Question 1

Cutting tool materials for high-speed machining For faster machining and higher productivity, which combination of properties must a cutting tool material possess to perform reliably at elevated temperatures and loads?

Accepted Answer

Introduction / Context: High-speed and heavy-duty machining generate substantial heat and mechanical stress at the tool–chip interface. A modern cutting tool material must sustain its cutting edge without premature wear, softening, or chipping. This question reinforces the triad of essential properties for tool materials in metal cutting. Given Data / Assumptions: Conventional single-point or multi-point cutting operations (turning, milling, drilling). Elevated cutting temperatures occur at the edge. Intermittent or continuous cuts may impose impact and cyclic loads. Concept / Approach: Three core properties govern tool performance: wear resistance (to slow flank/crater wear), red hardness (to retain hardness at high temperature), and toughness (to resist chipping in interrupted cuts or vibration). Lacking any of these leads to early failure or catastrophic edge breakdown. Step-by-Step Solution: Identify heat as the primary threat → need red hardness so the edge does not soften.Identify abrasion/adhesion at the interface → need high wear resistance to limit flank and crater wear.Identify mechanical shocks from entry/exit of cut → need toughness to prevent brittle chipping.Conclusion: the correct choice is the combination of all three properties. Verification / Alternative check: Tool families (HSS, carbides, cermets, ceramics, PCBN, PCD) are judged by these three attributes; selection charts always balance hot hardness versus toughness for the application. Why Other Options Are Wrong: Wear resistance only: tool may still soften or chip.Red hardness only: brittle edge may fracture; wear may be rapid.Toughness only: edge may wear quickly or lose hardness at temperature.Only high thermal conductivity: helpful for heat flow, but insufficient alone. Common Pitfalls: Choosing a very hard but brittle tool for interrupted cuts; or a very tough but low hot-hardness tool for high-speed finishing. Always match tool grade to operation and work material. Final Answer: All of these

Question 2

Lathe finishing practice After which machining operation is chamfering considered essential to remove burrs, protect the edge, and facilitate assembly?

Accepted Answer

Introduction / Context: Chamfering produces a small, angled surface that removes sharp edges and burrs. It is especially crucial where the geometry must allow easy engagement with mating parts, such as bolts, nuts, and screwed holes. Correct sequencing of chamfering improves safety, function, and appearance. Given Data / Assumptions: Operation performed on a lathe or machining center. Threads are newly cut on an external or internal feature. Goal is reliable assembly and protection of thread crests/starts. Concept / Approach: After thread cutting, a burr typically forms at the entry and exit. A chamfer at the thread start guides the fastener, reduces cross-threading, and prevents the first thread from damage. Standards for fasteners specify chamfering before gauging or assembly to ensure smooth engagement. Step-by-Step Solution: Recognize that threads require a lead-in to start properly.Chamfering removes burrs and creates a lead, improving fit and reducing cross-threading.Therefore, chamfering is essential immediately after thread cutting. Verification / Alternative check: Workshop practice and standards recommend 30–45 degree chamfers on threaded ends and at the mouth of tapped holes. Why Other Options Are Wrong: Knurling: produces a rough grip; chamfer not essential afterward.Rough turning: deburring may be needed, but chamfer is not always essential.Boring: internal sharp edges may be lightly broken, yet it is not as critical as after threading.Parting-off: edges are typically deburred; a chamfer is situational, not essential. Common Pitfalls: Skipping chamfer leads to damaged first thread and assembly difficulty. Over-chamfering may reduce engagement length and weaken the thread start. Final Answer: Thread cutting

Question 3

Grinding wheel structure selection An open-structure grinding wheel (more porosity, greater chip space) is recommended for which types of work materials?

