PRODUCTION
24. In a fabrication shop, a T-joint is to be made between two plates using a chain intermittent, double fillet weld of 6 mm
leg length. The intermittent welds are 40 mm long and spaced 80 mm apart, edge to edge. The welding symbol of the
joint is [PI-GATE-05]
a) 6 40(80) b) 6 40(80)
6 40(80) 6 40(80)
c) 40(80) 6 d) 40(80) 6
40(80) 6
40(80) 6
25. Two 8 mm thick steel plates are placed 5 mm apart and welded by a butt joint. Welding is carried out at 20 V and
speed of 5 mm/sec. Heat transfer efficiency is 0.80. If the heat required to melt steel is 10J/mm3 and melting efficiency
is 0.625, the weld current (in Amperes) will be [PI-GATE-05]
a) 100 b) 200 c) 300 d) 400
26. Match List - I (Welding problems) with List - II (Causes) and select the correct answer using the codes given below
the lists : [PI-GATE-05]
List - I List - II
(Welding problems) (Cause)
A. Cracking of weld metal 1. Excessive stresses
B. Cracking of base metal 2. High joint rigidity
C. Porosity 3. Failure to remove slag from previous deposit
D. Iinclusions 4. Oxidation
5. Excessive H2, O2, N2 in the welding atmosphere
Codes :
ABCD
a) 2 1 5 3
b) 3 4 2 1
c) 2 4 5 3
d) 3 1 4 2
27. Consider the following statements : [PI-GATE-05]
The size of the heat affected zone (HAZ) will increase with
1. increased starting temperature 2. increased welding speed
3. increased thermal conductivity of the base metal 4. increase in base metal thickness
Which of the statements given above are correct ?
a) 1, 2 and 3 b) 1 and 3 c) 1 and 4 d) 2 and 3
28. Consider the following statements : [PI-GATE-05]
The magnitude of residual stresses in welding depends upon
1. Metal melted / deposited
2. Which of design of weldment
3. Support and clamping of components
4. Welding process used amount the statements give above are correct ?
a) 1, 2 and 4 b) 1, 2 and 3 c) 1 and 3 d) 2 and 3
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MECHANICAL ENGINEERING
29. Assertion (A) : A sound welded joint should not only be strong enough but should also exhibits a good amount of
ducility. [PI-GATE-05]
Reason (R) : Welding process is used for fabricating mild steel components only.
30. Assertion (A) : In electron beam welding process, vacuum is an essential process parameter. [PI-GATE-05]
Reason (R) : Vaccum provides a highly efficiency shield on weld zone.
31. The DC power source for arc welding has the characteristic 3V + 1 = 240, where V = Voltage and I = current in amp.
For maximum arc power at the electrode, voltage should be set at [PI-GATE-07]
a) 20V b) 40V c) 60 V d) 80 V
32. Two pipes of inner diameter 100 mm and outer diameter 110 mm each are joined by flash butt welding suing 30V
power supply. At the interface, 1mm of material melts from each pipe which has a resistance of 42.0 Ohms, if the unit
melt energy is 64.4 MJ/m3, then time required for welding (in S) is [PI-GATE-08]
a) 1 b) 5 c) 10 d) 20
33. Aluminum strips of 2mm thickness are joined together by resistance spot welding process by applying an electric
current 6000A for 1.5 sec, the heat required for melting aluminum is 2.9 J/mm3, the diameter and thickness of the weld
nugget are found to be 5 mm and 2.5 mm respectively. Assuming the electrical resistance to be 75 micro-ohms, the
percentage of total energy utilized in forming the weld nugget is [PI-GATE-08]
a) 28 b) 35 c) 65 d) 72
34. Which pair among the following solid state welding processes uses heat from an external source [PI-GATE-08]
P. Diffusion welding Q. Friction welding R. Ultrasonic welding S. Forge welding
a) P & R b) R & S c) Q & S d) P & S
35. Which of the following powders should be fed for effective oxy-fuel cuting of stainless steel [PI-GATE-08]
a) Steel b) Aluminum c) Copper d) Ceramic
36. Autogeneous gas tungsten are welding of a steel plate is carried out with welding current of 500 A voltage of 20V
and weld speed of 20 mm/min, consider the heat transfer efficiency from the arc to the weld pool as 90%. The heat
input per unit length (in KJ / mm) is [PI-GATE-09]
a) 27 b) 35 c) 45 d) 55
37. During a steady gas metal arc welding with direct current electrode positive polarity, the welding current, voltage
and weld speed arc 150A, 30V and 6m/min respectively. A metallic wire electrode of diameter 1.2 mm is being fed at
a constant rate of 12m/min, the density, specific heat and melting temp of the wire electrode are 7000Kg/m3, 500 J/kg
and 1530 C respectively. Assume the ambient temp to be 30C and neglect the latent heat of melting. Further consider
that 2/3rd of the total electrical power is a available for melting of the wire electrode. The melting efficiency (in
percentage) of the wire electrode is [PI-GATE-10]
a) 39.58 b) 42.55 c) 49.38 d) 54.98
38. In a DC arc welding operating, the length characteristic was obtained as Varc = 20 + 5l where the arc length l was
varied between 5 mm and 7 mm. Here Varc denotes the arc voltage in Volts. The arc current was varied from 400 A to
500 A. Assuming linear power source characteristic, the open circuit voltage and the short circuit current for the
welding operation arc [ME & PI-GATE-12]
a) 45V, 450A
b) 75V, 750A
c) 95V, 950A
d) 150V, 1500A
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39. Two plates of the same metal having equal thickness are to be butt welded with electric arc. when the plate
thickness changes, welding is achieved by.
(a) adjusting the current (b) adjusting the duration of the current.
(c) changing the electrode size. (d) changing the electrode coating.
40 For gas welding a particular job using a neutral oxy-acetylene flame the acetylene consumption was 10 ltrs. The
oxygen consumption from the cylinder in litres will be.
(a) 5 (b) 10 (c) 15 (d) 20
41. In spot pulsed laser welding of aluminium plates (density = 2700 kg/m3,specific heat = 896j/kg, melting temp.=933K,
latent heat of melting = 398kJ/kg) at a temp of 30C, pulse with energy of 0.5J is focussed onto an area of 0.05mm2. if
the entire energy is couple in to the material, what will be the depth of weld assuming the CS area of th e weld is
circular and is uniform throughout its depth and only heat conduction in the direction of penetration.
(a) 5.34mm (b) 2.15mm (c) 4.23mm (d) 3.85mm
42. Match List-I with List-II and select the correct answer using the codes given below the lists.
List-I(Filler) List-II (Joining process)
A. Cu,Zn,Ag alloy - 1. Braze welding
B. Cu,Sn, alloy - 2. Brazing
C. Pb,Sn alloy - 3. Soldering
D. Iron oxide and aluminium powder - 4. TIG welding of aluminum.
Codes:-
ABCD
(a) 2 1 3 -
(b) 2 1 3 4
(c) 1 2 4 -
(d) 2 - 34
43 The voltage current characteristics of a ‘dc’ generator for arc welding is a straight line between an open - circuit
voltage of 80V and short - circuit current of 300 A.The generator settings for maximum arc power when arc
characteristic is V=20+40L.
(a) 80V and 150 A (b) 40V and 300 A (c) 40V and 150A (d) 80V and 300 A
44. Consider the following welding processes :
1. TIG welding 2. Submerged arc welding
3. Electro-slag padding 4. Thermit welding
Which of these welding process are used for welding thick pieces of metals?
(a) 1, 2, and 3 (b) 1, 2 and 4 (c) 1, 3 and 4 (d) 2, 3 and 4
45. A 900 mm long steel plate is welded by manual metal arc welding process using welding current of 150A, arc voltage
of 20V and welding speed of 300 mm/min. If the process efficiency of is 0.8 and surface resistance is 36 micro-ohm,
the heat input will be.
(a) 600 J/mm (b) 480 J/mm (c) 146 kJ (d) 116 kJ
46. The cold cracking susceptibility of the heat affected zone in an arc weld is influenced by .
P. entrapped hydrogen Q. Residual stresses
R. Marternsitic transformation S. slag inclusin
(a) P, S (b) P, Q, S (c) P, Q, R (d) R, S
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MECHANICAL ENGINEERING
47. Which of the following process can be used for welding of Aluminum alloys.
P. Submerged arc welding Q. Gas metal arc welding
R. Electroslag welding S. Gas tungsten arc welding
(a) P, Q (b) Q, S (c) Q, R (d) R, S
48. Match list - I (welding defects) with List-II (causes) and select the correct answer using the codes given below the
lists:
List - I List-II
A. spatter - 1. Damp electrodes
B. Distortion - 2. Arc blow
C. slag inclusion - 3. Improper clening in multi pass welding
D. Porosity - 4. Poor joint selection.
ABCD
(a) 4 2 3 1
(b) 4 2 1 3
(c) 2 4 1 3
(d) 2 4 3 1
49. High speed electron beam welding is focused on the weld spot using.
(a) vaccum lens (b) inert gas lens (c) optical lens (d) magnetic lens
50. The metal powder used in Thermit welding of steel is.
(a) Al (b) Cu (c) Pb (d) W
51. The strength of a brazed joint.
(a) Decreases with increase in gap between the two joining surfaces.
(b) Increases with increase in gap between the two joining surfaces.
(c) Decreases up to certain gap between the two joining surfaces beyond which it increases.
(d) Increases up to certain gap between the two joining surfaces beyond which it increases.
52. Match list -I (Welding problems) with list -II (causes) and select the correct answer using the codes given below the
lists:
Lists-I List-II
(Welding problems) (Causes)
A. Cracking of weld metal 1. Excessive stresses
B. Cracking of base metal 2. High joint rigidity
C. Porosity 3. Failure to remove slag from previous deposit.
D. Inclusions 4. Oxidation
5. Excessive H2,O2, N2, in the welding atmosphere.
Codes:
ABCD
(a) 2 1 5 3
(b) 3 4 2 1
(c) 2 4 5 3
(d) 3 1 4 2
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53. Consider the following statements:
The size of the heat affected zone (HAZ) will increase with.
1. increased starting temperature.
2. increased welding speed
3. increased thermal conductivity of the base metal.
4. increase in base metal thickness.
Which of the statements given above are correct?
(a) 1, 2 and 3 (b) 1 and 3 (c) 1 and 4 (d) 2 and 3
54. Consider the following statements:
The magnitude of residual stresses in welding depends upon.
1. design of weld ment
2. support and clamping of components
3. welding process used.
4. amount of metal melted / deposited.
Which of the statements given above are correct?
(a) 1, 2 and 4 (b) 1, 2 and 3 (c) 1 and 3 (d) 2 and 3
55. Assertion (A) : A sound welded joint should not only be strong enough but should also exhibits a good amount
of ductility.
Reason (R) : Welding process is used for fabricating mild steel components only.
56. Assertion (A) : In electron beam welding process, vaccum is an essential process parameter.
Reason (R) : Vaccum provides a highly efficeint shield on weld zone.
57. Crater wear is predominant in:
(a) carbon steel tools (b) tungsten carbide tools
(c) high speed steel tools (d) ceramic tools
58. Consider the following statements:
MIG welding process uses
1. Consumable electrode
2. non-comsumable electrode
3.D.C. power supply
4. A.C. power supply
Of these statements:
(a) 2 & 4 are correct (b) 2 & 3 are correct
(c) 1 & 4 are correct (d) 1 & 3 are correct
59 Consider the following statements:
Assertion (A): The electrodes of ac are welding are coated with sodium silicate, whereas electrodes used for dc arc
welding are coated with potassium silicate binders:
Reason (R) : Potassium has a lower ionisation potential than sodium.
(a) Both A and R are individually true and R is the correct explanation of A.
(b) Both A and R are individually true but R is not the correct explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
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MECHANICAL ENGINEERING
60. An arc welded joint is shown in the above fig.The part labelled’B’ in the fig is known as:
(a) Weld preparation (b) Penetration (c) Reinforcement (d) Slag
61. The voltage current Characteristics of a dc generator for arc welding is a straight line between an open circuit
voltage of 80 v and short circuit current of 300A. the generator settings for maximum are power will be:
(a) 80V & 150V (b) 40V & 300V (c) 40V & 150V (d) 80V & 300V
62. Which of the following joining processes are best suited for manufacturing pipes to carry gas products?
1. Riveting 2. Welding 3. Bolts and nuts
Select the correct answer using the codes given below:
(a) 1 and 2 (b) 1 and 3 (c) 2 alone (d) 1, 2 and 3
63. In oxy-acetylene gas welding, for complete combustion, the volume of oxygen required per unit of acetylene is:
(a) 1 (b) 1.5 (c) 2 (d) 2.5
64. Which of the following statements is correct ?
(a) No flux is used in gas welding of mild steel.
(b) Borax is the commonly used flux coating on welding electrodes.
(c) Laser Beam welding employs a vaccum chamber and thus avoids use of a shielding method.
(d) AC can be used for GTAW process.
65. The maximum heat in resistance welding is at the:
(a) tip of the positive electrode.
(b) tip of the negative electrode.
(c) for aligning the mould boxes.
(d) to support the cores.
66. Arc blow is more common line:
(a) a.c. welding
(b) d.c. welding with straight polarity.
(c) d.c. welding with bare electrodes.
(d) a.c. welding with bare electrodes.
67. Pinch effect in welding is the result of:
(a) expansion of gases in the arc
(b) electromagnetic forces.
(c) electric force.
