Work Holding Devices in Shaping Machine Operation
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Questions and Answers

What is the angle between the tool face and the plane parallel to the tool's base called?

  • Cutting angle
  • Nose angle
  • Clearance angle
  • Rake angle (correct)

The normal back rake angle of a carbide single point cutting tool for machining aluminum is usually between 0 to 50 degrees.

True (A)

What is the recommended value of rake angle for machining aluminum with a cemented carbide tool?

15 degrees

The side rake angle of a single point tool is crucial for controlling the ______ formation.

<p>chip</p> Signup and view all the answers

Which of the following would NOT be an example of oblique cutting?

<p>None of the above (D)</p> Signup and view all the answers

For softer materials, the point angle of a drill is recommended to be increased.

<p>False (B)</p> Signup and view all the answers

What happens to the cutting force with an increase in the nose radius of a single point cutting tool?

<p>It decreases slightly.</p> Signup and view all the answers

Match the following angles with their respective functions:

<p>Rake angle = Determines the profile of the tool Back rake angle = Prevents rubbing Side rake angle = Controls the chip formation Clearance angle = Decides the type of cutting action</p> Signup and view all the answers

Which work holding device is preferred for shaping a key-way in a cylindrical shaft?

<p>V-block (C)</p> Signup and view all the answers

The feeding of the job in a shaper is done using the movement of the ram.

<p>False (B)</p> Signup and view all the answers

What is the function of a clapper box in a shaper?

<p>To allow the tool to return without cutting on the return stroke.</p> Signup and view all the answers

The size of a planer is specified by its ______.

<p>capacity</p> Signup and view all the answers

Which of the following is not a part of a shaper?

<p>Lapper box (B)</p> Signup and view all the answers

Match the following components with their functions in shaping:

<p>Clapper Box = Prevents cutting during return stroke Ram = Holds the tool Table = Supports workpiece Feed Mechanism = Controls job feed rate</p> Signup and view all the answers

For accurately spaced splines in a shaft, the work should be mounted in:

<p>Between indexing centres (C)</p> Signup and view all the answers

Spinning on a lathe is considered a non-chip removal process.

<p>True (A)</p> Signup and view all the answers

Which of the following alloys is primarily used for cast tool alloys?

<p>Nickel, cobalt, and chromium (C)</p> Signup and view all the answers

A fly cutter is used on a lathe.

<p>False (B)</p> Signup and view all the answers

What is the purpose of the tumbler gear?

<p>It is used in lathes.</p> Signup and view all the answers

Power from the leadscrew to the carriage in a lathe is transmitted through a ______.

<p>half nut</p> Signup and view all the answers

Which machine tool applies feed motion to the tool?

<p>All of the above (D)</p> Signup and view all the answers

Match the machine tools with their uses:

<p>Lathe = Turning operations Milling Machine = Cutting flat or contoured surfaces Shaper = Cutting flat surfaces or grooves Broaching Machine = Removing material with a cutting tool</p> Signup and view all the answers

Cobalt, boron, and aluminium are principal components of cast tool alloys.

<p>False (B)</p> Signup and view all the answers

What type of machine tool uses a fly cutter?

<p>Milling machine</p> Signup and view all the answers

Which type of file is preferred for filing brass or bronze?

<p>The coarse-cut or rough-cut file (A)</p> Signup and view all the answers

A band saw machine employs a continuous looped blade driven by two wheels.

<p>True (A)</p> Signup and view all the answers

What is the next higher spindle speed in a geometrical progression series if the given speeds are 160, 229, 328, and 496?

<p>671</p> Signup and view all the answers

To clean a file, it should be cleaned with a __________.

<p>file card</p> Signup and view all the answers

What is the common ratio for spindle speeds in geometric progression?

<p>1.0 to 2.0 (D)</p> Signup and view all the answers

Collet chucks are suitable for machining castings on a lathe.

<p>False (B)</p> Signup and view all the answers

What type of power saw is known for its continuous looped blade?

<p>band saw machine</p> Signup and view all the answers

Match the following tools with their appropriate usage:

<p>Power hacksaw machine = Cutting metal with a reciprocating motion Circular saw machine = Making straight cuts in wood Filing machine = Removing surface material Band saw machine = Curved cuts in various materials</p> Signup and view all the answers

What is the typical depth of cut for finish grinding of steel in a surface grinder?

<p>0.001 to 0.005 mm (C)</p> Signup and view all the answers

Goose neck tools are preferred on planers because they minimize digging in and scoring of the work.

<p>True (A)</p> Signup and view all the answers

What angle should be used for drilling harder materials?

<p>increased</p> Signup and view all the answers

The cylindrical job should always be clamped on a ______ for drilling operations.

