Manufacturing Engineering-1- DPME-304

Module I
1. Classify various Lathe machine.

Lathes are machine tools used for shaping materials through rotation. There are several types of
lathe machines, each designed for specific applications. Here are some common classifications of
lathe machines:

1. Engine Lathe:
 Also known as a center lathe, it is the most common type of lathe used for general-
purpose machining.
 It features a horizontal spindle and a bed that supports the workpiece and tool.
2. Speed Lathe:
 Designed for light-duty operations and small-sized workpieces.
 It operates at high speeds and is often used for tasks like polishing and finishing.
3. Bench Lathe:
 Similar to a speed lathe but mounted on a workbench or table.
 Compact and suitable for small workshops.
4. Gap Bed Lathe:
 Has a removable section of the bed to accommodate larger workpieces.
 Suitable for machining longer and larger diameter components.
5. Turret Lathe:
 Features a turret with multiple tool stations, allowing for rapid tool changes.
 Suitable for high-production environments.
6. Capstan Lathe:
 Similar to a turret lathe but designed for higher production rates.
 Often used for repetitive and batch production.
7. Toolroom Lathe:
 Precision lathe designed for tool and die making, prototype work, and maintenance.
 Offers higher accuracy and versatility.
8. CNC Lathe (Computer Numerical Control):
 Controlled by a computer, allowing for automated and precise machining.
 Can perform complex operations with high accuracy.
9. Automatic Lathe:
 Capable of automatic tool changes and repetitive operations.
 Often used for high-volume production.
10. Swiss Lathe:
 Designed for precision machining of small, complex parts.
 Often used in the watchmaking and medical industries.
11. Vertical Lathe or VTL (Vertical Turret Lathe):
 Has a vertical spindle orientation.
 Suitable for large, heavy workpieces that are difficult to mount on a horizontal lathe.
12. Facing Lathe:
  Specialized for facing operations, where the cutting tool removes material from the end
of the workpiece.

These are just a few examples of the many lathe machine classifications available, and the choice
depends on the specific requirements of the machining task.

2. Explain various angles of single point cutting tool with net sketch.

A single-point cutting tool is a tool used in machining operations like turning, shaping, planning,
and similar processes. It has only one main cutting edge and is designed to remove material from
a workpiece in the form of chips. The angles of a single-point cutting tool are crucial in
determining its performance and efficiency. Here are the various angles of a single-point cutting
tool, along with a rough sketch for better understanding:

1. Back Rake Angle (γ):

 Definition: The angle between the rake face and a line parallel to the base of the tool
measured in a plane perpendicular to the base.
 Purpose: Back rake angle helps in controlling the chip flow and reduces cutting forces.
2. Side Rake Angle (η):
 Definition: The angle between the side cutting edge and a line parallel to the base
measured in a plane perpendicular to the base.
  Purpose: Side rake angle influences the sharpness of the cutting edge and helps in chip
control.
3. End Relief Angle (α):
 Definition: The angle by which the face of the tool is relieved to avoid interference with
the finished surface.
 Purpose: End relief angle prevents the tool from rubbing against the workpiece surface,
reducing friction and improving tool life.
4. Side Relief Angle (β):
 Definition: The angle between the side flank and a line perpendicular to the base
measured in a plane parallel to the base.
 Purpose: Side relief angle ensures that the tool does not rub against the workpiece,
reducing friction and heat generation.
5. Nose Radius (r):
 Definition: The radius on the nose of the tool where the cutting edge meets the end
cutting edge.
 Purpose: Nose radius influences the strength of the cutting edge and helps in achieving a
better surface finish.

These angles collectively determine the performance of the cutting tool in terms of cutting
forces, surface finish, and tool life. Proper selection and optimization of these angles are
essential for achieving efficient machining operations.

3. Explain various operations which can be performed on a lathe machine.

A lathe is a machine tool that rotates a workpiece about an axis of rotation to perform various
operations such as cutting, turning, facing, knurling, drilling, and more. Here are some of the
common operations that can be performed on a lathe machine:

1. Turning:
 External Turning: Involves removing material from the outer diameter of the workpiece
to reduce its diameter.
 Internal Turning: Involves cutting the inner diameter of the workpiece using a boring
tool.
2. Facing:
 The process of cutting a flat surface on the end of the workpiece to create a smooth and
flat surface.
3. Taper Turning:
 Involves cutting a taper on the cylindrical workpiece. This can be done manually or with
the help of special attachments on the lathe.
4. Knurling:
 The process of creating a raised pattern of ridges on the surface of the workpiece for
better gripping or aesthetic purposes.
5. Parting Off:
  Involves cutting the workpiece to separate it from the stock material. This is often done
using a parting tool.
6. Drilling:
 The lathe can be equipped with a drill chuck or a live center to perform drilling
operations on the workpiece.
7. Boring:
 Enlarging an existing hole or creating a cylindrical hole by removing material from the
inner diameter of the workpiece.
8. Threading:
 Creating external or internal threads on the workpiece. This can be done using a
threading tool and by coordinating the movement of the tool with the rotation of the
workpiece.
9. Grooving:
 Cutting a narrow recess or groove on the surface of the workpiece. This is often done to
create space for retaining rings or similar features.
10. Eccentric Turning:
 Involves turning a workpiece off-center, creating an eccentric (off-center) feature.
11. Polishing:
 Achieving a smooth and shiny surface finish on the workpiece using polishing tools or
abrasives.
12. Radius Turning:
 Creating a curved profile or radius on the workpiece, typically done using a special
turning tool or a form tool.
13. Contour Turning:
 Following a specific contour or profile on the workpiece, often used for intricate shapes
or designs.
14. Form Turning:
 Creating specific shapes or forms on the workpiece using specialized cutting tools.

