PRODUCTION
17. A milling cutter having 8 teeth is rotating at 100 rpm. The work piece feed is set at 40 m/min. the feed
per tooth is (PI-GATE-90)
a) 5 mm b) 0.05 mm c) 0.4 mm d) 0.2 mm
18. A600 mm x 30 mm flat surface of plate is to be finish machined on a shaper. The place has been fixed
with the 600 mm side along the tool travel direction. If the tool over-travel at each end of the plate is
20 mm, average cutting speed is 8 m/min, feed rate is 0.3 mm/stroke and the ratio of return time to
cutting time of the tool is 1:2, the time required for machining will be (ME-GATE-05)
a) 8 minutes b) 12 minutes c) 16 minutes d) 20 minutes
19. A 31.8 MM HSS drill is used to drill a hole in cast iron block 100 mm thick at cutting speed of
n20/m/min and feed 0.3 mm/rev. if the over travel of drill is 4 mm and approach 9 mm, the time
required to drill the hole is (PI-GATE-02)
a) 1 min 40s b) 1 min44s c) 1 min 49s d) 1min53s
20. Match the follwoing (PI-GATE-89)
List - 1 List -2
A. Grinding 1. Compound oil
B. Tapping 2. EP additive oil
C. Automatics 3. Chemical fluids
D. Broaching 4. Straight fatty oils
21. Find the spped range ratio for the drilling machine spindle if the minimum and maximum diameters of
drills used are 5 mm and 25 mm respectively and if the machinability indices for the work materials are
120 (brass) and 40 (alloy steel) (PI-GATE-92)
a) 3/5 b) 5/3 c) 5 d) 15
22. A side and face cutter 125 mm diameter has 10 teeth. It operates at a cutting speed of 14m/min with
a table traverse 100mm/min. the feed per tooth of the cutter is (PI-GATE-02)
a) 10 mm b) 2.86 mm c) 0.286 mm d) 0.8 mm
23. The diameter and rotational speed of a jobare 100 and 500 rpm respectively. The high spots (chatter
marks) are found at a spacing of 30 deg on the job surface. The chatter frequency is
(PI-GATE-90)
a) 5 Hz b) 12 Hz c) 100 Hz d) 500 Hz
24. A drilling machine has to be designed with 8 spindle speeds ranging approximately between 12o to
1200 rpm. The 5th spindle speed is (PI-GATE-91)
a) 445 b) 480 c) 620 d) 865
25. If the number of double strokes per minute in a shaper is calculate by (0.643 X cutting speed in
mm/min)/length for the stroke in m Then the return speed is faster than the cutting speed by
(PI-GATE-89)
a) 40% b) 60% c) 80% d) 100%
26. If the index crank of a dividing head is turned through one complete revolution and 10 hoes in a
30 holes circle plate, the work piece turns through (in degrees) (PI-GATE-92)
a) 6 b) 12 c) 240 d) 480
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MECHANICAL ENGINEERING
27. For cutting double start screw threads of pitch 2.0 mm on a lathe, the thread cutting tool should have
a feed rate to (PI-GATE-90)
a) 0.5 mm/rev b) 1.0 mm/rev c) 2.0 mm/rev d) 4.0 mm/rev
28. The base of a brass brackets has to be rough gound to remove the unevenness. The 4 wheels available
in the store. The appropriate wheel is (PI-GATE-90)
a) A 30 K 12 V b) C 90 M 4B c) C 30 Q 12V c) C 50 G 8V
29. A work-piece of 2000 mm length and 300 mm width was machined by a planning operation with the
feed set at 0.3 mm/stroke. If the machine tool executes 10 double stroke/min, the planning time for a
single pass will be (PI-GATE-93)
a) 50 min b) 100 min c) 200 min d) 220 min
30. A job of the shape shown in the figure below is to be machined on a lathe. The tool best suited for
machining of this job must have (PI-GATE-04)
a) positive side rake angle
b) positive back rake angle
c) positive cutting edge inclination angle
d) negative cutting edge inclination angle
31. One brand of milling machine has the following two index plates supplied along with the indexing
head : (PI-GATE-05)
Plate 1 : 15, 16, 17, 18, 19, 20 hole circles
Plate 2 : 21, 23, 27, 29, 31, 33 hole circles
It is proposed to mill a spur gear of 28 teeth using simple indexing metho. Which one of the following
conbinations of index plate and number of revolutions is correct ?
a) Plate 1 : 1 revolution and 9 holes in 18 hole circles
b) Plate 2 : 1 revolution and 9 holes in 21 hole circles
a) Plate 2 : 1 revolution and 9 holes in 33 hole circles
a) Plate 1 : 1 revolution and 9 holes in 15 hole circles
32. Match List I (Milling problem) with List - II (Probable causes) and select the correct answer using the
code given below the lists : (PI-GATE-05)
List - I List - II
(Milling problem) (Probable causes)
A. Chatter 1. Too high feed
B. Poor surface finish 2. Lack of rigidity in machine, fixutre, bar or workpiece
C. Loss of accuracy 3. High cutting load
D. Cutter burrs 4. Radial relief too great
5. Not enough lubricant
Codes :
a) A-2, B-1, C-5, D-3
b) A-2, B-1, C-3, D-5
c) A-4, B-5, C-2, D-3
d) A-4, B-2, C-3, D-5
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33. A non standard thread of pitch 3.175 mm is to be cut on a lathe having lead screw of pitch 6 mm. A
change gear set provided with the lathe has one gear each with the following number of teeth : 20, 30,
40, 50, 60, 70, 80, 90, 100, 110, 120, 127. The correct pairs of change rears (a/b x c/d) for
machining the given thread are (assuming that the transmission ratioof the rest of the kinematic train
between the lathe spindle and lead screw is equal to 1) (PI-GATE-04)
a) 127 x 20 127 x 20 c) 127 x 30 d) 127 x 30
30 80 b) 40 120 20 120 50 80
34. Match List I (Cutting tools) with List - II (Features) and select the correct answer using the
codes given below the lists : (PI-GATE-05)
List - I List - II
(Cutting tools) (Features)
A. Turning tool 1. Chisel edge
B. Reamer 2. Flutes
C. Milling cutter 3.Axial relief
4. Side relief
Codes :
a) A-1, B-2, C-3
b) A-4, B-3, C-2
c) A-4, B-2, C-3
d) A-1, B-3, C-2
35. Consider the following statements : (PI-GATE-04)
The helical flute in a twist drill provides the necessary
1. clearance angle for the cutting edge.
2. rake angle for the cuttinge edge.
3. space for the chip to come out during drilling
4. guidance for the drdill to enter into the work piece
Which of the statements given above are correct ?
a) 1 and 2 b) 2 and 3 c) 3 and 4 d) 1 and 4
36. Machanism Machine (PI-GATE-03)
P. Pantograph 1.Automobile
Q. Quick return 2. Lathe
R. Ackerman 3. Engraver
S. Toggle 4. Shaper
5. Press
Codes :
a) P-3, Q-1, R-2, S-4
b) P-3, Q-4, R-1, S-5
c) P-2, Q-4, R-5, S-3
d) P-2, Q-3, R-4, S-5
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MECHANICAL ENGINEERING
37. A φ 20 mm through hole is to be drilled in a 30 mm thick plate using a double fluted, 1200 lip angle drill.
The drill tip is at a distance of 3 mm from the plate surface when cutting is started and an over travel of
2 mm is recommended as a margin to ensure drilling through the full thickness of the palte. If the drill
rotates at 500 rev/min and the feed per tooth is 0.01 mm, the machining time of the operation (in sec)
will be. (PI-GATE-04)
a) 4.5 b) 7.5
c) 9 d) 10.5
38. Match the list I (machine tool) with list II (machine tool part)
List - I List - II
A. Lathe 1. lead scrw
B.millingmachine 2. Rocker arm
C. Shaper 3. universal indexing
D. drilling macine 4. Flute
. ABCD
a) 4 2 3 1
b) 1 3 2 4
c) 4 3 2 1
d) 1 2 3 4
39. The purpose of helical grooves in a twist drill is to (PI-GATE-03)
1. IMprove the stiffness 2. Save a tool material
3. Provide space for chip remoal 4. Provide rake angle for the cutting edge
Select the correct answer suitng the codes given below :
a) 1 & 2 b) 2 & 3 c) 3 & 4 d) 1
40. The quick return mechanism used in shaper has rocker arm drive of lenght 200 mm. If the crank radius
is 50 mm and the offset between crank center and rocker arm pivot is 20 mm, length ofthe stroke
(in mtrs) is (PI-GATE-08)
a) 0.5 b) 1.0 c) 1.5 c) 2.0
41. Match the following materails with their most appropriate applications: (PI-GATE-11)
Materails Application
1. Low carbon steel P. Machine tool base
2. Stainless steel Q. Aircraft parts
3. Gray cast iron R. Kitchen utensils
4.Titanium alloys S. Car body panels
a) 1-P, 2-R, 3-Q, 4-S
b) 1-P, 2-R, 3-S, 4-Q
c) 1-S, 2-Q, 3-P, 4-R
d) 1-S, 2-R, 3-P, 4-Q
42. The number of defective produced by a six sigma process (in Parts per million) is (PI-GATE-11)
a) 5.2 b) 4.2
c) 3.2 d) 2.2
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PRODUCTION
Statement for Linked Answer Quetsion for 43 & 44
Blind hole 10 mm diameter, 50 mm deep are being drilled in steel block, drilling spindle speed is
600 rpm, feed 0.2 mm/rev., point angle of drill is 120.
43. Machining time (in min) per hole will be (PI-GATE-07)
a) 0.08 b) 0.31 c) 0.44 d) 0.86
44. During the above operaion, the drill wears out after producing 200 holes. Taylor’s tool life equation is
of the from VT0.3 = C, where V = cutting speed in m/min and T = tool life in min. Taylor’s constant
C will be (PI-GATE-07)
a) 15 b) 72 c) 93 d) 490
45. In a shaping process, the number of double strokes per minute is 30 and the quick return ratio is 0.6.
if the length of the stroke is 250 mm, the average cuting velocity in mm/min is (PI-GATE-12)
a) 3.0 b) 4.5 c) 7.5 d) 12.0
46. In a single pass drilling operation, a though hole of 15 mm diameter is to be drilled in a steel plate of
50 mm thickness. Drill spindle speed is 500 rpm, feed is 0.2 mm/rev and drill point angle is 1180.
Assuming 2 mm clearance at approach and exit, the total drill time (in seocnds) is
(ME&PI-GATE-12)
a) 35.1 b) 32.4 c) 31.2 d) 30.1
Statement for Linked Answer Questions for 47 & 48
During orthogonal machining of a mild steel specimen with a cutting tool of zero rake angle, the
following data is obtained :
Uncut chip thickness = 0.25 mm
Chip thickness = 0.75 mm
Width of cut = 2.5 mm
Normal force = 950 N
Thrust force = 475 N
47. The shear angle and shear force, respectively, are (PI-GATE-11)
a) 71.5650, 150.12N b) 79.12180, 861.64N
c) 18.4350, 751.04N d) 23.1570, 686.66N
48. The ultimate shear stress (in N/mm2) of the work material is (PI-GATE-11)
a) 235 b) 139 c) 564 d) 380
************
“It’s easier to go down a hill than up it but the view is much
better at the top”
6. Machining (Ans) : Two Marks
1-d, 2-see sol, 3-d, 4-c, 5-b, 6-see sol, 7-c, 8-c, 9-a, 10-see sol, 11-see sol, 12-see sol, 13-b, 14-d, 15-
see sol., 16-c, 17-b, 18-b, 19-c, 20-see sol, 21-d, 22-c, 23-c, 24-a, 25-c, 26-b, 27-c, 28-a, 29-b, 30-a,
31-b, 32-b, 33-b, 34-c, 35-b, 36-b, 37-a, 38-b, 39-c, 40-b, 41-d, 42-c, 43-c, 44-b, 45-d, 46-a, 47-c,
48-d.
