting
2.
steels.
3. Cobalt:Contributestoredhardnessbyhardening
ferrite.
4. SiliconReducesoxidationresistance
Selectthecorrectanswerusingthecodesgivenbelow:
(a) 2,3and4 (b) 1,3and4
(c) 1,2and4
(d) 1,2and3
Rev.0
IES 1992
IES1992
g
Matchthefollowing:
ListI(Alloyingelementinsteel)
A. Lead
1.
B. Aluminium
2.
C. Copper
3.
D. Phosphorus
Codes:A
d
B
C
(a) 1
2
3
( ) 3
(c)
4
1
4.
D
4
2
(b)
(d)
IAS 1995
IAS1995
ListII(Effect)
Restrictsgraingrowth
Raisesyieldpoint
Reducesstrengthto
impact
Freemachining
A
B
C
D
2
3
4
1
4
1
2
3
St i l
St l
StainlessSteel
y typical
yp
g with other
y They
consists min.12% Cr along
alloying elements, thus highly corrosion resistant
owing to presence of chromium oxide.
y Three kinds ferritic & hardenable Cr steels, austenitic
and precipitation hardenable (martensitic, semi
austenitic)
t iti ) based
b d on presence off prominent
i
t micro
i
structural constituent.
y Typical
T pical applications cutlery,
cutler surgical knives,
kni es storage
tanks, domestic items.
y Ferritic steels are principally FeCrC
Fe Cr C alloys with 1214%
12 14%
Cr. And small additions of Mo, V, Nb, Ni.
WatchListI(Alloyingelementsfortoolsteel)withListII
(Improvedmechanicalproperty)andselectthecorrect
answerusingthecodesgivenbelowtheLists
ListI
ListII
(All i l
(Alloyingelementsfortoolsteel)
t f t l t l)
(I
(Improved
d
mechanicalproperty)
A. Carbon
1.
Hardness
B. Manganese
2.
HotHardness
d
C. Chromium
3.
LowerCritical
Temp
D. Vanadium
4.
Toughness
Codes:A
B
C
D
A
B
C
D
(a) 1
3
4
2
(b)
2
4
3
1
(c) 1
4
3
2
(d) 2
3
4
1
Contd
IES 2002
IES2002
p
Thecorrectcompositionofausteniticstainless
steelusedfordomesticutensilsis
(a) 0.08%C,18%Cr,.8%Ni,2%Mn,1%Si
(b) 0.08%C,24%Cr,12%Ni,2%Mn,1%Si
((c)) 0.15%C,12%Cr,0.5%Ni,1%Mn,1%Si
5
,
, 5
,
,
(d) 0.30%C,12%Cr,0.4%Ni,1%Mn,1%Si
IAS 2002
IAS2002
Assertion(A):Inhighspeedsteels,alloyingelements
tungsten,chromiumandvanadiumareaddedto
t
t h
i
d
di
dd dt
makethemsuitabletoworkathigherspeedsthan
toolsteelorlowalloysteels.
R
Reason(R):Vanadiumaddstothepropertyofred
(R) V
di
dd h
f d
hardnessandtungstenandchromiumaddtohigh
wearresistance.
(a) BothAandRareindividuallytrueandRisthecorrect
explanationofA
(b) BothAandRareindividuallytruebutRis not the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
Contd
IES 2008
IES2008
g
p
Considerthefollowingstatementsinrespectof
austeniticstainlesssteels:
1. Austeniticstainlesssteelsarehardenedand
strengthenedbycoldworking.
2. Austeniticstainlesssteelscannotbequenchedand
tempered.
Whichofthestatementsgivenaboveis/arecorrect?
(a) 1only
(b) 2only
(c) Both1and2
(d) Neither1nor2
IES 1997
IES1997
Assertion(A):Austeniticstainlesssteelcontains18%
chromiumand8%nickel.Sinceitretainsitsaustenitic
h
i d8% i k l Si it t i it t iti
structureatroomtemperature,itiscalledaustenitic
stainlesssteel.
R
Reason(R):Chromiumpresentinthesteelimprovesits
(R) Ch
i
i h
li
i
corrosionresistancebyformingathinfilmofchromium
oxideonthesurface.
(a) BothAandRareindividuallytrueandRisthecorrect
explanationofA
(b) BothAandRareindividuallytruebutRisnotthe
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
Rev.0
IES 2009
IES2009
g
Whichoneofthefollowingelementsisan
austeniticstabilizer?
(a) Chromium
(b) Tungsten
((c)) Nickel
(d) Molybdenum
IES 2005
IES2005
MatchListI(AlloyingElement)withListII(Effecton
Steel)andselectthecorrectanswerusingthecodegiven
S l) d l h
i h d i
belowtheLists:
ListII
ListI
A. Vanadium
1.
Increasesendurancestrength
B. Molybdenum
2.
Improvescreepproperties
C Silicon
C.
Sili
3.
I
Increaseshardness
h d
D. Chromium
4.
Increasesresistancetohigh
temperatureoxidation
Codes:A
B
C
D
A
B
C
D
(a) 2
1
3
4
(b) 1
3
2
4
( ) 2
(c)
1
4
3
(d) 1
2
3
4
IES 2010
IES2010
Consider the following statements:
Alloying elements are added to
1. Improve hardness and toughness.
2. Corrosion and oxidation resistance improvement.
33. Improve
p
machinabilityy and hardenability.
y
4. Increase weight and volume.
Which of the above statements are correct?
(a) 1, 2 and 3 only
(b) 2, 3 and 4 only
( ) 1, 2 and
(c)
d 4 only
l
(d) 1, 2, 3 and
d4
For-2015 (IES, GATE & PSUs)
IES 2009
IES2009
IES 2004
IES2004
g
Whichoneofthefollowingelementsisaferritic
stabilizer?
(a) Nickel
(b) Manganese
((c)) Copper
pp
(d) Chromium
MatchListI(Nameofalloy)withListII(Major
alloyingelements)andselectthecorrectanswerusing
ll i l
t ) d l tth
t
i
thecodesgivenbelowtheLists:
ListI
ListII
A. Invar
1.
Manganese
B. Hadfieldsteel
2.
Chromium
C Stellite
C.
3
3.
Nickel
D. Stainlesssteel
4.
Tungsten
y
5.
Molybdenum
Codes:A
B
C
D
A
B
C
D
(a) 5
1
4
2
(b) 3
2
5
1
(c) 5
2
4
1
(d) 3
1
5
2
IES
IES 2008
IES2008
MatchListI(Alloyingelementinsteel)withListII
(Propertyconferredonsteelbytheelement)and
(P
t
f
d t lb th l
t) d
selectthecorrectanswerusingthecodesgivenbelow
thelists:
Li I
ListI
Li II
ListII
A.Nickel
1.
Corrosionresistance
B.Chromium
2.
Magneticpermeability
C.Tungsten
3.
Heatresistance
D.Silicon
4.
Hardenability
Codes:A
d
B
C
D
A
B
C
D
(a) 4
1
3
2
(b) 4
1
2
3
(c) 1
4
3
2
(d) 1
4
2
3
g
g
Whichofthefollowingelementsgivenbelow
determine(s)themaximumattainablehardness
insteel?
1. Chromium
2.
Manganese
3. Carbon
4.
Molybdenum
electthecorrectanswerusingthecodegivenbelow:
(b) 1and2
a) 1only
(c) 3only
(d) 2and4
Rev.0
Contd
IES 2001
IES2001
IES 1996
IES1996
y
g
4
y
Thealloysteeldesignatedas40Cr18Ni2by
BureauofIndianStandardscontains
(a) 0.4%C,18%Crand2%Ni
(b) 4.0%C,1.8%Crand0.2%Ni
((c)) 0.4%C,1.8%Crand2%Ni
4
,
(d) 0.4%C,1.8%Crand0.2%Ni
group
of
engineered
18/8stainlesssteelcontains
(a) 18%stainless,8%chromium.
((b)) 18%chromium,8%nickel.
,
(c) 18%tungsten,8%nickel.
(d) 18%tungsten,8%chromium.
Properties of plastics
Propertiesofplastics
materials
g
g
y Lightweight
y Goodresistancetocorrosion
y Easyoffabricationintocomplexshapes
y Lowelectricalandthermalconductivity
y Goodsurfacefinish
d
f
f
h
y Goodopticalproperties
p
p p
y Goodresistancetoshockandvibration.
IES 2010
IES2010
Consider the following properties for
plastics:
l i
1. Become hard on heating.
2. Increasing plasticity.
3 Ability to deform with rise in temperature.
3.
temperature
4. Long chain structure.
Whi h off these
Which
h
properties
i
f
for
plastics
l i
are
correct?
(a) 1, 2, 3 and 4
(b) 3 and 4 only
(c) 1 and 4For-2015
only (IES,
(d) 2,GATE
3 and&4PSUs)
only
IES 2010
IES2010
Plasticmaterialisusedforthecomponent
whichrequirescharacteristicsof
hi h
i h
i i f
(a)Lowdensity,machinability andhighstrength
(b)Machinability,highstrengthandlargeplastic
deformation
(c)Highstrength,largeplasticdeformationand
lowdensity
(d) Low density, machinability and large plastic
deformation
Page 213 of 240
IAS 2007
IAS2007
g
Considerthefollowing:
Whichofthefollowingpropertiesarepossessedby
plastics?