(d) surface tension of the molten metal
68. In manual arc welding, the equipment should have dropping characteristics in order to maintain the
(a) voltage constant when arc length changes.
(b) current constant when arc length changes.
(c) temperature in the arc constant.
(d) weld pool red-hot.
69. In a fillet welded joint, the weakest area of the weld is:
(a) toe (b) root (c) throat (d) face
70. In which one of the following welding techniques is vaccum environment required?
(a) Ultrasonic welding (b) Laser beam welding (c) Plasma arc welding (d) Electron beam welding
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71. Match list-I (Welding defects) with List-II (causes) and select the correct answer using the codes given below
the lists:
List-I List-II
A. Spatter - 1. Damp electrodes
B. Distortion - 2. Arc blow
C. slag inclusion - 3. Improper cleaning inmultipass welding.
D. Porosity - 4. Poor joint selection
Codes:
ABCD
(a) 4 2 3 1
(b) 4 2 1 3
(c) 2 4 1 3
(d) 2 4 3 1
72. High speed electron beam of electron beam welding is focused on the weld spot using:
(a) Vaccum lens (b) Inert gas lens (c) Optical lens (d) Magnetic lens
73. In resistance welding, heat is generated due to the resistance between.
(a) Electrode and workpiece. (b) Asperities between touching plates.
(c) two dissimilar metals being in contact. (d) Interatomic forces
74. Match list-I (Welding problems) with List-II (Causes) and select the correct answer using the codes given below the
lists:
List-I List-II
A. Cracking of weld metal - 1. Excessive stress
B. Cracking of base metal - 2. High joint rigidity
C. Porosity - 3. Failure to remove slag from precious deposit.
D. Inclusion - 4. Oxidation.
5. Excessive H2,O2,N2, in the welding atmosphere.
Codes:
ABCD
(a) 2 1 5 3
(b) 3 4 2 1
(c) 2 4 5 3
(d) 3 1 4 2
75. Consider the following statements:
The side of Heat affected Zone will increase with:
1. Increase starting temperature.
2. Increase welding speed.
3. Increased thermal conductivity of base metal.
4. Increase in base metal thickness
Which of the following given above are correct?
(a) 1, 2 and 4 (b) 1, 2 and 3 (c) 1 and 3 (d) 2 and 3
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MECHANICAL ENGINEERING
76. Consider the following statements:
1. In gas welding, the torch should be held at an angle of 300to 450 from the horizontal plane.
2. In gas welding, the size of the torch depends upon thethickness of metal to be formed.
3. Drag is gas cutting is the time difference between heating of the plate and starting the oxygen gas for cutting.
Which of the statements given above are correct ?
(a) 1, 2 and 3 (b) 1 and 2 (c) 2 and 3 (d) 1 and 3
77. Which of the following are the major characteristics of submerged arc welding ?
1. High welding speeds. 2. High deposition rates 3. Low penetration 4. Low cleanliness
Select the correct answer using the code given below:
(a) 2 and 3 (b) 1, 2 and 3 (c) 3 and 4 (d) 1 and 2
78. In atomic hydrogen welding, hydrogen acts as:
(a) a heating agent
(b) one of the gases to generate the flame
(c) an effective shielding gas protecting theweld.
(d) A lubricant to increase the flow characteristics of weld metal.
79. Hot cracks occur in the weld and fusion zone as the metal solidifies.which of the following are the cases for hot
cracks?
1. Presence of sulphur and phosphorus in the base metal
2. High carbon or alloy content of the base metal
3. Moisture in the joint or electrode
4. Joint restiraint
Select the correct answer using the code given below:
(a) 1, 2 and 4 (b) 1, 2 and 3 (c) 3 and 4 (d) 1, 2, 3 and 4
80. Consider the following statements:
1. In arc welding, 65% to 75% heat is generated at the anode.
2. Duty cycle in case of arc welding is the cycle of complete welding of work piece from the beginning.
3. Arc blow is more common with DC welding Which of the statements given above are correct ?
(a) 1, 2 and 3 (b) 1 and 2 (c) 2 and 3 (d) 1 and 3
81. Which one of the following welding processes consists of minimum heat affected zone (HAZ) ?
(a) Sheilded Metal Arc Welding (SMAW)
(b) Laser Beam Welding (LBW)
(c) Ultrasonic Welding (USW)
(d) Metal Inert Gas Welding (MIG)
82. Fabrication weldability test is used to determine.
(a) Mechanical properties required for satisfactory performance of welded joint.
(b) susceptibility of welded joint for cracking.
(c) suitability for joint design
(d) appropriate machining process.
83. In which of the following welding process flux is used in the form of granules ?
(a) AC arc welding (b) Submerged arc welding
(c) Argon arc welding (d) DC arc welding
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PRODUCTION
84. Consider the following statements :
Assertion (A) : Aluminium has poor weldability.
Reason (R) : Aluminium has high thermal conductiv ity and high affinity to oxygen.
(a) Both A and R are individually true and R is the correct explanation of A.
(b) Both A and R are individually true and R is not the correct explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
85. The correct sequence of the given materials in ascending order of their weldability.
(a) MS, copper, cast iron, aluminium.
(b) Aluminium, Cast iron, copper ,MS.
(c) copper, cast iron, MS, aluminium.
(d) aluminium, copper, cast iron, MS.
86. Consider the following processes:
1. Gas welding 2. Thermit welding
3. Arc welding 4. Resistance welding
The correct sequence of these processes in increasing order of their welding temperatures is.
(a) 1,3,4,2 (b) 1,2,3,4 (c) 4,3,1,2 (d) 4,1,3,2
87. Match List-I with List-II and select the correct answer suing the codes given below the lists:
List-I List-II
(Filler rod material) (joining process)
A. Mild steel 1. MIG welding
B. Bronze 2. Soldering
C. Brass 3. Brazing
D. Lead and tin alloy 4. thermit welding
5. Braze welding
Codes:
ABCD
(a) 1 5 3 2
(b) 4 3 2 5
(c) 4 3 5 2
(d) 1 3 5 4
88. In which one of the following welding techniques is vaccum environment required .
(a) Ultrasonic welding (b) Laser beam welding
(c) Plasma arc welding (d) electron beam welding.
89 Match List-I (ingredients) with list II (welding defects)
List-I List-II
A. Silica 1. arc stabilizer
B. Potassium silicate 2. deoxidizers
C. Ferro silicon 3. Fluxing agent
D. Cellulose 4. Gas forming material
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MECHANICAL ENGINEERING
ABCD
a) P-2 P-6 P-4 P-5
b) Q-5 Q-3 Q-1 Q-4
c) R-1 R-4 R-6 R-2
d) S-3 S-4 S-2 S-6
90. Group- I Group-II
P. Arc welding 1. Diffusion
Q. Friction welding 2. Polarity
R. Solid state welding 3. Focusing
S. Laser welding 4. Kinetic energy
(a) P-4 Q-1 R-3 S-2
(b) P-3 Q-2 R-4 S-1
(c) P-1 Q-2 R-4 S-3
(d) P-2 Q-4 R-1 S-3
91. In resistance welding, heat is generated due to the resistance between.
(a) electrode and work piece (b) asperties between touching plates
(c) two dissimilar metals being in contact. (d) inter-atomic force is.
92. The correct sequence of the given materials in ascending order of their weldability is:
(a) MS, copper, cast-iron, aluminium. (b) Cast iron, MS, aluminium, copper.
(c) Copper, cast iron, MS, aluminum. (d) Aluminium, copper, cast-iron, MS.
93. Oxy-acetylene reducing flame is used while carrying out the welding on:
(a) mild steel (b) high carbon steel (c) grey cast iron (d) alloy steels
94. In arc welding d.c. reverse polarity is used to bear greater advantage in:
(a) overhead welding (b) flat welding of lap joints. (c) edge welding (d) flat welding of butt joints
*********************
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3. WELDING(CLASS WORKANS.)
1-b, 2-d, 3- 1:1, 4-b&c, 5-a, 6-b, 7-b, 8-c, 9-sol, 10-sol, 11-d, 12-b&c, 13-sol, 14-c, 15-True, 16-a, 17-b, 18-d, 19-a, 20-c,
21-sol, 22-sol, 23-d, 24-d, 25-b, 26-b, 27-a, 28-sol, 29-a, 30-sol, 31-b, 32-d, 33-d, 34-c, 35-a, 36-b, 37-a, 38-sol, 39-sol, 40-
sol, 41-sol, 42-sol, 43-sol, 44-c, 45-b, 46-d, 47-d, 48-c,
3. WELDING (PRACTICE ANS.)
1-b, 2-c, 3-b, 4-d, 5-sol, 6-2.5, 7-a, 8-d, 9-c, 10-d, 11-sol, 12-a, 13-sol, 14-c, 15-sol, 16-True, 17-d, 18-d, 19-a,
20-c, 21-d, 22-c, 23-d, 24-d, 25-b, 26-a, 27-b, 28-b, 29-c, 30-b, 31-b, 32-b, 33-b, 34-b, 35-a, 36-a, 37-a, 38-c, 39-sol, 40-sol,
41-d, 42-a, 43-c, 44-d, 45-d, 46-c, 47-b, 48-d, 49-d, 50-a, 51-d, 52-a, 53-b, 54-a, 55-T, 56-T, 57-b, 58-d, 59-a, 60-c, 61-c, 62-c,
63-d, 64-d, 65-d, 66-d, 67-b, 68-b, 69-c, 70-d, 71-d, 72-d, 73-b, 74-a, 75-c, 76-b, 77-d, 78-c, 89-d, 80-d, 81-b, 82-a, 83-b, 84-a.,
85-b, 86-b, 87-a, 88-d, 89-A3 B1 C2 D4, 90-d, 91-b, 92-d, 93-b, 94-b, 95-a.
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PRODUCTION
4 FORMING
CLASSROOM OBJECTIVE
METAL FORMING [1987 TO 2012]
ONE MARK QUESTIONS
1. The maximum possible draft in cold rolling of sheet increases with the [ME-GATE-11]
a) increase in coefficient of friction b) decrease in coefficient of friction
c) decrease in roll radius d) increase in roll velocity
2. The true strain for a low carbon steel bar which is doubled in length by forging is [ME-GATE-92]
a) 0.307 b) 0.5 c) 0.693 d) 1.0
3. Hot rolling of mild steel is carried out [ME-GATE-02]
a) at recrystallisation temp b) between 100C to 150C
c) below recrystallisation temp d) above recrystallization temp
4. The blank diameter used in thread rolling will be [PI-GATE-89]
a) Equal to the major diameter of the thread
b) Equal to the pitch diameter of the thread
c) little higher than the minor diameter of the tread
d) little higher than the pitch diameter of the thread
5. For wire drawing operation, the work material should essentially be [ME-GATE-87]
a) ductile b) tough c) hard d) malleable
6. A test specimen is tressed slightly beyond the yield point and then unloaded. Its yield strength
[ME-GATE-95]
a) Decreases b) increase
c) remains same d) become equal to UTS
7. Collapsible tubes are made by [PI-GATE-89]
a) Drawing b) spinning c) Extrusion d) Rolling
8. In forging operation the sticking friction condition occurs near the ................. (Centre / ends) while
sliding friction condition occurs near the ............... (Center / ends) [ME-GATE-87]
9. Ductility of material with work hardening [ME-GATE-02]
a) Increases b) Decreases c) Remains same d) Unpredictable
10. The process of hot extrusion in used to produce [ME-GATE-94]
a) Curtain rods made of aluminium b) Steel pipes of domestic water supply
c) Stainless steel tubes used in furniture d) Large size pipe used in city water mains
11. Cold working of steel is defined as working [ME-GATE-03]
a) at its recrystallisation temperature
b) above its recrystallisation temperature
c) below its recrystallisation temperature
d) at two thirds of the melting temperature of the metal
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MECHANICAL ENGINEERING
12. A moving mandrel is used in [PI-GATE-1994]
a) wire drawing b) tube drawing
c) metal cutting d) forging
13. A solid cylinder of diameter 100 mm and height 50 mm is forged between two frictionless flat dies to
a height of 25 mm. The percentage change in diameter is [ME & PI-GATE-12]
a) 0 b) 2.07 c) 20.7 d) 41.4
14. Seamless long steel tubes are manufactured by rolling, drawing and ................... [PI-GATE-91]
15. Flash and gutter are provided in drop forging dies at the following stages [PI-GATE-05]
a) Blocking b) Preforming (Edgering)
c) Finishing d) Fullering
16. Semi brittle materails can be extruded by [PI-GATE-90]
a) impact extrusion b) closed cavity extrusion
c) hydrostatic extrusion d) backward extrusion
17. Cold shut (lap) may occur in products obtained by : [PI-GATE-10]
a) Casting b) Forging
c) Machining d) Welding
18. In order to reduce roll pressure in strip rolling, back
tension must be applied to strip. (T/F) [PI-GATE-95]
19. While rolling a strip the peripherial velocity of the roll is .......... A.............. than the entry velocity of
the strip and is .......... B ............. the exit velocity of the strip. [PI-GATE-90]
a) greater / less / equal to
b) greater than / less than / equal to
20. At the last hammer stroke the excess material from the finishing cavity of a forging die is pushed into
.......... [PI-GATE-89]
21. Hot die steel, used for large solid dies in drop forging, should necessarily have [PI-GATE-10]
a) high strength and high copper content b) high hardness and low hardenability
c) high toughness and low thermal conductivity d) high hardness and high thermal conductivity
22. In order to reduce roll pressure in strip rolling, back tension can be applied to strip. [PI-GATE-94]
23. At 1000C the crystallographic strucre of iron is ............ [PI-GATE-92]
24. Which one of the following manufacturing processes requires the provision of ‘gutters’
[PI-GATE-94]
a) closed die forging b) centrifugal casting
c) Investment casting d) impact extrusion
25. Thread rolling is restricted to [PI-GATE-92]
a) ferrous materails b) ductile materials
c) hard materials d) none of the above
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26. Cold shut (lap) may occur in products obtained by : [PI-GATE-05]
