question set new 2013 2

7/27/2019 Question Set New 2013 2

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IES1995Consi er t e o owing statements a out noseradius

1. It improves tool life

2. re uces e cu ng orce

3. It improves the surface finish.Select the correct answer using the codes given below:

a 1 an 2 2 an 3

(c) 1 and 3 (d) 1, 2 and 3

Ans. (c)

IES1994

the following elements:

.

2. Side rake angle

3. End cutting edge angle

4. Side cutting edge angle5. Side relief angle

6. End relief an le

7. Nose radius

correctly specifying the tool geometry is

a 1,2,3, ,5,4,7 1,2, ,5,3,4,7

(c) 1,2,5,6,3,4,7 (d) 1, 2, 6, 3, 5, 4,7 Ans. (b)

IES2009

The following tool signature is specified foint cuttin tool in American s stem:

10, 12, 8, 6, 15, 20, 3

W at oes t e ang e 12 represent?

(a) Side cuttin ed ean le(b) Side rake angle

c Bac ra e ang e

d Side clearance an le

Ans. (b)

IES1993In ASA System, if the tool nomenclature is 8655101 2mm then the side rake an le will be

(a) 5 (b) 6 (c) 8 (d) 10

Ans.

cu ng oo av ng oo s gna ure as 10, 9, , ,

8 8 2 will haveside rakean le

(a) 10o (b) 9o (c) 8o (d) 2o

Ans. (b)

GATE2008In a sing e point turning too , t e si e and orthogonal rake angle are equal.principal cutting edge angle and its range

o o . The value of is closest to

(a) 00

(b) 450

c 600 d 900

Ans. (d) principal cutting edge angle is = 9

GATE2001

During orthogonal cutting of mild steel with ,

was obtained as 0.4. The shear angle (indegrees) evaluated from this data is

a .53 20.22

c 22. d 0.00

Ans.(c)

GATE2011A single point cutting tool with 12 rakused to machine a steel work iece. Thecut, i.e. uncut thickness is 0.81 mm.

1.8 mm. The shear angle is approximately

a 22

b 26(c) 56

76

Ans. b

For-2013 (IES, GATE, PSUs) Page 3


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IES2004,ISRO2009T e ra e ang e o a cutting too is 15, s earan le and cuttin velocit m min.What is the velocity of chip along the tool

ace

. .(c) 25.3 m/min (d) 23.5 m/min

Ans. (a)

IES2008onsi ert e o owingstatements:

Inanorthogonalcuttingthecuttingratioisfoundtobe075.Thecuttingspeedis60m/minanddepthofcut24mm.Whichofthefollowingarecorrect?

1. Chipvelocitywillbe45m/min.

2. pve oc yw e 0m m n.

3. Chipthicknesswillbe18mm.

4. Chipthicknesswillbe32mm.

(a) 1and3 (b) 1and4

(c) 2and3 (d) 2and4 Ans. b

IES2001I is t e ra e ang e o t e cutting tooshear an le and V is the cuttin velocit velocity of chip sliding along the sheag ven y

(a) (b)cosV sincos

V

c Anssin( ) sin( )

IES2003An ort ogona cutting operation is eingcarried out under the followin conditions:cutting speed = 2 m/s, depth of cut = 0.5 mm,c p c ness = 0. mm. en e c pvelocit is

(a) 2.0 m/s (b) 2.4 m/s

(c) 1.0 m/s (d) 1.66 m/s Ans. (d)

IAS2003nort ogona cutting,s earang eist eang e etween

(a) Shearplaneandthecuttingvelocity

(b) Shearplaneandtherakeplane

(d) Shearplaneandthedirectionofelongationofcrystalsin

t e

c p

Ans.(a)

IAS2002

IAS2000

Ans.(d)

IAS1998e cutting ve ocity in m sec, or turning a wor piece

of diameter 100 mm at the spindle speed of 480 RPM is

(a) 1.26 (b) 2.51

c 8 d 1 1

ns.

IAS1995n an ort ogona cutting, t e ept o cut is

the feed rate is double. If the chip thicknunaffected with the changed cutting condactual chip thickness will be

(a) Doubled (b) halved

.

Ans. b



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IES1998

The gauge factor of a resistive pickup of

ratio of

(a) Applied strain to the resistance of the wire

T e proportiona c ange in resistance to t ea lied strain

(c) The resistance to the applied strain

(d) Change in resistance to the applied strain

ns.

IES2000

Assertion (A): In metal cutting, the normal.

Reason (R : Ver hi h tem erature isproduced at the toolchip interface.

a Bot A an R are in ivi ua y true an R isthe correct ex lanation of A

(b) Both A and R are individually true but R isnot the correct explanation of A

d A is false but R is true Ans. (a

GATE1992The effect of rake angle on the mean fric

(A) sliding (Coulomb) model of friction

(B) sticking and then sliding model of friction

(D) Sliding and then sticking model of frictio

.

IES2004ssertion : e ratio o uncut c ip t ic ness to

actual chip thickness is always less than one and istermed as cutting ratio in orthogonal cutting

Reason (R): The frictional force is very high due to theoccurrence of sticking friction rather than slidingfriction

(a) Both A and R are individually true and R is the correct

(b) Both A and R are individually true but R is not thecorrect exp anat on o

(c) A is true but R is false

(d) A is false but R is true Ans. (b)

GATE1993The effect of rake angle on the mean friction angle in

(a) Sliding (coulomb) model of friction

(b) sticking and then siding model of friction

(d) sliding and then sticking model of friction

Ans. (b)

ToolWear,ToolLife&ToolWear,ToolLife&MachinMachin

y

y Ex lainsuddendeathmechanismoftoolfailure.

