Casting, Welding, Machine Tools, Material SC

S d
i
Sandcasting
y Sand casting uses ordinary sand as the primary
M t lC ti
MetalCasting
B SKM d l
BySKMondal
mould material.
y The sand grains are mixed with small amounts of
other materials, such as clay and water, to improve
mouldability and cohesive strength,
strength and are then
packed around a pattern that has the shape of the
desired casting.
casting
y The pattern must be removed before pouring, the
mold
ld is
i usually
ll made
d in
i two
t or more pieces.
i
y An opening called a sprue hole is cut from the top of
the mold through the sand and connected to a
system of channels called runners.
Contd.
Sequentialstepsinmakingasandcasting
i l
i
ki
d
i
y Apatternboardisplacedbetweenthebottom(drag)
andtop(cope)halvesofaflask,withthebottomsideup.
y Sandisthenpackedintothedraghalfofthemold.
y Abottomboardispositionedontopofthepackedsand,
andthemoldisturnedover,showingthetop(cope)half
ofpatternwithsprue andriserpinsinplace.
y Thecopehalfofthemoldisthenpackedwithsand.
Th
h lf fth ldi th k d ith d
y The molten metal is poured into the sprue hole, flows
y
y
y
y
through the runners,

runners and enters the mold cavity
through an opening called a gate.
G i
Gravity
fl
flow
i the
is
h most common means off
introducing the metal into the mold.
After solidification, the mold is broken and the
finished casting is removed.
The casting is then fettled by cutting off the ingate
and the feeder head.
Because the mold is destroyed, a new mold must be
made for each casting.
casting
Contd
y The mold is opened, the pattern board is drawn
(removed),
(removed) and the runner and gate are cut into the
surface of the sand.
y The mold is reassembled with the pattern board
removed,
d and
d molten
l
metall is poured
d through
h
h the
h
sprue.
y The contents are shaken from the flask and the metal
segment is separated from the sand, ready for further

p
processing.
g
Contd
CastingTerms
y Flask: A moulding flask is one which holds the sand
mould
ld intact.
i t t It is
i made
d up off wood
d for
f temporary
t
applications
pp
or metal for longterm
g
use.
y Drag: Lower moulding flask.
y Cope: Upper moulding flask.
y Cheek: Intermediate moulding flask used in three
For-2015 (IES, GATE & PSUs)
Page 1 of 240
piece
i
moulding.
ldi
Rev.0
Contd
p
j
y Pattern: Pattern is a replica
of the final object
to be
made with some modifications.
y Moulding sand: The freshly prepared refractory
material used for making the mould cavity. It is a

mixture of silica,
silica clay and moisture in appropriate
y Parting line: This is the dividing line between the two
moulding
ld
fl k that
flasks
h makes
k up the
h sand
d mould.
ld
proportions.
y Backing sand: This is made up of used and burnt
y Bottom board: This is a board normally made of wood,

wood
which is used at the start of the mould making.
sand.
y Core:
C
U d for
Used
f making
ki hollow
h ll cavities
i i in
i castings.
i
Threeflaskmould
Contd
g basin: A small funnelshaped

p cavityy at the top
p
y Pouring
of the mould into which the molten metal is poured.
y Sprue: The passage through which the molten metal
from the pouring basin reaches the mould cavity.

cavity
Padding
y Chaplet: Chaplets are used to support cores inside the
mould cavity.
y Chill: Chills are metallic objects, which are placed in
the
h mould
ld to increase
i
the
h cooling
li rate off castings.
i
y Runner: The passage ways in the parting plane through
y Riser: It is a reservoir of molten metal provided in the
which molten metal flow is regulated before they reach
casting so that hot metal can flow back into the mould
the
h mould
ld cavity.
cavity when there is a reduction in volume of metal due
y Gate: The actual entry point through which molten
Contd
IES2001
(a) To ensure directional solidification

(b) To provide efficient venting
(c) For aligning the mold boxes
(d) To
T support the
h cores
is known as 'padding'.
y This will require extra material.
y If p
padding
g is not p
provided, centre line shrinkage
g or
porosity will result in the thinner section.
to solidification
metal enters the mould cavity in a controlled rate. Contd
The main purpose of chaplets is
y Tapering
section
T
i off thinner
thi
ti towards
t
d thicker
thi k section
ti
IES1996
Which of the following methods are used for
obtaining
bt i i directional
di ti
l solidification
lidifi ti for
f riser
i design
d i
1.
Suitable placement of chills
2.
Suitable placement of chaplets
3.
Employing padding
Select the correct answer.

( ) 1 and
(a)
d 2 (b) 1 and
d 3 (c)
( ) 2 and
d 3 (d) 1, 2 and
d3
Page 2 of 240
IES2007
Which one of the following is the correct
statement?
t t
t?
Gate is provided in moulds to
(a) Feed the casting at a constant rate
((b)) Give p
passage
g to g
gases
(c) Compensate for shrinkage
(d) Avoid cavities
Rev.0
GATE2009
MatchtheitemsinColumnIandColumnII.
MatchtheitemsinColumnIandColumnII
ColumnIColumnII
P MetallicChills1 Supportforthecore
P.MetallicChills1.Supportforthecore
Q.MetallicChaplets2.Reservoirofthemoltenmetal
R Riser3 Controlcoolingofcritical
R.Riser3.Controlcoolingofcritical
sections
S ExothermicPadding4 Progressivesolidification
S.ExothermicPadding4.Progressivesolidification
(a) P1,Q3,R2,S4
(b)
P1,Q4,R2,S3
(c) P3,Q4,R2,S1
P 3 Q 4 R 2 S 1
(d)
P 4 Q 1 R 2 S 3
P4,Q1,R2,S3
Pattern
A pattern is a replica of the object to be made by the
gp
process,, with some modifications.
casting
The main modifications are
y The addition of pattern allowances,
allowances
y The provision of core prints, and
y Elimination of fine details, which cannot be obtained
by casting and hence are to be obtained by further
processing
GATE1992
Inagreensandmouldingprocess,uniform
rammingleadsto
(a) Lesschanceofgasporosity
(b) Uniformflowofmoltenmetalintothemould
cavity
(c) Greaterdimensionalstabilityofthecasting
(d) Lesssandexpansiontypeofcastingdefect
PatternAllowances
1. Shrinkageorcontractionallowance
2. Draftortaperallowance
3. Machiningorfinishallowance
M hi i fi i h ll
4 Distortionorcamberallowance
4.
55. Rappingallowance
pp g
GATE2011
Green sand mould indicates that
(a) polymeric mould has been cured
(b) mould has been totally dried
((c)) mould is g
green in colour
(d) mould contains moisture
Sh i k
Shrinkageallowance
ll
y All metals shrink when cooling except perhaps
bismuth.
bismuth
y This is because of the interatomic vibrations which
are amplified by an increase in temperature.

y The shrinkage allowance is always to be added to the
linear dimensions. Even in case of internal dimensions.
Contd
Liquidshrinkageandsolidshrinkage
y Liquid
refers
to the
in
Li id shrinkage
h i k
f
h reduction
d i
i volume
l
when the metal changes temperature from pouring to

solidus temperature in liquid state.
state To account for this,
this
risers are provided in the moulds.
y Solidification shrinkage
g refers to the reduction in
volume when metal changes from liquid to solid state
at the solidus temperature. To account for this, risers
are provided
id d in
i the
h moulds.
ld
y Solid shrinkage is the reduction in volume caused,
when a metal loses temperature in the solid state.
state The
shrinkage allowance is provided to take care of this
educt o .
reduction.
y Gray CI with a carbon equivalent of 4.3% has
negative shrinkage, that is, it actually expands

upto 2.5%
2 5% because of graphite precipitation.
precipitation So,
So
for this, no riser is needed.
Page 3 of 240
y Pattern Allowances
Cast Iron
Brass, Copper, Aluminium
Steell
Zinc, Lead
10 mm/m
15 mm/m
20 mm/m
25 mm/m
Rev.0
IES1995
IES1999
GATE1999
Which one of the following materials will require

the largest size of riser for the same size of casting?
((a)) Aluminium
(b) Cast iron
(c) Steel
In
off metal
casting,
I solidification
lidifi ti
t l during
d i
ti
Which of the following materials requires the
l
largest
t shrinkage
hi k
allowance,
ll
while
hil making
ki
a
pattern for casting?
( ) Aluminium
(a)
l
(b) Brass
(c) Cast Iron
(d) Plain Carbon Steel
(d) Copper.
compensation
p
for solid contraction is
(a) Provided by the oversize pattern
(b) Achieved by properly placed risers
(c) Obtained
by
promoting
directional
solidification
lidifi i
(d) Made by providing chills
GATE2001
ISRO2007
Shrinkage allowance is made by
( ) Adding
(a)
dd
to externall and
d internall dimensions
d
(b) Subtracting from external and internal
dimensions
((c)) Subtracting
g from external dimensions and
adding to internal dimensions
(d) Adding to external dimensions and subtracting
from internal dimensions
GATE2011
GATE2008
While cooling, a cubical casting of side 40 mm
undergoes 3%, 4% and 5% volume shrinkage
during the liquid state, phase transition and solid
state
state,
respectively
respectively.
The
volume
of
compensated from the riser is

(a) 2%
(b) 7%
(c) 8%
Shrinkage allowance on pattern is provided to

p
for shrinkage
g when
compensate
(a) The temperature of liquid metal drops from
pouring to freezing temperature
(b) The metal changes from liquid to solid state at
freezing temperature
(c) The temperature of solid phase drops from
f
freezing
i to room temperature
(d) The temperature of metal drops from pouring
to room temperature
(d) 9%
metal
A cubic casting of 50 mm side undergoes volumetric

solidification shrinkage and volumetric solid
contraction of 4% and 6% respectively.
respectively No riser is
used. Assume uniform cooling in all directions. The
side of the cube after solidification and contraction is
(a) 48.32 mm
(b) 49.90 mm
(c) 49
49.94
94 mm
(d) 49.96 mm
Page 4 of 240
GATE2004
Gray cast iron blocks 200 x 100 x 10 mm are to be
castt in
i sand
d moulds.
ld Shrinkage
Sh i k
allowance
ll
f
for
pattern making is 1%. The ratio of the volume of
pattern
tt
t that
to
th t off the
th casting
ti will
ill be
b
(a) 0.97
(b) 0.99
(c) 1.01
(d) 1.03
IAS1995
Assertion
(A):
A
i
(A) A pattern is
i made
d exactly
l similar
i il to
the part to be cast.
R
Reason
(R) Pattern
(R):
P
i used
is
d to make
k the
h mould
ld
cavity for pouring in molten for casting.
( ) Both
(a)
B h A and
d R are individually
i di id ll true and
d R is
i the
h
correct explanation of A
(b) Both
B h A and
i di id ll true but
b R is
i not the
h
( ) A is
(c)
i true but
b R is
i false
f l
(d) A is false but R is true
Rev.0
D ft
Draft
IAS2003
Match
I (Material
II
M h List
Li
(M
i l to be
b cast)) with
i h List
Li
(Shrinkage Allowance in mm/m) and select the
correct answer using the codes given below the lists:
ListI
ListII
(MaterialtoCast)(ShrinkageAllowanceinmm/m)
(A) Greycastiron
1.
7 10
(B) Brass
2
2.
15
(C) Steel
3.
20
(D) Zinc
4
4.
24
Codes:A
B
C
D
A
B
C
D
(a) 1
2
3
4
(b) 3
4
1
2
(c) 1
4
3
2
(d) 3
2
1
4
y To
the
off the
off the
T reduce
d
th chances
h
th damage
d
th mould
ld
cavityy at the time of p

pattern removal,, the vertical faces
of the pattern are always tapered from the parting line.
This provision is called draft allowance.
y Inner surfaces
f
off the
h pattern require higher
h h draft
d f than
h
outer surfaces.
surfaces
y Draft is always provided as an extra metal.
DRAFTALLOWANCE
Sh k ll
ShakeAllowance
y At the time of pattern removal, the pattern is rapped
y A metal when it has just solidified is very weak and
y Itt iss a negative

egat ve a
allowance
owa ce aand
d iss to be app
applied
ed o
onlyy to
those dimensions, which are parallel to the parting

plane.
y This is particularly so for weaker sections such as long
flat portions, V, U sections or in a complicated casting

which may have thin and long sections which are
connected to thick sections.
y The foundry practice should be to make extra
material provision for reducing the distortion.
Thepatternmaterialshouldbe
Which of the following materials can be used for
y Lightinweight
making patterns?
y Strong,hardanddurable
1. Aluminium
y Resistanttocorrosion,andtochemicalreactions
y Availableatlowcost.
y
y
GATE2000
Disposablepatternsaremadeof
2. Wax
33. Mercuryy 4
4. Lead
Select the correct answer using the codes given below:

Codes:
y Dimensionallystableandunaffectedbyvariationsin
temperatureandhumidity.
very dimensionally stable. Commonly used teak, white

pine and mahogany wood.
wood
Metal patterns are more expensive but are more
dimensionally stable and more durable.
durable Commonly used
CI, Brass, aluminium and white metal.
Hard plastics,
plastics such as urethanes,
urethanes and are often preferred
with processes that use strong, organically bonded sands
that tend to stick to other pattern materials.
materials
In the fullmold process, expanded polystyrene (EPS) is
used.
used
Investment casting uses wax patterns.
IES1994
y Easilyworked,shapedandjoined
y Resistanttowearandabrasion
y Wood
are relatively
W d patterns
tt
l ti l easy to
t make.
k Wood
W d is
i nott
prone.
therefore is likelyy to be distortion p
all around the vertical faces to enlarge the mould

cavity slightly to facilitates its removal.
removal
P
M
i l
PatternMaterials
ll
DistortionAllowance
(a) 1,3 and 4 (b) 2,3 and 4 (c) 1, 2 and 4 (d) 1, 2 and 3
Page 5 of 240
(a)
Wood
(b)
Rubber
(c)
Metal
(d)
P l
Polystyrene
Rev.0
T
f P tt
TypesofPattern
T
f P tt
TypesofPattern
Single
Pattern
Si l Piece
Pi
P tt
These are inexpensive and the simplest type of
patterns.
tt
A the
As
th name indicates,
i di t they
th are made
d off a
single piece.
Split Pattern or Two Piece Pattern

This is the most widely used type of pattern for intricate
castings When the contour of the casting makes its
castings.
withdrawal from the mould difficult, or when the depth
of the casting is too high,
high then the pattern is split into two
parts so that one part is in the drag and the other in the
cope.
p
Gated Pattern
Gating and runner system are integral with the

pattern. This would eliminate the hand cutting of
the runners and gates and help in improving the
productivity of a moulding.
TypesofPattern
y Match Plate Pattern
The
h cope and
d drag
d
patterns along
l
with
h the
h
gating and the risering are mounted on a single
matching metal or wooden plate on either side.
IES2008
TypesofPattern
y Loose Piece Pattern
This type of pattern is also used when the

contour of the part is such that withdrawing the
pattern from the mould is not possible.
possible
T
f P tt
TypesofPattern
y Cope and Drag Pattern
These
ese aaree ssimilar
a to sp
splitt patte
patterns.
s. In add
addition
t o to
splitting the pattern, the cope and drag halves of
pattern along
g with the g
gating
g and riser systems
y
the p
are attached separately to the metal or wooden
plates along
p
g with the alignment
g
pins. Theyy are
p
called the cope and drag patterns.
T
f P tt
TypesofPattern
y Follow Board Pattern
This type of pattern is adopted for those
castings where there are some portions,
portions which
are structurally weak and if not supported
properly are likely to break under the force of
ramming.
T
fP
TypesofPattern
y Skeleton Pattern
y Sweep Pattern
The pattern adopted for those castings where there

are some portions
ti
which
hi h are structurally
t t ll weak
k and
d
are likely to break by the force of ramming are
called:
ll d
(a) Loose piece pattern
(b) Follow board pattern
((c)) Skelton p
pattern
(d) Single piece pattern
TypesofPattern
It is used to sweep the complete casting by means

of a plane sweep.
s eep These are used for generating
large shapes, which are axisymmetrical or
prismatic in nature such as bellshaped
bell shaped or
cylindrical.
Page 6 of 240
A skeleton of the pattern made of strips of wood

is used for building the final pattern by packing
sand around the skeleton. After packing the
sand the desired form is obtained with the help
sand,
of a strickle. This type of pattern is useful
generally for very large castings,
castings required in
small quantities where large expense on
complete wooden pattern is not justified.
justified
Rev.0
CoolingCurve
Fluidity
The ability of a metal to flow and fill a mold is known
as fluidity.
Pouring Temperature
y The most important controlling factor of fluidity is the
pouring
p
g temperature
p
or the amount of superheat.
p
y Higher the pouring temperature, the higher the fluidity.
y Excessive temperatures should be avoided, however. At
high pouring temperatures, metalmold reactions are
accelerated and the fluidity may be so great as to permit
penetration.
i
y Penetration is a defect where the metal not only fills the
mold cavity
ca it but also fills the small voids
oids between
bet een the sand
particles in a sand mold.
ISRO2011
Fluidity in casting (CI) operation is greatly
i fl
influenced
d by
b
a) Melting temperature of molten metal
b) Pouring temperature of molten metal
c)) Finish of the mould
Core
y Used for making cavities and hollow projections.
y All sides of core are surrounded by the molten metal
and are therefore subjected to much more severe

thermal and mechanical conditions and as a result the
core sand should be of higher strength than the
moulding sand.
d) Carbon content of molten metal
( )
GATE2012(PI)
In sand casting, fluidity of the molten metal
i
increases
with
ith
(A) increase in degree of superheat
(B) decrease in pouring rate
((C)) increase in thermal conductivityy of the mould
(D) increase in sand grain size
Desiredcharacteristicsofacore
y Green Strength: A core made of green sand should
b strong
be
t
enough
h to
t retain
t i the
th shape
h
till it goes for
f
baking.
y Dry Strength:
h It should
h ld have
h
adequate
d
d strength
dry
h
so that when the core is placed in the mould, it
should
h ld be
b able
bl to resist the
h metall pressure acting on
it.
y Refractoriness: Since in most cases, the core is
surrounded all around it is desirable that the core
material should have higher refractoriness.
Contd
y Permeability: Gases evolving from the molten metal
and generated from the mould may have to go

through the core to escape out of the mould. Hence
cores are required to have higher permeability.
permeability
y Permeability Number: The rate of flow of air passing
through
th
h a standard
t d d specimen
i
under
d a standard
t d d pressure is
i
termed as permeability number.
y The
Th standard
d d permeability
bili test is
i to measure time
i
taken by a 2000 cu cm of air at a pressure typically of

980
8 Pa
P (10
( g/cm
/ 2),
) to pass through
h
h a standard
d d sand
d
specimen confined in a specimen tube. The standard
specimen
i
size
i is
i 50.8
8 mm in
i diameter
di
and
d a length
l
h off
50.8 mm. For-2015 (IES, GATE & PSUs)
y Then,, the p
permeabilityy number,, R is obtained byy
VH
R=
pAT
WhereV=volumeofair=2000cm3
H=heightofthesandspecimen=5.08cm
p=airpressure,g/cm
p
p
, g/ 2
A=crosssectionalareaofsandspecimen=20.268cm2
T timeinminutesforthecompleteairtopassthrough
T=timeinminutesforthecompleteairtopassthrough
Insertingtheabovestandardvaluesintothe
expression,weget
501.28
R=
p.T240
Page 7 of
y Calculatethepermeabilitynumberofsandifittakes1min
25stopass2000cm3 ofairatapressureof5g/cm2 through

thestandardsample.
p = 5.0 g / cm 2
T = 1 min 25 s = 1.417
1 417 min
501.28
R=
= 70.75
5 1.417
1 417
Rev.0
IES2007
y Friability: The ability to crumble should be a very
Whatispermeability?Permeabilityismoreimportant
inthebasicprocessofsandcastingthanporosity.Give
y Collapsibility:
p
y At the time of cooling,
g, casting
g shrinks,, and
unless the core has good collapsibility (ability to decrease
oneimportantreasonforthisfeature.
i
t t
f thi f t
[2marks]
in size) it is likely to provide resistance against shrinkage
important consideration at the time of removal.

y Smoothness: Surface of the core should be smooth
f good
for
d finish
fi i h to
t the
th casting.
ti
y Low Gas Emission
and thus can cause hot tears.
C
S d
CoreSands
y Used
silica
d clay
l free
f
l sand.
d
y Binders used are linseed oil,
oil core oil,
oil resins,
resins dextrin,
dextrin
molasses, etc.
y Core oils are mixtures of linseed, soy, fish and
petroleum oils and coal tar.

y The general composition of a core sand mixture could
be core oil (1%) and water (2.5

(2 5 to 6%).
6%)
C b Di id M ldi
CarbonDioxideMoulding
y Sodium silicate (water glass, SiO2:Na2O) is used as a binder.
This is essentially a quick process of core or mould

p p
preparation.
y The mould is prepared with a mixture of sodium silicate and
sand and then treated with carbon dioxide for two to three
minutes such that a dry compressive strength of over 1.4
MPa is arrived.
y The carbon dioxide is expected to form a weak acid, which
hydrolyses the sodium silicate resulting in amorphous silica,
which forms the bond.
y The introduction of CO2 g
gas starts the reaction byy forming
g
hydrated sodium carbonate (Na2CO3 + H2O).
y The compressive strength of the bond increases with
standing time due to dehydration.

y Because of the high strength of the bond, the core need not
provided with anyy other reinforcements.

be p
y It does not involve any distortions due to baking and also
better dimensional accuracies are achieved.

y The
Th sand
d mixture
i
d
does
not have
h
good
d shelf
h lf life
lif and
d
therefore should be used immediatelyy after p

preparation.
p
Contd
IES2002
Assertion (A): In CO2 casting process,
process the mould or
core attains maximum strength.
Reason (R): The optimum gassing time of CO2
through the mould or core forms Silica Gel which
imparts sufficient strength to the mould or core.
core
(a) Both A and R are individually true and R is the
(b) Both A and R are individually true but R is not the
(c) A is true but R is false
(d) A is
i false
f l but
b t R is
i true
t
GATE 2008(PI)
GATE
2008 (PI)
g of a hollow p
y
In sand casting
part of lead,, a cylindrical
core
of diameter 120 mm and height 180 mm is placed inside
the mould cavity. The densities of core material and lead
GATE2014
An
alloy
is
A aluminium
l i i
ll (density
(d i 2600 ) casting
i
i to be
b
produced. A cylindrical
p
y
hole of 100 mm diameter and
100 mm length is made in the casting using sand core
are 1600 kg/m3 and 11,300

11 300 kg/m3 respectively.
respecti el The net
(density 1600 ). The net buoyancy force (in Newton)
force ((in N)) that tends to lift the core during

gp
pouring
g of
acting on the core is ..
molten metal will be

(a) 19.7
(b) 64.5
(c) 193.7
(d) 257.6
Page 8 of 240
Rev.0
M ldi S d C
MouldingSandComposition
iti
y Sand:
silica
or olivine
S d Ordinary
O di
ili Sand
S d (SiO2),
) zircon,
i
li i
sands.
Oth Additi
OtherAdditives
y Cereal binder up to 2% increases the strength.
y Pitch
Pit h if used
d up to
t 3%
% would
ld improve
i
th hot
the
h t
y Clay: Acts as binding agents mixed to the moulding
sands
strength.
g
y Saw dust up to 2% may improve the collapsibility by
Kaolinite or fire clay (Al2O3 2SiO2 2H2O), and

B
Bentonite
i (Al2O3 4SiO
SiO2 H2O nH
H2O).
O)
y Water: Clay is activated by water.
water
slowly burning, and increase the permeability.

y Other materials: sea coal, asphalt, fuel oil, graphite,
molasses iron oxide,

molasses,
oxide etc.
etc
M ldi S d P
MouldingSandProperties
ti
y Porosity or Permeability: Permeability or porosity of
the moulding sand is the measure of its ability to

permit air to flow through it.
it
y Strength: It is defined as the property of holding
t th off sand
together
d grains.
i
A moulding
ldi sand
d should
h ld have
h
ample strength so that the mould does not collapse or
gett partially
ti ll destroyed
d t
d during
d i conveying,
i
t
turning
i over
or closing.
y Refractoriness: It is the ability of the moulding sand
mixture to withstand the heat of melt without showing
any signs of softening or fusion.
Contd
y Plasticity: Itisthemeasureofthemouldingsandtoflow
aroundandoverapatternduringrammingandtouniformly
filltheflask.
y Collapsibility:Thisistheabilityofthemouldingsandto
decreaseinvolumetosomeextentunderthecompressive
forcesdevelopedbytheshrinkageofmetalduringfreezing
p
y
g
g
g
andsubsequentcooling.
y Adhesiveness:Thisisthepropertyofsandmixtureto
p p y
adheretoanotherbody(here,themouldingflasks).The
mouldingsandshouldclingtothesidesofthemoulding
g
g
g
boxessothatitdoesnotfalloutwhentheflasksarelifted
andturnedover.Thispropertydependsonthetypeand
amountofbinderusedinthesandmix.
Oth S d
OtherSands
material sprinkled on the inner surface of the mold
give a better surface finish to the castings.
g
cavityy to g
y Backing sand: It is what constitutes most of the
refractory material found in the mould.
mould This is made
up of used and burnt sand.
y Green Sand: The molding sand that contains
moisture is termed as green sand. The green sand
should have enough strength so that the constructed
mould retains its shape.
y Dry
D sand:
d When
Wh the
th moisture
i t
i the
in
th moulding
ldi sand
d is
i
completely expelled, it is called dry sand.
Grainsizenumber
y ASTM (American
Society for Testing and Materials))
(
grain size number, defined as

n-1
N 2
y Where N is the number of grains per square inch
visible in a prepared specimen at 100X and n is the
ASTM
S Mg
grainsize
a s e number.
u be .
y Low ASTM numbers mean a few massive grains; high
numbers refer to many small grains.
grains
IES2008
g sand: The small amount of carbonaceous

y Facing
Small amount of carbonaceous material sprinkled

on the inner surface of mould cavity is called
(a) Backing sand
( ) Facing sand
(b)
(c) Green sand
(d) Dry sand
IES2002
In the grain size determination using standard
charts, the relation between the given size
number n and the average number of grains 'N'
per square inch at a magnification of 100 X is
( ) N = 2n
(a)
(b) N = 2nl
(c) N = 2n + 1
(d) N = 2n + 1
Page 9 of 240
S dSli
SandSlinger
Rev.0
Gating System
GatingSystem
CastingYield
Thecastingyieldistheproportionoftheactual
g
, ,
p
castingmass,w,tothemassofmetalpouredintothe
mould,W,expressedasapercentage.
Casting yield =
w
100
W
Contd
Gating System
GatingSystem
y Runner: A runner is commonly a horizontal channel
y Pouring basin: A small funnel shaped cavity at the
top of the mould into which the molten metal is

poured.
y Sprue:
S
Th passage through
The
th
h which
hi h the
th molten
lt metal,
t l
from the pouring basin, reaches the mould cavity. In

many cases it controls
t l the
th flow
fl
off metal
t l into
i t the
th
mould.
which connects the sprue with gates, thus allowing the

molten metal to enter the mould cavity.
cavity The runners
y Ingate: Achannelthroughwhichthemoltenmetal
entersthemouldcavity.
y Vent: Smallopeninginthemouldtofacilitateescape
p
g
p
ofairandgases.
are of larger crosssection and often streamlined to

slow down and smooth out the flow, and are designed
to provide approximately uniform flow rates to the
various parts of the mould cavity.
cavity Runners are
commonly made trapezoidal in crosssection.
Contd
fG
TypesofGateorIngate
Top
turbulence
in
T gate: Causes
C
b l
i the
h mould
ld cavity,
i it
i is
i prone
p
gradient towards the
g
to form dross,, favourable temperature
gate, only for ferrous alloys.
Bottom gate: No mould erosion, used for very deep moulds,
higher pouring time,
time Causes unfavourable temperature
gradients.
Parting Gate: most widely used gate, easiest and most
economical in preparation.
Step Gate: Used for heavy and large castings, size of ingates
are normally increased from top to bottom.
Contd
IES2011
In light metal casting,
casting runner should be so designed
that:
1. It avoids
id aspiration
i ti
2. It avoids turbulence
3. The path of runner is reduced in area so that
q
volume of flow through
g each g
gate
unequal
takes place
(a) 1 and 2 only
(b) 1 and 3 only
(c) 2 and 3 only
(d) 1, 2 and 3
Page 10 of 240
G
20 0 ( )
GATE
2010(PI)
During
the
process off a given
sand
D i
h filling
filli
i
d mould
ld cavity
i by
b
molten metal through a horizontal runner of circular cross
section the frictional head loss of the molten metal in the
runner will increase with the
(a) increase in runner diameter
(b) decrease in internal surface roughness of runner
(c) decrease in length of runner
(d) increase in average velocity of molten metal
Rev.0
IES 2011
IES2011
Match List I with List II and select the correct answer using
the code given below the lists :
ListI
ListII
A.Topgate
1.Heavyandlargecastings
B.Bottomgate
g
2.Mostwidelyusedandeconomical
y
C.Partinggate
3.Turbulence
D.Stepgate
4.Unfavourable temperaturegradient
Codes
C
d
A
( ) 3
(a)
(c) 3
B
4
2
C
2
4
D
1
1
(b)
(d)
A
1
1
B
4
2
C
2
4
D
3
3
Th
Thegoalsforthegatingsystem
l f th
ti
t
y To
to
T minimize
i i i turbulence
t b l
t avoid
id trapping
t
i gasses into
i t
the mold
y To get enough metal into the mold cavity before the
metal starts to solidify
y To avoid shrinkage
y Establish the best possible temperature gradient in the
solidifying casting so that the shrinkage if occurs must
be in the gating system not in the required cast part.
y Incorporates a system for trapping the nonmetallic
inclusions.
inclusions
T
TypesofGatingSystems
f G ti S t
Thegatingsystemsareoftwotypes:
y Pressurizedgatingsystem
y Unpressurizedgatingsystem
U
i d i
IES1998
A sand casting mould
assembly is shown in
the above figure. The
elements marked A
and B are respectively
(a) Sprue and riser
(b) Ingate
I
t and
d riser
i
(c) Drag and runner
(d) Riser and runner
GATE2002
The primary purpose of a sprue in a casting
mould
ou d iss to
(a)Feed the casting at a rate consistent with the rate
of solidification
(b)Act as a reservoir for molten metal
( ) d molten
(c)Feed
l
metall from
f
the
h pouring
i basin
b i to the
h
gate
(d)Help feed the casting until all solidification takes
place
IES 1998
IES1998
Whichofthefollowingaretherequirementsofanideal
gatingsystem?
1 Themoltenmetalshouldenterthemouldcavitywithas
1.
highavelocityaspossible.
2 Itshouldfacilitatecompletefillingofthemouldcavity.
2.
Itshouldfacilitatecompletefillingofthemouldcavity
3. Itshouldbeabletopreventtheabsorptionofairorgases
fromthesurroundingsonthemoltenmetalwhile
flowingthroughit.
Selectthecorrectanswerusingthecodesgivenbelow:
(a)1,2and3
(b)1and2 (c)2and3 (d)1and3
IES2009
Considerthefollowingstatements:
C
id th f ll i t t
t
1.Theactualentrypointthroughwhichthemolten
metalentersthemouldcavityiscalledingate.
2.Bottomgateincaseofamouldcreatesunfavourable
g
temperaturegradient.
3.Sprueincaseofamouldismadetaperedtoavoidair
inclusion.
Whichoftheabovestatementsis/arecorrect?
(a)1only (b)1and2 (c)2and3 (d)1and3
P
PressurizedGatingSystem
i d G ti S t
U P
i d G ti S t
UnPressurizedGatingSystem
y The total cross sectional area decreases towards the
y The total cross sectional area increases towards the
mold cavity
y Back pressure is maintained by the restrictions in the
metal flow
y Flow of liquid (volume) is almost equal from all gates
y Back pressure helps in reducing the aspiration as the
sprue always runs full
y Because
B
off the
h restrictions
i i
the
h metall flows
fl
at high
hi h
velocity leading to more turbulence and chances of
mold
ld erosion.
i
Page 11 of 240
mold cavity
y Restriction only
y at the bottom of sprue
p
y Flow of liquid (volume) is different from all gates
y Aspiration in the gating system as the system never
runs full
y Less
L
turbulence.
b l
Rev.0
Sprue Design
Sincethevelocitiesareproportionaltothesquareof
p
,
thepotentialheads,ascanbederivedfrom
Bernoulli'sequation,
y Sprue: Sprue is the channel through which the molten
metal is brought into the parting plane where it enters the

runners and g
gates to ultimatelyy reach the mould cavity.
y
y The molten metal when moving from the top of the cope to
the p
parting
gp
plane g
gains in velocityy and some lowpressure
p
area would be created around the metal in the sprue.
y Since the sand mould is permeable, atmospheric air would
be breathed into this lowpressure area which would then
be carried to the mould cavity.
y
y To eliminate this problem of air aspiration, the sprue is
tapered
p
to g
graduallyy reduce the cross section as it moves
away from the top of the cope as shown in Figure below (b).
At = Ac
Theexacttaperingcanbeobtainedbytheequationof
continuity.DenotingthetopandchokesectionsofThesprue by
thesubscriptstand'c'respectively,weget
A t Vt = A c Vc
At = Ac
The height of the downsprue is 175 mm and its

crosssectional
ti
l area att the
th base
b
i 200 mm2. The
is
Th
crosssectional area of the horizontal runner is
also
l 200 mm2. Assuming
A
i
no losses,
l
i di t the
indicate
th
correct choice for the time (in seconds) required to
fill a mould cavity
ca it of volume
olume 10
06 mm3. (Use g = 10
0
2
m/s ).
( )
(a)2.67
(b)
(b)8.45
( )
(c)26.72
(d)
(d)84.50
WhereH=actual
h
l
sprue height
andht=h+H
Vc
Vt
Contd
Contd
GATE2001
hc
ht
GATE 2007
GATE2007
g down sprue
p
A 200 mm long
has an area of cross
section of 650 mm2 where the pouring basin meets the
p
((i.e. at the beginning
g
g of the down sprue).
p )
down sprue
A constant head of molten metal is maintained by the
pouring
p
g basin. The Molten metal flow rate is 6.55 105
3
mm /s. Considering the end of down sprue to be open
p
and an acceleration due to g
gravityy of
to atmosphere
104mm/s2, the area of the down sprue in mm2 at its end
((avoiding
g aspiration
p
effect)) should be
(a)650.0 (b)350.0 (c)290.7 (d)190.0
Contd
G ti
Gatingratio
ti
y Gatingratioisdefinedas:Sprue area:Runnerarea:
Ingate area.
area
y Forhighqualitysteelcastings,agatingratioof1:2:2or
1:2:1.5willproducecastingsnearlyfreefromerosion,
willminimizeoxidation,andwillproduceuniform
ill i i i id i d ill d if
flow.
y Agatingratioof1:4:4mightfavour theformationof
oxidationdefects.
IES2003
A gating
ratio
ti
ti off 1: 2: 4 is
i used
d to
t design
d i the
th gating
ti
system for magnesium alloy casting. This gating ratio
refers to the cross section areas of the various gating
elements as given below:
1
1.
Down sprue 2.
2
Runner bar 3.
3
Ingates
The correct sequence of the above elements in the
ratio 1: 2: 4 is
(a) 1, 2 and 3
(b) 1,3 and
d2
(c) 2, 3 and 1
(d) 3, 1 an 2
Page 12 of 240
IES2005
The gating ratio 2: 8: 1 for copper in gating system
d i refers
design
f to
t the
th ratio
ti off areas of:
f
(a) Sprue: Runner: Ingate
(b) Runner: Ingate: Sprue
((c)) Runner: Sprue:
p
Ingate
g
(d) Ingate: Runner: Sprue
Rev.0
GATE2010
Inagatingsystem,theratio1:2:4represents
(a) Sprue basearea:runnerarea:ingate area
(b) Pouringbasinarea:ingate area:runnerarea
(c) Sprue basearea:ingate area:castingarea
(d) Runnerarea:ingate
R
i
area:castingarea
IAS1999
Assertion
off metall through
A
i (A):
(A) The
Th rate off flow
fl
h
h sprue
is NOT a function of the crosssectional areas of
sprue runner and gate.
sprue,
gate
Reason (R): If respective crosssectional areas of
p
, runner and g
gate are in the ratio of 1: 2: 2,, the
sprue,
system is known as unpressurised gating system.
(a) Both A and R are individuallyy true and R is the correct
explanation of A
correct explanation
l
i off A
(d) A is false
f l but
b R is true
Ri
RisersandRiserDesign
d Ri D i
y Risers are added reservoirs designed to feed liquid
metal to the solidifying casting as a means of

compensating for solidification shrinkage.
y To perform this function, the risers must solidify after
the casting.
casting
y According to Chvorinov's rule, a good shape for a riser
would
ld be
b one that
th t has
h a long
l
f
freezing
i time
ti
(i
(i.e.,
a small
ll
surface area per unit volume).
y Live risers (also known as hot risers) receive the last
hot metal that enters the mold and generally do so at a
time when the metal in the mold cavity has already
begun to cool and solidify.
TypesofRisers
Ch i
Chvorinovs
rule
l
IES 1994
IES1994
Assertion (A): In a mould, a riser is designed and placed
so that the riser will solidify after the casting has solidified.
Reason (R): A riser is a reservoir of molten metal which
will supply molten metal where a shrinkage cavity would
have occurred.
(a) Both A and R are individually true and R is the correct
explanation
p
of A
correct explanation
p
of A
IES2011
The relationship between total freezing time t,
t
volume of the casting V and its surface area A,
g to Chvorinovs rule is :
according
V
(a ) t = k
A
A
(b ) t = k
V
A
(c ) t = k
V
(d ) t = k
y Totalsolidificationtime(ts)=B(V/A) n
wheren=1.5to2.0
[Wh
[Where,B=mouldconstantandisafunctionof(mould
B
ld
di f
i f(
ld
material,castingmaterial,andconditionofcasting]
n=2 andtriser =1.25tcasting
2
or
Forcylinder
ofdiameterD
fdi
D
andheightH
V
V
= 1.25
A
riser
A casting
V = D2H / 4
2
A = DH + 2 D
)
GATE 2013 SameQuestion(PI)
GATE2013
IES 1998
IES1998
A spherical drop of molten metal of radius 2 mm
A cube
solidifies
in
The
b shaped
h
d casting
ti
lidifi
i 5 min.
i
Th
was found to solidify in 10 seconds. A similar drop of
solidification time in min for a cube of the same
radius 4 mm would solidify in
material, which is 8 times heavier than the original
(a) 14.14 seconds
casting, will be
(b) 20 seconds
d
( ) 10
(a)
(b) 20
( ) 24
(c)
(d) 40
(c) 28.30
28 30 seconds
2
Where K is a constant
(d) 4
40 seconds
Page 13 of 240
Rev.0
GATE2014
GATE2014(PI)
GATE2003
A cylindrical riser of 6 cm diameter and 6 cm height has
For a given volume of a riser, if the solidification

time of the molten metal in riser needs to be
quadrupled, the surface area of the riser should be
made
to be designed for a sand casting mould for producing a
With a solidification factor of 0.97 x 106 s/m2, the
steel rectangular plate casting of 7 cm 10 cm 2 cm
solidification time (in seconds) for a spherical
dimensions having the total solidification time of 1.36