a) Casting b) Forging
c) Machining d) Welding
27. Anisotropy in rolled components is caused by [PI-GATE-09]
a) Chnage in dimentions b) scale formation
c) closure of defects d) Grain orientation
28. Forces in hot extrusion is a function of the strain hardening component of the billet material.
[PI-GATE-94]
TWO MARKS QUESTIONS
1. The true stress-true strain curve is given by σ = 1400 ε0.33, where the stress σ is in MPa. The true
stress at maximum load in (MPa) is [PI-GATE-05]
a) 971 b) 750 c) 698 d) 350
2. During open die forging process using two flat and parallel dies, a solid steel dise of initial radius (RIN)
200 mm and Initial height (HIN) 50 mm attains a height (HIN) of 30mm and radius of RFN. Along the
die-disc interface [PI-GATE-10]
(i) The coefficient of friention (µ) is = 0.35 [ 1 + e ]-RIN/RFN
(ii) In the region RSS < r < RFN, sliding friction prevails and P = √3 K.e 2µ (RIN - r)/HFN and τ = µ.p
Where p and τ are the normal and the shear stress respectively ; K is the shear yield strength of steel
and r is the radial distance of any point
(i) In the region 0 < r < RIN, sticking condition prevails
The value of RSS (in mm), where sticking condition changes to sliding friction is
a) 241.76 b) 254.55 c) 265.45 d) 278.20
3. By application of tensile force, the cross sectional area of bar ‘P’ is first recduced by 30% and then by
an additional 20%. Another bar ‘Q’of the same material is reduced in cross sectional area by 50% in
a step by applying tensile force. After deformation, the true strain in bar ‘P’and bar ‘Q’will, respec
tively, be [PI-GATE-08]
a) 0.05 and 0.5 b) 0.58 and 0.69 c) 0.69 and 0.69 d) 0.78 and 1.00
4. The thickness of metallic sheet is reduced from an initial value of 16mm to a final value of 10mm in one
single pass rolling with a pair of cylindrical rollers each of diameter of 400 mm. The bite angle in
degrees will be [ME-GATE-07]
a) 5.936 b) 7.936 c) 8.936 d) 9.936
5. List - I List - II [ME-GATE-196]
A. Rivets for aircraft body 1. Forging
B. Carburetor body 2. Cold heading
C. Crank shafts 3.Aluminum base alloy
D. Nails 4. Pressure die casting
5. Investment casting
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MECHANICAL ENGINEERING
6. Cold working produces the following effects [PI-GATE-03]
1. Stresses are set up in the material
2. grain structure get distorted
3. Strength and hadrness of the metal are decreased
4. Surface finish is reduced
a) 1 & 2 b) 1, 2 & 3 c) 3 & 4 d) 1 & 4
Common data Question for 7 & 8
In a multi-pass operation, a round bar of 10 mm diameter and 100 mm legnth is reduced in
cross-section by drawing it successively through a series of seven dies of decreasing exit diameter.
During each of theses ddrawing operations, the reduction in cross-sectional area is 35%. the yield
strenght of the material is 200 MPa. Ignore strain harening. [PI-GATE-11]
7. The total true strain applied and the final length (in mm), respectively, are
a) 2.45 and 817 b) 2.45 and 345
c) 3.02 and 2043 d) 3.02 and 33
8. Neglecting friction and redundant work, the force in (kN) required for drawign the bar through the first
die is
a) 15.71 b) 10.21 c) 6.77 d) 4.39
9. Production processApplication [PI-GATE-92]
A. Extrusion 1. Cladding of noble metal to base metal
B. Hot foring 2. Long continuous metal tubes
C. Metal spinning 3. Connecting rod of IC engine
D. Explosive weling 4. Long flanged pipes
5. House hold utensils
10. A strip with cross sectional area 150 mm X 4.5 mm is being rolled with 20% reduction of area using
450 mm diameter rollers. The subtended by the defromation zone at the roll cener is (in radians)
[ME-GATE-98]
a) 0.01 b) 0.02 c) 0.03 d) 0.06
11. Assertion (A) : Cold working of metals results in increase of strength and harness.
Reason (R) : Cold working reduces the total number of dislocations per unit volume of the material.
[PI-GATE-05]
a) Both Aand R are individually true and R is the correct explanation of A
b) BothAand R are individually true but R is not the correct explanation of A
c) A is true but R is false
d) A is false but R is true
12. Using direct extrusion process, a round billet of 100 mm length and 50 mm diameter is extruded.
Considering an ideal deformation process (no friction and no redundant work), extrusion ratio 4 and
average flow stress of material 300 MPa, the pressure (MPa) on the ram will be [PI-GATE-09]
a) 416 b) 624 c) 700 d) 832
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PRODUCTION
13. An annealed copper wire of 25 mm dia is drawn into a wire of 5 mm. The average yield stress in this
operation if the flow curved of the material is given σ = 315 ∈ 0.54 MPa
[PI-GATE-94]
a) 592 MPa b) 458 MPa c) 342 MPa d) none
14. A wire of 0.1 mm dia is drawn from a rod of 15 mm dia. dies giving reductions of 20%, 40% and 80%
are avaible. For minimum error in the final size, the number of stages and reduction at each stage
respectively would be [ME-GATE-96]
a) 3 stages and 80% reduction for all three stages
b) 4 stages and 80% reduction for rist three stages followed by a finishing stage of 20% reduction
c) 5 stages and reduction of 80%, 80%, 40%, 40%, 20% in sequence
d) none of the above
15. A lever having 900 bend is to be produced by forging using mild steel bar as raw material. The various
operations to be permormed on it during forging are : [PI-GATE-05]
P-Cutting; Q-Bending; R-Fullerings:
S-Blocking cum finishing; T-Edgering
a) P-Q-R-T-S b) R-T-Q-S-P
c) T-R-S-Q-P d) T-R-S-Q-P
16. In a single pass rolling process using 410 mm diameter steel rollers, a strip of width 140 mm and
thickness 8 mm undergoes 10% redcution of thickness. The angle of bite in radians is
[ME&PI-GATE-12]
a) 0.006 b) 0.031 c) 0.062 d) 0.600
17. In a rolling process, sheet of 25 mm thickness is rolled to 20 mm thickness. Roll is of diameter 600 mm
and it rotates at 100 rpm. The roll strip contact length will be [ME-GATE-04]
a) 5 mm b) 39 mm c) 78 mm d) 120 mm
Statement For Linked Answer Question 18 & 19
A 10 mm diameter annealed steel wire is drawn through a die at a speed of 0.5 m/sec to reduce the
diameter by 20%. The yield stress of the material is 800 MPa [PI-GATE-08]
18. Neglecting friction and strain hardening, the stress reuired for drawing (in MPa) is
a) 178.6 b) 357.0 c) 1287.5 d) 2575.0
19. The power required for the drawing process (in KW) is
a) 8.97 b) 14.0 c) 17.95 d) 28.0
20. In a wire drawing operation, diameter of a sheet of steel wire is reduced from 10 mm to 8 mm. The
mean flow stress of the material is 400 MPa. The ideal force required for drawing ignoring friction and
redundant work is [ME-GATE-06]
a) 4.48 KN b) 8.97 KN c) 2011 KN d) 31.41 KN
21. Calculate the bite angle when rolling plates 12 mm thick using work rolls 600 mm diameter and
reducing the thickness by 3 mm. [ME-GATE-94]
22. If the elongation factor during rolling of an ingot is 1.22, the minimum number of passes needed to
produce a section 250 x 250 mm from an ingot of 750 x 750 mm are [PI-GATE-92]
a) 8 b) 9 c) 10 d) 17
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MECHANICAL ENGINEERING
23. Consider the following steps in forging a connecting rod rom the bar stock[PI-GATE-03]
1. blocking 2. trimming 3. finishing 4. edging
Select the correct sequence of these operations using the codes given below
a) 1-2-3-4 b) 2-3-4-1 c) 3-4-1-2 d) 4-1-3-2
24. In open die forging, a disc of diameter 200mm and height 60mm is compressed without any barreling
effect. The final diameter of the disc is 400 mm. The true strain is [ME-GATE-07]
a) 1.986 b) 1.686 c) 1.386 d) 0.602
25. The thickness of a plate is reduced from 30 mm to 10 mm by successive cold rolling passes using
identical rolls of diameter 600 mm.Assume that there is no change in width. If the coefficient of friction
between the rolls and the work piece is 0.1, the minimum number of passes required is [PI-GATE-11]
a) 3 b) 4 c) 6 d) 7
26. A brass billet is to be excluded from its initial diameter of 100 mm to a final diameter of 50 mm. The
working temperature is 7000C and the extrusion constant is 250 MPa. The force required for
extrusion is [ME-GATE-03]
a) 5.44 MN b) 2.72 MN c) 1.36 MN d) 0.36 MN
27. To stress relieve a cold worked steel part, it is heated to a temp close to ............. A ........... and grains
obtained after cooling are ............. B ............... [PI-GATE-92]
A. lower critical temp/upper critical temp
B. fine / coarser
28. Consider the following statements : [PI-GATE-05]
In comparision to hot working, in cold working,
1. higher forces are required
2. no heating is requried
3. less ductility is required
4. better surface finish is obtained.
Which of the statements given above are correct ?
a) 1, 2 and 3 b) 1, 2 and 4
c) 1 and 3 d) 2, 3 and 4
29. In a rolling process, the roll separating force can be decreased by [PI-GATE-10]
a) Reducing the roller diameter
b) Increasing friction between the rolls and the metal
c) Reducing front tension to rolled material
d) Providing back up rollers
30. The extrusion process(es) used for the production oftoothpaste tubes is / are [PI-GATE-04]
1. tube extrusion
2. forward extrusion
3. impact extrusion
a) 1 only b) 1 & 2 c) 2 & 3 d) 3 only
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PRODUCTION
31. Match the correct combination for following metal working processes. [ME-GATE-07]
Processes Associated state of stress
P. Banking 1. Tension
Q. Stretch forming 2. Compression
R. Coining 3. Shear
S. Deep drawing 4. Tension and compression
5. Tension and shear
a) P-2, Q-1, R-3, S-4 b) P-3, Q-4, R-1, S-5
c) P-5, Q-4, R-3, S-1 d) P-3, Q-1, R-2, S-4
32. A 4 mm thick sheet is rolled with 300 mm diameter rolls to reduce thickness without any change in its
width. The friction coefficient at work-roll interface is 0.1 the minimum possible thickness of the sheet
that can be produced in a single pass is [ME-GATE-06]
a) 1.0 mm b) 1.5 mm c) 2.5 mm d) 3.7 mm
33. A copper strip of 200 mm width and 30 mm thickness is to be rolled to a thickness of 25 mm. The roll
of radius 300 mm rotates at 100 rmp. The average shear strength of the work material is 180 MPa.
The roll strip contact length and the roll force are [PI-GATE-06]
a) 15.8 mm & 0.569 MN
b) 18.97 mm, 0.683 MN
c) 38.73 mm & 1.395 MN
d) 38.73 mm & 2.09MN
34. A round billet made of brass is to be extruded (extrusion constant = 250 MPa) at 7000C. The billet
diameter is 100 mm and the diameter of the extrusion is 50 mm. The extrusion force requried (in MN)
is [PI-GATE-05]
a) 1.932 b) 2.722 c) 3.423 d) 4.650
35. In a rolling process, thickness of a strip is reduced from 4 mm to 3mm using 300 mm diameter rolls
rotating at 100 rpm. The velocity of the strip (in m/sec(c) at the neutral point is [PI-GATE-08]
a) 1.57 b) 3.14 c) 47.10 d) 94.20
36. In a single pass rolling operation, a 20 mm thick plate with of 100 mm, is reduced to 18 mm thick. The
roller radius is 250 mm and rotational speed is 10 Rpm. The average flow stress for the plate material
is 300 Mpa. The power required for the rolling operation in K W is closer to [ME-GATE-08]
a) 15.2 b) 18.2 c) 30.4 d) 45.6
37. The maximum possible percentage reduction in area per pass during wire drawing of an ideal plastic
material without friction is of the order of [PI-GATE-07]
a) 37 b) 50 c) 63 d) 75
38. A solid cylindrical stainless steel work piece of 200 mm diameter and 150 mm height. This compoenent
is reduced by 50% in height with flat die in open die forging.Assuming the flow stress of the material
as 1000 MPa and the coefficient of friction to be 0.2, the estimated forging force at the end of the
stroke is [PI-GATE-06]
a) 20.8 KN b) 31 KN
c) 78.6 KN d) 78.6 MN
************************
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MECHANICAL ENGINEERING
4. FORMING : PREVIOUS GATE QUESTIONS.
ONE MAR QUESTIONS
1-a, 2-c, 3-d, 4-b, 5-a, 6-b, 7-c, 8- ends - center, 9-b, 10-b, 11-c, 12-b, 13-d, 14-Etrusion Process,
15-c, 16-c, 17-b, 18-True, 19- Greater, less than, 20-Gutter, 21-d, 22-True, 23-Austinite or γ-iron,
24-a, 25-b, 26-b, 27-d, 28-False.
