GATE ME
Production Engineering
Metal Cutting
Previous Years Questions

## Marks 1

In an orthogonal cutting process the tool used has rake angle of zero degree. The measured cutting force and thrust force are $$500$$ $$N$$ and $$250... Under certain cutting conditions, doubling the cutting speed reduces the tool life to$${\left( {{1 \over {16}}} \right)^{th}}$$of the original. Tayl... Better surface finish is obtained with a large rake angle because A straight turning operation is carried out using a single point cutting tool on an$$AISI1020$$steel rod. The feed is$$0.2mm/rev$$and th... Cutting tool is much harder than the work piece. Yet the tool wears out during the tool-work interaction, because If the Taylor's tool life exponent$$n$$is$$0.2,$$and the tool changing time is$$1.5min,$$then the tool life (in min) for maximum production... The main cutting force acting on a tool during the turning (orthogonal cutting) operation of a metal is$$400N.$$The turning was performed using$$2m...
The minimum shear strain in orthogonal turning with a cutting tool of zero rake angle is
Friction at the tool - chip interface can be reduced by
Formation on build-up edge during machining can be avoided by using
$$BUE$$ is formed while machining
A built up edge is formed while machining
Cutting power consumption in turning can be signification reduced by
The effect of rake angle on the mean friction angle in machining can be explained by
Most of the metal cutting heat goes into the
Most of the metal cutting heat goes into the
Crater wear always starts at some distance from the tool tip because at that point
The size of $$BLUE$$ in metal cutting increases with
The ideal cutting fluid for low speed machining of metals should be one which
Cutting tools are provided with large positive rake angle mainly for
If in a turning operation both the feed rate and the nose radius are doubled the surface finish values will be

## Marks 2

During the turning of a $$20$$ $$mm-$$diameter steel bar at a spindle speed of $$400$$ $$rpm,$$ a tool life of $$20$$ minute is obtained. When the sam...
In an orthogonal machining with a tool of $${9^ \circ }$$ orthogonal rake angle, the uncut chip thickness is $$0.2$$ $$mm.$$ The chip thickness fluctu...
Two cutting tools with tool life equations given below are being compared: \eqalign{ & Tool\,\,1:\,\,\,\,\,\,\,V{T^{0.1}} = 150 \cr &... For an orthogonal cutting operation, tool material isHSS,$$rake angle is$${22^ \circ },$$chip thickness is$$0.8mm,$$speed is$$48m/m...
In a single point turning operation with cemented carbide tool and steel work piece, it is found that the Taylor's exponent is $$0.25.$$ If the cuttin...
For a certain job, the cost of metal cutting is $$Rs.18C/V$$ and the cost of tooling is Rs.$$270C/(TV).$$ Where $$C$$ is a constant, $$V$$ is the cutt...
The too life equation for $$HSS$$ tool is $$V{T^{0.14}}\,\,{f^{0.7}}\,\,{d^{0.4}} =$$ Constant. The tool life $$(T)$$ of $$30$$ $$min$$ is obtained u...
Orthogonal turning of a mild steel tube with a tool of rake angle $${10^0}$$ is carried out at a feed of $$0.14$$ $$mm/rev.$$ If the thickness of the ...
A single point cutting tool with $${0^0}$$ rake angle is used in an orthogonal machining process. At a cutting speed of $$180$$ $$m/min$$ the thrust f...
An orthogonal turning operation is carried out under the following conditions; rake angle $$= {5^ \circ },$$ spindle rotational speed $$=400$$ $$rpm,... A cast iron block of$$200mm$$length is being shaped in a shaping machine with a depth of cut of$$4mm,$$feed of$$0.25mm/stroke$$an... Which pair of following statement is correct for orthogonal cutting using a single-point cutting tool?$$P.$$reduction in friction angle increases cu... During pure orthogonal turning operation of a hollow cylindrical pipe, it is found that the thickness of the chip produced is$$0.5mm.$$The feed give... Two cutting tools are being compared for a machining operation. The tool life equations are:$$\eqalign{ & \,\,\,\,\,\,\,\,\,\,\,\,Carbi{\mathop...
In orthogonal turning of a bar of $$100$$ $$mm$$ diameter with a feed of $$0.25$$ $$min/rev,$$ depth of cut of $$4$$ $$mm$$ and cutting velocity of $$... In orthogonal turning of a bar of$$100mm$$diameter with a feed of$$0.25min/rev,$$depth of cut of$$4mm$$and cutting velocity of$$...