1 36
casting of 200 mm diameter is
minute. The total solidification time (in minute) of the
(a) onefourth
(b) half
(c) double
(d) four times
IES2006
According
to
Chvorinov's
( ) 539
(a)
riser is ..
GATE 2010(PI)
equation,
the
Volume of a cube of side 'l' and volume of a sphere of
(a) v2
(b) Directlyy p
proportional
p
to the specific
p
heat of the
radius r are equal. Both the cube and the sphere are solid
and
d off same material.
t i l They
Th are being
b i cast.
t The
Th ratio
ti off the
th
cast material
p
is:
solidification time of the cube to the same of the sphere
(c) Directly proportional to the thermal diffusivity of
(c) 1/v
the
h molten
l
metall
(d) 1/v2
Where, v = volume of casting
(d)Inversely
proportional
to
the
A solid
D and
l d cylinder
l d off diameter
d
d height
h h equall to D, and
d a solid
ld
cube of side L are being sand cast by using the same material.
4 r

6 l
( b )
4 r

6 l
( c )
Assuming there is no superheat in both the cases, the ratio of

solidification time of the cylinder to the solidification time of the
diameter of the cylinder are equal. The ratio of the
cube is
solidification time of the sphere to that of the cylinder is
(a) (L/D)2
(d) 0.76
GATE2009(PI)
equal volumes are separately cast from the same molten
(c) 1.31
4 r
6 l
pouring
In a sand casting process,

process a sphere and a cylinder of
((b)) 0.877
(a )
temperature.
GATE 2011 (PI)

GATE2011(PI)
metal under identical conditions. The height and
(d) 3233
Solidification
off a metallic
S lidifi ti time
ti
t lli alloy
ll casting
ti is
i
(a) Directly proportional to its surface area
(b) v
( ) 4311
(c)
GATE2007
solidification
lidifi ti time
ti
off a casting
ti is
i proportional
ti
l to:
t
((a)) 1.14
4
(b) 1078
8
(b) (2L/D)2
(c) (2D/L)2
(d) (D/L)2
Page 14 of 240
Rev.0
4 r

6 l
( d )
IES 2011 Conventional

IES2011Conventional
IES 2012
IES
y A round casting is 20 mm in diameter and 50 mm in
Theratioofsurfaceareaofvolumeforaunitvolumeof
Th ti f f
f l
f it l
f
ConventionalQuestionESE2003
length. Another casting of the same metal is elliptical in
riserisminimumincaseof
cross section,
i
with
i h a major
j to minor
i
axis
i ratio
i off 2, and
d
Compare the solidification time of two optimum side
(a)Cylindricalriser
has the same length and cross

crosssectional
sectional area as the
risers of the same volume with one has cylindrical shape
(b)Sphericalriser
round casting. Both pieces are cast under the same
and other is parallopiped.
(c)Hemisphericalriser
conditions. What is the difference in the solidification
(d)Cuboidsriser
times
i
off the
h two castings
i
?
Area of ellipse = ab
[ Marks]
[10
M k ]
Ci
Circumference
f
= 3 ( a + b )
= 2
A cylindrical
with
li d i l blind
bli d riser
i
ith diameter
di
t d and
d height
h i ht h,
h is
i
placed on the top of the mold cavity of a closed type
sand
d mold
ld as shown
h
i the
in
th figure.
fi
If the
th riser
i
i off
is
constant volume, then the rate of solidification in the
riser
i is
i the
th least
l t when
h the
th ratio
ti h : d is
i
(a) 1 : 2
(c) 1 : 4
(b) 2 : 1
(d) 4 : 1
(a
( 3a + b )( a + 3b )
+ b2 ) / 2
(approx.)
M d l M th d
ModulusMethod
GATE2014
Sprue basin
[30 Marks]
Mold cavity
of the riser exceeds the modulus of the casting

g byy a
factor of 1.2, the feeding during solidification would be
D2
4
satisfactory.
f
+ D2
MR = 1.2
1 2 Mc
d
Riser
y It has
empirically
h been
b
i i ll established
t bli h d that
th t if the
th modulus
d l
y Modulus = volume/Surface area

y In steel castings, it is generally preferable to choose a
riser with a heighttodiameter ratio of 1.

Contd
Q
ConventionalQuestionIES2008
y Calculate the size of a cylindrical riser (height and diameter
C i Method
Caines
M th d
Freezingratio=ratio ofcoolingcharacteristicsofcastingto
theriser.
A
X=
equal) necessary to feed a steel slab casting of dimensions

30 x 30 x 6 cm with a side riser,
riser casting poured horizontally
( V)
( AV )
Casting
into the mould.
AccordingtoCaine
[Use Modulus Method]

[ 0 Marks]
[10
Riser
Th i h ld lidif l
Therisershouldsolidifylastsox>1
X=
a
+c
Yb
V
Vcasting
riser
Y=anda,b,careconstant.
Page 15 of 240
Rev.0
Table:ConstantsinCaines Method
Q
Conventional QuestionIES2007
y Calculate the size of a cylindrical riser (height and
diameter equal)) necessary to feed a steel slab

casting of dimensions 25 x 25 x 5 cm with a side
riser, casting poured horizontally into the mould.
[Use Caines Method]
[ For steel a = 0.10, b = 0.03 and c = 1.00 ]
IES1995
GATE1998,2007,2014(PI)
Directional solidification in castings can be
Chills are used in moulds to
improved by using
(a) Achieve directional solidification
(a) Chills and chaplets
(b) Reduce the possibility of blowholes
( ) Chills and padding

(b)
(c) Reduce freezing time
(c) Chaplets and padding
(d) Smoothen
S
h metall flow
fl for
f reducing
d i splatter.
l
Chills
Chill
g
p
y, highthermal
g
y External chills are masses of highheatcapacity,
conductivity material that are placed in the mould (adjacent to
the casting) to accelerate the cooling of various regions.
Chills can effectively promote directional solidification or
increase the effective feeding distance of a riser. They can often
b used
be
d to reduce
d
the
h number
b off risers
i
required
i d for
f a casting.
i
y Internal chills are pieces of metal that are placed within the
mould cavity to absorb heat and promote more rapid
solidification. Since some of this metal will melt during the
operation,
ope
at o , itt w
will abso
absorb
b not
ot o
onlyy tthee heatcapacity
eat capac ty eenergy,
e gy, but
also some heat of fusion. Since they ultimately become part of
the final casting, internal chills must be made from the same
alloy as that being cast.
IAS1994
Chillsareusedincastingmouldsto
(a) Achievedirectionalsolidification
(b) Reducepossibilityofblowholes
(c) Reducethefreezingtime
(d) Increasethesmoothnessofcastsurface
(d) Chills, chaplets and padding.
Cupola
y Cupola has been the most widely used furnace for
IES1997
melting cast iron.

iron
y In hot blast cupola, the flue gases are used to preheat the
air blast to the cupola so that the temperature in the
furnace is considerably higher than that in a
conventional cupola.
cupola Coke is fuel and Lime stone
(CaCO3) is mostly used flux.
y Cost
C off melting
l i low.
l
y Main disadvantages of cupola is that it is not possible to
produce iron below 2.8% carbon.
y Steel can be also p
prepared
p
in cupola
p
byy employing
p y g
duplexing and
triplexing
operations.
Assertion (A):
( ) Steell can be
b melted
l d in hot
h blast
bl cupola.
l
Reason (R): In hot blast cupola, the flue gases are used to
preheat the air blast to the cupola so that the temperature in
the furnace is considerably higher than that in a
conventional
i
l cupola.
l
explanation
l
i off A
correct explanation
l
i off A
Page 16 of 240
IES 2012
IES
) Cupola
C p
p y
Statement ((I):
furnace is not employed
for
melting steel in foundry
) The temperatures
p
generated within a
g
Statement ((II):
cupola are not adequate for melting Steel
((a)) Both Statement ((I)) and Statement ((II)) are
individually true and Statement (II) is the correct
explanation of Statement (I)
(b) Both Statement (I) and Statement (II) are
individually true but Statement (II) is not the correct
(c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement
(II) is true
Rev.0
Electric Arc Furnace

ElectricArcFurnace
y For heavy steel castings,
castings the
openhearth type of furnaces
Crucible Furnace or Pot Furnace

y Smaller foundries generally prefer the crucible furnace.
y The crucible is g
generallyy heated byy electric resistance
or gas flame.
with electric arc or oil fired
Induction Furnace
y The induction furnaces are used for all types of
materials, the chief advantage being that the heat
source is isolated from the charge and the slag and flux
get the necessary heat directly from the charge instead
of the heat source.
would be generally suitable in

view of the large heat required
for melting.
y Electric arc furnaces are more
suitable for ferrous materials and

are larger in capacity.
CastingCleaning(fettling)
g
g(
g)
Ladles
y Twotypesofladlesusedinthepouringofcastings.
Pouring time
Pouringtime
GATE2005
Timetakentofillthemouldwithtopgate
Where A=Areaofmould
A.H
tA =
H H i ht f
H=Heightofmould
ld
A g 2gh m
Ag =AreaofGate
Hm =Gateheight
Timetakentofillthemouldwithbottomgate
tB =
(
2g
2A
Ag
hm hm H
Impuritiesinthemoltenmetalarepreventedfromreaching
y yp
g
themouldcavitybyprovidinga
(i) Strainer
(ii) Bottomwell
(iii) Skimbob
A mould has a downsprue whose length is 20 cm

and
d the
th cross sectional
ti
l area att the
th base
b
off the
th
downsprue is 1cm2. The downsprue feeds a
h i
horizontal
t l runner leading
l di into
i t the
th mould
ld cavity
it off
volume 1000 cm3. The time required to fill the
mould cavity
ca it will
ill be
(a)4.05 s (b)5.05 s (c)6.05 s
(d)7.25 s
Page 17 of 240
GATE1996
Light impurities in the molten metal are prevented
f
from
reaching
hi the
th mould
ld cavity
it by
b providing
idi a
(a) Strainer
(b) Button well
((c)) Skim bob
(d) All of the above
GATE 2006
GATE2006
In a sand casting operation, the total liquid head is

maintained
i i d constant such
h that
h it
i is
i equall to the
h mould
ld
height. The time taken to fill the mould with a top gate
i tA. If the
is
h same mould
ld is
i filled
fill d with
i h a bottom
b
gate,
then the time taken is tB. Ignore the time required to
fill the
h
runner and
d frictional
fi i
l effects.
ff
A
Assume
atmospheric pressure at the top molten metal surfaces.
Th relation
The
l i between
b
tA and
d tB is
i
(A)
tB = 2 t A
(B)
tB = 2 t A
((C))
tB =
(D)
tB = 2 2 t A
tA
2
Rev.0
GATE 2007(PI)LinkedS1
2007 (PI) Li k d S 1
GATE
2007 (PI) Li k d S 2
GATE
In a sand casting process, a sprue of 10 mm base

diameter and 250 mm height leads to a runner
which fills a cubical mould cavity of 100 mm size
The volume flow rate (in mm3/s) is
(a) 0.8 x 105
(b) 1.1 x 105
(c) 1.7
1 7 x 105
(d) 2.3
2 3 x 105
In a sand casting process, a sprue of 10 mm base

diameter and 250 mm height leads to a runner
which fills a cubical mould cavity of 100 mm size
The mould filling time (in seconds) is
(a) 2.8
(b) 5.78
(c) 7.54
7 54
(d) 8.41
8 41
Expressionforchokearea
CA =
m
mm2
ct 2gH
Wherem=massofthecasting,kg
=Densityofmetal,kg/m3
t=pouringtime
p
g
c=Efficiencyfactorandisthefunctionofgate
systemused
y
H=Effectiveheadofliquidmetal
=hfortopgate
Contd
H=h
H h
hm
2
h2
=h c
2hm
IES2009
forbottomgate
f b tt t
IAS2011Main
y 2marks
Sketch a mould for two hollow components to be
forpartinglinegate
cast. On the diagram, indicate runner, gate, riser,

core, cope, sprue, pouring basin, sprue well, drag,
parting line.
line
hC
hm
hm
[
[10Marks]
]
hm
li
t t ti li t b tt t
topgatepartinglinegatebottomgate
IES2013
When an alloy solidifies over a range of
C ti D f t
CastingDefects
G D f t
GasDefects
Thefollowingarethemajordefects,whicharelikelyto
Th f ll i th j d f t hi h lik l t
y A condition existing in a casting caused by the
occurinsandcastings:
g
trapping of gas in the molten metal or by mold gases

evolved during the pouring of the casting.
y The defects in this category
g y can be classified into
blowholes and pinhole porosity.
y Blowholes
ow o es aaree sp
spherical
e ca o
or eelongated
o gated cav
cavities
t es p
present
ese t
in the casting on the surface or inside the casting.
y Pinhole porosity occurs due to the dissolution of
hydrogen gas, which gets entrapped during heating of
molten metal.
metal
temperature, the resulting casting structure is:
y Gasdefects
(a) Wholly equiaxed
y Shrinkagecavities
( ) Wholly columnar
(b)
y Moldingmaterialdefects
(c) Partially columnar partially equiaxed

equi axed
y Pouringmetaldefects
(d) Dendritic
y Moldshift.
M ld hift
Page 18 of 240
Rev.0
Shrinkage Cavities
ShrinkageCavities
y These are caused by liquid shrinkage occurring during the
solidification of the casting.

y To compensate for this, proper feeding of liquid metal is
required. For this reason risers are placed at the
appropriate places in the mold.
y Sprues may be too thin, too long or not attached in the
proper location, causing shrinkage cavities.
y It is recommended to use thick sprues to avoid shrinkage
cavities.
Scab
y This defect occurs when a portion of the face of a mould
lifts or breaks down and the recess thus made is filled by

metal.
y When the metal is poured into the cavity, gas may be
disengaged with such violence as to break up the sand,
which
hi h is
i then
h washed
h d away and
d the
h resulting
l i cavity
i filled
fill d
with metal.
y The
Th reasons can be:
b too fine
fi sand,
d low
l
permeability
bili off
sand, high moisture content of sand and uneven mould
ramming.
i
MoldingMaterialDefects
y These
appear as rough
Th
h spots
t and
d areas off excess metal,
t l and
d
are caused by erosion of molding sand by the flowing

metal.
metal
y This is caused by the molding sand not having enough
strength and the molten metal flowing at high velocity.
velocity
y The former can be taken care of by the proper choice of
molding sand and the latter can be overcome by the
proper design of the gating system.
y Cutsandwashes,
y Scab
y Metalpenetration,
y Fusion,and
y Swell
S ll
M t l
Metalpenetration
t ti
y When molten metal enters into the gaps between sand
grains, the result is a rough casting surface.

y This occurs because the sand is coarse or no mold wash was
applied on the surface of the mold. The coarser the sand
grains more the metal p
g
penetration.
Under the influence of metallostatic forces, the mold

wall may move back causing a swell in the dimension
off the
th casting.
ti
A proper ramming
i
off the
th mold
ld will
ill
correct this defect.
Inclusions
Particles of slag, refractory materials sand or
deoxidation products are trapped in the casting during
pouring solidification.
ldf
The
h provision off choke
h k in the
h
gating system and the pouring basin at the top of the
mold
ld can preventt this
thi defect
d f t
Fusion
y This is caused by the fusion of the sand grains with
th molten
the
lt metal,
t l giving
i i a brittle,
b ittl glassy
l
appearance
on the casting
g surface.
y The main reason for this is that the clay or the sand
particles are of lower refractoriness or that the

pouring temperature is too high.
P i M t lD f t
PouringMetalDefects
Swell
Cutandwashes
d
h
y The misrun and cold shut defects are caused either by
The likely defects in this category are

y Misruns and
y Cold shuts
y A misrun is caused when the metal is unable to fill
a lower fluidity of the mold or when the section

thickness of the casting is very small. Fluidity can be
improved by changing the composition of the metal
and by increasing the pouring temperature of the
metal.
metal
the mold cavity completely and thus leaves unfilled

cavities.
y A cold shut is caused when two streams while meeting
in the mold cavity, do not fuse together properly thus
forming a discontinuity in the casting.
casting
Page 19 of 240
Contd
Rev.0
GATE 2014
GATE2014
Match the casting defects (Group A) with the probable
causes (Group B):
GroupA
P: Hot tears
GroupB
1: Improper fusion of two streams of liquid
metal
Q: Shrinkage 2: Low permeability of the sand mould
q
and
R: Blow holes 33: Volumetric contraction both in liquid
solid stage
S: Cold Shut 4: Differential cooling rate
P
(a) 1
(c) 3
Q
3
4
R
2
2
S
4
1
(b)
(d)
P
4
1
Q
3
2
R
2
4
S
1
3
MoldShift
ld h f
The mold shift defect occurs when cope and drag
or molding
ldi boxes
b
h
have
nott been
b
properly
l aligned.
li
d
IES2001
Scabisa
(a) Sandcastingdefect
(b) Machiningdefect
(c) Weldingdefect
(d) Forgingdefect
F i d f
GATE2004
Misrun is a casting defect which occurs due to
(a) Very high pouring temperature of the metal
(b) Insufficient fluidity of the molten metal
(c) Absorption of gases by the liquid metal
(d) Improper
I
alignment
li
off the
h mould
ld flasks
fl k
GATE2009
Two streams of liquid metal which are not hot
enough
h to
t fuse
f
properly
l result
lt into
i t a casting
ti defect
d f t
known as
(a) Cold shut
(b) Swell
(c) Sand wash
(d) Scab
Metallurgical defects
Metallurgicaldefects
GATE2014
y Hot tears or hot cracking, cause of this defect is that
stresses and strains built up during solidification are too

high compared to the actual strength of the semisolid
material. This type of defects occurs in the lower part of
the solidification range, close to the solidus, when the
alloy has a wide solidification temperature range and a
small amount of liquid, when the solid fraction is more
than 0.9, the hot tearing is easy to occur. Proper mould
design prevents this type of defect.
y Hot spots are areas on the surface of casting that
quicklyy
become veryy hard because theyy cooled more q
than the surrounding material.
IAS2004
MatchListI(CastingDefects)withListII(Explanation)andselectthecorrect
MatchList I(CastingDefects)withList II(Explanation)andselectthecorrect
answerusingthecodesgivenbelowthelists:
ListI
ListII
(CastingDefects)
(Explanation)
A.Metallicprojections 1.Consistofroundedorroughinternalorexposedcavities
includingblowholesandpinholes
B.Cavities
2.Formedduringmelting,solidificationandmoulding.
C.Inclusions
3.Includessinglefolds,laps,scarsadheringsandlayersand
oxidescale
D.Discontinuities
4.Includecracks,coldorhottearingandcoldshuts
5.Consistoffins,flashormassiveprojectionsandrough
Consistoffins flashormassi eprojectionsandrough
surfaces
Codes:A
B
C
D
A
B
C
D
(a) 1
5
3
2
(b)
1
5
2
4
(c)
5
1
2
4
(d)
5
1
3
2
Page 20 of 240
The hot tearing in a metal casting is due to

(a) high fluidity
(b) high melt temperature
(c) wide range of solidification temperature
(d) low
l coefficient
ffi i
off thermal
h
l expansion
i
GATE2003
Hardnessofgreensandmouldincreaseswith
(a) Increaseinmoisturecontentbeyond6percent
y
p
(b) Increaseinpermeability
(c) Decreaseinpermeability
(d) Increaseinbothmoisturecontentand
permeability
bilit
Rev.0
IES1998
Assertion(A):Stiffeningmembers,suchaswebs
A
i (A) S iff i
b
h b
andribs,usedonacastingshouldbeliberally
provided
provided.
Reason(R):Theywillprovideadditionalstrength
toacastmember.
toacastmember
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
Ai f l b tRi t
IES2009
In which one of the following furnaces most of the
nonferrous alloys are melted?
(a) Reverberatory furnace
(b) Induction furnace
(c) Crucible furnace
(d) Pot
P t furnace
f
Cast Aluminium Code

CastAluminiumCode
y Fourdigitidentificationsystem
y Firstdigitindicatesalloygroup
1 Aluminium,99%ormore
, 99
2 copper
3 Silicon,withcopperand/ormagnesium
3
Silicon withcopperand/ormagnesium
4 silicon
5 magnesium
6 notused
7 zinc
8 tin
8
9 otherelements
IES2005
In gating system design, which one of the
following is the correct sequence in which choke
area, pouring time, pouring basin and sprue sizes
are calculated?
(a) Chokearea Pouringtime Pouringbasin Sprue
(b) Pouringbasin
ou g bas
Sprue
Sp
ue C
Chokearea
o e a ea Pouringtime
ou g t e
(c) Chokearea Sprue Pouringbasin Pouringtime
(d) Pouringbasin
P i b i Pouringtime
P i ti Chokearea
Ch k
Sprue
S
IES1997
If the melting ratio of a cupola is 10: 1, then the
coke requirement for one ton melt will be
(a) 0.1 ton
(b) 10 tons
(c) 1 ton
(d) 11 tons
t
IAS2001
Whichofthefollowingpatternmaterialsareused
inPrecisionCasting?
1. PlasterofParis
2. Plastics
3. AnodizedAluminium Alloy
4. FrozenMercury
F
M
(a)1and2(b) 2and4(c)3and4(d)1and3
IAS2004
Whichoneofthefollowinggatingsystemsisbest
suitedtoobtaindirectionalsolidification?
(a) Topgrating
(b) Part
Partlinegrating
linegrating
(c) Bottomgrating
(d) Steppedgrating
St
d ti
C
l i i
C d
CastAluminiumCode
Contd..
y Second two digits identify the aluminium alloy or
indicate the aluminium purity.

y The last digit is separating from the other three by a
decimal point and indicates the product form; that is,
castings or ingots
y A modification of the original alloy is indicated by a
serial
i l letter
l tt before
b f
th numerical
the
i l designation.
d i
ti
y Alloy A514.0 indicates an aluminium alloy casting with
magnesium as the principal alloy. One modification to
the original alloy has made, as indicated by the letter A.
Page 21 of 240
IES2011
In the designation of Aluminium casting A514.0
A514 0
indicates :
( ) Aluminium
(a)
Al i i
purity
it
(b) Aluminium content
(c) Percentage of alloy element
(d) Magnesium Content
A
Ans.
(d)
Rev.0
ShellMoulding
y The sand is mixed with a thermosetting resin is
SpecialCasting
BySKMondal
y Can produce complex parts.
allowed to come in contact with a heated metal pattern

(2000C).
y A skin
ki (shell)
( h ll) off about
b
3.5 mm off sand
d and
d plastic
l i
mixture adhere to the pattern.
y Then the shell is removed from the pattern.
y The cope
p and drag
g shells are kept
p in a flask with
necessary backup material and the molten metal is
poured into the mold.
p
y A good
d surface
f
fi i h and
finish
d good
d size
i
t l
tolerance
MoldingSandinShellMolding
y Hot coating: the mixture is heated to 150oC 180oC prior
y The molding sand is a mixture of fine grained quartz sand
y Materials can be cast: CI, Al and Cu alloys.
to loading the sand. In the course of sand mixing, the

soluble phenol formaldehyde resin is added.
added The mixer is
and
d powdered
d d bakelite.
b k li
y Cold coating and Hot coating methods are used for
allowed to cool up to 80 90o C. Hot coting gives better

properties to the mixtures than cold method.
coating the sand grains with bakelite.

y
reduce the need for machining.

g
Cold coating: quartz sand is poured into the mixer and

th the
then
th solution
l ti
off powdered
d d bakelite
b k lit in
i acetone
t
and
d
ethyl aldehyde are added. (mixture is 92% quartz sand,
Shellmouldingprocess
h ll
ldi
Ad t
Advantages
5% bakelite, 3% ethylaldehyde )
Contd
Li it ti
Limitations
y Dimensional
Di
i
l accuracy.
y Expensive pattern
y Smoother surface finish.

finish (Due to finer size grain used)
y Small size casting

g only.
y
y Very
y thin sections can be cast.
y Highly complicated shapes cannot be obtained.
y Very small amount of sand is needed.
y More sophisticated equipment is needed for handling
y Cylinders and cylinder heads for air cooled IC
engines
y Automobile transmission parts.
y Piston rings
the shell moldings.
Applications
Page 22 of 240
Rev.0
IES 2010
IES2010
Considerthefollowingadvantagesofshell
mouldcasting:
1.Closedimensionaltolerance.
Cl di
i
lt l
2.Goodsurfacefinish.
3.Lowcost.
4.Easier.
E i
Whichofthesearecorrect?
(a)1,2and3only (b)2,3and4only
( )
(c)1,2and4only
( )
(d)1,2,3and4
IES2006
Shellmouldingcanbeusedfor:
(a) Producingmillingcutters
g
g
(b) Makinggoldornaments
(c) Producingheavyandthickwalledcasting
(d) Producingthincasting
IES1996
IES2005
Consider the following ingredients used in

moulding:
1. Dry silica sand
2.Clay
3.Phenol formaldehyde
4.Sodium
S di
silicate
ili t
Those used for shell mould casting include
(a) 1, 2 and 4
(b) 2, 3 and 4
((c)) 1and 3
((d)) 1,, 2,, 3 and 4
Inshellmoulding,howcantheshellthickness
I h ll
ldi h
th h llthi k
beaccuratelymaintained?
( )
(a)Bycontrollingthetimeduringwhichthepattern
isincontactwithmould
(b)Bycontrollingthetimeduringwhichthepattern
isheated
(c)Bymaintainingthetemperatureofthepatternin
therangeof175oC
C 380oC
(d)Bythetypeofbinderused
IES2007
IAS2007
Which of the following are employed in shell

moulding?
ldi ?
1. Resin binder 2. Metal pattern 3. Heating coils
Select the correct answer using the code given
below:
(a) 1 and 2 only
(b) 1 and 3 only
(c) 2 and 3 only
(d) 1,
1 2 and 3
The mould in shell moulding process is made up

off which
hi h off the
th following?
f ll i ?
(a) Gypsum + setting agents
(b) Green sand + clayy
(c) Sodium silicate + dried sand
(d) Dried silica + phenolic resin
IAS1999
I
t
t C ti
InvestmentCasting
Match
Process)
M t h List
Li t I (Moulding
(M ldi
P
) with
ith List
Li t II (Binding
(Bi di
Agent) and select the correct answer using the codes
given below the lists:
g
List I
List II
A. Green sand
1. Silicate
B. Core sand
2. Organic
C. Shell moulding
3. Clay
D CO2
D.
CO process
4. Plaster
Pl
off Paris
P i
5. Plastic
Codes:A
B
C
D
A
B
C
D
(a) 3
2
5
1
(b) 3
2
4
1
(c) 2
3
5
4
(d) 2
3
4
5
Investment casting process or lost wax process

Basic steps:
1 Produce expendable wax,
1.
wax plastic,
plastic or polystyrene patterns.
patterns
2. Assemble these patterns onto a gating system
3 Investing or covering the pattern assembly with refractory
3.
slurry
4 Melting the pattern assembly to remove the pattern material
4.
5. Firing the mould to remove the last traces of the pattern
material
6. Pouring molten metal
7. Knockout, cutoff and finishing.
Page 23 of 240
Rev.0
Fig.Investmentflaskcastingprocedure
CeramicShellInvestmentCasting
IES2009
y In ceramic shell investment casting a ceramic shell is
y 2marks
built around a tree assembly by repeatedly dipping a

pattern into a slurry (refractory material such as
zircon with binder).
y After each dipping and stuccoing is completed, the
assembly is allowed to thoroughly dry before the next

coating is applied.
applied
Advantages
Limitations
Applications
y Tight dimensional tolerances

y Excellent surface finish (1.2
(1 2 to 3.0
3 0 m )
y Machining
g
can
be
reduced
or
completely
p
y
eliminated
y Costly patterns and moulds
y Aerospace and rocket components.
y Labour costs can be high
y Vanes and blades for gas turbines.
y Limited size
y Surgical instruments
y High melting point alloy can be cast, almost any
metal can be cast

y Almost unlimited intricacy
y
IES2011
The proper sequence of investment casting steps is :
(a) Slurry coating pattern melt outShakeout Stucco
coating
ti
(b) Stucco coating Slurry coating Shakeout Pattern
melt out
(c) Slurryy coating
g Stucco coating
g Pattern melt out
Shakeout
(d) Stucco coating Shakeout Slurry coating Pattern
melt out
GATE2006
An expendable pattern is used in
( ) Slush
(a)
l h casting
(b) Squeeze casting
(c) Centrifugal casting
(d) Investment casting
GATE2011(PI)
Which of the following casting processes uses
expendable pattern and expendable mould?
(a) Shell mould casting
( ) Investment casting
(b)
(c) Pressure die casting
(d) Centrifugal casting
Page 24 of 240
Rev.0
ISRO2010
Investment casting is used for
(a) Shapes which are made by difficulty using complex
patterns
tt
i sand
in
d casting
ti
(b) Mass production
p
IES1992
Themostpreferredprocessforcastinggasturbine
bladesis:
(a) Diemoulding
(b) Shellmoulding
(c) Investmentmoulding
(d) Sandcasting
S d ti
(c) Shapes which are very complex and intricate and

can't be cast by any other method
20 0
JWM2010
g
Considerthefollowingmaterials:
1.Wax
2 Wood
2.Wood
3.Plastic
Whichofthesematerialscanbeusedaspatternin
investmentcastingprocess?
(a)1,2and3
(b)1and2only
(c)2and3only
(d)1and3only
(d) There is nothing like investment casting
IES 2010
IES2010
( ) The investment casting
g is used for
Assertion (A):
precision parts such as turbine plates, sewing
machines etc.
Reason (R): The investment castings have a good
surface finish and are exact reproductions of the
master pattern.
(b) Both
B th A and
i di id ll true
t
b t R is
but
i NOT the
th
IAS1996
Light and intricate parts with close dimensional
tolerances of the order of 0.005 mm are
produced by
(a) Investment casting
g
(b) Die casting
(c) Centrifugal casting
(d) Shell mould casting
IES 2007
IES2007
Consider the following statements in respect of
investment castings:
1. The pattern or patterns is/are not joined to a stalk or
sprue also of wax to form a tree of patterns.
2.The prepared moulds are placed in an oven and heated
gently to dry off the invest and melt out the bulk of wax.
3.The moulds are usually poured by placing the moulds in
a vacuum chamber. Which of the statements given above
are correct?
(a) 1 and 2 only
(b) 1 and 3 only
(c)2 and 3 onlyy
(d) 1, 2 and 3
IES2006
Which of the following materials are used for
making patterns in investment casting method?
1. Wax
2. Rubber 3. Wood
4. Plastic
(a) Only 1 and 3
(b) Only 2 and 3
( ) Only
(c)
O l 1, 2 and
d4
(d) Only
O l 2, 3 and
d4
PermanentMouldCasting
y The process in which we use a die to make the
castings is called permanent mold casting or gravity

die casting, since the metal enters the mold under
gravity.
gravity
y Some time in diecasting we inject the molten metal
with a high pressure.
pressure When we apply pressure in
injecting the metal it is called pressure die casting
process.
process
y Grey cast iron is used for mould material.
Page 25 of 240
Advantages
y Good surface finish and dimensional accuracy
y Metal
M l mold
ld gives
i
rapid
id cooling
li
and
d finegrain
fi
i
structure
y Multipleuse molds.
Rev.0
Disadvantages
y High initial mold cost
y Shape,
Shape size
size, and complexity are limited
y Mold life is very limited with highmeltingpoint
metals such as steel.

