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Question Bank: Subject:Tool Engineering/Tool Design Q.No Question

The document contains a question bank with 35 questions related to tool engineering and tool design. The questions cover topics such as orthogonal cutting operations, tool design for boring and turning, limit gauge design, form tool design, press operations, bending operations, deep drawing operations, jig and fixture design, and forging die design. Parameters involved include cutting forces, shear angle, friction angle, power calculation, material properties, blank size determination, punch and die design, and various tool design allowances.

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hemendra
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88 views3 pages

Question Bank: Subject:Tool Engineering/Tool Design Q.No Question

The document contains a question bank with 35 questions related to tool engineering and tool design. The questions cover topics such as orthogonal cutting operations, tool design for boring and turning, limit gauge design, form tool design, press operations, bending operations, deep drawing operations, jig and fixture design, and forging die design. Parameters involved include cutting forces, shear angle, friction angle, power calculation, material properties, blank size determination, punch and die design, and various tool design allowances.

Uploaded by

hemendra
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Question Bank

Subject:Tool Engineering/Tool Design

Q.No Question
1 In an orthogonal cutting operation, following data is observed:
Uncut chip thickness = 0.13 mm
Width of cut = 6.0 mm
Cutting speed = 2.2 m/s
Rake angle = 100
Cutting force = 600N
Thrust force = 200 N
Chip thickness = 0.225 mm
Determine : Shear angle, friction angle, shear stress along the shear plane and the power for
the cutting operation.
In an orthogonal cutting operation, following data is observed:
Uncut chip thickness = 0.125 mm
Width of cut = 6.025 mm
Cutting speed = 2 m/s
Rake angle = 100
Cutting force = 560 N
Thrust force = 225 N
Chip thickness = 0.225 mm
Determine : Shear angle, friction angle, shear stress along the shear plane and the power for
the cutting operation.
2 Design a boring tool for turning a high grade Cast Iron material for a boring depth of 55 mm.
Internal diameter to be turned is 60 mm. Maximum depth of cut is 2.5 mm with a maximum feed
of 0.5 mm/rev. Assuming other suitable data design the tool completely.
3 A hole and shaft pair is designated by ф80H7d8. Design suitable limit gauges for this
designation and draw proportionate sketches of the gauges designed by you
4 . Design a form tool for turning a U shaped groove in 50 mm diameter bar of SAE 1010 with a
maximum feed of 0.375 mm/rev and a maximum depth of cut of 1.0 mm. Draw the sketches of
the tool.
5 Explain different types of chips formed during cutting operations

6 Explain maximum and minimum metal conditions with Taylor’s Principles

7 Explain the assumptions in the Merchant’s Polygon and derive the relations of various forces
involved there in.
8 Explain maximum and minimum metal conditions with Taylor’s Principles. Classify the gauges.

9 A hole and shaft pair is designated by ф60H7g6. Design suitable limit gauges for this
designation and draw proportionate sketches of the gauges designed by you.
10 Design a boring tool for turning a high grade Cast Iron material for a boring depth of 55 mm.
Internal diameter to be turned is 60 mm. Maximum depth of cut is 2.5 mm with a maximum feed
of 0.5 mm/rev. Assuming other suitable data design the tool completely
11 A blank of diameter 250 mm is to be produced from SAE 1010 material of thickness 2 mm.
Determine the press capacity, dimensions of punch and die block. If the tonnage is to be
reduced by 20%, find the amount of shear to be provided on punch
12 Explain various operations performed on presses with sketches

13 Explain different types of chips formed during cutting operations

14 Explain the effect of cutting clearance on cut portion of the part


15 Explain various bending operations with neat sketches. What is bend allowance and spring
back?. Give the methods of reducing spring back.
16 A U-bending part is to be produced from SAE1010 material of thickness 1.75 mm. Legs of bend
are 80 mm each and bottom is 100 mm total. Corner radius is 8 mm. Width of the part is 80
mm. Determine blank size and force required for bending.
17 Draw a neat sketch of π- bending die of suitable dimensions and explain die opening and die
opening factor for this die. Material thickness is 2.0 mm.
18 Discuss factors affecting metal flow in deep drawing operation
19 A Cup is to be drawn from SAE 1020 CRCA steel of thickness 2.0 mm. Diameter of cup is 30
mm and height of the cup is 80 mm. Determine: Number of draws, blank diameter, sizes of
punches and draw forces in each draw.
20 Draw neat sketches of single action and double action draw dies and explain the working
principles of these dies.
21 In an orthogonal cutting operation, following data is observed:
Uncut chip thickness = 0.125 mm
Width of cut = 6.025 mm
Cutting speed = 2 m/s
Rake angle = 100
Cutting force = 560 N
Thrust force = 225 N
Chip thickness = 0.225 mm
Determine : Shear angle, friction angle, shear stress along the shear plane and the power for
the cutting operation.
22 Design a boring tool for turning a high grade Cast Iron material for a boring depth of 65 mm.
Internal diameter to be turned is 50 mm. Maximum depth of cut is 2.0 mm with a maximum feed
of 0.375 mm/rev. Assuming other suitable data design the tool completely.
23 A blank of diameter 250 mm is to be produced from SAE 1010 material of thickness 2 mm.
Determine the press capacity, dimensions of punch and die block. If the tonnage is to be
reduced by 20%, find the amount of shear to be provided on punch
24 Explain various bending operations with neat sketches. What is bend allowance and spring
back?. Give the methods of reducing spring back
25 A U-bending part is to be produced from SAE1010 material of thickness 2.0 mm. Legs of bend
are 70 mm each and bottom is 80 mm total. Corner radius is 8 mm. Width of the part is 80 mm.
Determine blank size and force required for bending.
26 Draw a neat sketch of π- bending die and explain die opening and die opening factor for this
die. Material thickness is 2.0 mm.
27 Discuss factors affecting metal flow in deep drawing operation
28 A Cup is to be drawn from SAE 1020 CRCA steel of thickness 2.0 mm. Diameter of cup is 30
mm and height of the cup is 80 mm. Determine: Number of draws, blank diameter, sizes of
punches and draw forces in each draw.
29 Draw neat sketches of single action and double action draw dies and explain the working
principles of these dies.
30 State the principles of locating and clamping in Jig Fixture Design
31 List various types of Jigs and explain any three
32 List various types of Fixtures and explain any two
33 Differentiate between open and closed forging dies
34 Discuss various preliminary forging operations
35 Discuss the method of calculation of stock size for forging die design
36 Explain various allowances for forging die design

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