A single-point cutting tool with $${12^0}$$ rake angle is used to machine a steel work-piece. The depth of cut, $$i.e$$ uncut thickness is $$0.81$$ $$... For tool$$A,$$Taylor’s tool life exponent$$(n)$$is$$0.45$$and constant$$(K)$$is$$90.$$Similarly for tool$$B,n=0.3$$and$$K=60.$$The ... In a machining experiment, tool life was found to vary with the cutting speed in the following manner The exponent$$(n)$$and constant$$(K)$$of t... In a machining experiment, tool life was found to vary with the cutting speed in the following manner What is percentage increase in tool life when ... In a single point turning tool, the side rake angle and orthogonal rake angle are equal.$$\varphi $$is the principle cutting edge angle and its rang... Orthogonal turning is performed on a cylindrical work piece with shear strength of$$250Mpa.$$The following conditions are used: cutting velocity is ... Orthogonal turning is performed on a cylindrical work piece with shear strength of$$250Mpa.$$The following conditions are used: cutting velocity is ... A low carbon steel bar of$$147mm$$diameter with length of$$630mm$$is being turned with uncoated carbide insert. The observed tool lives ... A low carbon steel bar of$$147mm$$diameter with length of$$630mm$$is being turned with uncoated carbide insert. The observed tool lives ... In orthogonal turning of a low carbon steel bar of diameter$$150mm$$with uncoated carbide tool, the cutting velocity is$$90m/min,$$The feed is$$0...
In orthogonal turning of medium carbon steel, the specific machining energy is $$2$$ $$kJ/m{m^3},$$ the cutting velocity, feed and depth of cut are $$... In orthogonal turning of low carbon steel pipe with principal cutting edge angle of$$90,$$the main cutting force is$$1000N$$and the feed force... In an orthogonal machining operation:$$\,\,\,\,\,\,\,\,\,\,$$Uncut thickness$$\,\,\,\,\,= 0.5mm\,\,\,\,\,\,\,\,\,\,$$Cutting speed ... In an orthogonal machining operation:$$\,\,\,\,\,\,\,\,\,\,$$Uncut thickness$$\,\,\,\,\,= 0.5mm\,\,\,\,\,\,\,\,\,\,$$Cutting speed ... In an orthogonal machining operation:$$\,\,\,\,\,\,\,\,\,\,$$Uncut thickness$$\,\,\,\,\,= 0.5mm\,\,\,\,\,\,\,\,\,\,$$Cutting speed ... The figure below shows a graph, which qualitatively relates cutting speed and cost per piece produced. The three curves$$1,2$$and$$3$$respective... Two tools$$P$$and$$Q$$have signature$${5^ \circ } - {5^ \circ } - {6^ \circ } - {6^ \circ } - {8^ \circ } - {30^ \circ } - 0$$and$${5^ \circ } ...
In a machining operation, doubling the cutting speed reduces the tool life to $$1/{8^{th}}$$ of the original value. The exponent $$n$$ in Taylor's too...
A batch of $$10$$ cutting tools could produce $$500$$ components while working at $$50$$ $$rpm$$ with a tool feed of $$0.25$$ $$mm/rev$$ and depth of ...
During orthogonal cutting of mild steel with a $$10$$ degrees rake angle tool the chip thickness ratio was obtained as $$0.4.$$ The shear angle (in de...
For turning $$NiCr$$ alloy steel at cutting speeds of $$64m/min$$ and $$100m/min,$$ the respective tool lives are $$15min$$ and $$12$$ $$min.$$ The to...
A conventional lathe and a $$CNC$$ lathe are under consideration for machining a given part. The relevant data are shown below : The machine preferr...