4. Explain the functions of main parts of a lathe machine with the help of its diagram.
 A lathe is a machine tool that rotates a workpiece about an axis of rotation to perform various
operations, such as cutting, sanding, knurling, drilling, deformation, facing, and turning. Here are
the main parts of a lathe machine and their functions:

1. Bed:
 Function: The bed is the base of the lathe, providing a stable platform for other
components. It supports the headstock, tailstock, and carriage.
2. Headstock:
 Function: The headstock is located at the left end of the bed. It contains the spindle,
which rotates the workpiece. It also houses the gear mechanism for controlling spindle
speed.
3. Spindle:
 Function: The spindle is a rotating component that holds and rotates the workpiece. It is
connected to the headstock and is driven by a motor. Various types of chucks or collets
can be attached to the spindle to hold different types of workpieces.
4. Tailstock:
 Function: The tailstock is located at the right end of the bed, opposite the headstock. It
can be adjusted along the bed and provides support to the other end of the workpiece. The
tailstock often contains a quill that can move in and out to apply pressure to the
workpiece.
5. Carriage:
  Function: The carriage is mounted on the bed and can move along its length. It holds the
cutting tool and other tooling necessary for various operations. The movement of the
carriage is controlled manually or automatically to perform cutting operations.
6. Cross Slide:
 Function: The cross slide is mounted on the carriage and can move perpendicular to the
lathe axis. It allows for precise control of the depth of cut during turning operations.
7. Compound Rest:
 Function: The compound rest is mounted on the carriage and allows for angular
adjustments of the cutting tool. This enables the cutting tool to create tapered surfaces.
8. Apron:
 Function: The apron is located on the front of the carriage and houses the gears and levers
that control the movement of the carriage and cross slide. It also contains the mechanism
for engaging and disengaging the feed to the carriage.
9. Feed Rod and Lead Screw:
 Function: The feed rod and lead screw are components that enable automatic longitudinal
and cross feed movements of the carriage. They are connected to the carriage and can be
engaged to move the carriage automatically.

5. Give a comparison between a capstan lathe and a turret lathe.

Capstan lathes and turret lathes are both types of metalworking lathes, but they have some key
differences in terms of design, operation, and applications. Here's a comparison between a
capstan lathe and a turret lathe:

Capstan Lathe:

1. Tooling and Operation:

 Capstan lathes have a capstan and a turret head.
 The capstan is mounted on the lathe saddle and moves with it during turning operations.
 Tools are mounted on the capstan, and the capstan is moved longitudinally for turning
operations.
 Suitable for small to medium batch production.
2. Tool Change:
 Quick tool changes are possible due to the capstan and its ability to rotate.
 Limited tool capacity compared to turret lathes.
3. Complexity:
 Simpler design compared to turret lathes.
4. Speed:
 Generally operates at higher speeds compared to turret lathes.
5. Applications:
 Well-suited for repetitive and high-speed machining of small to medium-sized
components.
 Often used for production involving small batch sizes and frequent tool changes.

Turret Lathe:
1. Tooling and Operation:
 Turret lathes have a turret head that can hold multiple tools simultaneously.
 The turret is mounted on the lathe saddle and indexes to bring the desired tool into
position.
 Tools can be used for various operations without the need for frequent tool changes.
2. Tool Change:
 Turret lathes have a larger tool capacity compared to capstan lathes.
 Slower tool changes compared to capstan lathes due to turret indexing.
3. Complexity:
 More complex design due to the turret mechanism.
4. Speed:
 Operates at slightly lower speeds compared to capstan lathes.
5. Applications:
 Suitable for high-volume production with larger batch sizes.
 Ideal for situations where a variety of tools are needed for different machining operations
without frequent tool changes.
 Module II

6. Name the operations which can be performed on a drill machine and explain.

A drill machine, also known as a drill press, is a versatile tool used for various drilling
operations. The primary operations that can be performed on a drill machine include:

1. Drilling:
 Explanation: Drilling is the fundamental operation performed on a drill machine. It
involves creating holes in a workpiece by rotating a drill bit against the material. The drill
bit is secured in the chuck, and the spindle rotates to drive the drill bit into the workpiece.
2. Reaming:
 Explanation: Reaming is a precision operation used to enlarge and refine existing holes.
It is typically done after drilling to improve the accuracy and surface finish of the hole. A
reamer is a cutting tool with multiple edges that removes a small amount of material to
achieve the desired hole size and finish.
3. Tapping:
 Explanation: Tapping is the process of creating internal threads in a drilled hole. A tap,
which is a threaded cutting tool, is used to cut threads into the walls of the hole. This
operation is common in metalworking and is essential for creating threaded holes for
bolts, screws, and other fasteners.
4. Counterboring:
 Explanation: Counterboring involves enlarging the upper part of a hole to accommodate
the head of a fastener, such as a bolt or a screw. The counterbore tool enlarges the
opening at the top of the hole without affecting the bottom, allowing the fastener head to
sit flush with or below the material surface.
5. Countersinking:
 Explanation: Countersinking is the process of creating a conical recess at the top of a
drilled hole. This recess accommodates the tapered head of a screw or bolt, allowing it to
sit flush with the material surface. Countersinking improves the appearance of the
workpiece and prevents snagging.
6. Boring:
 Explanation: Boring is the operation of enlarging an existing hole or creating a larger-
diameter hole in a workpiece. It is often used for precision machining and can be done
with specialized boring tools. Boring can achieve high accuracy and improved surface
finish.
7. Grinding:
 Explanation: Some drill machines are equipped with grinding attachments, allowing
them to perform grinding operations. This is useful for sharpening drill bits or shaping
metal surfaces.