1. Goodresistancetocorrosiveatmosphere
2. Easeoffabricationintocomplexshapes.
p
p
3. Goodresistancetoshocksandvibrations.
g
g
Selectthecorrectanswerusingthecodegivenbelow:
(a) 1,2and3
(b) 2and3only
(c) 1and3only
(d) 1and2only
Rev.0
Classification Polymers
Pol mers
Classification
IES 2008
IES2008
p y
Structureofapolymeris:
(a) Longchain
(b) Rhombic
((c)) Cubic
((d)) Closedpackhexagonal
p
g
((a)) thermoplasts
th
l t and
d
(b) thermosets
Thermoplasts
Thermoplastics
(
y Fluorocarbons (PTFE
or TFE,Teflon))
y Acrylonitrilebutadienestyrene (ABS):
Contd
Contd
y Polycarbonates
y Polypropylene
Contd
Contd
Rev.0
IES 2003
IES2003
IES 2011
IES2011
Windows of aeroplane are made of :
(a) PVC
(b) PTFE
(c) PMMA
((d)) PEEK
IES 1992
IES1992
y
y
Polyamidesarecharacterizedby
(a) Flexiblechain
((b)) Rigidchain
g
(c) Amorphousstructure
(d) Crystallinestructure
IES 2002
IES2002
Thermosets
p y
g
Thestructureofapolymerisshowninthegiven
figure.Thispolymer
g
p y
Findsspecialapplicationin
(a) Packaging
(b) Adhesives
(c) Bearings
(d) Fertilizer
IAS 2000
IAS2000
Considerthefollowingstatements:
Polytetrafluoroethene is
1. Athermoplasticmaterial
2 Havinghighfrictioncoefficient
2.
3. Athermosettingmaterial
4. Havinglowfrictioncoefficient
5. Anelectricinsulator
6. Nonstickingtosurfaces
Whichoftheabovestatementsarecorrect?
(a) 1,2and5
(b) 2,3and6
(c) 3,4and5
(d) 3,2and5
IES 1995
IES1995
F F
C C
F F
Teflonisa
(a) Thermosettingfluorocarbonpolymer
((b)) Thermoplasticfluorocarbonpolymer
p
p y
(c) Inorganiccompoundoffluorineandcarbon
(d) Laminatedphenolic material
and/or pressure.
y This process is not reversible, hence thermosets can
not be
b recycled.
l d
y They consist of 3D network structures based on
strong covalent
l
b d to form
bonds
f
rigid
i id solids.
lid linear
li
molecular chains bonded together by weak secondary
bonds or by interwinding.
interwinding
y Characterized by high modulus / rigidity /dimensional
stability when compared with thermoplasts.
thermoplasts
y E.g.: Epoxies, Amino resins, some polyester resins, etc.
Contd
Page 215 of 240
yp p
( )
( )
Weldable typeplastic(s)include(s)
(a) Thermosets alone
((b)) Thermoplasticsalone
p
(c) Boththermosets andthermoplastics
(d) Neitherthermosets andthermoplast
necessity.
fibers
are mostt commonly
it Glass
Gl
fib
l used
d to
t form
f
structural and molding plastic compounds.
Two most important types of glass fibers are E (electrical)
and
d S (high
(h h strength)
h) glasses.
l
Eglass (limealuminiumborosilicate glass with zero or
potassium levels)) is often used for
low sodium and p
continuous fibers.
Sglass (65%SiO2, 25%Al2O3 and 10% MgO) has higher
strengthtoweight
strength
to weight ratio and is more expansive thus
primary applications include military and aerospace
applications.
Carbon fiber reinforced plastics are also often used in
aerospace applications. However they are very expansive.
Rev.0
Contd
polyamide) fibers.
fibers
y They are popularly known as Kevlar.
Examples Thermosettingpolymers
Thermo setting polymers
Examples
IES 2011
IES2011
KevlarEpoxycompositeiswidelyusedin:
(a)Automobiles
(b)Aerospace
(c)Navy
( )
(d)InteriorDecoration
y Epoxies
y Polyester(PETorPETE)
Chemical
classification
Tradename
characteristics
Typical
application
Epoxy
Aralditeoxiron
Goodtoughness.
Resistantto;acids.
R i
id
alkalies and
solvents.
excellent
adhesiontometal,
glassandwood.
Adhesiveand
coatings,tools
i
l
and
dies,filament
woundvessels,,
laminatesfor
aircraft,patching
compoundfor
metaland
t l d
plastics.
Characteristics:Oneofthetoughestofplasticfilms;
Ch
i i O f h
h f l i fil
excellentfatigueandtearstrength,andresistanceto
humidityacids greases oilsandsolvents
humidityacids,greases,oilsandsolvents
Application:Magneticrecordingtapes,clothing,
automotivetirecords beveragecontainers
automotivetirecords,beveragecontainers.
Melamineformal
dehyde
IES 1997
IES1997
MatchListIwithListIIandselectthecorrectanswer
usingthecodesgivenbelowtheLists:
ListI
ListII
A. Neoprene
1.
Electricswitches
B. Bakelite
2.
Adhesive
C. Foamedpolyurethane
3.
Thermalinsulator
D. Araldite
4.
Oilseal
Code:A
d
B
C
D
A
B
C
D
a) 4
1
2
3
(b) 1
4
2
3
c)) 4
1
3
2
(d) 1
4
3
2
Goodfor
application
requiringcycling
betweenwetand
dryconditions.
Hardandabrasion
d d b
resistant.Good
dielectric.
Tablcware,electric
insulation
insulation,
automotIve Ignition
parts,cutlery
handles,jars and
b l
bowls.
IES 1992
IES1992
Assertion (A): Linear polymers are rigid at low
temperatures but soft and mouldable at elevated
temperatures.
Reason (R): Linear polymers are thermosetting.
thermo setting
(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
Phenol
Bakelite
formaldehy Marblette Durez
de
Cataljn
Gooddimensional
stabilityExcellent
insulatingqualities.
Inert
I
t
tomostsolventsand
weakacids.
g
Goodstrengtharound
inserts.
Industrialelectrical
parts.
automotiveelectrical
components,
t
paperimpregnated
battery
p
separators.
Electricalinsulation.
Phenol
Phenol
furfural
Durite
Similarto
Phenolfonnaldehyde.
Electricalinsulation.
Electricalinsulation
Mechanical
parts.Housingsand
containers.
Alkyd
(Modified
polyester)
Glyptal Duraplex
Beckosol Teglac
Rezly
Canbemadeflexible,
resilientorrigid.Can
resistacidsbutnot
alkalies,withglassfibre
reinforcementresistssalt
waterandfungusgrowth.
Boats,Tanks,Trailerand
Tractor
components.Ducts,
shrouds.
Vaultingpoles.
IES
g
Considerthefollowingstatements:
Fibre ReinforcedPlasticsare
g
g
1. Madeofthermosettingresinsandglassfibre
2. Madeofthermoplasticresinsandglassfibre
3. Anisotropic
4. isotropic
Selectthecorrectanswerusingthecodesgivenbelow:
(a) 1and4
(b) 1and3
(c) 2and3
(d) 2and4
Rev.0
IES 1994
IES1994
IES 2007
IES2007
MatchListI(materials)withListII(applications)and
selectthecorrectanswerusingthecodesgivenbelow
l tth
t
i th d i
b l
theLists:
ListI
ListII
A. Engineeringceramics
1.
Bearings
B. Fibre reinforcedplastics 2.
Controlrodsin
nuclearreactors
C. Syntheticcarbon
3.
Aerospaceindustry
D. Boron
4.
Electricalinsulator
Codes:A
d
B
C
D
A
B
C
D
(a) 1
2
3
4
(b) 1
4
3
2
(c) 2
3
1
4
(d) 4
3
1
2
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowtheLists:
h
d
b l
h
ListI
ListII
(Material)
(Application)
A. Fibre reinforcedplastics 1.
Automobiletyres
B. Acrylics
2.
Aircraft
C. Phenolics
3.
Lenses
D. Butadienerubber
4.
Electricswitchcover
Code:A
B
C
D
A
B
C
D
(a) 1
4
3
2
(b) 2
3
4
1
( ) 1
(c)
3
4
2
( ) 2
(d)
4
3
1
IES
Considerthefollowingstatements:
Thermosettingplasticsare
1. Formedbyadditionpolymerisation.
2. Formedbycondensationpolymerisation.
3. Softenedonheatingandhardenedoncoolingfor
anynumberoftimes
b fti
4. Moulded byheatingandcooling.
Selectthecorrectans erusingthecodesgi enbelo
Selectthecorrectanswerusingthecodesgivenbelow:
(a) 1and3
(b) 2and4
(c) 1and4
(d) 2and3
IES 2006
IES2006
y
Phenolformaldehydeisa/an
(a) Thermoplasticpolymer (b)
((c)) Elastomer
((d))
IES 1999
IES1999
gp
p
Considerthefollowingpairsofplasticsandtheir
distinctcharacteristics:
1. Acrylics..............Verygoodtransparencytolight
2. Polycarbonate..Poorimpactresistance
33. PTFE....Lowcoefficientoffriction.
4. Polypropylene..Excellentfatiguestrength
Whichofthesepairsarecorrectlymatched?
p
y
(a) 2and3
(b) 1and3
(c) 1and4
(d) 2and4
Thermoset polymer
Rubber
IES
MatchListIwithListIIandselectthecorrectanswer
ListI(Material)
ListII(Natureofproduct)
A. Polyethylene
1.
Adhesive
B. Polyurethane
2.
Film
C. Cyanoacrylate
3.
Wire
D. Nylon
4.
Foam
Codes:A
B
C
D
A
B
C
D
(a) 2
4
3
1
(b) 4
2
3
1
(c) 2
4
1
3
(d) 4
2
1
3
Polymersynthesis
IAS 2003
IAS2003
Elastomers
g
Considerthefollowingstatements:
1. Thermoplasticspossessastrongintermolecular
bondingcomparedtothatofthermosettingplastics.
2. Plasticshaveahighcreepundercontinuousloading.
33. Embrittlement occursinplasticsatlowtemperature.
p
p
Whichofthesestatementsarecorrect?