steel
y Low melting point metals can be cast
Aluminum
Zinc
Magnesium alloys
Brass
Cast iron
Applications
y Pistons/cylinders/rods
y Gears
y Kitchenware
DieCasting
y Molten metal is injected into closed metal dies under
Die casting machines can be

Diecastingmachinescanbe
IES 2013
IES2013
Statement (I): Mould walls of a permanent mould are

kept thick.
thick
Statement (II): The thicker mould walls retain
maximum
i
h
heat
i
increasing
i flow
fl off molten
l
metal.
l
(a) Both Statement (I) and Statement (II) are individually
true and Statement (II) is the correct explanation of
Statement (I)
(b) Both Statement (I) and Statement (II) are individually
p
of
true but Statement ((II)) is not the correct explanation
Statement (I)
(d) Statement (I) is false but Statement (II) is true
Hotchambermachinesare
y Good for low temperature (approx. 400C)
y Faster than
h cold
ld chamber
h b machines
h
pressures ranging from 100 to 150 MPa.

y Pressure is maintained during solidification
y Hotchamber
y After which the dies separate and the casting is ejected
y Coldchamber
along with its attached sprues and runners.

y Cores must be simple and retractable and take the
y Cycle times must be short to minimize metal
contamination
y Metal starts in a heated cylinder
y
y A piston forces metal into the die
y The piston retracts,
retracts and draws metal in
y Metal: Lead, Tin, Zinc
form of moving metal segments
Coldchambermachines
y Castshighmeltingpointmetals(>600C)
y Highpressuresused
y Metalisheatedinaseparatecrucible
l h
d
bl
y Metalisladledintoacoldchamber
y Themetalisrapidlyforcedintothemoldbeforeit
cools
For-2015
(IES, GATE & PSUs)
HotChamber
y Copper
Copper,BrassandAluminiumcancast.
BrassandAluminiumcancast
Page 26 of 240
Rev.0
Advantages
y Extremelysmoothsurfaces(1m)
Limitations
y Excellentdimensionalaccuracy
y Highinitialdiecost
y Rapidproductionrate
y Limitedtohighfluiditynonferrousmetals
y Bettermechanicalpropertiescomparedtosand
y Partsizeislimited
y Intricatepartspossible
y Minimumfinishingoperations
y Carburettors
y Automotive
A t
ti parts
t
y Bathroom fixtures
y Toys
y Porositymaybeaproblem
P
it
b
bl
casting
Applications
y Somescrapinsprues,runners,andflash,butthiscan
p
p
,
,
,
bedirectlyrecycled
Common metals
y Alloys
All
off aluminum,
l i
zinc,
i
magnesium,
i
and
d lead
l d
y Also possible with alloys of copper and tin
y Thinsectionspossible
IES2011
Consider the following advantages of die casting over
sand casting :
1 Rapidity of the process
1.
2. Smooth surface
3 Strong dense metal structure
3.
Which of these advantages are correct ?
( ) 1, 2 and
(a)
d3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 onlyy
IES2005
Which one of the following processes produces a
casting when pressure forces the molten metal
into the mould cavity?
(a) Shell moulding
g
(b) Investment casting
g
(c) Die casting
(d) Continuous casting
IES2009
Which of the following are the most suitable
materials for die casting?
(a) Zinc and its alloys
(b) Copper and its alloys
(c) Aluminium and its alloys
(d) Lead
L d and
d its
it alloys
ll
IES2006
In which of the following are metal moulds used?
(a) Greensand mould
(b) Dry sand mould
(c) Die casting process
(d) Loam moulding
Page 27 of 240
20 0
JWM2010
( ) : In die casting
g method,, small
Assertion (A)
thickness can be filled with liquid metal.
Reason (R) : The air in die cavity trapped inside the
casting causes problems.
(b) BothAandRareindividuallytruebutRisnot
B hA dR i di id ll
b Ri
the
h
((d)) AisfalsebutRistrue
IES1995
Assertion
(A):
alloy
is
A
i
(A) An
A aluminium
l
i i
ll with
i h 11 % silicon
ili
i
used for making engine pistons by die casting
technique.
technique
Reason (R): Aluminium has low density and addition
p
its fluidity
y and therefore its
of silicon improves
castability.
(a) Both A and R are individuallyy true and R is the correct
explanation of A
correct explanation
l
i off A
(d) A is false
f l but
b R is true
Rev.0
IES1995
MatchListIwithListIIandselectthecorrectanswertakingthehelp
ofcodesgivenbelowthelists:
ListI
ListII
(Products)
(Processofmanufacture)
A.
Automobilepistoninaluminium alloy
1.Pressurediecasting
B.
Enginecrankshaftinspheroidal
graphiteiron
hi i
2.Gravitydiecasting
G i di
i
C.
Carburettor housinginaluminium alloy 3.Sandcasting
D.
Casttitaniumblades
4.Precisioninvestment
casting
i
5.Shellmoulding
Code: A
B
C
D
A
B
C
D
(a) 2
3
1
5
(b)
3
2
1
5
(c) 2
1
3
4
(d)
4
1
2
3
IAS2007
1. Zincdiecastingshavelowstrength.
g
g
2. Inthediecastingprocess,verythinsectionsor
complexshapescanbeobtainedeasily.
Whichofthestatementsgivenaboveis/arecorrect?
( ) 1only
(a)
l
(b) 2only
(c) Both1and2
((d)) Neither1nor2
IES2011
Consider the following statements :
1. Hot chamber machine is used for casting zinc, tin and
other
th low
l melting
lti alloys.
ll
2. Cold chamber machine is used for die casting of
ferrous alloys
33. Rapid
p
cooling
g rate in die casting
g p
produces high
g
strength and quality in many alloys.
Which of these statements are correct?
(a) 1, 2 and 3
(b) 1 and 2 only
( ) 2 and
(c)
d 3 only
l
(d) 1 and
d 3 only
l
( )
GATE2009(PI)
Hot chamber die casting process is NOT suited for
(a) Lead and its alloy
(b) Zinc and its alloy
( ) Tin
(c)
Ti and
d its
it alloy
ll
((d)) Aluminum and its alloyy
GATE2007
Which of the following engineering materials is
th mostt suitable
the
it bl candidate
did t for
f hot
h t chamber
h b die
di
casting?
( ) Low carbon
(a)
b steell
(b) Titanium
(c) Copper
(d) Tin
Assertion
off good
A
i (A):
(A) Die
Di casting
i yields
i ld a product
d
d
accuracy and finish.
R
Reason
(R) Low
(R):
L
melting
li
alloys
ll
used
d in
i die
di
casting.
( ) Both
(a)
B h A and
i di id ll true and
d R is
i the
h
(b) Both
B h A and
i di id ll true but
b R is
i not the
h
( ) A is
(c)
i true but
b R is
i false
f l
IES1995
Assertion
(A):
alloys
are cast in
A
i
(A) Aluminium
Al
i i
ll
i hot
h
chamber die casting machine.
Reason (R): Aluminium alloys require high melting
when compared to zinc alloys.
explanation of A
((c)) A is true but R is false
Centrifugal Casting
CentrifugalCasting
g sand,
y Process: Molten metal is introduced into a rotating
metal, or graphite mould, and held against the mould
wall by centrifugal force until it is solidified
y A mold is set up and rotated along a vertical (rpm is
reasonable), or horizontal (2001000 rpm is reasonable)

axis.
y The
Th mold
ld is
i coated
d with
i h a refractory
f
coating.
i
y During cooling lower density impurities will tend to rise
IAS1996
28 of 240
towards the center ofPage
rotation.
Fi T
Fig.Truecentrifugalcasting
if
l
i
Rev.0
P
Properties
ti
y The mechanical properties of centrifugally cast jobs are
better compared to other processes, because the inclusions

such as slag and oxides get segregated towards the centre
and can be easily removed by machining. Also, the
pressure acting
p
g on the metal throughout
g
the solidification
causes the porosity to be eliminated giving rise to dense
metal.
y No cores are required for making concentric holes in the
case of true centrifugal casting.
l
Commonmetals
y
y
y
y
Iron
steel
stainlesssteel
t i l t l
alloysofaluminium,copper,andnickel
( )
GATE2008(PI)
In hollow cylindrical parts, made by centrifugal casting,
the density of the part is
( ) maximum
(a)
i
at the
h outer region
i
(b) maximum at the inner region
((c)) maximum at the midpoint
p
between outer and inner
surfaces
(d) uniform throughout
Li it ti
Limitations
Advantages
y Fine
att the
off the
Fi grained
i d structure
t t
th outer
t surface
f
th
casting free of gas and shrinkage cavities and

porosity
it
y Formation of hollow interiors in cylinders without
cores
y Can p
produce a wide range
g of cylindrical
y
parts,
p
including ones of large size.
y Good dimensional accuracy, soundness, and
cleanliness
y There is no need for gates and runners,
runners which
increases the casting yield, reaching almost 100 %.
y More segregation of alloy component during pouring under
the forces of rotation

y Contamination of internal surface of castings with non
metallic
lli inclusions
i l i
y Inaccurate internal diameter
y Shape is limited.
y Spinning equipment can be expensive
y Poor machinability
GATE1993
GATE2002
In centrifugal casting, the impurities are
( ) Uniformly
(a)
f
l distributed
d
b d
(b) Forced towards the outer surface
(c) Trapped near the mean radius of the casting
(d) Collected at the centre of the casting
Centrifugally cast products have

(a) Large
g g
grain structure with high
g p
porosityy
(b) Fine grain structure with high density
(c) Fine grain structure with low density
(d) Segregation of slug towards the outer skin of the
casting
ti
IES2008
Which of the following casting processes does not
/do not require central core for producing pipe?
1 Sand casting process
1.
2. Die casting process
3 Centrifugal casting process
3.
Select the correct answer using the code given below:
( ) 1 and
(a)
d2
(b) 2 only
(c) 2 and 3
(d) 3 onlyy
Page 29 of 240
IES2009
Which one of the following casting processes is
b t
best
suited
it d
t
to
make
k
bi
bigger
size
i
symmetrical
y
pipes?
p
p
(a) Die casting
(b) Investment casting
(c) Shell moulding
(d) Centrifugal casting
Rev.0
h ll
hollow
IES2007
Which one of the following is the correct
statement?
In a centrifugal casting method
(a) No core is used
(b) Core may be made of any metal
( ) Core
(c)
C
i made
is
d off sand
d
(d) Core is made of ferrous metal
IES2007
MatchListIwithListIIandselectthecorrectanswerusingthecodegiven
belowtheLists:
ListI
ListII
(CastingProcess)
(Principle)
A.
Diecasting
1.Themetalsolidifiesinarotatingmould
B.
Investmentcasting
2.Thepatternclusterisrepeatedlydipped
intoaceramicslurryanddustedwith
refractory
f
C.
Shellmoulding
3.Moltenmetalisforcedbypressureinto
ametallicmould
D
D.
Centrifugalcasting
4 Aftercooling theinvestisremoved
4.Aftercooling,theinvestisremoved
fromthe Castingbypressurejettingor
vibratorycleaning
Code: A
B
C
D
A
B
C
D
(a) 2
1
3
4
(b)
3
4
2
1
(c) 2
4
3
1
(c)
3
1
2
4
IES1998
Poormachinability ofcentrifugallycastironpipe
isdueto
(a) Chilling
(b) Segregation
(c) Densestructure
(d) Highmouldrotationspeed
Hi h
ld t ti
d
MatchListI(Process)withListII(Products/materials)
M t hLi tI(P
) ithLi tII(P d t / t i l )
andselectthecorrectanswerusingthecodesgiven
belowtheLists:
ListI
ListII
A. Diecasting
1.Phenolformaldehyde
B. Shellmolding
2.C.I.pipes
C. CO2 molding
3.Nonferrousalloys
D Centrifugalcasting
D.
C
if
l
i
4.Sodiumsilicate
S di ili
Codes:A
B
C
D
A
B
C
D
(a) 1
3
4
2
(b) 3
1
4
2
(c) 3
1
2
4
(d) 1
3
2
4
IAS2004
MatchListI(NameoftheProcess)withListII(Advantage)andselectthecorrect
List I
ListI
List II
ListII
(NameoftheProcess)
(Advantage)
A.
SandCasting
1.Largecylindricalpartswithgoodquality
B
B.
C
Ceramicmoldcasting
i ld ti
2.Excellentdimensionalaccuracyandsurface
E ll tdi
i
l
d f
finish
C.
Diecasting
3.Intricateshapesandclosetoleranceparts
D
D.
C
Centrifugalcasting
if
l
i
4.Almostanymetaliscastandthereifnolimitto
Al

li
d h if li i
size,shapeandweight
5.Gooddimensionalaccuracy,finishandlow
porosity
Codes:A
B
C
D
A
B
C
(a)
2
3
5
1
(b)
4
1
2
D
3
(c)
(d)
IAS2003
Assertion
(A):
Semicentrifugal
process is
A
i
(A) S
i
if
l casting
i
i
similar to true centrifugal casting except that the
central core is used in it to form inner surface.
surface
Reason (R): In semicentrifugal casting process the
p is always
y vertical
axis of spin
p
of A
explanation
y Centrifugal force assists the flow of metal from a
central
t l reservoir
i to
t the
th extremities
t
iti
off a rotating
t ti
symmetrical
y
mold,, which mayy be either expendable
p
or
multipleuse
y Rotational speeds are lower than for true centrifugal
casting
product.
Which of the following are the most likely

characteristics in centrifugal casting?
(a) Fine grain size and high porosity
(b) Coarse grain size and high porosity
(c) Fine grain size and high density
(d) Coarse
C
grain
i size
i and
d high
hi h density
d it
IES2000
SemicentrifugalCasting
y Cores can be used to increase the complexity of the

IES2009
Page 30 of 240
Fig. Semicentrifugalcasting
Rev.0
IES2013
Statement (I): In semi centrifugal casting a particular

p of the casting
g is p
produced byy mould, core and the
shape
centrifugal force of molten metal.
Statement (II): The centrifugal force aids to proper
feeding to produce the casting free from porosity.
Statement (I)
t
true
b t Statement
but
St t
t (II) is
i nott the
th correctt explanation
l
ti off
Statement (I)
( ) Statement (I)
(c)
( ) is true but
b Statement (II)
( ) is false
f l
Centrifuging
y Uses centrifuging action to force the metal from a central
pouring reservoir into separate mold cavities that are

offset from the axis of rotation.
y Low speed
y May used to assist in the pouring of investment casting
trees.
Fig.Methodofcastingbythecentrifugingprocess
IES2000
MatchListI(Typeofcasting)withListII(Workingprinciples)
M t hLi tI(T
f ti ) ithLi tII(W ki i i l )
andselectthecorrectanswerusingthecodesgivenbelowthe
Lists:
Li tI
ListI
Li tII
ListII
A. Diecasting
1.Moltenmetalisforcedintothedie
underpressure
B. Centrifugalcasting
2.Axisofrotationdoesnotcoincidewith
axisofmould
C. Centrifuging
g g
33.Metalsolidifieswhenmouldisrotating
g
D. Continuouscasting 4.Continuouslypouringmoltenmetal
intomould
Codes: A
B
C
D
A
B
C
D
(a) 1
3
2
4
(b)
4
3
2
1
(c) 1
2
3
4
(d)
4
2
3
1
IAS2004
Which of the following are produced by slush
casting?
(a) Hollow castings with thick walls
(b) Hollow castings with thin walls
(c) Thin castings
(d) Thick
Thi k castings
ti
DrySandMolding
SlushCasting
y To reduce gas forming materials air dried mould used.
y Slush casting is a variation of the permanent mold process
Types:
1 Skin drying and
1.Skin
2.Complete mold drying
IES2011
The method of casting for producing ornamental pieces
are:
( ) Slush
(a)
Sl h and
d gravity
it casting
ti
(b) Pressed and slush casting
(c) Gravity and semi permanent mould casting
(d) Semi permanent mould and pressed casting
Page 31 of 240
in which the metal is permitted to remain in the mold only

until a shell of the desired thickness has formed.
y The mold is then inverted and the remaining liquid is
poured out.
y When the mold halves are separated, the resulting casting
is a hollow shape with good surface detail but variable wall
thickness.
y Frequently used to cast lowmeltingtemperature metals
into ornamental objects such as candlesticks, lamp bases,
and
d statuary.
IES 2012
IES
The process of making hollow castings of non
circular
noncircular
shape and desired thickness by permanent mould
without the use of cores is known as
(a) Die casting
(b) Slush casting
( ) Pressed
(c)
P
d casting
ti
(d) Centrifugal
C t if
l casting
ti
Rev.0
SqueezeCasting
IAS2002
Si l C
SingleCrystalCasting
lC i
Process:
1. Molten metal is p
poured into an open
p face die.
2. A punch is advanced into the die, and to the metal.
3 Pressure (less than forging) is applied to the punch
3.Pressure
and die while the part solidifies.
4.The
Th punch
h is
i retracted,
t t d and
d the
th partt is
i knocked
k
k d outt
with an ejector pin.
y Overcomes problems
bl
with
h feeding
f d
the
h die,
d
and
d
produces near net, highly detailed parts.
MatchListI(CastingProcess)withListII
M t hLi tI(C ti P
) ithLi tII
(Applications)andselectthecorrectanswerusingthe
codesgivenbelowtheLists:
g
ListI
ListII
(CastingProcess)
(Applications)
A. Centrifugalcasting
1.
Carburetor
B. Squeezecasting
2.
Pipes
C DieCasting
C.
Di C i
3.
Wh l f
Wheelsfor
automobiles
4
4.
Gearhousings
Codes:A
B
C
A
B
C
(a) 2
3
1
(b) 4
1
3
(c) 2
1
3
(d) 4
3
1
The process is effectively:

1. Prepare a mold so that one end is a heated oven, and
the other end chilled.
chilled The part should be oriented so
that the cooling happens over the longest distance.
2. Cast
C t metal
t l into
i t the
th mold
ld
3. Solidification will begin at the chill plate. These
dendrites will grow towards the heated end of the
part as long dendritic crystals. The part is slowly
pulled out of the oven, past the chill plate.
4. Remove the solidified p
4
part.
IES2009
l
i
PlasterCasting
y Process: A slurry of plaster,
plaster water,
water and various additives is
y Creepandthermalshockresistanceproperties.
2marks
PitMoulding
IES1996
y This method is used for very large castings and is done on
Whichofthefollowingpairsarecorrectlymatched?
1. Pitmoulding
g ..................Forlargejobs.
g j
2. Investmentmoulding ...Lostwaxprocess.
3 PlastermouldingMouldpreparedin
3.
Plastermoulding
Mouldpreparedin
gypsum.
( ) 1,2and3
(a)
d
(b) 1and2
d
(c) 1and3
(d) 2and3
the foundry floor.
additives is pouted over a pattern and allowed to set. The

pattern is removed and the mould is baked to remove
excess water. After pouring and solidification, the mould is
broken and the casting
g is removed.
y Advantage: High dimensional accuracy and smooth
surface finish,, thin sections and intricate detail can
produce.
y Limitations: Lowertemperature
p
nonferrous metals only:
y
y Common metals: Primarily aluminium and copper
LoamMoulding
y Moulding
g loam is g
generallyy artificiallyy composed
p
of
common brickclay, and sharp sand.

y Loam means mud.
y Loam Moulding is restricted to forms which cannot be
cast conveniently in any other process.

process
y It is costly.
y
Page 32 of 240
Rev.0
IES1997
Which one of the following pairs is not correctly
matched?
(a) Aluminium alloy piston Pressure die casting
(b) Jewellery.. Lost wax process
(c) Large pipes ..Centrifugal casting
(d) Large
L
b ll Loam
bells
L
moulding
ldi
GATE1998
ListI
Li tI
(A) Sandcasting
circularshapesonly
(B) Plastermouldcasting
skinsandsoftinterior
(C) Shellmouldcasting
castingprocessing
(D) Investmentcasting
ListII
Li tII
(1)
Symmetricaland
(2)
Partshavehardened
(3)
Minimumpost
(4)
Partshaveatendency
towarp
Partshavesoftskin
andhardinterior
Suitableonlyfornon
f
ferrousmetals
t l
(5)
(6)
GATE1996
IES2003
ListI
ListII
(A) Rivetsforaircraftbody
y 1.
Forging
g g
(B) Carburettor body
2.
Coldheading
(C) Crankshafts
3
3.
Aluminiumbased
alloy
(D) Nails
N il
4.
P
Pressurediecasting
di ti
5.
Investmentcasting
MatchListI(Products)withListII(CastingProcess)andselect
M t hLi tI(P d t ) ithLi tII(C ti P
) d l t
thecorrectanswerusingthecodesgivenbelowtheLists:
ListI
ListII
(Products)
(CastingProcess)
A. Hollowstatues
1.
CentrifugalCasting
B
B.
Dentures
2
2.
InvestmentCasting
C. Aluminium alloypistons
3.
SlushCasting
D. Rockerarms
4.
ShellMoulding
5.
G i Di C i
GravityDieCasting
Codes: A
B
C
D
A
B
C
D
((a)
) 33
2
4
4
5
((b)
)
1
33
4
4
5
(c) 1
2
3
4
(d)
3
2
5
4
IAS2004
GATE 2007(PI)
2007 (PI)
GATE
MatchListI(NameoftheCastingProcess)withListII(ProcessDefinition)andselect
M hLi I(N
f h C i P
) i hLi II(P
D fi i i ) d l
thecorrectanswerusingthecodesgivenbelowthelists:
ListI
ListII
(NameoftheCastin Process)
(NameoftheCastingProcess)
(ProcessDefinition)
A.
Diecasting
1.Thisprocessinvolvesuseofamouldmadeof
Driedsilicasandandphenolic resinmixture
B
B.
El t l casting
Electroslag
ti
2.Inthisprocess,moltenmetalisforcedby
I thi
lt t li f
db
Pressureintoametalmould
C.
Centrifugalcasting
3.Thisprocessemploysaconsumableelectrode
D
D.
P i i
Precisioncasting
i
4.Thisprocessinvolvesrotatingamouldwhilethe
Thi
i
l
i
ld hil h
metalsolidifies
5.Thisprocessproducesverysmooth,highly
Accuratecastingsfrombothferrousandnon
ferrousalloys
Codes:A
B
C
D
A
B
C
D
(a)
5
4
1
2
(b)
2
3
4
5
(c)
5
3
4
2
(d)
2
4
1
5
GATE1992
Matchthefollowingmoulding/castingprocesseswith
M h h f ll i
ldi /
i
i h
theproduct:
Moulding/Castingprocesses
Product
(A) Slushcasting
(P)Turbineblade
(B) Shellmoulding
(Q)Machinetoolbed
(C) Drysandmoulding
(R)Cylinderblock
(D) Centrifugalcasting
C t if
l ti
(S)H ll ti
(S)Hollowcastings
likelampshades
(T)Rainwaterpipe
(U)Castironshoe
brake
IES1993
MatchtheitemsofListI(Equipment)withtheitems
M h h i
fLi I(E i
) i h h i
ofListII(Process)andselectthecorrectanswerusing
thegivencodes.
thegivencodes
ListI(Equipment)
ListII(Process)
P HotChamberMachine 1.
1
Cleaning
Q Muller
2.
Coremaking
R DielectricBaker
3
3.
Diecasting
S SandBlaster
4.
Annealing
5
5.
Sandmixing
(a) P2,Q1,R4,S5
(b) P4,Q2,R3,S5
(c) P4,Q5,R1,S2
P 4 Q 5 R 1 S 2
(d) P3,Q5,R2,S1
P 3 Q 5 R 2 S 1
Match the lists
Group1
P.SandCasting
Q CentrifugalCasting
Q.CentrifugalCasting
R.InvestmentCasting
S.DieCasting
Group2
1.Turbineblades
2 ICEnginePistons
2.ICEnginePistons
3.Largebells
4.Pulleys
(a) P 4, Q 1, R 3, S 2
((c)) P 3, Q 4, R 1,, S 2
(b) P 2, Q 4, R 3, S 1
( ) P 3, Q 2,, R 1,, S 4
(d)
Page 33 of 240
BySKMondal
Rev.0
WeldingDefinition
y Welding is a process by which two materials, usually
metals, are permanently joined together by

coalescence, which is induced by a combination of
temperature, pressure, and metallurgical conditions.
y The particular combination of these variables can
g from high
g temperature with no pressure to high
g
range
pressure with no increase in temperature.
Cl ifi ti
Classificationofweldingprocesses
f ldi
Requirementforahighqualitywelding
Oxy fuel gas welding (OFW)

Arc
A welding
ldi (Aw)
(A )
1. A source of satisfactory heat and/or pressure,
Resistance welding
Solid
l d state welding
ld
(f
(friction
welding,
ld
ultrasonic
l
welding,
ld
2. A means of protecting or cleaning the metal, and

3 Caution to avoid,
3.
avoid or compensate for,
for harmful
forge welding etc.)
y Unique process
metallurgical
g
effects.
Thermit welding
g
Laser beam welding
y Welding (positive process)
Electroslag
g welding
g
Flash welding
y Machining (negative process)
Induction welding
y Forming, casting (zero process)
Electron beam welding
IES 2012
IES
Weldability /FabricationProcesses
CaseofAluminium
The advantage of the welding process is

(a) It relieves the joint from residual stresses
(b) It helps
h l in
i checking
h ki off distortion
di t ti off work
k piece
i
(c) Large number of metals and alloys, both similar and/or
dissimilar can be joined.
((d)) Heat p
produced during
g the welding
g does not p
produce
metallurgical changes.
y The
Th weldability
ld bilit off a material
t i l will
ill depend
d
d on the
th
y The
on aluminum
alloys
causes some
Th oxide
id coating
ti
l i
ll
specific welding or joining process being considered.

y For resistance welding of consistent quality, it is
usually necessary to remove the oxide immediately
before welding.
y Fabrication weldability
y test is used to determine
mechanical properties required for satisfactory
performance of welded jjoint.
p
y The correct sequence of the given materials in
ascending order of their weldability is
Aluminum < copper < cast iron < MS
Contd
difficulty in relation to its weldability.

y It also
l has
h high
hi h thermal
th
l conductivity
d ti it and
d a very short
h t
y
y
y
y
temperature range between liquidus and solidus and when

liquid its viscosity is very low.
low
Aluminium is poor absorber of laser light.
D i
During
f i
fusion
welding,
ldi
the
h aluminum
l i
would
ld oxidize
idi so
readily that special fluxes or protective inertgas
atmospheres must be employed.
employed
Friction welding and TIG welding is good for aluminium.
For aluminium
l
AC current plus
l high
h h frequency
f
is must.
CaseofCastIron
CaseofStainlessSteel
CaseofStainlessSteel
y Cast iron is more difficult to weld because of its high
y Stainless steel is a difficult metal to weld because it
y The ferritic stainless steels are generally less weldable
carbon content and brittleness (poor ductility)

y Massive carbon deposits have a tendency to form in
the areas adjacent to the weld, and highcarbon
martensite tends to form in the heat
heataffected
affected zones.
zones
These microstructures are very brittle and may crack
p
y while welding
g is in p
progress
g
or later
spontaneously
when load is applied to the workpiece.
y Cast iron can be jjoined by
y the oxyacetylene
y
y
brazing
g
process and shielded metalarc welding (stick)
process.
y Some cases preheating and/or post heating is required.
contains both nickel and chromium.

y The best method for welding stainless steel is TIG
welding.
y The electric arc is also preferred for welding stainless
steels. A heavily coated welding rod, which produce a
shielded arc,
arc is employed.
employed
y You must do a better job of precleaning.
y Using a low arc current setting with faster travel
speeds is important when welding stainless steel,
because some stainless steels are subject to carbide
precipitation.
Page 34 of 240
than the austenitic stainless steel and require both

preheating and postweld heat treatments.
treatments
y Welds of ferritic stainless steel can be by
Contd..
(i) autogenously (i.e.

(i e without the addition of filler
metal)
(ii) with an austenitic stainless steel
(iii) using a high nickel filler alloy.
(iv) Type 405 filler (low 11% Cr,
Cr low carbon and small
0.2% Al)
y Welding process:
TIG, MIG, Shielded

Shieldedmetal
metal arc
welding and Plasma arc welding
Rev.0
IES 2010
IES2010
( ) It is generally
g
y difficult to weld
Assertion (A):
Aluminum parts by normal arc welding process.
Reason (R): Hard and brittle Aluminum
Aluminumoxide
oxide film
is formed at the welded joints.
(b) Both
B h A and
i di id ll true but
b R is
i NOT the
h
((d)) A is false but R is true
IES2011
During plasma arc welding of aluminium,
aluminium improved
removal of the surface oxide from the base metal is
obtained with typical polarity of :
(a) DC Straight
(b) DC reverse
(c) AC potential
p
(d) Reverse polarity of phase of AC potential
IES1999
Thecorrectsequenceofthegivenmaterialsin
g
is
ascendingorderoftheirweldability
(a) MS,copper,castiron,aluminium
(b) Castiron,MS,aluminium
Castiron MS aluminium copper
(c) Copper,castiron,MS,aluminium
(d) Aluminium,copper,castiron,MS
Al i i
i
S
IES2006
Assertion(A):Aluminium
haspoorweldability.
( )
Reason(R):Aluminium hashighthermal
g
conductivityandhighaffinitytooxygen.
( ) AistruebutRisfalse
(c)
Ai t b tRi f l
IES2011
Considerthefollowingstatements.
Considerthefollowingstatements
Castironisdifficulttoweld,becauseof
1.Lowductility
L d tilit
2.Poorfusion
3.Tendencytocrackoncooling
Whichofthesestatementsarecorrect?
(a)1,2and3
(b)1and2only
(c)2and3only
(d)1and3only
IES 2010
IES2010
Weldability of ferritic stainless steel used in
automotive exhaust system is improved by
selecting stainless steel electrode having low
content of
(a) Carbon
(b) Nitrogen
(c) Chromium
(d) Carbon and Nitrogen
Page 35 of 240
GATE2014
The major difficulty during welding of aluminium is
due to its
(a) high tendency of oxidation
(b) high thermal conductivity
(c) low melting point
(d) low
l density
d it
IES2006
Fabricationweldability testisusedtodetermine
(a) Mechanicalpropertiesrequiredforsatisfactory
ec a ca p ope t es equ ed o sat s acto y
performanceofweldedjoint
(b) Susceptibilityofweldedjointforcracking
(c) Suitabilityforjointdesign
(d) Appropriatemachiningprocess
A
i
hi i
IES 2010
IES2010
g statements regarding
g
g
Consider the following
welded joints:
1 It is a permanent type of joint.
1.
joint
2. It is reliable and economical for pressure vessel
construction.
construction
3. It is free from fabricational residual stresses.
4. Such joints are suitable for static loading only.
55. Welding
g is a versatile and flexible metal jjoining
gp
process.
Which of the above statements are correct?
(a) 1,
1 2 and 3 only
(b) 2,
2 3 and 4 only
Rev.0
(c) 1, 2, 3, 4 and 5
(d) 1, 2 and 5 only
IES 2012
IES
Whichofthefollowingfactorsimproveweldabilityof
steel?
1 Lowcarboncontent
1.Lowcarboncontent
2.Highcarboncontent
3.Goodaffinitycontent
4
4.Pooraffinitytooxygen
y
yg
(a)1and3
(b)2and3
(c)1and4
(d)2and4
IES 2013
IES2013
Weldability dependson
GasFlameProcesses:
Welding Cutting and Straightening
Welding,CuttingandStraightening
y Oxyfuel gas Welding (OFW): Heat source is the
1.Thermalconductivityy
flame produced
fl
d d by
b the
h combustion
b i off a fuel
f l gas and
d
oxygen.
2.Surfacecondition
3.Changeinmicrostructure
y OFW has largely

g y been replaced
p
byy other p
processes but
(a)1and2only
(b)1and3only
(c)2and3only
(d)1,2and3
it is still popular because of its portability and the low

p
investment.
capital
y Acetylene is the principal fuel gas employed.
employed
y Combustionofoxygenandacetylene(C2H2)ina
Three types of flames can be obtained by varying

the oxygen/acetylene (or oxygen/fuel gas) ratio.
y If the ratio is about 1 : 1 to 1.15 : 1, all reactions are
carried to completion and a neutral flame is produced.
produced
y Most welding is done with a neutral flame. It is
chemically
h i ll neutral
t l and
d neither
ith oxidizes
idi
or carburizes
b i
the metal being welded.
weldingtorchproducesatemp.inatwostagereaction.
y Inthefirststage
C2 H2 + O2 2CO + H2
+Heat
H t
Thisreactionoccursnearthetipofthetorch.
y InthesecondstagecombustionoftheCOandH2 and
occursjustbeyondthefirstcombustionzone.
2CO+O2 2CO2+Heat
1
H2 +O
2 2 H2O+Heat
Oxygenforsecondaryreactionsisobtainedfromthe
atmosphere
atmosphere.
Oxyacetylenegasweldingneutralflame
y A higher ratio, such as 1.5 : 1, produces an oxidizing
flame,
flame hotter than the neutral flame (about 3300oC)
but similar in appearance.
y Used when
hen welding
elding copper and copper alloys
allo s but
harmful when welding steel because the excess oxygen
reacts with the carbon,
carbon decarburizing the region
around the weld.
OxyacetylenegasweldingOxidisingflame
y Excess fuel, on the other hand, produces a carburizing
flame. Carburizing flame can carburize metal also.

y The excess fuel decomposes to carbon and hydrogen,
p
is not as g
great ((about
and the flame temperature
3000oC).
y Flames of this type are used in welding Monel (a
nickelcopper alloy), highcarbon steels, and some
alloy steels, and for applying some types of hard
hardfacing
facing
material.
Page 36 of 240
OxyacetylenegasweldingCarburizingflame
Metal
MS
High carbon steel
Grey cast iron
Alloy steel
Aluminium
Brass
Copper, Bronze
Nickel alloys
y
Lead
Flame
N
R
N, slightly oxidizing
N
Slightly carburizing
Slightly oxidizing
N, slightly oxidizing
Slightly
g y carburizing
g
N
Rev.0
U
Uses,Advantages,andLimitations
Ad t
d Li it ti
y OFW is fusion welding.
welding
Diagram
y Exposer of the heated and molten metal to the various
y No pressure is involved.
gases in the flame and atmosphere makes it difficult to
y Filler
Fill metal
t l can be
b added
dd d in
i the
th form
f
off a wire
i or rod.
d
prevent contamination.
contamination
y Fluxes may be used to clean the surfaces and remove
contaminating oxide. The gaseous shield produced by

vaporizing flux can prevent oxidation during welding,
and the slag produced by solidifying flux can protect
the weld pool. Flux can be added as a powder, the
welding rod can be dipped in a flux paste, or the rods
can be precoated.
y Heat source is not concentrated, a large area of the
metal is heated and distortion is likely to occur.