It's important to note that the capability of a drill machine to perform these operations may
depend on its design, features, and attachments. Always follow proper safety procedures and
guidelines when using a drill machine for different operations.
 7. Explain the principle of boring. Describe the main parts of a horizontal boring
machine.

The principle of boring involves the use of a cutting tool, known as a boring bar, that is inserted
into an existing hole. The boring bar has cutting edges that remove material as it rotates,
resulting in the enlargement and improvement of the hole's dimensions. The process can be
applied to various materials, including metal, wood, or plastic.

Now, if you are asking about the main parts of a horizontal boring machine, here are the key
components:

1. Bed: The bed is the base of the machine, providing support and stability.
2. Column: The column is a vertical component attached to the bed, and it supports the horizontal
arm or spindle.
3. Horizontal Spindle: This is the main rotating component that holds the cutting tool. It can move
horizontally to perform the boring operation.
4. Headstock: The headstock houses the motor and gears that drive the spindle. It provides power
to the cutting tool.
5. Table: The table is the work surface where the material being machined is placed. It can move
horizontally and vertically to position the workpiece accurately.
6. Saddle: The saddle is a component that supports the table and allows it to move along the bed
horizontally.
7. Guideways: These are precision surfaces that guide the movement of various machine
components to ensure accuracy and repeatability.
8. Feed Mechanism: The feed mechanism controls the movement of the cutting tool, allowing it to
advance into the workpiece at a specified rate.
9. Coolant System: Boring machines often use coolant to lubricate the cutting tool, dissipate heat,
and remove chips from the work area.

These are the basic components of a horizontal boring machine, and their arrangement may vary
depending on the specific design and model of the machine.
8. What is Drilling machine? List various types of drilling machine and what are the
principle parts of drilling machine?

A drilling machine is a tool used for drilling holes in various materials, such as metal, wood,
plastic, and other workpieces. It is a versatile machine tool commonly found in workshops,
manufacturing plants, and construction sites. Drilling machines can be manual, semi-automatic,
or fully automatic, depending on the complexity of the operation and the level of automation.

Various types of drilling machines include:

1. Hand Drill:
 Simplest form of drilling machine.
 Operated by hand and suitable for light-duty tasks.
2. Pillar Drill (Drill Press):
  Mounted on a pillar or a column.
 Adjustable table and drill head.
 Suitable for accurate and repetitive drilling tasks.
3. Radial Drill:
 The drill head is movable along the arm, allowing drilling at different positions.
 Useful for large and heavy workpieces.
4. Sensitive Drill Machine:
 Lightweight and compact.
 Used for precision drilling in small and delicate workpieces.
5. Upright or Vertical Drill Machine:
 Similar to a pillar drill but has a vertical orientation.
 Suitable for heavy-duty tasks.
6. Gang Drilling Machine:
 Multiple drills are mounted on a common base.
 Used for simultaneous drilling of multiple holes.
7. Automatic Drilling Machine:
 Fully automated with computer control.
 Suitable for high-production environments.

The principle parts of a drilling machine typically include:

1. Base:
 The foundation of the drilling machine that provides stability.
2. Column:
 Vertical support structure that holds the drill head and can be adjustable in some
machines.
3. Table:
 A flat surface on which the workpiece is placed and secured.
4. Drill Head:
 Houses the motor, spindle, and other components responsible for drilling.
5. Spindle:
 Rotating part that holds the drill bit and is driven by the motor.
6. Drill Chuck:
 Holds and tightens the drill bit in place.
7. Power Feed Lever:
 Controls the automatic movement of the drill spindle during drilling.
8. Depth Gauge:
 Measures the depth of the drilled hole for accuracy.
9. Motor:
 Provides the power necessary for rotating the spindle and driving the drill bit.
10. Speed Control:
 Allows the operator to adjust the rotational speed of the drill bit based on the material
being drilled.
 Understanding these parts is essential for proper operation, maintenance, and troubleshooting of
drilling machines.

9. Explain working principle of Drilling machine and types of operations performed on

Drilling machine.

A drilling machine is a tool designed to drill holes in various materials, typically to create
cylindrical holes. The basic working principle involves rotating a cutting tool known as a drill
bit, which applies force and rotation to the workpiece, removing material and creating a hole.
Let's break down the working principle and discuss the types of operations performed on a
drilling machine:

Working Principle:

1. Rotation:
 The drill bit is mounted on the spindle of the drilling machine.
 The spindle rotates, providing the necessary motion to the drill bit.
2. Axial Force:
 The drill bit exerts an axial force on the workpiece, pushing it into the material.
 The axial force is applied along the axis of the drill bit, causing material removal.
3. Cutting Action:
 The drill bit has cutting edges that remove material as it rotates.
 The material removal is achieved by the combination of rotary motion and axial force.