((a)) 1and2
((b)) 2and33
(c) 1and3
(d) 1,2and3
followed by forming.
y Polymers
are synthesized
by process known as
polymerization.
l
i ti
y Polymerization
y
is p
process in which multifunctional
Rev.0
AdditionPolymerization
y This polymerization process involves single kind of
C d
i P l
i i
CondensationPolymerization
y Formation of a polyester from Ethylene glycol and Adipic
acid
AdditionPolymerization
d
i
l
i i
CondensationPolymerization
E.g.,
polyethylene
Combination:
one monomer.
y Repeat
p
unit in condensation p
process itself is p
product of
Disproportionation:
y Polyesters,
phenolformaldehyde,
nylons,
polycarbonates etc are produced by condensation
polymerization.
y Condensation polymerization reactions also occur in
solgel processing of ceramic materials.
y Polymers,
y
, unlike organic/inorganic
g
/
g
compounds,
p
, do
not have a fixed molecular weight. It is specified in
terms of degree of polymerization number of
repeat units in the chain or ratio of average molecular
weight of polymer to molecular weight of repeat unit.
y Weight
g
g molecular weight
g
two ways.
average
is
obtained by dividing the chains into size ranges
and determining the fraction of chains having
molecular weights within that range.
y Number average molecular weight is based on
the
h number
b
f
fraction,
rather
h
than
h
the
h weight
h
fraction, of the chains within each size range. It is
always smaller than the weight average molecular
weight.
Contd
IES 2001
IES2001
g
y chloride is 62.5.
5
The molecular weight
of vinyl
Thus the molecular weight of a polyvinyl chloride
with a degree of polymerization of 20000 is
(a)
62.5
20000
62 5
62.5
(b) 20000
(d) 20000
C
li ki
Th crosslinking
li ki can occur due
d to
t the
th presence
y Cross
linking:
The
of some elements called vulcanizing agents, e.g. S, Se, Te, and
O2.
y In case of poly isoprene (natural rubber), the sulphur bridges
are formed between two macromolecules during vulcanization.
y In this vulcanization p
process sulphur
p
bridge
g are formed at the
point of opening of double bonds. If the number of crosslinks
is small; the find product is soft and flexible. The stiffness of the
polymeric
p
y
material increases with the densityy of crosslines.
When the sulphur content in rubber is as high as 32 weight
percent, the hard product is called ebonite.
IES 2003
IES2003
,
Inthecaseofrubber,vulcanizationreferstothe
processofproducinga
(a) Linearpolymer
(b) Branchedpolymer
((c)) Crosslinkedpolymer
p y
(d) Networkpolymer
Rev.0
IES 2006
IES2006
IES 2000
IES2000
y
y
Assertion(A):Additionpolymerizationisaprimary
summationofindividualmoleculesintolongchains,
Reason(R):Inadditionpolymerization,thereaction
producesasmallmoleculeasbyproduct.
d
ll
l
l b
d
(a) BothAandRareindividuallytrueandRisthecorrect
explanationofA
(b) BothAandRareindividuallytruebutRisnot the
p
correctexplanationofA
(c) AistruebutRisfalse
((d)) AisfalsebutRistrue
IES 2008
IES2008
IES 2003
IES2003
y
Polyesterscanbedefinedasthecondensation
productsof
(a) Dicarboxylic acidswithdihydroxy alcohols
(b) BisphenolAandepichlorohydrin
((c)) Phenolandformaldehyde
y
(d) Benzeneandtoluene
IES 1994
IES1994
g
Whichofthefollowingpairsofplasticsandtheir
modesofformationarecorrectlymatched?
1. Polythene..Condensationpolymerization.
2. Polycarbonate.............Additionpolymerisation.
3. Polystyrene...Additionpolymerisation.
4. Polyamide.Eitherbyadditionorby
condensationpolymerisation.
S l tth
Selectthecorrectanswerusingthecodesgivenbelow:
t
i th d i b l
(a) 1and2
(b) 2and4
(c) 1and4
(d) 3and4
called "additives"
additives , whereas those that form a clearly
defined second phase are called "fillers".
Contd
1 Plastici ers
1.Plasticizers
y Plasticizers are liquids of high boiling point and low
2 Fillers
2.Fillers
y A filler is used to economize on the quantity of polymer
3. Catalysts:
y These are usually added to promote faster and more
complete
polymerization
and
l
l
i i
d as such
h they
h are also
l
called 'accelerators' and 'hardeners' e.g., ester is used
as a catalyst for Urea Formaldehyde.
4. Initiators:
y As the name indicates,, the initiators are used to
initiate the reaction, that is, to allow polymerization to
begin. They stabilize the ends of the reaction sites of
the molecular chains.
chains H2O2 is a common initiator.
initiator
5. Dyes and Pigments:
y These are added,
added in many cases,
cases to impart a desired
colour to the material.
Rev.0
6. Lubricants:
y Lubricants are added to the polymers for the following
purposes : to reduce friction during processing,
processing to prevent
parts from sticking to mould walls, to prevent polymer
films from sticking to each other and to impart an elegant
fi i h to
finish
t the
th final
fi l product.
d t Commonly
C
l used
d lubricants
l bi
t
include : oils, soaps and waxes.
77. Flame retardants:
y Most plastics will ignite at sufficiently high temperatures.
The noninflammability of the plastics can be enhanced
either by producing them from less inflammable raw
materials or by adding "flame retardants". The common
flame retardants are : compounds of chlorine, bromine and
phosphorous.
h
h
8 Solvents:
8.
y Solvents are useful for dissolving certain fillers or
p
p in manufacturing
g byy allowing
g
plasticizers and help
processing in the fluid state, For example, alcohol is
added in cellulose nitrate plastics to dissolve Camphor.
H
However,
subsequently,
b
tl the
th solvents
l
t mustt be
b removed
d
by evaporation.
9. Stabilisers and anti
antioxidants
oxidants are added to retard
the degradation of polymers due to heat, light and
oxidation.
10. Elastomers are added to plastics to enhance their
elastic properties.
N t Above,
Note:
Ab
excepting
ti fillers,
fill
all
ll other
th materials
t i l used,
d
fall under the category of "Additives.
IAS 2007
IAS2007
MatchListIwithListIIandselectthecorrectanswerusing
thecodegivenbelowtheLists:
ListI
ListII
(AdditiveforPolymers)
(Purpose)
A. Plasticizer
1.
Allowspolymerization
tobegin
B. Filler
2.
Colours thematerial
C. Initiator
3.
Actsasinternal
lubricants
4.
4
Improvesstrength
p
g
Code:A
B
C
A
B
C
(a) 1
4
3
(b)
3
2
1
(c) 1
2
3
(d)
3
4
1
IAS 1998
IAS1998
(a)
( )
(c)
3
5
1
3
2
1
5
4
(b)
(d)
3
3
1
5
5
l
2
4
Plastic Process
PlasticProcess
Injection Mo lding
InjectionMoulding
p
Fillersareaddedtoplasticsto
(a) Improveflow
((b)) Reducebrittleness
(c) Facilitateprocessability
(d) Reducecost
IAS 1994
IAS1994
IES 1992
IES1992
Contd
p
y
To reduce the consumption
of synthetic
resins,,
the ingredient added is
(a) Accelerator
(b) Elastomer
((c)) Modifier
(d) Filler
Fig.Injectionmoulding
Rev.0
E tr sion
Extrusion
readily
dil produced
d d by
b the
th extrusion
t i process.
y Thermoplastic pellets & powders are fed through a hopper
g
into the barrel chamber of a screw extruder. A rotating
screw propels the material through a preheating section,
where it is heated, homogenized, and compressed, and
then forces it through a heated die and onto a conveyor
belt.
y As the plastic passes onto the belt, it is cooled by jets of air
or sprays off water which
h h harden
h d it sufficiently
ff
l to preserve
its newly imparted shape.
y It continues to cool as it passes along the belt and is then
either cut into lengths or coiled.
Contd
Compression mo lding
Compressionmoulding
y A compression mould is made of two halves with one
each
off the
h being
b i connected
d to the
h platens
l
h press.
y The mould is electrically heated to maintain the
required temperature.
temperature
y Material is placed in the mould, and it is closed with a
hydraulic
y
cylinder,
y
, or toggle
gg clamp.
p
y The pressure maintained on the material is of the
Fig.Extrusion
Contd
Transfer Mo lding
TransferMoulding
C
i
i determined
d
i d by
b the
h thickest
hi k
i
y Cure
time
is
cross section,
mould temperature, material type and grade.
y After
the
Aft curing,
i
th mould
ld opens and
d the
th partt is
i ejected.
j t d
y The most widely used plastic is phenol formaldehyde,
commonly known as 'Bakelite
Bakelite.
Blo mo lding
Blowmoulding
y Blow moulding is the process of inflating a hot,
hot hollow,
hollow
Contd
Rev.0
Thermoforming
IES 2005
IES2005
p
p
y
Thermoplasticmaterialscannotbeproducedby:
(a) Injectionmoulding process
((b)) Extrusionprocess
p
(c) Blowmoulding process
(d) Both(a)and(b)above
three
three dimensional shape by the application of heat and
differential pressures.
First, the plastic sheet is clamped to a frame and uniformly
heated to make it soft and flowable.
flowable
Then a differential pressure (either vacuum or pressure or
both) is applied to make the sheet conform to the shape of
a mould
ld or die
di positioned
ii
d below
b l the
h frame.
f
It is possible to use most of the thermoplastic materials.
g material is a p
plastic sheet of uniform
The starting
thickness.
It is a relatively simple process and is used for making such
parts as covers,, displays,
p
p y , blister p
packaging,
g g, trays,
y , drinking
g
cups and food packaging.