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MECHANICAL ENGINEERING
7 SHEET METAL OPERATIONS
ONE MARK QUESTIONS
1. Wall thickness of drawn cup is controled by [PI-GATE-92]
a) Deep drawing b) Reverse drawing c) Redrawing d) Ironing
2. In progressive die (for sheet metal) , spring loaded stripeer plate is used to comaps the stock unitl :
[PI-GATE-91]
a) The punch penetrets twice the stock thickness b) It removes wrinkles on the product edges
c) Automatic feeder plate release it d) Punch is completely withdrawn from the stock
3. For blanking and pearcing operations, elcarnace is provided on the ..................... and the ......................
respectively. [ME-GATE-87]
4. In .............. A.............. operation the diameter of the desired hole will be smaller than the diameter of
the ................ B ...................... [PI-GATE-91]
A. blanking / piercing B. punch / die
5. In blanking operation the clearnace is provided on [ME-GATE-02]
a) The die b) The punch
c) Both die and punch equally d) Neither the punch nor the die
6. A cup of 10 cm height and 5 cm diameter is to be made from a sheet metal of 2 mm thickness. The
number of deductions necessary will be [PI-GATE-91]
a) One b) Two c) Three d) Four
7. Wrinkling is a common defect found in [ME-GATE-91]
a) Bent components b) Deep drawn components
c) Embossed components d) Blanked component
8. In a bending operation, if the modulus of elasticity E is increased keeping all other parameters
unchanged, the spring back will [PI-GATE-94]
a) increase b) decrease
c) remains unchanged d) be independent of E
9. The cutting force in punching & blanking operations mainly depends on [ME-GATE-01]
a) The modulus of elasticity of the material b) The shear strength of the material
c) The bulk modulus of the material d) The yield strenght of the material
10. In deep drawing of sheets, the values of limiting draw ratio depends on [ME-GATE-94]
a) Percentage elongation of the the sheet b) Yield strength of the sheet
c) Type of press used d) thickness of sheet
11. For 50% penetration of work material, a punch with single shear equal to thickness will
a) reduce the punch load to half the value
b) incrase the punch load by half the value
c) maintain the same punch load
d) reduce the punch load to quarter load
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PRODUCTION
12. Match the following metal forming processes with their associated stresses in the work-piece
[ME-12 & PI-GATE-12]
Metal forming Type of stress
1. Coining P. Tensile
2. Wire Drawing Q. Shear
3. Blanking R. Tensile and compressive
4. Deep Drawing S. Compressive
Code :
. 1234
a) S P Q R
b) P Q S R
c) S P R Q
d) P R Q S
13. In blanking operation, the best way to improve the smoothness and squarness of t he edges is to
[PI-GATE-94]
a) have reduced gap between punch and die b) increase the ductility of the sheet
c) decrease the speed of blanking d) provide shear on the punch
14. Product Manufacturing process [PI-GATE-03]
P. Food cansq 1. Forging
Q. Connecting rods 2. Rolling
R. Metal foils 3. Deep drawing
4. Extrusion
a) P-3 Q-1 R-2
b) P-1 Q-2 R-4
c) P-4 Q-3 R-3
d) P-2 Q-4 R-1
15. In producing a punched hole of 20 mm dia, the dimentions of the punch is ........... given the radial die
clearande of 0.1 mm. [PI-GATE-94]
16. Which on is not a method of reducing cutting forces to prevent the overloading of press
[PI-GATE-03]
a) providing shear on die b) providing shear on punch
c) increasing the clearnace d) stepping punches
17. A cup of 10 cm height and 5 cm diameter is to be made from a sheet metal of 2 mm thickness. The
number of deductions necessary will be [PI-GATE-02]
a) one b) two c) three d) four
18. The function of draw bead in the deep drawing operation is to [PI-GATE-94]
a) produce a balance between the amount of stretching and drawing
b) produce a circular groove on the flange
c) reduce the drawing load
d) reduce the wrinklees on the flange
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MECHANICAL ENGINEERING
TWO MARKS QUESTIONS
1. A 2 mm thick metal sheet is to be bent at an angle of one radian with a bend radius of 100 mm. If the
stretch factor is 0.5, the bend allowance is [ME-GATE-05]
a) 99 mm b) 100 mm c) 101 mm d) 102 mm
2. A shell of 100 mm diameter and 100 mm height with the corner radius of 0.4 mm is to be produced by
cup drawing. The required blank diameter is [ME-GATE-03]
a) 118 mm b) 161 mm c) 224 mm d) 312 mm
3. The thickness of the blank needed to produce, by power spinning a missilbe cone of thickness 1.5 mm
and half cone angle 30 deg [ME-GATE-92]
a) 3.0 mm b) 2.5 mm c) 2.0 mm d) 1.5 mm
4. Match the items in column I and II [ME-GATE-06]
Column - I Column - II
P. Wrinkling 1.Yield point elongation
Q. Orange peel 2. Anisotropy
R. Stretcher strain 3. Large grain size
S. Earing 4. INsufficient blank holding force
5. Fine grain size
6. Excessive blank holding force
a) P-6, Q-3, R-1, S-2 b) P-4, Q-5, R-6, S-1
c) P-2, Q-5, R-3, S-4 d) P-4, Q-3, R-1, S-2
Common Data for Questions 5 & 6
In shear cutting operation, a sheet of 5 mm thickness is cut along a length of 200 mm, the cutting blade is 400
mm long ( see figure ) and zero - shear ( S = 0 ) is provided on the edge. The ultimate shear strength of the
sheet is 100 MPa and penetration to thihckness ration is 0.2 neglect friction [ME-GATE-10]
5. Assuming force Vs displacement curve to be rectangular, the work done in J is
a) 100 b) 200 c) 250 d) 300
6. Ashear of 20 mm ( S 20 ) is now provides on the blade.Assuming force Vs displacement curve to be
trapezoidal, the maximum force ( in KN ) exerted is
a) 5 b) 10 c) 20 d) 40
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PRODUCTION
7. A metal disc of 20 mm diameter is to be punched from a sheet of 2 mm thickness. The punch and the
die clearance is 3%. The required punch diameter is [ME-GATE-03]
a) 19.88 mm b) 19.94 mm
c) 20.06 mm d) 20.12 mm
8. A 50 mm diameter disc is to be punched out from a carbon steel 1.0 mm thick. The dia. of the die
should be (Take clearance as 3% of sheet thickness ) [ME-GATE-96]
a) 49.925 mm b) 50.00 mm
c) 50.075 mm d) none
9. 10 mm diameter holes are to be punched in a steel of 3 mm thickness. Shear strength of the material is
400 N/mm2 and penetration is 40%. Shear provided on the punch is 2 mm. The blanking force during
the operation will be [ME-GATE-04]
a) 22.6 KN b) 37.7 KN
c) 61.6 KN d) 94.3 KN.
10. Identify the stress strain in the FLANGE portion of a PARTIALLY DRAWN CYLINDRICAL CUP
when deep drawing without a blank holder [ME-GATE-99]
a) tensile in all three directions
b) no stress in the flange at all, because there is no blank holder
c) tensile stress in one direction and compressive stress in other direction
d) tensile in two directions and compressive in third direction
11. It is required to punch a hole of diameter 10mm on a sheet of thickness 3mm. The shear strength of the
work material is 420 MPa. The required punch force is [PI-GATE-06]
a) 19.78 KN b) 39.56 KN c) 98.9 KN d) 395.6 KN
12. The force requirement in a blanking operation of low carbon steel sheet is 5.0 KN. The thickness of
the sheet is ‘t’ and diameter of the blanked part is ‘d’ , for the same work material, if the diameter of
the blanked part is increased to 1.5 d and thickness is reduced to 0.4 t, the new blanking force in KN
is [ME-GATE-07]
A) 3.0 b) 4.5 c) 5.0 d) 8.0
13. Determine the load required to punch a 20 mm diameter hole in 2 mm thick sheet. The properties of
the material of the sheet are : [PI-GATE-04]
Tensile strength - 580 MPa ; Yield strength in tension - 410 MPa
Shear strength - 350 MPa ; Yiled strength in shear - 250 MPa
The load in kN is :
a) 31.40 b) 43.98 c) 64.40 d) 91.10
14. A hole of 40 mm diameter is pierced in a steel sheet of 4 mm thickness without shear on the tool. Shear
strength of steel is 400 N/mm2 and penetration is 25%. What is the expected percentage load
reduction if a shear of 1 mm is provided on the punch ? [PI-GATE-04]
a) 25.00 b) 33.33 c) 50.00 d) 66.67
15. The shear strength of a sheet metal is 300 MPa. The blanking force required to produce a blank of
100 mm diameter from a 1.54 mm thick sheet is close to [ME-GATE-11]
a) 45 kN b) 70 kN c) 141 kN d) 3500 kN
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MECHANICAL ENGINEERING
16. A hydraulic press is used to produce circular blanks of 10 mm diameter from a sheet of 2 mm
thickness. If the shear strength of the sheet material is 400 N/mm2, the force required for producing a
circular blank is [PI-GATE-03]
a) 8 kN b) 25.13 kN c) 31.42 kN d) 125.66 kN
17. Calculate the smallest punch diameter that can be designed for piercing sheet metal strip with the
following data. Crushing strength of the punch material is 1500 MPa. Thickness of the sheet is 2 mm,
factor of safety is 3, shear strength of the sheet material 500 MPa is [PI-GATE-90]
a) 2 mm b) 6 mm c) 8 mm d) 24 mm
18. Consider the following statements related piercing and blanking [PI-GATE-03]
1. shear on the punch reduces the maximum cutting force
2. shear increases the capacity of the press needed
3. shear increases the life of the punch
4. total energy needed to make the cut remains unaltered due to provision of shear which of the above
statements are correct
a) 1 & 2 b) 1 & 4 c) 2 & 3 d) 3 & 4
19. In the deep drawing of cups, blanks show a tendency to wrinkle up around the periphery (glange). The
most likely cause and remedy of the phenomenon are respectively. [ME-GATE-08]
a) Buckling due to circumferential compression : increase blank holder pressure
b) High blank holder pressure and high friction : rreduce blank holder pressure and apply lubricant
c) HIgh temperature causing increase in circumferential length : apply coolant to blank
d) Buckling due to cirumferential compression : decrease blank holder pressure
20. In sheet metal working, the spring back increase when [PI-GATE-03]
P. ratio of bend radius to sheet thickness is small
Q. Young’s modulus of the sheet is low
R. yild strength of the sheet is high
S. tension is applied during bending
a) P, Q, R b) Q, R c) P, Q, S d) P, S, Q
21. A cylindrical cup of 48.5 mm diameter and 52 mm height has a corner radius of 1.5 mm cold rolled
steel sheet of thickness 1.5 mm is used to produce the cup. Assume trim allowance as 2 mm per
25 mm of cup diameter. What is the blank size in mm ? [PI-GATE-04]
a) 102.0 b) 115.4 c) 120.5 d) 128.5
22. In metal forming operation, the true strain in the X-direction is 0.3 and in the Y - direction is - 0.1, the
true strain in the Z - direction is [PI-GATE-94]
a) 0 b) -0.2 c) 0.2 d) -0.03
23. A hemispherical cup of radius ‘R’ is formed in a press working operation. The radius of blank would
be [PI-GATE-92]
a) √2R b) √3R c) √2/3R d) √3/2R
24. Calculate the punch size in mm, for a circular blanking operation for which details are given below
Size of the blank 25 mm, Thickness of the shet 2 mm [ME&PI-GATE-12]’
Radial clearnace between punch and die 0.06 mm. Die allowance 0.05 mm
a) 24.83 b) 24.89 c) 25.01 d) 25.17
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PRODUCTION
25. Match the items in Group I and II [PI-GATE-06]
Group - I Group II
P.Yield point elongation 1. distortion of dimension
Q. Spring back 2. Leuder’s bands
R. Wrinkling 3. plastic deformation