Accepted Answer

Introduction / Context: Grinding wheel structure refers to the spacing between abrasive grains. An open structure provides more voids to hold coolant and chips. Correct structure selection prevents wheel loading and improves thermal management and surface finish. Given Data / Assumptions: Conventional abrasives (Al2O3 or SiC) and vitrified or resinoid bonds. Goal is to reduce loading and maintain cutting efficiency. Materials include soft, tough, or ductile alloys prone to smearing. Concept / Approach: Soft, ductile, or tough materials (e.g., aluminium, low-carbon steels, copper alloys) produce long, continuous chips that tend to clog the wheel. An open structure creates larger chip pockets and improves coolant access, reducing glazing and burn. Hence these materials benefit from open structure combined with a relatively soft grade and coarser grit. Step-by-Step Solution: Identify wheel loading risk for soft/ductile/tough materials.Select open structure to increase chip space and coolant penetration.Confirm that this combination mitigates glazing and heat buildup. Verification / Alternative check: Handbooks recommend open-structure wheels for gummy or low-strength alloys; in contrast, hard-brittle materials often use denser structures and finer grits for surface integrity. Why Other Options Are Wrong: Limiting to only one category misses the broader application; all three categories can benefit.Only hardened tool steel: typically requires different grit/grade/structure and not necessarily very open structures. Common Pitfalls: Using dense, fine, hard wheels on soft metals causes glazing, heat, and poor finish. Balance wheel grade, structure, and coolant for best results. Final Answer: All of these

Question 4

Tapping blind holes Which tap is specifically used to cut threads to the full depth in a blind hole (minimal chamfer length)?

Accepted Answer

Introduction / Context: Tapping sets commonly include three taps: taper, second (plug/intermediate), and bottoming. Understanding the chamfer length and application ensures full thread depth in through and blind holes without damaging the tap or the workpiece. Given Data / Assumptions: Blind hole with limited depth. Need to produce full thread depth near the hole bottom. Standard hand taps with progressive chamfer lengths. Concept / Approach: The taper tap has the longest chamfer and is easiest to start but cannot reach near the bottom. The second tap has a moderate chamfer and deepens the thread. The bottoming tap has 1–2 lead threads, allowing the full thread profile to be formed close to the bottom of a blind hole. Step-by-Step Solution: Start with taper tap to align and begin the thread if needed.Follow with second tap to extend thread depth.Finish with bottoming tap to produce full-depth thread near the hole bottom. Verification / Alternative check: Manufacturer data sheets specify lead threads and intended use; bottoming taps are explicitly indicated for blind holes. Why Other Options Are Wrong: Taper/second taps cannot produce full depth near the bottom due to longer chamfer.“Any one of these” is incorrect because only the bottoming tap reaches near the bottom.Pipe taps are specialized for tapered pipe threads, not general metric/UN blind holes. Common Pitfalls: Attempting to use only a bottoming tap to start may cause misalignment or breakage; proceed progressively or use machine tapping with proper guides. Final Answer: Bottoming tap

Question 5

Drill helix selection Low-helix-angle (slow spiral) twist drills are preferred for drilling which of the following materials to reduce grabbing and improve chip control?

Accepted Answer

Introduction / Context: Helix angle (spiral) in a twist drill governs chip evacuation and the cutting action at the lip. In certain ductile, gummy materials the drill tends to “grab,” causing oversize holes, poor finish, or tool breakage. Adjusting helix helps stabilize cutting. Given Data / Assumptions: Conventional twist drill, right-hand cut. Material choices include ductile nonferrous metals and steels. Goal is to minimize grabbing and improve hole quality. Concept / Approach: Low-helix (slow spiral) drills are recommended for copper, brass, and some bronzes because a steep helix can pull the tool into the work (self-feeding), increasing the risk of grabbing. A slower spiral reduces the axial component of cutting force and stabilizes chip flow. For steels, a standard or higher helix may be used to aid chip evacuation. Step-by-Step Solution: Identify grabbing tendency in soft, ductile nonferrous metals like copper.Select slow spiral to reduce self-feeding and stabilize the cut.Confirm that this choice is widely recommended for copper/brass machining. Verification / Alternative check: Tool catalogs list special “slow spiral” or modified point geometry for copper and brass to minimize grabbing and improve roundness. Why Other Options Are Wrong: Plastics: often require special points and high rake; helix choice varies widely.Cast/Carbon steel: normally use standard or higher helix for chip evacuation.Hardened tool steel: requires carbide and different geometries, not slow spiral HSS drills. Common Pitfalls: Using a standard high-helix in copper can cause the drill to screw in, creating oversize/tapered holes. Control feed and use split-point geometry where appropriate. Final Answer: Copper

Question 6

Drill specification parameters A twist drill for shop use is commonly specified by which basic descriptors?