y Flame welding is still quite common in field work, in
maintenance and repairs, and in fabricating small

quantities of specialized products.
products
Contd
Oxyacetyleneweldingequipment
y Oxygen is stored in a cylinder at a pressure ranging
from 13.8 MPa to 18.2 MPa .

y Due to high explosiveness of free acetylene it is stored
y
with 8085% p
porous calcium silicate and
in a cylinder
then filled with acetone which absorb upto 420 times
by its volume at a pressure 1.75 MPa .
y At the time of acetylene release if acetone comes with
acetylene
ace
y e e thee flame
a e would
ou d g
givee a pu
purple
p e co
colour.
ou .
y Another option is acetylene generator.
PressureGasWeldingg
y Pressure gas welding (PGW) or Oxyacetylene
Pressure Welding is a process used to make butt

joints between the ends of objects such as pipe
aandrailroad
d a oad rail.
a .
y The ends are heated with a gas flame to a
p
below the melting
gp
point,, and the soft
temperature
metal is then forced together under considerable
pressure.
y This process, therefore, is actually a 'form of solid
state welding.
IES 2010
IES2010
The ratio between Oxygen and Acetylene
gases for neutral flame in gas welding is
( )2:1
(a)
(b) 1 : 2
((c)) 1 : 1
((d)) 4 : 1
CaC2 + 2 H 2O C2 H 2 + Ca (OH ) 2
GATE1994
The ratio of
acetylene to
oxygen
is
approximately
approximately.
for a neutral flames used in
gas welding.
( ) 1:1
(a)
(b) 1 : 2
(c) 1 : 3
(d) 1.5
15:1
GATE2003
InOxyacetylenegaswelding,temperatureatthe
innerconeoftheflameisaround
(a) 3500C
(b) 3200
3200C
C
(c) 2900C
(d) 2550C
C
Page 37 of 240
IES 2010
IES2010
) Oxidizing
g flame is used in gas
g
Assertion ((A):
welding to join medium carbon steels having high
gp
point.
melting
Reason (R): In gas welding, oxidizing flame
produces the maximum temperature compared to
neutral and reducing flame.
(b) Both
B th A and
i di id ll true
t
b t R is
but
i NOT the
th
Rev.0
IES2009
GATE2002
The temperature of a carburising flame in gas
welding is that of a neutral or an oxidising flame.
(a) Lowerthan
(b) Higherthan
(c) Equalto
(d) Unrelatedto
U l t dt
IAS1994
IES1998
By which one of the following methods gray cast

iron is usually welded?
(a) TIGwelding
(b) MIGwelding
(c) Gaswelding
(d) Arcwelding
IES 2012
IES
IAS1995
In gas welding of mild steel using an oxy

acetylene flame. the total amount of acetylene
consumed was 10 litre. The oxygen consumption
from the cylinder is
(a) 5litre
(b) 10litre
(c) 15litre
(d) 20litre
li
OxygenTorchCutting(GasCutting)
y Iron and steel oxidize (burn)
(
) when heated to a
temperature between 8000C to 10000C.

y Highpressure oxygen jet (300 KPa) is directed against
plate, the oxygen
yg jjet burns the metal and
a heated steel p
blows it away causing the cut (kerf).
y For
o cutt
cutting
g metallic
eta c p
plates
ates sshears
ea s aaree used. These
ese aaree
useful for straightline cuts and also for cuts up to 40
c ess.
mm thickness.
Assertion (A):
( ) If neutral flame is used in oxy
acetylene welding, both oxygen and acetylene
cylinders of same capacity will be emptied at the same
time.
Reason (R): Neutral flame uses equal amounts of
oxygen and
d acetylene.
l
(a) BothAandRareindividuallytrueandRisthecorrect
explanationofA
Contd
) In g
g the metal to be jjoined g
Statement ((I):
gas welding
gets
oxidized or carburized
) The neutral flame affects no chemical
Statement ((II):
change on the molten metal.
y For thicker plates with specified contour, shearing
y Larger size orifice produces kerf width wider and larger
cannot be used and oxyfuel gas cutting (OFC) is

useful.
y Gascutting
Gas cutting is similar to gas welding
elding except
e cept torch tip.
tip
oxygen consumed.
y At kindling temperature (about 870oC), iron form iron
oxide.
oxide
y Reaction:
3Fe + 2O2 Fe3O4 +6.67
+6 67 MJ/kg of iron
The other reactions:
2Fe + O2 2FeO + 3.18 MJ/kg
k off iron
4Fe + 3O2 2Fe2O3 + 4.9 MJ/kg of iron
y All exothermic reactions preheat the steel.
Fig differencesintorchtipsforgasweldingandgascutting
In oxyacetylene gas welding, for complete

g
required per
combustion, the volume of oxygen
unit of acetylene is
((a)) 1
(b) 1.5
(c) 2
(d) 2.5
Page 38 of 240
Contd
Rev.0
Contd
y For complete oxidation 0.287 m3 oxygen/kg of iron is
required
i d
y Due to unoxidized metal blown away the actual
requirement is much less.
y Torch tip
p held verticallyy or slightly
g y inclined in the
direction of travel.
y Torch position is about 1.5
1 5 to 3 mm vertical from plate.
plate
y The drag lines shows the characteristics of the movement
y If torch moved too rapidly, the bottom does not get
sufficient heat and produces large drag so very rough

and irregularshapedcut edges.
y If torch moved slowly a large amount of slag is
generated and produces irregular cut.
of the oxygen stream.
Fig positioningofcuttingtorchinoxy fuelgascutting
y Drag
g is the amount byy which the lower edge
g of the drag
g
line trails from the top edge.

y Good cut means negligible
g g
drag.
g
Contd
Contd
y Gas cutting is more useful with thick plates.
Contd
Application
IAS2011Main
y For thin sheets (less than 3 mm thick) tip size should
Draw a self explanatory sketch of oxyacetylene gas
be small. If small tips are not available then the tip is

inclined at an angle of 15 to 20 degrees.
cutting torch. Briefly explain how cutting is

effected.
[ M k ]
[20Marks]
y Useful only for materials which readily get oxidized
and
d the
th oxides
id have
h
l
lower
melting
lti
points
i t than
th
th
the
metals.
y Widely used for ferrous materials.
y Cannot be used for aluminum, bronze, stainless steel
and like metals since they resist oxidation.

Fig.Recommendedtorchpositionforcuttingthinsteel
Difficulties
y For high carbon steel material around the cut should
y Metal
temperature goes beyond lower critical

temperature and structural transformations occur.
y Final microstructure depends on cooling rate.
be preheated (about 250 to 300oC) and may post heat

also necessary.
necessary
y Cutting CI is difficult, since its melting temp. is lower
y Steels
St l with
ith less
l
th 0.3 % carbon
than
b
cause no problem.
bl
than iron oxide.

y If chromium and nickel etc are present in ferrous
IES1992
The edge of a steel plate cut by oxygen cutting will
get hardened when the carbon content is
g
(a) Less than 0.1 percent
(b) Less than 0.3
0 3 percent
(c) More than 0.3 percent
(d) Anywhere
A
h
b
between
0.1 to 1.0 percent
alloys oxidation and cutting is difficult.

Contd
Page 39 of 240
Rev.0
IES2007
Considerthefollowingstatementsinrespectofoxy
acetylenewelding:
1
1.
Thejointisnotheatedtoastateoffusion
Thejointisnotheatedtoastateoffusion.
2. Nopressureisused.
3 Oxygenisstoredinsteelcylinderatapressureof14
3.
MPa.
4. Whenthereisanexcessofacetyleneused,thereisa
d id d h
decidedchangeintheappearance
i h
offlame.
Whichofthestatementsgivenabovearecorrect?
(a)1,2and3
(b) 2,3and4
(c) 1,3and4
1 3and4
(d) 1,2and4
1 2and4
IES2005
Ingaswelding,thetorchshouldbeheldatanangleof
30 to45 fromthehorizontalplane.
f
h h
l l
2. Ingaswelding,theSizeofthetorchdependsuponthe
thi k
thicknessofmetaltobeformed.
f t lt b f
d
3. Dragingascuttingisthetimedifferencebetween
heatingoftheplateandstartingtheoxygengasfor
cutting.
1.
(a) 1,2and3 (b) 1and2
(c) 2and3
(d) 1and3
IES2001
Oxyacetylenereducingflameisusedwhile
g
g
carryingouttheweldingon
(a) Mildsteel
(b) Highcarbonsteel
(c) Greycastiron
(d) Alloysteels
IES1992
Thick steel plate cut with oxygen normally shows
g of cracking.
g This tendency for cracking
g can
signs
be minimised by
((a)) Slow speed
p
cutting
g
(b) Cutting in two or more stages
(c) Preheating the plate
(d) Using oxyacetylene flame
d C i
PowderCutting
( )
GATE2009(PI)
g alloyy steels are

y Cast iron,, stainless steel,, and others high
difficult to cut by oxyfuel cutting and we can use powder
g
cutting.
y By injecting a finely divided 200mesh iron powder into
the flame, a lower melting point eutectic oxide is formed
at the cutting interface, where additional ironoxygen
reaction is generated and cutting proceeds in a similar
way of oxyfuel cutting.
y The heat and the fluxing action of the burning iron
powder enable the cutting oxygen stream to oxidize the
base metal continuously,
continuously just as in cutting carbon steel.
steel
Which of the following powders should be fed for

effective oxyfuel cutting of stainless steel?
(a) Steel
( ) Aluminum
(b)
(c) Copper
(d) Ceramic
El t i A W ldi
ElectricArcWelding
Pl
C tti
PlasmaCutting
p
y Uses ionized g
gas jjet (plasma)
to cut materials resistant to
y
y
y
y
y
oxyfuel cutting,
High
g velocityy electrons g
generated byy the arc impact
p
gas
g
molecules, and ionize them.
The ionized g
gas is forced through
g nozzle ((upto
p 5500 m/s),
/ ), and
the jet heats the metal, and blasts the molten metal away.
More economical,, more versatile and much faster (5 to 8
times) than oxyfuel cutting, produces narrow kerfs and
smooth surfaces.
HAZ is 1/3 to th than oxyfuel cutting.
Maximum plate thickness = 200 mm
ElectricArcWelding
Fi B i i
Fig.Basiccircuitforarcwelding
i f ldi
Page 40 of 240
Rev.0
PrincipleofArc
ISRO2011
y Work is negative and electrode is positive is reverse
y An arc is generated between cathode and anode when
th are touched
they
t
h d to
t establish
t bli h the
th flow
fl
off currentt and
d
then separated
p
byy a small distance.
polarity (RPDC).
Inarcwelding,penetrationisminimumfor
g p
y SPDC conditions are preferred.

y DC arcwelding
ldi maintain
i t i a stable
t bl arc and
d preferred
f
d for
f
y 65% to 75% heat is generated at the anode.
(b)DCRP
difficult tasks such as overhead welding.

g
y If DC is used and the work is positive (the anode of the
(a)DCSP
(c)AC
y For a stable arc, the gap should be maintained.
circuit), the condition is known as straight polarity
(d)DCEN
(SPDC).
(SPDC)
Contd
y Manual arc welding is done with shielded (covered)
Contd
Threemodesofmetaltransferduringarcwelding
electrodes
MajorForcestakepartinMetalTransfer
(i)gravityforce
(i)
it f
y Baremetal wire used in automatic or semiautomatic
(ii)Surfacetension
machines
machines.
y Non consumable electrodes (e.g tungsten) is not
consumed
d by
b the
h arc and
d a separate metall wire is used
d
as filler.
y There are three modes of metal transfer (globular,
spray and shortcircuit).
20 0
JWM2010
Assertion
(A) : Bead
A
ti
B d is
i the
th metal
t l added
dd d during
d i
single pass of welding.
Reason (R)
( ) : Bead material is same as base metal.
(a) Both A and R are individuallyy true and R is the
(b) Both A and R are individually true but R is NOT the
(iii)electromagneticinteraction
g
(iv)hydrodynamicactionofplasma
GATE1993
Ind.c.welding,thestraightpolarity(electrode
(
negative)resultsin
(a) Lowerpenetration
(b) Lowerdepositionrate
(c) Lessheatingofworkpiece
(d) Smallerweldpool
S ll ld
l
Page 41 of 240
Arcweldingequipments
1. Droopers: Constant current welding machines
Good for manual welding
g
2. Constant voltage machines

Good for automatic welding
Rev.0
Contd
Formula
q
g current ((150
5 to 1000 A),
), voltage
g is
y Requires
a large
between 30 and 40 V, actual voltage across the arc
varying from 12 to 30 V.
y To initiate a weld,
ld the
h operator strike
k the
h electrode
l
d and
d
Fig.Machinewithdifferentsettings
start arc.
V
I
+
=1
OCV SCC
Fig.Characteristiccurveofaconstantvoltagearcweldingmachine
IES 2010
IES2010
In arc welding, the arc length should be equal to
(a) 4.5 times the rod diameter
(b) 3 times
ti
th rod
the
d diameter
di
t
(c) 1.5 times the rod diameter
(d) Rod diameter
IES2001
Inarcwelding,d.c.reversepolarityisusedtobear
g
greateradvantagein
g
(a) Overheadwelding
(b) Flatweldingoflapjoints
(c) Edgewelding
(d) Flatweldingofbuttjoints
l ldi fb j i
IES2005
IES2001
Inarcwelding,65%to75%heatisgeneratedatthe
anode.
2. Dutycycleincaseofarcweldingisthecycleof
completeweldingofworkpiecefromthe
beginning.
3 ArcblowismorecommonwithDCwelding.
3.
ArcblowismorecommonwithDCwelding
Inmanualarcwelding,theequipmentshould
Whichofthestatementsgivenaboveare
correct?
(a) 1,2and3 (b) 1and2
(c) 2and3 (d) 1and3
(c) Temperatureintheareconstant
1.
IES1998
The voltagecurrent characteristics of a dc
generator for arc welding
g
g is a straight
g
line
between an opencircuit voltage of 80 V and short
circuit current of 300 A. The generator settings for
maximum arc power will be
((a)) 0 V and 150
5 A
((b)) 4
40 V and 3300 A
(c) 40 V and 150 A
(d) 80 V and 300 A
Page 42 of 240
havedroopingcharacteristicsinordertomaintain
(a) Voltageconstantwhenarclengthchanges
(b) Currentconstantwhenarclengthchanges
(d) Weldpoolredhot
IAS1999
Opencircuit voltage of 60 V and current of 160A
were the welding
g conditions for arc welding
g of a
certain class of steel strip of thickness 10 mm. For
arc welding of 5mm thick strip of the same steel,
the welding voltage and current would be
((a)) 60 V and 80 A
(b) 120 V and 160 A
(c) 60 V and 40 A
(d) 120 V and 40 A
Rev.0
IAS1998
AssumingastraightlineVIcharacteristicsfora
gg
dcweldinggenerator,shortcircuitcurrentas400A
andopencircuitvoltageas400whichoneofthe
followingisthecorrectvoltageandcurrentsetting
formaximumarcpower?
((a)) 4
400Aand100V
((b)) 200Aand200V
(c) 400Aand50V
(d) 200Aand50V
GATE1992
A low carbon steel plate is to be welded by the manual
metal arc welding process using a linear V I
characteristic DC Power source. The following data are
available :
OCV of Power source = 62 V
Short
S
o t ccircuit
cu t cu
current
e t = 130
30 A
Arc length, L = 4 mm
T
Traverse
speed
d off welding
ldi = 15 cm/s
/
Efficiency of heat input = 85%
Voltage is given as V = 20 + 1.5 L
Calculate the heat input into the workprice
GATE2012SameQinGATE2012(PI)
In
operation,
the
I a DC arc welding
ldi
ti
th voltagearc
lt
length characteristic was obtained as Varc = 20 + 5L
where
h
th arc length
the
l
th L was varied
i d between
b t
5 mm
and 7 mm. Here Varc denotes the arc voltage in Volts.
Th arc currentt was varied
The
i d from
f
400 A to
t 500 A.
A
Assuming linear power source characteristic, the
open circuit
i
it voltage
lt
and
d the
th short
h t circuit
i
it currentt for
f
the welding operation are
( ) 45 V, 450 A
(a)
(b) 75 V, 750 A
(c) 95 V, 950 A
(d) 150 V, 1500 A
GATE 2014 (PI)

GATE2014(PI)
In an arc welding operation, carried out with a
power source maintained at 40 volts and 400
amperes, the
h consumable
bl electrode
l
d melts
l and
d just
j
fills the gap between the metal plates to be butt
butt
welded. The heat transfer efficiency for the process
is 0.8, melting efficiency is 0.3 and the heat required
DutyCycle
y The percentage of time in a 5 min period that a
welding machine can be used at its rated output

without overloading.
y Time is spent
p
in setting
g up,
p metal chipping,
pp g cleaning
g
and inspection.
y For
o manual
a ua we
welding
d g a 60% duty cyc
cyclee iss suggested aand
d
for automatic welding 100% duty cycle.
of tthe
o
ee
electrode
ect ode iss 4 mm/s,
/s, tthe
e ccrosssectional
oss sect o a a
area,
ea,
in mm2, of the weld joint is _______
What is the maximum output current that can be

drawn at 100% duty cycle from a welding power source
rated at 600A at 60% duty cycle.
[3 Marks]
[3Marks]
Where,T=rateddutycycle
I=ratedcurrentattherateddutycycle
Io =Maximumcurrentattherateddutycycle
The DC power source for arc welding has the

characteristic 3V + I = 240, where V = Voltage and
I = Current in amp.
amp For maximum arc power at
the electrode, voltage should be set at
(a) 20 V (b) 40 V (c) 60 V (d) 80 V
3. If the
to melt
l the
h electrode
l
d is
i 20 J/mm
J/
h travell speed
d
IFS2011
I
Requireddutycycle,Ta = T
Ia
GATE 2007(PI)
2007 (PI)
GATE
Page 43 of 240
Contd
Electrode
1. NonconsumableElectrodes
2. ConsumableElectrodes
NonconsumableElectrodes
Madeofcarbon,GraphiteorTungsten.
CarbonandGraphiteareusedforD.C.
b
d
h
df
Electrodeisnotconsumed,thearclengthremains
constant,arcisstableandeasytomaintain.
Rev.0
Contd
ConsumableElectrodes
Provides
P id filler
fill materials.
t i l
Same composition.
This requires that the electrode be moved toward or
away from the work to maintain the arc and
satisfactory welding conditions.
Consumable electrodes are three kinds:

(a)
( ) Bare
(b) Fluxed or lightly coated
(c) Coated or extruded / shielded
y For automatic welding,
welding bare electrode is in the form of
continuous wire (coil).
Electrodecoatingcharacteristic
1. Provide a protective atmosphere.
2. Stabilize the arc.
3. Provide a protective slag coating to accumulate
4
4.
5.
6.
7.
8.
impurities, prevent oxidation, and slow the cooling of

the weld metal.
Reduce spatter.
spatter
Add alloying elements.
Affect
ff arc penetration
Influence the shape of the weld bead.
Add additional filler metal.
Contd
Electrodecoatings
GATE1994
Theelectrodesusedinarcweldingarecoated.
Thiscoatingisnotexpectedto
(a) Provideprotectiveatmospheretoweld
(b) Stabilizetheare
(c) Addalloyingelements
(d) Preventselectrodefromcontamination
P
t l t d f
t i ti
l. Slag Forming Ingredients. asbestos, mica, silica,

fluorspar, titanium dioxide, Iron oxide, magnesium
carbonate, Calcium carbonate and aluminium oxide.
2. Arc Stabilizing Ingredients. or ionizing agents:
potassium
potass
u
ssilicate,
cate, TiO
O2 + ZrO
O2 (Rut
(Rutile),
e), M
Mica,
ca,
Calcium oxide, sodium oxide, magnesium oxide,
e dspa ((KAI Si3 O8)
feldspar
3.DeoxidizingIngredients. Cellulose,Calcium
carbonate,dolo
carbonate,dolo mite,starch,dextrin,woodflour,
graphite,aluminium,ferromanganese.
4.BindingMaterials Sodiumsilicate,potassiumsilicate,
asbestos.
5.AlloyingConstituentstoImproveStrengthofWeld
6.TiO2 andpotassiumcompoundsincreasethemelting
p
p
g
rateofthebasemetalforbetterpenetration.
7.Ironpowderprovideshigherdepositionrate.
Contd
Contd
i d
Binders
y The slag is then easily chipped.
y AC arc welding
used
binders.
ld
d potassium silicate
l
b d
y Coatings are designed to melt more slowly than the
f ll wire.
filler
y DC arc welding used sodium silicate binders.

binders
y Potassium
otass u has
as a lower
o e ionization
o at o pote
potential
t a as co
compared
pa ed
with sodium.
Contd
Page 44 of 240
Rev.0
IES2007
The coating material of an arc welding electrode
g
contains which of the following?
1. Deoxidising agent
2 Arc stabilizing agent
2.
3. Slag forming agent
S l
Select
the
h correct answer using
i the
h code
d given
i
b l
below:
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only
WeldingFlux
Availableinthreeforms
y Granular
y Electrodewirecoating
y Electrodecore
Welding Positions
WeldingPositions
IES1997
Assertion (A):
( ) The electrodes of ac arc welding are
coated with sodium silicate, whereas electrodes used
for dc arc welding are coated with potassium silicate
binders.
Reason (R): Potassium has a lower ionization
potential
i l than
h sodium.
di
explanation of A
Fig.Positioningofelectrodeforweldinginverticallyupwardposition
MatchListIwithListIIandselectthecorrectanswer:
ListI(Ingredients)
ListII(Welding
f
functions)
i
)
A. Silica
1.
Arc stabilizer
B. Potassium
i
oxalate
l
2.
Deoxidizer
idi
C. Ferrosilicon
3.
Fluxingagent
D. Cellulose
4.
Gasformingmaterial
Codes:A
B
C
D
A
B
C
D
(a) 3
4
2
1
(b) 2
1
3
4
(c) 3
1
2
4
(d) 2
4
3
1
y g
LowHydrogenElectrode
y The basic coatings contain large amount of
IFS2011
Whatismeantbylowhydrogenelectrode?
calcium
l i
carbonate
b
t (limestone)
(li
t
) and
d calcium
l i
fluoride (fluorspar) and produce low hydrogen.
y But it can absorb
b b moisture therefore
h f
coated
d low
l
hydrogen electrodes are backed before use to a
temperature off 200oC to 3000C and
d stored
d in an
oven at 110oC to 150oC
y Other types of electrode release large amount of
hydrogen, which can dissolve in the weld metal
and lead to embrittlement or cracking.
[
[2marks]
k ]
W ldi C
WeldingCurrent
t
y Weldingcurrentdependsupon:thethicknessofthe
Fig.Thepositionofelectrodeforhorizontalwelding
IES2002
weldedmetal,typeofjoint,weldingspeed,positionof
theweld,thethicknessandtypeofthecoatingonthe
electrodeanditsworkinglength.
y Weldingcurrent,I=k.d,amperes;disdia.(mm)
Page 45 of 240
WeldingVoltage
y Thearcvoltagedependsonlyuponthearclength
V=k1 +k2l
Volts
Wherelisthearclengthinmmandk1 andk2 are

constants,
t t
k1 =10to12;andk2 =2to3
TheminimumArcvoltageisgivenby
g
g
y
Vmin =(20+0.04l)Volt
Rev.0
ArcLength
y For good welds, a short arc length is necessary,
because:
1. Heat is concentrated.
2. More stable
3. More protective atmosphere.
A long arc results in

y Large heat
loss
into
atmosphere.
h
l
i
h
y Unstable arc.
y Weld pool is not protected.
y Weld has low strength,
strength less ductility,
ductility poor fusion and
excessive spatter.
Fig.ArcPowerVsArcLength
Contd
Arclengthshouldbeequaltothediameteroftheelectrodesize
G
2002 C
i
l
GATE2002,Conventional
The
characteristic
off a DC arc is given
h arc lengthvoltage
l
h l
h
by the equation: V = 24 + 4L,
4L where V is voltage in volts
and L is arc length in mm. The static voltampere
characteristic of the power source is approximated by a
Beadwidthshouldbeequaltothreediameteroftheelectrodesize
straight
h line
l
with
h a no load
l d voltage
l
off 80 V and
d a short
h
circuit current of 600A. Determine the optimum arc
length for maximum power.
GATE2008
In arc welding of a butt joint, the welding speed is
to be selected such that highest cooling rate is
achieved. Melting efficiency and heat transfer
efficiency are 0.5 and 0.7, respectively. The area of
the
h weld
ld cross section is 5 mm2 and
d the
h unit
energy required to melt the metal is 10 J/mm3. If
the
h welding
ld
power is 2 kW,
k
the
h welding
ld
speed
d in
mm/s is closest to
(a) 4
(b) 14
(c) 24
(d) 34
( )
GATE2010(PI)
g a steadyy g
g with direct
During
gas metal arc welding
current electrode positive polarity, the welding current,
voltage and weld speed are 150 A, 30 V and 6 m/min,
respectively. A metallic wire electrode of diameter 1.2
mm is being fed at a constant rate of 12 m/min. The
d it specific
density,
ifi heat
h t and
d melting
lti
t
temperature
t
off the
th
wire electrode are 7000 kg/m3, 500 J/kgoC and 1530oC,
respectively Assume the ambient temperature to be 30oC
respectively.
and neglect the latent heat of melting. Further, consider
that two
twothird
third of the total electrical power is available for
melting of the wire electrode. The melting efficiency (in
percentage)
p
g of the wire electrode is
(a) 39.58
(b) 45.25
(c) 49.38 (d) 54.98
GATE2006
In an arc welding process, the voltage and current
are 25 V and 300 A respectively. The arc heat
transfer efficiency is 0.85 and welding speed is 8
mm/sec. The net heat input (in J/mm) is
(a) 64
(b) 797
(c) 1103
(d) 79700
Page 46 of 240
( )
GATE2009(PI)
Autogenous gas tungsten arc welding of a steel
plate is carried out with welding current of 500 A,
voltage of 20 V, and weld speed of 20 mm/sec.
Consider the heat transfer efficiency from the arc
to the weld pool as 90%. The heat input per unit
length (in KJ/mm) is
(a) 0.25
(b) 0.35
(c) 0.45
(d) 0.55
Rev.0
Example
ArcblowinDCarcwelding
g the welding
g of magnetic
g
y Arc blow occurs during
Calculate the melting efficiency in the case of

arcwelding
g of steel with a p
potential of 20 V and
a current of 200 A. The travel speed is 5 mm/s
and .the
the cross
crosssectional
sectional area of the joint is 20
2
mm . Heat required to melt steel may be taken
as 10 J/mm3 and the heat transfer efficiency as
0.85.
materials with DC.

y The effect of arc blow is maximum when welding
g
corners where magnetic field concentration is

maximum.
y The effect is particularly noticeable when welding with
bare electrodes or when using currents below or above
y Again the problem of arc blow gets magnified when
welding highly magnetic materials such as Ni alloys,
because of the strong magnetic fields set up by these
metals.
y Cause: Unbalanced magnetic forces.
Contd
Effectofarcblow
y Low heat penetration.
y Excessive weld spatter.
p
y Pinch effect in welding is the result of electromagnetic
forces
y Weld spatter occurs due to
High
Hi h welding
ldi currentt
Too small an electrode arc
The effects of arc blow can be minimized with D.C.

welding by
y Shortening the arc.
y Reduce
R d
currentt
y Reducing weld speed.
y Balance magnetic field by placing one ground lead at
each end of the work piece.
y Wrapping the electrode cable a few turns around the
work piece.
p
Contd
IES2001
Arcblowismorecommonin
(a) A.C.welding
.C. e d g
(b) D.C.weldingwithstraightpolarity
(c) D.C.weldingwithbareelectrodes
D C elding ithbareelectrodes
(d) A.C.weldingwithbareelectrodes
Contd
IES 2013
IES2013
Statement (I): The deflection of Arc from its intended
path is called Arc
Arc blow.
blow
Statement (II): The chances of Arc blow is common in
A C Arc
A.C.
A welding.
ldi
Statement (I)
p
of
Statement (I)
GATE & PSUs)
(d) Statement For-2015
(I) is false(IES,
but Statement
(II) is true
IES2001
Pincheffectinweldingistheresultof
(a) Expansionofgasesinthearc
pa s o o gases t e a c
(b) Electromagneticforces
(c) Electricforce
(d) Surfacetensionofthemoltenmetal
Page 47 of 240
ISRO2006
Too
T high
hi h welding
ldi currentt in
i arc welding
ldi would
ld result
lt in
i
(a) Excessive spatter, under cutting along edges, irregular
deposits, wasted electrodes
(b) Excessive p
piling
g up
p of weld metal, p
poor p
penetration,
wasted electrodes
(c) Too small bead, weak weld and wasted electrodes
(d) Excessive piling up of weld metal, overlapping
without penetration of edges,
edges wasted electrodes
Rev.0
Gasshields
CarbonArcwelding
y Helium, most expensive, has a better thermal
y An inert gas is blown into the weld zone to drive away
conductivity, is useful for thicker sheets, copper and

aluminium welding,
welding higher deposition rate.
rate
other
th atmospheric
t
h i gases.
y Gases are argon,
argon helium,
helium nitrogen,
nitrogen carbon dioxide and
work.
k
y The arc in carbon dioxide shielding

g g
gas is unstable,
least expensive, deoxidizers needed.
a mixture of the above gases.

y Argon ionizes easily requiring smaller arc voltages.It is
y Shielding is not used.

used
y No pressure
p
y It is a heavy gas and therefore covers the weld zone
very well.
ll
good for welding thin sheets.
y Arc is produced between a carbon electrode and the
y With or without filler metal

y May be used in "twin arc method", that is, between
two carbon (graphite) electrodes.

