Manufacturing And Production Technology — Part 2 MCQs with Explanations

In this operation, surfaces which are at an angle to the axis of the cutter, is machined by the rotary cutter. -Milling machine can perform all other common operations like turning, facing, fillet making, chamfering, drilling, gear cutting, planning, slot cutting.

-The maximum production of small and slender parts is done by Multi-spindle automatic lathe -Multi Spindle Automatic Lathe can provide the various types of machining such as boring, turning, chamfering, threading, grooving.

End-feed grinding is a technique used in machining when working with a centerless grinder. A centerless grinder is a machine that has two wheels through which a material is placed in order to shaped and ground. This allows a faster rate of work because pieces can be more quickly engaged and disengaged from the process, and of its two wheels, one is a grinding wheel, and the other is a regulating wheel.

A drift is a tool used to withdraw a drill from the sleeve or spindle in drilling machines. It is a tapered, flat, and elongated tool that fits into the slot provided in the drill sleeve or spindle. When inserted and struck with a hammer, it forces the drill or taper shank tool out of the spindle or sleeve. Drifts are commonly used in machines like drill presses, lathes, and milling machines where taper shank tools are used. This tool ensures easy and safe removal of drills without causing damage to the spindle or tool.

A snag grinder cleans and removes excess metal from castings small enough to be moved to the face of the grinding wheel. -Trimming the surface left by spruces and risers on castings and Grinding the parting line left on castings and Removing flash on forgings are the examples of the snag grinding.

A twist drill is a rotating cutting tool, used for cutting holes in rigid materials which is consists of an essentially conical point, relieved and fluted to form cutting lips, and spiral flutes which direct the chips away from the lips and toward ejection from the hole. It is specified by it's shank, material and diameter.

The size of an engine lathe is determined by the largest piece of stock that can be machined. Before machining a workpiece, the following measurements must be considered. The diameter of the work that will swing over the bed and the length between lathe centers.

Lamellar tearing is a cracking phenomenon, which occurs beneath welds, and is principally found in rolled steel plate fabrications. The tearings always lies within the parent plate, often outside the transformed (visible) heat- affected zone (HAZ), and is generally parallel to the weld fusion boundary.

Continuous chips tend to be formed when the following condition exist: 1. ductile material 2. high cutting speed 3. small chip thickness 4. large rack angle

Following Steps Has to be taken to Improve the surface Finish: Increase the Speed. Reduce the Feed. Increase the Top Rake Angle. Use a Chip Breaker. Use a Large Nose Radius. Use the Correct Technique. Use Different Tools to Rough and Finish.

Lip angle is the angle between the rake surface and flank surface when viewed on orthogonal plane.

In a horizontal boring machine, the work is supporting on a table which is constant and the tool turns into a horizontal axis

The width of the cutting edge of a parting-off tool depends on the type of material being cut and the rigidity required for the operation. A typical range for parting-off tools used in lathe operations falls between 5 mm to 20 mm, which provides a balance between strength and precision. Narrower tools (closer to 5 mm) are used for smaller workpieces and precision cuts, while wider tools (up to 20 mm) are preferred for heavier and tougher materials to reduce deflection and ensure stability.

Twist drill is a rotating cutting tool, used for cutting holes in rigid materials which is consists of an essentially conical point, relieved and fluted to form cutting lips, and spiral flutes which direct the chips away from the lips and toward ejection from the hole.

The tool material should be such that indentation by the abrasive grits does not lead to brittle failure. Thus the tools are made of tough, strong and ductile materials like steel, stainless steel and other ductile metallic alloys

In hot machining, tool is made of Tungsten carbide

EDM involves the direction of high-frequency electrical spark discharges from a graphite or soft metal tool, which serves as an electrode, to disintegrate electrically conductive materials such as hardened steel or carbide.

In a gating system, the ratio 1 : 2 : 4 represents, sprue base area : runner area : ingate area.

The vector sum of cutting velocity and chip velocity is equal to shear velocity.

the surface roughness is directly influenced by the spindle speed and feed rate. It is observed that the surface roughness increases with increased feed rate and is higher at lower speeds and vice versa for all feed rates.

At the same feed rate, increasing the side cutting edge angle increases the chip contact length and decreases chip thickness. As a result, the cutting force is dispersed on a longer cutting edge and tool life is prolonged.

The seven elements that comprise the signature of a single point cutting tool are always stated in the following order: i. Back rake angle ii. Side rake angle iii. End relief angle iv. Side relief angle v. End cutting edge angle vi. Side cutting edge angle vii. Nose radius

A single-start thread has one continuous thread running along the body of the screw A trapezoidal thread is used in the leadscrew of lathe machine. It has a 30 degree included angle. Stronger at the root. Easy to manufacture compared to square thread.