S. Residual stresses 4. compressive stress
a) P-3, Q-4, R-2, S-1
b) P-4, Q-4, R-1, S-2
c) P-2, Q-3, R-4, S-1
d) P-2, Q-1, R-4, S-3
26. A φ mm hole is pierced in a t = 2.5 mm thick steel sheet having shear strength τ = 350 MPa. If the
diametral clearnce is given by the expresion c = 0.0064 t √ τ, the dia diameter (in mm), punch
diameter (in mm) and punch force in (k N) respectively are [PI-GATE-05]
a) 25.0, 25.3, 171.8 b) 25.0, 24.7, 68.75
c) 24.7, 25.0, 171.8 d) 25.3, 25.0, 68.75
Common Data for Questions 27 & 28
A cup is to be drawn to a diameter of 70 mm with 35 mm depth from a 0.5 mm thick sheet metal. The
cup is drawn in one operation. Assume σ = 430 MPa
u
27. The required blank diameter is [PI-GATE-06]
a) 86.7 mm b) 119.5 mm c) 121.24 mm d) 169 mm
28. The maximum drawing force is [PI-GATE-06]
a) 0.047 MN b) 0.82 MN c) 0.83MN d) 9.69 MN
29. A disc of 200 mm diameter is blanked from a strip of an aluminum alloy of thickness 3.2 mm, the
material shear strength to fracture is 150 MPa. The blanking force (in KN) is [PI-GATE-09]
a) 291 b) 301 c) 311 d) 421
30. It is required to punch a hole of diameter 10 mm on a sheet of thickness 3 mm. The shear strength of
the work material is 420 MPa. The required punch force is [PI-GATE-06]
a) 19.78 KN b) 39.56 KN c) 98.9 KN d) 395.6 KN
31. A blank of 50 mm diameter is to be sheared from a sheet of 2.5 mm thickness. The required radial
clearnce between the die and the punch is 6% of sheet thickness. The punch and die diameter (mm)
for this blanking operation respectively are [PI-GATE-08]
a) 50.00 and 50.30 b) 50.00 and 50.15
c) 49.70 and 50.00 d) 49.85 and 50.00
32. A gear with 84 teeth is to be machined using a milling process with indexing. The index plate has the
following four hole circles : 36, 38, 42, 48. the change gear ratio required is [PI-GATE-06]
a) 8/21 b) 10/21 c) 21/10 d) 21/8
33. Circular blanks of 35 mm dia are punched from a steel sheet of 2 mm thickness. If the clearance per
side between the punch and die is to kept as 40 microns, the sizes of punch and die should respectively
be. [PI-GATE-07]
a) 35 & 35.040 b) 34.92 & 35
c) 35 & 35.080 d) 35.040 & 34.92
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MECHANICAL ENGINEERING
34. In deep drawing of sheet metal, spring loaded stripper clamps the work until : [PI-GATE-04]
a) The punch penetrates twice the stock thickness
b) It removes wrinkles on the product edges
c) Shedder removes the work from the tools
d) Punch is completely withdrawn from the work material
35. Match the follwoing
Group - I Group - II
P. Wrinlking 1. Upsetting
Q. Center burst 2. Deep drawing
R. Barrelling 3. Extrusion
S. Cold shut 4. Closed die forging
a) P-2, Q-3, R-4, S-1
b) P-3, Q-4, R-1, S-2
c) P-2, Q-3, R-1, S-4
d) P-2, Q-4, R-3, S-1
36. A work piece of 1000 mm length and 300 mm width is machined by planning operation with a feed of
0.3 mm/stroke. The machine tool executes 10 double strokes per minute. The planning time for a
single pass is [PI-GATE-06]
a) 50 min b) 100 min c) 166.66 min d) 333.33 min
37. In a surface broaching process, a broach haivng 5 mm pitch and cut per teeth 0.05 mm is used for
reducing the thickness by 6 mm. If the length of the work piece is 50 mm and the cutting speed is
0.05 m/s, the time required / pass is seconds is [PI-GATE-06]
a) 11 b) 12 c) 13 d) 1200
FIVE MARKS QUETIONS
1. Circular blanks of 50 mm in diameter are to be produced from a 3 mm thick electrolytic copper sheets
for which the resistance to shear is 350 MPa. Calculate the force required for blanking assuming no
shear on the punch. How will the blanking force change if hexagonal blanks of 25 mm are produced by
a punch having a shear of 2 mm and 50% penetration. [ME-GATE-89] (4M)
2. The end view of a drawing board clip is shown in Fig. below. The width of the clip is 20 mm. The
length of flat starting strip is ............... [PI-GATE-93] [5M]
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3. A cylindrical cup of diameter 12 mm & height 16 mm has a corner radius of 0.5 mm, it is made out of
a sheet of 2 mm thick & the material has a constant flow of 35 MPa. Neglecting the corner radius.
[PI-GATE-94] [5M]
i) the diameter of the blank would be ....................
a) 20 mm b) 30.2 mm c) 36.1 mm d) 41.6 mm
ii) the drawing stress based on idle deformation (neglecting friction, blank holding force & effect of
punch corner radii) is ...............
a) 52 MPa b) 68 MPa c) 98 MPa d) 106 MPa
iii) the no. of draws required to draw the part if the draw reduction ratio for first and subsequent draws
is 40% and 25% is ......................
a) 2 b) 3 c) 4 d) 5
4. Determine the maximum possible axial force that may be needed to punch a hole of diameter 10 mm
in a metalsheet whose thickness is 2 mm and shear strength 200 MPa.Also determine the diameter of
the smallest hole that can be safely punched in the above steel with a factor of safety of 2.0, if the
compressive strength of the punch material is 1000 MPa. [ME-GATE-87] [6M]
5. A cup of 50 mm diameter & 75 mm deep is to be drawn from 1.5 mm thick steel sheet of deep
ddrawing quality of tensile strength 3000 N/sq mm. Neglecting the corner radius,
i) the diameter of the blank required is ...............
ii) force and energy must be applied for first draw with 40% reduction is ....... [PI-GATE-91] [4M]
6. A counter having a perimeter of 200 mm is pierced out from a 3 mm sheet having an Ultimate shear
strength of 250 MPa. What will be the amount of shear, if the punch force is to be reduced to 60%.
Where it be provided ? Assume the penetration to be 30%. [PI-GATE-89] [4M]
7. 15 mm diameter blanks are to be mass produced from sheet in cold working. The thickness of the
sheet is 3 mm and the clearnce between the punch and die is 0.3 mm, the nomial diameter of the die ia
............. [ME-GATE-88] [3M]
8. The part shown in fig is to be blanked from a steel strip of 2 mm thickness. Assuming the penetration
to be 40% & ultimate shear strength of the material to 145 MPa, [PI-GATE-95] [5M]
i) the force required for blanking operation would be .............
ii) work done in blanking operation would be .................
iii) the shear to be provided to carried out this operation on a 24 KN press is .............
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MECHANICAL ENGINEERING
9. A blank of 200 mm diameter is mass-produced from a sheet of 4 mm thick with ultimate shear
strength of 30 MPa, shear provided on one of the tools is 1 mm. [PI-GATE-92] [4M]
i) The punch force required assuming punch penetration as 35% is
a) 34 KN b) 44 KN c) 54 KN d) 64 KN
ii) The shear is provided on
a) punch b) die c) both d) any
10. A steel cup of height 30 mm and internal diameter 40 mm with a flange of width 10 mmis to be deep
drawn from a sheet of 1 mm thick. Determine the diameter of the blank and the drawing force. what
is the ddraw ratio ? Can the cup be drawn in single operation ? The properties of steel are : Yield point
= 150 MPa , UTS = 350 MPa, LDR = 1.9 and neglect the entry radius and blank holder force.
[ME-GATE-96] [5M]
11. A sheet of 1 mmthickness and 10 mm width is to be formed by bending as shown in the fig. what
should be the length of the blank ? [PI-GATE-90] [6M]
BENT SHAPE
12. A 5 mm thick MS plate is cut in a shearing machine and the length of cut is 500 mm, the shear strength
of the material is 300 MPa. Find the force required if the cutting blade is inclined at 1 edg. if the
percentage penetration is 40%. [ME-GATE-00] [5M]
13. A cup shown if fig is to be drawn from low carbon steel thickness 0.8 mm. the edge trimming allow
ance to be provided 4 mm on radius. Neglecting corner radius, thinning & spring back, the diameter
of the blank required is ................. [ME-GATE-88] [4M]
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14. Five holes of diameter 10 mm each are to be punched in a sheet 3 mm thick at a pitch of 25 mm. what
should be the minimum capacity of the press required (in Tonnes) if the yield point of material is
50 Mpa and (a) One hole is punched per stroke, (b) five holes are punched in a single stroke (hint no
shear is provided on the punches) [ME-GATE-96] [5M]
15. The strain in the cup extrusion for the part shown in fig is [PI-GATE-95] [5M]
a) In [Db / Dp]
b) In [Db/Db - Dp)]
c) In [Dp/Db - Dp)]
d) In [D2b/(D2b - D2p)]
16. Equal no. of circular blanks of 60 & 100 mm diameter is required for a product line. Design a strap
strip layout which is giving highest % utilization of sheet. [ME-GATE-90] [5M]
17. Estimate the reduction in piercing load for producting circular hole of 50 mm diameter in a 3 mm thick
steel strip, when the punch was provided with a shear of 1 mm. assuming 30% penetration and shear
strength of steel as 400 MPa.
**********************
“Knowing is not enough, we must apply. Willing is not enough,
we must do”
7. SHEET METAL OPERATIONS (ANS.)
ONE MARKS ANS : 1-d, 2-d, 3-sol, 4- piercing , die, 5-b, 6-b, 7-b, 8-b, 9-b, 10-b, 11-No Ans,
12-a, 13-a, 14-a, 15-sol., 16-c, 17-b, 18-d.
TWO MARKS ANS : 1-c, 2-c, 3-a, 4-d, 5-a, 6-b, 7-a, 8-b, 9-b.10-d, 11-b, 12-a, 13-b, 14-c, 15-c,
16-b, 17-c, 18-b, 19-a, 20-b, 21-b, 22-b, 23-, 24-a, 25-a, 26-d, 27-c, 28-a, 29-b, 30-c, 31-c, 32-b,
33-b, 34-d, 35-c, 36-b, 37-c.
FIVE MARKS ANS : 1-57%, 2- sol. , 3- sol, 4-3.2 mm, 5-3KJ, 6-0.6 mm, 7-14.4 mm, 8- sol,
9- sol, b, 10-2, 11-83.78 mm, 12-139.8 KN, 13-99.65 mm, 14-a)5.652 KN, b) 28.26 KN, 15-sol,
16-73%, 17-98.9 KN.
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8 NONTRADITIONAL MACHINING METHODS
ONE MARK QUESTIONS
1. Selection of electrolyte for ECM is as follows [ME-GATE-97]
a) non-passivating electrolyte for stock removal and passivating electrolyte for finish control
b) passivating electrolyte for stock removal and non-passivating electrolyte for finish control
c) selection of electrolyte is dependent on current density
d) electrolyte selection is based on tool-work electrodes
2. The two main criteria for selecting the electrolyte in ECM is that the electrolyte should
[ME-GATE-92]
a) chemically stable b) not allow dissolution of cathode material
c) not allow dissolution of anode material d) have high electrical conductivity
3. EDM is more efficient process than ECM for producing large non-circular holes. (T/F)
[ME-GATE-94]
4. In ultrasonic machining the tool ..................... at very high frequency with the help of .................
transducers. [ME-GATE-87]
5. Inter electrode gap in ECG is controlled by [ME-GATE-97]
a) controlling the pressure of electrolyte by
b) controlling the applied static load
c) controlling the size of diamond particle in the wheel
d) controlling the texture of the work
6. In USM the metal removal rate would ................. with increasing mean grain diameter of the abrasive
material. [ME-GATE-92]
a) increase b) decrease
c) increase and then decrease d) decrease and then increase
7. In ultrasonic machining process, the material removal rate will be higher for material with
[ME-GATE-93]
a) Higher toughness b) Higher ductility
c) Lower toughness d) Higher fracture strain
8. ECM .............. (Can/Cannot) be used for all such materials for which ultrasonic machining is possible,
while EDM ............. (Can/Cannot) be used for all such materials for which ECM is possible.
