Mechanical Engineering MCQs – Cutting-Tool Materials And Cutting Fluids ( Manufacturing Engineering – I ) MCQs
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Mechanical Engineering MCQs – Cutting-Tool Materials And Cutting Fluids ( Manufacturing Engineering – I ) MCQs
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Cutting Mechanics
1. In the orthogonal cutting of metals _________
a) the cutting edge of the tool is perpendicular to the direction of tool travel
b) the cutting forces occur in one direction only
c) the cutting edge is wider than the depth of cut
d) all of the mentioned
Answer: a
Explanation: In orthogonal cutting of metals, the cutting edge of the tool is perpendicular to the direction of tool travel. The cutting edge clears the width of the workpiece on either ends.
2. In oblique cutting of the metals, the cutting edge of the tool is
a) perpendicular to the workpiece
b) perpendicular to the direction of tool travel
c) parallel to the direction of tool travel
d) inclined at an angle less than 900 to the direction of tool travel
Answer: d
Explanation: The chip flows on the tool face at an angle of less than 900 with the normal on the cutting edge.
3. Discontinuous chips are formed during machining of
a) brittle metals
b) ductile metals
c) hard metals
d) soft metals
Answer: a
Explanation: Discontinuous chips are formed during machining of brittle metals while continuous chips are formed during machining of ductile materials.
4. The ductile materials, during machining, produces
a) continuous chips
b) discontinuous chips
c) continuous chips with built up edge
d) none of the mentioned
Answer: a
Explanation: Discontinuous chips are formed during machining of brittle metals while continuous chips are formed during machining of ductile materials.
5. Continuous chips with built up edge are formed during machining of
a) brittle metals
b) ductile metals
c) hard metals
d) soft metals
Answer: b
Explanation: Discontinuous chips are formed during machining of brittle metals while continuous chips with built up edge are formed during machining of ductile materials at low cutting speed.
6. The factor responsible for the formation of discontinuous chips is
a) low cutting speed and large rake angle
b) low cutting speed and small rake angle
c) high cutting speed and large rake angle
d) high cutting speed and small rake angle
Answer: b
Explanation: The low cutting speed and small rake angle of the tool are responsible for the formation of discontinuous chips while high cutting speed and large rake angle of the tool will result in the formation of continuous chips.
7. The high cutting speed and large rake angle of the tool will result in the formation of
a) continuous chips
b) discontinuous chips
c) continuous chips with built up edge
d) none of the mentioned
Answer: a
Explanation: The low cutting speed and small rake angle of the tool are responsible for the formation of discontinuous chips while high cutting speed and large rake angle of the tool will result in the formation of continuous chips.
8. A built-up-edge is formed while machining __________
a) ductile materials at high speed
b) ductile materials at low speed
c) brittle materials at high speed
d) brittle materials at low speed
Answer: b
Explanation: When machining ductile materials, conditions of high local temperature and extreme pressure in the cutting zone and also high friction in the tool chip interface, may cause the work material to adhere or weld to the cutting edge of the tool forming the built-up edge. Low-cutting speed contributes to the formation of the built-up edge. Increasing the cutting speed, increasing the rake angle and using a cutting fluid contribute to the reduction or elimination of built-up edge.
9. The continuous chips are in the form of long coils having the same thickness throughout.
a) True
b) False
Answer: a
Explanation: None
10. In oblique cutting system, the maximum chip thickness
a) occurs at the middle
b) may not occur at the middle
c) depends upon the material of the tool
d) none of the mentioned
Answer: b
Explanation: In orthogonal cutting, maximum chip thickness occurs at the middle but in oblique cutting, the maximum chip thickness may not occur at the middle.
Cutting Forces Power
1. A single-point cutting tool with 120C rake angle is used to machine a steel work-piece. The depth of cut, i.e., uncut thickness is 0.81 mm. The chip thickness under orthogonal machining condition is 1.8 mm. The shear angle is approximately
a) 220C
b) 260C
c) 560C
d) 760C
Answer: b
Explanation: Given : α= 12c, t= 0.81mm, tc= 1.8 mm
Shear angle, tanφ = [rcosα/1 – rsinα] ……….(i)
Chip thickness ratio, r = t/tc
= 0.81/1.8
= 0.45
From equation (i), tanφ = [0.45cos120/1 – 0.45sin120]
φ = tan-1(0.486) = 25.910 – 260.
