Question 1

Drilling tools for nonferrous soft metals: Which drill type is most suitable for drilling brass, copper, and other softer ductile materials (to avoid grabbing and ensure a smooth, accurate hole)?

Accepted Answer

Introduction / Context: Machining nonferrous soft metals like brass and copper presents unique challenges: these alloys are ductile, generate continuous chips, and can 'grab' a conventional helical twist drill. Selecting the correct drill geometry is essential to prevent self-feeding, maintain dimensional accuracy, and protect the work surface from burrs. Given Data / Assumptions: Work materials: brass, copper, and similar soft nonferrous alloys. Target: smooth hole entry, controlled chip formation, minimal grabbing. Standard shop drilling setup (manual or machine drill press). Concept / Approach: Conventional twist drills have helical flutes and positive rake that tends to pull the tool into soft materials, causing oversize holes or chatter. A straight fluted drill provides a neutral or lower effective rake at the cutting edge. This reduces the self-feeding tendency and stabilizes cutting forces, improving accuracy and finish. Flat drills and general-purpose twist drills may work, but they are not optimal for the anti-grab requirement in soft metals. Step-by-Step Solution: Identify problem → soft alloys tend to grab a helical, positive-rake drill.Relate geometry → straight flutes reduce effective rake and chip lift, preventing self-feeding.Select tool → straight fluted drill is the preferred choice for brass/copper. Verification / Alternative check: Many shop manuals recommend either straight fluted drills or modifying rake (dubbed cutting edges) on standard twist drills to neutral rake for brass. Both practices aim at the same physics: reduce grabbing by reducing rake and chip lift. Why Other Options Are Wrong: Flat drill: poor guidance; not standard for precision holes in soft metals. Parallel/tapered shank twist drills: still helical and prone to grabbing. Zero-rake masonry drill: wrong material and edge geometry for metals. Common Pitfalls: Using aggressive positive rake and high feed in brass leads to corkscrew chips and self-feeding. Always secure the work, use appropriate speed, and consider light dubbing if using a helical drill. Final Answer: straight fluted drill

Question 2

Tool wear mechanisms: On which regions of a single-point cutting tool does flank wear primarily occur during metal cutting?

Accepted Answer

Introduction / Context: Tool wear governs surface finish, dimensional accuracy, cutting forces, and tool life. Two dominant wear types on single-point tools are crater wear (on the rake face) and flank wear (on the relief faces). Understanding where flank wear appears helps in setting change criteria and selecting cutting conditions. Given Data / Assumptions: Continuous turning with a single-point tool. Typical steels/nonferrous alloys, no severe build-up edge assumed. Normal feeds and speeds. Concept / Approach: Flank wear is abrasion/adhesion wear on the relief faces that rub against the newly generated work surface. It is measured as land width on the side and end relief faces and is usually most pronounced at/near the tool nose where contact pressure and temperature are highest. Crater wear, by contrast, forms on the rake face due to chip flow and is a different indicator. Step-by-Step Solution: Identify wear type → flank wear = relief face rubbing.Locate rubbing interfaces → side and end (front) relief faces against the work.Recognize stress concentration → highest near the tool nose → visible wear land there. Verification / Alternative check: Inspection under a toolmaker’s microscope shows a bright, flattened land on the side/end relief faces, greatest at the nose. ISO wear criterion often limits VB (average flank wear land) and VBN (nose wear). Why Other Options Are Wrong: Rake-face-only wear away from edge describes crater wear, not flank wear. Wear exactly along a sharp line is unrealistic; flank wear forms a finite land. Chisel point/rake-only statements misidentify the mechanism. Shank wear is irrelevant to cutting performance. Common Pitfalls: Confusing crater and flank wear; measuring only nose recession and ignoring side land; running tools until catastrophic chipping instead of using VB limits. Final Answer: Nose region, front (end) relief face, and side relief face

Question 3

Tapping drill size rule: “The hole drilled for tapping should be smaller than the tap size by twice the thread depth.” Evaluate this statement for standard metric/Unified 60° threads.

