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WINTER– 16 EXAMINATION
Model Answer Subject Code: 17527
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model answer
scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not
applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The
figures drawn by candidate and model answer may vary. The examiner may give credit for any equivalent
figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values
may vary and there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer
based on candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.

Q. Sub Answer Marking

No. Q. Scheme
N.

1A a Needs of non traditional machining processes are :- 01 mark

each
- Traditional machining processes are not suitable for machining greater hardness ,high strength, heat
resistant alloys. The following are the reasons for the need of the non traditional machining process.

- 1. To machining High Strength ,heat resistant Alloys.

- [Link] produce desired intricate shapes and components like dies, molds, long holes of small sizes

and, machining complex surfaces.

-3. To obtained High accuracy and high degree of surface finish.

4. To machining new innovative materials like exotic materials due to technology advancement.

5. To manufacture innovative geometric design products and processes..

Any four of the above or others. 01 mark

each
Indexing methods in gear cutting are classified into four types :-
b.
- Direct or Rapid indexing

- Simple or Plain indexing

- Compound indexing

- Differential indexing

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c Gear shaping process Any 02

advantages
Advantages :-
01 mark
1. Most Accurate gear tooth profiles are generated by this method. each

2. Rate of production of gear is higher than form cutter mrthod.. Any 02

disadvantag
[Link] same cutter of any given pitch can cut gears of any number of teeth of same pitch. es

01 mark
Disadvantages :-
each
- Not Suitable for internal gears

Owing to the reciprocating action of cutter, there is no cutting on the return stroke in gear

shaper.

- Worms & Worm wheels cannot be generated on gear shaper.

- The rate of production is lower than gear hobbing process due to periodical indexing hence
More machining time.

d
Differentiation between EDM & W- EDM

EDM W-EDM

1. Complicated cutout cannot be easily Complicated cutout can be easily

machined. Mirror shaped tool is used to [Link] diameter thin wire is used to Any four
produce desired shape. cut desired profile or other
points 01
2. Electrode wear is more as compare to Electrode wear is negligible mark each

W-EDM

3. Surface roughness is more Surface roughness of machined part is less

4. Surface micro structure may be distorted No distortion in surface micro structure

5. Tolerances are relatively open Geometrical & dimensional tolerances are

tight.

Sketch milling cutters for following:

B a
i) side milling ( any one of below or similar )

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02

ii) Facing ( any one of below or similar )

02

iii) Plain ( any one of below or similar )

02

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b Output characteristics of EDM

01 mark
each

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a
list advantages and disadvantages of LBM
2
Advantages

- Machining of any material including non –metals is possible, irrespective of their hardness and
brittleness.

- Wide range of applications Micro drilling,welding,engraving,trimming and cutting are

possible.

- There is no direct contact between tool and work piece. Hence There is no tool wear problem.

- The properties of machined materials are not affected by LBM.

- Easy control of beam configuration and size of exposed area.

Any 02
advantages
- Extremely small holes can be machined.
01 mark
- During LBM process no chip/burr are produced. each
- In LBM laser can be sent and focussed at longer distance.

Disadvantages

- LBM has very low material removal [Link] overall efficiency is extremely low ( 10- 15%)
Any 02
- Process is limited to thin sheet plates disadvantag
es
- Machined holes may became taper. are not round and straight. 01 mark
each
- Life of the flash lamp is short.

- Effective safety procedures are required.

- High initial and maintenance Cost .

b Applications of AJM

- Machining of essentially brittle and heat sensitive materials like glass,quartzs,[Link].