Accepted Answer

Introduction / Context: Specifying a twist drill correctly ensures the right fit in the machine spindle or chuck, appropriate cutting performance for the work material, and accurate hole size. Industry practice uses a set of key descriptors to identify a drill. Given Data / Assumptions: Standard twist drills (jobber length or similar). Shop-level specification rather than full engineering standard. Focus on essential descriptors. Concept / Approach: While full drill specifications may include diameter, overall length, flute length, helix angle, point angle, material/coating, and shank type, the most common quick specification in workshops is by diameter, shank type/size, and material (HSS, carbide, etc.). These three directly affect fit, strength, and suitability. Step-by-Step Solution: Diameter controls hole size and strength.Shank (straight/taper) determines mounting method and runout.Material/coating influences allowable speed, wear, and toughness. Verification / Alternative check: Catalogs and purchasing documents commonly call out diameter, shank type, and material/coating as first-line identifiers, with additional details appended as needed. Why Other Options Are Wrong: Lip angle and flute size are important but not the primary shorthand for selection.Length of body and helix angle are secondary; they refine the choice after basics are fixed.“Any one of these” is too loose for procurement; “only diameter” is insufficient. Common Pitfalls: Specifying only diameter may lead to incompatible shanks or inadequate tool material for the job. Include core descriptors to avoid delays. Final Answer: Shank, material, and diameter

Question 7

Grinding wheel grade selection The grade (hardness) of a grinding wheel should be chosen considering which of the following factors?

Accepted Answer

Introduction / Context: Wheel grade indicates how strongly the bond holds abrasive grains. Selecting the correct grade controls self-sharpening behavior, heat generation, and surface quality. An inappropriate grade leads to glazing, burn, or rapid wheel wear. Given Data / Assumptions: Conventional surface/cylindrical grinding with Al2O3 or SiC wheels. Work materials vary from soft to hard, ductile to brittle. Machine stiffness and speed conditions differ. Concept / Approach: Hard work materials usually call for a softer wheel grade to expose fresh sharp grains. Higher speeds or light cuts often pair with softer grades to avoid glazing. On flexible machines, a softer grade helps prevent chatter by limiting rubbing and heat buildup. Thus, multiple factors must be weighed together. Step-by-Step Solution: Relate work hardness → choose softer grade for harder work to promote self-sharpening.Relate speed/load → higher speed and lighter DOC benefit from slightly softer grades.Relate machine condition → poor rigidity favors softer wheels to reduce forces. Verification / Alternative check: Manufacturer selection charts correlate grade with work hardness, speed, feed, and machine power/rigidity. Why Other Options Are Wrong: Focusing on only one parameter ignores interactions; tool–work dynamics are multivariate. Common Pitfalls: Selecting a hard grade for hard steels causes glazing and burn; selecting too soft a grade for robust setups leads to rapid wear and loss of form. Final Answer: All of these

Question 8

Cylindrical grinding methods In plunge (infeed) grinding, how are the work and wheel motions arranged and what component length can be produced relative to wheel face width?

Accepted Answer

Introduction / Context: External cylindrical grinding is performed either by traverse (longitudinal) grinding or plunge (infeed) grinding. Correct understanding of motion and capacity helps select the right method for part geometry and productivity. Given Data / Assumptions: Cylindrical work is mounted between centers or in a chuck and rotates. Grinding wheel feeds radially (in plunge grinding). Wheel face width is finite and determines maximum plunge-ground length. Concept / Approach: In plunge grinding, the wheel is fed radially into a rotating workpiece without table reciprocation. The wheel face covers the ground length; hence, the part length is typically equal to or less than the wheel face width. For longer parts, traverse grinding with work table reciprocation is used. Step-by-Step Solution: Identify plunge grinding → no longitudinal table motion, radial infeed only.Work must rotate to present fresh surface to the wheel.Part length capacity ≈ wheel face width → equal to or shorter than wheel face. Verification / Alternative check: Process texts classify plunge grinding for steps, shoulders, and short cylindrical surfaces; traverse grinding for longer shafts and journals. Why Other Options Are Wrong: Options with reciprocating work describe traverse grinding, not plunge.Producing lengths longer than the wheel face in plunge mode is not feasible without traversing.Non-rotating work would rub and burn; grinding requires relative speed. Common Pitfalls: Trying to plunge-grind long journals causes ridging and thermal issues; select traverse grinding or a wider wheel as appropriate. Final Answer: Work rotates in a fixed position; produces cylinders equal to or shorter than wheel face width

Question 9

Plain milling machine motions On a standard plain (horizontal) milling machine, the work table can be moved in which basic directions?