[4 marks]

IES2009ConventionalShowcraterwearandflankwearonasinglepoint

.onaturningtool.

2mar s

IES2010

an wear occurs on e

a Relief face of the tool

(b) Rake face

(c) Nose of the tool

utt ng e ge

Ans. (a)



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IES 2008W ataret ereasons orre uctiono too i eina

machiningoperation?

1. Temperatureriseofcuttingedge

2. pp ngo oo e ge ue omec an ca mpac

3. Gradualwearsattoolpoint4. Increaseinfeedofcutatconstantcuttingforce

e ec ecorrec answerus ng eco eg venbelow:

(a) 1,2and3 (b) 2,3and4

, , .

IAS 2002Consi ert e o owing actions:

1. Mechanical abrasion 2. Diffusion

3. Plasticdeformation 4. Oxidation

W c o t e a ove are t e causes o too wear?

a 2 and b 1 and 2(c) 1, 2 and 4 (d) 1 and 3

Ans. c

IAS 1999T e type o wear t at occurs ue to taction of the particles in the cuttinreferred to as

(b) Diffusion wear

(c) Erosive wear

Ans. (c)

IAS 2003Consi er t e o owing statements:

Chi in of a cuttin tool is due to

1. Tool material being too brittle

2. Hot ar nesso t e too mater a .

. Hi h ositive rake an le of the tool.

Which of these statements are correct?a 1, 2 an 3 1 an 3

c 2 and d 1 and 2

Ans. (b)

IES 2012InTay or stoo eequat onVTn =C,t econstantsn

andCdependupon

1.Workpiecematerial

.

3.Coolant

(a)1,2,and31an 2on y

(c)2and3only

(d)1and3only

ns. a

e e p o ay or s oo e e

of cutting and life of the tool. Assume an H

and steel as work material.

[10

IES1996C ip equiva ent is increase y

(b) An increase in nose radius and side cuttingedge angle of tool

c ncreas ng t e p ant area o cut

.Ans. (b)

IES 1992Too i eisgenera yspeci ie y

(a) Numberof iecesmachined

(b) Volumeofmetalremoved

c Actua cutt ngt me

d An oftheabove

Ans.(d)

GATE2004In a mac ining operation, ou cuttin s eed reduces the tool life the original value. The exponent n inoo e equa on = , s

1 1 1

8 4 3 a c

Ans. c



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IES 2000In a too i e test, ou ing t e cutting speereduces the tool life to 1/8th of the original. TheTaylor's tool life index is

( ) ( ) ( ) ( )1 1 1 1

a b c d 2 3 4 8

Ans. b

IES 1999Inasing epointturningoperationo steewit a

cementedcarbidetool,Taylor'stoollifeexponentis0.25.Ifthecuttingspeedishalved,thetoollifewillincreaseb

(a) Twotimes (b) Fourtimes

c Eig ttimes Sixteentimes

Ans.(d)

IES 2008InTay or stoo i eequationisVTn =const

Whatisthevalueofnforceramictools?

(a) 0.15to0.25 (b) 0.4to0.55

c 0.6to0.75 0.8to0.9

Ans.(c)

IES 2006W ic o t e o owing va ues o in ex n isassociated with carbide tools when Taylor's tool lifeequation, V.Tn = constant is applied?

(c) 0.45 to 06 (d) 065 to 09

.

IES 1999T e approximate y variation o t e too i eexponent 'n' of cemented carbide tools is

(a) 0.03 to 0.08 (b) 0.08 to 0.20

. . . .

Ans. (c)

IAS 1998a c s u ng oo ma er a w s

(Typicalvalueoftoollifeexponent'n'intheTn . =

thecodesgivenbelowthelists:

s s

A. HSS 1. 0.18

B. Castalloy 2. 0.12

C. Ceramic 3. 0.25

D. Sinteredcarbide 4. 0.5

(a) 1 2 3 4 (b) 2 1

c 2 1 4 3 1 2

n an or ogona mac n ng opera on, e oo e

,

while at 75 m/min cuttin s eed, the tool life is 30

min. The value of index (n) in the Taylors tool life

equation

(a) 0.262 (b) 0.323 (c) 0.423 (d) 0.521

Ans. (a)

ISRO2011

A 50 mm diameter steel rod was turned at 284 rpm and

tool failure occurred in 10 minutes. The speed was

c a nge to 232 rpm an t e too a e n 0 m nutes.

s eed and tool life, the value of Ta lorian Ex onent is(a) 0.21 (b) 0.13 (c) 0.11 (d) 0.23

Ans. (c)

IES2010The above figure shows a typicalrelationship between tool life andcutting speed for differentmaterials. Match the graphs for

, ar e an eram c toomaterials and select the correctanswer us ng e co e g venbelow the lists:

Co e: HSS Car i e Ceramic

(a) 1 2 3

(b) 3 2 1

c 1 2 (d) 3 1 2

ns.



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IAS 2002Usingt eTay orequationVTn =c,ca cu atet e

percentageincreaseintoollifewhenthecuttingspeedisreducedby50%(n=05andc=400)

(c) 100% (d) 50%

Ans.(a)

IAS 2002Optimum cutting spee or minimum cost Vc minand optimum cutting speed for maximumproduction rate (Vr max ) have which one of thefollowin relationshi s?