[ME-GATE-87]
9. USM is about the best process for making holes in glass which are comparable in size with thickness
of the sheet. [ME-GATE-94]
10. EDM impose larger forces on tool than ECM (T/F) [ME-GATE-94]
11. Which one of the following process conditions leads to higher MRR in ECM ? [PI-GATE-07]
a) Higher current, large atomic weight b) Higher valency, lower current
c) Lower atomic weight, lower valency d) Higher valency, lower atomic weight
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12. Arrange the processes in the increasing order of their maximum material removal rate [ME-GATE-06]
a) USM, LBM, EBM, EDM, ECM b) EBM, LBM, USM, ECM, EDM
c) LBM, EBM, USM, ECM, EDM d) LBM, EBM, USM, EDM, ECM
13. In PM process of manufacturing maximum temp is associated with [PI-GATE-91]
a) Briquetting b) Sintering c) Pre-sintering d) Blending
14. The maximum depth to width ratio in EBM welding is [PI-GATE-89]
a) 1:1 b) 2:1 c) 10:1 d) 25:1
15. The operation in which oil is permeated into the pores of a powder metallurgy product is knsown as
[ME-GATE-11]
a) mixing b) sintering c) impregnation d) infiltration
16. In EDM , the tool is made of [ME-GATE-99]
a) Copper b) HSS c) Cast iron d) Plain carbon steel
17. Electrochemical grinding removes material by ............ A ......... And ........... B .............. process .
[PI-GATE-92]
A. electrochemical / chemical B. mechanical / chemical
18. A tool and work are not in contact in EDM process [ME-GATE-03]
a) no relative motion occurs between them b) no wear of tool occurs
c) no power is consumed during metal cutting d) no force between tool and work occurs
19. In an AJM process, if Q = flow rate abrasives and d = the mean diameter of the abrasives, then MRR
is proportional to [PI-GATE-07]
a) Q/d2 b) Qd c) Qd2 d) Qd3
20. A 10 mm squre hole can be cut in a 2 mm thick glass plate by [PI-GATE-91]
a) USM b) EDM c) LBM d) ECM
21. In EDM, if the thermal conductivity of tool is high and the specific heat of work piece is low, then the
tool wear rate and material removal rate are expected to be respectively. [ME-GATE-07]
a) high and high b) low and low c) High and low d) low and high
22. In ECM the MRR is due to [ME-GATE-01]
a) Corrosion b) erosion c) Fusion d) Ion displacement
23. The crystal structure of austenite is [ME-GATE-11]
a) body centered cubic b) face centered cubic
c) hexagonal closed packed d) body centered tetragonal
24. The mechansim of material removal in EDM process is [ME-GATE-04]
a) Melting and Evaporation b) Melting and Corrosion
c) Erosion and Cavitation d) Cavitation and Evaporation
25. Arrange the process in the increasing order of their maximum material removal rate [PI-GATE-05]
a) USM, LBM, EBM, EDM, ECM b) EBM, LBM, USM, ECM, EDM
c) LBM, EBM, USM, ECM, EDM d) LBM, EBM, USM, EDM, ECM
26. Deep hole drilling of small diameter, say 0.2 mm is done with EDM by selecting the tool material as
[ME-GATE-00]
a) Copper wire b) Tungsten wire c) Brass wire d) Tungsten carbide
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MECHANICAL ENGINEERING
27. Ultrasonic machines used in material removal process, requires ultrasonic transducers. The transduceers
work on different working principles. One of the working principles of such ultrasonic transducers is
bassed on [PI-GATE-10]
a) Eddy current effect b) Seebeck effect c) Piezoresistive effecct d) Piezoelctric effect
28. In ultrasonic machining process, the material removal rate will be higher for material with
[ME-GATE-10]
a) Higher toughness b) Higher ductility
c) Lover toughness d) Higher fracture strain
29. The process of shot peening increases fatigue life of steel springs mainly because it results in
[PI-GATE-91]
a) Hardening of surface b) Increased stiffness of material
c) Compressive residual stresses d) microstructural changes in material
30. Choose the correct statement [ME-GATE-99]
a) Fixture is to guide the tool as well as to locate and clamp the work piece
b) Jig is to guide the tool as well as to locate and clamp the work piece
c) Jigs are used on CNC machines to locate and clamp the work piece and guide the tool
d) No arragement to guide the tool is provided in jig
31. In abrasive jet machining, as the distance between the nozzle tip and the work surface increase, the
material removal rate. [ME&PI-GATE-12]
a) increase continuously b) decrease continuously
c) decrease, becomes stable and then increase d) increases, becomes stable and then decreases
32. The use of fixture reduces [PI-GATE-91]
a) Only operation time b) Tooling cost
c) Only setting time d) Both setting time and operation
33. When a cylinder is located in a Vee-block, the number of degrees of freedom which are arrested is
[GATE-ME-2003]
a) 2 b) 4 c) 7 d) 8
34. Keeping all other parameters unchanged, the tool wear in electrical discharge machine (EDM) would
be less if the tool material has [PI-GATE-10]
a) High thermal conductivy and high specific heat
b) High thermal conductivity and low specific heat
c) Low thermal conductivity and low specific heat
d) Low thermal conductivity and high specific heat
35. Assertation (A) : In electron beam welding process, vaccum is an essential process parameter.
Reason (R) : Vaccum provides a highly efficient shield on weld zone. [PI-GATE-05]
36. Fixture are used in batch production for [PI-GATE-90]
a) Clamping the job b) Supporting and clamping the job
c) Supporting and clamping the job and guiding the tool
d) Supporting, locating and clamping the job.
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TWO MARKS QUESTIONS
1. A researcher conducts ECM on a binary alloy (density 6000 kg/m3) of iron (atomic weight 56,
valency 2) and metal P (atomic weight 24, valency 4) . Faradays constant 96500 coloumbs/mole.
Volumetric material removal rate of the alloy is 50 mm3/s at a current of 2000A. the percentage of the
metal P in the alloy is closed to [ME-GATE-08]
a) 40 b) 25 c) 15 d) 79
2. Match the following lists [ME-GATE-98]
List - I List - II
A. ECM 1. Plastic shear
B. EDM 2. Errosion / brittle fracture
C. USM 3. Corrosive reaction
D. LBM 4. melting vaporization
5. Ion displacement
6. Plastic shear and ion displacement
3. A zigzag cavity in a block of high strength alloy is to be finish machined. [ME-GATE-05]
This can be carried out by using
a) Electric discharge machining
b) Electric - chemical machining
c) Laser beam machining
d)Abrasive flow machining
4. Products Manufacturing process
A. porous bearings 1. Powder metallury
B. fly wheels 2. Casting
C. double end spanners 3. Closed die forging
D. plastic bottles 4. Blow molding
5. Typical machining operations are to be performed on hard-to-machine materials by using the
processes listed below. Choose best set of operation-Process combination Operation Process
[ME-GATE-04]
P. De-burring (internal surface) 1. PlasmaArc machining
Q. Die sinking 2.Abrasive Flow machining
R. Fine hole drilling in thin sheets 3. Electric Discharge Machining
S. Tool sharpending 4. Ultrasonic Machining
5. Laser beam Machining
6. Electrochemical Grinding
a) P-1, Q-5, R-3, S-4
b) P-1, Q-4, R-1, S-2
c) P-5, Q-1, R-2, S-6
d) P-2, Q-3, R-5, S-6
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MECHANICAL ENGINEERING
6. Process Defect (PI-GATE-90)
A. casting 1. Lack of penetration
B. welding 2. Penetration
C. extrusion 3. Flange wrinkles
D. deep drawing 4. Center burst
7. Electrochemical machining is performed to remove material from an iron surface of 20 X 20 mm under
the folllowing conditions [ME-GATE-09]
Inter electrode gap = 0.2 mm, Supply voltage ( Dc ) = 12V
Specific resistance of electrolyte = 2 ohm-cm
Atomic weight of iron = 55.85, Velency of iron = 2
Faradays constant = 96540 Couloumbs
The material removal rate ( in g/s ) is
a) 0.3471 b) 3.471 c) 34.71 d) 347.1
8. Machining process Associated problem [PI-GATE-91]
A. machining 1. Wrinkling
B. casting 2. Heat affected zone
C. welding 3. Hot tear
D. drawing 4. Built up edge
9. Estimate the MRR (in CC/hr) of an alloy containing 18% cobalt, 62% nickel and 20% chromium
during ECM with a current of 500 Amps. The density of the alloy is 8.28 g/cc. the following data is
availabe [ME-GATE-02]
Metal Gram atomic weight V al e n cy
2
Cobalt 58.93 2
6
N i ck e l 58.71
Chromium 51.99
Assume Faraday's constant as 96500 coulombs / mole.
10. A.Abrasive jet machining 1. Masking
B. PAM 2. Stamping die
C. Wire EDM 3. Engraving
D. Chemical machining 4. Drilling fine holes
11. In ECM, the material removal rate will be higher for metal with [ME-GATE-89]
a) large density b) larger valency
c) Larger chemical absorption tendency d) large chemical weight
12. Match the suitable manufacturing process for the following parts. [ME-GATE-07]
Parts Manufacturing processes
P. Computer chip 1. ECM
Q. Metal forming dies and tools 2. USM
R. Turbine blades 3. EDM
S. Glass 4. Photochemical machining
a) P-4, Q-3, R-1, S-2 b) P-4, Q-3, R-2, S-1
c) P-3, Q-1, R-4, S-2 d) P-1, Q-2, R-4, S-3
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13. Match the following lists [ME-GATE-98]
List - I List - II
A.Aluminium brake shoe 1. Deep drawing
B. Plastic water bottles 2. Blow molding
C. Stainless steel cups 3. Centrifugal casting
D. Soft drink can (aluminum) 4. Impact extrusion
5. Sand casting
6. Upset forging
14. 3-2-1 method of location in jig or fixture would collectively restricct the work piece in ‘n’ degress of
freedom, where the value of ‘n’ is [ME-GATE-01]
a) 6 b) 8 c) 9 d) 12
15. Electric switches made out of thermostats materials are produced by [ME-GATE-92]
a) compression molding b) transfer molding
c) injection molding d) vaccum molding.