Accepted Answer

Introduction / Context: Selecting the correct tapping drill size is critical. If the pilot hole is too small, taps break; if too large, thread engagement is insufficient. A common shop approximation uses the pitch, not “twice the thread depth,” particularly for 60° metric and Unified threads. Given Data / Assumptions: Standard 60° V threads (metric/Unified). Conventional percentage of thread engagement (typically 60–75%). Through or blind holes with suitable chamfering and lubrication. Concept / Approach: For 60° threads, an accepted quick rule is: tapping drill diameter ≈ major diameter − pitch. This ties directly to thread geometry where the fundamental triangle height is related to pitch, and practical engagement (not the theoretical full depth) is targeted to reduce torque. Saying “smaller by twice the depth of thread” overestimates removal and leads to an undersized drill, excessive torque, and potential tap failure. Step-by-Step Solution: Identify correct rule → tapping drill ≈ major diameter − pitch.Compare with statement → “minus twice depth” would produce a much smaller hole.Conclude → statement is incorrect for standard practice. Verification / Alternative check: Handbook tables corroborate the approximation and provide exact recommended drill sizes for specific engagement percentages. Practical experience shows dramatic torque rise if the hole is made too small relative to pitch-based recommendations. Why Other Options Are Wrong: Limiting agreement to coarse/fine/trapezoidal threads is misleading; these thread forms have specific geometry, but none uses “twice thread depth” as the general drilling rule for tapping standard 60° forms. Common Pitfalls: Confusing thread “height” with usable depth; assuming 100% engagement is desirable; ignoring material, lubrication, and tap type (spiral point/spiral flute) when selecting the drill. Final Answer: Disagree

Question 4

Cutting tool geometry statements: Identify the WRONG statement regarding rake angles, side cutting edge angle, and nose radius effects in turning.

Accepted Answer

Introduction / Context: Tool geometry (rake, relief, approach angle, and nose radius) strongly influences chip formation, forces, temperature, and surface finish. Some trends are well known: insufficient rake increases rubbing, and larger nose radii often improve tool life up to a limit. This question asks you to pick the incorrect statement based on these principles. Given Data / Assumptions: Single-point turning tool on steel. Normal feeds/depths of cut; machine rigidity is adequate. Continuous cutting without severe interruption. Concept / Approach: Side rake reduces shear deformation and cutting force but thins the edge as it increases, risking chipping at extremes. Very small rake raises ploughing and wear. The side cutting edge angle influences chip width and load distribution; too small an angle can focus load and hamper chip flow. Nose radius strengthens the tip, improves finish, and often prolongs life unless chatter or high radial forces occur from excessive radius. Step-by-Step Solution: Evaluate each statement with known trends.Note that increasing nose radius typically improves life and finish (to a practical limit).Therefore “increasing nose radius decreases tool life” is the wrong statement. Verification / Alternative check: Handbooks recommend larger nose radii for roughing (within rigidity limits) precisely to enhance edge strength and distribute heat; finishing uses small to moderate radii for surface quality control. Why Other Options Are Wrong: (a) Accurate: excessive side rake can weaken the edge. (b) Accurate: low rake increases rubbing and wear. (c) Overly small approach angles can reduce life; the claim that “less than 15° increases life” is not generally true, but among the choices, (d) is the clearly incorrect engineering trend. (e) Reasonable and commonly recommended. Common Pitfalls: Assuming “more is better” for any angle; ignoring machine rigidity and chatter when selecting nose radius; failing to balance finish requirements with edge strength. Final Answer: Increasing the nose radius decreases tool life.

Question 5

Lathe speed selection: In which situations is it necessary to select a slow spindle speed on a lathe?