Contd
Contd
IES 2004
IES2004
MatchListI(Typeofmoulding)ListII(Mechanisminvolved)and
selectthecollectanswerusingthecodesgivenbelowtheLists:
ListI
ListII
A.
Compressionmoulding
1.
Mouldcavitymustbeheated
tocuretheplasticforced
i i
intoit.
B.
Injectedmoulding
2.
SimilartoHydraulic
extrusion
C
C.
Jetmoulding
3
3.
Analogoustothehot
pressingofpoweredmetals
D.
Extrusionmoulding
4.
Analogoustodiecastingof
metals
A
B
C
D
A
B
C
D
(a) 2
4
1
3
(b)
3
1
4
2
(c) 2
1
4
3
(d)
3
4
1
2
IAS 1999
IAS1999
g
p
Whichoneofthefollowingaretheprocessesfor
thermosettingmaterials?
1. Compression
2. Transfermoulding
33. Injectionmoulding
j
g
4. Extrusion
g
g
Selectthecorrectanswerusingthecodesgivenbelow:
(a) 1and4
(b) 1and2
(c) 2and3
(d) 2,3and4
IES 2009
IES2009
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowtheLists:
ListI
ListII
(Article)
(ProcessingMethod)
A. Disposablecoffeecups
1.
Rotomoulding
B. Largewatertanks2.
Expandablebead
moulding
C. Plasticsheets
3.
Thermoforming
D. Cushionpads
4.
Blowmoulding
5
5.
Calendering
Code: A
B
C
D
A
B
C
D
(a) 3
5
1
2
(b)
4
5
1
2
( ) 4
(c)
3
2
1
(d)
3
1
5
2
IAS 2007
IAS2007
Whichoneofthefollowingstatementsisnot
correct?
(a) Ininjectiondiemoulding,exactamountof
materialtofillthecylinderisdelivered
(b) Injectiondiemoulding isgenerallylimitedto
formingthermoplasticmaterial
(c) Thermosettingplasticsaremoresuitablefor
extrusionmoulding
(d) Extrusionmoulding processisusedforgiving
shapes,suchasrods,tubes,pipes,ropesetc.
IAS 2004
IAS2004
Whichofthefollowingarethecharacteristicsofthe
injectionmoulding
ofplastics?
ld
f l
1. Itisthemosteconomicalmethodofmassproducinga
singleitem
2. Inmostcasesfinishedproductsareobtained
3.
Thereislotofwasteofthermoplasticsincethe
runnersandsprues cannotbereused.
Selectthecorrectanswerbyusingthefollowingcodes:
(a) 1and2
(b) 2and3
(c) 1and3
(d) 1,2and3
Rev.0
IAS 2003
IAS2003
IAS 1997
IAS1997
g
Considerthefollowingstatementsinrespectof
fabricationofplasticproducts:
1. Compressionmoulding isanalogoustohotpressingof
powderedmetals.
d d
l
2. Jetmoulding isamodificationofcompressionmoulding.
3. Injectionmoulding
I j ti
ldi isanalogoustodiecastingofmetals
i
l
t di ti f t l
4. Transfermoulding issimilartohydraulicextrusion.
Whi h fth t t
Whichofthesestatementsarecorrect?
t
t?
(a) 1and2
(b) 1and3
(c) 1,2and4
1 2and4
(d) 2,3and4
2 3and4
IES 2004
IES2004
g
g
Whichofthefollowingarefabricatedusing
engineeringplastics?
1. Surfaceplate
2. Gears
33. Guidewaysformachinetools
y
4. Foundrypatterns
g
g
Selectthecorrectanswerusingthecodesgivenbelow:
(a) 1,2and3
(b) 1
(c) 2,3and4
(d) 1,2,3and4
IES 2011
IES2011
MatchListI(Material)withListII(Typicaluse)and
thecorrectanswerusingthecodesgivenbelowthe
h
h
d
b l
h
Lists:
ListI
ListII
A. Branchedpolyethylene 1.
Bottles
B. Polyester
y
2.
Textilefibres
C. Polyvinylidene chloride 3.
Filmsforpackaging
D. LinearPolyethylene
4.
Transparentfilm
A
B
C
D
A
B
C
D
(a) 2
3
4
1
(b) 3
2
1
4
( ) 2
(c)
3
1
4
(d) 3
2
4
1
El t
Elastomers
y Elastomers are a special class, of linear polymers that
IES 2002
IES2002
Whichofthefollowingprocessescanbeusedfor
massproductionofplasticcontainers(withlid)of
5litercapacity?
1 Injectionmoulding
1.
2. Joltmoulding
3 Blowmoulding
3.
Selectthecorrectanswerusingthecodesgivenbelow:
Codes:
(a) 1and2
(b) 2and3
(c) 1and3
(d) 1,2and3
Contd
y
y
Rev.0
R bb
Rubber
IES 2011
IES2011
During tensile testing it has been observed that for
some material the deformation is fully recoverable
and timeindependent, but does not obey Hooks
l
law.
Th material
The
t i l is
i :
(a) Elastomer
(b) Rubber
R bb
(c) Polymer
(d) Aluminium
l
alloy
ll
from
the
f
h processed
d sap off a tropicall tree.
y It could be vulcanized (crosslinked) by the addition of
about 30% sulphur followed by heating to a suitable
temperature. The crosslinking restricts the movement of
the molecular chains and imparts strength.
y Properties
P
i could
ld be
b further
f h improved
i
d by
b various
i
additives
ddi i
(e.g., carbon black) which act as stiffeners, tougheners, and
antioxidants.
y Accelerators have been found that speed up the
vulcanization process. These have enabled a reduction in
the amount of sulfur such that most rubber compounds
now contain less than 3% sulphur.
y g
flexibility,
good electrical insulation, low internal
friction, and resistance to most inorganic acids, salts,
and alkalies.
y However, they have poor resistance to petroleum
products, such as oil, gasoline, and naphtha.
y In addition,
dd
they
h
l
lose
their
h
strength
h at elevated
l
d
temperatures, so it is advisable that they not be used at
temperatures above 175
175F
F (80
(80C)
C).
y They also deteriorate fairly rapidly in direct sunlight
unless specially compounded.
compounded
Contd
p
pp
y
Neoprene
have a varietyy of application
in machinery.
y Rubber should be protected from high temperature,
IES 1997
IES1997
g materials is used for
Which one of the following
car tyres as a standard material?
(a) Styrenebutadiene rubber (SBR)
(b) Butyl rubber
((c)) Nitrile rubber
(d) Any of the above depending upon the need
Differenttypesofrubber
Applications
Naturalrubber
Tires,gaskets,hose
Polyacrylate
Oilhose, Orings
EDPM(ethylenepropylene)
Electricinsulation,footwear,hose,belts
Chlorosulfonated polyethylene
Tanklining,chemicalhose,polyethyleneshoe,
solesandheels
Polychloroprene (neoprene)
Wireinsulation,belts,hose,(neoprene)gaskets,
Wireinsulation
belts hose (neoprene)gaskets
seals,linings
Polybutadiene
Tires,solesandheels,gaskets,seals
Polyisoprene
Sameasnaturalrubber
Polysulfide
Seals,gaskets,diaphragms,valvedisks
SBR(styrenebutadiene)
Mouldedmechanicalgoods,disposable
pharmaceuticalitems tyres
pharmaceuticalitems,tyres
Silicone
Electricinsulation,seals,gaskets,Orings
Epichlorohydrin
Diaphragms,seals,mouldedgoods,low
ttemperatureparts
t t
Urethane
Casterwheels,heels,foampadding
Fluoroelastomers
Orings,seals,gaskets,rollcoverings
IES 2008
IES2008
C
i
Ceramic
Whichmaterialisusedforbushesinthebushed
pintypeofflexiblecoupling?
(a) Gunmetal
(b) Plastic
(c) Rubber
(d) Aluminium
Contd
Contd
g electrons are g
g ionic
bonding
generally captive in strong
or covalent bonds. The absence of free electrons makes
the ceramic materials poor electrical conductors and
results
l in
i many being
b i transparent in
i thin
hi sections.
i
y Because of the strength of the primary bonds, most
ceramics
i have
h
hi h melting
high
lti temperatures.
t
t
y Ceramic articles of industry are : Dinner ware,
electrical and chemical porcelain,
porcelain refractory bricks and
tiles, glass, porcelain enamels, abrasives, cutting tools,
bricks and tiles, cements and concretes, whitewares,
mineral Ores, slags and fluxes and insulators etc.
Contd
Rev.0
P
ti
fC
i
PropertiesofCeramics
y Ingeneral,ceramicsarehard,brittleandhigh
q
y used,
y Natural Ceramics : The most frequently
meltingpointmaterialswith:
y desirableelectrical,magneticandoptical
desirableelectrical magneticandoptical
properties,i.e.,lowelectricalandthermal
conductivity.
y goodchemicalandthermalstability,thatis,high
hotstrengthandhighcorrosionresistance,and
freedomfromoxidation.
y goodcreepresistance,and
y Highcompressivestrengthandexcellent
g
p
g
resistancetowear.
y Theirlowdensityisalsoanattractivefeatureto
minimisecentrifugalstressesinpartsrotatingat
highspeed.
Contd
IES 2008
IES2008
Considerthefollowingstatementsrelatingto
mechanicalpropertiesofceramics:
h
l
f
1. Tensilestrengthistheoreticallyhighbutinpractice
quitelow.
quitelow
2. Compressivestrengthismanytimeslowerthantensile
strength.
3. Shearstrengthishigh.
4. Transversestrengthiseasytoascertain.
Whi h f h
Whichofthestatementsgivenabovearecorrect?
i b
?
(a) 1and3
(b) 1and4
(c) 2and3
(d) 2and4
M hi i
fC
i
MachiningofCeramics
y Mostceramicsaresinteredtotheirfinish
dimensions.
y However,sometimes,theyaremachinedtogetbetter
dimensionalaccuracyandsurfacefinish.
y MachiningofceramicscanbedonewithDiamond
abrasives,LBM,EBMandCHM.