2. In a single point turning tool, the side rake angle and orthogonal rake angle are equal. ϕ is the principal cutting edge angle and its range is 00<ϕ<900. The chip flows in the orthogonal plane. The value of ϕ is closest to
a) 00
b) 450
c) 600
d) 900
Answer: d
Explanation: Interconversion between ASA (American Standards Association) system and ORS (Orthogonal Rake System)
tanαs = sinφtanα − cosφtani
where αs = Side rake angle
α = orthogonal rake angle
φ = principle cutting edge angle = 00<ϕ<900
i = inclination angle (i = 0 for ORS)
αs = α (Given)
tanαs =sinφtanα − cosφtan(00)
tanαs = sinφtanα
tanαs/tanα = sinφ
φ =sin-1(1)=900.
3. In an orthogonal machining operation :
Uncut thickness = 0.5 mm
Cutting speed = 20 m/min
Rake angel = 150
Width of cut = 5 mm Chip thickness = 0.7 mm
Thrust force = 200 N Cutting force = 1200 N
The values of shear angle and shear strain, respectively, are
a) 30.30 and 1.98
b) 30.30 and 4.23
c) 40.20 and 2.97
d) 40.20 and 1.65
Answer: d
Explanation: Given : t= 0.5mm, V = 20 m/min, α= 150, w= 5mm, tc = 0.7 mm,
Ft = 200 N, Fc = 1200 N
We know, from the merchant’s theory
Chip thickness ratio, r = t/tc = 0.5/0.7 = 0.714
For shear angle, tanφ = [rcosα/1 – rsinα]
Substitute the values, we get
tanφ = [0.714cos150/1 – 0.714sin150] = 0.689/0.815 = 0.845
φ = tan-1(0.845) = 40.20
Shear strain, s = cotφ + tan(φ − α)
s = cot(40.20) + tan(40.20 − 150)
= cot 40.20 + tan 25.2 = 1.183 + 0.470 = 1.65.
4. Which of the following parameters govern the value of the shear angle in continuous chip formation?
a) true feed
b) chip thickness
c) rake angle of the cutting tool
d) all of the mentioned
Answer: d
Explanation: To find a shear angle in continuous chip feed, rake angle, chip thickness, cutting ratio are required.
5. In determining the various forces on the chip, Merchant assumed that the
a) cutting edge of the tool is sharp and it does not make any flank contact with the workpiece
b) only continuous chip without built up edge is produced
c) cutting velocity remains constant
d) all of the mentioned
Answer: d
Explanation: None
6. Cutting forces can be measured using a
a) transducer
b) dynamometer
c) load cell
d) all of the mentioned
Answer: d
Explanation: Cutting forces can be measured using a force transducer (typically with quartz piezoelectric sensors), a dynamometer, or a load cell (with resistance-wire strain gages placed on octagonal rings) mounted on the cutting-tool holder.
7. Transducers have a much __________ natural frequency and stiffness than dynamometers.
a) higher
b) lower
c) equal
d) none of the mentioned
Answer: a
Explanation: Transducers have a much higher natural frequency and stiffness than dynamometers, which are prone to excessive deflection and vibration.
8. In metal machining, the zone where the heat is generated due to friction between the moving chip and the tool face is called
a) friction zone
b) work tool contact zone
c) shear zone
d) none of the mentioned
Answer: a
Explanation: In metal machining, the zone where the maximum heat is generated due to the plastic deformation of metal, is called shear zone while the zone where the heat is generated due to friction between the moving chip and the tool face, is called friction zone.
9. In metal machining, the zone where the maximum heat is generated due to the plastic deformation of metal is called:
a) friction zone
b) work tool contact zone
c) shear zone
d) none of the mentioned
Answer: c
Explanation: In metal machining, the zone where the maximum heat is generated due to the plastic deformation of metal, is called shear zone while the zone where the heat is generated due to friction between the moving chip and the tool face, is called friction zone.
10. The ratio of the cutting force to the cross-sectional area being cut is called:
a) specific cutting force
b) thrust force
c) frictional force
d) none of the mentioned
Answer: a
Explanation: The ratio of the cutting force to the cross-sectional area being cut (i.e., the product of the width of cut and depth of cut) is referred to as the specific cutting force. The thrust force, Ft, acts in a direction normal to the cutting force.
Tool Wear Failure
1. Crater wear occurs mainly on the
a) nose part, front relief face and side relief face of the cutting tool
b) face of the cutting tool at a short distance from the cutting edge only
c) cutting edge only
d) front face only
Answer: b
Explanation: Crater wear occurs on the rake face of the tool, while flank wear occurs on the relief (flank) face of the tool.