Broaches are shaped similar to a saw, except the height of the teeth increases over the length of the tool. Moreover, the broach contains three distinct sections: one for roughing, another for semi-finishing, and the final one for finishing.

The taper tap has 7 to 10 chamfered threads; the plug tap has 3 to 5 threads chamfered; while the bottoming tap has one thread chamfered. Hand taps have short square-ended shanks and are used for both machine and hand tapping. Taps are usually made either of carbon tool steel or high-speed steel.

In a plain milling machine, the table can be moved -Longitudinally -Crosswise - Vertically

Cast iron during machining produces Discountinuous chips. It often happens in high brittle materials, such as cast iron

Soluble oil of the highest grade is used as a lubricant. It is used in metalworking industries as a cutting fluid for aluminum. For machining, tapping and drilling aluminum, it is superior to kerosene and various water-based cutting fluids.

Discontinuous chips are formed during machining of brittle metals while continuous chips are formed during machining of ductile materials.

The point angle is located at the head of the twist drill. For hard materials such as stainless steel, the point angle should be large and e.g. 130° or 135°. For soft materials, point angles of e.g. 118° are used. With a large point angle, more of the cutting edge engages in the workpiece when drilling

According To ASA System the tool nomenclature is to be followed by this procedure : Back rake angle, Side rake angle, Front or end clearance or relief angle, Side clearance angle or relief angle, End cutting edge angle, Side cutting edge angle, Nose radius. From the System Side rake angle is 6°

The function of a chip breaker is to improve chip control and to reduce cutting resistance. A better balance between the two will increase the machining performance. Reduced cutting resistance can avoid chipping and fracturing of the cutting edge caused by vibration

Negative rake angles are more commonly used for carbide tipped tools. Negative rake angles can be considered for intermittent cuts and heavy stock removal. And also when machining hard and brittle materials, such as titanium or stainless steel.

milling is carried out at a minimum cutting velocity if the machines are equally rigid and the tool work materials are the same.

Planetary Mills are ideally suited for fine grinding of hard, medium-hard, soft, brittle, tough and moist materials. Internal or external threads of different pitches can be produced by Planetary milling machine

Neutral flame is type of welding flows, which is the result of a perfect proportion and mixture of acetylene and oxygen and is used for fusion welding of steel and cast iron. The neutral flame is the flame in which the amount of oxygen is precisely enough for burning, and neither oxidation nor reduction occurs. A flame with a good balance of oxygen is clear blue. The reducing and neutral flames are useful in soldering and annealing. Neutral flame has a 1:1 ratio of acetylene and oxygen. It's the most preferred flame for welding.

The lathe spindles are usually made hollow and provided with Internal taper: - Lathe spindles are used for machine-cutting of workpieces - It can also be referred to as workpiece spindles - As the workpiece is clamped via the chuck of the lathe spindle

Transverse Cylindrical Grinding. Considering plunge grinding, in which the wheel and the workpiece motions act on the same plane. -transverse grinding involves the addition of crossfeed (transverse motion) of the workpiece relative to the grinding wheel in a direction perpendicular to the plane of wheel rotation.

If a particular Fe-C alloy contains less than 0.83% carbon, it is categorized as hypo eutectoid steel . In metallurgy, the carbon content in steel alloys determines their properties and classifications. Hypo eutectoid steel has a carbon content below the eutectoid composition (0.83% carbon) and exhibits specific mechanical and thermal properties suited for various applications in manufacturing and production technology.

A grinding wheel is made up of tiny cutting points called abrasive grains. These grains are held together by a bonding material — think of it like glue. Now, when we talk about the “hardness” of a grinding wheel, we’re not talking about how hard those grains are, but rather about how tightly the bond holds onto them . Option A: Hardness of abrasive grains – This is about the toughness of each tiny grain. Yes, it matters for cutting performance, but it’s not what defines the wheel’s hardness. Option B: Ability of the bond to retain abrasives – This is the real meaning of hardness here. A hard wheel has a strong bond that holds the grains for a long time, even when they get worn. A soft wheel’s bond lets go of the grains more easily, constantly exposing fresh cutting points. Option C: Hardness of the bond – The bond might be physically hard, but if it can’t hold the grains well, the wheel won’t be considered “hard.” It’s the holding strength that matters. Option D: Ability to penetrate the work piece – That’s about cutting action, not hardness. In fact, a softer wheel might cut faster because it exposes new grains more often. In short: If the wheel holds onto its abrasive grains stubbornly, it’s “hard.” If it lets them go quickly, it’s “soft.” That holding power — the ability of the bond to retain abrasives — is what truly defines grinding wheel hardness.