IES 2002
IES2002
g
Whichoneofthefollowingistrue?
(a) Structureofmetallicmaterialsconsistsofatoms
havingvalenceof5,6or7
(b) Ceramicmaterialshavelongrangeelectronmatrix
bond
(c) Polymersarecomposedoflongchainofrepeating
molecules
(d) Ceramicsareweakerthanmetalsbecauseofweak
electrostaticbond
P
i
fC
i
ProcessingofCeramics
The processing of ceramics,
ceramics except glass,
glass follows the
Powder Metallurgy route, that is, consists of the
following steps :
1 Preparation of powders
1.
2. Mixing and Blending of powders
3. Compacting of powders
4. Firing or Sintering.
PRODUCT APPLICATIONS
PRODUCTAPPLICATIONS
2 R f t i
2.Refractories
y p
1. Clay
products : Clayy bodyy ceramics include
whitewares and stoneware.
y Whitewares includes such families of products as
earthenwares, China and porcelain.
y Whitewares are largely used as tile, sanitary ware, low
and high voltage insulators, and high frequency
applications.
y Stoneware applications
l
are : Glazed
l d pipes, roofing
f
tiles
l
and tableware.
withstanding
in
situations.
The
ith t di high
hi h temperature
t
t
i various
i
it ti
Th
refractory materials are of three types.
y Acidic refractories are based on aluminasilica
composition,
ii
varying
i
f
from
pure silica
ili
to nearly
l pure
alumina, through a wide range of alumina silicates.
y The basic constituent of basic refractories is magnesia,
g
,
MgO. Basic refractories include chromemagnesite,
dolomite, limestone and magnesite.
y Neutral refractories include substances which do not
combine with either acidic or basic oxides. With increasing
alumina content, silicaalumina refractories may gradually
g from an acidic to neutral type.
yp A typical
yp
neutral
change
character is exhibited by such refractories as Carbon,
graphite, carbide, chromite, bauxite and forsterite.
Rev.0
Contd
furnaces,
furnaces boilers,
boilers flues,
flues regenerators,
regenerators convertors,
convertors
crucibles, dryers, pyrometer tubes and in many others,
primarly to withstand the high temperature.
Al2O3
alumina
spark
k plug
l insulators,
l
h h temperature tubes,
high
b melting
l
crucibles, wear components and substrates for
electronic circuits and resistors.
C bid
f t
Carbiderefractory
y Carbides have the highest melting point of all the
substances.
b t
electronic industries.
y As
A
i
insulators,
l
semiconductors,
i
d
di l
dielectrics,
i
ferroelectrics, piezoelectric crystals.
y Ceramics such as glass,
glass porcelain,
porcelain alumina,
alumina quartz and
mica, are getting heavy demands.
y Ceramics,, such as SiC,, are used as resistors and
heating elements for furnaces.
y Ceramics, having semiconducting properties, are used
f thermistors
for
h
i
and
d rectifiers.
ifi
B i
Barium
titantate,
i
f
for
example, is used in capacitors and transducers.
4 O ti l A li ti
4.OpticalApplications
5 Ph h
5.Phosphorescence
y useful as a p
g
, because it is
y Ceramics are notably
pigment,
p
g of a characteristic wave
y Ceramic p
phosphors
emit light
IES 2002
IES2002
Gl
Glass
MatchListIwithListIIandselectthecorrectanswer:
ListI(Material)
ListII(Application)
A. Ceramics
1.
Constructionof
chemicalplants
B. Refractory
2.
Columnsandpillars
C. Stones
3.
Liningoffurnaces
D. Highsilicaglass
4.
Tiles
Codes:A
d
B
C
D
A
B
C
D
(a) 4
3
2
1
(b) 2
1
4
3
( ) 4
(c)
1
2
3
(d) 2
3
4
1
Rev.0
Contd
for a g
glass. Fluxes lower the fusion temperature of the
glass and render the molten glass workable at
reasonable temperature.
y However, fluxes may reduce the resistance of glass to
chemical attack, render it water soluble or make it
subject
bj t to
t partial
ti l or complete
l t devitrification
d it ifi ti
(th t is,
(that
i
crystallisation) uponcooling; Such a glass is
undesirable since the crystalline are extremely weak
and brittle.
y Stabilizers are therefore, added to the glass batch to
overcome these problems.
C
it
Composites
y
y
y
IES 2011
IES2011
IES 2011
IES2011
Structure of common glass is
(a) Amorphous
(b) Partially crystalline
(c) Fully crystalline
((d)) None of the above
Contd
Th matrix
i material
i l should
h ld be
b : ductile
d il with
i h its
i
y The
modulus of elasticity much lower than that of the
dispersed phase.
phase Also,
Also the bonding forces between the
two phases must be very strong.
y Depending upon the nature of the reinforcing
materials (shape and size), the reinforced composites
can be classified as:
1. Particle reinforced composites or particulate
reinforced composites.
2. Fibre reinforced composites.
y In p
particle reinforced composites,
p
, the dispersed
p
phase
p
is in the form of exiaxed particles, whereas in fibre
reinforced composites,
is inofthe
form of fibres. Contd
Pageit227
240
IES 2008
IES2008
g
Whichoneofthefollowingiscorrect?
When"devitrification"ofinorganicglassesisdone,
((a)) Glasstransformsfromcrystallinetonon
y
crystallinestate
((b)) Glasstransformsintoafullytransparentmaterial
y
p
(c) Glasstransformsfromnoncrystallinestateto
polycrystallinestate
(d) Glassisrelievedofinternalstresses
IES 2009
IES2009
p
g yp
Nano compositematerialsarehighlypreferablein
designconsiderationfortheir
(a) Highresistancetocrackpropagation
(b) Vibrationresistance
((c)) Impactresistance
p
(d) Highresilience
A l
t dM t i l
AgglomeratedMaterials
y Agglomerated materials or particulate composites
IES 2009
IES2009
C
d carbides,
bid
i which
hi h particles
i l off ceramic
i
2. Cemented
in
materials, such as WC, TaC, TiC and of Cobalt and nickle,
are bonded together via Powder Metallurgy process, to
produce
cutting
d
i tooll materials.
i l Cobalt
C b l acts as the
h binder
bi d for
f
ceramic particles. During sintering, the binder melts and
forms a continuous matrix between the ceramic particles.
Thi method
This
th d is
i called
ll d as "Vitreous
"Vit
sintering",
i t i " that
th t is,
i
sintering with the formation of liquid phase.
3. Cermets (Ceramics + metals). Metals (W, Mo, Ni, Co
act as binders
bi d
and
d the
h product
d
i made
is
d by
b Powder
P d
Metallurgy method.
y The sintering
g temperature
p
is the melting
gp
point of the metal.
y In the resulting composite material, the metal contributes
high toughness and thermal shock resistance, while the
ceramic
ce
a c co
contributes
t butes higher
g e refractoriness
e acto ess aand
d ccreep
eep
resistance, superior chemical stability and abrasion
resistance.
g
p
Whichofthefollowingcompositesare
dispersionstrengthenedcomposites?
((a)) Particulatecomposites
p
(b) Laminarcomposites
(c) Fiberreinforcedcomposites
(d) Shortfiberdiscontinuouscomposites
Reinforced Materials
ReinforcedMaterials
y Reinforced materials form the biggest and most
strength properties.
properties
y Reinforcement may involve the use of a dispersed phase
or strong fibre,
fibre thread or rod.
rod
y The matrix material provides ductility and toughness
y
y
Contd
IES 2007
IES2007
IES 2002
IES2002
p
g
Woodisanaturalcompositeconsistingofwhich
ofthefollowing?
(a) Ligninfibres incollagenmatrix
(b) Ligninfibres inapatitematrix
((c)) Cellulosefibres inapatitematrix
p
(d) Cellulosefibres inligninmatrix
g
Whichofthefollowingfibre
materialsareused
forreinforcementincompositematerials?
1. Glass
2. Boroncarbide
33. Graphite
p
Selectthecorrectanswerusingthecodesgivenbelow:
((a)) 1and2
((b)) 1and3
3
(c) 2and3
(d) 1,2and3
IES 2010
IES2010
Consider the following statements regarding
composite materials:
1. Material is termed as advanced composite, if fibers are
directionally oriented and continuous.
continuous
2. Reinforced fiber glass products are strong and light
weight.
g
3. Concrete is reinforced with steel rebar, the rebar becomes
matrix.
4. Pearlitic steels are composite materials.
Which of the above statements are correct?
(a) 1, 2 and 3 only
(b) 2, 3 and 4 only
(c) 1, 2 and 4 only
(d) 1, 2, 3 and 4
IES 1999
IES1999
g
Considerthefollowingstatements:
Thestrengthofthefibre reinforcedplasticproduct
p
p
g
alone
1. Dependsuponthestrengthofthefibre
2. Dependsuponthefibre andplastic
3. Isisotropic
4. Isanisotropic
Whichofthesestatementsarecorrect?
(a) 1and3
(b) 1and4
(c) 2and3
(d) 2and4
Rev.0
Whi k
Whiskers
g crystals in the form of fine filaments, a
y Whiskers are single
y
y
y
y
IES 2011
IES2011
Whiskers are
(a) Very thin metallic particles
g crystals
(b) Very thin single
(c) Very thin polycrystals
((d)) Fiber p
particles of aspect
p ratio less than 10
Hardness
Hardness is the resistance offered by a material
to indentation.
1. Glassfibre reinforced p
plastics : Here,, we have g
glass
fibres in a matrix of unsaturated polyester.
y Glass fibrereinforced plastics are used to make : boat
hulls, Car bodies, truck, cabins and aircraft fittings.
