UNIT - I: Fundamentals of Machining
2 Marks Questions:
- Define tool signature and explain its importance in single point cutting tools.
- What are the different types of chips formed during metal cutting?
- State Taylor's tool life equation and explain its significance.
5 Marks Questions:
- Explain the mechanism of metal cutting with neat sketches showing different types of chips formed.
- Draw and explain Merchant's force diagram for orthogonal cutting process.
- Derive the relationship between cutting forces in orthogonal cutting and explain the mechanics involved.
- Explain the different tool wear mechanisms and factors affecting tool life with Taylor's equation.
- Discuss the economics of machining including tool materials, coolants and their properties.
- Compare orthogonal and oblique cutting processes with their applications and advantages.
UNIT - II: Lathe, Shaping, Slotting and Planning Machines
2 Marks Questions:
- What are the main specifications of a lathe machine?
- Explain the slider crank mechanism used in shaping machines.
- List the different taper turning methods on lathe.
5 Marks Questions:
- Explain the construction and working principle of engine lathe with neat diagram.
- Describe the different types of lathe machines and their applications.
- Explain various lathe operations including taper turning and thread cutting methods.
- Describe the construction and working principle of shaping machine with slider crank mechanism.
- Calculate machining time for different operations on shaping and planning machines.
- Compare shaping, slotting and planning machines with their specifications and operations.
UNIT - III: Drilling, Boring and Milling Machines
2 Marks Questions:
- What are the different types of drilling machines?
- Explain the classification of milling machines.
- Define indexing and state its types in milling operations.
5 Marks Questions:
- Explain the construction and working principle of drilling machines with different types.
- Describe various drilling operations and calculate machining time for drilling processes.
- Explain the principle of working and specifications of milling machines.
- Describe different milling methods and types of milling cutters used.
- Explain various methods of indexing in milling machines with calculations.
- Compare drilling and boring machines with their types and applications.
UNIT - IV: Finishing Processes & Systems of Limits and Fits
2 Marks Questions:
- What are the different types of fits in limit system?
- Explain Taylor's principle of gauge design.
- Define unilateral and bilateral tolerance systems.
5 Marks Questions:
- Classify grinding machines and explain types of abrasives and bonds used in grinding wheels.
- Explain the specification and selection criteria for grinding wheels.
- Compare lapping, honing and broaching operations with grinding processes.
- Explain hole basis and shaft basis systems with numerical problems on limits and fits.
- Describe the International Standard System of tolerances and interchangeability concepts.
- Design go and no-go gauges including plug, ring, snap, gap, taper and profile gauges.
UNIT - V: Angular Measurement, Surface Roughness & Optical Instruments
2 Marks Questions:
- What is the difference between surface roughness and surface waviness?
- Explain the working principle of sine bar.
- List the ISI symbols used for surface finish representation.
5 Marks Questions:
- Explain angular measuring instruments including bevel protractor, angle slip gauges and angle dekkor.
- Describe the construction and working of sine bar and sine table for angular measurements.
- Explain surface roughness measurement techniques and numerical assessment methods.
- Describe the working principle and applications of Profilograph and Talysurf instruments.
- Explain optical measuring instruments including tool maker's microscope and autocollimators.
- Describe optical projector, optical flats and optical comparators with their merits and demerits.