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BT-106 · Manufacturing Practices/Important Questions

Manufacturing Practices (BT-106) - Important Questions

  1. Unit 37 Marks High Priority

    Define machining. Explain the classification of machining operations with suitable examples (turning, milling, drilling, grinding, broaching and shaping).

    Fundamental definition and classification question; core conceptual topic for Unit 3.

  2. Unit 310 Marks High Priority

    Explain the principle of turning on a lathe. Derive the expression for cutting speed $V$ (in m/min) for a workpiece of diameter $D$ (mm) rotating at $N$ (rpm) and show how spindle speed is related to $V$ and $D$. Provide the formulas.

    Core formula derivation used repeatedly for turning/milling calculations.

  3. Unit 37 Marks Medium Priority

    Define Material Removal Rate (MRR) in turning. Write the formula for MRR and explain each term. If cutting speed is denoted by $V$, feed by $f$ and depth of cut by $d$, give the expression for MRR and explain unit conversions required.

    Standard quantitative computation used in process planning and RGPV numerical problems.

  4. Unit 37 Marks High Priority

    State and explain Taylor's tool life equation. In the equation $VT^{n}=C$, define each symbol and explain how it is used to determine cutting parameters for a given tool life.

    Core empirical relation for tool life calculations; commonly asked.

  5. Unit 37 Marks Medium Priority

    Describe the types of cutting tool materials used in machining (HSS, cemented carbide, ceramics, CBN, PCD). For each material state its main properties, typical applications and limitations.

    Core knowledge of cutting tool materials required for machining processes.

  6. Unit 310 Marks Medium Priority

    Explain the principle of milling. Derive the relation between cutting speed $V$ (m/min), cutter diameter $D$ (mm) and spindle speed $N$ (rpm). Using the relation, compute the spindle speed when $V$ and $D$ are given.

    Typical milling calculation/problem frequently required in exams.

  7. Unit 37 Marks Low Priority

    Describe the drilling operation and types of drills. Explain how to select spindle speed and feed for drilling a hole of diameter $D$ in a given material. Discuss the effect of drill point angle on drilling performance.

    Common question testing drilling basics and parameter selection.

  8. Unit 37 Marks Low Priority

    Explain the principle of grinding. Describe the types of grinding wheels and their specifications (abrasive, bond, grit size, hardness). Discuss parameters affecting surface finish in grinding and criteria for wheel selection.

    Fundamental grinding concepts included in Unit 3; conceptual plus selection criteria.

  9. Unit 35 Marks Low Priority

    Explain the functions of cutting fluids in machining. List common types of cutting fluids and describe methods of application (flood, mist, emulsion, minimum quantity lubrication).

    Practical and often short-answer topic on supporting processes.

  10. Unit 37 Marks Medium Priority

    Describe the common tool wear mechanisms in metal cutting (abrasive wear, adhesive wear, diffusion, oxidation, chipping). Explain methods to monitor tool wear and remedies to reduce wear.

    Conceptual question on wear mechanisms; useful for design of machining processes.

  11. Unit 310 Marks Medium Priority

    Give an overview of CNC machine tools. Explain coordinate systems used in CNC and write a simple G-code program to face-off a rectangular job on a CNC milling machine (briefly explain the G and M codes used).

    Basic CNC knowledge and programming which is commonly tested in modern manufacturing sections of Unit 3.

  12. Unit 314 Marks Medium Priority

    A cylindrical workpiece of diameter $D$ (mm) is to be turned for a length $L$ (mm) on a lathe. Given spindle speed $N$ (rpm), feed $f$ (mm/rev) and depth of cut $d$ (mm):

    (a) Calculate the cutting speed $V$ in m/min using $D$ and $N$.

    (b) Derive the expression for Material Removal Rate (MRR) and compute its value.

    (c) Estimate the machining time required to machine the length $L$ at the given feed and spindle speed.

    Comprehensive numerical problem combining turning parameter calculations, typical of full-length questions.

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