Accepted Answer

Introduction / Context: Spindle speed affects cutting speed at the tool–work interface. Excessive surface speed causes overheating, rapid tool wear, and dimensional errors. Lathes require careful speed selection, especially during thread cutting, on large diameters, or with hard/tough materials. Given Data / Assumptions: Turning with a single-point tool. Target is safe cutting speed and accurate geometry. Conventional HSS/carbide tooling. Concept / Approach: Cutting speed (m/min) = pi * diameter * rpm / 1000. For a fixed rpm, larger diameters generate higher surface speeds, so rpm must be reduced. Thread cutting demands coordinated tool advance with the lead; lower rpm gives control and prevents tool crash at thread roots. Hard/tough materials require lower surface speeds to limit tool temperature and preserve edge integrity. Step-by-Step Solution: For large diameter → reduce rpm to maintain recommended cutting speed.For thread cutting → lower rpm aids synchronization and avoids tool damage.For hard/tough materials → reduce speed to limit wear and thermal softening. Verification / Alternative check: Tool data charts list recommended speeds significantly lower for hard alloys; threading procedures universally suggest slow speeds, especially for manual lathes. Why Other Options Are Wrong: Each individual option (a, b, c) is correct, so the comprehensive choice “all of these” is the best answer. Common Pitfalls: Keeping rpm fixed when changing work diameter; attempting high-speed threading; ignoring coolant and feed adjustments when speed is lowered. Final Answer: all of these

Question 6

Determinants of tool life: Which parameters significantly affect the life of a single-point cutting tool in turning?

Accepted Answer

Introduction / Context: Tool life determines productivity and cost. While cutting speed is the most dominant variable in the Taylor tool life equation, feed and depth of cut also influence heat generation, chip load, and contact stresses, thereby affecting wear mechanisms and life. Given Data / Assumptions: Turning with HSS/carbide tools. Steady state, continuous cutting. Acceptable chip control and coolant application. Concept / Approach: Taylor’s relation V * T^n = C highlights speed sensitivity. However, increasing feed raises chip thickness, forces, and temperature; increasing depth of cut expands the contact area and may shift wear from flank to notch/crater and increase power demands. All three parameters interact with material, tool grade, and cooling to set practical life. Step-by-Step Solution: Recognize speed dominance → higher speed usually shortens life exponentially.Account for feed → higher feed increases heat and edge loading → shorter life.Account for depth → larger depth elevates forces and may accelerate wear and chipping. Verification / Alternative check: Machining handbooks and manufacturer data provide tool life maps vs. speed, feed, and depth, confirming significant, coupled effects. Why Other Options Are Wrong: Choosing only one parameter ignores the practical multi-variable nature of wear and life; “none of these” is clearly false. Common Pitfalls: Optimizing speed without adjusting feed/depth; ignoring machine rigidity and chatter limits; overlooking coolant’s role in life extension. Final Answer: all of these

Question 7

EDM tool (electrode) materials: In electro-discharge machining, which of the following are commonly used electrode materials?

Accepted Answer

Introduction / Context: Electro-discharge machining (EDM) removes material by controlled spark erosion between a shaped electrode and the workpiece. Electrode material selection affects wear rate, machinability of the electrode itself, electrical/thermal properties, and ability to hold fine detail. Given Data / Assumptions: Sinker EDM context. Work materials may be hardened steels, superalloys, or carbides. Normal dielectric fluids and power settings. Concept / Approach: Common electrodes include copper (excellent conductivity and finish), brass (cost-effective, good for small holes and fine details), copper–tungsten (high temperature strength and good wear resistance), and graphite (very common for complex cavities with good wear behavior). The best choice balances electrode wear, detail fidelity, and surface finish targets. Step-by-Step Solution: List standard electrode materials → brass, copper, Cu–W, graphite.Match to applications → copper for fine finish, brass for ease, Cu–W for heat resistance, graphite for complex cavities.Conclude → all listed metals are valid EDM electrode choices. Verification / Alternative check: EDM vendor catalogs consistently offer brass tubes (for EDM drilling), oxygen-free copper plates/rods, and Cu–W grades for wear-resistant electrodes, alongside many graphite grades. Why Other Options Are Wrong: “Graphite only” is incorrect; metals listed are widely used. Any single choice would be incomplete, hence “all of these” is correct. Common Pitfalls: Ignoring electrode wear compensation in toolpathing; selecting copper in delicate thin-ribs where graphite may be stiffer/lighter; overlooking flushing design that interacts with material choice. Final Answer: all of these

Question 8

Cutting speed with HSS tools: For which material is the recommended cutting speed generally the highest when machining with high-speed steel tooling?