Types of Operations:

1. Drilling:
 Creating a hole by removing material from the workpiece.
 Common drill bits include twist drills, flat drills, and center drills.
2. Reaming:
 Enlarging and improving the accuracy of a previously drilled hole.
 Uses a reamer, a precision tool with multiple cutting edges.
3. Boring:
 Enlarging an existing hole or creating a hole with a precise diameter.
 Involves rotating a single-point cutting tool.
4. Counterboring:
 Enlarging the opening of a hole to allow the head of a fastener to sit flush with the
surface.
 Uses a counterbore tool.
5. Countersinking:
 Creating a conical depression at the top of a drilled hole to accommodate a screw or bolt
head.
 Uses a countersink tool.
6. Tapping:
  Creating internal threads in a hole.
 Involves the use of a tap, which aligns with the existing hole and cuts threads as it's
turned.
7. Spot Facing:
 Machining a flat surface around a hole to provide a smooth, level area.
 Utilizes a spot facing tool.
8. Trepanning:
 Creating a large hole by removing a disc-shaped piece of material.
 Involves a trepanning tool.
9. Deep Hole Drilling:
 Drilling holes with a depth-to-diameter ratio significantly higher than traditional drilling.
 Requires specialized tools and techniques.
10. Gun Drilling:
 A specialized deep hole drilling method often used in firearms manufacturing.
11. Radial Drilling:
 The drilling machine's arm can be adjusted radially, allowing drilling at different
positions on the workpiece.

Understanding the working principle and various operations on a drilling machine is crucial for
precision machining and manufacturing processes across industries. Different drill bits and tools
are employed based on the specific requirements of each operation.
 Module III

10. Explain submerged arc welding with advantages and disadvantages.

Submerged Arc Welding (SAW) is a welding process that involves the formation of an arc
between a continuously fed electrode and the workpiece. The arc is submerged beneath a layer of
granular flux, which protects the molten weld pool from atmospheric contamination. Here's an
explanation of submerged arc welding along with its advantages and disadvantages:

Submerged Arc Welding Process:

1. Electrode and Flux:

 SAW uses a consumable bare wire electrode.
 A layer of granular flux covers the electrode and the welding area.
2. Arc Formation:
 The electrode is continuously fed into the welding zone.
 An electrical arc is struck between the electrode and the workpiece.
3. Flux Coverage:
 The granular flux melts, creating a protective blanket over the arc and the molten weld
pool.
 The flux also provides additional alloying elements, refining the weld metal.
4. Weld Pool Formation:
 The heat generated by the arc melts both the electrode and the workpiece, forming a
molten weld pool.
5. Solidification:
 As the weld pool solidifies, it forms a strong and durable weld joint.

Advantages of Submerged Arc Welding:

1. High Productivity:
 SAW is a high-speed welding process, making it suitable for applications requiring high
productivity.
2. Deep Weld Penetration:
 SAW provides deep weld penetration, resulting in strong and reliable welds.
3. High Deposition Rates:
 The process allows for high deposition rates, contributing to faster welding.
4. Reduced Welding Fumes:
 The flux covering the arc reduces the emission of welding fumes, creating a safer
working environment.
5. Automated Operation:
 SAW can be easily automated, leading to consistent and repeatable welds.
6. Excellent Weld Quality:
 The submerged arc welding process often produces welds with excellent mechanical
properties and minimal defects.
 Disadvantages of Submerged Arc Welding:

1. Limited Application Thickness:

 SAW is most effective for welding thick materials, and it may not be suitable for thin
sections.
2. Equipment Cost:
 The initial setup cost for submerged arc welding equipment can be relatively high.
3. Limited Portability:
 Submerged arc welding is less portable compared to some other welding processes,
making it less suitable for on-site applications.
4. Complex Flux Handling:
 Handling and disposing of the granular flux can be more complex than dealing with other
types of welding consumables.
5. Flux Cleanup:
 After welding, the flux needs to be cleaned from the weld, which may require additional
post-welding processes.
6. Not Suitable for All Positions:
 SAW is generally better suited for flat and horizontal welding positions, and it may be
less convenient for vertical or overhead welding.

In summary, submerged arc welding is a highly productive and efficient process, especially for
welding thick materials in a controlled environment. However, it has some limitations and
considerations, making it important to choose the welding process based on the specific
requirements of the application.

11. Describe gas welding techniques in detail? Give the advantages, limitations and
applications of gas welding?

Gas welding is a welding process that uses a flame produced by the combustion of a fuel gas
mixed with oxygen to join metals. One of the most common types of gas welding is oxy-
acetylene welding, where acetylene and oxygen are used. Here is a detailed description of gas
welding techniques, along with the advantages, limitations, and applications:

Gas Welding Techniques:

1. Setup:
 Gas welding requires a welding torch that mixes the fuel gas (e.g., acetylene) with
oxygen in the right proportions.
 The torch typically has a handle with valves to control the flow of oxygen and fuel gas.
2. Ignition:
 The fuel gas is ignited at the torch tip, creating a high-temperature flame.
3. Adjustment:
 The ratio of oxygen to fuel gas can be adjusted to control the temperature of the flame.
 A neutral flame (equal amounts of oxygen and fuel gas) is often used for welding.
4. Welding Process:
 The flame is directed at the metal workpieces to melt and join them.
 A filler rod may be added to the joint to provide additional material for the weld.
5. Cooling:
 The welded area is allowed to cool gradually to avoid stresses and cracking.