<p>V-block</p> Signup and view all the answers

Match the machining operations with their characteristics:

<p>Drilling = Simple cutting Grinding = Uniform cutting Milling = Orthogonal cutting Turning = Oblique cutting</p> Signup and view all the answers

For ferrous materials, what is the typical helix angle of a drill?

<p>30 degrees (B), 30 degrees (D)</p> Signup and view all the answers

The cutting edges of a standard twist drill are called flutes.

<p>False (B)</p> Signup and view all the answers

What is the purpose of thinning the point of a twist drill?

<p>reduce the axial feed pressure</p> Signup and view all the answers

Which cutting fluid is suitable for use with carbide tools?

<p>Any one of the above depending on other factors (D)</p> Signup and view all the answers

Crater wear primarily occurs due to the phenomenon of diffusion.

<p>True (A)</p> Signup and view all the answers

What is the best coolant and lubricant for steel and wrought iron?

<p>Water soluble oils or sulphur-based and mineral oils</p> Signup and view all the answers

Chips with built up edge can be expected when machining ______ materials.

<p>ductile</p> Signup and view all the answers

How is the sector arm in the indexing head adjusted?

<p>Equal to the number of holes to be indexed +1 (D)</p> Signup and view all the answers

What is the degree of movement produced by one complete turn of the index crank?

<p>3600 (C)</p> Signup and view all the answers

Match the following cutting phenomena with their definitions:

<p>Abrasion = Wear caused by friction and contact with hard materials Diffusion = Material transfer and wear at high temperatures Oxidation = Chemical reaction between tool material and air Adhesion = Bonding of workpiece material to tool surface</p> Signup and view all the answers

The highest cutting speed with H.S.S tools is used while machining bronze.

<p>False (B)</p> Signup and view all the answers

Flashcards

Rake angle

The angle between the face of a cutting tool and a plane parallel to the base of the tool.

Rake angle for machining aluminium (carbide tool)

Ideally 15 degrees.

Back rake angle (carbide tool, aluminium)

Between -5 and 0 degrees.

Drill point angle (softer materials)

Decreased.

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Cutting force and nose radius

Decreases slightly with increasing nose radius

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Rake angle's role

Controls chip formation.

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Oblique cutting example

Knife turning. (Not slotting, broaching.)

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Oblique cutting

Cutting where the tool's cutting edge is inclined to the workpiece.

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Work holding device for keyways

A V-block is the preferred work holding device for shaping a keyway in a cylindrical shaft.

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Planer work holding for cylindrical parts

V-blocks, T-blocks, and clamps are used to hold cylindrical parts on a planer.

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Shaper job feeding mechanism

The table of the shaper machine moves to feed the work.

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Shaper job feed timing

The shaper feeds the job at the end of the return stroke.

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Shaper part not involved in shaping

The cross slide is not a part of the shaper machine.

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Splines shaping fixture

Splines in a shaft are accurately shaped using indexing centers.

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Non-chip removal process

Spinning on a lathe is a non-chip removal process.

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Planer size specification

The size of a planer is specified by its dimensions.

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Cast tool alloys composition

Cast tool alloys are primarily made of cobalt, chromium, and tungsten.

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Tumbler gear application

Tumbler gears are used primarily on lathes.

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Fly cutter use

Fly cutters are used on milling machines.

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Lathe carriage power transmission

Power from the leadscrew to the carriage in a lathe is transmitted through a half nut.

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Workpiece motion application machine tool

In a shaper machine tool, motion is applied to the workpiece

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Lathe tool part from figure 1.1

A lathe dog is a part shown in figure 1.1.

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Tool feed motion application machine tool

In a vertical bed type mill, feed motion to the tool is applied.

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Machine motion applied to the workpiece

The shaper machine applies motion to the workpiece during operation.

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Finish Grinding Depth

The depth of cut during finish grinding of steel is typically very small, ranging from 0.005 to 0.01 mm.

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Goose Neck Tools

Goose neck tools are preferred on planers and slotters because they minimize digging and scoring of the workpiece.

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Drill Point Thinning

The point of a twist drill is thinned to reduce the axial feed pressure required for drilling.

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Drill Point Angle (Hardness)

For harder materials, the point angle of a drill is increased to reduce the force required to penetrate the material.

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Drilling Clamping

For drilling operations on cylindrical jobs, a V-block is the best work-holding device.

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Drilling as Cutting

Drilling is considered a uniform cutting process, where the cutting edge continuously removes material.

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Standard Drill Cutting Edges

The cutting edges of a standard twist drill are called the lips.

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Drill Helix Angle (Ferrous Metals)

The helix angle of a drill for ferrous materials is typically 30 degrees.

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File type for brass/bronze

A coarse-cut or rough-cut file is best for shaping brass or bronze due to their relatively soft nature, requiring a larger tooth size for efficient material removal.