Accepted Answer

Introduction / Context: Cutting speed guidelines depend on tool material and work material. With high-speed steel (HSS) tools, soft, thermally conductive, non-hardening materials typically permit the highest surface speeds before tool softening and wear mechanisms become limiting. Among the listed options, aluminium commonly allows the highest speeds. Given Data / Assumptions: Dry or light coolant conditions. Sharp HSS tooling, conventional turning/milling. Average machinability grades for each material class. Concept / Approach: Aluminium alloys have good machinability, low yield strength, and high thermal conductivity, enabling higher safe cutting speeds with HSS. Brass also machines well but is often run somewhat slower than aluminium with HSS to avoid smearing and to maintain edge integrity. Cast iron and steels require lower speeds due to abrasive constituents, higher strength, and heat generation. Austenitic stainless steels are the most speed-limited due to work-hardening and poor thermal conductivity. Step-by-Step Solution: Rank typical HSS speed ranges → Aluminium > Brass > Mild steel > Cast iron > Austenitic stainless.Select the highest → Aluminium. Verification / Alternative check: Shop charts often show aluminium with HSS in the 90–200 m/min range (or higher in favorable cases), brass in moderate-high ranges, mild steel lower, and stainless/cast iron lower still. Why Other Options Are Wrong: Cast iron and steels have lower allowable speeds due to wear and heat; brass is good but typically below aluminium with HSS; austenitic stainless is notably speed sensitive. Common Pitfalls: Running too slow on aluminium causing built-up edge; using unpolished cutting edges that smear aluminium; neglecting coolant or chip evacuation leading to poor finish even at proper speeds. Final Answer: Aluminium

Question 9

Relief (clearance) angles for HSS single-point tools: What is the usual range of relief angles on high-speed steel turning tools?

Accepted Answer

Introduction / Context: Relief (clearance) angles prevent rubbing of the flank against the freshly machined surface. Too little relief causes friction and heat; too much relief weakens the edge. For HSS tools in general turning, moderate relief angles are used to balance edge strength and friction control. Given Data / Assumptions: Standard single-point HSS tools. General purpose turning of steels and nonferrous alloys. Normal feeds and depths. Concept / Approach: Typical end and side relief angles for HSS fall within modest ranges, commonly around 5–8 degrees, with some variation depending on material and operation (finishing vs roughing). Angles below about 3° risk rubbing; above about 10° can over-sharpen and weaken the edge, leading to chipping. Step-by-Step Solution: Identify practical range → mid-single digits to around ten degrees.Match to options → 3° to 10° fits the common handbook values. Verification / Alternative check: Tool grinding charts list typical side/end relief in the ~5–12° band depending on work material; most general-purpose tools are ground near 5–8°. Why Other Options Are Wrong: 0–3° is too low (rubbing); 10–20° or more is excessive for general HSS turning and reduces edge strength; very large values are reserved for special cases. Common Pitfalls: Confusing rake with relief; using excessive relief to “cure” chatter (which actually weakens the edge and can worsen chatter if rigidity is the root cause). Final Answer: 3° to 10°

Question 10

Twist drill geometry: The lip clearance (relief) angle of a drill is defined as the angle between which two elements?