TWO MARKS QUESTIONS
1-a, 2-d, 3-b, 4-d, 5-A 3 B4 C5 D2, 6-a, 7-c, 8-b, 9- A2 B3 C5 D1, 10-d, 11-c, 12-a, 13-a, 14-b,
15-b, 16-c, 17-b, 18-b, 19-a, 20-b, 21- 0.570, 22-c, 23-d, 24-c, 25-d, 26-b, 27- A. Lower critical temp,
B. Fine, 28-b, 29-a, 30-d, 31-d, 32-c, 33-c, 34-b, 35-a, 36-a, 37-a, 38-c.
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4 FORMING
PRACTICE QUESTIONS :
1 Which one of the following processes is performed in powder metallurgy to promote self-lubricating
properties in sintered parts?
(a) Infiltration (b) Impregnation (c) Plating (d) Graphitisation
2. Extrusion force DOES NOT depend upon the.
(a) extrusion ratio (b) type of extrusion process
(c) material of the die (d) working temperature.
3 The forging defect due to hindrance to smooth flow of metal in the component called ‘Lap’ occurs
because.
(a) the corner radius provided is too large. (b) the corner radius provided is too small
(c) draft is not provided (d) the shrinkage allowance is inadequate
4 Magnesium is extruded and not rolled because .
(a) it has a low melting point. (b) it has a low density.
(c) its reactivity with roll material is high. (d) it has a close-packed hexagonal structure.
5 Rolling very thin strips of mild steel requires.
(a) large diameter rolls (b) small diameter rolls
(c) high speed rolling (d) rolling without a lubricant
6 Drop forging is used to produce.
(a) small components (b) large components
(c) identical components in large numbers. (d) medium - size components
7 In deciding the clearance between punch and die in press work in shearing, the following rule is helpful:
(a) punch size controls hole size, die size controls blank size.
(b) punch size controls both hole size and blank size.
(c) die size controls both hole size and blank size.
(d) die size controls hole size, punch size controls blank size.
8 The ‘spring back’ effect in press working is.
(a) elastic recovery of the sheet metal after removal of the load.
(b) regaining the original shape of the sheet metal.
(c) release of stored energy in the sheet metal.
(d) partial recovery of the sheet metal.
9 In one setting of rolls is a 3 high rolling mill, one gets.
(a) one reduction in thickness
(b) two reduction in thickness.
(c) three reduction in thickness
(d) two or three reduction in thickness depending upon the setting.
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MECHANICAL ENGINEERING
10 In parts produced by powder metallurgy process, presintering is done to.
(a) increase the toughness of the component.
(b) increase the density of the component.
(c) facilitate bonding of non-metallic paricles
(d) facilitate machining of the part.
11 Gear cutting on a milling machine using an involute profile cutter is a .
(a) gear forming process. (b) gear generating process.
(c) gear shapping process. (d) highly accurate gear producing process.
12 In wire drawing process, the bright shining surface on the wire is obtained if one.
(a) does not use a lubricant. (b) Low tooling cost.
(c) uses thick past lubricant. (d) use thin fluid lubricant.
13 Which one of the following is an advantage of forging?
(a) Good surface finish (b) Low tooling cost
(c) Close tolerance (d) improved physical property.
14 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) increase the punch load by the value.
(c) maintain the same punch load. (d) reduce the punch load to quarter load.
15 A cup of 10 cm height and 5 cm diameter is to be made from a sheet metal of 2mm thickness. The
number of deductions necessary will be.
(a) 1 (b) 2 (c) 3 (d) 4
16 In powder metallurgy, the operation carried out to improve the bearing properly of a bush is called.
(a) Infiltration (b) Impregnation
(c) plating (d) Heat treatment
17 Which one of the following is the correct temperature range for hot extrusion of aluminum?
(a) 300-3400C (b) 350-4000C
(c) 430-4800C (d) 550-6500C
18 The correct sequence of the given processes in manufacturing by powder metallurgy is.
(a) Blending, compacting, sintering and sizing (b) Blending, compacting, sizing and sintering.
(c) Compacting, sizing, blending and sintering. (d) Compacting, blending, sizing and sintering.
19 In the rolling process, roll separating force can be decreased by.
(a) reducing the roll diameter.
(b) increasing the roll diameter.
(c) providing back-up rolls
(d) increasing the friction between the rolls and the metal.
20 Which one of the following lubricants is most suitable for drawing mild steel wires?
(a) Sodium stearate (b) Water
(c) Lime-water (d) Kerosene
21 In the forging operation, fullering is done to
(a) draw out the material (b) bend the material
(c) upset the material (d) extrude the material.
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22 Carbide-tipped cutting tools are manufactured by powder-metal technology process and have a
composition of.
(a) Zirconium - Tungsten (35%-65%) (b) Tungsten carbide-Cobalt (90%-10%)
(c)Aluminium oxide Silica (70%-30%) (d) Nickel-Chromium Tungsten (30%-15%-55%)
23 The rate of production of a powder metallurgy part depends on
(a) flow rate of powder (b) green strength of compact.
(c) apparent density of compact. (d) compressibility of powder.
24 Which one is not a method of reducing cutting forces to prevent the overloading of press?
(a) Providing shear on die (b) Providing shear on punch
(c) Increasing die clearance (d) Stepping punches.
25 In rolling a strip between tow rolls, the position of the neutral point in the arc of contact does not
depend on.
(a) amount of reduction (b) diameter of the rolls
(c) coefficient of friction (d) material of the rolls
26 A forging method for reducing the diameter of a bar and in the process making it longer is termed as.
(a) Fullering (b) Punching
(c) Upsetting (d) Extruding
27 Impact extrusion is used for making.
(a) small workpieces from more ductile metals. (b) large workpieces from more ductile metals.
(c) large workpieces from more brittle metals. (d) small workpieces from more brittle metals.
28 Which one of the following is an ingot defect of forging.
(a) Dirt (b) Piping (c) Brunt metal (d) Decarburisation
29 Which one of the following is not a secondary operation in power metallurgy.
(a) Impregnation (b) Infiltration
(c) Coining (d) Blending
30 Back-up rolls are larger than driving rolls because.
(a) to increase rigidity
(b) to decrease the roller separating force.
(c) to increase rigidity & decrease the roller separating force.
(d) None of above.
31 In piercing operation,
(a) punch governs the size of hole & clearance is provided on die
(b) clearance is provided on the punch & die governs the size of hole.
(c) punch governs the size of hole & clearance are also provided on the punch.
(d) Die governs the size of hole & clearance & are also provided on the die.
32 For mild steel, the hot forging temperature range is
(a) 4000C to 6000C
(b) 7000C to 9000C
(c) 10000C to 12000C
(d) 13000C to 15000C
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MECHANICAL ENGINEERING
33 Which one of the following factors promotes the tendency for wrinkling in the process of drawing?
(a) Increase in the ratio of thickness to blank diameter of work material.
(b) Decrease in the ratio of thickness to blankdiameter of work material.
(c) Decrease in the holding force on the blank
(d) Use of solid lubricants
34 Which one of the following process is most commonly used for the forging of bolt heads of
hexagonal shape?
(a) Closed die drop forging
(b) Open die upset forging
(c) Close die press forging
(d) Open die progressive forging
35 One of the pins in a dual locator of a jig or fixture is shaped as a “diamond pin locator” because
(a) Diamond pin does not wear fast
(b) it is easy of clamp
(c)Any variation between the centres of the hole.
(d) It will be easy to machine afterwards when the locator is worm out.
36 Best position of crank for blanking operation in a mechanical press is .
(a) top dead centre
(b) 200 below top dead centre
(c) 200 below bottom dead centre
(d) bottom dead centre
37 Which are the governing variable of the sintering process.
(a) time & temperature
(b) time & sintering temperature
(c) temperature & sintering atmosphere
(d) time, temperature & sintering atmosphere
38 Which one of the following sequence is correct in decending order of cutting speed.
(a) filing- straight turning -forming - knurling
(b) filing - straight turning - knurling - forming
(c) straight turning - filing - knurling - forming
(d) striaght turning- filing - forming - knurling
39 Which one of the following gives higher accuracy
(a) drilling (b) reaming (c) counter boring (d) boring
40 Operation of producing number of holes evenly spaceed in a regular pattern on a sheet of metal is
known as.
41 Which one of the following statements about lapping is incorrect ?
(a) It has high acuracy
(b) It has very high efficeincy
(c) It produces geometrically true surfaces.
(d) It correct minor surface imperfections
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42 Match List-I (Metal forming process) with List-II (Associated feature) and select the correct answer
using the codes given below the lists:
List - I List - II
A. Blanking 1. Shear angle
B. Flow forming 2. Coiled stock
C. Roll forming 3. Mandrel
D. Embossing 4. Closed matching dies.
Codes:
ABCD
(a) 1 3 4 2
(b) 3 1 4 2
(c) 1 3 2 4
(d) 3 1 2 4
43 Match List -I (item to be produced) with List - II (Process to be used ) and select the correct
answer using the codes given below the lists:-
List - I List- II
A. Railway wagon wheels 1. Hydrostatic extrusion
B. Reactor fuel rods 2. Machine forging
C. Gear blanks 3. Rolling
D. Dished ends of pressure vessels 4. hot spinning
Codes:
ABCD
(a) 2 1 3 4
(b) 3 1 2 4
(c) 4 3 1 2
(d) 3 4 2 1
44 Which of the following methods are suitable for the production of super alloys?
(a)Atomisation from molten state using inert gas.
(b)Atomisation using plasma arc and rotating electrode.
(c) Reduction and crushing
(d) Select the correct answer using th e codes given below:
(a) 1 and 2 (b) 2 and 3 (c) 1 and 3 (d) 1,2 and 3
45 Match List-I(Process) with List-II(Production ) ofparts and select the correct answer using the codes
given below the lists:)
List - I List-II
A. Rolling 1. Discrete parts
B. Forging 2. Rod and Wire
C. Extrusion 3. Wide variety of shapes with thin walls.
D. Drawing 4. Flat plates and sheets.
5. Solid and hollow parts.
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MECHANICAL ENGINEERING
Codes:-
ABCD
(a) 2 5 3 4
(b) 1 2 5 4
(c) 4 1 3 2
(d) 4 1 5 2
46 Which of the following are the processes for thermosetting materials?
1. Compression
2. Transfer Moulding
3. Injection moulding
4. Extrusion
Select the correct answer using the codes givenbelow:
(a) 1 and 4 (b) 1 and 2 (c) 2 and 3 (d) 2, 3 and 4
47 Consider the following processes:
1. Mechanical pulverization 2.Atomization
3. Chemical reduction 4. Sintering
Which of these processes are used for powder preparation in powder metallurgy?
(a) 2 , 3 and 4 (b) 1, 2 and 3
(c) 1, 3 and 4 (d) 1, 2 and 4
48 Match List-I (Products) with List-II (Suitable prcesses) and select the correct answer using the
codes given below the lists:
List-I List-II
A. Connecting rods 1. Welding
B. Pressure vessels 2. Extrusion
C. Machines tool beds 3. Forging
D. Collapsible tubes 4. Casting
Codes:-
ABCD
(a) 3 1 4 2
(b) 4 1 3 2
(c) 3 2 4 1
(d) 4 2 3 1
49 Match List-I(Operations) with List-II (Stresses induced) and select the correct answer using the
codes given below the lists:
List-I List-II
A. Blanking 1. Tension
B. Stretch forming 2. Compression
C. Coining 3. Shearing
D. Deep drawing 4. Tension and compresion.
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PRODUCTION
Codes:
ABCD
(a) 2 1 3 4
(b) 2 4 3 1
(c) 3 4 2 1
(d) 3 1 2 4
50 Match list-I (Forging operations) list-II (Descriptions) and select the correct answer using the codes
given below the lists:
List-I List-II
A. Flattening 1. Thickness is reduced continously at different sections along length.
B. Drawing 2.Metal is displaced away from centre, reducing thickness in middle and
increasing length.
C. Fullering 3.Rod is pulled through a die.
D. Wire drawing 4. Pressing a workpiece between two flat dies.
Codes:
ABCD
(a) 3 2 1 4
(b) 4 1 2 3
(c) 3 1 2 4
(d) 4 2 1 3
51 Match List-I (Operation) with List-II (Explanation) and select the correct answer using the codes
given below the lists:
List-I List-II
A. Bending 1. The edge of the sheet metal is bent into the cavity of a die.
B. Flanging 2. The process of punching a hole first and then expanding into a flange.
C. Hemming 3. The edge of the sheet metal is folded over itself.
D. Roll Forming 4. Bending continous lengths of sheet metal .
5. The process of bending the edges of sheet metals.
Codes:
ABCD
(a) 1 5 3 4
(b) 4 2 1 3
(c) 1 2 3 4
(d) 4 5 1 3
52 Consider the following statements related to forging:
1. Flash is excess material added to stock which flows around parting line
2. Flash helps in filling of thin ribs and bosses in upper die.
3.Amount of flash depends upon forging force.
Which of the above statements is/are correct?
(a) 1 and 3 (b) 1 and 2 (c) 1 and 3 (d) 2 and 3
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MECHANICAL ENGINEERING
53 Consider the following statements:
1. Thermoplastics posses a strong intermolecular bonding compared to that of thermosetting plastics.
2. Plastics have a high creep under continous loading
3. Embrittlement occurs in plastics at low temperature.
Which of these statements are correct?