Accepted Answer

Introduction / Context: Milling accuracy and versatility rely on the machine’s available axes. Understanding table motions helps plan setups, cutter approach, and surface generation on prismatic parts. Given Data / Assumptions: Plain (horizontal) knee-and-column milling machine. Standard work table with feeds. Spindle axis horizontal; arbor carries the cutter. Concept / Approach: Conventional knee-and-column mills provide three orthogonal motions: longitudinal (X) along the saddle/bed, cross (Y) perpendicular to the spindle axis, and vertical (Z) by raising/lowering the knee. These allow positioning the work relative to the rotating cutter for a wide variety of operations. Step-by-Step Solution: Confirm longitudinal (X) motion for table feed along the bed.Confirm cross (Y) motion for in/out feed toward the cutter.Confirm vertical (Z) motion via knee elevation to set depth. Verification / Alternative check: Operator handwheels and feed mechanisms correspond to these three axes; DROs on modern machines show X/Y/Z. Why Other Options Are Wrong: Limiting to fewer axes understates the machine’s capability; all three are standard on plain mills. Common Pitfalls: Mixing axis nomenclature with that of vertical mills; always visualize relative to the table and knee on your specific machine. Final Answer: All of these

Question 10

Reaming soft nonferrous alloys Which type of machine reamer is recommended for reaming soft aluminium or copper to manage ductile chips and improve surface finish?

Accepted Answer

Introduction / Context: Reaming is a sizing and finishing operation that corrects hole geometry and improves surface finish. In soft, ductile materials (aluminium, copper), chip control is essential to avoid galling, chatter, and poor finish. Given Data / Assumptions: Ductile, gummy materials that form continuous chips. Through holes are common for these materials in production. Conventional right-hand cutting action. Concept / Approach: Left-hand spiral fluted reamers (with right-hand cutting direction) push chips forward, away from the cutting edges and out through the far side in through-hole work. This reduces clogging at the cutting zone and improves finish in soft nonferrous materials. Straight flutes may pack chips, while right-hand spiral flutes tend to pull chips back toward the entrance, which can mar the surface in ductile alloys—though they are useful in blind holes for chip evacuation toward the top. Step-by-Step Solution: Identify chip behavior in soft aluminium/copper → long, ductile chips prone to clogging.Select left-hand spiral to drive chips forward in through holes.Benefit: smoother surface, reduced built-up edge and galling. Verification / Alternative check: Cutting tool handbooks recommend left-hand spiral for through holes in ductile nonferrous alloys; right-hand spiral for blind holes to lift chips out. Why Other Options Are Wrong: Straight fluted: higher risk of chip packing in soft metals.Right-hand spiral: tends to pull chips back, better for blind holes; not ideal for through-hole finishing in soft aluminium/copper.“Any one of these” overlooks chip control differences; expansion reamers are special-purpose. Common Pitfalls: Using incorrect spiral direction causes scoring and poor finish. Apply correct coolant and maintain low runout for best results. Final Answer: Left-hand spiral fluted reamer

Question 11

Single-point cutting tool geometry: defining the side relief angle  In metal cutting (turning) with a single-point tool, which description correctly defines the side relief angle of the tool?

Accepted Answer

Introduction / Context: Single-point cutting tool geometry uses standard angles (rake, relief/clearance, cutting edge and nose angles) to control chip flow, cutting forces, and surface finish. Understanding what each angle physically represents helps operators set up tools correctly and avoid rubbing. Given Data / Assumptions: Conventional tool nomenclature per ASA/ISO with clearly defined rake and relief faces. Focus on the side relief (side clearance) angle measured on the side flank beneath the cutting edge. Tool set on center and cutting a typical turning operation on a lathe. Concept / Approach: Relief (clearance) angles prevent the flank from rubbing the newly machined surface. The side relief angle is measured on the side flank, whereas the end relief angle is measured on the end flank. Rake angles are measured on the tool face and should not be confused with relief. Step-by-Step Solution: Identify what is being compared: side flank vs. a reference plane perpendicular to the tool’s center line.Side relief angle = angle between the side flank under the point and a plane perpendicular to the reference (center) line at the point.This definition ensures clearance in the direction of lateral chip flow along the side cutting edge. Verification / Alternative check: Standard tool diagrams show separate gauges for end relief and side relief, each referenced to a perpendicular plane, confirming the stated definition. Why Other Options Are Wrong: Back rake (A) and side rake (B) concern the face, not the flank. (D) uses a line rather than a reference plane, which is not the standard metrology basis. (E) relates to a different plan-view angle, not relief. Common Pitfalls: Confusing rake with relief; measuring in the wrong reference plane; setting too little relief causing rubbing and poor finish. Final Answer: The angle between the side flank surface immediately below the cutting point and a plane at right angles to the tool's center line at the point

Question 12

Grinding practice: choosing grain size for brittle materials  For grinding brittle materials (e.g., hardened tool steels, ceramics), is a coarse-grained grinding wheel preferred?