2. CC Composites : These composites have graphite
fibres in a carbon matrix.
y This material is being used to make : Nose cone and
l d
leading
edge
d off the
h missiles
l and
d space shuttles,
h l racing
car disk brakes, aerospace turbine and jet engine
components rocket nozzles and surgical implants.
components,
implants
Contd
IES 2009
IES2009
g
Whichoneofthefollowingmaterialsisnota
composite?
(a) Wood
(b) Concrete
((c)) Plywood
y
(d) Sialon
H d
T
HardnessTest
Definition: Hardness is a very important but hard to
define property of materials.
A li i
f i f
d
i l
Applicationsofreinforcedmaterials
IES 1992
IES1992
Hardnessasafunctionofcarboncontentisshown
in
( ) g
(a)FigA
(b)Fig B
(b)FigB
IAS 2001
IAS2001
With the
off percentage
off carbon
in
th increase
i
t
b
i the
th
steel, which one of the following properties does
increase?
(a) Modulus of elasticity (b) Ductility
(c) Toughness
(d) Hardness
(c)Fig C
(c)FigC
(d)Fig D
(d)FigD
Rev.0
M h ScaleofHardness
S l fH d
Mohs
Material
Talc
Gypsum
Calcite
Fluorite
A tit
Apatite
Orthoclase
Quartz
Topaz
Corundum
Diamond
Mohs hardness
1
2
3
4
5
6
7
8
9
10
Brinell Hardnesstest
y A 10 mm tungsten carbide or hardened steel ball
intended.
y Gradually applied load.
load
y Load applied at right angle to the specimen surface
y Indentation diameter made on the specimen is
measured.
BHN =
Load
oad
=
Surface Areaof Indentation
(D
D d
y Itisbestifthethicknessofthematerialisatleast10
timesthedepth.
y Tensilestrength=kBHN MPa
k =3.296foralloysteel
3 34
=3.342forPlainCarbonsteel.
y Forsteel,flexuralendurancelimit e
e = 1.75 BHN
k f / mm2
kgf
MPa
VHN BHN
P Kgf ; D and d in mm
IES 2010
IES2010
Thehardnessoflathebedmaterialshouldbe
measuredby
db
(a)Rockwelltester
(b)Brinell hardnesstester
(c)ShoreScleroscope
(d)Vickershardnesstester
y Itcannotbeusedonveryhardorverysoftmaterial.
Rc
Contd
IES 1992
IES1992
A carbon steel having Brinell Hardness
number 100 should ultimate tensile
strength closer it
(a) 100 N/mm2
(b) 200 N/mm2
2
2
( ) 350 N/mm
(c)
N/
(d) 1000 N/mm
N/
BHN
10
R k ll H d
RockwellHardnesstest
y A sphere conical diamond cone of 120
120 angle and a
IAS 1999
IAS1999
AmeasureofRockwellhardnessisthe
(a) Depthofpenetrationofindenter
(b) Surfaceareaofindentation
(c) Projectedareaofindentation
(d) Heightofrebound
Vi k h d
Vickershardnesstest
(i) A square based diamond pyramid having 136
136
between the opposite faces is used.
((ii)) Average
g Diagonal
g
of the indention
((D)) is
measured.
VHN =
1.854
1
854 p
,
D2
p in kgf
D in mm.
Th S l
TheScleroscope
(i) Based on the rebound height of a ball from the
specimen.
((ii)) Harder the material,, higher
g
is the height
g to which
the ball rebounds.
((iii)) Scleroscope
p hardness numbers are comparable
p
only among similar materials. A comparison between
steel and rubber would not be valid.
(iii) Even
E
a light
li ht load
l d will
ill produce
d
plastic
l ti deformation
d f
ti
that so why we may use VHT on very hard material
likes Tungsten Carbide.
Carbide
Rev.0
Knoop Test(MicroHardnessTest)
y Various micro hardness tests have been developed for
IES 1992
IES1992
Herbert cloudburst Hardness test is conducted to
know
((a)) Uniformityy of hardness over a surface
(b) Softness of nonmetallic components
(c) Hardness of non
nonmetallic
metallic components
(d) Hardness at specified depth inside the surface.
Sh
F
bili T
SheetFormabilityTests
y During the various sheet metal forming processes, the
IES 1992
IES1992
Whichofthefollowingwouldyoupreferfor
checkingthehardnessofverythinsections?
((a)) Hebertcloudbursttest
(b) Shore'sScleroscope
(c) Knoop hardnesstest
(d) Vickershardnesstest
Durometer
y When
testing
soft,
Wh
i
f elastic
l i materials,
i l such
h as
rubbers and non rigid plastics, a durometer is
use
Herbert Cloudburst hardness test:
y It is used to know the uniformity of hardness
over a surface.
tests.
y Notched bar prepared as per standard from the test
material, is held in a vice and a weight is allowed to swing
from a known height in such a way that it hits the notched
bar in its path and breaks it.
y Since the material has absorbed some amount of energy
gy
during its fracture, the swinging mass loses part of its
energy and therefore will not be able to reach the same
h i ht from
height
f
where
h
it started.
t t d
y The loss in height (h) multiplied by the weight represents
the energy absorbed by the specimen during fracture,
fracture
which can be directly measured from the indicator on the
Contd
tester.
GATE 2006
GATE2006
MatchtheitemsinColumnIandColumnII.
ColumnI
ColumnII
P. Charpy test
1.
Fluidity
Q. Knoop test
2.
Microhardness
R. Spiraltest
3.
Formability
S Cuppingtest
S.
C
i t t
4.
T
Toughness
h
5.
Permeability
(a) P 4,Q 5,R 3,S 2
((c)) P 2,Q
, Q 4,
4,R 3,
3,S 5
(b)
((d))
IES 2002
IES2002
) The hardness test is a slow,, expensive
p
Assertion ((A):
method of assessing the mechanical properties of
materials.
Reason (R): The hardness is a function of yield stress
and the work hardening rate of material.
((a)) Both A and R are individuallyy 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
Rev.0
Duralumin
IES 1993
IES1993
y
pp
DuraluminAlloycontainsaluminium
andcopper
intheratioof
%Al
%Cu
(a) 94
4
((b)) 9
90
8
(c) 88
10
((d)) 86
12
M
Magnesium
i
= 0.4 0.7%,
% and
d the
th remainder
i d
i
is
aluminium.
y This alloy possesses maximum tensile strength (upto
400 MPa) after heat treatment and age hardening.
After working, if the metal is allowed to age for 3 or 4
d
days,
i will
it
ill be
b hardened.
h d
d This
Thi phenomenon
h
i known
is
k
as age hardening.
y It is widely used in wrought conditions for forging,
forging
stamping, bars, sheets, tubes and rivets.
Magnalium
IES 1992
IES1992
g
Whichofthefollowingstatementisincorrect
aboutduralumin?
(a) Itispronetoagehardening
(b) Itcanbeforged
((c)) Ithasgoodmachiningproperties
g
gp p
(d) Itislighterthanpurealuminium
proportions
p
p
of copper
pp and zinc.
y This is fundamentally a binary alloy of copper with
Contd
Hindalium
y Itisanalloyofaluminium andmagnesiumwitha
smallquantityofchromium.
IES 1992
IES1992
g
p
Additionofwhichofthefollowingimproves
machiningofcopper?
(a) Sulphur
(b) Vanadium
((c)) Tin
(d) Zinc
Rev.0
IES 1992
IES1992
g
Cartridgebrasscanbe
(a) Coldrolledintosheets
((b)) Drawnintowires
(c) Formedintotubes
(d) Anyoftheabove.
bronzes.
y The useful range of composition is 75 to 95% copper
and
d 5 to 25%
% tin.
y The metal is comparatively hard, resists surface wear
and
d can be
b shaped
h
d or rolled
ll d into
i
wires,
i
rods
d and
d sheets
h
very easily.
y In
I corrosion
i resistant
i t t properties,
ti bronzes
b
are superior
i
to brasses.
Contd
Phosphor bronze
Phosphorbronze
IES 2011
IES2011
Aluminium Bronze is also known as :
(a) Muntz metal
(b) White metal
(c) Duraluminium
((d)) Imitation g
gold
phosphor bronze.
y Phosphorus increases the strength, ductility and
soundness
d
off castings.
y This alloy possesses good wearing qualities and high
elasticity.
l i i
y A common type of phosphor bronze has the following
composition
iti
according
di to
t Indian
I di standards
t d d Copper
C
=
8790%, Tin = 910%, and Phosphorus = 0.13%.
y The material is specified for pump parts,
parts gears,
gears
springs, power screw nuts and bearings.
Gun Metal
GunMetal
IES 1992
IES1992
p
g
p
p
p
p
Thepercentageofphosphorousinphosphorbronze
is
(a) 0.1
(b) 1
(c) 11.1
(d) 98
fluidity.
y It is not suitable for being worked in the cold state but
IES 2006
IES2006
Incaseofpowerscrews,whatisthecombination
ofmaterialsusedforthescrewandthenut?
((a)) Castironscrewandmildsteelnut
(b) Carbonsteelscrewandphosphorbronzenut
(c) Castironscrewandcastironnut
(d) Aluminium screwandalloysteelnut
IES 2003
IES2003
,
j
g ,
Gunmetal,whichisusedinjournalbearings,
contains
(a) 88%Cu,10%Sn,2%Zn
(b) 80%Cu,10%Zn,10%Al
((c)) 85%Cu,5%Mg,10%Al
5
,5
g,
(d) 85%Cu,5%Sn,10%Pb
Rev.0
IES 1994
IES1994
gp
y
Whichofthefollowingpairsarecorrectly
matched?