(a) 1 and 2 (b) 2 and 3 (b) 1 and 3 (d) 1,2 and 3\
54 Match List-I (Forging Operation) with List-II (View of the forging Operation) and select the correct
answer using the codes given below the lists:
List-I List-II
A. Edging 1.
B. Fullering
↓
2.
C. Drawing 3. 1111111111111222222222222233333333333334444444444444555555555555566666666666667777777777777888888888888899999999999990000000000000111111111111122222222222223333333333333444444444444455555555555556666666666666777777777777788888888888889999999999999000000000000011111111111112222222222222333333333333344444444444445555555555555666666666666677777777777778888888888888 ↓
4. ↓111111111111222222222222333333333333444444444444555555555555666666666666777777777777888888888888999999999999000000000000111111111111222222222222333333333333 ↓
D. Swaging
Codes:
ABCD
(a) 4 3 2 1
(b) 2 1 4 3
(c) 4 1 2 3
(d) 2 3 4 1
55 Which of the following are the characteristics of extrusion process?
1. Faster speed of production
2. Good surface finish
3. Dimensions can be maintained with close tole ances.
4. Mechanical propeties of the extruded products are inferior to that of the rolled products.
Select the correct answer using the codes given below
(a) 1 and 2 (b) 1,2 and 3
(c) 3 and 4 (d) 1 and 4
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PRODUCTION
56 Which of the following are produced by powder metallurgy process?
1. Cemented carbide dies.
2. Porous bearings
2. Small magnets
3. Parts with intricate shapes
Select the correct answer using the codes given below
(a) 1, 2 and 3 (b) 1, 2 and 4
(c) 2, 3 and 4 (d) 1, 3 and 4
57 Match List-I (metal forming process) with List-II (Associated force) and select the correct answer.
List - I List - II
A. Wire drawing 1. Shear force
B. Extrusion 2. Tensile force
C. Blanking 3. Compressive force
D. Bending 4. Spring back force.
Codes:
ABCD
(a) 4 2 1 3
(b) 2 1 3 4
(c) 2 3 1 4
(d) 4 3 2 1
58 Match List-I with List-II and select the correct answer codes given below the lists:
List - I List - II
A. Drawing 1. Soap solution
B. Rolling 2. Camber
C. Wire drawing 3. Pilots
D. Sheet metal operations using 4. Crater
progressive dies. 5. Ironing
Codes:
ABCD
(a) 2 5 1 4
(b) 4 1 5 3
(c) 5 2 3 4
(d) 5 2 1 3
59 Consider the following operations involved in forging a hexagonal bolt from a round bar stock, whose
diameter is equal to the bolt diameter.
1. Flattening 2. Upsetting 3. Swaging 4. Cambering
The correct sequence of these operations is
(a) 1, 2, 3, 4 (b) 2, 3, 4, 1 (c) 2, 1, 3, 4 (d) 3, 2, 1, 4
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MECHANICAL ENGINEERING
60 Consider the following statements:
In forward extrusion process
1. the ram and the extruded product travel in thesame direction.
2. the ram and the extruded product travel in the opposite direction.
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?
(a) 1 and 3 (b) 2 and 3 (c) 1 and 4 (d) 2 and 4
61 Which of the following statements are the salient features of hydrostatic extrusion?
1. It is suitable for soft and ductile material.
2. It is suitabel for high - strength super alloys.
3. The biller is inserted in to the extrusion chamberand pressure is applied by a ram to extrude the
billet through the die.
4. The billet is inserted into the extrusion chamber where it is surrounded by a suitable liquid . the
billet is extruded through the die by applying pressure to the liquid .
Select the correct answer using the codes given below
(a) 1 and 3 (b) 1 and 4 (c) 2 and 3 (d) 2 and 4
62 Consider the following steps involved in hammer forging a connecting rod from bar stock:
1. Blocking 2.Trimming 3. Finishing 4. Fullering
5. Edging
Which of the following is the correct sequence of operations?
(a) 1, 4, 3, 2 and 5 (b) 4, 5, 1, 3 and 2
(c) 5, 4, 3, 2 and 1 (d) 5, 1, 4, 2 and 3
63 Match List-I(Parts) with List-II (Manufacturing Processes) and select the correct answer using the
codes given below the lists:
List-I List-II
A. Seamless tubes 1. Roll forming
B. Accurate and smooth tubes 2. Shot peening
C. Surfaces having higher 3. Forging
hardness and fatigue strength 4. Cold forming.
Codes:
ABC
(a) 1 4 2
(b) 2 3 1
(c) 1 3 2
(d) 2 4 1
64 Consider the following steps in forging a connecting rod from the bar stock:
(a) Blocking (b)Trimming (c) Finishing (d) Edging
Select the correct sequence of these operations using the codes given below:
(a) 1-2-3-4 (b) 2-3-4-1 (c) 3-4-1-2 (d) 4-1-3-2
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PRODUCTION
65 The extrussion processes used for the production of toothpaste tube is / are.
1. Tube extrusion
2. Forward extrusion
3.Impact extrusion
Select the correct using the codes given below:
(a) 1 only (b) 1 and 2 (c) 2 and 3 (d) 3 only
66 Consider the following products of powder metalurgy
1. Bi-metallic strips
2. Self-lubricating bearings.
2. Vaccum cleaner
4. Gas diffusers
Which of the above produced by powder metallurgy?
(a) 1, 2 and 3 (b) 2, 3 and 4 (c) 1, 3 and 4 (d) 1, 2, 3 and 4
67 Match List-I (Working) with List-II (Application) and select the correct answer using the codes given
below the lists:
List-I List-II
A. Piercing 1. Collapsible medicine tubes
B. Impact Extrusion 2. Seamless tube
C. Cold heading 3. Threads.
D. Thread rolling 4. Bolts and screws
Codes:
ABCD
(a) 1 2 3 4
(b) 2 1 4 3
(c) 1 2 4 3
(d) 2 1 3 4
68 Match List-I with List-II and select the correct answer using the codes given below the lists:
List-I List-II
A. Upsetting 1. Increasing the thickness of bar at the expenseof length
B. Swaging 2. Increasing the length of the bar at the expense of the width or thickness
or both.
C. Bending 3. Spreading the metal along the length of job .
D. Fullering 4. Shortening and stretching of layers.
Codes:
ABCD
(a) 1 2 4 3
(b) 1 2 3 4
(c) 2 1 4 3
(d) 2 1 3 4
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MECHANICAL ENGINEERING
69 Match List-I (Operation) with List-II (Stresses induced) and select the correct answer using the
codes given below the lists:
List - I List - II
A. Blanking 1. Tension & compression
B. Stretch forming 2. Tension
C. Coining 3. Shearing
D. Deep drawing 4. Compression
Codes:
ABCD
(a) 3 1 4 2
(b) 4 1 3 2
(c) 3 2 4 1
(d) 4 2 3 1
70 Which of the following pairs are correctly matched?
1. Drill press : Trepanning
2. Centre less grinding : Through feeding
3. Capstan lathe : Ram type turret
Select the correct answer using the codes given below
(a) 1 and 2 (b) 1, 2 and 3
(c) 1 and 3 (d) 2 and 3
71 Match list - I (Operation) with list - II (Application) and select the correct answer using the codes
given below the lists:
list - I list - II
A. Reaming - 1. Used for enlarging the end of a hole to give it a conical shape for a short distance.
B. Boring - 2. Used for enlarging only a limited portion of the hole.
C. Counter boring - 3. Used for finishing a hole
d. Counter sinking - 4. Used for enlarging a hole
Codes :
ABCD
(a) 3 2 4 1
(b) 1 4 2 3
(c) 3 4 2 1
(d) 1 2 4 3
72 Consider the following statements:
In comparison to hot working in cold working
1. higher forces are required
2. no heating is required
3. less ductility is required
4. better surface finish is obtained
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73 Match list - I with list - II and select the correct answer using the codes given below the lists:
List - I List - II
A. Reaming - 1. Smoothing and squaring surface around the hole for proper seating.
B. Counter boring - 2. Sizing and finishing the hole
C. Counter sinking - 3. Enlarging the end of the hole
D. Spot facing - 4. Making a conical enlargement at the end of the hole.
Codes:
ABCD
(a) 3 2 4 1
(b) 2 3 1 4
(c) 3 2 1 4
(d) 2 3 4 1
74 Consider the following statements:
Earing in a drawn cup can be due to non - uniform
1. Speed of the press 2. Clearance between tools
3. Material properties 4. Blank holding
Which of these statements are correct?
(a) 1, 2 and 3 (b) 2, 3 and 4 (c) 1, 3 and 4 (d) 1, 2 and 4
75 Match list - I (Components used in jigs and fixtures) with list - II (Their functions) and select the
correct answer using the coded given below the lists:
List - I List - II
A. Jack pin - 1. To guide the drill bit during machining
B. V-locator - 2. For easy removal of the work piece from the jig or fixture after piece
from the jig or fixture after the machining operation is over.
C. Bushes - 3. To locate the circular or semicircuar objects.
D. Ejectors - 4. To locate work pieces whose dimensions are subject to variations.
Codes :
ABCD
(a) 3 4 1 2
(b) 3 4 2 1
(c) 4 3 1 2
(d) 4 3 2 1
76 Which of the following assumptions are correct for cold rolling?
1.The material is plastic
2. The arc of contact is circular with a radius greater than the radius of the roll.
3. Coefficient of friction is constant over the arc of contact and acts in one direction througout the
arc of contact.
Select the correct answer using the codes given below;
(a) 1 and 2 (b) 1 and 3
(b) 2 and 3 (d) 1, 2 and 3
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MECHANICAL ENGINEERING
77 Which of the following are fabricated using engineering plastics?
1. Surface plate 2. Gears
3. Guide ways for machine tools 4. Foundry patterns.
Select the correct answer using the codes given below:
(a) 1, 2 and 3 (b) 1, 2, 4 (c) 2, 3 and 4 (d) 1, 2, 3 and 4
78 Consider the following statements related to piercing and blanking:
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. The total energy needed to make the cut remains unaltered due to provision of shear.
Which of the above statements are correct?
(a) 1 and 2 (b) 1 and 4 (c) 2 and 3 (d) 3 and 4
79 Cold working produces the following effects:
1. Stresses are set up in the metal
2. Grain structure gets distored
3. Strength and hardness of the metal are decreased
4. Surface finish is reduced
Which of these statements are correct?
(a) 1 and 2 (b) 1, 2 and 3 (c) 3 and 4 (d) 1 and 4
80 Consider the following advantage of power metallurgy
1. High production rate
2. Wide range of density, porosity & particle size
3. No contamination
4. No waste during fabrication
Which of the above statements are correct?
(a) 1, 2 and 3 (b) 1, 3 and 4 (b) 1, 2 and 4 (d) 1, 2, 3 and 4
81 Match list - I (Drilling operation) with list - II and select the correct answer using the codes given
below the lists:
List - I List - II
A. Counter boring - 1. Making a cone - shaped enlargement of the end of a hole.
B. Counter sinking - 2. Enlarging the end of a hole cylindrically.
C. Boring - 3. Sizing & finishing a previously drilled hole .
D. Reaming - 4. Enlarging a hole
82 Match list - I with list - II and select the correct answer using the codes given below the lists:
List - I List - II
A. Embossing - 1. Operation of production of medals or ornamental parts.
B. Flattering - 2. Operation of giving impression of fig.
C. Coining - 3. Operation of straighting a curved sheet.
D. Parting - 4. Cutting a sheet metal parts into two parts.
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PRODUCTION
83. A blank of 30 mm diameter is to be produced out of 10mm thick sheet on a simple die. If 60%
clearance is recommended then the nominal diameters of die and punch are respectively.
(a) 30.6mm and 29.4mm (b) 30.6mm and 30mm
(c) 30mm and 29.4 mm (d) 30mm and 28.8mm
84 A strip is to be rolled from a thickness of 30mm to 15mm using a two-high mill having rolls of
diameter 300mm. The coefficient of friction for unaided bits should nearly be.
(a) 0.35 (b) 0.5 (c) 0.25 (d) 0.07
85 If initial & final thickness in rolling process arc 6mm & 4.8mm, while using a 400 mm diameter roll,
the angle subtended by the deformation zone at the roll entre will be.
(a) 0.00775 rad (b) 0.0775 rad (c) 0.775 rad (d) 7.75 rad
86 If neutral Point in above promblem is 1.88, the location of neurtral point, Qn will be.
(a) 0.012 rad (b) 0.024 rad (c) 0.036 rad (d) 0.048 rad
87 A lead strip of 24mm x 24mm x 150mm is forged between two flat dies to a find size of 6mm x 96
mm x 150mm. If coefficient of friction between the job & dies is 0.25, the value of x, at which
frictional stress is equal shear yield stress, will be.
(a) 7.82mm (b) 8.32 mm (c) 9.32 mm (d) 10.32 mm
88 If a steel wire of 12mm is drawn to final diameter of 10mm , the true strain will be.
(a) 0.255 (b) 0.365 (c) 0.405 (d) 0.485
89 In above problem , the drawing operation is .
(a) 0.153 (b) 0.306 (c) 0.3417 (d) 0.694
90 In drawing operation , the diameter of the blank will be equal to, if diameter & height of the cup are
100mm & 60mm.