(a) Vc min = Vr max (b) Vc min > Vr maxc Vc min < Vr max V

2c min = Vr max

Ans. (c)

IES2010ncreas ng cu ng ve oc y,

time for machining a component

(a) Decreases

(b) Increases

d First decreases and then increases

Ans. (d)

IAS 2000Consi ert e o owingstatements:

Thetoollifeisincreasedb

1. Built upedgeformation

2. Increas ngcutt ngve oc ty

. Increasin backrakean leu tocertainvalue

Whichofthesestatementsarecorrect?a 1an 3 1an 2

c 2and d 1 2and

Ans.(a)

IAS 1997In t e Tay or s too i e equation, VTn = C, t e va ueof n = 0.5. The tool has a life of 180 minutes at acutting speed of 18 m/min. If the tool life is reducedto minutes then the cuttin s eed will be

(a) 9 m/min (b) 18 m/min

c 36 m/min 72 m/min

Ans. (c)

IAS 1996T etoo i eincreaseswit t e

(a) Increaseinsidecuttin ed ean le

(b) Decreaseinsiderakeangle

c Decrease nnosera us

d Decreaseinbackrakean le

Ans. a

IAS 1995

Inasing epointturningoperationwit acemente carbideandsteelcombinationhavingaTaylorexponentof0.25,ifthecuttingspeedishalved,thenthetoollifewillbecome

(a) Half

(b) Twotimes

c Ei httimes(d) Sixteentimes.

Ans. d

IAS 1995

Assertion A : An increase in ept o cut s ortensthe tool life.

Reason(R): Increases in depth of cut gives rise to.

(a) Both A and R are individually true and R is thecorrect explanation of A

b Both A and R are individuall true but R is not thecorrect explanation of A

c s rue u s a se

(d) A is false but R is true [Ans. (a)]

IES 2006

conventional

An HSS too is use or turning operatool life is 1 hr. when turnin is carm/min. The tool life will be reduced to

e cu ng spee s ou e . n s eed in RPM for turnin 00 mm dithat tool life is 30 min.

Ans. (36.66 rpm)



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IES 1995 IES 1992

IAS 1996


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IES 1995In owcar onstee s,presenceo sma quantities

sulphur improves

(a) Weldability (b) Formability

c ac na y ar ena y

Ans.(c)

IES 1992Mac iningo titaniumis i icu t ueto

(a) Hi hthermalconductivit oftitanium

(b) Chemicalreactionbetweentoolandwork

c Lowtoo c pcontactarea

d None

of

the

above

Ans. b

IAS 1996Assertion A :T emac ina i ityo amate

bemeasuredasanabsolutequantity.

Reason(R):Machinabilityindexindicates

(a) BothAandRareindividuallytrueandRcorrectexp anationo A

b BothAandRareindividuall truebutRicorrectexplanationofA

c s rue u s a se

(d) AisfalsebutRistrue

Ans.(d)

GATE2009Frictionatt etoo c ipinter acecan e

reducedb

(a)decreasingtherakeangle

(b)increasingthedepthofcut

c ecreas ngt ecutt ngspee

Ans.(d)

IES 2002T e va ue o sur ace roug ness o taine uringthe turning operating at a feed 'f' with a round nosetool having radius 'r' is given as

.

IAS 1996Given t at

S = feed in mm/rev. and

R = nose radius in mm,

t e max mum e g t o sur ace roug produced by a singlepoint turning tool is give

(a) S2

/2R4

(c) S2/4R

(d) S2/8R

ns.

IES

1999In turning operation, t e ee cou e ou e toincrease the metal removal rate. To keep the samelevel of surface finish, the nose radius of the toolshould be

(a) Halved (b) Kept unchanged

(c) doubled (d) Made four times

Ans. d

GATE

1997Acuttingtoo asara iuso 1.8mm.T e ee rate

foratheoreticalsurfaceroughnessofRa =5 mis

(a) 0.36mm/rev

.

(c) 0.036mm/rev

(d) 0.0187mm/rev

Ans.(none)

GATE 2007

(PI)

oo w e u ng ge ang e oEnd Cutting Edge angle of 10o is useturning with a feed of 1 mm/rev. Negle

,height of surface roughness produced w

(a) 0.16 mm (b) 0.26 mm

c 0.32 mm 0.48 mm.



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IES 2011 GATE 2003


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IES2011Assertion (A): Lead, Zinc and Tin are always hotworked.

Reason (R) : If they are worked in cold state.

(a) Both A and R are individually true and R is thecorrect explanation of A

the correct explanation of A


d A is false but R is true Ans. b

GATE2003Co wor ing o stee is e ine as wor in

(a) At its recr stallisation tem erature

(b) Above its recrystallisation temperature

c Be ow ts recrysta sat on temperature

d At two thirds of the meltin tem erametal

Ans. (c)

GATE2002,ISRO2012Hotro ing o mi stee iscarrie out

(a) At recr stallisation tem erature

(b) Between 100C to 150C

c Be ow recrysta sat on temperature

d Above recr stallisation tem erature

Ans.

a er a s a er co wor ng are su ec e o

o ow ng process o re eve s resses

a ot wor ng

(b) Tempering(c) Normalizing

(d) Annealing Ans. (d)

IES 2006W ic one o t e o owing is t e procesthe grains of metal after it has been dihammering or cold working?

(c) Recrystallizing (d) Normalizing

Ans. (c)

IES 2004

Consi er t e o owing statements:

In com arison to hot workin , in cold workin ,

1. Higher forces are required

2. No eat ng s requ re

. Less ductilit is re uired

4. Better surface finish is obtained

Which of the statements given above are correct?a 1 2 and b 1 2 and

(c) 1 and 3 (d) 2, 3 and 4

Ans. (b)

IES 2009

Consi er t e o owing c aracteristics:

1. Porosit in the metal is lar el eliminated.

2. Strength is decreased.

3. C ose to erances cannot e ma nta ne .

Which of the above characteristics of hot workin is arecorrect?

a 1 on y 3 on y (c) 2 and 3 (d) 1 and 3

Ans. (d)

IES 2008

Consi er t e o owing statements:

1. Metal formin decreases harmful impurities and improves mechanical strength

.process.

