10.04.
2026
IIITDM
ME2007- Manufacturing Processes – 2
Assignment -5
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1. Explain the principle of abrasive machining processes. Compare grinding with conventional
machining processes in terms of material removal mechanism, accuracy, and surface finish.
2. Describe the standard marking system of grinding wheels. Explain the significance of each
element such as abrasive type, grain size, grade, structure, and bond with a suitable example.
3. Discuss the factors affecting the selection of a grinding wheel for a given application. Explain
how work material, wheel speed, and type of grinding influence the selection.
4. Classify and explain different types of grinding processes such as surface grinding, cylindrical
grinding, center less grinding, and internal grinding with neat sketches.
5. Explain the concept of surface integrity in machining. Discuss how grinding affects surface
integrity, including residual stresses, microstructure changes, and surface roughness.
6. Describe the working principle and types of broaching machines. Compare horizontal and
vertical broaching machines with their advantages and applications.
7. Explain the construction of a broach tool. Describe different parts such as pull end, cutting
section, finishing section, and pitch. Discuss types of broaches and their applications.
8. A broaching machine has a maximum power capacity of P=2.0 kW. Using this machine, a
circular hole of initial diameter d1=18 mm in a steel plate of thickness t=30 mm is to be enlarged
to a final diameter d2=24 . The rise per tooth (feed per tooth) is f=0.08 mm, and the rake angle
of the broach teeth is α=12∘. Assume the coefficient of friction at the tool–chip interface is
μ=0.5, and the shear stress of the material is τs =380 N/mm2. Using the Lee and Shaffer shear
angle relation, determine the minimum time required to machine one component.
9. During surface grinding of a 25 mm-wide medium carbon steel work piece, a depth of cut of
0.06 mm and a table feed of 150 mm/min are employed. The grinding wheel has a diameter of
180 mm and rotates at 1800 rpm. The grit density of the wheel surface is 5 grits/mm2. It is
observed that the grinding wheel undergoes excessive wear under these conditions. When the
depth of cut is reduced to 0.03 mm, the grinding process becomes stable and acceptable. To
maintain the same material removal rate, it is proposed to increase the wheel speed so that the
apparent hardness of the wheel improves. Estimate the new required wheel speed in rpm. Also,
calculate the power consumption during the grinding operation for both the original and
modified conditions.
10.04.2026
IIITDM
10. During plunge grinding of a rectangular work piece (30 mm×12 mm), a grinding wheel of
300 diameter rotating at 2200 rpm is used. The plunge feed rate is 6 mm/min. Determine the
percentage change in power consumption when the grinding wheel specification is altered such
that the grit density changes from: 4 grits/mm2 →12grits/mm2 Assume all other operating
conditions remain unchanged.
11. During the surface grinding operation with a depth of cut of 0.07 mm and a feed rate of 200
mm/min, the surface temperature of the workpiece is found to be 850°[Link] avoid martensitic
transformation of the ferrous workpiece, it is required to maintain the surface temperature
below 700°C. However, to maintain productivity, the material removal rate (MRR) should
remain constant. Determine the required depth of cut and feed combination.
12. During a surface grinding operation, a depth of cut of 0.04 mm and a table feed rate of
180 mm/min. result in a workpiece surface temperature of 780∘C. To prevent undesirable phase
transformation in the ferrous material, the surface temperature must be limited to below 650∘C.
However, to maintain productivity, the material removal rate (MRR) must remain constant.
Determine a suitable combination of depth of cut and feed rate that satisfies the temperature
constraint while keeping the MRR unchanged.
13. Estimate the grinding force during surface grinding of a 30 mm wide medium carbon steel block
with a depth of cut of 0.04 mm. The grinding wheel has a diameter of 180 mm and rotates at
2500 rpm. The grit density is 4 grits/mm and the table feed is 120 mm/min.