(a) 184.4 mm (b) 174.4 mm (c) 164.4 mm (d) 154.4 mm
91 A round billet is extruded at a temperature of 6750C. The billet diameter is 125mm & diameter of
the extrusion is 50 mm . Calculate the extrusion force required if extrusion constant is 56 N/mm2.
(a) 0.52MN (b) 6.22MN (c) 2.45MN (d) 1.26MN
******************
“Recovering from failure is often easier than building
from success”
(FORMING ) PR ACTICE QUESTIONS (ANS.) :
1.b, 2.c, 3.b, 4.c, 5.b, 6.c ,7.a, 8.a, 9.b, 10.c, 11.b, 12.a, 13.d, 14.b, 15.c, 16.b, 17.b, 18.a, 19.a, 20.a,
21.a, 22.b ,23.b, 24.d, 25.d, 26.a, 27.a, 28.b, 29.d, 30.a, 31.a, 32.c, 33.c, 34.b, 35.c, 36 .b,37.d,
38.a, 39.d, 40.d, 41.b, 42.c, 43.a, 44.c, 45.c, 46.b, 47.b, 48.a, 49.d, 50.b, 51.a, 52.b, 53.b, 54.a,
55.d, 56.a, 57.c, 58.d, 59.d, 60.c, 61.d, 62.b, 63.a, 64.d, 65.d, 66.d, 67.b, 68.a, 69.a, 70.b, 71.c,
72.b, 73.d, 74.c, 75.c, 76.a, 77.b, 78.b, 79.a, 80.d, 81.c, 82.a, 83.d, 84.a, 85.b, 86.b, 87.b, , 88.b,
89.b, 90.a, 91.d,
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MECHANICAL ENGINEERING
5 METALCUTTING
(OBJECTIVE QUESTIONS)
1. Cutting tools are provided with large positive rake angle mainly for (ME - GATE - 87)
(a) Increasing the strength of the cutting edge
(b)Avoiding rubbing action with the finished surfaces
(c) Reducing the magnitude of the cutting force
(d) Better heat dissipation
2. The size of BUE in metal cutting increases with (ME - GATE - 89)
(a) very high speed (b) large uncut chip thickness
(c) use of cutting fluid (d) increase in positive rake angle
3. Crater wear always starts at some distance from the tool tip because at that point
(ME - GATE - 89)
(a) cutting fluid does not penertrate (b) chip tool interface temp is maximum
(c) normal stress on rake face is maximum (d) tool strength is minimum
4. Most of the metal cutting heat goes into the (ME - GATE - 90)
(a) Moving chip (b) cutting tool
(c) Work material (d) machine tool
5. BUE is formed while machining (ME - GATE - 02)
(a) Ductile material at high speed (b) Ductile materials at low speed
(c) Brittle materials at high speed (d) Brittle materials at low speed
6. Friction at the tool - chip interface can be reduced by (ME - GATE - 09)
(a) Decreasing the rake angle (b) Increasing the depth of cut
(c) Decreasing the cutting speed (d) Increasing the cutting speed
7. The minimum shear strain in orthogonal turning with a cutting tool of zero rake angle is
(ME - GATE - 09)
(a) 0.00 (b) 0.5 (c) 1.0 (d) 2.0
8. When the depth of cut is increased, the specific cutting energy (PI - GATE - 95)
(a) Increases (b) Decreases
(c) remains same (d) Reaches an optimum value
9. Diamond cutting tools are not recommended for machining of ferrous metal to
(PI - GATE - 08)
(a) High tool hardness
(b) High thermal conductivity of work material
(c) poor tool toughness
(d) Chemical affinity of tool material with iron.
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PRODUCTION
10. In which of the choices given below, the cutting tool materials are placed in the ascending order of
permissible cutting speed for machining of steel ? (PI - GATE - 04)
(A) K Group Cemented Carbide - P Group Cemented Carbide - Ceramic - Cubic Boron Nitride
(b) Cubic Boron Nitride - K Group Cemented Carbide - P Group Cemented Carbide - Ceramic
(c) P Group Cemented Carbide - K Group Cemented Carbide - Cubic Boron Nitride Ceramic
(d) Cermic - Cubic Boron Nitride - K Group Cemented Carbide - P Group Cemented Carbide
11. Consider the following statements (PI - GATE - 05)
1.As the cutting speed increases, the cost of production initially reduces, then after an optimum cutting
speed it increases.
2. As the cutting speed increases the cost of production also increases and after a critical value to it
reduces.
3. Higher feed rate for the same cutting speed reduces cost of production.
4. Higher feed rate for the same cutting speed increases the cost production
Which of the statements given above are correct ?
(a) 1 and 3 (b) 2 and 3 (c) 1 and 4 (d) 3 only
12. During turning of a low carbon steel bar with TiN carbide insert, one needs to improve surface finish
without sacrificing material removal rate. To achieve improved surface finish one should
(PI - GATE - 10)
13. What is the approximate % change in the life, t, of the tool with zero rake angle used in orthogonal
cutting when its clearance angle, α, is changed from 10 to 7 deg ? (ME - GATE - 99)
(a) 30% increase (b) 30% decrease
(c) 70% increase (d) 70% decrease
14. Two tools P and Q have signature -5o -5o -6o -60 -8o -30o -0 and 5o -5o -7o -7o -8o -15o -0 (both ASA)
respectively. They are used to turn components under the same machining conditions. If hP and hQ
denote the peak-to-valley heights of surfaces produced by the tools P and Q, the ratio hP / hQ will be
(ME - GATE - 05)
tan8o + cot15o tan15o + cot8o tan15o + cot7o tan7o + cot15o
(a) ____________ (b) ____________ (c) ___________ (d) ___________
tan8o + cot30o tan30o + cot8o tan30o + cot7o tan7o + cot30o
15. In orthogonal turning of a low corbon steel of diameter 150mm with uncoated carbide tool, the cutting
velocity is 90m/min. the feed is 0.24mm/rev and the depth of cut is 2mm. The chip thickness obtained
is 0.48mm. if the orthogonal rake angle is zero, and the principle cutting edge angle is 90, the shear
angle in degrees is (ME - GATE - 07)
(a) 20.56 (b) 26.65
(c) 30.56 (d) 36.56
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MECHANICAL ENGINEERING
Statement
In nachining experiment, tool life was found to vary with the cutting speed in the following manner
Cutting speed (m/min) Tool life ( min )
60 81
90 36
16. The exponent (n) and constant © of the Taylor’s tool life equation are (PI - GATE - 03)
(a) n = 0.5, and K = 540 (b) n = 1.0, and K = 4860
(c) n = -1.0, and K = 0.74 (d) n = -0.5, and K = 1.155
17. Tool life equations for two tools under consideration are as follows (PI - GATE - 03)
HSS : VT0.2 = 150 Carbide : VT0.3 = 250
Where V is the cutting speed in m/min and T is the tool life in min. the breakeven cutting speed above
which the carbide tool will be beneficial is
(a) 54m/min (b) 150 m/min (c) 194 m / min (d) 250m/min
Statement for Linked Answer Question 18 & 19
The following data relate to an orthogonal turning process: (PI - GATE - 05) (4M)
back rake angle = 15deg, width of cut = 2mm,
Chip thickness = 0.4 mm, feed rate = 0.2 mm/rev.
18. The shear angle is (b) 25o (c) 29o (d) 75o
(a) 14o
19. If the cutting force and the thrust force are 900N and 810N, the mean strength in Mpa
(a) 137.94 (b) 477.91 (c) 500.58 (d) 635.84
Statement for Linked Answer Question 20 & 21
In an orthogonal cutting experiment, an HSS tool having the following tool signature in the orthogonal
reference system ( ORS ) has been used : 0- 10-7-7-10-75-1
Given: Width of cut = 3.6 mm; coefficient of friction at chip tool interface = 0.7, depth of cut = 0.25 mm,
mean strength = 460 Mpa.
20. Shear plane angle ( in degrees ) for minimum cutting force is (PI - GATE - 08)
(a) 20.5 (b) 24.5 (c) 3.35 (d) 32.5
21. Minimum Power requirement (in KW) at a cutting speed of 150m/min is (PI - GATE - 08)
(a) 2.6 (b) 3.25 (c) 3.35 (d) 3.45
22. Details pertaining to an orthogonal metal cutting process are given below.
Chip thickness ratio 0.4
Under formed thickness 0.6mm
Rake angle + 10o
Cutting speed 2.5m/s
Mean thickness of primary shear zone 25 microns
The shear strain rate in s-1 during the process is (ME&PI - GATE - 12)
(d) 4.397 × 105
(a) 0.1781 × 105 (b) 0.7754 × 105 (c) 1.0104 × 105
23. During turning a carbon steel rod of 160 mm diameter by a carbide tool of geometry ; 00, 0, 100,
80, 150, 750, 0 (mm) at speed of 400 rpm, fees of 0.32 mm/rev and 4.0 mm depth of cut, the
following observations were made :
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PRODUCTION
Tangential component of the cutting force , Pz = 1200 N
Axial component of the cutting force, Px = 800 N
Chip thickness (after cut), t2 = 0.8 mm
For the above machining condition determine the value of
1. Friction force, F and normal force, N acting at the chip-toll interface.
2. Yield shear strength of the work meterial nunder this machining conditon
3. Cutting power consumption in kW.
24. A seamless tube 32 mm outer diameter is turned on the lathe t’ cutting velocity of tool relative to
workplece is 10m/min. Rake angle, α = 350, depth of cut, t1 = 0.125 mm, length of chip = 60 mm.
Horizontal cutting force of the tool on workplece = 200 N vertical cutting force required to hold the
tool against work = 80 N. Calculate
1. Coefficient of friction
2. Chip thickness ratio
3. Shear plane angle
4. Velocity of chip relative to tool
5. Velocity of chip relavive to workpiece
25. A turning tool with sharp corner and a major cutting edge angle of 600 is to be used at a feed of
0.05 mm. What minor cutting edge angle should be provided to obtain an arithertical mean surface
roughness of 3µm. Under ideal contition?
26. Ageneralized Traylor’s tool life equation was obtained for HSS tool ;
A 60 min tool life was obtained using the following cutting perameters, V = 40 m/min, f= 0.25 mm,
d = 2.00 mm. Compute the took life if cutting speed, feed and depth of cut are increased by 25% and
also if they are incrased individually by 25% where v-cutting sped f= feed, d = depth of cut.
27. In an orthogonal cutting operation, the following data have been observed :
Uncut chip thickness = 0.127
Width of cut = 6.35 mm
Rake angle = 100
Cutting force = 567 N
Cutting speed = 2 m/s
Thrust force = 227 N
Chip thickness = 0.228 mm
Determine the shear angle , the friction angle, shear stress along the shear plane and the power for the
cutting operation.Aslo find trhe chip velocity, shear strain in chip and the strain rate.
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5 METALCUTTING
PRACTICE QEUSTIONS
1. A single point turning tool is designated as 100- 120-70-50-200-500-00-(ORS). The values of normal
rake and normal clearance of the above mentioned tool..................................
2. A seam less tube 32 mm outside diameter is turned on a lathe, Cutting velocity of the tool relative to the
work piece 10m/min , rake angle is 350, depth of cut is 0.125mm, length of chip is 60mm, horizontal
cutting force is 200N and vertical cutting force is 80N.
i) The coefficient of friction is.
(a) 1.52 (b) 0.86 (c) 0.93 (d) 0.54
ii) The chip thickness ratio and shear plane angle respectively are.
(a) 36.4 & 0.59 (b) 25.7 & 1.67 (c) 0.59 & 36.4 (d) none.
iii) The velocity of chip relative to the tool and velocity of chip relative to work piece m/min are
respectively.
(a) 8.42 & 5.9 (b) 10 & 8.42 (c) 5.9 & 9.6 (d) 5.9 & 8.42
3. The following equation for tool life has been obtained for HSS tool. VT0.13 f 0.6 d 0.3 = C,a 60 min
tool life was obtained using the following cutting conditions, V = 40m/min, f = 0.25mm, d = 2mm.
If the cutting speed is doubled by keeping feed and depth of cut are constant, the tool life
is......................................
4 A 0.2% C-steel is machined with a triple carbide cutting tool having 00-100-60-60-80-750- 1mm ORS
shape, a feed of 0.15mm/min have been employed.Achip thickness of 0.36mm has been obtained.
The chip reduction coefficient and shear angle are .................................
5 During orthogonal machining with a rake angle 100 and an uncut chip thickness 0.125mm, the values
of Fc and Ft are found to be 517 and 217 N respectively. the average chip thickness is also measured
and found to be 0.43mm. The machining constant for the work material is................................
6. A cutting tool has a nose radius of 1.8mm. the feed rate for a theoretical surface roughness of
Rt = 5 microns is (b) 0.187mm/rev (c) 0.036mm/rev (d) 0.0187mm/rev
(a) 0.268mm/rev
7. If the chip-tool contact length is reduced slightly by grinding the tool face, then
(a) both cutting force and interface temperature would decrease.
(b) both cutting force and interface temperature would increase.
(c) the cutting force would decrease but the interface temperature would increase.
(d) the cutting force would increase but the interface temperature would decrease.
8. In facing operation of ductile material on lathe, as the HSS cutting tool proceeds towards the center
of the work piece.
(a) the chip is continous in the beginining but discontinous towards the end .
(b) the chip remains continuous through out the cut.
(c) the chip is discontinous in the beginining but continous towards the end .
(d) the chip remains discontinuous through out the operation.