Contd
IES 2010
IES2010
)
g
p
y is always
y
Assertion ((A):
Straight
polarity
recommended for Carbonelectrode welding.
Reason (R): Carbon arc is stable in straight polarity.
correct explanation
l
i off A
TungstenInertGaswelding(TIG)
y Arc
is established between a nonconsumable

tungsten electrode and the workpiece.
y Tungsten is alloyed with thorium or zirconium for
y g
and
electronemission
better currentcarrying
characteristics.
y Arcc length
e gt iss co
constant,
sta t, aarcc iss stab
stablee aand
d easy to
maintain.
y With or without filler.
filler
y Very clean welds.

y All metals and alloys can be welded.
welded (Al,
(Al Mg also)
y Straight polarity is used.
y Weld voltage 20 to 40 V and weld current 125 A for
RPDC to 1000 A for SPDC.

y Shielded Gas: Argon
y Torch
h is water or air cooled.
l d
Contd
GATE2011
Whichoneamongthefollowingweldingprocesses
usednon consumableelectrode?
( )G t l ldi
(a)Gasmetalarcwelding
(b)Submergedarcwelding
(c)Gastungstenarcwelding
(d)Fluxcoatedarcwelding
Fig.TIG
For-2015 (IES,
GATE & PSUs)
Page 48 of 240
IES 2010
IES2010
gp
y used
In an inert g
gas welding
process,, the commonly
gas is
(a) Hydrogen
(b) Oxygen
( ) Helium
(c)
H li
or Argon
A
(d) Krypton
Rev.0
ISRO2009
Following gases are used in tungsten inert
gas welding
ldi
(a) CO2 and H2
(b) Argon and neon
(c) Argon and helium
(d) Helium and neon
GATE2002
Whichofthefollowingarcweldingprocessesdoes
notuseconsumableelectrodes?
(a) GMAW
(b) GTAW
(c) SubmergedArcWelding
(d) Noneofthese
N
fth
IES1994
Whichoneofthefollowingweldingprocesses
usesnon consumableelectrodes?
(a) TIGwelding
(b) MIGwelding
(c) Manualarcwelding
(d) Submergedarcwelding.
S b
d ldi
IES2013
IES2000
Whichoneofthefollowingstatementsiscorrect?
(a) Nofluxisusedingasweldingofmildsteel
o u s used gas e d g o
d stee
(b) Boraxisthecommonlyusedfluxcoatingon
weldingelectrodes
(c) Laserbeamweldingemploysavacuumchamber
andthusavoidsuseofashieldingmethod
(d) ACcanbeusedforGTAWprocess
Statement ((I):
) Non consumable electrodes,, used in arc
welding are made of high melting point temperature
g of electrode g
goes on
materials,, even then the length
decreasing with passage of time.
Statement (II): The electrode material gets oxidized
and melts on the weld material to form a strong flux.
Statement (I)
true but
b Statement
S
(II) is
i not the
h correct explanation
l
i off
Statement (I)
GasMetalArcWelding(GMAW)orMIG
y A consumable electrode in a gas shield.
y Arc is between workpiece
p
and an automaticallyy fed
barewire electrode.
y Argon, helium, and mixtures of the two can be used.
y Any metal can be welded but are used primarily with
the nonferrous metals.
metals
y When welding steel, some O2 or CO2 is usually added
t improve
to
i
th arc stability
the
t bilit and
d reduce
d
weld
ld spatter.
tt
Contd
IES2007
InMIGwelding,themetalistransferredintothe
g
formofwhichoneofthefollowing?
(a) Afinesprayofmetal
(b) Moltendrops
(c) Weldpool
(d) Molecules
l
l
y Fast and economical.

y A reversepolarity
l
d arc is generally
dc
ll used
d because
b
of its deep penetration, spray transfer, and ability

to produce
d
smooth
h welds
ld with
h good
d profile.
fl
Page 49 of 240
Fig.MIG
Rev.0
IES1997
MIGweldingprocessuses
gp
1.Consumableelectrode2. nonconsumableelectrode
3.D.C.powersupply
4.A.C.powersupply
Ofthesestatements
(a) 2and4arecorrect
(b) 2and3arecorrect
( ) 1and4arecorrect
(c)
d
(d) 1and3arecorrect
IES 2012
IES
() C
p
y
G
Statement(I):DCwithreversepolarityisusedinMIG
welding
( )
p
y
Statement(II):UseofDCwithreversepolarityenables
deeperpenetrationandacleanSurface
IES 2013
IES2013
IES 2010
IES2010
g statements:
In metal are welding
1. Utilizes a consumable electrode
2. A welding torch used is connected to acetylene gas
supply
3. The
Th electrode
l t d and
d workpiece
k i
are connected
t d to
t the
th
welding power supply
(a) 1,
1 2 and 3
(b) 1 and 2 only
(c) 1 and 3 only
(d) 2 and 3 only
( )
g
Assertion(A):Inertgasandbareelectrodeinstead
offluxcoatedelectrodeisusedinthecaseof
gp
automaticTIGandMIGweldingprocesses.
Reason(R):Betterprotectionisprovidedbyacloud
ofinertgasthanthecovercreatedbytheflux.
correctt explanation
l
ti off A
SubmergedArcwelding(SAW)
y A thick layer of granular flux is deposited just ahead of
a bare
b
wire
i consumable
bl electrode,
l t d and
d an arc is
i
maintained beneath the blanket of flux with onlyy a few
y Most suitable
or fillet
bl for
f flat
fl butt
b
f ll welds
ld in low
l
carbon steel (< 0.3% carbon).

y The process is not recommended for highcarbon
g
steels,
small flames being visible.

y A portion of the flux melts. Molten flux and flux
tool
steels,
aluminum,
magnesium,
titanium, lead, or zinc.
provides thermal insulation, slows cooling rate and

produce soft,
soft ductile welds.
welds
Contd
Advantages
Characteristicofsubmergedarcwelding
y Highspeeds,
y Wireelectrodesareinexpensive.
y Highdepositionrates,
y Noweldspatter.
y Deeppenetration,
Deeppenetration
y Nearly100%depositionefficiency.
Nearly100%depositionefficiency
y Highcleanliness(duetothefluxaction).
y Lesserelectrodeconsumption.
Page 50 of 240
Rev.0
IES2011
Limitations
The welding process in which bare wire is used as

electrode, granular flux is used and the process is
characterized by its high speed welding,
welding is known as:
(a) Shielded arc welding
(b) Plasma arc welding
(c) Submerged
g arc welding
g
(d) Gas metal arc welding
y Extensive flux handling,

y Contamination of the flux by moisture.
y Largegrainsize
Large grain size structures.
structures
y Welding is restricted to the horizontal position.
y Chemical control is important
IES2005
IES2008
Whichofthefollowingarethemajor
characteristicsofsubmergedarcwelding?
1. Highweldingspeeds.
2. Highdepositionrates.
3. Lowpenetration.
4. Lowcleanliness.
4
Selectthecorrectanswerusingthecodegivenbelow:
(a) 2and3
(b) 1,2and3
1 2and3
(c) 3and4
(d) 1and2
AtomicHydrogenwelding(AHW)
y An
two tungsten electrodes
A a.c. arc is
i formed
f
d between
b
l
d
along which streams of hydrogen are fed to the

welding zone.
zone The molecules of hydrogen are
dissociated by the high heat of the arc in the gap
between the electrodes.
electrodes The formation of atomic
hydrogen proceeds with the absorption of heat:
H2 = 2H 421.2
421 2 k J / mol
y This atomic hydrogen recombines to form molecular
hydrogen outside the arc, particularly on the relatively
cold surface of the work being welded, releasing the
gained p
previously:
y
heat g
2H =For-2015
k J GATE
/ mol. & PSUs)
H2 + 421.2
(IES,
Contd
Assertion (A):
( ) Submerged arc welding is not
recommended for high carbon steels, tool steels,
aluminium, magnesium etc.
Reason (R): This is because of unavailability of
suitable fluxes, reactivity at high temperatures and
l
low
sublimation
bli
i temperatures.
(a) Both A and R are true and R is the correct explanation
of A
(b) Both A and R are true but R is NOT the correct
explanation of A
p
y Temperature
of about 37
3700oC.
y Hydrogen acts as shielding also.
y Used for very thin sheets or small diameter wires.
y Lower thermal efficiency than Arc welding.
y Ceramics may be arc welded.
IES2006
Inwhichofthefollowingweldingprocesses,flux
g
isusedintheformofgranules?
(a) ACarcwelding
(b) Submergedarcwelding
(c) Argonarcwelding
(d) DCarcwelding
C ldi
GATE1999
For butt welding 40 mm thick steel plates, when
the expected quantity of such jobs is 5000 per
month over a period of 10 year, choose the best
suitable welding process out of the following
available
l bl alternatives.
l
(a) Submerged
g arc welding
g
(b) Oxyacetylene welding
(c) Electron beam welding
(d) MIG welding
IES2005
Inatomichydrogenwelding,hydrogenactsas
(a) Aheatingagent
eat g age t
(b) Oneofthegasestogeneratetheflame
(c) Aneffectiveshieldinggasprotectingtheweld
Aneffecti eshieldinggasprotectingthe eld
(d) Alubricanttoincreasetheflowcharacteristicsof
weldmetal
ld
l
y AC used.
used
Page 51 of 240
Rev.0
ResistanceWelding
ResistanceWelding
Principle
y Both heat and pressure are used.
y Heat is generated by the electrical resistance of the
work pieces and the interface between them.
y Pressure is supplied externally and is varied
g
the weld cycle.
y
throughout
y Due to pressure, a lower temperature needed than
oxyfuel
oxy
fuel or arc welding.
BySKMondal
y They are not officially classified as solidstate welding
by the American Welding Society.

y Very rapid and economical.
y Extremely
l well
ll suited
d to automated
d manufacturing.
f
y No filler metal,
metal no flux,
flux no shielding gases.
gases
Contd
Contd
y Overall resistance very low.

y Very highcurrent (up to 100,000 A)
y Very lowvoltage
l
l
(
(0.5
to 10 V)) is
i used.
d
Fig. The desired temperature

distribution
across
the
electrodes and the work
pieces in lap resistance
welding.
Fig.
g
Typical
yp
pressure cycle
welding. The
forging and
operations.
current
and
for resistance
cycle includes
post heating
FIG.Thefundamentalresistanceweldingcircuit
Advantages
IES2007
What is the principle of resistance welding?
Indicate where the resistance is maximum in spot
welding operation.
[
[2marks]
k ]
Fig. The arrangement of the electrodes and the work in spot

welding, showing design for replaceable electrode tips.
Limitations
1. Very rapid.
1. High initial cost.
2. Fully automation possible.
2. Limitations to the type of joints (mostly lap joints).
3 Conserve material; no filler metal,

3.
metal shielding gases,
gases or
3 Skilled maintenance personne1 are required:

3.
flux is required.
q
4. special surface treatment needed.
4. Skilled operators are not required.

5.Dissimilar metals can be easily joined.
6. High reliability and

High
Page
52reproducibility.
of 240
Rev.0
Application
Differenttypes
y The resistance welding processes are among the
most common technique for high volume

joining.
1. Resistance spot welding

2. Resistance seam welding
3 Projection welding
3.
Resistancespotwelding
y The process description given so far is called resistance
spot welding (RSW) or simply spot welding.

y This is essentially done to join two sheetmetal jobs in
p jjoint, forming
g a small nugget
gg at the interface of
a lap
the two plates.
4. Upset welding
5. Flash welding
6. Percussion welding
HeatinputandEfficiencyCalculations
Electric Resistance Welding

JJoules law applicable
pp
Q = I2 Rt, Joules
IES2003
Inresistancewelding,heatisgeneratedduetothe
resistancebetween
(a) Electrodeandworkpiece
(b) Asperitiesbetweentouchingplates
(c) Twodissimilarmetalsbeingincontact
(d) Interatomicforces
i f
Contd
IES2001
Themaximumheatinresistanceweldingisatthe
(a) Tipofthepositiveelectrode
p o t e pos t e e ect ode
(b) Tipofthenegativeelectrode
(c) Topsurfaceoftheplateatthetimeofelectric
contactwiththeelectrode
(d) InterfacebetweenthetwoplatesbeingJoined
f b
h
l
b i i d
GATE2007
p jjoint
Two metallic sheets,, each of 2.0 mm thickness,, are welded in a lap
configuration by resistance spot welding at a welding current of 10 kA
and welding time of 10 millisecond. A spherical fusion zone extending
up to the full thickness of each sheet is formed. The properties of the
metallic sheets are given as:
ambient temperature = 293 K
melting temperature = 1793 K
l t t heat
latent
h t off fusion
f i = 300 kJ/kg
kJ/k
density = 7000 kg/m3
specific heat = 800 J/kg K
Assume:
(i) Contact resistance along sheetsheet interface is 500 microohm and
along electrodesheet interface is zero;
( ) No conductive heat loss through the bulk sheet materials; and
(ii)
(iii) The complete weld fusion zone is at the melting temperature.
g efficiencyy (in %) of the p
process is
The melting
(a) 50.37 (b)
60.37 (c)
70.37 (d)
80.37
Page 53 of 240
GATE2009(PI)LinkedS1
Resistance spot welding of two steel sheets is carried out in
lap joint configuration by using a welding current of 3 kA and
a weld time of 0.2 S. A molten weld nugget
gg of volume 20 mm3
is obtained. The effective contact resistance is 200
(microohms). The material properties of steel are given as:
(i) latent heat of melting: 1400 kJ/kg, (ii) density: 8000
kg/m3, (iii) melting temperature: 1520oC, (iv) specific heat:
0.5 kJ/kg
kJ/k oC.
C The
Th ambient
bi
temperature is
i 20oC.
C
Heat (in Joules) used for producing weld nugget will be
(
(assuming
100%
% heat
h
transfer
f efficiency)
ff
)
(a) 324
(b) 334
(c) 344
(d) 354
Rev.0
GATE2009(PI)LinkedS2
Resistance spot welding of two steel sheets is carried out in
lap joint configuration by using a welding current of 3 kA and
a weld time of 0.2 S. A molten weld nugget
gg of volume 20 mm3
is obtained. The effective contact resistance is 200
(microohms). The material properties of steel are given as:
(i) latent heat of melting: 1400 kJ/kg, (ii) density: 8000
kg/m3, (iii) melting temperature: 1520oC, (iv) specific heat:
0.5 kJ/kg
kJ/k oC.
C The
Th ambient
bi
temperature is
i 20oC.
C
Heat (in Joules) dissipated to the base metal will be
(
(neglecting
l
all
ll other
h heat
h
l
losses)
)
(a) 10
(b) 16
(c) 22
(d) 32
GATE2004
Two 1 mm thick steel sheets are to be spot welded
at a current of 5000 A. Assuming effective
resistance to be 200 microohms and current flow
time of 0.2 second, heat generated during the
process will
ll be
b
(a) 0.2 Joule (b) 1 Joule
(c) 5 Joule
(d) 1000 Joules
GATE2014
For
metal)
F spott welding
ldi off two
t steel
t l sheets
h t (base
(b
t l) each
h off
3 mm thickness,, welding
g current of 10000 A is applied
pp
for 0.2 s. The heat dissipated to the base metal is 1000 J.
Assuming that the heat required for melting 1 mm3
volume
l
off steel
t l is
i 20 J and
d interfacial
i t f i l contact
t t resistance
i t
between sheets is 0.0002,, the volume ((in mm3) of weld
GATE2005
Spot welding of two 1 mm thick sheets of steel
(density = 8000 kg/m3) is carried out successfully
by passing a certain amount of current for 0.1
second through the electrodes. The resultant weld
nugget formed
f
d is 5 mm in diameter
d
and
d 1.5 mm
thick. If the latent heat of fusion of steel is 1400
k k and
kJ/kg
d the
h effective
ff
resistance in the
h welding
ld
operation in 200 , the current passing through
the
h electrodes
l
d is approximately
l
(a) 1480A
(b) 3300 A
(c) 4060 A
(d) 9400 A
Resistance spot welding is performed on two

plates of 1.5 mm thickness with 6 mm diameter
electrode, using 15000 A current for a time
duration of 0.25 seconds. Assuming the interface
resistance to be
b 0.0001 , the
h heat
h
generated
d to
form the weld is
(a) 5625 Wsec
(b) 8437 Wsec
(c) 22500
5 Wsec
sec
(d) 3375
33750 Wsec
sec
GATE1992
For resistance spot welding of 1.5 mm thick steel
sheets, the current required is of the order of
(a) 10 A
(b) 100 A
(c) 1000 A
(d) 10,000 A
GATE2010
Two pipes of inner diameter 100 mm and outer
diameter 110 mm each joined by flash butt
welding using 30 V power supply. At the interface,
1 mm of material melts from each pipe which has
a resistance off 42.4 . Iff the
h unit melt
l energy is
64.4 MJm3, then time required for welding in
seconds
d is
(a) 1
(b) 5
(c) 10
(d) 20
IES 2007 C
ti
l
IES2007Conventional
Two steel sheets of thickness one mm are welded
by resistance projection welding technique. A
current of 30,000 A for 0005 second is made to
flow. The effective resistance of joint can be taken
as 100 micro ohms. The joint can be considered as
a cylinder of diameter 5 mm and height 15 mm.
The density of steel is 000786 gm/mm3. The heat
needed for welding steel is 10 J/mm3. Calculate the
efficiency of welding.
[20]
nugget is .
GATE2001
GATE 2008(PI)
Aluminum strips of 2 mm thickness are joined together
by resistance spot welding process by applying an
electric current of 6000 A for 0.15 sec. The heat required
for melting
g aluminum is 2.9
9 J/
J/mm3. The diameter and
the thickness of weld nugget are found to be 5 mm and
2 5 mm,
2.5
mm respectively.
respectively Assuming the electrical resistance
to be 75 (micro ohms), the percentage of total
energy utilized in forming the weld nugget is
(a) 28
Page 54 of 240
(b) 35
(c) 65
(d) 72
Rev.0
IAS2003
Resistanceseamwelding
Assertion (A):
( ) Spot welding is adopted to weld two
overlapped metal pieces between two electrode
points.
Reason (R): In this process when current is switched
on, the lapped pieces of metal are heated in a
restricted
i d area.
explanation of A
y Welding current is a bit higher than spot welding, to
y Weld is made between overlapping sheets of metal.
Th seam is
The
i a series
i off overlapping
l
i spott welds.
ld
compensate short circuit of the adjacent weld.

y In other process a continuous seam is produced by
passing a continuous current through the rotating
electrodes with a speed of 1.5 m/min for thin sheet.
y The basic equipment is the same as for spot welding.

welding
except that the electrodes are now in the form of

rotating disks.
y Timed pulses of current pass to form the overlapping
welds.
welds
Contd
( )
GATE 2012(PI)
In resistance seam welding, the electrode is in the
f
form
off a
(a) cylinder
(b) flat plate
((c)) coil of wire
(d) circular disc
Contd
Projectionwelding
y Limitations of spot welding.
1. Electrode
condition must be maintained

continually, and only one spot weld at a time.
2. For additional strength multiple welds needed.
y Projection welding
(RPW) overcomes above
limitations.
limitations
Fig.Resistanceseamwelding
Contd
y Dimples are embossed on work pieces at the weld
g
placed between largearea
locations and then p
electrodes, and pressure and current applied like spot
welding.
g
y Current flows through the dimples and heats them
and pressure causes the dimples to flatten and form a
weld.
For-2015 (IES, GATE
Fig.Principleof
projectionwelding,
j ti ldi
(a)priortoapplicationof
currentandpressure
( )
(b)andafterformationof
&welds
PSUs)
Contd
Upsetwelding
y Projections are pressformed in any shape.

y Multiple welds at a time.
y Made butt joint compared to lap joint.
y No indentation mark on the surface.
y Pieces are held tightly and current is applied.
y Bolts and nuts can be attached to other metal parts.
y Due to pressure joints get slightly upset and hence its
name.
y Useful for joining rods or similar pieces.
Page 55 of 240
Rev.0
Contd
FlashWelding
y This is the process used for making electric resistance
welded (ERW) pipes starting from a metal plate of suitable

thickness.
y The plate is first formed into the shape of the pipe with the
help of the three roll set as shown in Fig. above. The ends
of the p
plate would then be forming
g the butt jjoint.
y The two rotating copper disc electrodes are made to
contact the two ends of the p
plate through
g which the
current is passed. The ends get heated and then forge
welded under the p
pressure of the rolls.
y The ends of the pieces to be upset welded must be perfectly
parallel. Anyy high
p
g spots
p
if p
present on the ends would g
get
melted first before the two ends are completely joined.
y It is similar to upset welding except the arc rather than
resistance
i t
h ti
heating.
y One pieces is clamped with cam controlled movable
platen and other with is fixed platen.
Contd
Contd
PercussionWelding
y Two pieces are brought together and the power supply is
p
pieces are separated
switched on. Momentarilyy the two p
to create the arc to melt the ends of the two pieces.
g
the p
pieces are brought
g together
g
and the
Then again
power switched off while the two ends are fused under
force. Most of the metal melted would flash out
through the joint and forms like a fin around the joint.
y Faster than upset welding.
y Similar to flash welding except arc power by a rapid
discharge of stored electrical energy.

energy
y The arc duration is only
y 1 to 10 ms, heat is intense and
highly concentrated.
y Small weld metal is produced, little or no upsetting, and
low HAZ.
HAZ
y Application: Butt welding of bar or tube where heat
damage is a major concern.
Contd
Thermit Welding
y Temp. 2750C produced in 30 seconds, superheating
y Heating and coalescence is by superheated molten
OtherWelding
Technique
h i
metal
t l obtained
bt i d from
f
a chemical
h i l reaction
ti
b t
between
a
metal oxide and a metallic reducing
g agent.
g
y Used mixture one part aluminum and three parts iron
y Copper, brass, and bronze can be welded using a
different starting mixture.
8Al+3Fe3O4 9Fe+4Al2O3 +heat

Page 56 of 240
metal.
metal
y Runners and risers are provided like casting.
oxide and ignited by a magnesium fuse. (1150C).
the molten iron which provide both heat and filler
y Used to joint thick sections, in remote locations.
Contd
Rev.0
IES2000
ElectroSlagWelding
Considerthefollowingprocesses:
1. Gaswelding
2. Thermit welding
33. Arcwelding
g
4. Resistancewelding
Thecorrectsequenceoftheseprocessesinincreasing
orderoftheirweldingtemperaturesis
(a) 1,3,4,2
1 3 4 2
(b) 1,2,3,4
1 2 3 4
(c) 4,3,1,2
(d)4,1,3,2
y A 65mm deep layer of molten slag, protect and
cleanse the molten metal.
y Very effective for welding thick sections.

y Heat is derived from the passage of electrical current
y Watercooled
W
l d copper molding
ldi
plates
l
confined
fi d the
h
liquid and moved upward.
through a liquid slag and temp.

temp 1760
1760C
C
y Multiple electrodes are used to provide an adequate
supply of filler.
Contd
Contd
IAS2003
y Applications: Shipbuilding, machine manufacture,
heavy pressure vessels, and the joining of large
Whichoneofthefollowingisnotanelectric
g
resistancemethodofwelding?
(a) Electroslagwelding
(b) Percussionwelding
(c) Seamwelding
(d) Flashwelding
l h ldi
castings and forgings.

forgings
y Slow cooling
gp
produces a coarse g
grain structure.
y Large HAZ.
Contd
IAS2000
Considerthefollowingweldingprocesses:
1.. TIGwelding
G ed g
2.. Sub
Submergedarcwelding
e ged a c e d g
3. Electroslagwelding4. Thermit welding
Whichofthese eldingprocessesareusedfor elding
Whichoftheseweldingprocessesareusedforwelding
thickpiecesofmetals?
( ) 1,2and3
(a)
d (b) 1,2and4
d
(c) 1,3and4 (d) 2,3and4
ElectronBeamWelding
y A beam of electrons is magnetically focused on the
work
k piece
i
i a vacuum chamber.
in
h b
y Heat of fusion is produced by electrons decelerate.
decelerate
y Allows
precise
p
beam
control
and
deep
p
weld
penetration.
y No shield gas (vacuum chamber used)
Page 57 of 240
Rev.0
IES2004
IES2002
Assertion (A): In electron beam welding process,

vacuum is an essential process parameter
Reason (R): Vacuum provides a highly efficient
shield on weld zone
IAS2004
IES1993
Inwhichoneofthefollowingweldingtechniques
isvacuumenvironmentrequired?
(a) Ultrasonicwelding
(b) Laserbeamwelding
(c) Plasmaarcwelding
(d) Electronbeamwelding
l
b
ldi
LaserBeamWelding
consistsofsmallerHeatAffectedZone(HAZ)?
(a) Arcwelding
(b) Electronbeamwelding
(c) MIGwelding
(d) Thermit welding
Electronbeamweldingcanbecarriedoutin
(a) Ope
Openair
a
(b) Ashieldinggasenvironment
(c) Apressurizedinertgaschamber
Apressuri edinertgaschamber
(d) Vacuum
y Very thin HAZ and little thermal distortion.
y Used a focused laser beam provides power intensities
i excess off 10kW/cm

in
kW/ 2
y Filler metal and inert gas shield may or may not used.
y Deep penetration.
y The high
highintensity
intensity beam produces a very thin column
of vaporized metal with a surrounding liquid pool.
y No
N vacuum needed.
d d
y No direct contact needed.
needed
y Depthtowidth ratio greater than 4: 1.
Contd
IES2007
y Heat input is very low, often in the range 0.1 to 10 J.

y Adopted by the electronics industry.
y Possible
to weld
wires without removing
the
polyurethane insulation.
insulation
Contd
Considerthefollowingstatementsinrespectofthe
laserbeamwelding:
1. Itcanbeusedforweldinganymetalortheir
I b df ldi
l h i
combinationsbecauseofveryhightemperatureofthe
focalpoints.
focalpoints
2. Heataffectedzoneisverylargebecauseofquick
heating.
3. Highvacuumisrequiredtocarrytheprocess.
(a) 1and2only (b) 2and3only
(c) 1only
(d) 1,2and3
Page 58 of 240
Contd
IES2006
consistsofminimumheataffectedzone(HAZ)?
(a) ShieldedMetalArcWelding(SMAW)
(b) LaserBeamWelding(LBW)
(c) UltrasonicWelding(USW)
(d) MetalInertGasWelding(MIG)
l
G ldi ( G)
Rev.0
GATE2012(PI)
IAS2007
Which of the following welding processes results in

the smallest heat affected zone?
(a) Shielded metal arc welding
(b) Gas welding
(c) Laser beam welding
(d) Thermit
h
i welding
ldi
ForgeWelding
IAS1999
Consider the following welding processes:

1.. Arcc welding
ed g
2..
MIG
G welding
ed g
3. Laser beam welding
4.
Submerged arc
welding
Select the correct sequence in increasing order of Heat
affected zone (HAZ) using the code
given below:
(a) 1 2 3 4 (b) 1 4 2 3
((c)) 3 2 4 1 ((d)) 4 3 2 1
FrictionWelding
y Blacksmith do this.
y Machine is similar to a centre lathe.
y Heat is obtained by the friction between the ends of
th two
the
t parts
t to
t be
b joined.
j i d
y Borax is used as a flux.

y The ends to be joined were then overlapped on the
anvil and hammered to the degree

g
necessaryy to
y Quality depends on the skill of the worker and not
y Power requirements 25 kVA to 175 kVA.

y The axial pressure depends on the strength and
y One part is rotated at a high speed and other part is
axially aligned and pressed tightly against it.
h d
hardness
off the
h metals
l being
b
joined.
d
y Pressure 40 MPa for lowcarbon
low carbon steels to as high as 450
y Friction raises the temperature of both the ends. Then
produce an acceptable weld.
Match List I (Shielding

method)) with List II (Welding
(
(
process) and select the correct answer using the codes
g
List I
List II
A. Flux coating
1.
Gas metal arc welding
B
B.
Fl granules
Flux
l
2.
S b
Submerged
d arc welding
ldi
C. CO2
3.
Shielded metal arc welding
D Vacuum
D.
4
4.
Laser beam welding
5.
Electron beam welding
Codes:A B
C
D
A
B
C
D
(a) 1
2
5
3
(b)
1
4
2
5
(c) 3
5
1
4
(d)
3
2
1
5
MPa for alloy steels.
rotation is stopped abruptly and the pressure is

increased to join.
join
used
d by
b industry.
i d
Contd
Contd
GATE2007
y Very efficient.
y Wide variety of metals or combinations of metals can
be jjoined such as aluminium to steel.

y Grain size is refined
y Strength is same as base metal.
metal
y Only round bars or tubes of the same size, or
connecting
i bars
b or tubes
b to flat
fl surfaces
f
can join.
j i
y One of the components must be ductile.
y Friction welding is a solid state welding.
y A low contact pressure may be applied initially to
permit cleaning
of the
surfaces
burnishing action.
For-2015
(IES,
GATEby
& aPSUs)
Contd
Whichoneofthefollowingisasolidstatejoining
process??
(a) Gastungstenarcwelding
(b) Resistancespotwelding
p
g
(c) Frictionwelding
(d) submergedarcwelding
Page
59 of 240
Fig
frictionweldingprocess
Rev.0
GATE2013
pairs
Match the CORRECT pairs.
GATE2014
In solidstate welding, the contamination layers
b t
between
th surfaces
the
f
t be
to
b welded
ld d are removed
d by
b
(a) alcohol
(b) p
plastic deformation
(c) water jet
(d) sand blasting
Characteristics/Applications
1.Nonconsumableelectrode
Two steell bars,

each
10 mm, are coaxially
b
h off diameter
d
ll
Q.GasMetalArc
Q
GasMetalArc
Welding
R T
R.TungstenInertGas
t I tG
Welding
2 Joiningofthickplates
2.Joiningofthickplates
friction welded,
welded end to end,
end at an axial pressure of 200
S.Electroslag Welding
4.Joiningofcylindrical
dissimilarmaterials
MPa and at a rotational speed of 4000 rpm. The

3.Consumableelectrodewire
C
bl l t d i
( ) 4 Q3
(a)P4,Q3,R1,S2
(c)P2,Q3,R4,S1
3/4th radius of the rotating bar. The power (in KW)

consumed at the interface for welding is
( ) 4 Q
(b)P4,Q2,R3,S1
3
(d)P2,Q4,R1,S3
(a) 12.33 (b) 16.44
(d) 24.66
sheet, foil, and wire

or the
Weld thin materials
materialssheet,
wireor
Discusswithfigurethevariousstepsrequiredfor
Highfrequency
g
q
y (10 to 200, KHz) is applied.
pp
frictionwelding,mentioningatleasttwomethods
Surfaces are held together under light normal
[
[5marks]
k ]
(c) 18.50
Restricted to the lap joint
USW is a solidstate welding.
ofcontrol.
coefficient of friction between the mating faces of the

rotating bars
b
is 0.50. The
h torque is assumed
d to act at the
h
UltrasonicWelding(USW)
IFS2011
G
20 0 ( )
GATE2010(PI)
Processes
P.FrictionWelding
pressure.
Temp. do not exceed onehalf of the melting point.
The
Th ultrasonic
lt
i transducer
t
d
i same as ultrasonic
is
lt
i
machining.
attaching thin sheets to heavier structural members.

Maximum thickness 2.5
2 5 mm for aluminum and 1.0
10
mm for harder metals.
N b off metals
Number
t l and
d dissimilar
di i il metal
t l combinations
bi ti
and non metals can be joined such as aluminum to
ceramics
i or glass.
l
Equipment is simple and reliable.
Less surface preparation and less energy is needed.
Contd
pp
Applications
y Joiningthedissimilarmetalsinbimetallics
y Makingmicrocircuitelectricalcontacts.
Contd
ExplosionWelding
y Done at room temperature in air, water or vacuum.
y Surface contaminants tend to be blown off the surface.
y Weldingrefractoryorreactivemetals
W ldi f

i
l
y Typical impact pressures are millions of psi.

psi
y Bondingultrathinmetal.
g
y Well suited to metals that is prone to brittle joints
Important factors are,

y Critical velocity
y
y Critical angle
y The cladding plate can be supported with tack welded
supports at the edges, or the metal inserts.
when heat welded, such as,

y Aluminum on steel
y Titanium on steel
Page 60 of 240
Contd
Rev.0
Contd
y Typically the detonation velocity should not exceed
120% of the sonic velocity in the metal.
High velocity explosives, 45727620 m/s.

y TNT
y RDX
y PETN
y Composition
C
iti B
y Composition C4
y Datasheet
y Primacord
Medium velocity explosives, 15244572 m/s
y Ammonium nitrate
y Ammonium perchlorate
y Amatol
y Nitroguonidine
y Dynamites
y diluted PETN
Contd
Disadvantages,
y The metals must have high enough impact resistance,
and ductilityy ((at least 55%))
y The cladding plate cannot be too large.
y Noise and blast can require worker protection,
protection vacuum
chambers, buried in sand/water.
g ,
Advantages,
y Can bond many dissimilar, normally unweldable
metals
y The lack of heating preserves metal treatment
y The
Th process is
i compact, portable,
bl and
d easy to contain
i
y Inexpensive
y No need for surface preparation
Contd
Contd
yp
pp
Typicalapplications:
y Verylargeplatescanbecladded.
y Joinsdissimilarmetals.
(titaniumtosteel,Altosteel,AltoCuetc.)
y Jointubetotubesheetsoflargeheatexchangers.
Contd
Contd
IES2011S1Contd
GATE1992
Inanexplosiveweldingprocess,the..
(maximum/minimum)velocityofimpactisfixed
bythevelocityofsoundinthe
(flyer/target)platematerial
(a) Maximum;target
(b) M
Minimum;target
u ; ta get
(c) Maximum;flyer
(d) Minimum;flyer
Mi i
fl
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowthelists:
ListI
A.Laserbeam
welding
B.Electron
beamwelding
ListII
1.Canbeappliedforweldingorrefractorymetals
likeniobium,tantalum,molybdenumandtungsten.
2.Asoundandcleanweldedjointiscreateddueto
rubbingoftwopartsagainsteachotherwith
adequatespeedandpressureproducingintenseheat
raisingtemperatureabovemeltingpoint.
raisingtemperatureabovemeltingpoint
C.Ultrasonic 3.Cleanheatsourcecreatedmuchawayfromjob,a
welding
narrowspotisheated workchamberoperatesina
narrowspotisheated,workchamberoperatesina
highvacuum.
D.Friction
D
Friction
welding
4.Cleanheatsourceveryquickheating,verysmall
4
Cleanheatsourceveryquickheating,verysmall
focalspot,novacuumchamberisrequired.
Page 61 of 240
IES2011FromS1
Codes:
A
(a) 4
((c)) 4
B
3
1
C
1
3
D
2
4
(b)
( )
(d)
A
2
2
B
3
1
Rev.0
C
1
3
D
4
4
IES2009
IAS2002
MatchListIwithListIIandselectthecorrectanswerusingthecodegiven
belowtheLists:
ListI
ListII
(WeldingProcess)
(Application)
A. Laserwelding
1.
Unitinglargeareasheets
B. Frictionwelding
2.
Repairinglargeparts
C Ultrasonicwelding
C.
3
3.
Weldingarodtoaflatsurface
D. Explosivewelding
4.
Fabricationofnuclearreactor
components
55.
Weldingverythinmaterials
g
y
Code:
(a)
A
B
C
D
(b)
A
B
C
D
5
4
3
2
1
4
2
5
(c)
A
1
B
3
C
4
D
2
(d)
A
5
B
3
C
4
D
1
MatchListI,(Welding)withListII(Application)andselectthecorrect
(
)
(
)
answerusingthecodesgivenbelowtheLists:
ListI
ListII
(
(Welding)
)
(
(Application)
)
A.
Explosive
1.
Joiningthicksheets
g
B.
Ultrasonic
2.
Manufactureofheatexchanges
C.
Thermit
3.
Joiningthinsheetsorwiresof
similar/dissimilar metals
D.
Projection
4.
Joininghydraulicpistonrodsfor
agricultural
l
l machinery
h
5.
Joiningrails,pipesandthicksteel
sections
Codes:A
d
B
C
D
A
B
C
D
(a) 2
5
1
3
(b)
4
5
1
3
(c) 2
3
5
1
(d)
4
3
5
1
Autogeneous Welding
MicroPlasmaArcWeld(PAW)
y Autogeneous welding or fusion of the parent
y Similar to GTAW except the plasma caused by the arc
material in an inert g
gas shield without the use
of filler metals.
i constricted
is
t i t d by
b a watercooled
t
l d orifice
ifi
y Capable of high welding speeds where size permits
y Argon
g is used as the shielding
gg
gas.
IFS 2009
Two plates of aluminium and stainless steel are to
be welded back to back to create a single plate of
thickness equal to the sum of the thicknesses of
the two plates.
plates Suggest the suitable process and
explain it in brief.
[10 marks]
DiffusionWelding
g p
y It is a solid state welding
process which p
produces
coalescence of the faying surfaces by the application of
pressure and elevated temperatures (about 50 to 80%
of absolute melting point of the parent materials) for a
time ranging from a couple of minutes to a few hours.
y Produces high quality bonds with good strength with
little or no distortion.
y Can join very dissimilar materials.
y A solid filler metal may or may not be inserted.
y Materials welded for aircraft and rocket industry:
Boron, Titanium, Aluminium, Ceramic, Composite,
Graphite, Magnesium etc.
JWM2010
GATE 2008(PI)
Which
solid
h h pair among the
h following
f ll
l d state welding
ld
processes uses heat from an external source?
P Diffusion welding;
Q Friction welding
R Ultrasonic welding
S Forge welding
(a) P and R
(b) R and S
(c) Q and S
(d) P and S
IAS2001
MatchListI(Weldingprocesses)withListII(Features)and
(
)
(
)
selectthecorrectanswerusingthecodesgivenbelowtheLists:
ListI
A. Ultrasonicwelding
1.
B.
Electronbeamwelding2.
C
C.
Plasmaarcwelding
3
3.
4.
Codes:A
C
d A
(a) 1
(c) 2
B
2
1
C
4
4
(b)
(d)
ListII
Gasheatedtoionizedcondition
forconductionofelectriccurrent
Highfrequencyandhigh
intensityvibrations
Concentratedstreamofhigh
Concentratedstreamofhigh
energyelectrons
Exothermalchemicalreaction
A
B
C
4
3
1
2
3
1
Page 62 of 240
M hLi I i hLi II d l h
usingthecodegivenbelowthelists:
ListI
ListII
A.Atomic
1.Twopiecesarebroughttogetherand
h d
hydrogenwelding
ldi powersupplyisswitchedon
l i i h d
B.Plasmaarc
B
Plasma arc
welding
22.Nuggetisformedattheinterfaceof
Nuggetisformedattheinterfaceof
twoplates
C Spotwelding
C.Spotwelding
3 Gasisionized
3.Gasisionized
D.Flashwelding
4.Inertgasshieldedarcwelding
Code:A
(a) 4
(c) 4
B
3
2
C
2
3
D
1
1
(b)
(d)
A
B
1
3
Rev.0
1
2
C
2
3
D
4
4
IES 2011 Conventional

IES2011Conventional
BrazingandSoldering
Discuss the process capabilities and applications of Gas
y Brazing
is
off metals
B i
i the
th joining
j i i
t l through
th
h the
th use off heat
h t
Metal Arc Welding, Gas tungsten Arc Welding, and
BrazingandSoldering
g
g
Diffusion Bonding processes.