2. Flank wear depends upon the
a) hardness of the work and tool material at the operating temperature
b) amount and distribution of hard constituents in the work material
c) degree of strain hardening in the chip
d) none of the mentioned
Answer: b
Explanation: Flank wear occurs as a result of friction between the progressively increasing contact area on the tool flank.
3. Crater wear is predominant in
a) carbon steels
b) tungsten carbide tools
c) high speed steel tools
d) ceramic tools
Answer: b
Explanation: Crater wear is usually found while machining brittle materials and tungsten carbide tools favour this phenomenon.
4. Flank wear is due to the abrasive action of hard mis-constituents.
a) True
b) False
Answer: a
Explanation: Flank wear is due to the abrasive action of hard mis-constituents including debris from built up edge as the work material rubs the work surface.
5. Crater wear is mainly due to the phenomenon is known as
a) adhesion of metals
b) oxidation of metals
c) diffusion of metals
d) none of the mentioned
Answer: c
Explanation: Flank wear is due to the abrasive action and crater wear is due to diffusion of metals.
6. Crater wear leads to
a) increase in cutting temperature
b) weakening of tool
c) friction and cutting forces
d) all of the mentioned
Answer: d
Explanation: None
7. Crater wear is usually found while machining ductile materials.
a) True
b) False
Answer: b
Explanation: Crater wear is usually found while machining brittle materials.
8. The tool may fail due to
a) cracking at the cutting edge due to thermal stresses
b) chipping of the cutting edge
c) plastic deformation of the cutting edge
d) all of the mentioned
Answer: d
Explanation: None
9. Flank wear occurs mainly on the
a) nose part, front relief face and side relief face of the cutting tool
b) face of the cutting tool at a short distance from the cutting edge only
c) cutting edge only
d) front face only
Answer: a
Explanation: Crater wear occurs on the rake face of the tool, while flank wear occurs on the relief (flank) face of the tool.
10. Tool life is measured by the
a) number of pieces machined between tool sharpenings
b) time the tool is in contact with the job
c) volume of material removed between tool sharpenings
d) all of the mentioned
Answer: d
Explanation: None
11. The tool life is said to be over if
a) poor surface finish is obtained
b) there is sudden increase in cutting forces and power consumption
c) overheating and fuming due to heat of friction starts
d) all of the mentioned
Answer: d
Explanation: None
12. Tool life is generally better when
a) grain size of the metal is large
b) grain size of the metal is small
c) hard constituents are present in the micro structure of the tool material
d) none of the mentioned
Answer: a
Explanation: None
13. The relation between the tool life(T) in minutes and cutting speed (V) in m/min is
a) VnT = C
b) VTn = C
c) Vn/T = C
d) V/Tn = C
Answer: b
Explanation: None
14. Using the Taylor Equation for tool life and letting n = 0.5 and C = 120, calculate the percentage increase in tool life when the cutting speed is reduced by 50%.
a) 100%
b) 200%
c) 300%
d) 400%
Answer: c
Explanation: Since n = 0.5, the Taylor equation can be rewritten as VT0.5 = 120.
Let’s denote V1 as the initial speed and V2 the reduced speed; thus, V2 = 0.5 V1. Because C is the constant 120, we have the relationship
0.5V1 sqrt T2 = V1sqrt T1
Simplifying this equation, T2/T1 = 1/0.25 = 4. This
indicates that the change in tool life is
(T2 – T1/ T1) = (T2/T1) – 1 = 4 – 1 = 3,
or that tool life is increased by 300%. Thus, a reduction in cutting speed has resulted in a major increase in tool life. Note also that, for this problem, the magnitude of C is not relevant.
Machinability
1. The specific cutting energy used for establishing the machinability of the metal depends upon its
a) coefficient of friction
b) micro-structure
c) work hardening characteristics
d) all of the mentioned
Answer: d
Explanation: None
2. For machining a mild steel workpiece using carbide tool, the maximum material will be removed at a temperature of
a) 500
b) 1000
c) 1750
d) 2750
Answer: b
Explanation: None
3. For machining a mild steel workpiece by a high speed steel tool, the average cutting speed is
a) 5 m/min
b) 10 m/ min
c) 15 m/min
d) 30 m/min
Answer: d
Explanation: For machining a cast iron workpiece by a high speed steel tool, the average cutting speed is 22 m/min and for a mild steel is 30 m/min.
4. For machining a cast iron workpiece by a high speed steel tool, the average cutting speed is
a) 10 m/min
b) 15 m/min
c) 22 m/min
d) 30 m/min
Answer: c
Explanation: For machining a cast iron workpiece by a high speed steel tool, the average cutting speed is 22 m/min and for a mild steel is 30 m/min.