16. Match the following non-traditional machining process with the corresponding material removal
mechanisms : [ME-GATE-11]
Machining process Mechanism of material removal
P. Checmial machining 1. Erosion
Q. Electro-chemical machining 2. Corrosive reaction
R. Electro-discharge machining 3. Iron displacement
S. Ultrasoni machining 4. Fusion and vaporization
a) P-2, Q-3, R-4, S-1 b) P-2, Q-4, R-3, S-1
c) P-3, Q-2, R-4, S-1 d) P-2, Q-3, R-1, S-4
17. Manufacturing process Property [PI-GATE-93]
A. cold rolling 1. Machinability
B.milling 2. Weldability
C. brazing 3. Ductility
D. powder metallurgy 4. Tensile strength
5. Compact ability
18. In ECM, the metal removal rate is directly proportainal to [PI-GATE-91]
a) density of work material
b) gram atomic weight of the work material
c) concentration of the electrolyte used
d) thermal conductivity of the work material
19. Machine components material used [PI-GATE-91]
A. machine tool bed 1. Forged steel
B. machine tool spindle 2. HSS
C. cutting tool 3. bronze
D. worm wheel 4. Cast iron
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MECHANICAL ENGINEERING
20. Machining process job [PI-GATE-90]
A. LBM 1. Making a printed circuit board
B. EDM 2. Drilling a hole in glass plate
C. Chemical milling 3. Making a die out of a die-steel block
D. USM 4. Cutting a polyester sheet
21. Process Properties of work material [PI-GATE-91]
A. casting 1. Ductility
B. forging 2. Malleability
C. wire drawing 3. Machinability
D. turning 4. Fluidity
22. Polymer product [PI-GATE-93]
A. polyster resin 1. Molded luggage
B. methyl methacrylate 2. Refrigerator insulation
C. polyurethane 3. FRP
D. polyvinyl chloride 4. Contact lenses
5. Floor tiles
23. Process Associated mechanism [PI-GATE-91]
A. Explosive welding 1. Liquid state
B. brazing 2. Solid state
C. Thermit welding 3. Solid-liquid state
D. manual metal arc weldign 4. Liquid state chemical
24. Products Manufacturing process [PI-GATE-90]
A. porous bearings 1. Powder metallurgy
B. fly wheels 2. Casting
C. double end spanners 3. Closed die forging
D. plastic bottles 4. Blow molding
25. Process Media used [PI-GATE-91]
A. EDM 1. Electrolyte
B. ECM 2. Dielectric
C. USM 3.Abrasive slurry
D. EBM 4. Vaccum
26. Match the following [PI-GATE-89]
List - 1 List - 2
A. ECM 1. Erosion
B. USM 2. Fusion and vaporization
C. EDM 3. Vaporization and ablation
D. LBM 4. Ion displacement
27. In an electrochemical machining (ECM) operation, a square hole of dimensions 5m X mm is drilled in
a block of copper. The current used is 5000A. automic weight of copper is 63 and valence of
dissolution is 1. faradays constant is 96500 coulomb. the material removal rate (g/s) is [PI-GATE-08]
a) 0.326 b) 3.26 c) 3.15 X 103 d) 3.15 X 155
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PRODUCTION
28. Match List - I (Machining process) with List - II (Operating medi(a) and select the correct answer
using the codes given below the lists : [PI-GATE-05]
List - I List - II
(Machining process) (Operating medi(a)
A.Abrasive jet machining 1. Dielectric
B. Electron beam machining 2. Electrolyte
C. Electro-chemical maching 3.Abrasive slurry
D. Electro-discharge machinig 4. Vaccum
5. Air
Codes
a) A-5, B-4, C-2, D-1 b) A-4, B-5, C-2, D-1
c) A-4, B-2, C-3, D-5 d) A-2, B-5, C-3, D-4
29. A. Stamping die plate 1. EDM
B. Gas turbine bladees 2. LBM
C. Twist drill 3. ECM
D. Carbide tool inserts 4. EBM
E. Hole in a ceramic plate 5. ECG
6. Friction welding
7. Wire EDM
8. USM
9. Ultrasonic welding
30. Requirement in the design of jigs and fixtures Recommended device : [PI-GATE-04]
P - Heavy clampiong force on the work piece 1 - Clamp with a floating pad
Q - Clamping on rough surfaces of work piece 2- Slip renewable bush
R - Four work pieces in a line to be machined 3-indexing bush
Machined in one loading 4- Equalizing clamp
S - Drilling and reaming of work piece in one 5- Starp clamp
Loading
a) P-5, Q-1, R-4, S-2
b) P-1, Q-4, R-5, S-3
c) P-5, Q-1, R-2, S-3
d) P-4, Q-5, R-3, S-2
31. Mechanism of Material Removal Process [PI-GATE-05]
P:Abrasive grain throwing and hammering 1 - ECM
Q : Erosion due to vaporization 2 - USM
R : Chipping and erosion 3 - PAM
S : Melting and partial vaporization 4 - EDM
T : Elctrolysis 5- AJM
a) P-3, Q-2, R-5, S-1, T-4 b) P-4, Q-3, R-2, S-1, T-5
c) P-2, Q-4, R-5, S-3, T-1 d) P-2, Q-5, R-3, S-1, T-4
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MECHANICAL ENGINEERING
32. Process Mechanism of material removal [PI-GATE-03]
[PI-GATE-95]
P. EDM 1. Erosion [PI-GATE-09]
Q. ECM 2. Thermaol evaporation
R. AJM 3.Anodic dissolution
4. Etching
a) P-2, Q-3, R-1 b) P-2, Q-4, R-1
c) P-1, Q-3, R-4 d) P-4, Q-3, R-1
33. A.Abrasive jet machinig 1. Horn
b. EDM 2. Wire as cutting tool
c. LBM 3. Light
d. USM 4. Vaccum
5. Nozzle
6. Cladding
34. Match the follwoing
DEVICE FUNCTION
P. Jig 1. Helps to place work piece in the same position cycle after cycle
Q. Fixture 2. Holds the work piece only
R. Clamp 3. Holds and position the work piece
S. Locator 4. Holds and position the work piece and guides the cutting tool
during a machinig operation
a) P-4, Q-3, R-1, S-2
b) P-1, Q-2, R-3, S-4
c) P-1, Q-4, R-3, S-2
d) P-4, Q-3, R-2, S-1
35. Match list - I (material) with list - II (machining) and select the correcct answer suing the code given
below the list [PI-GATE-04]
List - I List - II
A. machining of conductived material 1. ECM
B. ruby rod 2. EDM
C. electrolyte 3. USM
D. abrasive slurry 4. LBM
a) A-4, B-2, C-1, D-3
b) A-4, B-2, C-3, D-1
c) A-2, B-4, C-1, D-3
d) A-2, B-4, C-3, D-1
36. A. Rail sections 1. Powder metallury [PI-GATE-95]
B. Plastic sheets 2. Rolling
C.Allen bolts 3. Cold forming
D. Porous bearing 4. Transfer molding
5. Calendering
6. Injection molding
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37. Match the following [PI-GATE-06]
P. Permaloy 1. EDM
Q. Dielectric 2. USM
R. Accumulator 3. De-ionized water
S. Anodic erosion 4. Water jet machining
a) P-3, Q-4, R-1, S-2 b) P-2, Q-3, R-4, S-1
c) P-4, Q-1, R-2, S-3 d) P-2, Q-3, R-1, S-4
38. While removing material from iron (atomic weight = 56, valency = 2 and density = 7.8 g/c(c) by
electrochemical machining, a metal removal rate of 2 cc/min is desired. The current (in (A) required for
achieving this material removal rate is [PI-GATE-11]
a) 896.07 b) 14.93 c) 448.03 d) 53764.29
39. Match the follwoing :
Type of material Name of material
1. Thermoplastic P. SiAloN
2. Thermosets Q. Polyvinychloride
3. Elastomers R. Epoxy
4. Ceramics S. Latex
a) 1-Q, 2-R, 3-S, 4-P b) 1-R, 2-Q, 3-S, 4-P
c) 1-S, 2-R, 3-Q, 4-P d) 1-R, 2-Q, 3-P, 4-S
FIVE MARKS QUESTIONS
1. A square block is located on 3 pins (two on one side and the one on the second side) as indicated in
fig. If the reactions on the pins are to be the same as 100 Kgs after clamping from the top side.
[PI-GATE-92] (5M)
2. A cylindrical work piece can be clamped by using [PI-GATE-89] (5M)
a) fixed rectangular block and movalbe V-clamp
b) fixed V-block and movalbe rectangular block
c) fixed V-block and movable V-block for making axial hole in vertical drilling machine of the diameter
of the work piece is given as 60+0.05 -- --0.00 mm and included angle of V-block 120 degrees.
Calculate the positional error of the hole in each case. Also recommend the choice of location for
fixture design.
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MECHANICAL ENGINEERING
3. A jig with 900 V - locater and clamps as shown in fig is used to drill holes on cylindrical work piece of
60 mm diameter. Drill guide bush axis is aligned with respect to job axis. To drill an eccentric hole
block P of 4 mm thickness and block Q 3 mm thickness and placed on the V - faces of the block and
then the job is located and clmaped, what is the eccentricity achieved. For a same eccentricity of
block of identical thickness used on either face, what should be the thickness of block used ? which of
the two methods are selected and why. [PI-GATE-93] (5M)
4. Fig slows a jig plate with two holes. The true position coordinate dimensions and positional tolerence
call outs are indicated in the fig, determine the minimum and maximum center distance between the
holes. [PI-GATE-90] (5M)
ALL DIMENSIONS IN mm
5. STATEMENT FOR LINKED ANSWER QUESTION
In an EDM process using RC relaxation circuit, a 12 mm diameter through hole is made in a steel plate
of 50 mm thickness using a graphite tool and kerosense as dielectric assume discharge time to be
negligible. Machining is carried out under the follwoing conditions
Resistance = 40 Ω Capacitance = 20 µF
Supply voltage = 220 V Discharge voltage = 110 V
i) The for one cycle, in milliseconds, is
a) 0.55 b) 0.32 c) 0.89 d) 0.24
ii)Average power input (in KW) is
a) 0.373 b) 0.137 c) 0.218 d) 0.5
*****************
“Success is going failure to failure without losing
your enthusiasm”
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8. NONTRADITIONAL MACHINING METHODS
ONE MARK QUESTIONS (ANS.) : 1-b, 2- a&d, 3-True, 4- sol, 5-c, 6-c, 7-c, 8- cannot, cannot,
9-True, 10-False, 11-a, 12-b, 13-b, 14-d, 15-d, 16-a, 17-sol, 18-d, 19-d, 20-a, 21-d, 22-d, 23-b,
24-c, 25-b, 26-b, 27-d, 28-c, 29-c, 30-b&c, 31-d, 32-c, 33-b, 34-a, 35-sol, 36-d.
TWO MARKS QUESTIONS (ANS.) : 1-b, 2-A4 B3 C6 D5, 3-c, 4-sol, 5-d, 6-sol, 7-a, 8-sol,
9-sol, 10-sol, 11-a, 12-a, 13-sol, 14-c, 15-b, 16-a, 17-sol, 18-b, 19-sol, 20-sol, 21-sol, 22-sol, 23-sol,
24-sol, 25-sol, 26-sol, 27-c, 28-a, 29-sol, 30-d, 31-c, 32-c, 33-sol, 34-d, 35-c, 36-sol, 37-b, 38-c,
39-a.
FIVE MARKS QUESTIONS (ANS.) : 1-sol., 2-sol, 3- sol, 4-sol, 5-sol.
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MECHANICAL ENGINEERING
9 ADVANCED MACHINING METHODS
ONE MARK QUESTIONS
1. NC contouring is an example of [PI-GATE-06]
a) continuous path positioning
b) point to point positioning
c) absolute positioning
d) incremental positioning
2. CNC machines are more accurate than conventional machines because they have a high resolution
encoder and digital readouts for positioning (T/F). [ME-GATE-94]
3. Cellular manufacturing is suitable for [ME-GATE-00]
a) a single production in large volumes
b) one-off production of several varieties
c) production with similar features made in batches
d) large variety of products in large volumes
4. In NC part programming spindle speed of 730 rpm will be coded by the magic - 3 rule as
[ME-GATE-89]
a) S673 b) S730 c) S630 d) S037
5. Machining of complex shapes on CNC machines requires [ME-GATE-02]
A) simultaneous control of x, y and z axes b) simultaneous control xand y axes
c) independent control of x and y axes d) independent control x, y and z axes
6. CNC machines are more economical to use even for simple turing jobs. (T/F) [ME-GATE-94]
7. In PTP type of NC system [ME-GATE-92]
a) Control of posotion and velocity of the tool is essential
b) Control of only position of the tool is sufficient
c) Control of only velocity of the tool is sufficient
d) Neither position nor velocity need be controlled
8. In computer aided drafting practice, an arc is defined by [ME-GATE-00]
a) two end points only
b) center and radius
c) radius and one end point
d) two end pionts and center
9. Numerically controlled machine tools are better suited for ............... (batch / mass) production,
because their setup time is .................. (larger / smaller) in comparison to special purpose machine
tools. [ME-GATE-91]
10. The interpolator in a CNC machine controls [PI-GATE-07]
a) Spindle speed b) Coolant flow
c) feed rate d) Tool change
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11. FMS is well suited to mass scale manufacturing. (T/F) [PI-GATE-94]
12. The most common inerpolation method in continuous path NC machining are [PI-GATE-90]
a) linear and circular b) linear and parabolic
c) circular and parabolic d) circular and elliptic
13. Feed motion can be provided with stepper motors in CNC. [PI-GATE-91]
a) lathe b) drilling machine
c) milling machine d) grinding machine
14. For generating coon’s surface we equire [ME-GATE-08]
a) a set of grid points on the surface
b) a set of grid control points
c) four bounding caves defining the surface
d) two bounding curves and a set of grid control points
15. A CNC vertical milling machine has to cut a straight slot of 10 mm width and 2 mm depth bya cutter
of 10 mm diameter between points (0, 0) and ( 100, 100 ) on the XY plane (dimensions in mm). The
feed rate used for milling is 50 mm/min.,. Milling time for the slot (in second) is [ME&PI-GATE-12]
a) 120 b) 170
c) 180 d) 240
16. Which type of motor is used in axial or spindle drives of CNC m/c tools. [ME-GATE-07]
a) Induction motors b) DC servomotors c) stepper motor d) linear servo motor
17. FAPT is part programming language. (T/F) [PI-GATE-94]
18. Use of a robot for spray painting is primarily justified for improved ...................... A ....................
and reduced ....................... B ............... [PI-GATE-91]
A. productivity / consistency B. cost / hazard
19. If the z-axis & x-axis of CNC lathe are provided with straight line controls, it is possible to carry out
[PI-GATE-89]
a) Turning and facing only
b) Turning, facing and taper turning
c) Turning, facing and thread cutting
d) Turning, facing and drilling
20. Control of group of NC machines by a supervisory computer is known is ............ control.
[PI-GATE-92]
21. In DNC each machine tool is controlled by a dedicated computer. (T/F/) [PI-GATE-94]
22. NC contouring is an exmaple of [PI-GATE-05]
a) continuous path positioning
b) point to point positioning
c) absolute positioning
d) incremental positioning
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MECHANICAL ENGINEERING
TWO MARKS QUESTIONS
1. Which among the NC operations give below are continous path operations ?
Arc welding ( AW) Milling(M)
Drilling (D) Punching in Sheet Metal (P)
Laser Cutting of Sheet Metal (LC) Spot Welding (SW)
a) AW ,LC and M b) AW, D, LC and M
c) D, LC, P and SW d) D, LC and SW
2. In finish maching of an island on a casting with CNC milling machine, an end mill with 10 mm diameter
is employed. The corner points of the island are represented by (0, 0), (0, 30), (50, 30), and (50, 0).