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9. Match List I with List-II and select the correct answer using the codes given below the lists:
List I List II
(Cutting tool Material) (Major characteristic constituent)
A. High speed steel 1. Carbon
B. Stellite 2. Molybdenum
C. Diamond 3. Nitride
D. Coated carbide tool 4. Columbium
5. Cobalt
Codes: A B C D
(a) 2 1 3 5
(b) 2 5 1 3
(c) 5 2 4 3
(d) 5 4 2 3
10. Consider the following tool materials:
1. Carbide 2. Cermets 3. Ceramic 4. Borazon.
The correct sequence of these tool materials in increasing order of their ability to remain their hot
hardness is
(a) 1,2,3,4 (b) 1,2,4,3 (c) 2,1,3,4 (d) 2,1,4,3
11. Chip equivalent is increased by.
(a) an increase in side-cutting edge angle of tool.
(b) an increase in nose radius and side cutting edge angle of tool.
(c) increasing the plan area of cut.
(d) increasing the depth of cut.
12. A medium carbon steel workpiece is turned on a lathe at 50m/min cutting speed, 0.8mm/rev feed and
1.5 mm depth of cut. What is the rate of metal removal?
(a) 1000mm3/min (b) 60,000mm3/min
(c) 20,000mm3/min (d) Cannot be calculated with the given data.
13. Match list - I (ISO classification of carbide tools) with List - II (Applications) and select the correct
answer using the codes given below the Lists:
List- I List-II
A. P- 10 1. Non-ferrous, roughing cut
B. P- 50 2. Non-ferrous, finishing cut
C. K-10 3. Ferrous material, roughing cut
C. K-50 4. Ferrous material, finishing cut
Codes :
ABCD
(a) 4 3 1 2
(b) 3 4 2 1
(c) 4 3 2 1
(d) 3 4 1 2
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14. The ratio of thrust force to cutting force is nearly 2.5 in
(a) turning (b) broaching (c) grinding (d) plain milling
15 Consider the following work materials
1. Titanium 2. Mild steel 3. Stainless steel 4. Grey cast iron
The correct sequence of these materials in terms of increasing order of difficulty in machining is.
(a) 4,2,3,1 (b) 4,2,1,3 (c) 2,4,3,1 (d) 2,4,1,3
16. Percentage of various alloying elements present in different steel materials are given below.
1 18% W: 4% Cr.: 1%V: 5% Co: 0.7%C
2 18% Mo: 4% Cr.: 2%V: 6% W: 0.7%C
3 27% W: 3% Ni.: 5%Mo: 0.25%C
4 18% Cr: 8% Ni: 1%V: 0.15%C
which one of these relate to that of high speed steel?
(a) 1 & 2 (b) 1 & 3 (c) 2 & 3 (d) 2 & 4
17. Formation of build up edge during machining can be a voided by using.
(a) tool with low positive rake angle
(b) high feed rate
(c) high cutting speed
(d) large depth of cut.
18 A cylinder is turned on a lathe with orthogonal machining principle. Spindle rotates at 200 rpm. the
axial feed rate is 0.25mm per revolution. Depth of cut is 0.4mm. the rake angle is 100. In the analysis
it is found that the shear angle is 27.750,
i) The thickness of the produced chip is.
(a) 0.511mm (b) 0.528mm (c) 0.818mm (d) 0.846mm
ii) In the above problem, the coefficient friction at the chip tool interface obtained using Earnest and
merchant theory is.
(a) 0.18 (b) 0.36 (c) 0.71 (d) 0.98
19. Crater wear always starts at some distance from the tool tip because at that point.
(a) cutting fluid does not penetrate.
(b) temperature is maximum
(c) normal stress on rake face is maximum
(d) tool strength is minimum
20. Consider the following statements : the strength of a single point cutting tool depends upon.
1. rake angle 2. clearance angle 3. lip angle
which of the above statements are correct.
(a) 1 & 3 (b) 2 & 3 (c) 1 & 2 (d) 1,2 & 3
21. The angle of inclination of the rake face with respect to the tool base measurement is a plane
perpendicular to the base and parallel to the width of the tool is called.
(a) back rake angle (b) side rake angle
(c) side cutting edge angle (d) endcuttingedge angle
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22. The correct sequence of cutting tools in the ascending order of their wear resistance is.
(a) HSS - Cast - nonferrous alloy - carbide - nitride
(b) Cast - nonferrous alloy HSS - carbide - nitride
(c) HSS - Cast - nonferrous alloy - nitride - carbide
(a) HSS - Cast - nonferrous alloy - nitride - HSS
23. In an orthogonal cutting test on mild steel, the following data were obtained.
Cutting speed : 40m/min, Depth of cut : 0.3mm
Tool rake angle : +50, Chip thickness : 1.5mm
Cutting force : 900N, Thrust force : 450N
Using Merchant’s analysis, the Friction angle during the machining will be.
(a) 26.50. (b) 31.50. (c) 450. (d) 63.400.
24. In which of the choice given below, the cutting tool materials are placed in the ascending order of
permis sible cutting speed for machining of steel /
a) K Group cemented carbide - P Group cemented carbide - ceramic - cubic boron nitride
b) Cubic Boron Nitride - K Group Cemented Carbide - P Group Cemented Carbide Ceramic
c) P Group Cemented Carbide - K Group Cemented carbide - Cubic Boron Nitride - Ceramic
d) Ceramic - Cubic Boron Nitride - K Group Cemented Carbide - P Group Cemented Carbide
25. Consider the following statements.
During the third stage of tool wear, rapid deterioration of tool edge takes place because .
1. flank wear is only marginal.
2. flank wear is large
3. temperature of the tool increases gradually
4. temperarture of the tool increases drastically.
Which of the statements given above are correct?
(a) 1 and 3 (b) 2 and 4 (c) 1 and 4 (d) 2 and 3
26. Common data for triplet
In an Orthogonal cutting operation
Uncutchip thickness = 0.5mm
Cutting Speed = 20m/min, width of cut = 5mm
chip thickness = 0.7mm Thrust force = 200N
cutting force = 1200N
The cutting tool material normally used for turning steel of very high hardness is .
(a) HSS (b) Tungsten Carbide (c) CBN (d) Diamond
27. The tool life increases with the
(a) increase inside cutting edge angle. (b) decrease inside rake angle
(c) decrease in nose radius (d) decrease in back rake angle.
28. The approximate variation of the tool life exponent ‘n’ of cemented carbide tools is
(a) 0.03 to 0.08 (b) 0.08 to 0.20
(c) 0.20 to 0.48 (d) 0.48 to 0.70
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29. The chip thickness ratio r is given by. sin(φ - α)
cosφ (b) cosφ
(a) sin (φ - α)
(c) cos (φ - α) (d) sinφ
sin φ cos (φ - α)
30. If V = cutting velocity, φ = shear angle,α = rake angle , the chip velocity is.
Vsinφ (b) Vcos(φ - α)
(a) cos(φ - α) sinφ
(c) Vcosφ (d) Vsin (φ - α)
sin (φ - α) sinφ
31. As the cutting speed increases.
(a) more heat is transmitted to the workpiece and less heat is transmitted to the tool.
(b) more heat is carried away by the chip and less heat is transmitted to the tool.
(c) more heat is transmitted to both the chip and the tool.
(d)more heat is transmitted to both the workpiece and the tool..
32. The limit of the maximum hardness of a work material which can be machined with HSS tools even at
low speeds is set by which one of the following tool failure mechanisms?
(a) Attrition (b) Abrasion
(c) Diffusion (d) Plastic deformation under compression.
33. Small amounts of which one of the following elements/pairs of elements is added to steel to increase its
machinability?
(a) Nickel (b) Sulphur and phosphorus.
(c) Silicon (d) Manganese and copper.
34. In turning of slender rods, it necessary to keep the
transverse force minimum mainly to.
(a) improve the surface finish (b) increase productivity.
(c) improve cutting efficiency (d) reduce vibrations and chatter.
35. Specific energy requirements in a grinding process are more than those in turning for the same metal
removal rate because of the .
(a) specific pressures between wheel and work being high.
(b) size effect of the larger contact areas between wheel and work .
(c) high cutting velocities.
(d) high heat produced during griding.
36. For cutting of brass with single-point cutting tool on a lathe, tool should have.
(a) negative rake angle (b) positive rake angle
(c) zero rake angle (d) zero side relief angle
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37. Power consumption in metal cutting is mainly due to.
(a) tangential component of the force. (b) longitudinal component of the force.
(c) normal component of the force. (d) friction at the metal-tool interface.
38. Which one of the following condition does not tend to promote the fomation of built up edges.
(a) Low cutting speed (b) low rake angle (c) low feed (d) large depth of cut.
39. Flank wear takes place when machining with.
(a) brittle materials with feed more than 0.15 mm/rev
(b) brittle materials with feed less than 0.15 mm/rev
(c) ductile materials with feed less than 0.15 mm/rev
(d) ductile materials with feed more than 0.15 mm/rev.
40. Which one of the following is not an advantage of negative rake.
(a) it can work against very high cutting speed.
(b) it decreases the lip angle.
(c) carbide tip are capable of with standing compressive loads 3 to 4 times than bending loads.
(d) it decreases the tool wear & increases the tool life.
41. With increase in cutting speed, (cutting force (Fc) & cutting ratio r).
(a) Both Fc & r increases. (b) Both Fc & r decreases.
(c) Fc decreases while r increases. (d) Fc increases while r decreases.
42. Diamond pin location is used in a fixture because.
(a) it does not wear out.
(b) it takes care of any variation in centre distance between two holes.
(c) easy to clamp the part on diamond pins.
(d) easy to manufactur.
43. The approximate value of tool life exponent ‘n’ of the HSS is.
(a) 0.1 (b) 0.25 (c) 0.38 (d) 0.48
44. Which of the following pair of tool materials have cobalt in their constitutent element ?
a) Tungesten carbide & CBN b) Tungsten carbide & Stellite
c) CBN & UCON d) Stellite & CBN
45. Match List-I (Cutting tools) with List -II (Major constituent) and select the correct answer using the
codes given below the lists:
List - I List - II
A. Stellite 1. Tungsten
B. HSS 2. Cobalt
C. Ceramic 3.Alumina
D. UCON 4. Columbium
Codes:-
ABCD
(a) 3 1 2 4
(b) 2 1 4 3
(c) 2 1 3 4
(d) 2 1 3 4
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46. Match List-I (Cutting tool material) with list -II (Typical value of tool life exponent ‘n’in the Taylor’s
equation V. Tn=C) and select the correct answer using the codes given below the lists:
List-I List-II
A. HSS 1. 0.18
B. Cast alloy 2. 0.12
C. Ceramic 3. 0.25
D. Sintered carbide 4. 0.5
Codes:-
ABCD
(a) 1 2 3 4
(b) 2 1 3 4
(c) 2 1 4 3
(d) 1 2 4 3
47. Consider the following statements:
The tool life is increased
1. built-up edge formation
2. increasing cutting velocity
3. increasing back rake angle up to a certain value
which of these statements are correct?
(a) 1 and 3 (b) 1 and 2 (c) 2 and 3 (d) 1,2 and 3
48. Consider the following cutting tool materials used for metal-cutting operation at high speed:
1. Tungsten carbide 2. Cemented titanium carbide
3. High - speed steel 4. Ceramic.
The correct sequence in increasing order of the range of cutting speeds for optimum use of these
materials is.
(a) 3,1,4,2 (b) 1,3,2,4 (c) 3,1,2,4 (d) 1,3,4,2
49. Consider the following forces acting on a finish turning tool:
1. Feed force 2. Thrust force 3. Cutting force
The correct sequence of the decreasing order of the magnitudes of these forces is.
(a) 1, 2, 3 (b) 2, 3, 1 (c) 3, 1, 2 (d) 3, 2, 1
50. During the orthogonal machining with a cutting tool having a 100 rake angle, the chip thickness is
measured to be 0.4mm, the uncut thickness being 0.15mm. The shear angle will be.
(a) 15.60 (b) 18.60 (c) 21.60 (d) 24.60
********************
“Determination is the wake-up call to thee human will”
5. METAL CUTTING (Practice Questions) Ans. :
1-sol, 2 (i)-d, (ii)-a, (iii)-d, 3- 0.29. 4- 0.105, 6.01, 5- 50, 6- a, 7-c, 8-a, 9-b, 10-a, 11-d, 12-b, 13-
sol, 14-c, 15-c, 16-a, 17-c, 18(i)-c, (ii)-d, 19-b, 20-c, 21-sol, 22-sol, 23-b, 24-sol, 25-b, 26-sol, 27-
sol, 28-sol, 29-sol, 30-sol, 31-sol, 32-sol, 33-sol, 34-sol, 35-sol, 36-sol, 37-sol, 38-sol, 39-sol, 40-sol,
41-sol, 42-sol, 43-sol, 44-sol, 45-sol, 47-sol, 48-sol, 49-sol, 50-sol.