3. Very intricate shapes can be produced

rocess as com ared to castin rocess.Which of the statements given above are corr

a 1, 2 an 3 1 an 2 on y

c 2 and onl d 1 and onl



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IAS 1996

IAS 2004

IAS2002


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IAS 1996For mi stee , t e ot orging temperature range is

(a) 000C to 6000C

(b) 7000C to 9000C

c 10000C to 12000C

d 1 000

Cto 1 000

C

Ans. c

IAS 2004Assertion A : Hot wor ing oes not pro uce strainhardening.

Reason (R): Hot working is done above the re.

(a) Both A and R are individually true and R is the

correct exp anation o Ab Both A and R are individuall true but R is not the

correct explanation of A

c s rue u s a se

(d) A is false but R is true Ans. (a)

IAS 2002Assertion A : T ere is goo grain re inemworking.

Reason (R): In hot working physical prop.

(a) Both A and R are individually true an

correct exp anation o Ab Both A and R are individuall true but R


c s rue u s a se

(d) A is false but R is true

Ans. (b) Ulta hai. Assertion reason me hon

IES2008W ic one o t e o owing is correct?

Malleabilit is the ro ert b which a metal oralloy can be plastically deformed by applying

(c) Shear stress (d) Compressive stress

ns.

y on a

c o e o ow ng processes wou

a Hot rollin

(b) Extrusion

(c) Cold rollin

(d) Forging Ans. (c)

Rin rollin is used

(a) To decrease the thickness and increaseameter

(b) To increase the thickness of a rin

(c) For producing a seamless tube

orpro uc ng arge cy n er

Ans. (a)

IES 2006

W ic one o t e o owing is a continuous en ingprocess in which opposing rolls are used to producelong sections of formed shapes from coil or stripstock?

(a) Stretch forming (b) Roll forming

(c) Roll bending (d) Spinning

Ans. (c)

n so ropy n ro e componen s s caus

d rain orientation

Ans. d



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StressEquilibrium

of

an

Element

in

Rolling

xFor sliding friction, = p Simplifying and neglecting

secon or er erms, s n an cos , we ge

d h

=

'

0Due to cold rolling, increases as h decrease

'

0thus nearly a constant and itsderivative zeh


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Considering the thickness of the element perpendicular to the

,

direction as,- + + + -

x

+ 2 R d cos = 0

x x x

d h2 ( )x pR

d

=

'

0 0

2x

p = =

'

2

d

h R =

d

( )'0 '0

1 2h pRd

=

' d p p 'd

0 ' '

0 0d 0

d

( )'0/ 2p Rd

'

0/p h

( )

'

2 1 cosf f

h h R h R = + +

( )0

2'

/ 2d p Rd

=

0 fp

' 2R d 2R0

nf

ph

=+ 2 2

fR h R

=+

2

2Rd 2Rd 2d hI ln

= = = = f

2fh

=R

d hor 2

d R=

2

2 II d

h R=

+

22 d=f

+

f f

2 . tan .h h

=

( )

= + ' 10 h R Rl n p / ln 2 . tan . ln C

f f

' h =

0p e

R

= 1R Rwhere H 2 . tan .

h h

=Now at entry,

=

=0

Hence H H with replaced by inabove equation

= '0

Therefor p

= ' ohIntheentry zone, p C. e

= oH

o

and C .eh

( )= 0 H H'h

. e0

h

n e ex zone

= ' H

0

f

p .eh

At the neutral po int above equati

willgivesameresults

( ) =0 n n H H Hn n

h h. e . e

0 f

. .h h

( )= 0 n H 2Ho

f

or eh

= 0

h1 1

n 0

f2 h

= 1R RFrom H 2 . tan .

f f

=

f f nn

. tan .R R 2

( )= + n f nand h h 2R 1 cos

b

H H

,h

= o b

0

p . eh

fIf front tension is thereat Exit,

( )= Ho fh

p . ef

Calculate the neutral lane to roll 2 0 mannealed copper strip from 2.5 mm to thickness wit 0 mm diameter steel rolls .0.05 and o =180 MPa.

1


RollingCh14.

1 C

GATE 2010(PI)


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2 B

3 D

4 D

6 A

7 B

8 D

9 C

11 B

12 CB SKMondal

Hot die steel, used for large solid dies in dr

s ou necessari y ave

a g strengt a n g copper content

g ar ness an ow ar ena y

.

a a van ages oes press org ng ave over rop

for in ? Wh are ure metals more easil cold worked

than alloys ?

[5

marks]

ompare m org ng, rop org ng, press

.

for each.

[10 Marks]

ome mes e par ng p ane e ween wo

,

for this design aspect, why is partin

provided, in closed die forging?

[

GATE2007

In open ie orging, a isc o iameter 200 mm anheight 60 mm is compressed without any barrelingeffect. The final diameter of the disc is 400 mm. Thetrue strain is

(a) 1.986 (b) 1.686

(c) 1.386 (d) 0.602

Ans. (c)

GATE1992,

ISRO

2012

Thetruestrainforalowcarbonsteelbarwhichis

(a) 0.307

(b) 0.5

.

(d) 1.0

.

GATE2012

SameQ

GATE

2012

A solid cylinder of diameter 100 mm and

mm is forged between two frictionless fla

.

diameter is

(a)0 (b)2.0 (c)20. (d) 1.