By applying cutter radius compensation, the trajectory of the cutter will be [ME-GATE-00]
a) (-5, 0), (-5, 35), (55, 35), (55, -5), (-5, -5)
b) (0, -5), (55, -5), (55, 35), (-5, 35), (-5, -5)
c) (5, 5), (5, 25), (45, 25), (45, 5), (5, 5)
d) (5, 5), (45, 5), (45, 25), (5, 25), (5, 5)
3. In a point to point contol NC m/c, the slides are positioned by an integrally mounted stepper motor
drive. If the specification of the motor is 1 deg/pulse, and the pitch of the lead screw is 3.6 mm, what
is the expected positioning accuracy ? [ME-GATE-97]
a) 1 micron b) 10 micron c) 50 micron d) 100 micron
4. The tool of an NC machine has to move along a circular arc from (5, 5) to ( 10, 10) while performing
an operation. The centre of the arc is at (10, 5). Which of the following NC toll path commands
performs the above mentioend operation ? [ME-GATE-05]
a) N010 G02 X 10 Y 10 X5 Y5 R5 b) N010 G03 X 10 Y 10 X5 Y5 R5
c) N010 G01 X 5 Y5 X10 Y10 R5 d) N010 G02 X 5 Y 5 X10 Y 10 R5
5. During the execution of a CNC part program block [ME-GATE-04]
a) circular INterpolation - Clockwise
b) Circular INterpolation - counterclockwise
c) linear Interpolation
d) rapid feed.
6. With reference to NC machine, which of the following statement is wrong ? [ME-GATE-93]
a) Both closed loop and open loop systems are used
b) Paper tapes, floppy drives and cassettes are used for data storage
c) Digitisers may be used as interactive input devices
d) Post-processor is an item of hardware
7. In a 2-D CAD package, clockwise circular are of radius 5, specified from P1 (15, 10) to P2 (10, 15)
will have its center at [ME-GATE-04]
a) (10, 10) b) (15, 10) c) (15, 15) d) (10, 15)
8. A cylinder of 155 mm diameter is to be reduced to 150 mm diameter in one turning cut with a feed of
0.15 mm/rev and a cutting speed of 150 m/min on a NC lathe. What are the programmed feed rate
and t he material removal rate. [ME-GATE-98]
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9. Match the following [PI-GATE-94]
Group - I Group - II
P. G09 1. Linear interpolation
Q. G41 2. Retardation
R. G01 3. Circular interpolation
S. G03 4. Cutter radius compensation
a) P-3, Q-1, R-4, S-2 b) P-4, Q-1, R-3, S-2
c) P-3, Q-4, R-1, S-2 d) P-2, Q-4, R-1, S-3
10. A 21/2 axis control in a typical CNC machine provides [PI-GATE-90]
a) simultaneous tool movements along 2 axes
b) programmable movement along 3 axes but allows simultaneous movement along 2 axes
c) simultaneous programmable movement along 3 axes in boht directions
d) simultaneous programmable movement along 3 axes but only in one direction
11. A DC servomotor is directly driving an NC table. The pitch of the lead screw of the table is 5 mm. The
motor rotates at 100 rpm for an applied voltage of 10V , if the voltage speed characteristic of the
motor is linear, the applied voltage for a table of 3m/min equal to : [PI-GATE-92]
a) 30 V b) 60 V d) 33 V d) 50 V
12. Given that the notations of robot joints are L-linear, O-orthogonal, R - rotational, T - twisting, and
V - revolving, the anatomy of a polar configuration robot is described by the alphabetical string.
[PI-GATE-04]
a) TOO b) TLL c) TRL d) TVO
Statement for Linked Answer Question 14 & 15
In the feed drive of a point to open loop CNC drive, a stepper motor rotating at 200 setps/rev drives a table
through a gear box and lead screw-nut mechanism (pitch = 4 mm, number of starts = 1). The gear ratio =
Output speed / input speed is given by U = 1/4, . The stepper motor (driven by voltage pulses from a pulse
generator) executes 1 step / pulse of the generator. The frequency of the pulse train from the pulse generator
is f = 10000 pulses per minute.
13. The basic length unit (BLU) , i.e. the table movement corresponding to 1 pulse of the pulse generator
[ME-GATE-08]
a) 0.5 microns b) 5 microns c) 50 microns d) 500 microns
14. A customer insists on a modification to change the BLU of the CNC drive to 10 Microns without
changing the table speed. The modification can be accomplished by [ME-GATE-08]
15. When 3-2-1 principle is used to support and locate a three diemensional work-piece during
machining, the number of degrees of freedom that are restricted is [PI-GATE-03]
a) 7 b) 8 c) 9 d) 10
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MECHANICAL ENGINEERING
16. The component development and manufacturing activities when assisted by a computer are ;
computer aided graphics (CAG), CAD, CAM, CAPP and computer aided quality control (CAQ(C).
The most appropriate sequence of these activities is [PI-GATE-92]
a) CAD - CAG - CAPP - CAM - CAQC
b) CAG - CAD - CAM - CAPP - CAQC
c) CAD - CAG - CAPP - CAQC - CAM
d) CAD - CAPP - CAG - CAM - CAQC
17. Match the following [ME-GATE-09]
NC Code Definition
P. M05 1. Absolute coordinate system
Q. G01 2. Dwell
R. G04 3. Spindle stop
S. G90 4. Linear imterpolation
a) P-2, Q-3, R-4, S-1 b) P-3, Q-4, R-1, S-2
c) P-3, Q-4, R-2, S-1 d) P-4, Q-3, R-3, S-1
18. A. CNC 1. Zero inventory
B. MRP 2. Stepper motor
C. JIT 3. Batch production
D. FMS 4. Post processor
5. Lumped demand [PI-GATE-93]
19. A. CNC 1. Zero inventory
B. MRP 2. Rout sheet
C. JIT 3. DNC
D. FMS 4. Cutter path
5. Lumped demand [PI-GATE-93]
20. In a CNC program block, N002 G02 G91 X40 Z40.., G02 & G91 refers to [ME-GATE-10]
a) Circular interpolation conterclock wise direction and Incremental dimension
b) Circular interpolation conterclock wise direction and absolute dimension
c) Circular interpolation clock wise direction and Incremental dimension
d) Circular interpolation clock wise direction and absolute dimension
21. The geometric transformation specified by [PI-GATE-07]
[x y 1] = [x y 1] 0.5 0 0
0 0.25 0 in a 2D
1 1
2
In a 2D CAD system represents b) scaling and rotation
a) Scaling and translation d) rotation
c) rotation and translation
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PRODUCTION
22. Suppose point inAPT (Autmatically programmed Tool) programming is coded by statement
PI = POINT / XSMALL, INTOF, LN1, CR1 [PI-GATE-08]
The coded geometric situation without causing error is
23. Match the following [PI-GATE-06]
Group - I Group - II
P. G08 1. Liner interpolation
Q. G41 2. Acceleration
R. G01 3. Circular interpolation
S. G02 4. Cutter radius compensation
a) P-3, Q-1, R-4, S-2 b) P-4, Q-1, R-3, S-2
c) P-3, Q-4, R-1, S-2 d) P-2, Q-4, R-1, S-3
24. The Toatl angular movement ( in degrees) of a lead screw with a pitch of 5.0 mm to drive the work
table by distance of 200 mm in a NC machine is [PI-GATE-09]
a) 14400 b) 28800 c) 57600 d) 72000
25. For machining the circular arc shown in the figure below on a NC machine, the interpolation parameterse
(I, K) and the incremental movements in the direction of the X and Z axes are programmed as
[PI-GATE-04]
a) I = 0, K = R, X = -(R - P), Z = -Q
b) I = R, K = 0, X = -(R - P), Z = -Q
c) I = P, K = Q, X = R, Z = R - Q
d) I = Q, K = P, X = (R - P), Z = R
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MECHANICAL ENGINEERING
26. Consider the follwoing characteristics : [PI-GATE-05]
1. Single machine tool
2. Manual materials handling system
3. Computer control
4. Random sequencing of part to machines
Which of the above characteristics are associated with flexible manufacturing system ?
a) 1, 2 and 3 b) 1 and 2 c) 3 and 4 d) 2, 3 and 4
27. A stepper motor has 150 steps. The output shaft of the motor is directly coupled to a lead screw of
pitch 4mm, which drives a table. If the frequency of pulse supply to the motor is 200 Hz, the speed of
the table ( in mm/min) is [PI-GATE-08]
a) 400 b) 320 c) 300 d) 280
28. Automation Strategy Type of equipment [PI-GATE-04]
P : Standalone programmable 1- Transfer line
manufacturing automation
Q : Programmable automation with 2 - CNC
atuomatic tool changing
R : Dedicated automation with 3 - FMS
automated material transfer
S : Programmable automation with 4 - Machining center
programmable material handing
and transfer
a) P-2, Q-3, R-4, S-1 b) P-4, Q-2, R-3, S-1
c) P-1, Q-2, R-3, S-4 d) P-2, Q-4, R-1, S-3
29. In a CNC feed drive, a stepper motor with step angle of 1.8 deg drives a lead screw with pitch of 2
mm. The basic length unit (BLU) for this drive is [PI-GATE-08]
a) 10 microns b) 20 microns c) 40 micrdons d) 100 microns
30. Complete the manual part program for drilling a hole located at piont (20 , 20) from the target point.
The depth of the hole to be drilled is 15 mm. [PI-GATE-06]
FROM/TARG
GOTO/20, 20, 0
a) GODLTA/0,0,-15 b) GODLTA/0,0,15
GODLTA/0,015 GODLTA/0,0,-15
GOTO/SETPT GOTO/SETPT
c) GOTO/SETPT d) GOTO/SETPT
GODLTA/0,0,-15 GODLTA/0,0,15
GODLTA.0,0,15 GODLT/0,0, -15
31. In a CAD packate, a point P ( 6, 3 , 2) is projected along a vector v ( -2, 1, -1 ). The projection of this
point on X - Y plane will be
[PI-GATE-07]
a) ( 4, 4, 0 ) b) ( 8 , 2, 0 ) c) ( 7 , 4 , 0 ) d) ( 2, 5 , 0 )
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PRODUCTION
32. Atitanium sheet of 5.0 mm thickness is cut by wire cut EDM process using a wire of 1.0 mm diameter.
A uniform spark gap of 0.5 mm on both sides of the wire is maintained during cutting operation. If the
feed rate of the wire into the sheet is 20 mm/min , the material removal rate (in mm3/min) will be
[PI-GATE-09]
a) 150 b) 200 c) 300 d) 400
33. For a 3 - axes CNC table, the slide along the vertical axis of the table driven by a DC servo motor via
lead screw nut mechanism. The lead screw has a pitch of 5 mm, this lead screw is fitted with a relative
( incremental ) circular encoder. The basic length unit ( BLU ) of the slide along the vertical axis of the
table is 0.005 mm, when the table moves along the vertical axis by 9 mm, the corresponding number
of pulses generated by the encoder is [PI-GATE-10]
a) 1400 b) 1800 c) 4200 d) 9000
*************************
“A diamond is a chunk of caol that made good under pressure”
9. ADVANCED MACHINING METHODS (ANS.) :
ONE MARK QUESTIONS (Ans.) : 1-a, 2-True, 3-c, 4-b, 5-a, 6-False, 7-b, 8-d, 9-sol, 10-c,
11-False, 12-a, 13-b, 14-b, 15-c, 16-b, 17-False, 18-sol, 19-b, 20-sol, 21-False, 22-a.
TWO MARKS QUESTIONS (Ans.) : 1-a, 2-a, 3-b, 4-d, 5-a, 6-d, 7-c, 8-sol, 9-d, 10-b, 11-b,
12-c, 13-b, 14-a, 15-c, 16-a, 17-c, 18-sol, 19-sol, 20-c, 21-c, 22-b, 23-d, 24-a, 25-b, 26-c, 27-c,
28-d, 29-a, 30-a, 31-a, 32-b, 33-b.
