[4 Basic Machining Calculations

and 20 mm are available. Assurning that the

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C op y ri gh t :
M Multiple Choice Questions cutting speed is 10 m/min and the feed for drill
is 0.2 mm/rev, calculate the drilling time. Neglect
Q. The ratio between two consecutive spindle
speeds for a six-speed drilling machine using Subject approach and over travel. Maximurm [Link]
at a time cannot exceed 10 mm.
drills of diameter 6.25 mm to 25 mm size andat
a cutting velocity of 18 m/min
mat er (a) 1.6 min (b) 13 min
(c) 16miín . (d) 2.4 min
MADE
to

(a) 1.02 o) 1.32

(c) 1.06 (d) 1.82 Q.6 The diameter and rotational speed of a job are
EASY 100 m and 500 rpm respectively. The high

Publicatons,
Q.2 The spindle speed range in a general-purpose
lathe is divided into steps which approximately spots (chatter marks) are found at a spacing
olow: of 30 deg on the job surface. The chatter
(a) arithmetic progression frequency is
Y(b) geometric progression New (a) 5 Hz (b) 12 Hz
(c) harmonic progression Delhi. () 100. Hz (d) 500 Hz
(d) logarithmic progression [GATE (PI): 1990]
No

[ESE:2001] p ar t
Q.7/ A shaft of length 90 mm has a tapered portion
of

Q.3 A 400 mm long shaft has a 100 mm tapered t h i s of length 55 [Link] diameter of the taper is
/ step at the middle with 4° included angle. The b o k • 80 mm at one end and 65 mm at the ther. If
tailstock offset required to produce this taper oay the taper is made by tailstock set over method,
on a lathe would be: the taper angle and the set over respectively are

repoduc
be

(a) 400 sin 4° 6) 400 sin 2° (a) 15°32 and 12.16 mm

(c) 100 sin 4° (d) 100sin 2° (b) 15°32 and 15.66 mm
[ESE: 1998] (c) 11°22' and 10.26 mm
utlised
or

Estimate the boring time to enlarge a spindle bore (d) 10°32' and 14.46 mm
from diameter 30 mm to diameter 40 mm for. a [GATE : 2045]
in

any
length of 100 mm taking cutting speed as form
30 m/min,feed 0.01 cm/rev, Allcuts are 2 mm
deep.
(a) 3.2 min b) 10.7 min
witthhoeut Numerical Data Type
Questions
(c) 3.7 min (d) 4.2 min
writ en (Q.8) For cutting double start screw threads of pitch
.5) A through hole of diameter 20 mm has to be
drilled in a lathe in a rectangular plate of size
500 x 400 x 50 mm. Drills of diameter 10 mm
permis or < Mm on a lathe, the thread cutting tool should
have a feed óf mm/rev.

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18 Mechanical Engineering Production Engineering MADE EASy
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Q.9 A medium carbon steel work piece is
turned over a length of 200 mm with a high speed stes
9 a lathe at 50 m/min cutting speed, © tool. The approach length for the tool is 5 rnm

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0.8 mm/rev feed and 1.5 mm depth of cut. The
Roughing cot: d= 3 mm, v=35 m/rnin, f=0%
MRR is yb,e0_mm³/min. mm/rev
910The broaching machine having power capacity finishing cut: d= 1 mm, v= 50 m/rnin,f=01
Subject
of 10 kW using this machine a circular hole of
mm/rev.
diameter 40mm in a 50mm thick, MS plate hasi
to be enlarged to a diameter of 48 mm. A cut Q,16 While turning a diameter of 90 mm, the turning
per tooth of 0.01 mm is used and the pitch of
teeth is 15 mm/tooth. The minimum possible
mater tool is set below centre line by 5 mm if actua
rake angle is 10° and actual clearance angle is

to
time in which one part can be machined if
cutting speed of 0.35 m/min is
the
wn
MADE 5, find the effective rake and clearance angle.

EASY
T

de:36
Conventional Questions Publi
Q.11 Find the time required to
turn a 60 mm o Q.17 Find the cutting
diameter rod into the dimensions shown, take length of the broach if keyway
of depth 4.5 mm is to be produced
cutting speed as 20 m/ min. f= 1.2 mm/rev. with number
All cuts are 3 mm deep. of finishing teeth = 4 and number of semi
finishing teeth = 8.
Rise per Pitch
tooth
o 54
42 Roughing teeth: 0.1 mm 22 mm
Semi-finishing teeth: 0.0125 mm 20 mm
100
.Finishing teeth: 20 mm
115
Q.12 Find the time for threading on 3 cm
spindle of9
M.S. for length of 15 cm. The number of
threads Try Yourself
to be cut are 3/crm. The lathe runs
at 88 rpm.
Assume Approach and over travel are 0.5 cm TY. A six speed gear box has to be
each and number of cuts for M.S. are 7. designed for
the head stock of centre lathe for
turning mild
Q.13 Estimate the machining time to turn steel and cast iron rods of
MS Rod diameter ranging
from 4 cm diameter to 3.5 cm diameter for a from 100 mm to 200 mm by carbide tools. Ii
length of 15 cm in a single cut. Assume the maximum and minimum cutting
speec
cutting 9 permissible as 120 m/min and 40 m/min
speed 30 m/min. Feed 0.4 mm/rey. Sina
respectively. What should be the values of al
a.14 Evaluate the machining time of a the 6 spindle speed.
50
Adiameter brass bar to 42 mm diameter overmma
d length of 50 mm at a spindle T2. Find the speed range ratio for the drilling machine
speed of 450 rpm. spindle if the minimum and maximum diameter
The maximum depth of cut is
limited to 3 mm of drills used are 5 mmand 25
And feed is set at 0.2 mm/rev. The mm respectivey
allowance can be taken as 3 mmn. approach and if the machinability
indices for work material
are 120 (brass) and 40
.15 Determine the time of machining of mild (alloy steel).
steel
bar of 52 mm diameter down to 44 mm chain [Ans. 15]
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