1. SiliconsteelsTransformerstampings
2. DuraluminCookingutensils.
33. Gunmetal.................Bearings
g
Selectthecorrectanswerusingthecodesgivenbelow.
C
Codes:
(a) 1,2and3
(b) 1and2
(c) 1and3
(d) 2and3
IES 2011
IES2011
MatchListIwithListIIandselectthecorrectanswerusing
thecodegivenbelowthelists:
ListI
1 Wormwheel
1.Wormwheel
B.Phosphorbronze
2.Cylinderblock
C.Graycastiron
3.Piston
D Alallo
D.Alalloy
4 Bushings
4.Bushings
Codes
A
(a) 3
(c) 3
B
1
2
C
2
1
D
4
4
(b)
(d)
A
4
4
B
1
2
ListII
A GunMetal
A.GunMetal
Monel metal
C
2
1
D
3
3
IES 2011
IES2011
Admirality Brass is used for
(a) Condenser Tubes
(b) Rivets
(c) Piston rods
((d)) Utensils
IES 2006
IES2006
MatchListI(Composition)withListII(Application)andselect
thecorrectanswerusingthecodegivenbelowtheLists:
List I
ListII
A. Commercialbronze(10%Zn)
1.Radiator
B
B.
Redbrass(15%Zn)
2 Springmetal
2.Springmetal
C. Aluminiumbrass(22%Zn,2%Al)
3.Forgingand
stamping
D
D.
Pbronze(11%tin)smallamountofP)
4 Powerplant
4.Powerplant
andchemical
equipment
Codes: A
B
C
D
A
B
C
D
(a) 2
4
1
3
(b)
3
1
4
2
(c) 2
1
4
3
(d)
3
4
1
2
IES 2003
IES2003
y
Monel metalisanalloyof
(a) Ironandcarbon
((b)) Copperandzinc
pp
(c) Aluminium andcopper
(d) Copperandnickel
IES 2004
IES2004
y
pp
MatchListI(Alloy)withListII(Application)andselect
thecorrectanswerusingthecodesgivenbelowtheLists:
ListI
ListII
A Siliconsteel
A.
1
1.
Marinebearings
B. Highcarbonsteel
2.
Cuttingtools
C. Highspeedsteel
3.
Springs
D. Monel metal
4.
Transformer
laminations
Codes:A
B
C
D
A
B
C
D
(a) 1
2
3
4
(b) 4
3
2
1
(c) 4
2
3
1
(d) 1
3
2
4
Rev.0
Inconel
y It consists of 80% nickel, 14% chromium, and 6% iron.
y This alloy has excellent mechanical properties at
Babbit metal
y The tin base and lead base babbits are widely used as a
IES 2009
IES2009
y
y
g
Whyarebabbit
alloysusedforbearingmaterial?
(a) Theyhaveexcellentembeddability
((b)) Theyarerelativelystrongerthanotherbearing
y
y
g
g
materials
((c)) Theydonotlosestrengthwithincreasein
y
g
temperature
(d) Theyhavehighfatiguestrength
Nichrome
y It consists of 65% nickel,
nickel 15% chromium and 20% iron.
iron
y It has high heat and oxidation resistance.
y It is used in making electrical resistance wire for
IES 2011
IES2011
Babbit is an alloy of
(a) Sn, Cu, Sb and Pb
(b) Sn and Cu
(c) Sn, Cu and Pb
((d)) Sn,, Cu and Sb
IES 2008
IES2008
g
Whichoneofthefollowingiscorrect?
Babbittareusedfor
((a)) Gears
((b)) Bearings
g
(c) Bolts
(d) Clutchliners
Nimonic
y It consists of 80% nickel and 20% chromium.
y It has high strength and ability to operate under
IES 1995
IES1995
g
g
Babbit liningisusedonbrass/bronzebearingsto
(a) Increasebearingresistance
((b)) Increasecompressivestrength
p
g
(c) Provideantifrictionproperties
(d) Increasewearresistance.
IES
g
Tinbasewhitemetalsareusedwherethebearings
aresubjectedto
(a) Largesurfacewear
(b) Elevatedtemperatures.
((c)) Lightloadandpressure
g
p
(d) Highpressureandload.
Rev.0
IES 1998
IES1998
IES 2005
IES2005
MatchListI(Alloys)withListII(Applications)and
selectthecorrectanswerusingthecodesgivenbelow
l
h
h
d
b l
thelists:
ListII
List
ListII
List
II
A. Chromel
1.
Journalbearing
B. Babbit alloyy
2.
Millingcutter
g
C. Nimonic alloy
3.
Thermocouplewire
D. Highspeedsteel
4.
Gasturbineblades
Code:A
B
C
D
A
B
C
D
(a) 3
1
4
2
(b) 3
4
1
2
( ) 2
(c)
4
1
3
(d) 2
1
4
3
MatchListI(Alloy)withListII(MajorConstituent)
andselectthecorrectanswerusingthecodegiven
d l
h
h
d
belowtheLists:
ListI
ListII
A. Babbitt
1.
Nickel
B. Invar
2.
Tinandlead
C. GunMetal
3.
Aluminium
D. Duralumin
4.
Copper
Code:A
B
C
D
A
B
C
D
(a) 2
4
1
3
(b) 3
1
4
2
( ) 2
(c)
1
4
3
(d) 3
4
1
2
IES 2011
IES2011
such
The
h as steel
t l for
f automobile
t
bil bodies
b di and
d pipelines.
i li
Th use
that probably will consume most of the columbium is
microalloying.
y Relatively small amount of columbium lend high strength
to steel. The microalloyed, or highstrenght, lowalloy
(HSLA) steels,
steels are used for automobile bodies,
bodies structures
of all kinds, and highpressure pipe, particulary in the oil
and gas industry.
y Columbium
l b
with
h oxygen as dominant
d
substiutitional
b
l
alloying atoms is used in the nuclear fusion reactor.
y Nuclear material refers to the metals uranium,
uranium plutonium,
plutonium
and thorium, in any form, according to the IAEA
Columbiumisa:
(a)Nuclearmaterial
(b)Automobilematerial
(c)Filmmaterial
( )
(d)Foammaterial
y
y
Ferro electricity
Ferroelectricity
Piezo electricity
Piezoelectricity
y Piezoelectricity, or pressure electricity, is defined as
Nimonic 90
y A precipitation hardenable nickelchromiumcobalt alloy,
off electric
by
in
l t i dipoles
di l
b their
th i mutual
t l interaction
i t
ti
i the
th
absence of an applied electric field.
y This arises from the fact that the local field increases in
proportion to the polarization. Thus, ferroelectric
materials must posses permanent dipoles. Ex.: BaTiO3,
Rochelle salt (NaKC4H4O6.4H2O), potassium dihydrogen
phosphate (KH2PO4), potassium niobate (KNbO3).
y These
Th
materials
t i l have
h
extremely
t
l high
hi h dielectric
di l t i constants
t t att
relatively low applied field frequencies.
y Thus,
Thus capacitors made from ferro
ferroelectric
electric materials are
smaller than capacitors made of other dielectric materials.
IES 2007
IES2007
MatchListIwithListIIandselectthecorrectanswerusingthecode
givenbelowtheLists:
ListI
ListII
(Component)
(RequiredProperty)
A.
Bladesofbulldozer
1.
Highwearresistanceand
g
hightoughness
B.
Gasturbineblades
2.
LowYoungsmodulusand
highfatiguestrength
C
C.
Drillbit
3
3.
Highwearandabrasion
resistance
D.
Springsofautomobiles
4.
Highcreepstrengthand
goodcorrosionresistance
Code: A
B
C
D
A
B
C
D
(a) 3
2
1
4
(b)
1
4
3
2
(b) 3
4
1
2
(d)
1
2
3
4
having
strength
att
h i high
hi h stressrupture
t
t
t
th and
d creep resistance
i t
elevated temperatures up to about 950 C.
For springs exposed to lower loads,
loads the material can be used
up to 700 C.
Nimonic 9
90 offers g
good resistance to corrosion and is non
magnetic.
Applications include the aircraft industry, gas turbines,
vehicle
h l components and
d springs in high
h h temperature
environments, and thermal.
Operating temperature: 100
100 + 550 C
IES 1993
IES1993
Q
Quartzisa
(a) Ferroelectricmaterial
((b)) Ferromagneticmaterial
g
(c) Piezoelectricmaterial
(d) Diamagneticmaterial
Rev.0
Welding cracks
Weldingcracks
y Cracksmayoccuratthefollowinglocations:
(i)Intheweld(Fuse)MetalZone
(ii)IntheBasemetalzone
(iii)S
(iii)Sometimes,thecracksoriginateinoneZoneand
ti
th
k i i t i
Z
d
thenspreadtotheotherZone.
y Cracksinthebasemetalusuallyoccuratlow
y Coldcrackingcanoccurdueanytothefollowing
temperatures(around200C)andareknownasCold
cracks.
y Ontheotherhand,thecracksintheweldmetalzone
occurwhilethemetalisstillveryhot.Suchcracksare
hil h
li ill
h S h
k
calledHotcracks.
y Cracksintheweldmaybeduetostructuralstressesin
C k i th ld
b d t t t l t
i
themetal(forexample,theformationofmartensite),
heavyshrinkage extrahighamountofsulphur
heavyshrinkage,extrahighamountofsulphur,
phosphorousorcarboninthemetal,excessivelyrigid
clampingofthepartsbeingweldedorthepresenceof
p g
p
g
p
gasesintheweldmetal.
severalfactors: improperweldingconditions,the
presenceofgasandotherimpuritiesintheweld,
f d h i
i i i h ld
wrongchoiceoffillerrodandmetallurgicalfactors
suchasexcessivecoolingrateresultinginthe
formationofmartensiteandformationofbrittle
phasesintheweldwhencoldortheformationof
phaseswhicharebrittleathightemperatures
h
hi h b ittl thi ht
t
[Allotropictransformations].
y Cracksinthebasemetalcanoccurduetothe
followingreasons: Corrosion,Basemetaldefects,
Basemetalcompositionvariations,hydrogen
embrittlement
bi l
andinternalstressessetupdueto
di
l
d
restrainedshrinkingafterwelding.