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MECHANICAL ENGINEERING
10 METROLOGY
ONE MARK QUESTIONS
1. In order to have interference fit, it is essential that the lower limit of shaft should be
[ME-GATE-05]
a) Greater than the upper limit of the hold b) Lessere than the upper limit of the hole
c) Greater than the lower limit of the hole d) Lesser than the lower of the hole
2. Checking the diameter of a hole using GO and NOGO gages in an example of inspection by .........
Variable / attributes) [ME-GATE-95]
3. The hole 40+0.020 & shaft , 40+0.010 when assembled will result it. [ME-GATE-87]
+0.000 d) drive fit
a) clearance fit b) Interference fit c) transition fit
4. Ring gage is used to measure [ME-GATE-06]
a) outside diameter but not roundness b) roundness but not outside dia
c) both outside diameter and roundness d) only external threads
5. Appropriate instrument to check the flatness of slip gage is [ME-GATE-89]
a) dial indicator
b) Pneumatic comparator
c) Optical interferometer
d) Tool makers microscope with projection facility
6. The iron carbon diagram and the TTT curves are determined under [ME-GATE-96]
a) Euilibrium and non-equilibrium conditions respectively
b) Non-Equilibrium and equilibrium conditions respectively
c) Equilibrium conditions for both
d) Non-equilibrium conditions for both
7. In an engineering drawing one finds the designation of 20G7f8, the position of tolerance of the hole is
indicated by [ME-GATE-88]
a) Letter G b) Letter f c) Number 7 d) Number 8
8. Allowance in limits and fits refer to [ME-GATE-01]
a) Maximum clearance between the shaft and hole
b) Minimum clearance between the shaft and hole
c) Difference between the maximum and minimum size of hole
d) Difference betweene the maximum and minimum size of shaft
9. The fit on a hole-shaft pair system is pecified as H7-s6 the type of fit is [ME-GATE-96]
a) Clearance fit b) running fit (sliding fit)
d) Push fit (transition fit) d) force fit (interference fit)
10. Slip gauges are calibrated by outside micrometer. (T/F) [ME-GATE-95]
11. In an intereference imcroscope, a groove products a band distortion of 4 band spacing. If the wave
length of the monochromatic light source is 0.5 microns, the groove depth is .................... mm.
[PI-GATE-92]
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PRODUCTION
12. Which one of the Instrument is a comparator [PI-GATE-07]
b) GO/NOGO gage
a) Tool makers microscope d) Dial gage
c) Optical interferometer [PI-GATE-92]
b) higher density than cast products
13. Powder metallurgical components have d) higher desnsity than forged products
a) same density as that of cast products [PI-GATE-03]
Non contact
c) lower density than cast products Limit of size
Comparator
14. Instrument Principles of inspection CD
P-1 P-2
P. Dial indicator 1 Q-2 Q-1
R-3 R-3
Q. Pneumatic gage 2
R. GO/NO GO gage 3
AB
P-2 P-3
Q-3 Q-1
R-1 R-2
+0.015
15. A hole is of dimension φ9 +0 mm. The corresponding shaft is of dimension
φ9 +0.015 The resulting assembly has [ME-GATE-11]
+0 mm.
a) loose running fit b) close running fit c) transition fit d) interference fit
16. The skid in a stylus type roughness measuring instrument is used to provide .......... A ............ and
define .......... B ............ geometrical profile of the surface. [PI-GATE-92]
A. support / datum B. micro / macro
17. The fit on a hole-shaft pair system is specified at H7s6. the type of fit is [PI-GATE-92]
a) Clearance fit b) running fit (sliding fit)
c) Push fit (transition fit) d) force fit (interference fit)
18. Outside micrometer is calibrated with the help of [PI-GATE-91]
a) inside micrometer b) depth micrometer c) ring gages d) slip gages
19. The combination of slip gaugees to obtain a dimension of 10.35 mm will be [PI-GATE-94]
a) 10.00 + 0.30 + 0.05 b) 8.00 + 1.30 + 1.05
c) 10.00 + 0.35 d) 5.00 + 4.00 + 1.00 + 0.35
20. For angle measurement in metrology, the following pair can be used in conjunction with each other
[PI-GATE-91]
a) sine bar and vernier calipers b) bevel protractor and slip gages
c) slip gages and sine bar d) sine bar and bevel protractor
+0.040
21. In an interchangeable assembly, shafts of size 25.000 -0.010 mm mate with holes of size
+0.030
25.000 +0.020mm. The maximum interference (in microns) in the asssembly is
[ME & PI-GATE-12]
a) 40 b) 30 c) 20 d) 10
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MECHANICAL ENGINEERING
22. In mass manufacturing, two holes in a plate type of component are ideally located with the help of
[PI-GATE-92]
a) one solid pin in the larger hole and one diamond pin in the smaller hole
b) two solid pins in either holes
c) two diamond pins in either holes
d) one solid pin in the smaller hole and one diamond pin in the larger hole
23. Ring gage is used to measure [PI-GATE-05]
a) outside diameter but not roundness b) roundness but not outisde dia
c) both outside diameter and roundness d) only external threads
24. A shaft of diameter 20+0.05 mm and a hole of diameter 20+0.20 mm when assembled would yield
-0.15 +0.10
a)Transition fit b) Interference fit [PI-GATE-92]
c) Clearnace fit d) done
25. The most widely used reinforcemente in modern day FRP tennis racket is [PI-GATE-92]
a) glass b) carbon c) aluminium d) magnesium
26. A straight edge is inspected on a coordinate measuring machine. The readings obtained at intervals of
100 mm along the top edge are 100.01, 100.05 and 100.04 mm the straightness error, making the end
points as reference, is ........ mm. [PI-GATE-92]
27. The geometric tolerance that does not need a datum for its specification is [PI-GATE-07]
a) Concentricity b) Run out c) perpendicularity d) Flatness
28. Abbe’s principle of alignment states that the scale axis must coincide with the line of
[PI-GATE-91]
29. The diameter of the best wire to measure the effective diameter of a metric screw threads of 0.5 mm
pitch is .............. mm. [PI-GATE-92]
30. Abbe’s principle of alignment is followed in : [PI-GATE-95]
a) vernier calipers b) depth veriner
c) internal caliper micrometer d) height vernier
31. Flatness of slip gages is checked with [PI-GATE-89]
a) Interferometer b) Optical flat
c) Electronic comparator d) Linear measuring machine
32. Abbe’s principle of aligment is uded in measurements made in ........ [PI-GATE-94]
TWO MARKS QUESTIONS
1. Two shaftsAand B have their diameters specified as 100+0.1 mm and 0.1+0.0001 mm respectively,
which of the following statements is / are true [ME-GATE-92]
a) Tolerance in the dimension is greater in shaftA
b) the relative error in the dimension is greater in shaftA
c) Tolerance in the dimension is greater in shaft B
d) The relative error in the dimension is same for shaft Aand shaft B
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PRODUCTION
2. A hole is specified as 400.050 mm. The mating shaft has a clearance fit with minimum clearance of
0.000
0.01 mm. the tolerance on the shaft is 0.04 mm. the maximum clearance in mm between the hole and
the shaft is [ME-GATE-07]
a) 0.04 b) 0.05
c) 0.10 d) 0.11
3. A part shown in the fig is machined to the sizes given below [ME-GATE-03]
P = 35.00 + 0.08 mm
Q = 12.00 + 0.02 mm
R = 13.00+0.04 mm
-0.02
With 100% confidence, the resultant dimension W will have the specificaion
a) 9.99 + 0.03 mm b) 9.99 + 0.13 mm
c) 9.99 + 0.23 mm d) 9.99 + 0.43 mm
4. What are the upper and lower limits respectively of the shaft represented by 60f8 Use the following
data [ME-GATE-09]
Diameter 60 lies in the diameter step of 50 - 80 mm
Fundamental tolerence unit , i in microns = 0.45 D1/3 + 0.001 D, where D is the respective size in mm.
tolerence value for IT8 = 25i, Fundamental deviation for “f” shaft = - 5.5D0.41
a) 59.970 & 59.924 b) 60.00 & 59.954
c) 60.016 & 59.970 d) 60.046 & 60.00
5. A bush was turned after mounting the same on a mandrel. The mandrel diameter in millimeteres is
40+0.00 and bore diameter of bush is 40+0.06-0.00. The maximum eccentricity of the bush, in mm will
- 0.05
be [ME-GATE-91]
a) 0.01 b) 0.055
b) 0.01 d) 0.11
6. 3 blocks of B1, B2, B3 are to be inserted in a channel of width ‘ S”. maintaining a min gap of width
T = 0.125 mm, as shown in fig. For P = 18.75 + 0.08, Q = 25.00 + 0.12, R = 28.125 + 0.1 and
S = 72.35 + X. the tolerence “X” is [ME-GATE-97]
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MECHANICAL ENGINEERING
7. A hole of diameter 25.00+0.01 mm is to be inspected by using GO / NO GO gages. The size of the
GO plug gage should be [ME-GATE-04]
a) 25.00 mm b) 25.01 mm
c) 25.02 mm d) 25.03 mm
8. The diamensional limit on a shaft of 25h7 are [ME-GATE-03]
a) 25.000, 25.021 mm b) 25.000, 24.979 mm
c) 25.000, 25.007 mm d) 25.000, 24.993 mm
9. A displacement sensor (a dial indicator) measures the lateral dispalcement of a mandrel on the taper
hole inside a drill spindle. The mandrel axis is an extension of he drill spindle taper hole axis and the
protruding portion of the mandrel surface is perfectly cylindrical. Measurement the recorded as
Rx = maximum deflection minus minimun deflection, corresponding to sensor position at X, over one
rotation. [ME-GATE-08]
If Rp = Rq > 0, which one of the following would be consistent with the observation ?
a) The drill spindle rotational axis is coincident with the drill spindle taper hole axis
b) The drill spindle rotation axis instersects the drill spindle taper hole axis at point P
c) The drill spindle rotation axis is parallel to the drill spindle taper hole axis
d) The drill spindle rotation axis intersects the drill spindle taper hole axis at point Q
10. A shaft of diameter 20+0.05 mm and a hole of diameter 20+0.20 mm when assembled would yield
-0.15 +0.10
[ME-GATE-93]
a) Transition fit b) Interference fit
c) Clearance fit d) None of the above
11. A keyway of 5 mm depth is to be milled in a shaft of diameter 60+0.1 by positioning the shaft in a
V-block of angle 120 deg and setting the tool with reference to the intersection of the face of the
V-block. The error due to shaft tolerance which would be transferred on to the component is
[PI-GATE-06]
a) 0.09 mm b) 0.119 mm c) 0.22 mm d) 0.3 mm
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PRODUCTION
12. Assertion (A) : Basic hole system is advocated by Indian Standards for fit design
Explanation (B) : Holes can be produced to any size [PI-GATE-90]
a) Both A and E are correct & E explains A
b) Both A and E are true but E not explains A
c) A is true but E is false
d) A is false but E is true
13. The least count of a 200 mm long spirit level is given as 10 seconds per division. The gradient of the
spirit level expressed as mm over one meter is ................ [PI-GATE-95]
14. A shaft has a dimension 35-0.099-0.025. The respective values of fundamental deviation and tolerance are
[ME-GATE-10]
a) -0.025, +0.008 b) -0.025, -0.008 c) -0.0009 +0.008 d) -0.09, 0.016
15. Holees 1, 2, 3, 4 drilled in sequence, with angular positions and tolerances are shown in fig. Evaluate
closing angle ‘X’ with its tolerance band. [PI-GATE-93]
16. Outside diameter of bush is turned using a mandrel. The mandrel diameter is mainained as
300.000 mm and the bore diameter is 30 +0.050 mm. the maximum value in mm of the eccentricity
-0.050 -0.000
on the bush due to the locating mandrel. [PI-GATE-89]
a) 0.050 b) 0.100 c) 0.020 d) 0.025
+0.0015 +0.0015
17. A cylindrical pin of diameter 1.996 -0.0015 mm is assembled into a hole of dimeter 2.000 -0.0015mm
The allowance (in mm) provided for this assembly is [PI-GATE-05]
a) 0.001 b) 0.015
c) 0.025 d) 0.035
18. The maximum interference in mm after assembly between a bush of size 30.00+0.06+0.03 and a shaft of
size 30.00+0.04-0.02 is [PI-GATE-93]
a) 0.07 b) 0.05
c) 0.02 d) 0.01
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MECHANICAL ENGINEERING
19. To obtain dimension of 61.18 mm using slip gages, the most appropriate combination is
a) 1.18 + 50.00 + 10.00 b) 0.08 + 1.10 +60.00
c) 1.08 + 0.10 + 50.00 + 10.00 d) 1.08 + 1.10 + 50.00 + 9.00
20. The dia of a hole is given as 50+0.015+0.00 mm. The upper limit on the dimension in mm of the shaft
for achieving maximum interference of 50 micron is ............... [PI-GATE-95]
21. Assertion : End standards are used for precision component inspection [PI-GATE-93]
Reason : in end standards line of measurement coincides with line of indication.