Advantages of Gas Welding:

1. Versatility:
 Gas welding is versatile and can be used on various metals, including ferrous and non-
ferrous materials.
2. Portability:
 Gas welding equipment is relatively portable, making it suitable for on-site and field
welding applications.
3. Low Cost:
 The equipment and consumables for gas welding are often more affordable compared to
some other welding processes.
4. Precision:
 Gas welding allows for precise control of the flame temperature, which is beneficial for
certain applications.

Limitations of Gas Welding:

1. Limited Thickness:
 Gas welding is not suitable for welding thick sections of metal.
2. Joint Quality:
 The quality of the weld joint may not be as high as some other welding processes.
3. Slower Process:
 Gas welding is generally slower compared to some modern welding techniques.
4. Heat-Affected Zone:
 The heat generated in gas welding can lead to a larger heat-affected zone, affecting the
material properties.

Applications of Gas Welding:

1. Automotive Repair:
 Gas welding is commonly used for repairing automotive components and body panels.
2. Plumbing:
 It is used in plumbing for joining copper pipes and fittings.
3. Sheet Metal Work:
 Gas welding is suitable for welding thin sheets of metal, making it useful in sheet metal
fabrication.
4. Maintenance and Repair:
 Gas welding is widely used for maintenance and repair work due to its versatility and
portability.
5. Artistic Welding:
 Artists and sculptors may use gas welding for its precision in creating metal artwork.

While gas welding has been widely used historically, it has been partially replaced by more
advanced processes such as TIG (Tungsten Inert Gas) and MIG (Metal Inert Gas) welding for
certain applications. These processes offer faster welding speeds, better control, and improved
joint quality, especially for thicker materials.

12. Sketch the three types of gas welding flames and give differences between them.

Gas welding flames are classified into three main types based on their characteristics and the
ratio of oxygen to acetylene in the welding torch. These three types of flames are:

1. Carburizing (or Neutral) Flame:

 Appearance: The carburizing flame has a luminous inner cone surrounded by a light
blue outer envelope.
  Characteristics: In this flame, the oxygen and acetylene are not mixed in the correct
proportion. There is an excess of acetylene, resulting in a reducing atmosphere. The
excess carbon in the flame can lead to carbonization of the metal, and it is generally not
suitable for welding ferrous metals.
 Use: It is often used for welding non-ferrous metals like copper and aluminum.
2. Neutral Flame:
 Appearance: The neutral flame has a well-defined inner cone surrounded by a light blue
outer envelope.
 Characteristics: In the neutral flame, the oxygen and acetylene are mixed in the correct
proportion, providing a balanced and stable flame. This flame is neither oxidizing nor
carburizing, making it suitable for welding ferrous metals like steel and cast iron.
 Use: It is commonly used for general welding applications on ferrous metals.
3. Oxidizing Flame:
 Appearance: The oxidizing flame has a short, sharply defined inner cone with a light
blue outer envelope.
 Characteristics: In the oxidizing flame, there is an excess of oxygen compared to
acetylene. This results in an oxidizing atmosphere, which can lead to the oxidation of the
metal being welded. It is not suitable for welding ferrous metals but can be used for some
non-ferrous metals.
 Use: It is often used for cutting and welding certain non-ferrous metals.

Differences between the Three Flames:

1. Carburizing (or Neutral) vs. Neutral Flame:

 Carburizing flame has a luminous inner cone, while the neutral flame has a well-defined
inner cone.
 Carburizing flame is reducing, while the neutral flame is balanced and suitable for
welding ferrous metals.
2. Neutral Flame vs. Oxidizing Flame:
 The neutral flame has a balanced ratio of oxygen and acetylene, suitable for welding
ferrous metals.
 The oxidizing flame has an excess of oxygen, leading to oxidation and is not suitable for
welding ferrous metals.
3. Carburizing Flame vs. Oxidizing Flame:
 Carburizing flame is reducing and has an excess of acetylene, while the oxidizing flame
has an excess of oxygen and is oxidizing.
 Carburizing flame is used for non-ferrous metals, while the oxidizing flame is used for
cutting and welding certain non-ferrous metals.

13. Explain TIG welding and MIG welding with its merits, demerits and application.

TIG Welding (Tungsten Inert Gas Welding):

 Process: TIG welding, also known as Gas Tungsten Arc Welding (GTAW), uses a non-
consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric
contamination by an inert gas, usually argon or helium.

Merits:

1. Precision and Control: TIG welding offers excellent control over the welding process, making
it suitable for delicate and intricate work.
2. Versatility: It can be used to weld a wide variety of metals, including aluminum, stainless steel,
and exotic alloys.
3. High-Quality Welds: TIG welding produces high-quality, clean welds with minimal spatter.
4. No Flux Required: As it's a gas shielded process, no flux is needed, reducing the need for post-
weld cleaning.

Demerits:

1. Complexity: TIG welding requires a higher skill level, and the process can be more complex
than some other welding methods.
2. Speed: It is generally slower than some other welding methods, making it less efficient for large-
scale production.

Applications:

1. Aerospace: TIG welding is often used in the aerospace industry for its precision and ability to
weld lightweight materials like aluminum.
2. Automotive: Commonly used for welding exhaust systems, bike frames, and other components.
3. Pipeline Construction: TIG welding can be used for high-quality welds in pipelines carrying
various materials.