Accepted Answer

Introduction / Context: Wheel selection involves four key parameters: grain size (grit), grade (hard/soft), structure (open/dense), and bond. For brittle materials, preventing micro-chipping and achieving a fine finish are paramount. Given Data / Assumptions: Work materials are brittle, tending to fracture at edges. Goal is to balance stock removal, surface integrity, and wheel life. Coolant is available but not relied upon to solve edge damage alone. Concept / Approach: Fine grit produces small chips and lower cutting point penetration, reducing crack initiation at the surface. Coarse grit creates larger, deeper scratches, which can nucleate edge fractures and cause micro-chipping on brittle substrates. Step-by-Step Solution: Relate brittleness to chip formation: brittle → crack-sensitive → require small chip thickness.Select finer grit to reduce indentation depth and scratch size.Complement with an open structure and appropriate (often softer) grade to avoid loading while maintaining edge integrity. Verification / Alternative check: Process handbooks recommend finer grits for hardened steels/carbides/ceramics where finish and edge integrity dominate. Why Other Options Are Wrong: (A) reverses best practice for brittle materials; coarse grits suit soft, ductile, loading-prone materials. (C) references soft/gummy materials, not brittle ones. (D) Grade and grain are independent; soft grade does not justify coarse grit on brittle parts. Common Pitfalls: Using coarse grit to chase removal rate and then seeing chipped edges; confusing grade with grit size. Final Answer: Disagree — finer grain is preferred to limit edge chipping

Question 13

Centreless grinding kinematics: actual axial feed expression  In centerless grinding, with regulating wheel diameter d (in meters), speed n (rev/min), and inclination angle α of the regulating wheel axis, what is the actual feed rate imparted to the…

Accepted Answer

Introduction / Context: In centerless grinding, the regulating wheel controls both the rotational speed and the axial feed of the workpiece. The axial feed results from inclining the regulating wheel axis by a small angle α relative to the work axis. Given Data / Assumptions: d = diameter of the regulating wheel. n = rotational speed of the regulating wheel in rev/min. α = inclination angle of the regulating wheel axis. No slip assumption at the work–regulating wheel interface. Concept / Approach: The peripheral (tangential) speed of the regulating wheel is v = π d n. The axial feed component is the projection of this velocity along the work axis, determined by the inclination angle α. Step-by-Step Solution: Compute peripheral speed: v = π * d * n.Resolve along work axis: feed = v * sin α.Therefore, actual axial feed = π d n sin α. Verification / Alternative check: Dimensional check: d (m) * n (rev/min) gives m/min when multiplied by π; sin α is dimensionless. Why Other Options Are Wrong: π d and π d n omit the angular component; they are circumferential, not axial. cos α projects onto the transverse direction, not along the axis. 2 π d n tan α is not the standard kinematic decomposition for this geometry. Common Pitfalls: Using cos α instead of sin α; mixing wheel diameter units; forgetting to express d in meters for consistent units. Final Answer: π d n sin α

Question 14

Taylor's tool-life law application  In single-point turning with a cemented carbide tool on steel (Taylor exponent n = 0.25), if cutting speed is halved, by what factor does the tool life change according to V * T^n = C?

Accepted Answer

Introduction / Context: Taylor’s tool-life equation relates cutting speed V and tool life T via V * T^n = C for given tool-work combinations. It allows quick what-if predictions when speeds or materials change. Given Data / Assumptions: n = 0.25 (typical for carbide on steel). Initial speed V1, life T1; new speed V2 = V1 / 2. Same feed, depth, environment so constant C applies. Concept / Approach: Using V1 * T1^n = C and V2 * T2^n = C, equate and solve for T2/T1 when V2 = V1/2. Step-by-Step Solution: V1 * T1^n = (V1/2) * T2^nT1^n = (1/2) * T2^nT2^n = 2 * T1^n → T2 = T1 * 2^(1/n)With n = 0.25, 1/n = 4, so T2 = T1 * 2^4 = 16 * T1 Verification / Alternative check: Trend matches intuition: lower speed increases life, and a small n magnifies the effect strongly. Why Other Options Are Wrong: Half or two times contradict the power-law sensitivity with n = 0.25. Eight times corresponds to n = 1/3, not 1/4. “Unchanged” ignores Taylor’s empirical relation. Common Pitfalls: Mishandling exponents; using 2^n instead of 2^(1/n); changing multiple variables simultaneously. Final Answer: Tool life becomes sixteen times the original

Question 15

Best mass-production process for gears  Considering productivity, accuracy, and economy in large batches, which manufacturing process is most suitable for mass production of gears?