Ans.(d)



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IES 1993Assertion A : Direct extrusion requires arger orce

IES 1994Meta extrusion process is genera y use or

IES 2009W ic one o t e o owing statements is


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q gthan indirect extrusion.

Reason (R): In indirect extrusion of cold steel, zinc.

(a) Both A and R are individually true and R is the

correct exp anation o Ab Both A and R are individuall true but R is not the


c s rue u s a se

(d) A is false but R is true Ans.(b)

p g yproducing

(a) Uniform solid sections

n orm o owsec ons

(c) Uniform solid and hollow sections

(d) Varying solid and hollow sections.

ns. c

g

(a) In extrusion rocess, thicker walls can bby increasing the forming pressure

x rus on s an ea process or o a n nmetal having poor density

(c) As compared to roll forming, extruding sp

including the flow of metal being in the same

Ans. (c)

IES 1999W ic one o t e o owing is t e correcttemperature range for hot extrusion of aluminium?

(a) 300340C (b) 350400C

Ans. (c)

IES 2000ons er e o ow ng s a emen s:

In forward extrusion process

1. The ram and the extruded product travel in the samedirection.

2. The ram and the extruded product travel in the oppositedirection.

3. The speed of travel of the extruded product is same as that

of the ram.4. The speed of travel of the extruded product is greater than

that of the ram.

Which of these Statements are correct?

(c) 1 and 4 (d) 2 and 4 Ans. (c)

IES 2009W at is t e major pro em in ot extrusio

(a) Desi n of u nch (b) Desi n of d

(c) Wear and tear of die (d) Wear of pu

Ans. (b)

IES2012

Extrus on process can e ect ve y re uce t e cost oproduct through

(a) Material saving

(c) Saving in tooling cost

(d) saving in administrative cost

Ans. (c)

IES 2008

W ic one o t e o owing met o s is use or t emanufacture of collapsible toothpaste tubes?

(a) Impactextrusion (b) Directextrusion

Ans. (a)

IES 2003

T e extrusion process s use or t e protoothpaste tube is/are

1. Tube extrusion

.

3. Impact extrusion

Select the correct answer using the codes give

o es:(a) 1 only (b) 1 and 2

(c) 2 and 3 (d) 3 only

ns.



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2B =

.

x o

sB C at r r = =

1

For a roundbar both wiredrawing and extrusion willgive

ssame equationexceptB C

oat r r =

( )11

B

o oB r

+

=

fB r


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2Bb o

Cr

=

2 2

o

B B

1 .ox bo o

orB r r = +

2 2B B ( ) 1 .o

d b

o o

Drawing stressB r r

= +

same equationexceptB.C

( ) ( )2

1B

x oB B rC + =

. , 0 (at exit stressis zero)s f xB C at r r = =

( )1

21 Bo

B +

fr

=

( )2

1B

o B r +

= xfB r

2

Extrusion ratio for round baro oA r

R

= =f f

A r

for flat stockoh= f

21o B

xo RB

=

rampressurerequiredbycontainer frictionfp =

uniforminterfaceshear stressbetweeni =

billetandcontainerwall

2

0 0. 2i

f i fp r r L or pr

= =

tTotalExtrusion Pressure(P )

o

xo fp = +a 20nd Extrusion Load .tp r=

Ch17:Extrusion

. o p on . o p on

1 D 8 B

2 C 9 B

4 D 11 B

6 C 13 A7 B

Ch16:Drawing

. No O tion

1 A

3 C

4 B

5 C

6 D

B SKMondal

Exampleeterm ne t e e an punc s zes or an ng a c rcu ar

disc of 20mm diameter from a sheet whose thickness is 1.5mm.

Shear strength of sheet material = 294 MPa

Also determine the die and punch sizes for punching a

circular hole of 20mm diameter from a sheet whosethickness is 1.5 mm.

ExampleEstimate the blanking force to cut a blank 2

and 30 mm long from a 1.5 mm thick metal

Also determine the work done if the

penetration is 25 percent of material thicknes

Ans. 74.25 kN, 27.84 Nm



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ISRO2009

The force required to punch a 25 mm hole in a

GATE2007T e orce requirement in a an ing operation olow carbon steel sheet is 5 0 kN The thickness of

GATE200410 mm iameter o es are to e punc e sheet of 3 mm thickness Shear streng


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q p 5

mild steel plate 10 mm thick, when ultimate shear

stress of the plate is 500 N/mm2will be nearly

(a) 78 kN (b) 393 kN (c) 98 kN (d) 158 kN

Ans. (b)

low carbon steel sheet is 5.0 kN. The thickness ofthe sheet is t and diameter of the blanked part isd. For the same work material if the diameter ofthe blanked part is increased to 1.5 d and thickness

. ,

(a) 3.0 (b) 4.5

(c) 5.0 (d) 8.0

.

sheet of 3 mm thickness. Shear strengmaterial is 400 N / mm2 and penetratiShear rovided on the unch is 2 mm. Thforce during the operation will be

a 22. 37.7(c) 61.6 kN (d) 94.3 kN

ns. a

GATE2003A meta isc o 20 mm iameter is to e punc efrom a sheet of 2 mm thickness. The punch and thedie clearance is 3%. The required punch diameter is

. .

(c) 20.06 mm (d) 20.12 mm

.