[15Marks]
Brazingprocesshasseveraldistinct
Brazing
process has several distinct
advantages:
g
1. All metals can be joined.
2. Suited for dissimilar metals.
3. Quick and economical.
4. Less defects.
d f
5 Corrosion prone
5.
and a filler metal whose melting temperature is above

450C; but below the melting
45
g p
point of the metals being
g
joined.
Comparison with welding and the brazing process
1. The
Th composition
ii
off the
h brazing
b i
alloy
ll is
i significantly
i ifi
l
different from that of the base metal.
2 The strength of the brazing alloy is substantially lower
2.
than that of the base metal.
3. The melting point of the brazing alloy is lower than that
off the
h base
b
metal,
l so the
h base
b
metall is not melted.
l d
4. Capillary action or capillary attraction draws the
molten filler metal into the joint,
joint even against the flow of
gravity.
Brazingmetalsaretypicallyalloyssuchas,
y Brazingbrass(60%Cu,40%Zn)
g
y Manganesebronze
y Nickelsilver
y Coppersilicon
y Silveralloys(with/withoutphosphorous)
l
ll
( h
h
h
h
)
y Copperphosphorous
Contd
y Extremely clean surface needed.
y A popular composition is 75% borax and 25% boric
y Fluxes used are combinations of borax, boric acid,
acid.
chlorides fluorides,
chlorides,
fluorides tetraborates
tetra borates and other wetting
y Sodium
S di
cyanide
id is
i used
d in
i brazing
b i tungsten to copper.
agents.
g
y Base materials not melted.

melted
Contd
Contd
Page 63 of 240
Rev.0
S O 20 0
ISRO2010
IES2006
GATE2005
Thestrengthofabrazedjoint
(a) Decreaseswithincreaseingapbetweenthetwo
g p
joiningsurfaces
(b) Increaseswithincreaseingapbetweenthetwo
joiningsurfaces
(c) Decreasesuptocertaingapbetweenthetwo
joiningsurfacesbeyondwhichitincreases
(d) Increasesuptocertaingapbetweenthetwo
I
t t i b t
th t
joiningsurfacesbeyondwhichitdecreases
BrazeWelding
Whichoneofthefollowingisnotafusionwelding
process?
(a) Gaswelding
(b) Arcwelding
(c) Brazing
(d) Resistancewelding
i
ldi
Which is not correct statement about the function of

flux in brazing
(a) To avoid thermal distortion and cracking
(b) To dissolve surface oxide coatings which have formed
prior to brazing
(c) To prevent oxides from forming during the brazing
operation
i
on both
b h the
h base
b
metall and
d the
h brazing
b i
material
(d) To facilitate the wetting process by reducing the
viscosity of the melt
Soldering
y Done with an oxyacetylene torch.
y Capillary action is not required.
y By definition, soldering is a brazing type of operation
y Edge preparation needed.
where
h
th filler
the
fill metal
t l has
h
a melting
lti
t
temperature
t
y Can join cast iron.

iron
below 450C.
45
y Strength of the filler metal is low.
y Soldering is used for a neat leakproof joint or a low
resistance electrical joint.

y Not
N suitable
i bl for
f hightemp.
hi h
application.
li i
Contd
Effective soldering generally involves six important

steps:
(1) Design of an acceptable solder joint,
( ) Selection
(2)
l
off the
h correct solder
ld for
f the
h job,
b
(3) Selection of the proper type of flux,
(4) Cleaning the surfaces to be joined,
(5) Application of flux,
flux solder,
solder and sufficient heat to
allow the molten solder to fill the joint by capillary
action and solidify,
solidify and
(6) Removal of the flux residue, if necessary.
Fig.BrazeWelding
Contd
S ld M t l
SolderMetals
S ld
l
SolderFlux
y Ammonium
chloride
A
i
hl id or rosin
i for
f soldering
ld i tin
ti
y Most solders are alloys of lead and tin.

y Three commonly used alloys contain 60, 50, and 40%
y Hydrochloric acid and zinc chloride for soldering
galvanized iron
tin and all melt below 240

240C
C.
y Some fluxes are corrosive and should be removed after
use
Page 64 of 240
Contd
Rev.0
g
p
y Silver solders uses for highertemperature
service,,
Electrical and Electronic purpose.
GATE2014(PI)
BrazingandSolderingare
d ld
(a)plasticjoiningmethods
(b) o oge eous jo
(b)homogeneousjoiningmethods
g et ods
y
DifficultieswithGreyCastIron
Soldering and brazing are difficult of grey cast Iron due
to surface contamination with graphite having a very low
surface energy.
(c)autogenous joiningmethods
(d)heterogeneousjoiningmethods
IES1994
MatchList IwithList IIandselectthecorrect
answerusingthecodesgivenbelowtheLists:
List I(Filler)
List
List II(Joiningprocess)
List
A. Cu,Zn,Agalloy
1.
Brazewelding.
B Cu,Sn,alloy
B.
Cu Sn alloy
2
2.
Brazing
C. Pb,Sb,alloy
3.
Soldering
D.Iron oxideandaluminium p
powder4.
4
TIGweldingof
g
aluminium
Codes:A B
C
D
A
B
C
D
( ) 2
(a)
1
3
(b) 1
2
4
(c) 2
1
3
4
(d) 2
3
4
IES2004
MatchListI(Weldingproblems)withListII(Causes)andselect
(
)
(
)
ListI
ListII
A. Crackingofweldmetal
1.
Excessivestresses
B. Crackingofbasemetal
2.
Highjointrigidity
C
C.
Porosity
3
3.
Failuretoremoveslag
frompreviousdeposit
D. Inclusions
4.
Oxidation
5.
E
ExcessiveH
i H2,O
O2,N
N2,in
i
theweldingatmosphere
Codes:A
B
C
D
A
B
C
D
(a) 2
1
5
3
(b)
3
4
2
1
(c) 2
4
5
3
(d)
3
1
4
2
W ldi d i
Weldingdesignanddefect
dd f
IAS1996
MatchListIwithListIIandselectthecorrectanswerusing
thecodesgivenbelowthelists
ListII
List
ListII
List
II
(Fillerrodmaterial) (Joiningprocess)
A. Mildsteel
1.
MIGwelding
B. Bronze
2.
Soldering
C. Brass
3.
Brazing
D Leadandtinalloy
D.
L d dti ll 4.
Th
Thermit
it welding
ldi
5.
Brazewelding
Codes:A
B
C
D
A
B
C
D
(a) 1
5
3
2
(b)
4
3
2
5
(c) 4
3
5
2
(d) 1
3
5
4
IES2003,ISRO2011
MatchListI(WeldingDefects)withListII(Causes)and
(
)
(
)
selectthecorrectanswerusingthecodesgivenbelowthe
Lists:
ListI
ListII
(WeldingDefects)
(Causes)
A Spatter
A.
S
1.
D
Dampelectrodes
l
d
B. Distortion
2.
Arcblow
C Slaginclusion
C.
3
3.
Impropercleaningin
multipasswelding
D. Porosity
4.
Poorjointselection
Codes:A B
C
D
A
B
C
D
(a) 4
2
3
1
(b) 4
2
1
3
(c) 2
4
1
3
(d) 2
4
3
1
Page 65 of 240
Welding
Problem
W ldi
P
bl
Cracking of weld metal
Cracking of base metal
Spatter
Distortion
Slag inclusion
Porosity
LamellarTearing
Causes
C
High joint rigidity
Excessive stresses
Arc blow
Poor joint selection
Improper cleaning in multipass welding
Excessive H2, O2, N2, in the
welding atmosphere or Damp
electrodes
inclusionssuchasMn FeandS
inthebasemetaland/or
h b
l d
residualstress
C k
Cracks
y Cracks may be of micro or macro size and may appear in
the weld metal or base metal or base metal and weld

metal boundary.
y Different categories of cracks are longitudinal cracks,
g/
cracks and cracks in
transverse cracks or radiating/star
the weld crater.
y Cracks occur when localized stresses exceed the ultimate
tensile strength of material.
y These stresses are developed due to shrinkage during
solidification of weld metal.
Rev.0
Cracks may be developed due to poor ductility of base

metal,
metal high sulphur and carbon contents,
contents high arc travel
speeds i.e. fast cooling rates, too concave or convex weld
bead and high hydrogen contents in the weld metal.
metal
HAZ Cracking
HAZCracking
g
y
y
y Crackinginheataffectedzonemaybecausedby:
(i)Hydrogeninweldingatmosphere
(ii)hotcracking
(iii)lowductility
(iv)highresidualstresses
(v)brittlephaseinthemicrostructure
Fig.VariousTypesofCracksinWelds
f
k
ld
Hydrogen Induced Cracking

HydrogenInducedCracking
y Duetothepresenceofmoisture,grease,rustetc.,
hydrogenmayentertheweldpoolandgetdissolvedin
h d
h ld
l d di l di
theweldmetal.
y DuringcoolinghydrogendiffusestotheHAZ.
y Crackingmaydevelopduetoresidualstressesassistedby
g
y
p
y
hydrogencoalesence.
y Thefactorsthatdeterminetheprobabilityofhydrogen
inducedembrittlementandcrackingofweldare:
(a)Hydrogencontent
(b)fracturetoughnessofweldandHAZ
(c)stresstowhichthejointisexposedasaresultof
theweldthermalcycle.
Residualstress
Porosity
y The residual stresses result from the restrained expansion
y Porosity results when the gases are entrapped in the

solidifying weld metal.
y These gases are generated from the flux or coating
constituents of the electrode or shielding gases used
during welding or from absorbed moisture in the
coating.
y Porosity
P
it can also
l
b controlled
be
t ll d if excessively
i l high
hi h
welding currents, faster welding speeds and long arc
l
lengths
th are avoided
id d flux
fl
and
d coated
t d electrodes
l t d
are
properly baked.
and contraction that occur during localized heating and

cooling in the region of weld deposit.
y The magnitude of residual stresses depends on the weldment
design support and clamping of the components being
design,
welded, their materials, welding process used, part
dimensions,, welding
g sequence,
q
,p
post weld treatment,, size of
the deposited weld beads, etc.
y Residual stresses should not have a harmful effect on the
strength performance of weldments, reduces fatigue
strength,
g
Mayy cause distortion. This residual stress mayy
result in the cracking of a brittle material and is not
important as far as a ductile material.
Solid Inclusion
SolidInclusion
y Solid inclusions may be in the form of slag or any other
Fig DifferentFormsofPorosities
Fig.DifferentFormsofPorosities
nonmetallic material entrapped in the weld metal as

these may not able to float on the surface of the
solidifying weld metal.
metal
y During arc welding flux either in the form of granules or
coating after melting,
melting reacts with the molten weld metal
removing oxides and other impurities in the form of slag
and it floats on the surface of weld metal due to its low
density.
y Slag
Sl
i l i
inclusion
can be
b prevented
d if proper groove is
i
selected, all the slag from the previously deposited bead
i removed,
is
d too high
hi h or too low
l
welding
ldi
currents and
d
long arcs are avoided.Page 66 of 240
Fig SlagInclusioninWeldments
Fig.SlagInclusioninWeldments
Rev.0
Lack of Fusion
LackofFusion
y Lack of fusion is the failure to fuse together either the
base
metall and
beads
b
d weld
ld metall or subsequent
b
b d in
i
multipass welding because of failure to raise the
temperature off base
b
metall or previously
i
l deposited
d
i d weld
ld
layer to melting point during welding.
y Lack of fusion can be avoided by properly cleaning of
surfaces to be welded, selecting proper current, proper
welding technique and correct size of electrode.
I
l t P
t ti
IncompletePenetration
y Incomplete penetration means that the weld depth is not
upto the desired level or root faces have not reached to

melting point in a groove joint.
y If either low currents or larger arc lengths or large root
face or small root gap or too narrow groove angles are
used then it results into poor penetration.
ImperfectShape,Distortions
p
p
y Imperfect shape means the variation from the desired shape and
size of the weld bead.

y During undercutting a notch is formed either on one side of the
weld bead or both sides in which stresses tend to concentrate and

it can result in the early failure of the joint. Main reasons for
undercutting are the excessive welding currents, long arc lengths
and fast travel speeds.
y Underfilling may be due to low currents, fast travel speeds and
small size of electrodes. Overlap may occur due to low currents,
longer arc lengths and slower welding speeds.
speeds
y Excessive reinforcement is formed if high currents, low voltages,
slow travel speeds and large size electrodes are used. Excessive
root penetration and sag occur if excessive high currents and slow
travel speeds are used for relatively thinner members.
y Distortion is caused because of shrinkage occurring due to large
heat input during welding.
IES 2011 C
ti
l
IES2011Conventional
y Enumeratefourdefectscausedduetoresidualstressesin
weldedjoints.
[2Marks]
Ans.
1 Distortion
1.
2. Crackinginthebasemetal
g
3.
LamellarTearing
4. Reductionoffatiguestrength
IES2004
Consider the following statements:
The magnitude of residual stresses in welding
d
depends
d upon
1. Designofweldment
2. Supportandclampingofcomponents
S
d l
i f
3. weldingprocessused
4. Amountofmetalmelted/deposited
(a) 1,2and4
(b)1,2and3
(c) 1and3
(d)2and3
GATE2003
Matchthefollowing
M h h f ll i
Workmaterial
P Aluminium
P.Aluminium
Q.DieSteel
R.CopperWire
S.Titaniumsheet
(a)P 2
(a)P
(b)P 6
(c)P 4
(d)P 5
Q 5
Q
Q 3
Q 1
Q 4
R 1
R
R 4
R 6
R 2
Typeofjoining
1
1.
SubmergedArcWelding
2.
Soldering
3.
Thermit Welding
4.
AtomicHydrogenWelding
5.
GasTungstenArcWelding
6
6.
L
LaserBeamWelding
B
W ldi
7.
Brazing
S 3
S
S 4
S 2
S 6
Page 67 of 240
IES2004
Thesizeoftheheataffectedzone(HAZ)willincreasewith
1. Increasedstartingtemperature
2. Increasedweldingspeed
3. Increasedthermalconductivityofthebasemetal
4 Increaseinbasemetalthickness
4.
( ) 1,2and3
(a)
d
(b) 1and3
d
(c) 1and4
(d) 2and3
Rev.0
IES1992
Weld spatter occurs due to any of the following
except
(a) High welding current
(b) Too small an electrode
(c) Arc
(d) Wrong polarity
l i
IES2004
Assertion (A): A sound welded joint should not only
be strong enough but should also exhibits a good
amount of ductility
Reason (R): Welding process is used for fabricating
mild steel components only
explanation of A
p
of A
correct explanation
((d)) A is false but R is true
IES2011
Coldcrackinginsteelweldments
Cold crackinginsteelweldments dependson
1.Carbonequivalent
2.Heatinput
3
3.Effectivethickness
3.Hydrogencontentinweldpool
(a)1 2and3only
(a)1,2and3only
(b)1,2and4only
( )
(c)2,3and4only
3
(d)1,2,3and4
20 0
JWM2010
p
g defects.
Assertion ((A)) : Spatter
is one of the welding
Reason (R) : In submerged arc welding process,
there is no spatter of molten metal.
correct explanation
l
i off A
IES1998
An arc welded joint is shown in the above figure.
g
is known as
The part labelled 'B' in the figure
(a) Weld preparation
(b) Penetration
(c) Reinforcement
(d) Slag
Sl
IAS2003
GATE1996
Toolmaterialnotsuitedtoresistanceweldingis
Preheatingbeforeweldingisdoneto
(a) Makethesteelsofter
(b) Bumawayoil,grease,etc,fromtheplatesurface
(c) Preventcoldcracks
(d) Preventplatedistortion
(a) Aluminium oxide

(c) Highspeedsteel
(b)
(d)
Stellite
Masonite
GATE2001
Two plates of the same metal having equal
thickness are to be butt welded with electric arc.
When the plate thickness changes, welding is
achieved by
(a) Adjusting the current
(b) Adjusting
djust g tthee du
duration
at o o
of cu
current
e t
(c) Changing the electrode size
(d) Changing
Ch
i the
th electrode
l t d coating
ti
Page 68 of 240
IES 2012
IES
Brittle welds are mainly obtained due to
(a) Wrong electrode, faulty preheating and metal
hardened by air
(b) Faulty welds, faulty sequence and rigid joints
(c) Wrong speed, current improperly adjusted and faulty
preparation
(d) Uneven heat, improper sequence and deposited
metal shrinks
Rev.0
IES 2012
IES
Which of the following are associated with Heat
Affected Zone?
1 Coldcracking
1.Coldcracking
2.Notchtoughness
3.Hydrogenembrittlement
4
4.Stresscorrosioncracking
g
(a)1,2and3only
(b)1 3and4only
(b)1,3and4only
(c)2,3and4only
(d)1,2,3and4
GATE 2014
GATE2014
Within the Heat Affected Zone (HAZ) in a fusion
welding process, the work material undergoes
(a) microstructural changes but does not melt
(b) neither melting nor microstructural changes
(c) both melting and microstructural changes after
solidification
(d) melting and retains the original microstructure after
solidification
Page 69 of 240
IES 2012
IES
) Hydrogen
y
g induced cracking
g occurs in the
Statement ((I):
heat effected zone adjacent to fusion zone and
classified as solid state cracking
Statement (II):Hydrogen from burning of flux coating
penetrates martensitic micro cracks preventing healing
as well as enlarging them.
them
Statement (I)
((b)) Both Statement ((I)) and Statement ((II)) are individuallyy
true but Statement (II) is not the correct explanation of
Statement (I)
Rev.0
Lathe
h
B SKM d l
BySKMondal
L th
Lathe
L th
Lathe
g machine that rotates the work,, and

y A lathe is a large
cutting is done with a nonrotating cutting tool. The
shapes cut are generally round, or helical. The tool is
typically moved parallel to the axis of rotation during
cutting.
y headstock thisendofthelathecontainsthedriving
motorandgears.Powertorotatethepartisdelivered
f
fromhere.Thistypicallyhasleversthatletthespeeds
h
Thi t i ll h l
th tl tth
d
andfeedsbeset.
y ways thesearehardenedrailsthatthecarriagerides
th h d
d il th tth
i id
on.
y tailstock
t il t k thiscanbeusedtoholdtheotherendofthe
thi b dt h ldth th d fth
part.
NumberofSpindleSpeed
y Number of spindle speed is in a geometric progression.
progression
y If n number of spindle speed is required with N1 is the
minimum speed then
N1 , N1r, N1r 2 , N1r 3 ,.............N1r n1

N1 = N min and N1r n1 = N max
1
y Bed this is a bottom pan on the lathe that catches chips,

chips
cutting fluids, etc.
y carriage this part of the lathe carries the cutting tool and
moves based on the rotation of the lead screw or rod.
y Lead
L d screw A large
l
screw with
ith a few
f threads
th d per inch
i h used
d
for cutting threads. It has ACME threads with included angle

of 29o for easy engagement and disengagement of half nut.
nut
y Lead rod a rod with a shaft down the side used for driving
normal cutting feeds.
feeds
y The critical parameters on the lathe are speed of rotation
(speed in RPM) and how far the tool moves across the work
for each rotation (feed in IPR)
Generalclassificationsusedwhendescribinglathes
y Swing the largest diameter of work that can be rotated.
rotated
y Distance Between Centres the longest length of
workpiece
y Length of Bed Related to the Distance Between
C t
Centres
y Power The range of speeds and feeds, and the
horsepower available
IES 2001
IES
IES 1992
IES
Thespindlespeedrangeinageneralpurposelathe
isdividedintostepswhichapproximatelyfollow
(a) Arithmeticprogression
(b) Geometricprogression
(c) Harmonicprogression
((d)) Logarithmicprogression
g
p g
Feedgearboxforascrewcuttinglatheisdesigned
onthebasisof
(a) Geometricprogression
(b) Arithmeticprogression
(c) Harmonicprogression
((d)) None.
N n1
Therefore, Step Ratio ( r ) = max
N min
y The values of step ratios are 1.06, 1.12, 1.26, 1.41, 1.58 and 2
Page 70 of 240
Rev.0
Threading
T i
Turning
y Turning
Turning producesasmoothandstraightoutsideradius
onapart.
y Threading
Threading Thecuttingtoolismovedquicklycutting
threads.
IES 1998
IES
h di
Threading
y Inonerevolutionofthespindle,carriagemusttravel
thepitchofthescrewthreadtobecut.
N s Pz s = N L Lz L
P = Pitch of the screw thread to be cut
L = Pitch of the lead screw
z s = Number of start of the screw thread to be cut
z L = Number of start of the lead screw
icg = gear ratio
ti off spindle
i dl ( N s ) to
t carriage
i ( N L ) gear train
t i
A single start thread of pitch 2 mm is to be produced

on a lathe having a lead screw with a double start
thread of pitch 4 mm. The ratio of speeds between
the spindle and lead screw for this operation is
(a) 1 : 2 (b) 2: 1
(c) 1: 4 (d) 4: 1
Facing
y Facing The end of the part is turned to be square.
square
Tapering
y Tapering
Tapering thetoolismovessoastocutataper(cone
shape).
IES 1993,ISRO2009
1993 ISRO 2009
IES
It is required to cut screw threads of 2 mm pitch on
a lathe. The lead screw has a pitch of 6 mm. If the
spindle speed is 60 rpm, then the speed of the lead
screw will be
(a) 10 rpm
(b) 20 rpm
(c) 120 rpm
(d) 180 rpm
P ti /Sl tti /G
i
Parting/Slotting/Grooving
y A tool is moved in/out of the work.
work shallow cut will leave
a formed cut, a deep cut will cut off the unsupported

part.
Page 71 of 240
Rev.0
D illi /B i
Drilling/Boring
K li
Knurling
S i i
Spinning
y Drilling/Boring a cutter or drill bit is pushed into the
y Knurling is a manufacturing process whereby a
y Metal Spinning is a process by which circles of metal are
visuallyattractive diamondshaped (crisscross)

pattern is cut or rolled into metal.
y This pattern allows human hands or fingers to get a
better grip on the knurled object than would be
provided by the originallysmooth metal surface.
shaped over mandrels (also called forms) while mounted

on a spinning lathe by the application of levered force
with various tools.
end to create an internal feature.
ISRO2007
Spinning operation is carried out on
(a) Hydraulic press
(b) Mechanical press
Reaming
y A reamer enters the workpiece axially through the end
and enlarges an existing hole to the diameter of the

tool. Reaming removes a minimal amount of material
and is often performed after drilling to obtain both a
more accurate diameter and a smoother internal
finish.
Tapping
y A tap enters the workpiece axially through the end and
cuts internal threads into an existing hole. The

existing hole is typically drilled by the required tap
drill size that will accommodate the desired tap.
(c) Lathe
(d) Milling
Milli machine
hi
W k h ldi D i
f L th
WorkholdingDevicesforLathes
y Held between centers
y 3 jaw self centering chuck (Disc type jobs being held
in chucks )
y 4 jaw independently adjusted chuck
y Held in a collet (Slender rod like jobs being held in
collets )
y Mounted on a face plate (Odd shape jobs, being held
p
)
in face plate)
y Mounted on the carriage
y Mandrels
(IES,
GATE
y MagneticFor-2015
chuck for
thin
job & PSUs)
L th h k
Lathechucks
pp
y Lathe chucks are used to support
a wider varietyy of
workpiece shapes and to permit more operations to be
performed than can be accomplished when the work is
held between centers.
y Threejaw, selfcentering chucks are used for work that
has a round or hexagonal cross section.
y Each jaw in a fourjaw independent chuck can be moved
inward and outward independent of the others by means
of a chuck wrench. Thus they can be used to support a
wide
id variety
i t off work
k shapes.
h
y Combination fourjaw chucks are available in which each
j
jaw
can be
b moved
d independently
i d
d tl or can be
b moved
d
Page of
72 aofspiral
240 cam.
simultaneously by means
3JawChuck
4JawChuck
Rev.0
T i
Turning
F
l f T i
FormulaforTurning
y Depth of cut,
cut d = DOC =
Collets
D1 D2
mm
2
y Average diameter of workpiece
Magnetic Chuck
MagneticChuck
Davgg =
D1 + D2
mm
2
y Cutting Time,
Time CT = L + A + O
fN
y Metal Removal Rate
M RR =
y Cutting Speed, V =
Face Plate
FacePlate
Example
How much
time will
h machining
h
ll be
b required
d to reduce
d
the diameter of a cast iron rod from 120 mm to 116 mm
over a length of 100 mm by turning using a carbide
insert. Cutting velocity is 100 m/min and feed rate = 0.2
mm/rev.
GATE 2013 (PI) C

D
GATE2013(PI)CommonData
A disc of 200 mm outer and 80 mm inner diameter is
faced of 0.1 mm/rev with a depth of cut of 1 mm. The
facing operation is undertaken at a constant cutting
speed of 90 m/min in a CNC lathe. The main
(tangential) cutting force is 200 N.
Assuming approach and overtravel of the cutting
tool to be zero,
zero the machining time in min is
(a) 2.93
(b) 5.86
(c) 6.66
(d) 13.33
IES 2010
IES2010
In turning a solid round bar, if the travel
of the cutting tool in the direction of
f d motion
feed
i
i 1000 mm, rotational
is
i
l
speed
p
of the workpiece
p
is 5500 rpm,
p , and
rate of feed is 0.2 mm/revolution, then
th machining
the
hi i time
ti
will
ill be
b
(a) 10 seconds
(b) 100 seconds
(c) 5 minutes
(d) 10 minutes
IAS 2002
IAS
A 150 mm long, 12 mm diameter 304 stainless steel
rod is being reduced in diameter to 115 mm by
turning on a lathe. The spindle rotates at N = 400
rpm and the tool is travelling at an axial speed of
200 mm/min. The time taken for cutting is given by
(a) 30 s
(b) 36 s
( ) 1 minute
(c)
i t
(d) 45 s
Page 73 of 240
(D
2
1
D 22
4 / fN
)=
D a v g d fN
D1N
,m / min
1000
IES 2003
IES
The time taken to face a workpiece of 72 mm
diameter, if the spindle speed is 80 r.p.m. and cross
feed is 0.3 mm/rev, is
(a) 1.5 minutes (b) 3.0 minutes
( ) 5.4 minutes
(c)
i t (d) 8.5
8 minutes
i t
IES 2004
IES
A medium carbon steel workpiece is turned on a
lathe at 50 m/min. cutting speed 0.8 mm/rev feed
and 1.5 mm depth of cut. What is the rate of metal
removal?
(a) 1000 mm3/min
(b) 60,000 mm3/min
(c) 20,000 mm3/min
((d)) Can not be calculated with the g
given data
Rev.0
T i T
L th
TurningTapersonLathes
y Usingacompoundslide,
d ld
y Usingformtools,
y Offsettingthetailstock,and
Using a Compound Slide

UsingaCompoundSlide
y Limited movement of the compound slide
y Feeding is by hand and is nonuniform. This is
responsible for lowproductivity and poor surface

finish.
y Can be employed
p y
for turning
g short internal and
external tapers with a large angle of (steep) taper.
y Usingtaperturningattachment.
IES 2006
IES
For taper turning on centre lathes, the method of
swiveling the compound rest is preferred for:
(a) Long jobs with small taper angles
(b) Long jobs with steep taper angles
(c) Short jobs with small taper angles
((d)) Short jjobs with steep
p taper
p angles
g
Off tti th t il t k Contd..

Offsettingthetailstock
y Tailstock offset (h) can be determined by
h=
L(D d )
or h = L tan
2l
E
l
Example
Find the angle at which the compound rest should
be set up to turn taper on the workpiece having a
length of 200 mm, larger diameter 45 mm and the
smaller 30 mm.
IES 1992
IES
Tailstocksetovermethodoftaperturningis
preferredfor
(a) Internaltapers
(b) Smalltapers
(c) Longslendertapers
((d)) Steeptapers
p p
Page 74 of 240
UsingaCompoundSlidecontd..
y The angle is determined by
tan =
= Half taper angle
Dd
2l
D = Diameter of stock
d = smaller diameter
l = length of the taper
Off tti th t il t k
Offsettingthetailstock
y It is necessary to measure the tailstock offset when using
this method.
y This method is limited to small tapers (Not exceeding 8o
) over long lengths.
y By
B offsetting
ff tti the
th tailstock,
t il t k the
th axis
i off rotation
t ti off the
th job
j b
is inclined by the half angle of taper.
IAS 2002
IAS
The amount of offset of tail stock for turning taper
on full length of a job 300 mm long which is to have
its two diameters at 50 mm and 38 mm respectively
is
(a) 6 mm
(b) 12 mm
(c) 25 mm
(d) 44 mm
Rev.0
IES 1998
IES
A 400 mm long shaft has a 100 mm tapered step at
the middle with 4 included angle. The tailstock
offset required to produce this taper on a lathe
would be
(a) 400 sin 4
4 (b) 400 sin 22
(c) 100 sin 4 (d) 100 sin 2
F
t l
Formtool
Taper Turning Attachment

TaperTurningAttachment
y Special form tool for generating the tapers is used.

used The
y Additional equipment is attached at the rear of the lathe.

lathe
feed is given by plunging the tool directly into the work.

This method is useful for short external tapers, where
the steepness is of no consequence, such as for
chamfering.
E
i t l tti
Errorsintoolsettings
y Setting the tool below the centre decrease actual rake angle,
while clearance angle increases by the same amount. Thus

cutting force
f
increased.
d
y Setting the tool above the centre causes the rake angle to
increase, while clearance angle reduces. More rubbing with
flank.
T
t L th
TurretLathe
TurretLathe
y The cross slide is disconnected from the cross feed nut.

y The
Th cross slide
lid is
i then
th connected
t d to
t the
th attachment.
tt h
t
y As the carriage is engaged, and travels along the bed, the
attachment will cause the cutter to move in/out to cut

the taper.
y For turning tapers over a comprehensive range is the use
p turning
g attachment.
of taper
IES 2010
IES2010
The effect of centering error
when the tool is set above the
center line as shown in the figure
results
lt effectively
ff ti l in
i
1. Increase in rake angle.
2. Reduction
R d ti in
i rake
k angle.
l
3. Increase in clearance angle.
4. Reduction
R d i in
i clearance
l
angle.
l
Which of these statements is/are
correct?
t?
(a) 1 only
(b) 1 and 4 only
( ) 2 and
(c)
d 4 only
l
(d) 1, 2, 3 and
d4
CapstanLathe
p
A turret lathe, a number of tools can be set up on the

machine and then quickly be brought successively into
working position so that a complete part can be
machined without the necessity for further adjusting,
changing tools, or making measurements.
Page 75 of 240
Rev.0
Capstan lathe
Turret lathe
slide since the saddle is Saddle moves along the bed,

bed
Short slide,
thus allowing the turret to be of
clamped on the bed in position.
g size.
large
Light duty machine, generally for Heavy duty machine, generally
components
p
whose diameter is for components
p
with large
g
less than 50 mm.
diameters, such as 200 mm.
Too much overhang of the turret Since the turret slides on the
when it is nearing cut.
bed, there is no such difference.
Ram type turret lathe,
Ramtype
lathe the ram and
the turret are moved up to the
cutting position by means of the
capstan Wheel. As the ram is
moved toward the headstock, the
t
turret
t is
i automatically
t
ti ll locked
l k d into
i t
position.
Saddle type lathes,

Saddletype
lathes the main
turret is mounted directly on the
saddle, and the entire saddle
and
turret
assembly
reciprocates.
A t
ti L th
AutomaticLathe
y The term automatic is somewhat loosely applied, but is
normally restricted to those machine tools capable of

producing identical pieces without the attention of an
operator, after each piece is completed. Thus, after
setting up and providing an initial supply of material,
further attention beyond replenishing the material
supply is not required until the dimensions of the work
pieces change owing to tool wear.
y A number of types of automatic lathes are developed
that can be used for large volume manufacture
application such as single spindle automatics,
application,
automatics Swiss type
automatics, and multispindle automatics.
l i S i dl
i
h
MultiSpindleAutomaticLathe
IES 2012
IES
Lathe machine with turret can turn a work piece of
limited length only because,
(a) Cross slide motion is obstructed by turret
(b) Turret cannot work on a long job
(c) Chuck cannot be replaced by a face plate
((d)) Turret replaces
p
the loose centre
i d i
h i
Turretindexingmechanism
y The
indexing)
h hexagonal
h
l turret is rotated
d (for
(f
d
) by
b a
Geneva mechanism where a Geneva disc having six

radial slots is driven by a revolving pin. Before starting
rotation, the locking pin is withdrawn by a cam lever
mechanism.
h
The
h single
l rotation off the
h disc
d holding
h ld
the
h
indexing pin is derived from the auxiliary shaft with the
help of another single revolution clutch as indicated.
y For automatic lathe: Ratchet and Pawl mechanism
Swiss type Automatic Lathe Or Sliding Headstock Automatics

SwisstypeAutomaticLatheOrSlidingHeadstockAutomatics
y Headstock travels enabling axial feed of the bar stock
against the cutting tools.

y There is no tailstock or turret
y High spindle speed (2000 10,000 rpm) for small job
diameter
y The cutting tools (upto five in number including two on
the rocker arm) are fed radially
y Used for lot or mass production of thin slender rod or
tubular
b l jobs,
j b like
lik components off small
ll clocks
l k and
d wrist
i
watches, by precision machining.
Norton type Tumbler gear quick change Gear box

NortontypeTumblergearquickchangeGearbox
N t t
T bl
i k h
G
b
NortontypeTumblergearquickchangeGearbox
p
y It comprises
a cone of g
gears 1 to 8 mounted on shaft S2.
y For increase in rate of production of jobs usually of
y The tumbler gear can slide on shaft S1. It can mesh with any
smaller size and simpler geometry.
gear on shaft S2 through an intermediate gear which is
y Having four to eight parallel spindles are preferably used.
located
ocated o
on a sswinging
g g aand
d ssliding
d g lever
e e so tthat
at itt ca
can eengage
gage
y Multiple spindle automats also may be parallel action or
gears 1 to 8 of different diameters, on shaft S2.
progressively working type.
y The lever can be fixed in any desired ratio position with the
help of a stop pin.

y The drive is usually from the driving shaft S1 to the driven
Page 76 of 240
shaft S2.
Rev.0
GATE 2002
GATE
A leadscrew
with
to
l d
ith half
h lf nuts
t in
i a lathe,
l th free
f
t rotate
t t
in both directions has
(a) Vthreads
(b) Whitworth threads
(c) Buttress threads
GATE 2008
2008
GATE
GATE 2008
GATE2008
Contd.
The figure shows an incomplete schematic of a

conventional lathe to be used for cutting threads
with different pitches. The speed gear box Uv, is
shown and the feed gear box Us, is to be placed. P, Q.
R and S denote locations and have no other
significance. Changes in Uv, should NOT affect the
pitch of the thread being cut and changes in Us,
should NOT affect the cutting speed.
(d) ACME threads