Accepted Answer

Introduction / Context: Lip clearance (also called relief) on a twist drill ensures that only the cutting lips contact the work, while the flank behind the edge clears the fresh surface. Correct understanding of the angle's definition supports proper grinding and troubleshooting of drill performance (e.g., rubbing, overheating). Given Data / Assumptions: Standard two-flute twist drill. Conventional point geometry and helix. Measurement near the periphery unless otherwise specified. Concept / Approach: The lip clearance angle is measured between the flank surface behind the cutting lip and a plane normal to the drill axis (i.e., a plane perpendicular to the axis). This geometry provides clearance to prevent rubbing while maintaining edge strength. Other angles—rake, point, chisel—are important but are defined differently. Step-by-Step Solution: Identify the flank → surface immediately behind each cutting lip.Identify reference plane → plane perpendicular to the drill axis at the point.Define angle → between flank and that perpendicular plane = lip clearance. Verification / Alternative check: Drill point gauges and standards specify lip clearance seen in end view and side view; correct grinding shows a relief that increases from chisel toward periphery and is referenced to a plane normal to the axis. Why Other Options Are Wrong: (a) Land leading edge reference is not the standard definition. (c) Chisel edge relation defines chisel angle, not clearance. (d) Rake face vs. axis corresponds to helix/rake relationships. (e) Helix vs. centerline defines helix angle, not lip clearance. Common Pitfalls: Unequal lip clearance on the two lips causes one lip to do most of the cutting, leading to oversize holes and rapid wear; verify symmetry during sharpening. Final Answer: Flank (relief) surface and a plane at right angles to the drill axis

Question 11

Reaming as a finishing process in machining Compared with drilling or boring, which statement best captures the primary advantages and characteristics of the reaming operation?

Accepted Answer

Introduction / Context: Reaming is a precision finishing operation used after drilling or boring to bring a hole to an accurate size with an improved surface finish. Unlike roughing operations, reaming removes a very small allowance and is designed primarily for quality rather than speed. This question evaluates your understanding of what reaming actually achieves on a workpiece. Given Data / Assumptions: Reaming follows a pre-formed hole (drilled or bored). Only a small allowance (typically 0.1 mm to 0.5 mm, depending on diameter) is left for reaming. Goal is accuracy and finish, not bulk metal removal. Concept / Approach: The performance indicators for reaming are dimensional accuracy (size control), form/roundness improvement in a modest sense, and a much smoother surface. Since allowance is small, the metal removal rate is inherently low. Selecting the best option requires recognizing that several of these benefits occur together in a properly set up reaming operation. Step-by-Step Solution: Identify the nature of reaming: a finishing, sizing, and smoothing process.Link low removal rate to the small allowance characteristic of finishing operations.Link high surface finish to multi-tooth, low feed/low chip thickness action of a reamer.Link high dimensional accuracy to guided tool geometry and minimal deflection.Therefore, all listed positive effects apply simultaneously. Verification / Alternative check: Inspection after reaming usually shows a tighter tolerance band and a lower roughness average than after drilling. Production handbooks specify typical H7/H8 grades after reaming (depending on setup), confirming accuracy and finish improvements. Why Other Options Are Wrong: Options (a), (b), and (c) are individually true but incomplete; reaming confers all three advantages at once. Option (e) is the opposite of reaming’s purpose. Common Pitfalls: Leaving too much allowance (causing chatter) or too little (tool rubs and burnsish only). Misalignment of the pre-formed hole can limit form correction; reaming improves size and finish but does not relocate a badly off-axis hole. Final Answer: All of the above

Question 12

Flat (spade) drill geometry The cutting (point) angle commonly used on a flat drill generally varies over which range?

Accepted Answer

Introduction / Context: The cutting angle (often called the point angle) of a drill strongly influences cutting forces, chip formation, and guidance. Flat or spade-type drills use relatively large point angles to provide strength at the cutting edge and to accommodate a variety of materials. Given Data / Assumptions: Flat (spade) drill used for general-purpose drilling. Conventional practice for steels and nonferrous alloys. Normal shop grinding without special-purpose geometry. Concept / Approach: Point angle increases tool strength and changes thrust vs. torque balance. Spade drills typically employ a relatively obtuse angle, commonly around 90° to roughly 118°, extending to as high as 120° for specific applications, balancing chisel-edge length and lip loading. Step-by-Step Solution: Identify realistic ranges used in practice for spade drills.Exclude very small angles (3°–30°) as these are for rake/clearance, not point angles.Select the wide, commonly adopted range covering 90° to about 120°. Verification / Alternative check: Tooling catalogs list recommended point angles near 90°–118° for spade drills, with 118° a common standard similar to twist drills for many materials. Why Other Options Are Wrong: 3°–8° and 20°–30° are not point angles; they resemble clearance/relief angle values. 60°–90° is too acute for most spade drilling in metals. 130°–150° is reserved for very hard or special materials and is not the general flat drill recommendation. Common Pitfalls: Confusing point angle with rake or clearance; using an overly acute angle causes weak lips and high thrust, while overly obtuse angles may increase rubbing at low feeds. Final Answer: 90° to 120°