Calculate the unch size in mm for a circular blankinoperation for which details are given below.

ze o t e an 25 mm

Thickness o f the s heet 2 mm

Radial clearance between punch and die 0.06 mm

e a owance 0.05 mm

(a) 2 .8 (b) 2 .8

(c) 25.01 (d) 25.17

Ans. a

sheet of 2.5 mm thickness. The require

clearance between the die and the punch

sheet thickness. The punch and die diameters

, ,

(a) 50.00 and 50.30 (b) 50.00 and 5

(c) 49.70 and 50.00 (d) 49.85 and 5

Ans. (c)

GATE2002

In a an ing operation, t e c earance is provi eon

(a) The die

(c) The punch

(d) Brittle the punch nor the die

Ans. (c)

GATE2001

T e cutting orce in punc ing an an ingoperations mainly depends on

(a) The modulus of elasticity of metal

(c) The bulk modulus of metal

(d) The yield strength of metal

Ans. (b)

GATE1996

A 50 mm iameter isc is to e punc e carbon steel sheet 1.0 mm thick. The dithe punch should be

. .

(c) 50.075 mm (d) none of the above

.



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IES 2007W ic one o t e o owing meta ormingprocesses is not a high energy rate forming process?

IES 2009W ic one o t e o owing is a ig energy rateforming process?

IES 2005Magnetic orming is an examp e o :

(a) Cold formin (b) Hot f


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(a) Electromechanical forming

o orm ng

(c) Explosive forming

(d) Electrohydraulic forming

Ans. (b)

(a) Roll forming

ec ro y rau c orm ng

(c) Rotary forging

(d) Forward extrusion

Ans. (b)

(c) High energy rate forming (d) Roll f

Ans. c

Writefouradvanta esofhi hvelocit formin rocess.

[2marks]

GATE2000A 1.5 mm t ic s eet is su ject to unequa iaxiastretching and the true strains in the directions ofstretching are 0.05 and 0.09. The final thickness ofthe sheet in mm is

(a) 1.414 (b) 1.304

c 1.362 289

Ans. (b)

e en ng orce requ re or en bending and Edge bending will be in the ra

(a) 1 : 2 : 0.5 (b) 2: 1 : 0.5

Ans. (a)

GATE2005

A 2 mm t ic meta s eet is to e ent at an ang e oone radian with a bend radius of 100 mm. If thestretch factor is 0.5, the bend allowance is

(c) 101 mm (d) 102 mm

2mm

1 radian

Ans. (c)

GATE2007

a c e correc com na on or o ow ng me aworking processes.

Processes Associated state o f stress

P. Blankin 1. Tension

Q. Stretch Forming 2. Compression

. o n ng 3. ear

S. Deep Drawing 4. Tension and Compression

5. Tension and Shear

(a) 2 1 3 4 (b) 3 4 1 5

c 5 4 3 1 3 1 2 4

Ans.(d)

GATE2012

SameQ

in

GATE

201

Match the following metal forming processeassociated stresses in the work iece.

Metalformingprocess Typeofstress

1.Coining P.Tensile

. .

3.Blanking R.Tensileand

compress ve.Dee Drawin S.Com ressive

(a) 1S, 2P, 3Q, 4R (b) 1S, 2P, 3R, 4

(c) 1P, 2Q, 3S, 4R (d) 1P, 2R, 3Q,


GATE2004Matc t e o owing

Product Process

IAS 1999a c s rocess w s ro uc on o par s

and select the correct answer using the codes given

IAS 1997Matc ListI meta orming process w(Associated feature) and select the correusing the codes gi en below the Lists


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P. Moulded luggage 1. Injection moulding

Q. Pac ag ng conta ners or qu 2. Hot ro ng

R. Lon structural sha es . Im act extrusion

S. Collapsible tubes 4. Transfer moulding

5. B ow mou ing

6. Coinin

(a) P1 Q4 R6 S3 (b) P4 Q5 R2 S3

(c) P1 Q5 R3 S2 (d) P5 Q1 R2 S2Ans. (b)

ListI ListII

A. Rolling 1. Discrete parts

B. Forging 2. Rod and Wire

C. Extrusion 3. Wide variety of shapes with thinwalls

D. Drawing 4. Flat plates and sheets

. .

Codes:A B C D A B C D

a 2 5 3 4 1 2 5 4

(c) 4 1 3 2 (d) 4 1 5 2

using the codes given below the Lists:

A. Blanking 1. Shear angle

B. Flow forming 2. Coiled stoc. .

D. Embossing 4. Closed mat

Codes:A B C D A B

(c) 1 3 2 4 (d) 3 1

IES2010

ons er e o ow ng s a emen s:

The material ro erties which rinci alldetermine how well a metal may be drawn are

1. a o o y e s ress o u ma e s ress.

2.Rate of increase of ield stress relative toprogressive amounts of cold work.

3. ate o wor ar en ng.

(a) 1 and 2 only (b) 2 and 3 only

(c) 1 only (d) 1, 2 and 3 Ans. (d)

Ch18:SheetMetalForming

. o p on . o p on

1 C 10 C

2 B 11 C

4 A 13 C

6 A 15 A7 A 16 B

9 A

By SKM

Which of the followin owder roductionmethods produces spongy and porous

(a) Atomization

(b) Reduction of metal oxides

(d) Pulverization

Ans. (b)

IES2012

In e ectro ysis

(a) For makin co er owder, co er late is madecathode in electrolyte tank

,made anode

(c) High amperage produces powdery deposit of cathodemetal on anode

(d) Atomization process is more suitable for low meltingpo n me a s

Ans. (b)

e a pow ers are compac e y many me

sinterin is re uired to achieve which ro er

is hot isostatic pressing?


n pow er me a urgy, s n er ng o a componen

y Whatisisostatic ressin ofmetal owders?

c o e o ow ng process s


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p gy, g p

Ans. b

y Whatareitsadvantage?