Contd..
IES 2004
IES
Match List I (Cutting tools) with List II (Features)
and select the correct answer using the codes given
below the Lists:
List I
List II
A Turning
A.
T i tool
t l
1.
Chi l edge
Chisel
d
B. Reamer
2.
Flutes
C. Milling cutter
3.
Axial relief
4.
Side relief
Codes: A
B
C
A
B
C
( ) 1
(a)
2
3
(b) 4
3
2
(c) 4
2
3
(d) 1
3
2
IES 2009
IES
Whatisthenumberofjawsinself
centred chuck?
Whatisthenumberofjawsinselfcentred
(a) Eight
(b) Six
Si
(c) Four
(d) Three
G
99
GATE1994
To get good surface finish on a turned job,
job
one should use a sharp tool with a ..feed
and
d
speed
d off rotation
t ti off the
th job.
j b
((a)) Minimum, minimum
(b) Minimum, maximum
( ) Maximum,
(c)
M i
maximum
i
((d)) Maximum,, minimum
IES 1999
IES
Which one of the following sets of forces are
encountered by a lathe parting tool while groove
cutting?
(a) Tangential, radial and axial
(b) Tangential
T
ti l and
d radial
di l
(c) Tangential and axial
(d) Radial and axial
Page 77 of 240
ThecorrectconnectionsandthecorrectplacementofUsare
givenby
((a)) Q
QandEareconnected. Us,,isplacedbetweenPandQ.
p
Q
(b) SandEareconnected.Us isplacedbetweenRandS.
((c)) Q
QandEareconnected.Us,,isplacedbetweenQandE.
p
Q
(d) SandEareconnected.Us,isplacedbetweenSandE.
IES 1996
IES
Inturningofslenderrods,itisnecessarytokeep
thetransverseforceminimummainlyto
(a) Improvethesurfacefinish
(b) Increaseproductivity
(c) Improvecuttingefficiency
((d)) Reducevibrationsandchatter.
IES 2009
IES
Whichoneofthefollowingmethodsshouldbeused
forturninginternaltaperonly?
(a) Tailstockoffset
(b) Taperattachment
(c) Formtool
((d)) Compoundrest
p
Rev.0
IES 1992
IES
Whichofthefollowingstatementisincorrectwith
referenceoflathecuttingtools?
(a) Theflankofthetoolisthesurfacebelowand
adjacenttothecuttingedges
(b) Thenoseisthecorner,orchamferjoiningtheside
Th
i th
h f j i i th id
cuttingandtheendcuttingedges
(c) Theheelisthatpartofthewhichisshapedto
producethecuttingedgesandface
(d) Thebaseisthatsurfaceoftheshankwhichagainst
pp
g
thesupportandtakestangent
IES 2006
IES
It is required to cut screw threads with double start
and 2 mm pitch on a lathe having lead screw pitch
of 6 mm. What is the speed ratio between lathe
spindle and lead screw?
(a) 1 : 3 (b) 3: 1
(c) 2 : 3 (d) 3: 2
IES 2009
IES
A capstan lathe is used to mass
produce, in batches
massproduce,
of 200, a particular component. The direct material
cost is Rs 4 per piece, the direct labour cost is Rs 3
per piece and the overhead costs are 400% of the
labour costs. What is the production cost per piece?
(a) Rs 19 (b) Rs 23
( ) Rs
(c)
R 16
6 (d) Rs
R 15
IES 1995
IES
C
g characteristics:
1. Multiple operations can be performed
2 Operator
2.
Operator'ss fatigue is greatly reduced.
reduced
3. Ideally suited for batch production
4 A breakdown
4.
break down in one machine does not affect the
flow of products.
5 Can accommodate modifications in design of
5.
components, within certain limits.
The characteristics which can be attributed to special
purpose machines would include
(a) 1,
1 3 and 4 (b) 1,
1 2 and 4
GATE
(c) 2, 3 and For-2015
5 (d) (IES,
1, 2 and
5 & PSUs)
IES 1996
IES
Assertion (A): Special purpose machine tools and
automatic machine tools are quite useful for job
shops
Reason (R): Special purpose machine tools can do
special types of machining work automatically
l
ti off A
(d) A is false but R isPage
true78 of 240
IES 1997
IES
Consider the following operations:
1. Under cutting
2.
Plain turning
3. Taper
T
t
turning
i
4.
Th d cutting
Thread
tti
The correct sequence of these operations in machining a
product is
((a)) 2, 33, 4
4, 1
((b)) 33, 2, 4
4, 1
(c) 2, 3, 1, 4
(d) 3, 2, 1, 4
IES 2007
IES
Assertion (A): In a multi
spindle automatic lathe, the
multispindle
turret tool holder is indexed to engage the cutting tools
one by
y one for successive machining
g operations.
p
Reason (R): Turret is a multiple tool holder so that for
successive machining
g operation,
p
, the tools need not be
changed.
((a)) Both A and R are individuallyy true and R is the correct
explanation of A
((b)) Both A and R are individuallyy true but R is not the
IES 2003
IES
Which one of the following mechanisms is
employed for indexing of turret in an automatic
lathe?
(a) Whitworth
(b) Rack and pinion
( ) Ratchet
(c)
R t h t and
d pawll
(d) Geneva
G
wheel
h l
Rev.0
IES 2009
IES
For the manufacture of screw fasteners on a mass
scale, which is the most suitable machine tool?
(a) Capstan lathe
(b) Singlespindle automatic lathe
(c) CNC turning centre (lathe)
((d)) CNC machining
g centre
IES 1992
IES
Maximum production of small and slender parts is
done by
(a) Watch maker
maker'ss lathe
(b) Sliding head stock automatic lathe
(c) Multispindle automatic lathe
((d)) Capstan
p
lathe
IAS 1996
IAS
Apart from hexagonal turret, the elements (s) in a
turret lathe include (s)
(a) Crossslide
Cross slide tool post
(b) Crossslide tool post and rear tool post
(c) Crossslide tool post and tail stock
((d)) Teal tool p
post and tail stock
IES 2001
IES
The indexing of the turret in a single
spindle
singlespindle
automatic lathe is done using
(a) Geneva mechanism
(b) Ratchet and Pawl mechanism
(c) Rack and pinion mechanism
((d)) Whitworth mechanism
IAS 2007
IAS
Which one of the following is the characteristic for
capstan lathe?
(a) Rate of production is low
(b) Labour cost is high
(c) Used for handling jobs of varying shapes and sizes
((d)) Capstan
p
head is mounted on a slide
IAS 2004
IAS
Swiss type screw machines have
(a) Turrets
(b) Radial slides
( ) Spindle
(c)
S i dl carriers
i
(d) Tool
T l posts
t
Page 79 of 240
IES 1995
IES
) In a Swiss type
yp automatic lathe,, the
Assertion ((A):
turret is given longitudinal feed for each tool in a
specific order with suitable indexing.
Reason (R): A turret is a multiple tool holder to
facilitate machining with each tool by indexing
without the need to change the tools.
IAS 2002
IAS
Consider the following statements related to Turret
lathe:
1 Turret is mounted directly on the saddle.
1.
saddle
2. Turret is mounted on an auxiliary slide.
3. Much heavier and larger jobs than Capstan lathe can
be produced.
Which of the above statements is/are correct?
(a) 1 and 3
(b) 2 and 3
(c) 1 only
(d) 2 only
IAS 2001
IAS
Consider the following operations and time
required on a multi spindle automatic machine to
produce a particular job
1. Turning
1.2 minutes
2. Drilling
D illi
1.6
6 minutes
i t
3. Forming
0.2 minute
4. Parting
0.6 minute
The time required to make one piece (cycle time) will be
(a) 0.6 minutes
(b) 1.6 minutes
( ) 3.6
(c)
6 minutes
i t
(d) 0.9 minute
i t
Rev.0
IAS 1995
IAS
) In a multispindle
p
Assertion ((A):
automat,, the turret
is indexed to engage each of the cutting tool
mounted on it.
Reason(R): Turret is a multiple tool holder so that
the machining can be continued with each tool
without the need to change the tool.
IAS 1994
IAS
A multi
spindle automat performs four operations
multispindle
with times 50, 60, 65 and 75 seconds at each of its
work centers. The cycle time (time required to
manufacture one work piece) in seconds will be
(a) 50 + 60 + 65 + 75
(b) (50 + 60 + 65 + 75) /4
(c) 75/4
((d)) 75
IAS 1998
IAS
Consider the following features:

1. All spindles operate simultaneously,
2. One
O
piece
i
i completed
is
l t d each
h time
ti
th tools
the
t l are
withdrawn and the spindles are indexed
3. The tool slide indexes or revolves with the spindle
carrier
Which of these features are characteristics of a multi
p
automatic machine used for bar work?
spindle
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3
(d) 1 and 3
Assertion (A): For thread cutting, the spindle speed

selected on a lathe, is very low.
Reason (R): The required feed rate is low in
threading operation.
( ) Both
(a)
B th A and
i di id ll true
t
and
d R is
i the
th
IES2011
Consider the following statements associated with

the lathe accessories:
1 Steady rest is used for supporting a long job in
1.
between head stock and tail stock.
2. Mandrel
M d l is
i used
d for
f turning
t
i small
ll cylindrical
li d i l job.
j b
3. Collects are used for turning discshaped job.
Of these statements:
(a) 1 and 2 are correct
(b) 2 and 3 are correct
(c) 3 alone is correct
(d) 1 alone is correct
IAS 2000
IAS
IAS 1998
IAS
In Norton type feed gearbox for cutting Whitworth

standard threads with a standard TPI Leadscrew, power
flows from:
(a) Spindle to Tumbler gear to Norton cone to Meander
drive to Leadscrew
(b) Spindle to Norton cone to Tumbler geat to Meander
drive to Leadscrew
(c) Spindle t o Tumbler gear to Meander drive to Norton
cone to Leadscrew
(d) Spindle to Norton cone to Meander drive to Tumbler
gear to Leadscrew
g
Drilling
D illi
Drilling
y Drilling is a operation that cuts cylindrical holes.
holes
BySKMondal
Page 80 of 240
Rev.0
TYPES OF DRILL PRESSES

TYPESOFDRILLPRESSES
D illi O
ti
DrillingOperations
Chip formation
of a drill
y Verticalorpillartype
V ti l ill t
y RadialArmtype
y Gangdrill
g
y MultiSpindledrill
y NumericalControldrill
Drill
y The twist drill does most of the cutting with the tip of
D ill
Drill
the bit.
There are flutes
to carry the chips
up
from
the
cutting edges to
the top of the
hole where they
are cast off.
IES 2004
IES
The helical flute in a twist drill provides the necessary
1. Clearance
Cl
angle
l for
f the
th cutting
tti edge
d
2. Rake angle for the cutting edge
3. Space for the chip to come out during drilling
4. Guidance for the drill to enter into the workpiece
Which of the statements given above are correct?
( ) 1 and
(a)
d2
(b) 2 and
d3
(c) 3 and 4
(d) 1 and 4
IES 2003
IES
D ill
Drill
D ill
Drill
The purpose of helical grooves in a twist drill is to

1. Improve the stiffness
2. Save
S
a tool
t l material
t i l
3. Provide space for chip removal
4. Provide rake angle for the cutting edge
Codes:
( ) 1 and
(a)
d2
(b) 2 and
d3
(c) 3 and 4
(d) 1 and 4
y Axial rake angle is the angle between the face and the line
y Drill sizes
si es are typically
t picall measured across the drill points with
ith
parallel to the drill axis. At the periphery of the drill, it is

equivalent to the helix angle.
y The lip clearance angle is the angle formed by the portion of
the flank adjacent to the land and a plane at right angles to

the drill axis measured at the periphery of the drill.
y Lead
L d off the
th helix
h li is
i the
th distance
di t
measured
d parallel
ll l to
t the
th drill
d ill
axis, between corresponding point on the leading edge of the

land in one complete revolution.
Page 81 of 240
a micrometer
y Most widely used material is High Speed Steel
y The drill blanks are made by forging and then are twisted to
provide the torsional rigidity.

rigidity Then the flutes are machined
and hardened before the final grinding of the geometry.
y Deep hole drilling requires special precautions to take care of
the removal of large volume of chips.
Rev.0
GATE 1996
GATE
The rake angle in a drill
(a) Increases from centre to periphery
(b) decreases
d
f
from
centre
t to
t periphery
i h
(c) Remains constant
(d) Is irrelevant to the drilling operation
H li A l ()
HelixAngle()
y Helix angle is the angle between the leading edge of the
land and the axis of the drill. Sometimes it is also called

as spiral angle.
y The helix results in a positive cutting rake
y This angle is equivalent to back rake angle of a single
point cutting tool.
y Usual 20
20 to 35
35 most common
y Large helix : 45 to 60 suitable for deep holes and softer
work
k materials
i l
y Small helix : for harder / stronger materials
y Zero helix : spade drills for high production drilling
microdrilling and hard work materials
IES 1992
IES
Low helix angle drills are preferred for drilling
holes in
(a) Plastics
(b) Copper
(c) Cast steel
(d) Carbon steel
IES 1997
IES
P i t A l (2)
PointAngle(2)
The rake angle in a twist drill

(a) Varies from minimum near the dead centre to a
maximum value at the periphery
(b) Is maximum at the dead centre and zero at the
periphery
i h
(c) Is constant at every point of the cutting edge
(d) Is a function of the size of the chisel edge.
y The point angle is selected to suit the hardness and brittleness of
the material being drilled.

drilled
y Harder materials have higher point angles, soft materials have
lower point angles.

y An increase in the drill point angle leads to an increase in the
y
y
y
y
y
y
thrust force and a decrease in the torque due to increase of the

orthogonal
h
l rake
k angle.
l
This angle (half) refers to side cutting edge angle of a single point
tool.
tool
Standard Point Angle is 118
It is 116 to 118 for medium hard steel and cast iron
It is 125 for hardened steel
It is 130
3 to 140
4 for brass and bronze
It is only 60 for wood and plastics
IES 1992
IES
A drill for drilling deep
have
(a) High helix angle
(c) Small point angle
GATE 1997
GATE
holes in aluminum should

(b)
(d)
Taper shank
No lip
Helix angle of fast helix drill is normally

(a) 35o
(b) 60
6 o
(c) 90o
(d) 5o
Cutting Speed in Drilling

CuttingSpeedinDrilling
IFS2011
y Thecuttingspeedindrillingisthesurfacespeedofthe
Discuss deephole drilling keeping in mind speed and

feed, mentioning the technique of applying coolant.
twistdrill.
V=
DN
1000
m / min
i
[5marks]
Page 82 of 240
Rev.0
D illi Ti
DrillingTime
y Time for drilling the hole
T=
L
, min
i
fN
MRR i D illi
MRRinDrilling
D2
3
MRR =
fN , mm / min
4
E
l
Example
A hole
h l with
ith 40mm diameter
di
t and
d 50mm depth
d th is
i to
t
be drilled in mild steel component.
p
The cutting
g
speed can be taken as 65 m/min and the feed rate as
0.25 mm/rev. Calculate the machining time and the
material
t i l removall rate.
t
Some Formulae for Drilling

SomeFormulaeforDrilling
D
Cone height (h) =
2 tan
U t chip
Uncut
hi thickness
thi k
(t ) =
Width of cut (b) =
f
sin
i
2
D
2sin
GATE 2002
GATE
The time taken to drill a hole through a 25 mm thick
plate with the drill rotating at 300 r.p.m. and
moving at a feed rate of 0.25 mm/revolution is
(a) 10 sec
(b) 20 sec
( ) 60
(c)
6 sec
(d) 100 sec
t
( 2r / D ) tan
Orthogonal rake angle ( ) = tan 1
sin
GATE 2012
GATE
In
a through
I a single
i l pass drilling
d illi operation,
ti
th
h hole
h l off
155 mm diameter is to be drilled in a steel p
plate of 550
mm thickness. Drill spindle speed is 500 rpm, feed
is 0.2 mm/rev and drill point angle is 118. Assuming
2 mm clearance
l
att approach
h and
d exit,
it the
th total
t t l drill
d ill
time ((in seconds)) is
(a) 35.1
(c) 31.2
IES 2002
IES
The arm of a radial drilling machine is being raised
at a speed of 3.9 m/min by single start square
threads of 6 mm pitch and 30 mm diameter. The
speed of the screw
(a) Is 650 rpm
(b) Is 180 rpm
(c) Is 130 rpm
((d)) Cannot be determined as the data is insufficient
GATE 2004
GATE
Through holes of 10 mm diameter are to be drilled
in a steel plate of 20 mm thickness. Drill spindle
speed is 300 rpm, feed 0.2 mm/ rev and drill point
angle is 120. Assuming drill over travel of 2 mm, the
time for producing a hole will be
(a) 4 seconds
(b) 25 seconds
( ) 100 seconds
(c)
d
(d) 110 seconds
d
IES 1994
IES
The ratio between two consecutive spindle speeds
for a sixspeed drilling machine using drills of
diameter 6.25 to 25 mm size and at a cutting velocity
of 18 m/min is
(a) 1.02
1 02 (b) 1.32
1 32
(c) 1.62 (d) 1.82
(b) 32.4
For-2015 (IES,
GATE & PSUs)
(d) 30.1
Page 83 of 240
Rev.0
IES 2009
IES
What is the drilling time for producing a hole in an
MS sheet of 25 mm thickness using an HSS drill of
20 mm diameter? The cutting speed and feed for
drill are 20 m/min and 0.25 mm/revolution
respectively, Neglect time taken for setting up,
approaching and travelling of tools.
(a) 0.314
0 314 min (b) 0.236
0 236 min
(c) 0.438 min (d) 0.443 min
IES 2002
IES
A 31.8 mm H.S.S. drill is used to drill a hole in a cast
iron block 100 mm thick at a cutting speed 20
m/min and feed 0.3 mm/rev. If the over travel of
drill is 4 mm and approach 9 mm, the time required
to drill the hole is
(a) 1 min 40 s (b) 1 min 44 s
( ) 1 min
(c)
i 49 s (d) 1 min
i 53 s
GATE 2014
GATE
A hole
h l off 20 mm diameter
di
t is
i to
t be
b drilled
d ill d in
i a steel
t l block
bl k
of 4
40 mm thickness. The drilling
g is p
performed at
rotational speed of 400 rpm and feed rate of 0.1 mm/rev.
The required approach and over run of the drill together
i equall to
is
t the
th radius
di
off drill.
d ill The
Th drilling
d illi
ti
time
(i
(in
minute)) is
(a) 1.00
IAS 1999
IAS
GATE2014(PI)
An HSS drill of 20 mm diameter with 5 mm cone
height is used to drill a through hole in a steel work
work
piece of 50 mm thickness. Cutting speed of 10
m/min and feed rate of 0.3 mm/rev are used. The
To drill a 10 mm diameter hole through a 20 mm

thick M.S. plate with a drill bit running at 300 rpm
and a feed of 0.25 mm per revolution, time taken
will be
(a) 8 s (b) 16 s
(c) 24 s (d) 32 s
drilling time, in seconds, neglecting the approach
(b) 1.25
(c) 1.50
(d) 1.75
2007 (PI) Li k d S 1
GATE
Blind holes 10 mm diameter, 50 mm deep are
being drilled in steel block. Drilling spindle
speed is 600 rpm,
rpm feed 0.2
0 2 mm/rev,
mm/rev point angle of
drill is 120o.
Machining time (in minutes) per hole will be
(a) 0.08
0 08
(b) 0.31
0 31 (c) 0.44
0 44 (d) 0.86
0 86
and over travel,

travel is _______
2007 (PI) Li k d S 2
GATE
Blind holes 10 mm diameter, 50 mm deep are
being drilled in steel block. Drilling spindle
speed is 600 rpm,
rpm feed 0.2
0 2 mm/rev,
mm/rev point angle of
drill is 120o.
During the above operation, the drill wears out
after p
producing
g 200 holes. Taylors
y
tool life
equation is of the form VT0.3 = C, where V =
cutting speed in m/minute and T = tool life in
minutes. Taylors constant C will be
( ) 15
(a)
( ) 72
(b)
( ) 93
(c)
( ) 490
(d)
IAS 1994
IAS
The time (in minutes) for drilling a hole is given by
t=
Depth of the hole + h

Feed RPM
where 'h' is the

(a) Length of the drill
(b) Drill diameter
(c) Flute length of the drill
(d) Cone
C
h i ht off the
height
th drill.
d ill
Page 84 of 240
IES 1999
IES
pp
Match ListI (Drill bits) with ListII (Applications)
and select the correct
answer using the codes given below the Lists:
ListI
ListII
A Core
A.
C
d ill
drill
1.
T enlarge
To
l
a hole
h l to
t a certain
t i depth
d th so as to
t
accommodate the bolt head of a screw
g an alreadyy existing
g hole in a
B.
Reamer 2.
To drill and enlarge
casting
C.
Counter bore drill 3.
To drill a hole before making internal
thread
h d
D.
Tap drill
4.
To improve the surface finish and dimensional
accuracy of the already drilled hole
Code:A
B
C
D
A
B
C
D
(a) 1
3
2
4
(b)
2
3
1
4
(c) 2
4
1
3
(d)
3
2
4
1
Rev.0
R
i
Reaming
Reamer
g removes a small amount of material from the

y Reaming
surface of holes.
y It is done for two purposes: to bring holes to a more exact
Reaming,Boring,Broaching
size and to improve the finish of an existing hole.

y Multiage cutting tools that has many flutes, which may be
straight
i h or in
i a helix
h li are used.
d
y No special machines are built for reaming. The same
B SKM d l
BySKMondal
machine that was employed for drilling the hole can be used
for reaming by changing the cutting tool.
y Only a minimum amount of materials should be left for
removal by reaming. As little as 0.1 mm is desirable, and in
no case should the amount exceed 0.4 mm.
y A properly reamed hole will be within 0.025 mm of the
correct size and have a fine finish.
Reamer Flutes
ReamerFlutes
y The reamer flutes are either straight or helical.
y The helical flutes promote smoother cutting and should be
y
y
used specifically for holes that are not continuous, such as

y y p
parallel to the axis of the hole.
those with keyways
The cutting action of the helical flutes is smoother and helps
in preventing chatter.
The reamers are termed as left hand or right hand,
depending upon the direction in which they are moved,
l ki from
looking
f
th shank
the
h k to
t the
th cutting
tti portion.
ti
The righthand reamer with righthand helix is used for
roughing cuts,
cuts since the tool tends to go into the workpiece
more efficiently and thereby promotes the material removal.
A right
righthand
hand reamer with left
lefthand
hand flutes is used for
finishing cuts.
R
i
Reaming
R
i
Reaming
y To meet quality requirements, including both finish and
y Reamers,, like drills,, should not be allowed to become dull.
accuracy (tolerances on
diameter,
roundness,
straightness, and absence of bell
bellmouth
mouth at ends of
holes). Reamers must have adequate support for the
cutting edges, and reamer deflection must be minimal.
y Reaming speed is usually twothirds the speed for
drilling the same materials.
materials However,
However for close tolerances
and fine finish, speeds should be slower.
y Feeds
F d are usually
ll much
h higher
hi h than
th
th
those
f drilling
for
d illi
and depend upon material.
y Recommended cutting fluids are the same as those for
drilling.
The chamfer must be reground long before it exhibits

excessive wear. Sharpening is usually restricted to the
starting
t ti taper
t
or chamfer.
h f Each
E h flute
fl t mustt be
b ground
d exactly
tl
evenly or the tool will cut oversize.
y Reamers tend to chatter when not held securely,
securely when the
work or work holder is loose, or when the reamer is not
properly
p
p yg
ground.
y Irregularly spaced teeth may help reduce chatter. Other cures
for chatter in reaming are to reduce the speed, vary the feed
rate, chamfer the hole opening, use a piloted reamer, reduce
the relief angle on the chamfer, or change the cutting fluid.
y Any
A misalignment
i li
b
between
the
h work
k piece
i
and
d the
h reamer
85 ofreaming.
240
will cause chatter and Page
improper
T
fR
TypesofReamers
Theprincipaltypesofreamersare:
1. Handreamers
a.
St i ht
Straight
b.
Taper
2. Machineorchuckingreamers
a.
Rose
b.
Fluted
3. Shellreamers
Sh ll
4. Expansionreamers
5. Adjustablereamers
RoseReamer
Rose chucking reamers
are ground
d cylindrical
li d i l
and have no relief
b hi d the
behind
th outer
t edges
d
of the teeth. All cutting
is done on the beveled
be eled
ends of the teeth
Rev.0
g
ChuckingReamer
Fluted
chucking
reamers have
h
relief
li f
behind the edges of the
t th as well
teeth
ll as beveled
b l d
ends. They can cut on
all portions of the teeth.
teeth
Their
flutes
are
relatively short and they
are intended for light
finishing cuts.
cuts
Trepanning
y Trepanning is a annular groove producing operation
which leaves a solid cylindrical core in the centre. In

trepanning a cutter consisting of one or more cutting
edges placed along the circumference of a circle is used
to produce the annular groove.
ShellReamer
Shell reamers often are
used
d for
f sizes
i
over 20
mm to save cuttingtool
material.
t i l
Th
The
shell,
h ll
made of HSS for smaller
si es and with
sizes
ith carbide
edges for larger sizes or
for
mass production
massproduction
work.
IES 1999
IES
Which one of the following processes results in the
best accuracy of the hole made?
(a) Drilling
(b) Reaming
(c) Broaching (d) Boring
IFS2011
What is the main difference between rose reamer
and chucking reamer ? Write in short about shell
reamer.
[
[5marks]
k ]
IES 1999
IES
Consider the following statements regarding
reaming process:
1 Reaming generally produces a hole larger than its
1.
own diameter
2. Generally
G
ll rake
k angles
l are nott provided
id d on reamers.
3. Even numbers of teeth are preferred in reamer
design.
(a) 1 and 2
(b) 2 and 3
(c) 1 and 3
(d) 1,
1 2 and 3
TrepanningTool
IES 1998
1998
IES
Match List
II and select the correct answer
ListII with List
ListII
using the codes given below the lists:
ListII
List
ListII
List
II
A. Reaming
1. Smoothing and squaring surface
around the hole for proper seating
B. Counterboring 2.Sizing and finishing the hole
C Countersinking
C.
Counter sinking 3.
3 Enlarging the end of the hole
D. Spot facing
4. Making a conical enlargement at the
end of the hole
Code:A
B
C
D
A
B
C
D
( ) 3
(a)
2
4
1
( ) 2
(b)
3
1
4
(c) 3
2
1
4
(d) 2
3
4
1
IES 1994
IES
In reaming process
(a) Metal removal rate is high
(b) High
Hi h surface
f
fi i h is
finish
i obtained.
bt i d
(c) High form accuracy is obtained
(d) High dimensional accuracy is obtained.
Page 86 of 240
GATE 2007(PI)
2007 (PI)
GATE
Reaming is primarily used for achieving
(a) Higher MRR
(b) Improved
I
d dimensional
di
i
l tolerance
t l
(c) Fine surface finish
(d) Improved positional tolerance
Rev.0
GATE 2014(PI)
2014 (PI)
GATE
Reamingisaprocessusedfor
R
i i
df
(a)creatingacircularholeinmetals
(b)cuttingaslotontheexistingholesurface
g
g
(c)finishinganexistingholesurface
(d)makingnoncircularholesinmetals
IES 1993
IES
A hole of 30 mm diameter is to be produced by reaming.
The minimum diameter permissible is 30.00 mm while
the maximum diameter p
permissible is 330.055 mm. In this
regard, consider the following statements about the
reamer size:
1. The minimum diameter of the reamer can be less than 30 mm.
2. The minimum diameter of the reamer cannot be less than 30 mm.
3. The maximum diameter of the reamer can be more than 30.05 mm.
4.The maximum diameter of the reamer must be less than 30.05 mm.
Of these statements
(a)
1 and 4 are correct
(c)
2 and 3 are correct
IAS 1999
IAS
For reaming operation of blind hole, the type of
reamer required is
(a) Straight flute reamer
(b) Right hand spiral fluted reamer
(c) Left hand spiral fluted reamer
((d)) None of the above
Boring
(b)
(d)
1 and 3 are correct

2 and 4 are correct
IAS 2003
IAS
p
) with List II ((Application)
pp
) and select
Match List I ((Operation)
the correct answer using the codes given below the lists:
ListI
ListII
(
(Operation)
)
(
(Application)
)
(A) Reaming 1. Used for enlarging the end of a hole to give it a
conical
i l shape
h
f a short
for
h distance
di
(B) Boring
2. Used for enlarging only a limited portion of the
hole
(C) Counter boring
3.
Used for finishing a hole
(D) Counter sinking
4
4.
Used for enlarging a hole
Codes:A
B
C
D
A
B
C
D
(a) 3
2
4
1
(b)
1
4
2
3
(c) 3
4
2
1
(d)
1
2
4
3
IES 1998
IES
A component requires a hole which must be within
the two limits of 25.03 and 25.04 mm diameter.
Which of the following statements about the
reamer size are correct?
1 Reamer size cannot be below 25.03
1.
25 03 mm.
mm
2. Reamer size cannot be above 25.04 mm.
3. Reamer size can be 25.04 mm.
4. Reamer size can be 25.03
4
5 3 mm.
(a) 1 and 3
(b) 1 and 2
(c) 3 and 4
(d) 2 and 4
IES 1992
IES
Shell reamers are mounted on
(a) Tool holders
(b) Amour plates
( ) Arbor
(c)
Ab
(d) Shanks
Sh k
Boring
y Boring always involves the enlarging of an existing hole,
which may have been made by a drill or may be the result of a

core in a casting.
g
y An equally important and concurrent purpose of boring may
be to make the hole concentric with the axis of rotation of
the workpiece and thus correct any eccentricity that may
have resulted from the drill drifting off the centerline.
Concentricity is an important attribute of bored holes.
y When boring is done in a lathe, the work usually is held in a
chuck or on a faceplate. Holes may be bored straight,
tapered, or to irregular contours.
y Boring is essentially internal turning while feeding the tool
Page 87 of 240
parallel to the rotation axis of the workpiece.
Rev.0
B i
Boring
B i
Boring
y The same principles are used for boring as for turning.

turning
y Because the tool overhang will be greater, feeds and
y The tool should be set exactly at the same height as the
depths of cut may be somewhat less than for turning to

prevent tool vibration and chatter.
y In some cases, the boring bar may be made of tungsten
carbide because of this material
material'ss greater stiffness.
stiffness
y The boring tool is a singlepoint cutting tool.
y Hole quality, finish boring can typically achieve holes
within tolerances of IT9.
y Surface finishes better than Ra 1 micron can be achieved.
axis of rotation.
rotation Slightly larger end clearance angles
sometimes have to be used to prevent the heel of the tool
from rubbing on the inner surface of the hole.
hole
F
l f B i
FormulaforBoring
y Average diameter of workpiece
Davg =
IES 1993
IES
D1 + D2
mm
2
y Cutting Time,
Time CT = L + A + O
fN
The main purpose of boring operation, as compared

to drilling is to:
(a) Drill a hole
(b) Finish the drilled hole
(c) Correct the hole
((d)) Enlarge
g the existing
g hole
IES2009
IES 1994,ISRO2008
1994 ISRO 2008
IES
Enlarging an existing circular hole with a rotating
single point tool is called
(a) Boring
(b) Drilling
(c) Reaming (d) Internal turning.
y Metal Removal Rate

M RR =
(D
2
1
D 22
4 / fN
)=
D a v g d fN
IES 1992,ISRO2010
1992 ISRO 2010
IES
Which of the machine tools can be used for boring
1. Lathe
2. Drilling
D illi machine
hi
3. Vertical milling machine
4. Horizontal milling machine
(a) 1, 2, 3
(b) 1, 3, 4
(c) 2 and 4
(d) 1, 2, 3, 4
IES 2000
IES
Which one of the following sets of tools or tools and
processes are normally employed for making large
diameter holes?
(a) Boring tool
(b) BTA tools
t l (Boring
(B i and
d trepanning
t
i association)
i ti ) and
d
gun drill
(c) Gun drill and boring tool
((d)) Boring
g tools and trepanning
p
g
Page 88 of 240
IES 1996
IES
Which of the following statements are correct?
1. A boring machine is suitable for a job shop.
2. A jig
ji boring
b i machine
hi is
i designed
d i
d specially
i ll for
f doing
d i
more accurate work when compared to a vertical
milling
illi machine.
hi
3. A vertical precision boring machine is suitable for
boring holes in cylinder blocks and liners.
((a)) 1, 2 and 3 ((b)) 1 and 2
(c) 2 and 3
(d) 1 and 3.
Rev.0
IES 1995
IES
The effects of setting a boring tool above centre
height leads to a/an.
(a) Increase in the effective rake angle and a decrease in
the effective clearance angle.
(b) Increase
I
i both
in
b th effective
ff ti rake
k angle
l and
d effective
ff ti
clearance angle.
(c) Decrease in the effective rake angle and an increase
in the effective clearance angle.
(d) Decrease in both effective rank angle and effective
g
clearance angle.
JWM2010
Considerthefollowingoperationsregardingboring
machines:
1.Counterboring
C
t b i
2.Countersinking
3.Trepanning
Whichoftheaboveoperationsis/arecorrect?
(a)1,2and3
(b)1and2only
( ) d l (d)1only
(c)2and3only
(d) l
Broaching
B
hi
Broaching
g is a multipletooth
p
g operation
p
y Broaching
cutting
with the
y The material removal using the broach teeth is shown
tool reciprocating.
y Since in broaching
g the machining
g operation
p
is
completed in a singlestroke as the teeth on the cutting
tool, called broach, are at gradually increasing height
corresponding to the feed per tooth of a milling cutter.
y The shape of the broach determines the shape of the
machined part.
y Broaching was originally developed for machining
internal keyways, but looking at the advantages, it has
been extensively used in the mass production of
automobile
t
bil componentt manufacture
f t
f various
for
i
other
th
surfaces as well.
Broaching
B
h C t ti
BroachConstruction
schematically in Fig. shown in below. The dotted line in

the figure indicates the amount of material being
removed by successive individual teeth.
B
h C t ti
BroachConstruction
B
h C t ti
BroachConstruction
B
h C t ti
BroachConstruction
y The broach is composed of a series of teeth, each tooth
y The last set of teeth is called the finishing or sizing teeth.

teeth
y The rear pilot helps to keep the broach to remain square
standing slightly higher than the previous one. This rise

per tooth is the feed per tooth and determines the
material removed by the tooth.
y There are basically three sets of teeth present in a broach
as shown in Fig. shown above.
y The
Th roughing
hi teeth
t th that
th t have
h
th highest
the
hi h t rise
i per tooth
t th
remove bulk of the material.
y The semifinishing teeth, whose rise per tooth is smaller,
remove relatively smaller amounts of material compared
to the roughing teeth.
Very little material will be removed by these teeth.