MIG Welding (Metal Inert Gas Welding):

Process: MIG welding, also known as Gas Metal Arc Welding (GMAW), uses a continuously
fed wire electrode and a shielding gas to protect the weld from atmospheric contamination.

Merits:

1. High Productivity: MIG welding is faster than TIG welding, making it more suitable for high-
volume production.
2. Ease of Learning: It is relatively easy to learn, making it suitable for beginners.
3. Versatility: Can be used on a wide range of materials, including steel, aluminum, and stainless
steel.
4. Less Clean-Up: MIG welding produces less slag, reducing the need for post-weld cleaning.

Demerits:

1. Less Precision: Compared to TIG welding, MIG welding is generally considered less precise.
2. Spatter: MIG welding can produce more spatter, which may require additional cleaning.
3. Limited for Thin Materials: It may not be as suitable for welding thin materials due to its
higher heat input.

Applications:

1. Automotive Industry: MIG welding is widely used in the automotive industry for bodywork
and structural components.
2. Construction: Used for welding structural components like beams and columns.
3. Fabrication Shops: Common in general fabrication for its speed and efficiency.

In summary, the choice between TIG and MIG welding depends on factors such as the material,
precision requirements, skill level, and the scale of production. TIG is favored for its precision,
while MIG is chosen for its speed and ease of use in high-volume applications.
 Module IV

14. Define recrystallization temperature. List various factors on which recrystallization

temperature of metal depends.

Recrystallization temperature refers to the temperature at which a metal undergoes

recrystallization, a process in which new strain-free grains are formed within a metal or alloy.
This process is important for relieving internal stresses and improving the mechanical properties
of the material. The recrystallization temperature varies for different metals and alloys.

Various factors influence the recrystallization temperature of a metal. These factors include:

1. Material Composition: Different metals and alloys have different recrystallization

temperatures. The presence of alloying elements can also affect this temperature.
2. Initial Grain Size: The initial grain size of the metal or alloy plays a role. Finer-grained
materials often have lower recrystallization temperatures.
3. Strain or Cold Work: The degree of prior plastic deformation or cold work influences the
recrystallization temperature. Higher levels of cold work generally lead to lower recrystallization
temperatures.
4. Rate of Deformation: The speed at which plastic deformation occurs can impact the
recrystallization temperature. Higher deformation rates may result in a lower recrystallization
temperature.
5. Annealing Time: The time the material is held at an elevated temperature during the annealing
process affects recrystallization. Longer annealing times may lead to more complete
recrystallization.
6. Impurities: The presence of impurities can influence the recrystallization temperature. Some
impurities may act as inhibitors or promoters of recrystallization.
7. Alloying Elements: Certain alloying elements can raise or lower the recrystallization
temperature. For example, the addition of certain elements may increase the temperature at
which recrystallization occurs.
8. Heating Rate: The rate at which the material is heated can influence the recrystallization
temperature. Faster heating rates may shift the recrystallization temperature to higher values.

Understanding these factors is essential for optimizing the heat treatment process and obtaining
desired material properties. Heat treatments involving recrystallization, such as annealing, are
commonly employed in the metallurgical industry to improve the mechanical properties of
metals and alloys.

15. Define extrusion. Sketch and explain types of extrusion process.

Extrusion is a manufacturing process that involves shaping a material, typically a metal or

polymer, by forcing it through a die to produce a continuous profile with a specific cross-
sectional shape. The material is pushed or pulled through the die, and the resulting product is
known as an extrudate. Extrusion is commonly used in the production of various products such
as pipes, tubes, rods, and profiles with consistent cross-sectional shapes.
 There are several types of extrusion processes, including:

1. Direct Extrusion:
 In direct extrusion, also known as forward extrusion, the material is pushed through the
die in the same direction as the ram movement. This process is suitable for materials that
do not have complex shapes or intricate details.

2. Indirect Extrusion:
 In indirect extrusion, also known as backward extrusion, the material is held stationary,
and the die and the ram move toward each other. This method is often used for materials
that may not flow easily or when intricate details are required.

3. Hydrostatic Extrusion:
 Hydrostatic extrusion involves the use of a fluid (usually water or oil) to pressurize the
material in the chamber, forcing it through the die. This process is suitable for materials
that are difficult to extrude using conventional methods.

4. Impact Extrusion:
 Impact extrusion is a process where a punch strikes a metal billet, forcing it to flow and
take the shape of the die. This process is commonly used in the production of small,
hollow, and cylindrical parts.

5. Cold Extrusion:
 Cold extrusion is conducted at or near room temperature, and it is commonly used for
materials that are sensitive to high temperatures. Cold extrusion can produce high-
strength products with minimal material waste.

6. Hot Extrusion:
 Hot extrusion is performed at elevated temperatures, which reduces the material's
resistance to deformation. This process is suitable for materials that require higher
temperatures for effective shaping.

These extrusion processes are widely used in various industries to create products with specific
shapes and properties. The choice of the extrusion method depends on the material properties,
desired product characteristics, and the complexity of the final shape.

16. What is Milling? Describe the basic working principle of milling machine.
 Milling is a machining process that involves the removal of material from a workpiece using
rotary cutters. The milling machine is a versatile tool that can perform a variety of tasks, such as
cutting, drilling, and shaping, by removing material from the workpiece. It is widely used in
manufacturing and metalworking industries.