Question 13

Fundamental mechanism of chip formation in machining In metal cutting operations (turning, milling, drilling), chips are formed primarily due to which material behavior?

Accepted Answer

Introduction / Context: Understanding how chips form is central to machining science. Chips separate from the workpiece along a shear plane under significant compressive and shear stresses at the tool–work interface. This behavior determines forces, temperature, surface integrity, and tool wear. Given Data / Assumptions: Conventional cutting with sharp tools at typical speeds. Homogeneous metallic work material. No special processes like EDM or laser cutting. Concept / Approach: Chip formation is governed by plastic deformation. Material ahead of the cutting edge is forced to shear along a narrow zone (primary shear zone). Elastic deformation occurs first but is small; once yield is exceeded, plastic deformation accommodates chip flow over the rake face. Step-by-Step Solution: Tool engages work; stress builds ahead of the tool.Material yields and shears plastically along a shear plane.Chip slides over the rake face with secondary deformation and frictional heating.After removal, elastic recovery affects the final machined dimension slightly. Verification / Alternative check: Metallographic examination shows severe plastic strain and heat-affected bands in chips. Specific cutting energy models also assume plastic work plus friction work. Why Other Options Are Wrong: Elastic spring-back alone cannot separate material. Pure thermal softening or phase change alone does not describe mechanical chip formation in conventional cutting. Thus, “Disagree” is incorrect. Common Pitfalls: Overlooking the role of friction and secondary deformation; assuming material “melts” during normal cutting—it generally does not, despite high temperatures. Final Answer: Agree

Question 14

Negative rake angle application Negative rake angles are most commonly provided on which class of cutting tools due to their hot hardness and edge strength requirements?

Accepted Answer

Introduction / Context: Tool rake angle affects cutting forces, temperature, edge strength, and tool life. Negative rake is often used to strengthen the cutting edge and withstand high cutting speeds that produce elevated temperatures. Given Data / Assumptions: Comparing typical rake choices for tool materials. Operations at moderate to high cutting speeds. Need for edge strength and hot hardness. Concept / Approach: Cemented carbide has excellent hot hardness and compressive strength. Negative rake reduces the wedge angle thinning, making the edge stronger under heavy loads and intermittent cuts. HSS and carbon steel tools typically use positive rake to lower forces, because their hot hardness is lower than carbides. Step-by-Step Solution: Identify the tool requiring high edge strength at high speeds: cemented carbide.Relate negative rake to improved wedge strength and crater wear resistance.Select the option that matches common industrial practice. Verification / Alternative check: Carbide insert catalogs list many neutral/negative rake geometries for steel machining and roughing, confirming widespread use. Why Other Options Are Wrong: High carbon steel and HSS normally rely on positive rake to control forces and heat; they lack the hot hardness for sustained negative-rake, high-speed work. Common Pitfalls: Assuming negative rake always improves life; in finishing cuts on ductile materials, positive rake may still be preferable for lower forces and better finish. Final Answer: Cemented carbide tools

Question 15

Lathe spindle nose configuration On traditional engine lathes, the spindle nose end commonly has which thread arrangement for mounting chucks and faceplates?