- It is used for drilling holes, cutting slots, polishing,cleaning hard surfaces, such as removal of

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smudges is also possible. Any 02
application
- Used to removal of metallic smears on ceramics ,oxides, resistive coating different materials.
s of AJM

, 01 mark
Applications of WJM each
- Used to cut thin non metallic sheets.
- Used to rubber, wood, ceramics and many other soft materials.
- Machining of circuit boards.
- Used in food industry. Any 02
application
s of WJM

01 mark
each

c Sketch of CNC Tool magazines :

02 marks
each

Chain type tool magazine

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Drum type tool magazine

Honing process :-
d
Honing is a low velocity abrading process which is primarily used for finishing .ususlly
applied to internal cylindrical [Link] is removed small amount of sockup to 0.25 mm for
primary honing and about0. 01 mm for secondary. In honing simultaneous rotating and
02+02
reciprocating motion is given to the stick, the surface produced will have a characteristics
cross hatch lay [Link] figure shows typical honing tool which consists of acylindrical
body having four or six abrasive sticks space around the [Link] can not only produce
high finish but also corrects the out of roundness, taper and axial distortion in the work

Bores of any size can be [Link] produce any required surface finish.

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e Broaching tools: any two of the sketches or similar sketches

Simple Broach

02 for
each

Replaceable Shell type broach

3 a

02+06

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Pt X Z
P1 0 3
P2 0 0
P3 30 0
P4 50 -50
P5 80 -50
P6 80 -80
P7 85 -80

N10 G28 U0 W0
N20 G90 G21 G99
N30 G97 S1000 M03
N40 T0101
N50 G00 X0 Z3 OR G00 X80 Z0 (If separate facing operation is done)
N60 G01 X0 Z0 F0.2
N70 G01 X30 Z0
N80 G01 X50 Z-50
N90 G01 X80 Z-50
N100 G01 X80 Z-80
N110 GO1 X85 Z-80
N120 G28 U0 W0
N130 M09 M05
N140 M30

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02+06

Pt X Y R
Ps -10 0
P1 0 0
P2 105 0
P3 120 15 15
P4 120 65
P5 105 80 15
P6 40 80
P7 40 40
P8 0 40
P1 0 0

N10 G90 G21

N20 T01 M06
N30 S1000 M03
N40 G00 X-10 Y0
N50 G00 Z5 M08
N60 G01 Z-10
N70 G01 G42 D01 X0 Y0
N80 G01 X105 Y0
N90 G03 X120 Y15 R15 OR G03 X120 Y15 I0 J15 ( If I & J method is used for arc)
N100 G01 X120 Y65
N120 G03 X105 Y80 R15 OR G03 X105 Y80 I-15 J0
N130 G01 X40 Y80
N140 G01 X40 Y40
N150 G01 X0 Y40
N160 G01 X0 Y0
N170 G00 G40 Z5
N180 G91 G28 Z0
N190 M05 M09
N200 M30

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for co-ordinates of cutting points = 2 marks

For Program = 6 marks

Plasma Arc Machining:-

Plasma-arc machining (PAM) is a metal removal process in which metal is

removed by directing high about 11000 to 30000 degree centigrade ionized
gas on the work piece. The principle PAM is shown in the [Link] this 02+02+02
process ,plasma torch is used in which a volume of a gas such as H2,N2,O2 is +02
passed through a small chamber in which highfrquency spark is maintained
between cathode and [Link] plasma jet melts the work piece material.
The depth of hat zone depends on the work material,its thickness and
cutting speed.

Advantages of PAM

1. [Link] speed of [Link] smooth cutting.

2. [Link] is no contact between tool and work piece.
3. [Link] investment and operating costs
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[Link] good for automation with economical cost.
[Link] effective on any metal with its hardness.
[Link] cutting of stainless steel and aluminiumcan be easily cut.

Disadvantages of PAM
1. Due to high heat metallurgical change on the work piece surface.
2. Due to High heat input, water colling is needed.
3. Safety arrangements and equipments are necessary. It increases cost 04
of process.

4A a a) Horizontal Broaching Machine & label the parts.

02+02

b Differentiate between Broaching and Burnishing any four

Sr. Broaching Burnishing
No.

01 Broaching is material It is a Process of super finishing, 01 for

removing finishing process in which mirror like/glazed smooth each
by using multi point broach surface is produced, by using ball
tool. or roller type of tool.

02 It is machining process It is rubbing process no metal

removal

03 Tools have small and Smooth rollers/balls act as tool

multiple teeths.

04 Pulling or pushing force is Pressure is required to press the

required to remove the balls or rollers.

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material.