The basic working principle of a milling machine involves a cutter mounted on a spindle, which
is capable of rotating and moving in different directions. The workpiece is securely clamped on a
table or other work-holding device, and the milling machine removes material from the
workpiece as the cutter rotates. The primary motions involved in milling are:

1. Rotation of the Cutter: The cutter is mounted on the spindle, and the spindle can rotate at various
speeds. The rotational speed is determined by factors such as the material being machined, the
type of cutter, and the desired surface finish.
2. Movement of the Workpiece: The workpiece can be moved in multiple directions relative to the
cutter. The movements are typically along the X, Y, and Z axes, providing three-dimensional
control over the machining process.
3. Feeding of the Cutter: The cutter is fed into the workpiece to remove material. The feed rate is
adjustable and determines the amount of material removed per revolution of the cutter.

The combination of these motions allows the milling machine to create a wide range of shapes,
contours, and features on the workpiece. Milling machines can be classified into different types
based on factors such as the orientation of the spindle (vertical or horizontal), the type of control
(manual or CNC), and the number of axes they can control.

Milling is a versatile and precise machining process used in various industries, including
automotive, aerospace, electronics, and general manufacturing, to produce complex parts and
components.

17. Describe the difference between up milling and down milling.

Up milling and down milling are two types of milling processes used in machining operations,
especially in the context of milling machines. These processes refer to the direction in which the
cutting tool (usually a milling cutter) rotates in relation to the workpiece. The main difference
between up milling and down milling lies in the direction of the cutting forces and the motion of
the workpiece.

1. Up Milling (Conventional Milling):

 In up milling, the cutting tool rotates in the opposite direction to the motion of the
workpiece.
 The cutting edge of the tool starts at the bottom of the workpiece and gradually works its
way up.
 The cutting forces tend to lift the workpiece, which can result in a less stable cutting
operation.
 The chips produced during the cutting process are forced against the cutting edge, which
can lead to a more gradual and predictable cutting action.
 Up milling is often used for roughing operations because it is less prone to workpiece
deflection.
2. Down Milling (Climb Milling):
 In down milling, the cutting tool rotates in the same direction as the motion of the
workpiece.
 The cutting edge of the tool starts at the top of the workpiece and works its way down.
 The cutting forces tend to press the workpiece against the milling machine table,
providing better stability.
 The chips produced are removed in the direction of the cutting tool rotation, reducing the
chances of the chips interfering with the cutting process.
 Down milling is often preferred for finishing operations as it can result in a better surface
finish.

In summary, the key distinction is the relationship between the cutting tool and the workpiece
motion. Up milling is characterized by a cutting tool rotation opposite to the workpiece motion,
while down milling involves a cutting tool rotation in the same direction as the workpiece
motion. Each type has its advantages and disadvantages, and the choice between them depends
on factors such as the type of operation, material being machined, and desired surface finish.

18. Briefly explain End milling, Gang milling, Straddle milling

End Milling:
a. Description: End milling is a type of milling operation where a milling cutter,
which has cutting teeth on the end face and the periphery, is used to remove
material from the surface of a workpiece.
b. Application: It is commonly used for machining flat surfaces, slots, and pockets.
The end mill can be used for both roughing and finishing operations.
Gang Milling:
c. Description: Gang milling involves the use of multiple cutters mounted on the
arbor of a milling machine simultaneously. The cutters are aligned in a row, or
"gang," and they work together to perform various milling operations on the
workpiece.
d. Application: Gang milling is efficient for producing multiple identical parts in
one setup, as it allows for the simultaneous machining of different features on a
workpiece.
Straddle Milling:
e. Description: Straddle milling is a milling operation where two or more parallel
vertical surfaces are machined in a single pass. Two side milling cutters are
mounted on an arbor, and they straddle the workpiece.
f. Application: Straddle milling is often used to machine two parallel vertical faces
on a workpiece simultaneously. It is useful for saving time and ensuring accuracy
when machining multiple surfaces.

In summary, end milling is focused on using a single cutter for various operations, gang milling
involves multiple cutters working together, and straddle milling is used for machining two
parallel surfaces simultaneously. Each technique has its specific applications and advantages
based on the desired machining outcome.
 Module V

19. What are the five principal parameters of a grinding wheel?

The five principal parameters of a grinding wheel are:

1. Abrasive Material: This is the material that actually does the cutting in the grinding process.
Common abrasive materials include aluminum oxide, silicon carbide, diamond, and cubic boron
nitride (CBN).
2. Grit Size: Grit size refers to the size of the abrasive particles in the grinding wheel. It is usually
indicated by a number, such as 20, 30, 60, etc. A smaller grit number corresponds to larger
abrasive particles, resulting in a coarser surface finish, whereas a larger grit number indicates
smaller particles and a finer surface finish.
3. Grade: The grade of a grinding wheel indicates its hardness or strength. It is classified using
letters (A to Z), with A being the softest and Z the hardest. Softer grades are used for harder
materials, and harder grades are used for softer materials.
4. Structure: The structure of a grinding wheel refers to the spacing between the abrasive grains. It
is denoted by a number, with lower numbers indicating a more open structure (larger gaps
between grains) and higher numbers indicating a denser structure.
5. Bond Type: The bond in a grinding wheel holds the abrasive grains together. Different bonds
are suitable for different applications. Common bond types include vitrified, resinoid, rubber,
and metal. The choice of bond depends on factors such as the type of material being ground and
the grinding process conditions.