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6 MACHINING
CLASS ROOM OBJECTIVE & PRACTICE QUEESTIONS :
ONE MARK QUESTIONS
1. When 1.0% plain carbon steel is slowly cooled from the molten state to 740C, the resulting strucutre
will contain (ME-GATE-90)
a) Pearlite and cementite b) Ferrite and cementite
c)Austinite and ferrite d) austenite and Cementite
2. Dimnd wheels should not be used for grinding steel components (T/F) (ME-GATE-95)
3. A lead screw with half nuts in a lathe, free to rotate in both directions has
a) V-threads b) With-worth threads
c) Buttress threads d)Acme threads
4. The standard specification of a grinding wheel is A-46-M6-V-21. It means a wheel of (ME-GATE)
a)Aluminum oxide of mesh size 6 b) Boron carbide of mesh size 46
c)Aluminum oxide of mesh size 46 c) Silicon carbide of mesh size 6
5. In horizontal milling process ................. (up/down) milling provides better surface finish and .............
(up/down) milling provide longer tool life. (ME-GATE-92)
6. Helix angle of fast helix drill is normally (ME-GATE-97)
a) 35deg b) 60 deg c) 90deg d) 5deg
7. Gear hobbing produces more accurate gears than milling becaue in hobbing (ME-GATE-89)
a) There is a continuous indexing operation b) Pressure angle is larger than in milling
c) Hob and work piece both are rotating d)Aspecial multi-tooth cutter (hob) is used
8. The hardness of a grinding wheel is determined by the (ME-GATE-02)
a) hardness of abrasive grains
b) ability of the bond to retain abrasives
c) hardness of the bond
d) ability of the griding wheel to penetrate the work piece
9. To get good surface finish on a turned job, one should used a sharp tool with a ............ feed rate and
........... speed of rotation of the job. (ME-GATE-94)
10. If the longitudinal feed in center-less grinding is expressed by Vf = π D. N Sin α, D stands for
(ME-GATE-90)
a) Dimeter of blank b) Diameter of fnished work piece
c) Diameter of control wheel d) Diameter of grinding wheel
11. Abrasive material used in grinding wheel selected for grinding ferrous alloys is (ME-GATE-00)
a) Sic b) diamond
c) Al2O3 d) boron carbide
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12. In twist drills ............ (small/large) point angle and ............ (small/large) helix angle are provided for
drilling soft, low strength steel. (ME-GATE-88)
13. Allowance in limits and fits refers to (ME-GATE-01)
a) maximum clearance between shaft and hole
b) minimum clearnace between shaft and hole
c) difference between maximum and minimum size of hole
d) difference between maximum and minimum size of shaft
14. In small lot production for maching T-slots on machine tables, it is expected to use
a) Shaping machine b) Broaching machine (ME-GATE-90)
c)Vertical milling machine d) Horizontal milling machine
15. Plain milling of mild steel plates produces (ME-GATE-95)
a) irregular shaped discontinuous chips b) regular shaped discontinous chips
c) continuous chips wihtout BUE d) jointed chips
16. Teeth of internal spur gears can be accurately cut in a (ME-GATE-89)
a) Milling machine b) Gear shaping machine
c) Slotting machine d) Hobbing machine
17. Deep hole drilling of small dia, say 0.2 mm is done with EDM by selecting the tool material as
a) copper wire b) tungsten wire
c) brass wire d) tungsten carbide
18. Cutting speed in grinding is set to a high value to (ME-GATE-88)
a) Reduce the cutting time b) Increase the bond strength
c) Improve cooling of job and wheel d) Reduce the wheel wear
19. The rake angle in drill (ME-GATE-96)
a) Increases from center to periphery b) Decreases from center to periphery
c) Remains constant d) Is irrelevant to the drilling operation
20. Minimum dimensional and form accuracy can be obtained in the cylinder bores of automobile engines
if the bores are finished by (ME-GATE-89)
a) Lappiong b) Reaming c) Internal grinding d) honing
21. Among the converntional machining processes, maximum specific energy is consumed in
a) Turning b) drilling (ME-GATE-95)
c) planing d) grinding
22. The drawing shows a machined shaft. The purpose of providing rounded grooves at M and N is to
(ME-GATE-03)
a) Supply lubricatin oil for bearing mounting
b) facilitate facing operation
c) Facilitate grinding of bearing mounting surface
d) Reduce stress concentration
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23. Assertion : Single start threads are used for fastening purpose. (PI-GATE-90)
Reason : Single start threads are easier to produce in a lathe.
24. Trepanning is performed for (ME-GATE-02)
a) finishing a drilled hole b) producing a large hole without drilling
c) truing a hole for alignment d) enlarging a drilled hole
25. In a shaper machine, the mechanism for tool feed is (PE-GATE-05)
a) Geneva mechanism b) Whitworth mechanism
c) Ratchet and Pawl mechanism d) Ward - Leonard system
26. In with-worth quick return mechanism (used in shapers) the velocity of the ram is maximum at
a) middle of the forward stroke b) beginning of return stroke (PI-GATE-01)
c) end of return stroke d) middle of the return stroke
27. The cutting portion of a drill is to be welded to its shank. The process best suited for this is
a) ultrasonic welding b) elctron beam welding (PI-GATE-04)
c) friction welding d) laser welding
28. Internal gear cutting operation can be performed by (ME-GATE-08)
a) Milling b) shaping with rack cutter
c) Shaping with pinion cutter d) Hobbing
29. A grinding wheel is said to be glazed if (PI-GATE-95)
a) grains have become blunt, but do not fall out b) grap between the grains is filled by swarf
c) it becomes balck due to burning d) part of the wheel is chipped off
30. In a grinding wheel marked with AA-48-L-7-V-25, L refer to (PI-GATE-92)
a) abrasive type b) wheel structure c) wheel hardness d) manufactures code
31. The flanks of teeth of rack-type gear cutter used for cutting involute gear profiles are :
a) Cyloidal b) Circular c) Involute d) Straight (PI-GATE-03)
32. A good cutting fluid should have (ME-GATE-05)
a) low thermal conductivity b) high specific heat
c) high viscosity d) high density
33. The material most commonly used for manufacturing of machine tool beds is (PI-GATE-95)
a) MS b) Gray CI c) White CI d) Galvanized iron
34. In turning operation the surface finish can be improved by decreasing (PI-GATE-89)
a) cutting speed b) Feed per revolution c) Rake angle d) Nose radius
35. Tool life in the case of a grinding wheel is the time (PI-GATE-05)
a) between two successive regrinds of the wheel
b) taken for the wheel to the balanced
c) taken between two successive wheel dressings
d) taken for a wear of 1 mm on its diameter
36. Which one of the following is not a synthetic abrasive materails (PI-GATE-03)
a) silican carbide b) aluminum oxide c) titanium nitride d) cubic boron nitride
37. Amount of energy consumption per unit volume of metal removal is maximum in
a) Turning b) Milling c) Reaming d) Grinding (PI-GATE-91)
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38. Quality scrw threads are produced by (ME-GATE-03)
a) thread milling b) thread chasing
c) thread cutting with single point tool d) thread casting
39. The teeth of tooth external and internal spur gears can be cut on (PI-GARE-91)
a) milling machine b) gear shaping machine
c) gear hobbing machine d) gear shaving machine
40. A blind hole is better tapped with a tap having (PI-GATE-92)
a) right hand flutes b) left hand flutes c) straight flutes d) no flutes
41. Reamer is designed to have even number of flutes to (PI-GATE-90)
a) Balance the cutting forces b) Conform to shop floor standard
c) Enable measrement of the reamer diameter d) Help in regrinding of reamer
42. Ramers have usually even number of teeth so that the cutting forces on teeth are properly balanced.
(T/F) (PI-GATE-95)
43. Abrasives are not used in (PI-GATE-89)
a) Buffing process b) Burnishing process
c) Polishing process d) Super finishing process
44. In the manufacture of twist drills, the shank is joined to the body of the drill using (PI-GATE-06)
a) spot welding b) TIG welding c) projection welding d) friction wedling
45. Grinding ratio is defined as (PI-GATE-11)
a) Volume of wheel wear b) Volume of work material removed
Volume of work material removed Volume of wheel wear
c) Cutting speed d) longitudinal feed
feed transverse feed
46. The final finishing process for the surface plate made of cast iron which is used as a reference surface
is (PI-GATE-06)
a) Buffing b) Grinding c) hand scraping d) honing
47. Which of the following powder production methods produces spongy and porous particles ?
a) Atomization b) Reduction of metal oxides (PI-GATE-06)
c) Electrolytic deposition d) Pulverization
48. Which of the following gear manufacturing processes is based on generation principle (PI-GATE-07)
a) Gear hobbing b) Gear shaping c) Gear milling d) Gear shaving
49. The binding material used in cemented carbide cutting tools is (PI-GATE-11)
a) graphite b) tungsten c) nickel d) cobalt
50. Reaming is primarily used for achieving (PI-GATE-07)
a) Higher MRR b) Improved dimensional tolerance
c) Fine surface finish d) Improved positoinal tolerance
6. Machining (Ans) : One Marks
1-d, 2-T, 3-c, 4-c, 5-see sol, 6-b, 7-a, 8-c, 9-see sol, 10-c, 11-c, 12-see sol, 13-b, 14-c, 15-c, 16-b,
17-a, 18-a, 19-a, 20-d, 21-d, 22-a, 23-a, 24-b, 25-c, 26-d, 27-c, 28-c, 29-a, 30-c, 31-c, 32-b, 33-b,
34-b, 35-c, 36-a, 37-d, 38-c, 39-b, 40-a, 41-a, 42-T, 43-b, 44-d, 45-b, 46-a, 47-b, 48-a, 49-d, 50-b.
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Machining : Two Marks Questions
01. If each abrasive grain is viewed as a cutting tool, then which of the following represents the cutting
parameters in common grinding operation ? (ME-GATE-06)
a) Large negative rake angle, low shear angle and high cutting speed
b) Large positive rake angle, low shear angle and high cutting speed
c) Large negative rake angle, high shear angle and low cutting speed
d) Zero rake angle, high shear angle and high cutting speed02.
02. Manufacturing process Conditions (ME-GATE-95)
a. Finish turning 1. backlash eliminator
b. Forming 2. Zero rake
c. Thread cutting 3. Nose radius
d. Down milling 4. low speed
03. A milling cutter having 10 teeth is rotating at 100 rpm. The table feed is set at 50 mm per minute. The
feed per tooth in mm is (ME-GATE-91)
a) 5 b) 0.5 c) 0.2 d) 0.05
04. A grinding wheel A 27 K 7 V is specified for finishgrindings of a HSS cutting tool. What do you
understand about the wheel from the above code. Is this an appropriate choice ? (ME-GATE-94)
a) yes b) no, because abrasive is not correct
c) no, grain size is not correct d) no, because grade is not correct choice
05. Through hole of 10 mm diameter are to be drilled in steel plate of 20 mm thickness. Drill spindle speed
is 300 rpm, feed 0.2 mm/rev and drill point angle is 1200.Assuming drill over travel of 2mm the time
for producing a hole will be (ME-GATE-04)
a) 4 seconds b) 25 seconds c) 100 seconds d) 110 seconds
06. Component process (ME-GATE-92)
a. Square hole in a high strength alloy 1. Milling
b. Square hole in a ceramic component 2. Drilling
c. Blind hole in a die 3. ECM
d. Turbine blade profile on high strength alloy 4. Jig boring
5. EDM
6. USM
07. For cutting double start screw threads of pitch 1.0 mm on a lathe, the thread cuting tool should have a
feed rate of (ME-GATE-91)
a) 0.5 mm/rev b) 1.0 mm/rev c) 2.0 mm/rev d) 4.0 mm/rev
08. The abrasive material used in grinding wheel selected for grinding of ferrous alloys is (ME-GATE-00)
a) Silicon carbide b) Diamond c)Aluminum oxide d) Boron carbide
09. A milling cutter having 8 teeth is rotating at 150 rpm. If the feed per tooth is 0.1 mm, the speed is mm
per minute is (ME-GATE-93)
a) 120 b) 187 c) 125 d) 70
10. Determine the transformation ratio (TR) of the gear train connecting the spindle and the lead screw of
4TPI required to cut 1.0 mm pitch screw threads in a center lathe. (ME-GATE-95)
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MECHANICAL ENGINEERING
11. Machine tool, structures are made ........... for high proces capability (tough/rigid/strong)
(ME-GATE-95)
12. Match the products and their manufacturing process (ME-GATE-91)
Products Manufacturing process
a. porous bearing 1. powder metallugy
b. fly wheels 2. casting
c. double end spanners 3. closed die forging
d. plastic bottles 4. blow molding
13. The time taken to drill a hole through a 25 mm thick plate with the drill rotating at 300 rpm and moving
at a feed rate of 0.25 mm/rev is (ME-GATE-02)
a) 10 sec b) 20 sec c) 60 sec d) 100 sec
14. The figure shows an incomplete schematic of a conventional lathe to be used for cutting threads with
different pitches. The speed gear box Uv is shown and the feed gear box Us is to be placed. P, Q, R
and S denote locations and have to other significance. Changes in Uv should NOT affect the pitch of
thread being cut and changes in Us should NOT affect the cutting speed. (ME-GATE-08)
The correct connections and the correct placement of Us are given below
a) Q &E are connected. Us is place between Q and Q
b) S & E are connected. Us is place between R and S
c) Q & E are connected. Us is place between Q and E
d) S & E are connected. Us is place between s and E
15. Assertion (A) : Grinding needs higher specific cutting energy than milling.
Reason (R) : Milling cutter material is harder than abrasive grains. (PI-GATE-93)
16. Group I Group II (PI-GATE-02)
P. Dressing 1. Blunting of grinding wheels
Q. Loading 2. Shaping of grinding wheels
R. Glazing 3. Sharpening of grinding wheels
S. Trueing 4. Clogging of grinding wheels
(a) (b) (c) (d)
P-2 P-3 P-3 P-4
Q-1 Q-1 Q-4 Q-3
R-4 R-4 R-1 R-1
S-3 S-2 S-2 S-2
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