05 Broaching components are- Burnishing components are- Cam

Bearing caps, cylinder & followers, matting parts of
blocks, connecting rods etc. engine, aesthetical components etc.

c Planomiller :
04

d Sketch of slitting

02+02

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Sketch of gang milling :

4B Differentiate between Turret & Automats Lathes any four

a
Sr. Turret Automats
01 for
No.
each
01 Turrets are of Semi Jobs are done Automatically
Automatic Type

02 Skilled operator is needed. Semi-skilled operator can work.

One operator can handle One operator can handle number
single machine. of machines.

03 Tools are need to be fixed Automatic selection the tool with

manually automatic feeding of work piece
facility.

04 Used for medium Used for mass production

production

05 Cost is less Cost is high

06 These machines are These machines can be single or

generally single spindle multispindles.

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01 for
each
B
Differentiate between End Milling & Gang Milling any four

Sr. End Milling Facing operation

No.

01 In this process End Milling In this milling operation number of

cutters are used to produce flat surfaces are machined which are
sloting,recessing and small right angles to the axis of rotating
facing operations. cutter.

02 Cutter used here is End mill Cutter used here is side and face mill
cutters. Like shell end mill cutter. Number of cutters of diffent
cutter and solid end mill diameter can be used at a time.
[Link] cutter is used at
a time.

03 This process is used when Used for small machining area

machining area is large
02+02
04 Single face is machined at a Number of parallel or perpendicular
time. face can be machined simultaniosly.

05 Used for simple geometry jobs Used for complicated geometry jobs

5 a Construction of Boring Machine:

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02+02

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02+02

Sketch of gear hobbing process: 04

d List of gear finishing processes: Any four

1. Gear shaving 04
2. Gear grinding
3. Gear lapping

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4. Gear honing
5. Gear burnishing.

e Advantages of CNC machine: ( Any four )

1. Reduced lead time

2. Elimination of operator error
02
3. Lower labour cost
4. High accuracy
5. Elimination of jigs and fixture
6. Flexibility
7. Reduced inspection
8. Less scrap

Applications of CNC machine: Any four

1) Electronics Parts Manufacturing.

2) Engraving Machine Applications.
3) Machining Composites.
4) 5 Axis Machining. 02
5) Dental Milling Applications.
6) Micro Hole Drilling.
7) Machining Aluminum.
8) Machining Plastics

Grinding wheel designation:

f

Grinding wheel is designated by six symbols representing following properties of grinding

wheel.

1) Manufacturers symbol
2) Type of abrasive.
3) Grain size.
4) Grade.
5) Structure .
6) Type of bond.

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7) Manufacture symbol (optional) for reference
Eg.5I A 36 L 5 V 40 02+02
 5I-manufacturers symbol indicating type of abrasive.
 A-abrasive (aluminium oxide)
 36-grain size (medium)
 L-grade (medium)
 5-structure (dense)
 V-bond (vitrified)
 40-manufacture symbol (optional)

6 a Centre-less grinding

This grinding machine is a production machine in which outside diameter of the workpiece is
ground. The workpiece is not held between centres but by a work support blade. It is rotated
by means of a regulating wheel and ground by the grinding wheel. In through-feed centre-less
grinding, the regulating wheel revolving at a much lower surface speed than grinding wheel
controls the rotation and longitudinal motion of the workpiece. The regulating wheel is kept
slightly inclined to the axis of the grinding wheel and the workpiece is fed longitudinally as
shown in Fig.

Methods of Feed in the centre-less grinding are:

1) Through Feed
2) In Feed
3) End Feed
1) Through Feed- It is the simplest method and is applied only to the plain parallel parts such 02+02
as roller pins and straight long bars.
2) In Feed -In the method there is no axial movement of the work-piece, the only movement

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is the rotating movement.
3) End Feed -The work-piece is fed as in case of in feed method and after certain portion of
length of work-piece has been ground ,the axial movement takes place until whole length has
been ground.