Accepted Answer

Introduction / Context: Spindle noses provide standardized interfaces for mounting chucks, faceplates, and drive plates. Older and many general-purpose lathes employ threaded spindle noses, while more modern heavy-duty machines often use camlock or long-taper key fittings. Given Data / Assumptions: Conventional engine lathe. No camlock or A-type short taper specification implied. Question focuses on the traditional threaded style. Concept / Approach: In the threaded spindle nose system, the male thread is on the spindle nose (external), and mating female thread is on the chuck backplate. This allows easy mounting/removal while a register fits for concentricity. Step-by-Step Solution: Identify traditional spindle nose style: externally threaded spindle.Recognize mating backplate with internal threads.Select the corresponding option. Verification / Alternative check: Lathe manuals and standards show common nose threads (e.g., 1.5 in–8 TPI, M68×6) with external spindle threads. Why Other Options Are Wrong: Internal threads exist on the backplate, not the spindle. Tapered threads are uncommon for this purpose. Smooth noses are used with camlock/taper systems, not for threaded mounting. Common Pitfalls: Confusing spindle nose types across different standards; always verify the specific nose standard when selecting chucks. Final Answer: External screw threads

Question 16

Turning operation identification — grooving on a lathe In lathe work, which description best matches the grooving operation?

Accepted Answer

Introduction / Context: Lathe operations include facing, turning, parting, threading, knurling, chamfering, and grooving. Each has a characteristic tool form and purpose. Grooving creates narrow recesses used for snap-ring seats, oil-retaining grooves, or reliefs before threading. Given Data / Assumptions: External grooving on a cylindrical workpiece. Use of a form tool with a width equal to groove width. Standard engine lathe setup. Concept / Approach: Grooving is essentially localized turning confined to a small axial length. The tool plunges radially to a set depth to form a recess of controlled width. This differs from chamfering (bevel), knurling (pattern), or counterboring (internal enlargement). Step-by-Step Solution: Select a grooving tool with correct width and nose geometry.Align tool perpendicular to the axis, position at groove location.Feed radially to the specified depth, with light passes as needed.Finish with a dwell or light skim for clean flanks. Verification / Alternative check: Drawings will call out groove width, depth, and position tolerances; the lathe operation must meet these dimensions precisely. Why Other Options Are Wrong: (a) is chamfering, (b) is knurling, (d) is counterboring or internal enlargement, and none of these describe the narrow recess characteristic of grooving. Common Pitfalls: Using an overly wide tool causing chatter; not deburring groove edges; ignoring minimum fillet radius for stress relief. Final Answer: Reducing the diameter of a workpiece over a very narrow axial width

Question 17

Role of dielectric in Electro-Discharge Machining (EDM) In EDM, what is the primary purpose of the dielectric working fluid in the inter-electrode gap?

Accepted Answer

Introduction / Context: Electro-Discharge Machining removes material by a series of controlled electrical discharges between a tool (electrode) and a conductive workpiece, separated by a small gap filled with a dielectric fluid such as kerosene, deionized water, or EDM oil. Given Data / Assumptions: Sparking occurs when the dielectric breaks down locally. Debris must be carried away to sustain stable machining. Heat from each discharge must be dissipated. Concept / Approach: The dielectric serves multiple critical functions: it initially insulates the gap until the applied voltage causes breakdown, localizes and channels the discharge, cools the electrode and work, and flushes eroded particles to maintain a clean gap that prevents arcing and short circuits. Step-by-Step Solution: Before breakdown: dielectric insulates and controls where/when a spark can occur.At breakdown: the dielectric ionizes, allowing a short-duration plasma channel (spark) to form.After discharge: flow of dielectric cools the zone and removes debris (recast, vaporized particles). Verification / Alternative check: EDM instability (arcing, shorting) often traces to poor flushing or degraded dielectric; improving circulation restores stable pulsing, confirming the roles described. Why Other Options Are Wrong: Each listed function is valid; choosing only one ignores the multi-function nature. Therefore, “All of these” is correct. Common Pitfalls: Using contaminated dielectric, inadequate flushing, or incorrect viscosity—each leads to poor surface finish and tool wear. Final Answer: All of these

Question 18

Cutting speed distribution on a twist drill Considering a rotating twist drill, is the cutting speed zero at the periphery and maximum at the centre?