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File cleaning method

A file card is used to clean a file by removing metal chips and debris that accumulate between its teeth, ensuring efficient cutting action.

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Continuous loop blade saw

A band saw uses a continuous looped blade driven by two wheels, allowing for precise and versatile cutting operations.

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Spindle speed progression

In geometric progression, the ratio between each spindle speed in a lathe is typically between 1.0 and 2.0. This ensures efficient cutting across a wide range of speeds.

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Next spindle speed

To find the next spindle speed in a geometric sequence, multiply the previous speed by the common ratio.

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Holding a casting on a lathe

A four-jaw chuck is best for holding castings on a lathe, as it offers greater flexibility and control over the workpiece's position.

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Work holding for bar machining

A collet chuck is the ideal work-holding device for bar machining, allowing for accurate and efficient processing.

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Lathe work-holding options

A lathe may use several work-holding devices including a collet chuck, magnetic chuck, three-jaw chuck, four-jaw chuck, and face plate, each suited for specific applications.

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Cutting Fluid for Carbide Tools

A special cutting fluid is required for carbide tools, typically discontinuous, as it provides better lubrication and heat dissipation during cutting operations.

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Best Coolant for Steel and Wrought Iron

Water-soluble oils, sulfur-based oils, or mineral oils are the best coolants for steel and wrought iron due to their ability to effectively lubricate and cool the cutting zone.

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Cause of Crater Wear

Crater wear is primarily caused by diffusion, a process where atoms from the tool material move into the workpiece material, leading to tool wear.

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Chip Formation in Ductile Material

When machining ductile materials, chips with a built-up edge are formed due to the material's ability to deform and stick to the tool.

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Highest Cutting Speed: Aluminium

When using HSS tools, the highest cutting speed is typically achieved when machining aluminium, due to its lower hardness and good thermal conductivity.

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Indexing Head Sector Arm Adjustment

The sector arm in an indexing head is adjusted so that the number of holes between the bevelled edges is one more than the number of holes to be indexed.

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Index Crank Movement

One complete turn of the index crank produces a movement of 90 degrees.

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Crater Wear Location

Crater wear mainly occurs on the face of a single point cutting tool, the part that directly interacts with the workpiece.

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Study Notes

Work Holding Devices

  • Cylindrical parts are held on planers using V-blocks, T-blocks, and clamps.
  • Toe dogs and clamping stops are work holding devices.
  • Magnetic vises are also used.
  • V-blocks are preferred for shaping keyways in cylindrical shafts.
  • A shaper vise is suitable for shaping splines.
  • Workpieces are often held between indexing centers when accurately spacing splines.

Shaping Machine Operation

  • The job is fed in a shaper by table movement.
  • Feeding occurs at the end of the return stroke.
  • Clapper box movements and/or ram movements don't feed the job.
  • Shapers have tools as well as a table and ram. The cross slide is not a shaper part.

Cutting Tool Angles and Materials

  • Rake angle is the angle between the tool face and a plane parallel to the tool's base.
  • Rake angle affects chip formation.
  • Recommended rake angle for aluminum machining with carbide tools is 15 degrees.
  • Back rake angles for carbide tools machining aluminum are generally between 0 and 5 degrees.
  • Point angles for drills are adjusted for material hardness—softer materials require smaller angles.

Drilling Operations

  • Twist drill cutting edges are thinned to reduce axial feed pressure.
  • Cylindrical jobs are typically clamped on V-blocks for drilling.
  • Drilling is considered a uniform cutting process.
  • Helix angle for ferrous materials is typically 30 degrees.

Other Machine Tools and Operations

  • Tool alloys high-temperature strength and wear resistance are cobalt, chromium, and tungsten.
  • Power from the lathe's leadscrew is transmitted through a half-nut.
  • Fly cutters are used on milling machines.
  • Tumbler gears are related to lathe mechanisms.
  • Coolants like water-soluble oils are well-suited for steels and wrought iron.
  • Tool wear such as crater wear is mostly due to diffusion.
  • Finish grinding depth of cut is between 0.005 and 0.01 mm for steel.
  • Goose-neck tools are preferred on planers and slotters to minimize digging in and scoring the workpiece.
  • The number of holes between the indexing head's bevelled edges equals the indexing number plus one.
  • Spindle speeds are often in geometric progressions
  • File type preference for brass or bronze is the coarse-cut or rough-cut file.
  • A file cleaning method is a file card.
  • Band saws are continuous looped blade power saws.
  • A lathe holding device for castings is a four-jaw chuck.

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Workshop Practices & Gen Engineering Objective (1) PDF Past Paper

Description

This quiz covers the essential work holding devices used in shaping machine operations, including various clamps and vises. It also explores cutting tool angles and materials for effective machining. Test your understanding of how these components interact in manufacturing processes.

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