Grinding wheel dressing & truing:

b Dressing is an operation performed on the grinding wheel with an aim to restore the cutting
ability. The basic principle for dressing is the generation and exposure of the new cutting
egdes on the surface of the wheel. The principle of dressing is demonstrated in Fig. 1. It is
achieved by fracturing the existing abrasive grains and allowing desired protrusion of abrasive
01+01
particles on the surface. The operation also unloads the grinding wheel i.e. removes work
piece material that is embedded on wheel surface after the grinding operation. On performing
this operation, the wheel can machine again with higher feed and in-feed (depth of cut) rate,
which permits to conclude the machining in less time but with higher accuracy. Dressing is
required at regular intervals to maintain the desired grain edge sharpness and the grain
protrusion.

Truing is another operation performed with the purpose to restore the shape of the grinding
01+01
wheel that is out of shape due to wear and deformation. The purpose of truing operation can
be understood by referring to Fig. 2. Truing makes the periphery of the wheel concentric to
the central bore and also imparts a perfect form to the surface of the wheel. It is carried out
with the same tool but with lighter depth of cut.

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c Types of maintenance of machine tools: 04

Basically two types of maintenances
1) Unplanned maintenance
i) Breakdown maintenance
ii) Corrective maintenance
iii) Opportunistic maintenance
2) Planned maintenance
i) Preventive maintenance
ii) Predictive maintenance
iii) Corrective maintenance
iv) Routine maintenance
v) Design out maintenance
vi) Total productive maintenance.

“Maintenance Manual”:
d 04
When purchase a new vehicle then maintenance booklet or service booklet is provided by
manufacturer, called as maintenance manual. This booklet in printed format given the user of
the equipment about the preventive maintenance to be done with respect to time scale of that
machine tool. It is prepared on the vast experience of manufacturer and feedback collected
from the customers who had used that type of machine tool already. It is a systematically
maintenance of m/c tool in a right manner. Standardized maintenance procedure is adopted.
Contents of maintenance manuals
Maintenance manuals contents following things
1) Safety precautions.
2) Service center details.
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3) Procedure for maintenance of different parts one by one.
4) Maintenance schedule for different parts.
5) Instructions for safe handling.
6) Important terms and abbreviations.
(if formats of the manuals given with explanation should be given full marks.)

e Maintenance practice for coupling (2 marks for maintenance practice & 2 for
procedure) 04
They are used to connect the shaft ends together for transmitting torque or rotary motion
directly from one shaft to the other. The bearings are classified 1) Rigid coupling. 2) Flexible
coupling. e.g. flanged coupling, muff coupling, bushed-pin coupling, and Oldham coupling.
Maintenance procedure of coupling
 Due to misalignment, loose bolts etc abnormal noise comes out.
 Observe the vibrations due to run out.
 Visual inspection for misalignment, wear out parts.
 Checking the lubrication regularly and change oil after certain interval.
 Prepare maintenance report for showing history of maintenance of each coupling

Need of maintenance record:

f
Records are indispensable for smooth, systematic and successful working of an industry or
02+02
manufacturing plant.

The need of maintenance records is as below-

1. Any industry has to maintain certain maintenance records of the machine tools to meet
legal requirements. Sometimes court maters require accurate information about the
plant, machine tools, workers, supervisors if any accident happens.

2. It is also important from administrative point of view. Planning & scheduling of

various production & inspection related activities are to be based on records. It is also
clear from the records available that how much time a machine tool requires to get
repaired after breakdown.

3. It is also needed to meet certain financial needs such as preparation of budget for
maintenance & repair work for various machine tools for upcoming year and records
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provides the expenditure.

4. It provides a clear picture and up to date information regarding machine tools & their
conditions which will be helpful for purchase department for procurement of some
new equipments & tools well in advance to avoid delay if any.

For example maintenance chart for milling machine is given below:

Kind of maintenance work Interval

1. Cleaning of guideways daily
2. Inspection of oil level (sight glasses) daily
3. Lubrication as per lubrication chart as per instructions on lubrication
chart
4. Oil renewal semi-annually/annually
5. Inspection and, if necessary, refilling of coolant tank weekly
6. Thorough cleaning of the machine weekly
7. Inspection of slackness of bearings annually
e 8. Inspection of electrics (contactors, limit switches, cable every 3 months
connections)
9. Inspection of lubrication pump semi-annually
10. Coolant renewal semi-annually

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