These parameters collectively determine the performance characteristics of a grinding wheel,

influencing factors such as material removal rate, surface finish, and wheel life.

20. What are the three mechanisms of grinding wheel wear?

Grinding wheel wear refers to the gradual loss of abrasive grains from the surface of the grinding
wheel during the grinding process. There are three main mechanisms of grinding wheel wear:

1. Abrasive Wear:
 This is the most common type of wear and occurs when individual abrasive grains
become dull or fractured during the grinding process.
 As the grains wear down, the cutting edges become less effective, leading to a reduction
in the grinding efficiency.
 Abrasive wear is influenced by factors such as the hardness of the workpiece material,
grinding wheel speed, and the grinding force applied.
2. Bond Wear:
 Grinding wheels are often made with a binder material (bond) that holds the abrasive
grains together. This bond can also wear away during grinding.
 Bond wear is characterized by the breakdown or erosion of the bond material, leading to
the exposure of new abrasive grains.
  Factors such as the type of bond, wheel speed, and the grinding pressure affect the rate of
bond wear.
3. Load-Induced Thermal Damage:
 This type of wear is caused by the heat generated during grinding, which can lead to
thermal damage to both the abrasive grains and the bond.
 High grinding temperatures can cause the abrasive grains to lose their cutting ability or
even result in their chemical decomposition.
 Thermal damage can also affect the bond, leading to softening or other changes in its
properties.
 Factors influencing load-induced thermal damage include grinding speed, workpiece
material properties, and the cooling conditions during grinding.

Understanding and managing these wear mechanisms are crucial for optimizing the grinding
process, extending the life of the grinding wheel, and achieving consistent and high-quality
results.

21. What is dressing, truing, glazing in reference to grinding wheels?

In the context of grinding wheels, dressing, truing, and glazing are important processes to
maintain the effectiveness and efficiency of the grinding wheel. Here's a brief explanation of
each:

1. Dressing:
 Purpose: Grinding wheels can become loaded with swarf (metal particles), worn, or lose
their cutting ability over time. Dressing is the process of restoring the cutting edges and
removing the dull or loaded abrasive grains from the surface of the wheel.
 Methods: Dressing can be done using a variety of tools, including dressing sticks,
diamond dressers, and abrasive dressing tools. The choice of method depends on the type
of grinding wheel and the specific requirements of the grinding operation.
2. Truing:
 Purpose: Truing is the process of restoring the geometric shape of the grinding wheel.
Over time, a grinding wheel may wear unevenly, leading to an irregular shape. Truing
ensures that the wheel remains concentric and true to its original shape.
 Methods: Truing is often done using a diamond truing tool. This tool is moved across the
surface of the rotating grinding wheel to remove material and bring the wheel back to its
desired shape.
3. Glazing:
 Issue: Grinding wheels can develop a glazed or clogged surface due to the accumulation
of swarf and worn abrasive particles. This glazing reduces the cutting efficiency of the
wheel.
 Solution: Glazing is addressed by dressing the wheel to expose fresh abrasive grains or
by using a dressing tool to break down the glazed surface. This process helps to maintain
the sharpness and cutting effectiveness of the grinding wheel.
 In summary, dressing is focused on removing dull abrasive particles and restoring the cutting
ability, truing is about maintaining the correct geometric shape of the wheel, and glazing is
addressed by breaking down the glazed surface to expose fresh abrasive grains. These processes
are essential for ensuring the optimal performance and longevity of grinding wheels in various
machining applications.

22. What are some of the principal abrasive materials used in grinding wheels?

Grinding wheels are composed of abrasive particles bonded together. The choice of abrasive
material depends on the specific application and the material being ground. Some of the principal
abrasive materials used in grinding wheels include:

1. Aluminum Oxide (Al2O3): This is the most commonly used abrasive in grinding wheels. It is
versatile and suitable for a wide range of materials, including ferrous metals, non-ferrous metals,
and non-metallic materials.
2. Silicon Carbide (SiC): Silicon carbide is used for grinding harder materials like carbides,
ceramics, and glass. It is also suitable for non-ferrous metals.
3. Diamond: Diamond is an extremely hard and wear-resistant material, making it ideal for
grinding hard and brittle materials such as carbides, ceramics, and glass. Diamond wheels are
used for precision grinding.
4. Cubic Boron Nitride (CBN): CBN is another superhard material used for grinding. It is
particularly effective for grinding ferrous materials like hardened steels and high-speed steels.
5. Zirconia Alumina: This is a tough abrasive material suitable for heavy-duty grinding
applications. It is often used in the production of high-performance grinding wheels.
6. Ceramic Aluminum Oxide: This abrasive material combines the toughness of aluminum oxide
with the cutting ability of ceramics. It is used for high-pressure applications and provides a cool
cutting action.
7. Garnet: Garnet abrasives are used for grinding softer materials like wood and plastic. They are
less aggressive than some other abrasives but can provide a smooth finish.

The choice of abrasive material depends on factors such as the hardness of the workpiece, the
desired surface finish, and the type of grinding operation (e.g., rough grinding, precision
grinding). Additionally, the bonding material in the grinding wheel also plays a crucial role in its
performance. Common bonding materials include vitrified bonds, resin bonds, and metal bonds.