22. Ataper hole is inspected using a CMM, with a probe of 2 mm diameter.At a height, Z = 10 mm from
the bottom, 5 points are touched and a diameter of circle (not compensated for probe size) is obtained
as 20 mm, similarly , a 40 mm diameter at a height Z = 40 mm, the smaller diameter ( in mm) of the hole
at Z = 0 is [ME-GATE-10]
a) 13.334
b) 15.334
c) 15.442
d) 15.542
23. A hole is specified as φ 30+0.04 mm with −φ 0.01 M. The virtual diameter of the hole (i.e. the
maximum diameter of t he pin that can enter the hole) is ................... [PI-GATE-94]
24. The combination of slip gauges to obtain a dimension of 10.35 mm will be [PI-GATE-91]
a) 10.00 + 0.30 + 0.05 b) 8.00 + 1.30 + 1.05
c) 10.00 + 0.35 s) 5.00 + 4.00 + 1.00 + 0.35
-0.015 -0.015
25. In an interchangeable assembly, a shaft of 20.00-0.005 mm diameter and a hole of 20.00-0.005 mm
diameter from a mating pair. In the worst assembly conditions, the clearance between them will be
[PI-GATE-04]
a) 40 microns b) 30 microns c) 25 microns d) 15 microns
26. A 30 mm hole shaft assembly results in minimum and maximum clearance of 0.03 mm and 0.30 mm
respectively. The hole has a unilateral tolerance with zero fundamental deviation. If the tolereance on
the shaft is 0.08 mm, the maximum size of the hole is [PI-GATE-92]
a) 230.11 b) 30.16 c) 30.19 d) 30.27
27. A threaded nut of M16, ISO metric type, having 2 mm pitch with a pitch diameter of 14.701 mm is to
be checked for its pitch diameter using two or three number of balls or rollers of the following sizes
a) Rollers of 2 mm φ [ME-GATE-03]
c) Balls of 2 mm φ b) Rollers of 1.155 φ
d) Balls of 1.155 mm φ
28. A Sine bar has a length of 250 mm. each roller has a diameter of 20 mm. during taper angle
measurement of component, the height from the surface plate to the center of a roller is 100 mm, the
calculated taper angle (in degrees) is [PI-GATE-72]
a) 21.1 b) 22.8 c) 23.6 d) 98.9
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PRODUCTION
29. Match the follwoing [PI-GATE-09]
DEVICE FUNCTION
P. Jig 1. Helps to place work piece in the same position cycle after cycle
Q. Fixture 2. Holds the work piece only
R. Clamp 3. Holds and position the work piece
S. Locator 4. Holds and position the work piece and guides the cutting tool during a
machining operation
a) P-4, Q-3, R-1, S-2 b) P-1, Q-2, R-3, S-4
c) P-1, Q-4, R-3, S-2 d) P-4, Q-3, R-2, S-1
30. An experimental setup is planned to determine the taper of work piece as shown in the figure. If the
two precision rollers have radii 8 mm and 5 mm and the total thickness of slip gauges inserted between
the rollers is 15.54 mm, the taper angle “θ” is [PI-GATE-08]
a) 6 deg
b) 10 Deg
c) 11 Degree
d) 12 Deg
31. The surface finish of the component produced by a grinding process was measured. Based on
roughness parameters obtained, which one of the following is true [PI-GATE-06]
a) Ra < Rs < Rz < Rt b) Rs < Ra < Rz < Rt
c) Rz < Ra < Rs < Rt d) Ra < Rz < Rs < Rt
32. To measure the effective diameter of an external metric thread (included angle is 600) of 3.5 mm pitch,
a cylindrical standard of 30.5 mm diameter and two wires of 2 mm diameter each are used. The
micrometer reading over the standard and over the wires are 16.532 mm and 15.398 mm
respectively. The effecctive diameter (in mm) of the thread is : [PI-GATE-11]
a) 33.366 b) 30.397 c) 29.366 d) 26.397
33. The following data are given for calculating limits of dimensions and tolerances for a hole : Tolerance
unit ‘i’ (microns) = 0.45 (D)1/3 + 0.001D. The unit of D is mm. Diameter step is 18 - 30, if the
fundamental deviation for hole H is zero and IT8 = 26i, the maximum and minimum limits of dimension
for a 25H8 hole (in mm) are [PI-GATE-08]
a) 24.984 & 24.967 b) 25.017 & 24.984
c) 25.033 & 25.00 d) 25.00, 24.967
34. An autocollimator is used to [PI-GATE-09]
a) Measure small angular displacements on flat surfaces
b) Compare known and unknown dimensions
c) Measure the flatness erro
d) Measure roundness error between centers +0.05
35. Diameter of a hole after plating needs to be controlled between 30 +0.010mm, if the plating thickness
varies between 10 - 15 microns, diameter f the hole before plating should be [PI-GATE-07]
+0.07 +0.65 +0.08 +0.070
a) 30 +0.030 mm b) 30 +0.020 mm c) 30 +0.030 mm d) 30 +0.040 mm
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MECHANICAL ENGINEERING
36. Observation of a slip gauge on a flatness interferometer product fringe counts numbering 10 and 14 for
two readings. The second reading is taken by rotating the set up by 1800.Assume the both faces of the
slip gauge are flat and the wavelength of the radiation is 0.5086 µm. The parallelsim error (in µm)
between the two faces of the slip gauge is [PI-GATE-11]
a) 0.2543 b) 1.172 c) 0.5086 d) 0.800
37. Tolerence on the dimension ‘x’in the two component assembly shown below is (all dimensions are in
mm) [PI-GATE-07]
a) +0.025
b) +0.030
c) +0.040
d) +0.045
38. A small bore is designated as 25H7. The lower (minimum) and upper (maximum) limits of the bore are
25.000 mm and 25.021 respectively. When the bore is designated as 25H8, then the upper limit is
25.033 mm, when the bore is designated as 25H6, then the upper limit of the bore in mm is
[PI-GATE-10]
a) 25.001 b) 25.005 c) 25.009 d) 25.013
39. A tool with side cutting edge angle of 30 deg and end cutting edge angle 10 deg is used for fine turning
with a feed of 1 mm/rev. neglecting nose radius of the tool, the maximum (peak to valley) height of the
surface roughness produced will be [PI-GATE-07]
a) 0.16 mm b) 0.26 mm c) 0.32 mm d) 0.48 mm
FIVE MARKS QUESTIONS
1. A ‘V’block is produced with a 900 angle cutter. The height difference measured over two standard
rollerse of diameter difference 10 mm placed in this ‘V’ block is 12.138. Derive an expression to find
the error in the angle of the ‘V’ block. [PI-GATE-92]
2. A plate with two pins, another plate with two holes is to be assembled with the pins entering the holes
as shown in the fig. InAssembly the pins touch the outer most points of the holes as shown, the limits
on center distance between the holes is [PI-GATE-95]
For the above fig, the center distance between the holes, when the size of the holes and the center
distance between pins are at their maximum limits, and pins are at the minimum limit and also specify whetehr
the assembly is possible or not.
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PRODUCTION
3. The bore dia “D” of a plain ring having a height of 35 mm was measured using two sphericals balls,
each of dia d = 25 mm. The ring was placed on a surface table and then both balls were placed inside
the ring. In this position, the height “h” of the top of the upper ball from the surface table was found to
be 42.00 mm, the dia of the ring is ............
4. A product shown in Figure is turned, step turned and parted off from a rod of to get dimension ‘A’in
the second setting is is through drilled and counter bored to get dimension ‘B’ . (a) Calculate the
dimension A and B and their tolerance ∆ A and ∆ B.
5 Statement For Linked Answer Question
In a three wire inspection of external thread of M 16 x 2 , the measurement over the wires was found
to be 16.455 mm [PI-GATE-06]
(i) The best wire size is
a) 1.155 b) 2 mm c) 2.309 d) 4 mm
(ii) The effective pitch diameter of the thread is
a) 14.723 b) 126.705 c) 17.122 d) 17.455
6. Straightness measurement is carried out using a device shown below :
1 div = 10 µ m [PI-GATE-94]
Initially the device is kept on a reference surface and the dial is set to zero. On the test surface, the
following readings are obtained ( 1 division = 10 µ m )
Position : 1 2 3 4
Reading : +2 0 -1 +1
a) sketch the straightnes deviations using the above readings
b) Calculate the maximum straightness error using end-points reference line.
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MECHANICAL ENGINEERING
7. Calculate the size of GO and NOGO (Plug and Ring) gages to inspect the holes shaft pair given below
[ME-GATE-89]
Shaft = 35-060 Hole = 35+0.40
-0.025 -0.000
Neglect the gage tolerances and mention the type of fit and also calculate the maximum clearance /
interference in the above shaft and hole assembly.
8. With reference to the fig given, write down the equation relating the dimension “h” with the diameter
“D” and the angle “α” . If a unit increase in D has to result in a unit increase in “h” , what must be the
angle “α” ? [PI-GATE-94]
9. A machine operator needs a gage for checking the dia of holes being machined to diameter 20 +0.06
-0.04
mm. if wear allowance and gage tolerance are equal to 10% of work tolerance,
i) the size of GO gage with unilateral tolerance is [PI-GATE-91]
a) 20-0.02 mm b) 20-0.05 mm c) 20-0.05 mm d) 20-0.08 mm
-0.03 -0.06 -0.04 -0.07
ii) the size of NOGO gage with unilateral tolerance is [PI-GATE-91]
a) 20+0.06 mm b) 20+0.07 mm c) 20-0.04 mm d) 20-0.03 mm
=0.05 +0.06 -0.05 -0.04
10. Mention which angle gages will be used to make an angle of 7056’48”. The angle, so obtained is
checked with a sine bar of length 250 mm what slip gages combination will be required ?
[PI-GATE--91]
11. While measuring the effective dia of external metric screw thread gauge of 3.5 mm pitch, 1 30.5 mm
dia cylindrical standard and 2 mm dia wires were used. the micrometer reading over the standard and
wires was 13.3768, the corresponding reading over the thread and wires was 12.2428 mm. find the
thread gage effective diameter ? [ME-GATE-2002]
12. Two slip gauges of 10 mm width measuring 1.00 mm 1.002 mm are kept side by side in contact with
each other length wise.An optical flat is kept resting on the slip gages as shown in the fig. monochromiatic
light of wave length 0.0058928 mm is used in the inspecion. The total number of straight fringes that
can be obsserved on both slip gauges is [ME-GATE-03]
********************
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PRODUCTION
10. METROLOGY
ONE MARK QUESTIONS (Ans.) : 1-a, 2- attributes, 3-c, 4-a, 5-c, 6-a, 7-a, 8-b, 9-d, 10-False,
11-sol, 12-d, 13-b, 14-b, 15-c, 16-sol, 17-d, 18-d, 19-b, 20-c, 21-c, 22-c, 23-a, 24-c, 25-b, 26-
0.25, 27-a, 28-sol, 29-sol, 30-a, 31-a, 32-sol.
TWO MARKS QUESTIONS (Ans.) : 1-a&d, 2-a, 3-b, 4-a, 5-b, 6-sol, 7-a, 8-b, 9-a, 10-c, 11-c,
12-b, 13-sol, 14-d, 15-sol, 16-a, 17-a, 18-d, 19-a, 20-sol, 21-sol, 22-c, 23-sol, 24-b, 25-b, 26-c, 27-
d, 28-a, 29-d, 30-d, 31-c, 32-d, 33-c, 34-c, 35-c, 36-c, 37-d, 38-d, 39-c,
“Success is how high you bounce when you hit bottom”
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