5. The machining of titanium is difficult due to
a) high thermal conductivity of titanium
b) chemical reaction between tool and work
c) low tool-chip contact area
d) none of the mentioned
Answer: c
Explanation: None
6. The factor considered for evaluation of maintainability is
a) cutting forces and power consumption
b) tool life
c) type of chips and shear angle
d) all of the mentioned
Answer: d
Explanation: None
7. In machining metals, chips break due to _____________ of work material.
a) toughness
b) ductility
c) elasticity
d) work hardening
Answer: d
Explanation: None
8. In machining metals, surface roughness is due to
a) feed marks or ridges left by the cutting tool
b) fragment of built up edge on the machined surface
c) cutting tool vibrations
d) all of the mentioned
Answer: d
Explanation: None
9. In machining soft materials, a tool with a negative relief angle is used
a) True
b) False
Answer: a
Explanation: None
10. The tool material, for faster machining, should have
a) wear resistance
b) red hardness
c) toughness
d) all of the mentioned
Answer: d
Explanation: None
Cutting Tool Materials
1. The various cutting tool materials used are:
a) high speed steels
b) cast cobalt alloys
c) carbides
d) all of the mentioned
Answer: d
Explanation: Materials used for cutting tools are
a) high speed steels
b) cast cobalt alloys
c) carbides
d) coated tools
e) alumina-based ceramics
f) cubic boron nitride
g) silicon nitride based ceramics
h) diamond
i) whisker reinforced materials and nano materials
2. High speed steels are suitable for making
a) high positive rake angle tools
b) interrupted cuts
c) machine tools with ow stiffness that are subject to vibration
d) all of the mentioned
Answer: d
Explanation: Because of their toughness (hence high resistance to fracture), high-speed steels are suitable especially for (a) high positive rake-angle tools (i.e., those with small included angles), (b) interrupted cuts, (c) machine tools with low stiffness that are subject to vibration and chatter, and (d) complex and single-piece tools, such as drills, reamers, taps, and gear cutters.
3. ___________ improves toughness, wear resistance, and high temperature strength.
a) Chromium
b) vanadium
c) Tungsten
d) None of the mentioned
Answer: a
Explanation: Chromium improves toughness, wear resistance, and high-temperature strength. Vanadium improves toughness, abrasion resistance, and hot hardness.
Tungsten and cobalt have similar effects, namely, improved strength and hot hardness.
Molybdenum improves wear resistance, toughness, and high-temperature strength and hardness.
4. _____________ contains nickel molybdenum matrix.
a) Chromium
b) Titanium carbide
c) Tungsten
d) None of the mentioned
Answer: b
Explanation: Titanium carbide (TiC) consists of a nickel-molybdenum matrix. It has higher Wear resistance than tungsten carbide but is not as tough. Titanium carbide is suitable for machining hard materials (mainly steels and cast irons) and for cutting at speeds higher than those appropriate for tungsten carbide.
5. Coating materials used are
a) titaniun nitride
b) titanium carbide
c) titanium carbonitride
d) all of the mentioned
Answer: d
Explanation: Commonly used coating materials are titanium nitride (TiN), titanium carbide (TiC), titanium carbonitride (TiCN), and aluminum oxide (Al2O3).
6. Characteristics of coated cutting tools are:
a) high hardness
b) chemical stability
c) low thermal conductivity
d) all of the mentioned
Answer: d
Explanation: Coatings for cutting tools and dies should have the following general characteristics:
-> High hardness at elevated temperatures, to resist wear.
-> Chemical stability and inertness to the workpiece material, to reduce wear.
-> Low thermal conductivity, to prevent temperature rise in the substrate.
-> Compatibility and good bonding to the substrate, to prevent flaking or spalling.
-> Little or no porosity in the coating, to maintain its integrity and strength.
7. Ceramic tools are fixed to a tool body by ___________
a) soldering
b) brazing
c) welding
d) clamping
Answer: b
Explanation: The ceramic tools are fixed to a tool body by brazing. These tools have greater tool life than carbide tools.
8. The carbide tools operating at very low cutting speeds
a) reduces tool life
b) increases tool life
c) have no effect on tool life
d) spoils the work piece
Answer: a
Explanation: The carbide tools operating at very low cutting speeds below 30m/min reduces tool life.