Accepted Answer

Introduction / Context: Cutting speed in drilling is the tangential velocity of a point on the cutting edge and is proportional to radius times angular speed. Understanding this radial variation explains why the chisel edge at the center behaves differently than the lips at the periphery. Given Data / Assumptions: Circular motion with angular speed omega. Local cutting speed v(r) = omega * r. Standard right-hand twist drill. Concept / Approach: Because v(r) increases linearly with radius, the cutting speed is zero at the center (r = 0) and maximum at the periphery (r = R). The statement in the question reverses this reality and is therefore false. Step-by-Step Solution: Define v(r) = omega * r.At the center (r = 0): v = 0.At the periphery (r = R): v = omega * R (maximum for the tool). Verification / Alternative check: High thrust and rubbing at the chisel edge occur because the cutting speed there is near zero, explaining why web thinning reduces thrust. Why Other Options Are Wrong: Hand of the drill or feed mode does not change the basic kinematics; speed depends on radius, not on these factors. Common Pitfalls: Using cutting speed values based on diameter without accounting for the center’s low speed; excessive feed causes chisel-edge extrusion rather than cutting. Final Answer: No

Question 19

Machine tool design comparison For machines of the same size, which statement about a plain (horizontal) milling machine versus a universal milling machine is generally true?

Accepted Answer

Introduction / Context: A plain (horizontal) milling machine is designed for rigidity in slab milling and heavy stock removal. A universal milling machine adds a swiveling table and other mechanisms to enable helical milling and multi-axis setups, often at some cost to stiffness and mass for a given size. Given Data / Assumptions: Comparing machines of the same nominal size class. Universal adds flexibility (swivel table), not necessarily rigidity. Focus is on general construction and stiffness. Concept / Approach: Additional articulations in universal mills introduce more joints and overhangs. Plain mills concentrate mass in a simpler column–knee–table system, usually giving higher rigidity and weight for heavy horizontal arbor work. Step-by-Step Solution: Identify design differences: swivel table, gear trains for helical milling (universal).Assess impact: more versatility but slightly reduced stiffness/weight for same size.Conclude the statement that plain mills are more rigid/heavier is generally correct. Verification / Alternative check: Manufacturer catalogs list machine weights: plain versions typically weigh more than universal counterparts in the same size range. Why Other Options Are Wrong: “Incorrect” contradicts common design practice. Limiting validity to CNC or small benches is unnecessary; the principle holds broadly. Common Pitfalls: Equating versatility with rigidity; in milling, rigidity is paramount for finish and tool life when using large slab cutters or wide face mills. Final Answer: Correct

Question 20

Process identification by mechanism of metal removal When metal is removed by erosion caused by rapidly recurring electrical spark discharges between a shaped tool and a conductive workpiece, the process is called:

Accepted Answer

Introduction / Context: Advanced machining processes are categorized by their dominant energy interaction with the workpiece. EDM is a thermal erosion process relying on controlled spark discharges in a dielectric to shape conductive materials, independent of mechanical cutting forces. Given Data / Assumptions: Tool and work are conductive. A pulsed power supply generates controlled discharges. Dielectric fluid fills the inter-electrode gap. Concept / Approach: Each spark melts and vaporizes a tiny amount of material from both the tool and work surface. Flushing removes debris, leaving a characteristic cratered surface. This mechanism distinguishes EDM from other nontraditional processes such as ECM (ionic dissolution) or USM (abrasive micro-chipping). Step-by-Step Solution: Recognize the keyword “spark discharges” indicating an electrical breakdown event.Associate dielectric and pulsed power with EDM.Select EDM as the matching process. Verification / Alternative check: EDM can produce sharp internal corners and deep cavities in hardened steels where conventional cutting is difficult—typical application evidence. Why Other Options Are Wrong: ECM uses electrochemical dissolution (no sparks). USM uses high-frequency vibrations with slurry abrasives. LBM uses a focused laser for melting/ablation. Thus, they do not match the “spark erosion” description. Common Pitfalls: Confusing EDM with ECM due to both being “non-traditional” and fluid-based; remember that only EDM involves sparking and dielectric breakdown. Final Answer: Electro-discharge machining (EDM)

Production Engineering Questions