[2Marks]

g p

a Castin

(b) weldin

(c) formation

(d) Powder metallurgy An

The bindin material used in cementedcarbide cutting tools is

a grap te

(b) tun sten

(c) nickel

co a t

Ans. (d)

IES2010

ons er e o ow ng par s:

1. Grindin wheel

2. Brake lining

3. Selflubricating bearings

ic o t ese parts are ma e y pow e r

metallur techni ue?(a) 1, 2 and 3 (b) 2 only

(c) 2 and 3 only (d) 1 and 2 only

ns. c

IES2010

e a c pow ers can e pro uce y

a Atomization

(b) Pulverization

(c) Electrodeposition process

o t e a o v e

Ans. (d)

IES 2002

T e rate o pro uction o a pow er meta urgy partdepends on

(a) Flow rate of powder

(c) Apparent density of compact

(d) Compressibility of powder

Ans. (c)

IES 2001

Matc ListI Components wit ListII(Manufacturing Processes) and select the correctanswer using the codes given below the lists:

A. Car body (metal) 1. Machining

B. Clutch lining 2. Casting

. .

D. Engine block 4. Powder metallurgy Ans.(d)

Codes:A B C D A B C D

(c) 4 3 2 1 (d) 3 4 1 2

GATE2011

The operation in which oil is permeatedores of a owder metallur roduct is kno

(a) mixing

s nter ng

c im re nation

(d) Infiltration

Ans. (c)



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IAS 2004T e o owing are t e constituent steps in t eprocess of powder metallurgy:

1. Powder conditioning

IAS 2003ssertion : tomization met o or pro uction o

metal powders consists of mechanical disintegration ofmolten stream into fine particles.

IAS 2007Consi er t e o owing asic steps invo production of porous bearings:

1. Sintering


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1. Powder conditioning

2. n er ng

3. Production of metallic powder

4. Pressing or compacting into the desired shapen en y e correc or er n w c ey ave o e

performed and select the correct answer using the codesgiven below:

a 12 b 1 2

(c) 2413 (d) 4321 Ans. (b)

Reason (R): Atomization method is an excellent meansof making powders from high temperature metals.

explanation of Ao an are n v ua y rue u s no e



d A is false but R is true Ans. c

1. Sintering

2. x ng

3. Repressing

4. Impregnation5. o ecompac on

Which one of the following is the correct sequabove steps?

ConventionalQuestions1. Exp a n w y meta pow ers are en e . Descr e w at

happens during sintering. [IES2010, 2 Marks]

ConventionalQuestions1. scuss e erms neness an par c e s ze

distribution in powder metallurgy. [IES2010, 2ar s

Ans.

Fineness: Is the diameter of spherical shaped particleand mean diameter of nons herical sha ed article.

Particle size distribution: Geometric standarddeviation (a measure for the bredth or width of adistribution), is the ratio of particle size diameterstaken at 84.1 and 50% of the cumulative undersized

weight plot, respectively and mean mass diameterdefine the particle size distribution.

ConventionalQuestionsEnumerate t e steps nvo ve n pow er process. Discuss these steps. Name the main powder metallurgy. What are the lim

owder metallur ? IES200 , 1

Q. No Option Q. No Option

1 D 5 C

2 B 6 B

3 C 7 D


Tolerancesares ecified

(a) To obtain desired fits


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Limit Tolerance&Fits

By SKMondal

(a) Toobtaindesiredfits

(b) becauseitisnotpossibletomanufactureexactl

(c) toobtainhigheraccuracyto avepropera owances

Ans.(b)

xpress ng a mens on as 25.3 . mm s e c ase o

Ans. b

GATE 2010,

ISRO

2012

A shaft has a dimension0.0090.02535

The respective values of fundamental deviation and

(a) 0.025, 0.008 (b) 0.025, 0.016

(c) 0.009, 0.008 (d) 0.009, 0.016

.

GATE

1992Twos a tsAan B avet eir iameterssp

100 0.1mmand0.1 0.0001mmrespect

Whichofthefollowingstatementsis/aretrue

(b) TherelativeerrorinthedimensionisgreaA

(d) Therelativeerrorinthedimensionissam

AandshaftB

Ans.(a)

GATE

2004In an interc angea e assem y, s a ts o size

mm mate with holes of size mm.0.040

0.010025.000

+

0.020

0.00025.000

+

The maximum possible clearance in the assembly

(a) 10 microns

(b) 20 microns

(d) 60 microns

.

ISRO2010

0.02 0.02

0.00 0.00Dimension of the hole is 50 mm and shaft is 50 mm.+ +

+

(a) 0.02 mm (b) 0.00 mm

(c) -0.02 mm (d) 0.01 mm

.

GATE

20070 . 0 5 0A o e is speci ie as mm. Tshaft has a clearance fit with minimum cl

0 . 0 0 04 0

0.01 mm. The tolerance on the shaft is 0.0maximum clearance in mm between thethe shaft is

a 0.04

(b) 0.05

(c) 0.100.11

Ans. (c)For-2013 (IES, GATE, PSUs) Page 54


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GATE 2003T e imensiona imits on a s a t o 25 7 are

(a) 2 .000, 2 .021 mm

(b) 25.000, 24.979 mm

GATE2010(PI)A small bore is designated as 25H7. The lower

(minimum) and upper (maximum) limits of the bore

a s e erence e ween o e as s sy

shaft basis s stem ? Wh is hole basis s stem


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c 25.000, 25.007 mm

d 2 .000 2 . mm

Ans.

are 25.000 mm an 25.021 mm, respec ve y. en e

bore is desi nated as 2 H8 then the u er maximum

limit is 25.033 mm. When the bore is designated as

25H6, then the upper (maximum) limit of the bore (in

mm) is

a 25.001 25.005 c 25.009 25.013

Ans. d

shaft basis s stem ? Wh is hole basis s stem

extensive in use ?