Contd
IES 2005
IES2005
ot c ac s occu
t e e d a d us o o e as t e
Hotcracksoccurintheweldandfusionzoneasthe
metalsolidifies.Whichofthefollowingarethecauses
forhotcracks?
1. Presenceofsulphur andphosphorusinthebasemetal
2. Highcarbonoralloycontentofthebasemetal
3. Moistureinthejointorelectrode
4. Jointrestraint
Selectthecorrectanswerusingthecodegivenbelow:
l
h
h
d
b l
(a) 1,2and4
(b) 1,2and3
( ) 3and4
(c)
d
(d) 1,2,3and4
d
Contd
H
bi l
dP i i
Hembrittlement
andPassivity
yd oge e b tt e e t isformoffailurethan
s o o a u et a
y Hydrogenembrittlement
corrosion,but occursasaresultofhydrogenproduced
duringcorrosion.Atomichydrogendiffusesintocrystals
andinhibitsdislocationmotion,causingfailure.
di hibi di l
i
i
i f il
y Countermeasures:heattreatment;removalofhydrogen
source.
source
y Passivity:Itisformprotectionagainstcorrosion.Itresults
,
g
y
fromthin,strongadherentoxidelayerformedoverthe
surface.UsuallyobservedinAl,Cr,Fe,Ni,Tiandtheir
alloys.Passivelayersmaygetdamagedduringmechanical
vibrations,andsothesemetalsarepronetoerosion
ib i
d h
l
i
corrosion.
IES 2006
IES2006
Otherquestions
Incaseofpowerscrews,whatisthecombination
ofmaterialsusedforthescrewandthenut?
((a)) Castironscrewandmildsteelnut
(b) Carbonsteelscrewandphosphorbronzenut
(c) Castironscrewandcastironnut
(d) Aluminium screwandalloysteelnut
IES 1992
IES1992
Presenceofhydrogeninsteelcauses
(a) Reducedneutronabsorptioncrosssection
(b)improvedweldability
(c) Embrittlement
(d)corrosionresistance
IES 1992
IES1992
Forthepipefittinglikeelbow,tee,unionetc.
whichofthefollowingispreferred?
((a)) Pigiron
g
(b) Malleableiron
(c) Spheroidal graphitecastiron
(d) Highcarbonsteel
Rev.0
IES 1992
IES1992
g
p yp p
Whichofthefollowingdisplaypropertiessimilar
tothatofsteel
1. Blackheartcastiron
2. Whiteheartcastiron
33. Graycastiron
y
4. Pigiron
((a)) 1and2onlyy
((b)
) 33and4only
4
y
(c) 2and4only
(d) 1and3only
IES 1992
IES1992
g
p
Additionofwhichofthefollowingimproves
machiningofcopper?
(a) Sulphur
(b) Vanadium
((c)) Tin
(d) Zinc
IES 2006
IES2006
p
g
g
Disruptivestrengthisthemaximumstrengthofa
metal,when
(a) Subjectedto3principaltensilestressesatright
anglestooneanotherandofequalmagnitude
(b) Loadedintension
(c) Loadedincompression
(d) Loadedinshear
IAS 1996
IAS1996
IAS 1998
IAS1998
IES 1996
IES1996
MatchListIwithListIIandselectthecorrectanswer
usingthecodesgivenbelowthelists:
h
d
b l
h l
ListI(Cuttingtools)
ListII(Majorconstituent)
A Stellite
A.
l
l.
Tungsten
B. H.S.S.
2.
Cobalt
C. Ceramic
3.
Alumina
D. DCON
4.
Columbium
5.
Titanium
Codes:A B
C
D
A
B
C
D
(a) 5
1
3
4
(b)
2
1
4
3
( ) 2
(c)
1
3
4
( )
(d)
2
5
3
4
Whichofthefollowingmethodsaresuitablefor
theproductionofsuperalloys?
1. Atomizationfrommoltenstateusinginertgas.
2. Atomizationusingplasmaarcandrotating
A
i i i l
d
i
electrode.
3 Reductionandcrushing.
3.
Reductionandcrushing
Selectthecorrectanswerusingthecodesgivenbelow:
Codes:
(a) 1and2
(b) 2and3
(c) 1and3
(d) 1,2and3
Thelimittothemaximumhardnessofawork
materialwhichcanbemachinedwithHSStools
evenatlowspeedsissetbywhichoneofthe
f ll i
followingtoolfailuremechanisms?
lf il
h i
(a) Attrition
(b) Abrasion
(c) Diffusion
(d) Plasticdeformationundercompression.
GATE 2002
GATE2002
y
g
Theductilityofamaterialwithworkhardening
(a) Increases
(b) Decreases
((c)) Remainsunaffected
((d)) Unpredictable
p
IES 2009
IES2009
p
g yp
Nano compositematerialsarehighlypreferablein
designconsiderationfortheir
(a) Highresistancetocrackpropagation
(b) Vibrationresistance
((c)) Impactresistance
p
(d) Highresilience
IES 1992
IES1992
Machinetoolframeshouldhave
(a) Highrigiditytoweightratio
((b)) Graphiteintheformofnodules
p
(c) Lowhardness
(d) Highworkhardness
Rev.0
GATE 1995
GATE1995
g
Machinetoolstructuresaremade..forhigh
processcapability.(tough/strong/rigid)
IES 2011
IES2011
Materialswhichshowdirectiondependentpropertiesare
called:
(a)Homogeneous
(b)Viscoelastic
(c)Isotropic
(d)Anisotropic
IES 2009
IES2009
gp
p p y
Whichoneofthefollowingpossessestheproperty
ofnonsparking character?
(a) Hadfield'smanganesesteel (b) Springsteel
(c) Stellite
(d) Invar
IES 2011
IES2011
Lead is widely used in:
(a) Transformers
g
(b) Switch gear
(c) Galvanized pipes
((d)) Batteries
JWM 2010
JWM2010
Considerthefollowingpropertiesofengineering
materials
1.Density
2.Conductivity
C d ti it
3.Elasticity
4.Hardness
H d
5.Ductility
Whichofthesearemechanicalpropertiesofa
material?
( ) d l (b) d
(a)1,2and4only(b)1,2,3and4
(c)3,4and5(d)2,4and5
IES 2011
IES2011
Match List I with List II and select the correct answer using
the code given below the lists :
ListI
A.System
y
1.Freeenergyisaminimum
gy
B.Phase
2.Chemicalelementsorchemical
compounds
3.Consistsofsolids,liquidsorgassesortheir
combination
4.Homogeneousportionofasystemthat
hasuniformphysicalcharacteristics
C
D
A
B
C
D
C.Phase
equilibrium
D.Components
Codes
A
(a) 2
(c) 2
GATE2005
When
off a solid
Wh the
th temperature
t
t
lid metal
t l increases
i
(a) Strength of the metal decreases but ductility
increases
(b) Both strength and ductility of the metal decrease
( ) Both
(c)
B th strength
t
th and
d ductility
d tilit off the
th metal
t l increase
i
(d) Strength of the metal increases but ductility
decreases
ListII
IAS1998
Magnesiumisextrudedandnotrolledbecause
M
i
i t d d d t ll db
(a) Ithasalowmeltingpoint
(b) Ithasalowdensity
I h l d i
(c) Itsreactivitywithrollmaterialishigh
( ) Ithasadosepackedhexagonalstructure
(d)
B
1
4
4
1
3
3
(b)
(d)
3
3
1
4
4
1
2
2
IES 2011
IES2011
Match List I with List II and select the correct answer using
the code given below the lists :
ListI
ListII
A.Elasticityy
1.Deformnonelasticallywithoutfracture
y
B.Malleability
2.Undergoplasticdeformationundertensile
load
3.Undergoplasticdeformationunder
compressiveload
4.Returntoitsoriginalshapeonunloading
C.Ductility
D.Plasticity
Codes
A
B
(a) 1
2
(c) 1
3
C
3
2
D
4
4
(b)
(d)
A
4
4
B
2
3
Rev.0
C
3
2
D
1
1
IES 2011
IES2011
Injection moulding process used to produce
thermoplastic matrix composites with fibre
reinforcement normally gives:
( ) Short
(a)
h fibre
f b composites
(b) Two layer structure composites
(c) Continuous fibre composites
(d) Single layer composites
IES 2011
IES2011
Assertion (A) : Solid solutions of metal are
crystall whose
properties
to those
off
h
i are close
l
h
the solvent.
Reason (R) : They retain the same crystal lattice
and type of bond.
((a)) Both A and R are individuallyy true and R is the
correct explanation of A
(b) Both A and R are individually true but R is NOT
the
h correct explanation
l
i off A
(c) A is true but R is false
(d) A is
i false
f l but
b t R is
i true
t
JWM 2010
JWM2010
IES 2010
IES2010
Assertion(A):Electricarcfurnacecanbeusedfor
acidandbasicmethodofsteelmaking.
acidandbasicmethodofsteelmaking
Reason(R):Impuritiesareeliminatedextensively
inacidareprocess.
inacidareprocess
IES 2010
IES2010
The correct statement is
(a) Characteristic of any series of alloys cannot be
found by phase diagram.
(b) Phase diagram does not give amount of
phases which are a function of composition,
p
p
,
temperature and pressure.
(c) The phase may be liquid or vapour with
ordered crystal structure.
(d) Phase diagram provides the information on
how rapidly equilibrium is reached.
The End
TheEnd
Rev.0