Accepted Answer

Introduction / Context: Gear manufacturing methods include forming, generating, and finishing processes. For large quantities, the chosen method must combine speed with acceptable accuracy and surface quality before finishing (if required). Given Data / Assumptions: External spur/helical gears are considered. Mass production (high throughput) is the primary objective. Subsequent finishing (e.g., shaving/honing) can be added if needed. Concept / Approach: Hobbing is a continuous generating process, cutting multiple teeth simultaneously with a helical hob under a constant relative rolling motion. It offers excellent productivity, versatility in tooth forms, and good accuracy for most industrial needs. Step-by-Step Solution: Compare cycle times: hobbing < shaping for like modules and widths.Consider tooling: hobs last long, are re-sharpenable, and changeover is quick.Match quality/cost: hobbing provides consistent gear quality at high rates. Verification / Alternative check: Automotive and industrial gear lines overwhelmingly use hobbing as the base generating process. Why Other Options Are Wrong: Shaping is slower, indexing each tooth or using a pinion cutter reciprocating. Casting alone lacks accuracy/surface finish; typically needs machining. Forming by dies applies to powder metallurgy or rolling but is less universal than hobbing. Common Pitfalls: Confusing hobbing (generating) with form milling; underestimating hob lead/helix setup. Final Answer: Hobbing with a generating hob

Question 16

Can gears be cut on a shaper?  Evaluate the statement: “Gears can be cut on a shaper.” Consider attachments and special cutters used on shaping machines.

Accepted Answer

Introduction / Context: While dedicated gear machines (hobbers, gear shapers) are preferred, conventional shapers equipped with the right attachments can generate gear teeth, especially for small batches or maintenance work. Given Data / Assumptions: Use of a gear shaping attachment or a rack-type form tool on a standard shaper. Indexing or generating motion provided via dividing head and linkage. Accuracy needs are moderate, not ultra-precision production. Concept / Approach: Gear tooth profiles can be generated by relative rolling motion between a cutter (often a pinion- or rack-shaped tool) and the blank. A shaper can replicate this through reciprocating motion plus timed indexing or generating linkage. Step-by-Step Solution: Mount gear attachment and align a rack-type cutter on the shaper.Index or generate each tooth space via dividing head/linkage.Reciprocate the ram to cut successive tooth spaces until the gear is complete. Verification / Alternative check: Workshop practice texts show examples of gear cutting on shapers for one-off and repair jobs. Why Other Options Are Wrong: (B) is too restrictive; shapers can generate forms with attachments. (C) Involute forms are achievable with proper generating methods. (D) Material is not restricted to plastics; steels and bronzes can be cut. Common Pitfalls: Expecting mass-production accuracy/throughput on a general shaper; inadequate indexing leading to pitch errors. Final Answer: Agree — with a gear shaping attachment or rack-type cutter, gears can be cut

Question 17

Jigs vs. fixtures vs. gauges: primary purpose of a jig In production tooling, what is the main function of a jig?

Accepted Answer

Introduction / Context: Production tooling uses jigs, fixtures, and gauges to improve accuracy, speed, and interchangeability. Each has a distinct role in the manufacturing system. Given Data / Assumptions: Common hole-making operations (drilling, reaming, tapping). Need for repeatable tool location without extensive layout/marking. Concept / Approach: A jig locates and holds the workpiece and additionally guides the tool (via drill bushings), ensuring precise hole location. A fixture locates and holds but does not guide the tool; it is used for processes like milling or turning. A gauge checks dimensions/geometry after processing. Step-by-Step Solution: Identify the need to guide the tool → select jig.If only holding/supporting the work → fixture.For inspection → gauge. Verification / Alternative check: Standard manufacturing texts define jigs by their tool-guiding function through hardened bushings. Why Other Options Are Wrong: (B) describes fixtures (no tool guidance). (C) describes gauges, not jigs. (E) is a coolant delivery system function, unrelated to jigs. Common Pitfalls: Using “jig” and “fixture” interchangeably; omitting bushings leading to rapid wear in guide holes. Final Answer: To hold the work and also guide the cutting tool in drilling, reaming, or tapping

Question 18

Tap drill sizing rule  For internal threads produced by tapping, the diameter of the drilled hole (tap drill) is generally how related to the outside (major) diameter of the tap/thread?