What is the approximate $$\%$$ change in the life, $$t,$$ of the tool with zero rake angle used in orthogonal cutting when its clearance angle, $$\al... In orthogonal machining operation, the chip thickness and the uncut chip thickness are equal to$$0.45mm$$. If the tool rake angle is$$0$$deg. The s... In a typical metal cutting operation, using a cutting tool of positive rake$$\gamma = 10\deg ,$$it was observed that the shear angle was$$20deg$$.... A cutting tool has a nose radius of$$1.8mm$$. The feed rate for a theoretical surface roughness of$${R_t} = 5$$microns is In turning operation the feed rate could be doubled to increase the metal removal rate To keep the same level of surface finish, the nose radius of th... Pure metal pose machinability problem in turning operations. The reason is the ## Marks 5 A standard machine tool and an automatic machine tool are being compared for the production of a component. Following data refers to the two machines.... In an orthogonal cutting test on mild steel, the following data were obtained Cutting speed:$$40m/min,$$Depth of cut:$$0.3mm,$$Tool rak... A cylinder is turned on a lathe with orthogonal machining principle. Spindle rotates at$$200rpm$$. The axial feed rate is$$0.25mm$$per revolut... A cylinder is turned on a lathe with orthogonal machining principle. Spindle rotates at$$200rpm$$. The axial feed rate is$$0.25mm$$per revolut... A tube of$$32mm$$outside diameter was turned on a lathe and the following data was obtained Rake angle$$=35deg,$$Feed rate$$=0.1mm/rev$$Cuttin... Tool life testing on a lathe under dry cutting conditions gave$$'n'$$and$$'C'$$of Taylor tool life equation as$$0.12$$and$$130m/min,$$re... Identical straight turning operation was carried out using two tools :$$8 - 8 - 5 - 5 - 5 - 25 - 0\,(ASA)$$and$$8-8-5-5-7-30-0(ASA)$$. For same fe... In an orthogonal cutting experiment with a tool of rake angle$$7deg$$, the chip thickness was found to be$$2.5mm$$when the uncut chip thickness... The lives of two tools$$A$$&$$B$$, governed by the equation$$V{T^{0.125}} = 2.5$$and$$V{T^{0.25}} = 7$$respectively in certain machining op... In a turning trail using orthogonal tool geometry, a chip length of$$84mm$$was obtained for an uncut chip length of$$200mm.$$The cutting condition... A Throwaway carbide insert was used to machine a steel work pieces with a cutting speed of$$60m/min,$$tool life of$$40$$minutes was observed,... Tool life of a$$10$$hours is obtained when cutting with a single point tool at$$63m/min.$$If Taylor's constant$$C=257.35,$$tool life on doublin... A single point turning tool is designated as$$\${10^ \circ } - {12^ \circ } - {7^ \circ } - {5^ \circ } - {20^ \circ } - {50^ \circ } - {0^ \circ }\l...
If under a condition of plain turning the life of the cutting tool decreases by $$50\%$$ due to increase in the cutting velocity by $$20\%$$, then w...
While turning a $$C15$$ steel of $$160mm$$ diameter at $$215rpm,$$ $$2.5mm$$ depth of cut and feed of $$0.16mm/rev$$ by a tool of geometry $$0-10-8-9-... A single point cutting tool made of$$HSS$$has the value of constant$$'C'80,$$and$$n=0.2$$in the basic tool life equation. If the tool cost ... A mild steel block of width$$40mm$$is being milled using a straight slab cutter$$70mm$$diameter with$$30$$teeth. If the cutter rotates at$$...
In an orthogonal cutting operation on a work piece of width $$2.5mm,$$ the uncut chip thickness was $$0.25$$ $$mm$$ and the tool rake angle was $$0$$(...
Find the percentage change in cutting speed required to give a $$50\%$$ reduction in tool life (that is required tool life is half of the original to...
Determine the Merchants constant $$'C'$$ (shear angle relation) for aluminium from the following orthogonal machining data. Rake angle $${35^ \circ }... Calculate the$$MRR$$and Specific cutting pressure for the following cutting conditions Work material : steel, Tool material :$$HSS,$$Depth of cut... A tube is orthogonally machined in lathe to reduce its length under the following conditions. Outside diameter of the tube :$$100mm,$$Inside diamete... In an orthogonal cutting test on the following data were obtained Uncut chip thickness$$=0.25mm,$$Cutting speed:$$60m/min,$$Tool rake angle:$$0$$... The following data is available for machining a component on a turret or center lathe: find out the total number of components to be machined to justi... The cutting tool are being tried for an operation. Tailors tool life equation for them are as follows$$\eqalign{ & HSS\,\,tool\,:\,\,\,\,\,\,\,...
During orthogonal turning of a steel rod by zero rake tool at feed $$0.25mm/rev$$ and depth of cut $$2.0mm,$$ the following observations were obtained...
In a turning operation the tool life of the carbide tool was found to be $$20min$$ and $$100min,$$ at cutting speeds of $$120m/min$$ and $$80m/min$$ r...
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Joint Entrance Examination