9. High speed steel tools retain their hardness upto a temperature of
a) 2500
b) 3500
c) 5000
d) 9000
Answer: d
Explanation: None
10. The trade name of a non ferrous cast alloy composed of cobalt, chromium and tungsten is called
a) ceramic
b) stellite
c) diamond
d) cemented carbide
Answer: b
Explanation: None
Cutting Fluids and Turning Process
1. In machining cast iron, no cutting fluid is required.
a) True
b) False
Answer: a
Explanation: None
2. The cutting fluid mostly used for machining alloy steels is :
a) water
b) soluble oil
c) dry
d) sulphurised mineral oil
Answer: d
Explanation: None
3. Cutting fluids are used to:
a) cool the tool
b) improve surface finish
c) cool the workpiece
d) all of the mentioned
Answer: d
Explanation: Functions of cutting fluids are
a) to cool the cutting tool and the workpiece
b) to lubricate the chip, tool and workpiece
c) to help carry away the chips
d) to lubricate some of the moving parts of the machine tool
e) to improve the surface finish
f) to prevent the formation of built up ridge
g) to protect the work against rusting
4. The cutting fluid mostly used for machining steel is:
a) water
b) soluble oil
c) dry
d) heavy oils
Answer: b
Explanation: Soluble oils are used for machining metals of high machinability.
5. Functions of cutting fluids are
a) to cool the cutting tool and the workpiece
b) to lubricate the chip, tool and workpiece
c) to help carry away the chips
d) all of the mentioned
Answer: d
Explanation: Functions of cutting fluids are
a) to cool the cutting tool and the workpiece
b) to lubricate the chip, tool and workpiece
c) to help carry away the chips
d) to lubricate some of the moving parts of the machine tool
e) to improve the surface finish
f) to prevent the formation of built up ridge
g) to protect the work against rusting
6. ______________ form mixtures ranging from emulsions to solutions.
a) Water miscible fluids
b) Neat oils
c) Synthetics
d) None of the mentioned
Answer: a
Explanation: Water miscible fluids form mixtures ranging from emulsions to solutions, which due to their high specific heat, high thermal conductivity, and high heat of vaporisation, are used on about 90% of all metal cutting and grinding operations.
7. Advantages of chemical fluids are
a) a very light residual film that is easy to remove
b) heat dissipation is rapid
c) good detergent properties
d) all of the mentioned
Answer: d
Explanation: Advantages of chemical fluids are
a) a very light residual film that is easy to remove
b) heat dissipation is rapid
c) good detergent properties
d) an easy concentration to control with no interference from tramp oils
8. The methods of application of cutting fluids are
a) flooding
b) jet application
c) mist application
d) all of the mentioned
Answer: d
Explanation: None.
9. In _____________ a high volume flow of the cutting fluid is generally applied on the back of the chip.
a) flooding
b) jet application
c) mist application
d) all of the mentioned
Answer: a
Explanation: In flooding, a high volume flow of the cutting fluid is generally applied on the back of the chip while in a jet application the cutting fluid, which may be either a liquid or a gas is applied in the form of a fine jet under pressure.
10. In _________ the cutting fluid, which may be either a liquid or a gas is applied in the form of a fine jet under pressure.
a) flooding
b) jet application
c) mist application
d) all of the mentioned
Answer: b
Explanation: In flooding, a high volume flow of the cutting fluid is generally applied on the back of the chip while in jet application the cutting fluid, which may be either a liquid or a gas is applied in the form of a fine jet under pressure.
11. ______________ controls both direction of chip flow and the strength of the tool tip.
a) Side rake angle
b) Relief angle
c) Rake angle
d) None of the mentioned
Answer: c
Explanation: Rake angle is important in controlling both the direction of chip flow and the strength of the tool tip.
12. _______________ acts downward on the tool tip.
a) Cutting force
b) Radial force
c) Thrust force
d) None of the mentioned
Answer: a
Explanation: The cutting force, FC, acts downward on the tool tip and thus tends to deflect the tool downward and the workpiece upward. The cutting force supplies the energy required for the cutting operation.
13. _________ acts in the longitudinal direction.
a) Cutting force
b) Radial force
c) Thrust force
d) None of the mentioned
Answer: c
Explanation: The thrust force, Ft, acts in the longitudinal direction. It also is called the feed force, because it is in the feed direction of the tool.
14. ____________ acts in the radial direction.
a) Cutting force
b) Radial force
c) Thrust force
d) None of the mentioned
Answer: b
Explanation: The radial force, Fr, acts in the radial direction and tends to push the tool away from the workpiece.
15. For turning a small taper on a long workpiece, the suitable method is
a) by a form tool
b) by setting over the tail stock
c) by a taper turning attachment
d) none of the mentioned
Answer: b
Explanation: None