What are the differences between interchan

and selective assembly ?

1

GATE

2003

[Ans.(b)]

GATE

1997ree oc s 1 , 2 an 3 are

to be inserted in a channel of

minimum gap of width T =. , .

For P = 18. 75 0.08;

= 25.00 0.12;

R = 28.125 0.1 and

S = 72.35 + X, (where alldimensions are in mm), thetolerance X is

(a)+0.38 (b) 0.38 (c)+0.05 (d) 0.05

Ans.(d)

IES

2000W ic one o t e o owing to erances sediameter and outer diameter respectivelyjig bush for press fit is correct?

(c) H 7h 6 (d) F7j6

.

Plu au es are used to

(a) Measure the diameter of the workpieces

easure e ame er o e o es n eworkpieces

(c) Check the diameter of the holes in theworkpieces

(d) Check the length of holes in the workpieces

Ans. (c)

GATE

2004GO an NOGO p ug gagesare to e esigne or a

hole mm. Ga e tolerances can be taken as 10%0.0520

of the hole tolerance. Following ISO system of gage

.

,respectively

(a) 20.010 mm and 20.050 mm

b 20.01 mm and 20.0 6 mm

(c) 20.006 mm and 20.054 mm20.014 mm an 20.054 mm

Ans. b

GATE

1995C ec ing t e iameter o a o e using Ggauges is an, example of inspe..(variables/attributes)

(a) Variables

(b) Attributes

(d) Insufficient data

.



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ee ergauge suse oc ec e

s ne ar s spec e y

GATE 2012(PI)

A sine bar has a length of 250 mm. Eac

has a diameter of 20 mm. During tape


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Ans. c Ans. c

measurement o a component, t e

is 100 mm.

The calculated taper angle (in degrees)

(a) 21.1 (b) 22.8 (c) 23.6 (d) 68.9

Ans. (a)

The best wire size in mm for measurineffective diameter of a metric thread

o

2.5 mm pitch using two wire method is

(a) 1.443 (b) 0.723

. .

Ans. (a)

IES

1992W ic gra e sym o represents sur ace roug obroaching?

(a) N12 (b) N8

4 1

Ans. (b)

IFS2011What is meant by interchangeable manufa

Laser light has unique advantages for inspe

What are they ? Define the terms 'ro

' ' ' ' 'e g , wav ness w an ay n co

.

10

va uean va uesareuse or

measurementof

(a)Metalhardness

(b)Sharpnessoftooledge

(c)Surfacedimensions

(d)Surfaceroughness

Ans.(d)

IES

2006The M and Esystem in metrology are related to

measurement of:

a crew t rea s atness

c ngu ar y ur ace n s

.

IES

2007W at is t e ominant irection o t e tooscratches in a surface texture having a dquality, called?

(c) Lay (d) Flaw

.


IES 2008

What term is used to designate the direction of the

pre ominant sur ace pattern pro uce y

IES2010Match List I with List II and select the correct answerusing the code given below the lists:List I List II

(Symbols for direction of lay) (Surface texture)

IES 2008


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Ans. (b)

A B C D A B C D

ns.

(a) 4 2 1 3 (b) 3 2 1 4(c) 4 1 2 3 (d) 3 1 2 4

Ans.(c)

b

(a) Triangles

(b) Circles

(c) Squares

(d) Rectangles

Ans. (a)

GATE

1997

s s

(A) Surface profilometer 1. Calibration

(B) Light Section Microscope 2. Form tester

.measurement

n er erome er 4. en re ne average

5. Comparator

6. Surface lay measurement

(a) 4 1 2 3 (b) 4 3 5 1

c 4 2 1 3 3 1 2 4Ans.(b)

GATE

2003Two s p gauges o 10 mm w t measur ngand 1.002 mm are kept side by side in contacother lengthwise. An optical flat is kept ressli au es as shown in the fi ure. Monochroof wavelength 0.0058928 mm is used in the

on both slip gauges is

(a) 2 (b)6

Ans.(a)

MiscellaneousofMetrology

By SKMondal

GATE

1998

Auto co mator s use to c ec

(a) Rou hness

(b) Flatness

c Ang e

d Automobile balance.

Ans. (c)

n au oco ma or s u se o

d measure roundness error between centers

Ans. c



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LinkedAnswerQuestionsGATE2013 S1

In orthogonal turning of a bar of 100 mm diameter

with a feed of 0.2 mm rev de th of cut of mm

and cutting velocity of 90 m/min, it is observed that

LinkedAnswerQuestionsGATE2013 S2

In orthogonal turning of a bar of 100 mm diameter

with a feed of 0.2 mm rev de th of cut of mm

and cutting velocity of 90 m/min, it is observed that


65/65

g y 9 ,

the main (tangential)cutting force is perpendicular

.

The main (tangential) cutting force is 1500 N.

y The orthogonal rake angle of the cutting tool in degree is

(a) zero (b) 3.58 (c) 5 (d) 7.16

g y 9 ,

the main (tangential)cutting force is perpendicular

.

The main (tangential) cutting force is 1500 N.

y The normal force acting at the chiptool interface in N is

(a) 1000 (b) 1500 (c) 20oo (d) 2500

GATE-2013 Asked Questions Page 2 of 2

question set new 2013 2

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