Accepted Answer

Introduction / Context: Before tapping a nut or a threaded hole, an appropriately sized tap drill is used so that the cutting action forms the thread profile without excessive force or inadequate engagement. Given Data / Assumptions: Standard metric or unified coarse threads. Through or blind holes with adequate allowance for chip evacuation. Concept / Approach: The tap drill diameter must be less than the major diameter to leave sufficient material for the thread flanks. A common quick rule for metric coarse threads is: tap drill ≈ major diameter − pitch. For unified threads, charts give specific values close to major diameter minus thread height allowance. Step-by-Step Solution: Define need: leave material for full thread height.Choose drill < major diameter to achieve the desired percentage of thread (often 60–75%).Confirm from standard tap drill charts for the thread size. Verification / Alternative check: Reference tables universally list tap drills smaller than the major diameter for both metric and inch series threads. Why Other Options Are Wrong: Equal or greater than major diameter would leave no flank engagement. “Independent of size” is false; each thread size has a specific recommended drill. Pitch diameter is not used as the drill size; it is a different geometric parameter. Common Pitfalls: Using too small a drill leading to high torque/broken taps; using too large a drill yielding weak threads. Final Answer: Smaller than the outside (major) diameter

Question 19

Non-traditional machining: dielectric usage In which non-traditional machining process is a dielectric fluid essential to initiate and sustain controlled material removal?

Accepted Answer

Introduction / Context: Non-traditional processes remove material via chemical reactions, thermal energy, mechanical abrasion, or electrical discharges. Each process uses a different working medium. Given Data / Assumptions: EDM requires spark discharges between tool and work. Dielectric fluid fills the spark gap. Typical dielectrics: kerosene, deionized water, specialized oils. Concept / Approach: In EDM, the dielectric provides insulation until breakdown voltage is reached, then collapses to form a spark channel that melts/vaporizes a tiny volume of work material. It also flushes debris and cools the zone, restoring dielectric strength between discharges. Step-by-Step Solution: Establish need for controlled sparking → requires dielectric medium.Identify process using sparks for erosion → EDM.Therefore, dielectric is essential in EDM. Verification / Alternative check: Process schematics always depict a dielectric tank or flushing system in EDM setups. Why Other Options Are Wrong: ECM uses an electrolyte, not a dielectric; it relies on ionic dissolution. USM uses abrasive slurry mechanically; no dielectric needed. LBM uses focused light in air/inert gas; again, no dielectric. Common Pitfalls: Confusing electrolyte (conductive) with dielectric (insulating); inadequate flushing causes arcing and poor surface finish in EDM. Final Answer: Electro-discharge machining (EDM)

Question 20

Lathe “size” specification standards  When specifying the size/capacity of a center lathe for purchase or comparison, which of the following parameters are commonly stated as part of the size?

Accepted Answer

Introduction / Context: Lathe “size” communicates the envelope of work that can be accommodated. Buyers rely on standardized terms to compare machines across brands and models. Given Data / Assumptions: Conventional engine/center lathes. Manufacturers list several capacity numbers in catalogs. Concept / Approach: The most common capacity descriptors are: swing over bed (maximum diameter that clears the bed), swing over carriage or cross-slide (smaller than swing over bed), and distance between centers (maximum length of work mounted between centers). Together they express the practical workpiece envelope. Step-by-Step Solution: Identify key diametral limits: swing over bed and swing over carriage.Identify length limit: distance between centers.Combine these to form the machine’s stated size/capacity. Verification / Alternative check: Machine brochures typically list all three figures prominently for quick comparison. Why Other Options Are Wrong: Listing only one parameter gives an incomplete picture of capacity. Spindle nose type concerns tooling interface, not overall size capacity. Common Pitfalls: Ignoring swing over carriage when planning setups; assuming distance between centers equals actual machining length after chuck/center drill allowances. Final Answer: All of these are quoted together as size/capacity parameters

Production Engineering Questions