y The necessary size will be achieved by these teeth and
hence all the teeth will be of the same size as that
required finally.
finally With the progress of time,
time when the
first set of teeth wear out, the next set of teeth will be
able to provide the sizing function.
function
y The pull end of the broach (Fig. shown in above) is
attached
tt h d to
t the
th pulling
lli
mechanism
h i
off the
th broaching
b
hi
machine with the front pilot aligning the broach
properly
l with
ith respectt to
t the
th workpiece
k i
axis
i before
b f
th
the
actual cutting starts.Page 89 of 240
with the workpiece as it leaves the workpiece after

broaching.
y Broaching speeds are relatively low, of the order of 6 to 15
m/min However,
m/min.
However the production rate is high with the
cycle times being about 5 to 30 seconds, including the
workpiece and tool handling times.
times The low cutting
speeds are conducive to very high tool life with very
small tool wear rates.
rates
Rev.0
B
h C t ti
BroachConstruction
B
h C t ti
BroachConstruction
y Broaches are generally made of high speed steel in view
y For smooth operation, it is essential that at least two or
of its high impact strength. Sometimes, the titanium

nitride coating helps to improve the tool life further.
Also, the carbide inserttype broaches are used more for
surface broaching of cast iron for very large volume
production to reduce the frequent resharpening of the
broach, which is a very difficult operation.
y Standard broaches are available for common and more
often used forms,
forms such as round and square holes,
holes
keyways, etc.
Li it ti
fb
hi
Limitationsofbroaching
p
1. C
Custom made broaches are veryy expensive
and can
therefore be justified only for very large volume
production.
2. A broach has to be designed for a specific application
and can be used only for that application. Hence, the
lead time for manufacture is more for custom designed
broaches.
3. Broaching, being a very heavy metal removal
operation, requires that the workpiece is rigid and
capable
bl off withstanding
ith t di the
th large
l
f
forces.
4. Broaching can only be carried out on the workpiece
whose
h
geometry
t is
i such
h that
th t there
th
i no interference
is
i t f
f
for
the broach movement for the cutting.
IES 1993,2001
1993 2001
IES
Assertion (A): No separate feed motion is required
during broaching.
Reason (R): The broaching machines are generally
hydraulically operated.
( ) Both
(a)
B th A and
i di id ll true
t
and
d R is
i the
th
three teeth be simultaneously engaged.

y The thumb rule for tooth spacing,
spacing s =1.75
1 75 l , mm
y The cut per tooth f is kept in the range 0.05 mm 0.09
mm.
y In the normal speed BUE may be a problem. To avoid
this a copious supply of the cutting fluid is provided.
IES 2007
IES
Among the following machining processes, which
can be used for machining flat surfaces?
1 Shaping
1.
2
2.
Milling
3
3.
Broaching
(a) 1 and 2 only
(b) 1 and 3 only
((c)) 2 and 3 onlyy
((d)) 1, 2 and 3
IES 2001
IES
The screw and nut in a broaching machine are
changed from square thread to ACME thread. The
power requirement of the machine at the same
r.p.m. will
(a) Remain same
(b) Decrease
(c) Increase
((d)) Depend
p
on the operator
p
Page 90 of 240
Ad t
fb
hi
Advantagesofbroaching
g an operation
p
g
1. It is the fastest wayy of finishing
with a single
stroke.
2. Since all the machining parameters are built into the
broach very little skill is required from the operator.
broach,
operator
3. Broaching machine is simple since only a single
reciprocating
p
g motion is required
q
for cutting.
g
4. Final cost of the machining operation is one of the lowest
for mass production.
5. Any
A type off surface,
f
i
internal
l or external,
l can be
b generated
d
with broaching.
6 Many surfaces,
6.
surfaces which are very difficult or impossible by
other means, can be done by broaching. For example, square
hole and internal splines.
7. Good surface finish and fine dimensional tolerances can be
achieved by broaching, often better than boring or reaming
IES 1993
IES
Assertion (A): Soluble oils are employed with
broaching machine.
Reason (R): Soluble oils have excellent cooling
effect.
( ) Both
(a)
B th A and
i di id ll true
t
and
d R is
i the
th
IAS 2004
IAS
Which one of the following is true for the last few
teeth of a broach which are meant for fine
finishing?
(a) They have equal diameter
(b) They
Th have
h
i
increasing
i diameter
di
t
(c) They have decreasing diameter
(d) They have alternately increasing and decreasing
diameter.
Rev.0
IES 2005
2005
IES
IES 2002
IES
(
) with List II (Element
(
Match List I (Tool)
of Tool)) and
select the correct answer using the code given below the
Lists:
List I
List II
A Broach
1.
Tang
B. Reamer
2.
Pilot
C. Drill
3.
Front taper
D. Carbide insert face mill 4.
Bond
5.
Sweeper tooth
Codes:A
B
C
D
A
B
C
D
(a) 2
5
1
3
(b) 1
3
4
5
(c) 2
3
1
5
(d) 1
5
4
3
Match List I with List II and select the correct answer:

List I (Machine tool)
List II (Features)
A Lathe
A.
1
1.
Push or pull tool
B. Drilling machine
2.
Rachet and pawl
mechanism
C. Shaper
3.
Dividing head
D Broaching
D.
B
hi machine
hi
4.
H ll tapered
Hollow
d spindle
i dl
5.
Face plate
Codes:A
B
C
D
A
B
C
D
(a) 2
4
5
1
(b) 5
3
2
4
(c) 2
3
5
4
(d) 5
4
2
1
Milli
Milling
Milli
Milling
Milling machines of various types are widely used

for the following purposes using proper cutting
tools called milling cutters:
y Flat surface in vertical, horizontal and inclined planes
y Making
M ki slots
l t or ribs
ib off various
i
sections
ti
y Slitting or parting
y Often producing surfaces of revolution
y Making helical grooves like flutes of the drills
y Long thread milling on large lead screws, power screws,
worms etc and short thread milling for small size
fastening screws, bolts etc.
y 2D
clutches
D contouring
t i like
lik cam profiles,
fil
l t h etc
t and
d 3D
D
U
illi
dd
illi
Upmillinganddownmilling
Ad t
fD
Milli
AdvantagesofDownMilling
y In down milling, though the cut starts with a full chip
thickness, the cut gradually reduces to zero. This helps in

eliminating the feed marks present in the case of up
milling and consequently better surface finish.
y Climb milling also allows greater feeds per tooth and
longer cutting life between regrinds than the
conventional milling.
milling
y Up milling needs stronger holding of the job and down
milling
illi
needs
d backlash
b kl h free
f
screwnutt systems
t
f
for
feeding.
Milling
B SKM d l
BySKMondal
U
illi
dd
illi
Upmillinganddownmilling
contouring
g like die or mould cavities
y Cutting teeth in piece or batch production of spur gears,
straight toothed bevel gears, worm wheels, sprockets,

clutches
l h etc.
y Producing some salient features like grooves,
grooves flutes,
flutes
gushing and profiles in various cutting tools, e.g., drills,

taps, reamers, hobs, gear shaping cutters etc.
1.
to hold parts since
1 Suited to machine thin and hard
hardtohold
the workpiece is forced against the table or holding
device by the cutter.
2. Work need not be clamped as tightly.
3. Consistent
C
i t t parallelism
ll li
and
d size
i may be
b maintained,
i t i d
particularly on thin parts.
4. It may be used where breakout at the edge of the
workpiece could not be tolerated.
5. It requires upto 20% less power to cut by this method.
6. It may be used when cutting off stock or when milling
deep, thin slots.
Page 91 of 240
Di d t
fD
Milli
DisadvantagesofDownMilling
1. It cannot be used unless the machine has a backlash
eliminator and the table jibs have been tightened.
2. It cannot be used for machining castings or hot rolled
steel, since the hard outer scale will damage the cutter.
Rev.0
IES 2007
IES
What is the process of removing metal by a milling
cutter which is rotated against the direction of
travel of the work piece, called?
(a) Down milling
(b) Up milling
( ) End
(c)
E d milling
illi
(d) Face
F
milling
illi
IES 1997
IES
g statements:
In Up milling process,
1. The cutter starts the cut from the machined surface and
proceeds upwards.
p surface and
2. The cutter starts the cut from the top
proceeds downwards.
3. The job is fed in a direction opposite to that of cutter
rotation.
i
4. The job is fed in the same direction as that of cutter
rotation.
rotation
Of these statements correct are:
( ) 1 and
(a)
d3
(b) 1 and
d4
(c) 2 and 3
(d) 2 and 4
IES 2010
IES2010
Assertion (A): Climb or down milling operation ensures
smoother operation of the machine tool and longer tool life
as compared to the conventional up milling operation.
Reason (R):
( ) In climb or down milling operation, the
rotational motion of the cutter as well as the feed motion of
the workpiece
work piece are in the same direction,
direction and the depth of
cut is maximum at the entry point as the cutter engages the
workpiece.
p
explanation of A
(b) Both A and R are individually true but R is NOT the correct
explanation of A
Cl ifi ti
f illi
hi
Classificationofmillingmachines
Cl ifi ti
f illi
hi
Classificationofmillingmachines
(a) According to nature of purposes of use:

y
General purpose
y
Si l purpose
Single
y
Special purpose
(b) According to configuration and motion of the
workholding
g table / bed
y
Knee type
y
Bed type
y
Planer type
y
Rotary table type
((c)) According
g to the orientation of the spindle(s).
p
( )
y Plain horizontal knee type
y Horizontal axis ((spindle)
p
) and swiveling
g bed type
yp
y Vertical spindle type
y Universal head milling machine
(d) According to mechanization / automation and
production rate
p
y Hand mill (milling machine)
y Planer and rotary
y table type
yp vertical axis milling
g machines
y Tracer controlled copy milling machine,
y Milling
g machines for short thread milling
g
y Computer Numerical Controlled (CNC) milling machine
Cl ifi ti
f illi
tt
Classificationsofmillingcutters
Cl ifi ti
f illi
tt
Classificationsofmillingcutters
Sl b Pl i
illi
tt
SlaborPlainmillingcutters
(a) Profile sharpened cutters where the geometry of

the machined surfaces are not related with the tool
shape, viz;
i. Slab or plain milling cutter: straight or helical
fluted
ii. Side milling cutters single side or both sided type
iii. Slotting cutter
iv. Slitting
g or p
parting
g tools
v. End milling cutters with straight or taper shank
vi Face milling cutters.
vi.
cutters
(b) Form relieved cutters where the job profile

becomes the replica of the
Tool form e.g.,
Toolform,
e g viz.;
viz ;
i. Form cutters
ii. Gear (teeth) milling cutters
iii. Spline
p
shaft cutters
iv. Tool form cutters
v Tslotcutters
v.
T slotcutters
vi. Threadmillingcutter
Page 92 of 240
IAS2009main
Definethetermfeedinmilling
Definetheterm
feedinmilling.[2Marks]
[2Marks]
Rev.0
Sid
d l t illi
tt
Sideandslotmillingcutters
Slitti
ti t l
Slittingsaworpartingtool
E d illi
tt
E d ill
EndmillingcuttersorEndmills
F
illi
tt
Facemillingcutters
U
ff
li d
( illi )
Useofformrelievedcutters(milling)
Toolformcutters
T slotcutter
l t tt
T
G
t th illi
tt
Gearteethmillingcutters
S li shaftcutters
h ft tt
Spline
Page 93 of 240
Rev.0
St ddl
illi
Straddlemilling
IES 1995,ISRO2010
1995 ISRO 2010
IES
G
illi
Gangmilling
In a milling operation two side milling cutters are

mounted with a desired distance between them so
that both sides of a work piece can be milled
simultaneously. This set up is called.
(a) Gang milling
(b) Straddle milling
(c) String milling
(d) Side milling.
IES 2006
IES
IAS2009Main
With a sketch, explain the principle of working
and variations of bedtype milling machine.
[9marks]
T i b
l ( illi
)
Turningbyrotarytools(millingcutters)
Gang milling is a
(a) Milling process for generating hexagonal surfaces
(b) Process
P
off cutting
tti gears
(c) Process in which two or more cutters are used
simultaneously
((d)) Milling
g operation
p
combined with turning
g
I d i
Indexing
IES 2009
IES
For machining, which one of the following gang
milling operations is employed?
(a) Threads
(b) Bores
(c) Grooves
((d)) Steps
p on p
prismatic p
parts
Si l
Pl i I d i
SimpleorPlainIndexing
y Plain indexing is the name given to the indexing method
carried out using any of the indexing plates in

conjunction with the worm.
Page 94 of 240
Rev.0
IES 2004,ISRO2011
2004 ISRO 2011
IES
One brand of milling machine has the following two
index plates supplied along with the indexing head:
Plate 1: 15, 16, 17, 18, 19, 20 hole circles
Plate 2: 21, 23, 27, 29, 31, 33 hole circles
It is proposed to mill a spur gear of 28 teeth using simple
indexing method. Which one of the following combinations
of index plate and number of revolutions is correct?
(a) Plate 1: 1 revolution and 9 holes in 18 hole circles
(b) Plate 2:
2 1 revolution
re olution and 9 holes in 21 hole circles
(c) Plate 2: 1 revolution and 9 holes In 33 hole circles
( ) Plate 1: 1 revolution and 9 holes In 15 hole circles
(d)
Milli V l it
MillingVelocity
IES 2000
IES
One of the index plates of a milling machine
dividing head has the following hole circles: 15; 16;
17; 18; 19; 20
A gear wheel of 34 teeth has to be milled by simple
indexing method.
method To machine each tooth,
tooth the index
crank has to be rotated through
( ) 17 holes
(a)
h l in
i the
th 20hole
h l circle
i l
(b) 18 holes in the 20hole circle
(c) 1 revolution and 3 holes in 17hole circle
(d) 1 revolution and 2 holes in 18
18hole
hole circle
V=
DN
DN
1000
MRR i Milli
MRRinMilling
Consideringtheparametersdefinedinthediscussionof
speedsandfeeds,etc,theMRRisgivenbelow,
Where,
Where
y Approach distance,
d=depthofcut
p
AC50steelflatsurfaceofdimensions100mm 250
mmistobeproducedonahorizontalaxismilling
machine.AnHSSslabmillwitha100mmdiameter
and150mmwidthistobeusedforthepurpose.The
millingcutterhas8teeth.
Calculatethemachiningtimeassumingthatentire
stockcanberemovedinonedepthof2mm.
stockcanberemovedinonedepthof2mm
Given,
Feed,f=0.13mm/tooth,
Cuttingspeed,V=20m/min.
g p
L + 2 A minutes
fZN
2
D D
A = d = d (D d )
2 2
Some Formulae for Milling

SomeFormulaeforMilling
Maximum uncut chip thickness (t max ) =
2f
NZ
f
Average uncut chip thickness (t a vg ) =
NZ
wd F
MRR =
where,w=widthofcut,
y Time for one pass =
d
D
d
D
f2
Peak to valley surface roughness (h max ) =
4DN 2 Z 2
Page 95 of 240
A standard dividing head is equipped with the

following index plates
1 Plate with 12,
1.
12 16,
16 17,
17 18,
18 19,
19 20 holes circles
2. Plate with 21, 23, 27, 29, 31, 33 holes circles
3. Plate with 37, 39, 41,43,47,49 holes circles
For obtaining
g 24
4 divisions on a work p
piece byy simple
p
indexing
(a) Hole plate 2 alone can be used
(b) Hole plates 1 and 2 can be used
( ) Hole
(c)
H l plates
l t 1 and
d 3 can be
b used
d
(d) Any of the three hole plates can be used
Example
Milli Ti
MillingTime
y The cutting speed in milling is the surface speed of the
milling cutter.
IAS 1994
IAS
GATE 2014
GATE
Two
separate
operations,
1 and
T
t slab
l b milling
illi
ti
d 2, are
performed with identical milling
p
g cutters. The depth
p of
cut in operation 2 is twice that in operation 1. The other
cutting parameters are identical. The ratio of maximum
uncutt chip
hi thicknesses
thi k
i operations
in
ti
1 and
d 2 is
i
Rev.0
GATE 1995
GATE
List
ListII
(Manufacturing Processes)
(A) Finish
Fi i h turning
t
i
1.
(B) Forming
2.
(C) Thread cutting
3.
(D) Down milling
4.
Codes:A B
C
D
( ) 2
(a)
3
4
1
(b)
(c) 1
2
3
4
(d)
List
List II
(Condition)
B kl h eliminator
Backlash
li i t
Zero rake
Nose radius
Low speed
A
B
C
D
3
4
1
2
4
1
2
3
IES 2009
IES
The arbor of a milling machine is used to hold
which one of the following?
(a) Spindle
(b) Overarm
Over arm
(c) Cutting tool
(d) Mandrel
GATE 1992
GATE
In horizontal milling process. (up/down)
milling provides better surface finish and..
(updown)
(up
down) milling provides longer tool life.
GATE 1993
GATE
A milling cutter having 8 teeth is rotating at 150
rpm. If the feed per tooth is 0.1 mm, the table speed
in mm per minute is
(a) 120 (b) 187
( ) 125 (d) 70
(c)
IES 1994
IES
Consider the following operations:
1. Cutting key ways on shafts
2. Cutting
C tti external
t
l screw threads.
th d
3. Cutting teeth of spur gears
4. Cutting external splines.
Those which can be performed with milling cutters
would include
(a) 1 and 2
(b) 2,3
2 3 and 4
(c) 1 and 3
(d) 1,2,3 and 4 .
IES 1995
IES
Assertion (A): Up milling or climb milling is
commonly used for machining castings and
forgings.
Reason (R): Up milling can be done on universal
milling machines.
machines
l
ti off A
(d) A is false but R isPage
true96 of 240
IES 2003
IES
In milling machine, the cutting tool is held in
position by
(a) Chuck
(b) Spindle
(c) Arbor
(d) Tool holder
IES 1992
IES
A set of eight form relieved milling cutters for each
module is provided to enable cutting of gears of
different
(a) Materials
(b) Types
T
e.g. spur, helical,
h li l etc.
t
(c) Number of teeth
(d) Width of gears
IES 2005
IES
Which one of the following statements is correct?
In upmilling operation, the undeformed chip thickness,
a)) Is
I zero att the
th start
t t off the
th cutt and
d increases
i
t a
to
maximum value just before the tooth disengages the
workpiece.
k i
b) Increases to the maximum value at the centre of the
travel and decreases towards the end of tooth
engagement.
c) Has a maximum value just after the cut is started and
p to zero at the end of the cut.
drops
d) Remains unchanged.
Rev.0
IES 1993
IES
Climb milling is chosen while machining because
(a) The chip thickness increases gradually
(b) It enables
bl the
th cutter
tt to
t dig
di in
i and
d depth
d th off cutt
(c) The specific power consumption is reduced
(d) Better surface finish can be obtained
IES 1999
IES
A straight teeth slab milling cutter of 100 mm
diameter and 10 teeth rotating at 200 r.p.m. is used
to remove a layer of 3 mm thickness from a steel bar.
If the table feed is 400 mm/minute, the feed per
tooth in this operation will be
(a) 0.2 mm
(b) 0.4 mm
( ) 0.5 mm
(c)
(d) 0.6
6 mm
GATE 2012(PI)CommonDataS2
Data for a plain milling operation are given below.
below
Length of workpiece
200 mm
Cutter diameter
100 mm
No. of teeth
4
Cutter speed
100 rpm
Feed
200 mm/min
Depth of cut
2 mm
Total clearance (entry
(
and exit)) 5 mm
g
g p
Machiningtimeforasinglepass(inseconds)is
(a)60 (b)66
(c)126
For-2015 (IES,
GATE &(d)150
PSUs)
IES 2002
IES
) Virtually
y all modern milling
g machines
Assertion ((A):
are capable of doing downmilling.
Reason (R): In downmilling the cutter tends to push
the work along and lift it upward from the table. This
action tends to eliminate any effect in looseness in the
feed screw and nut of the milling machine table and
results in smooth cut.
explanation of A
IES 2002
IES
A side and face cutter 125 mm diameter has 10 teeth.
It operates at a cutting speed of 14 m/min with a
table traverse 100 mm/min. The feed per tooth of
the cutter is
(a) 10 mm
(b) 2.86
2 86 mm
(c) 0.286 mm (d) 0.8 mm
IES 2004
IES
(
g p
Match List I (Milling
problem)) with List II ((Probable
causes) and select the correct answer using the codes
given below the Lists:
List I
List II
A. Chatter
1.
Too high feed
B. Poor surface finish 2.
Lack of rigidity in machine
fixtures, bar or workpiece
C Loss
C.
L
off accuracy 3.
Hi h cutting
High
i load
l d
D. Cutter burrs
4.
Radial relief too great
5.
Not enough
h lubricant
l b
Codes:A
B
C
D
A
B
C
D
( ) 2
(a)
1
5
3
( ) 2
(b)
1
3
5
of 2404
(c) 4
5
2 Page
3 97(d)
2
3
5
IES 2004
IES
The cutting speed of a milling cutter while cutting
brass is:
(a) 45 to 60 m/min
(b) 30 to 40 m/min
(c) 25 to 35 m/min
(d) 15 to 20 m/min
GATE 2012(PI)CommonDataS1
Data for a plain milling operation are given below.
below
Length of workpiece
200 mm
Cutter diameter
100 mm
No. of teeth
4
Cutter speed
100 rpm
Feed
200 mm/min
Depth of cut
2 mm
Total clearance (entry
(
and exit)) 5 mm
Mean undeformed chip
p thickness (in microns) is
(a) 142
(b) 100
(c) 71
(d) 50
IAS 2001
IAS
Which one of the following statements are correct in respect of
upmilling
illi and
d downmilling?
d
illi ?
1.
In upmilling the cutter rotates in a direction opposite to that of
workpiece travel whereas in downmilling the cutter rotates in a
di
direction
i similar
i il to that
h off workpiece
k i
travel.
l
2.
In downmilling chip will be thin at the beginning and increase to a
maximum at the end of the cut and reverse will be the case for a chip
p
f
formed
d by
b upmilling.
ll
3.
Downmilling is desirable with milling cutters having a high radial
g when compared
p
to upmilling.
p
g
rake angle
4.
Downmilling forces the workpiece against the milling table to
exert more pressure while upmilling tends to lift the workpiece from the
table.
Codes:
(a) 1,
1 2 and 3
(b)
1 2 and 4
1,
(c) 3 and 4
(d)
1, 3 and 4
Rev.0
IAS 1998
IAS
IAS 2001
IAS
g statements are true of face

Which of the following
milling?
g cutter is held on an arbor.
1. Face milling
2. It has two rake angles axial rake and radial rake.
3 The maximum chip thickness equals the feed per
3.
tooth.
4 The chip thickness varies from a minimum at the
4.
start of cut to a maximum at the end of cut.
Codes :
(a) 1 and 2
(b) 2 and 3
(c) 2 and 4
(d) 3 and 4
IAS 2003
IAS
S 99
IES1994
A milling cutter of 70 mm diameter with 12 teeth is

operating at a cutting speed of 22 m/min and a feed
of 0.05 mm/tooth. The feed per minute is
(a) 110 m/min (b) 35 mm/min
( ) 6 mm/min
(c)
/ i (d) 60
6 mm/min
/ i
IES 2011
IES2011
thecodegivenbelowthelists:
ListI
ListII
A.Lathe
1.Flute
B.Shaper
2.Universalindexing
C D illi
C.Drillingmachine
hi
3.Leadscrew
L d
D.Millingmachine
g
C d
Codes
4.Rockerarm
4
A
((a)) 2
(c) 2
Which of the following mechanisms are suitable for

indexing the table of rotary transfer line?
1 Rack and pinion
1.
2
2.
Ratchet and pawl
3. Lead screw
4.
Geneva mechanism
Select the correct answer by using the codes given below:
Codes:
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1,
1 3 and 4 (d) 1,
1 2 and 4
B
C
D
A
B
4
1
3
(b) 3
4
(IES,
GATE
1 For-2015
4
3
(d) &3PSUs)
1
C
1
4
D
2
2
Whichoneofthefollowingoperationsiscarriedout
attheminimumcuttingvelocityifthemachinesare
equallyrigidandthetoolworkmaterialsarethe
same?
(a) Turning
(b) Grinding
(c) Boring
((d)) Milling
g
IAS 2000
IAS
Consider the following mechanisms:
1. Geneva gearing
2. Rack
R k and
d pinion
i i
3. Ratchet and pawl
Which of these mechanisms are used to index the work
table on a transfer machine?
(a) 1 and 2
(b) 2 and 3
(c) 1 and 3
(d) 1,
1 2 and 3
IES 2012
IES
) Vibrations in milling
g are induced due to
Statement ((I):
interrupted cutting operation.
Statement (II):Vibrations can be suppressed to a large extent
by using equal spacing of teeth along the periphery of the
cutters.
( ) Both
(a)
B h Statement
S
(I) and
d Statement
S
(II) are individually
i di id ll
Statement (I)
p
of
Statement (I)
IES 2002
IES
Match List I with List
answer:
List I (Machine tools)
A. Lathe
B. Milling machine
C. Shaper
p
D. Drilling machine
Codes:A B
C
D
(a) 4
2
3
1
(c) 4
3
2
1
II and select the correct

List II (Machine tool parts)
1.
Lead strew
2.
Rocker arm
33.
Universal indexing
g
4.
Flute
A
B
C
D
(b) 1
3
2
4
(d) 1
2
3
4
Page 98 of 240
GearManufacturing
G M
f t i
BySKMondal
Rev.0
M
f t
fG
ManufactureofGears
Manufacture of gears needs several processing operations in
sequentiall stages depending
upon the
d
d
h materiall and
d type off the
h
gears and quality desired. Those stages generally are:
y Preforming the blank without or with teeth
y Annealing of the blank, if required, as in case of forged or
cast steels
y Preparation of the gear blank to the required dimensions
by machining
y Producing teeth or finishing the preformed teeth by
b
machining
y Full or surface hardening of the machined gear (teeth), if
required
y Finishing teeth, if required, by shaving, grinding etc
y Inspection of the finished gears
F
i
dG
ti
FormingandGeneration
Gear teeth are produced by machining based on
Forming
g where the p
profile of the teeth are obtained as
the replica of the form of the cutting tool (edge); e.g.,
milling, broaching etc.
Sunderlandmethodusingracktypecutter
y The rack type HSS cutter (having rake and
clearance angles) reciprocates to accomplish the

machining
hi i
( tti ) action
(cutting)
ti
while
hil rolling
lli
t
type
interaction with the gear blank like a pair of rack
and pinion.
Generation where the complicated tooth profile are

provided by much simpler form cutting tool (edges)
through rolling type, tool work motions, e.g., hobbing,
gear shaping etc.
External gear teeth generation by rack type cutter (Sunderland method)
Sunderlandmethodusingracktypecutter
G
h i
Gearshaping
G
h i
Gearshaping
y Applicationsofthismethod(andmachine)include:
A li ti
fthi th d( d
hi )i l d
y Gear shaping is similar to the rack type cutting process,
y automatic indexing
g
y Generation method is characterised by
y Moderatesizestraightandhelicaltoothedexternal
spurgearswithhighaccuracyandfinish
excepting that, the linear type rack cutter is replaced by a

circular cutter where both the cutter and the blank
rotate as a pair of spur gears in addition to the
reciprocation of the cutter.
y Cuttingtheteethofdoublehelicalorherringbone
gearswithacentralrecess(groove)
y Cuttingteethofstraightorhelicalflutedclustergears
C i
h f
i h h li lfl d l
y Howeverthismethodneeds,thoughautomatic,few
Howeverthismethodneeds thoughautomatic few
indexingoperations.
G
H bbi
GearHobbing
g teeth like g
g
y The HSS or carbide cutter having
gear milling
cutter and the gear blank apparently interact like a pair

of worm and worm wheel.
y The
Th hob
h b (cutter)
(
) looks
l k and
d behaves
b h
lik a single
like
i l or
multiple start worms.
G
H bbi
GearHobbing
y Having
lesser
number
(only
H i
l
b
( l three)
th ) off tool
t l work
k
motions,, hobbing
g machines are much more rigid,
g , strong
g
and productive than gear shaping machine.
y But hobbing provides lesser accuracy and finish and is
used
d only
l for
f cutting straight
h or helical
h l l teeth
h (single)
(
l ) off
external spur gears and worm wheels.
wheels
(a)Straight(b)helicaltoothand(c)wormwheel
Page 99 of 240
and ability of a single cutter to cover the entire range of

number of teeth for a given combination of module and
pressure angle
l and
d hence
h
provides
id high
hi h productivity
d ti it and
d
economy.
y The gear type cutter is made of HSS and possesses proper
rake and clearance angles.
y The additional advantages of gear shaping over rack type
cutting are:
Separate
p
indexing
g is not required
q
at all
Straight or helical teeth of both external and internal
p g
gears can be p
produced with high
g accuracyy and
spur
finish
Productivity is also higher.
Ad t
fG
H bbi
AdvantagesofGearHobbing
(a) The method is versatile and can generate spur,
helical, worm and worm wheels.
(b) Since gear hobbing is a continuous process,
process it is
rapid; economical and highly productive.
( ) The
(c)
Th method
th d produces
d
accurate
t gears and
d is
i suitable
it bl
for medium and large batch production.
(d) The cutter is universal, because it can cut all gears of
same module, irrespective of number of teeth on the
gear.
Rev.0
Di d t
f
H bbi
DisadvantagesofgearHobbing
(a) Gear hobbing cannot generate internal gears and
bevel gears.
(b) Enough
h space has
h
to be
b there
h
in component
configuration for hob approach.
Milli
Milling
Milli
Milling
yp
y Gear teeth can be p
produced byy both disc and end mill type
g
g are characterised
Production of gear
teeth byy form milling
by:
y Use of HSS form milling cutters
y Use of ordinary milling machines
y Low p
production rate for
form milling cutter.
Need of indexing after machining each tooth gap

Slow speed and feed
ApplicationsofHobbing
pp
g
y Low accuracy and surface finish

y Inventory problem due to need of a set of eight cutters for
y The gears produced by gear hobbing are used in
automobiles, machine tools, various instruments, clocks

and other equipments.
Fig.
(a) disc type and end mill type for

( ) single
(b)
g helical and
(c) double helical teeth
Sh i
Pl
i
d Sl tti
Shaping,PlanningandSlotting
module.
F
d i
f
h f
Fastproductionofteethofspurgears
y Straight toothed spur gear can be produced in shaping
machine.
y Both productivity and product quality are very low in
this process which therefore, is used, if at all, for making
one or few teeth on one or two pieces of gears as and
when required for repair and maintenance purpose.
y Planning
Pl
i
and
d slotting
l tti
machines
hi
work
k on the
th same
principle. Planning machine is used for making teeth of
l
large
gears whereas
h
slotting
l tti for
f internal
i t
l gears.
Fig gearteethcuttinginordinaryshapingmachine
F
d i
f
h f
Fastproductionofteethofspurgears
M
f t
f
b
lli
Manufactureofgearsbyrolling
Broaching
y Teeth of small internal and external spur gears; straight
or single helical,
helical of relatively softer materials are
produced in large quantity by broaching.
y This
Thi method
th d leads
l d to
t very high
hi h productivity
d ti it and
d quality
lit
but cost of machine and broach are very high.
y The straight and helical teeth of disc or rod type external
each module pressure angle combination

y End mill type
yp cutters are used for teeth of large
g g
gears and / or
steel gears of small to medium diameter and module are

generated by cold rolling by either flat dies or circular
dies.
y Such rolling imparts high accuracy and surface integrity
of the teeth which are formed by material flow unlike
cutting.
cutting
y Gear rolling is reasonably employed for high productivity
and
d high
hi h quality
lit though
th
h initial
i iti l machinery
hi
costs
t are
relatively high.
y Larger size gears are formed by hot rolling and then
Page 100 of 240
finished by machining.
Parallel multiple teeth

shaping
y It is similar to ordinary
shaping but all the tooth gaps
are made simultaneously,
simultaneously
without requiring indexing,
by a set of radially in feeding
single point form tools.
y This
Thi old
ld process was highly
hi hl
productive but became almost
obsolete
b l t for
f very high
hi h initial
i iti l
and running costs.
Rev.0
Powder Metallurgy
PowderMetallurgy
Wire EDM
WireEDM
y Small size high quality external or internal spur, bevel or
y Geometrically accurate but moderately finished straight
spiral gears are also produced by powder metallurgy

process.
y Large size gears are rolled after briquetting and sintering
for more strength and life.
life
y Powder metallurgically produced gears hardly require
any further
f th finishing
fi i hi work.
k
toothed metallic spur gears, both external and internal

type, can be produced by wire type Electro
Electrodischarge
discharge
Machining (EDM).
to obtain a certain level of toughness in the gear teeth to

reduce and/or eliminate bending and contact fatigue
failures.
y Reduction of index undulation errors associated with
helical gear teeth caused by the grinding process during
the manufacture of the gears without degrading other
gear accuracies
i (e.g.
(
profile,
fil tooth
t th spacing)
i ) below
b l
l l
levels
required for precision (AGMA16 or DIN1) gears.
y A mold
ld off the
th space between
b t
severall gear teeth
t th is
i
obtained, with the mold having a length equal to or
greater than the wavelength of the undulation error to be
reduced.
y Sandcasting
y Metalmouldcasting
y Diecasting
Di ti
y Investmentcasting
y Shellmouldcasting
y Centrifugalcasting
G
fi i hi
Gearfinishingprocess
gp
yO
One of the g
goals of the g
gear finishing
process in g
gears is
Casting
G
h i
Gearshaving
y A micro finishing film is affixed to the mold and the
mold is placed relative to a gear tooth so that the micro

finishing film rests against a tooth surface having the
undulation error.
y The grit size of the micro finishing film is such as to
remove approximately 2 to 3 millionths of gear material
with each pass through the teeth by the mold.
mold Multiple
passes are made by hand until the undulation error is
reduced to an acceptable value.
value During the process the
micro finishing film is replaced after approximately 3 or
4 passes and the process is repeated for each tooth of the
gear.
g is a g
g operation
p
g
yG
Gear shaving
gear finishing
with high
efficiency and high precision.
y When a work g
gear has been shaved byy a shaving
g cutter
with a true involute profile, the ''midconcave''

phenomena inevitably exist around the pitch points of
the work gear tooth flanks.
y Aiming at this problem, a newstyle shaving cutter with
unequal depth gashes is designed and manufactured.
y This paper analyses the forming of the gash on the basis
of the slotting principle, and proposes a gashdesigning
method.
y Experiment has proven that the shaved gear has a better
surface finish that achieves the anticipated effect.
G
b i hi
Gearburnishing
G
L
i
GearLapping
IES 1992
IES
y It is designed
gear tooth
d
d to remove or reduce
d
h nicks
k and
d
y Gear lapping is used to finish hardened gears by
Gear lapping
(a) An operation after heat treatment
(b) An
A operation
ti prior
i to
t heat
h t treatment
t t
t
(c) An independent operation for gear reconditioning
(d) None of the above
burrs along with improving the smoothness of the

burrs,
tooth's active p
profile finish.
correcting small errors in spacing, profile, helix

angle, and eccentricity.
y The operation is performed with all forms of gears
y The action of the burnishing

g dies on the tooth surface
running
i together
t th with
ith mating
ti gears, and
d castt iron
i
allows the machine to accomplish these quality
toothed laps,
p , under a flow of fine oil mixed with
improvements without altering the tooth profile or lead.
an abrasive compound.
y Both internalFor-2015
and external
possible to burnish.
(IES, gears
GATEare
& PSUs)
Page 101 of 240
Rev.0
IES 1999
IES
Consider the following processes for the
manufacture of gears:
1 Casting
1.
2. Powder metallurgy
3. Machining from bar stock
4. Closed die forging
4
g g
The correct sequence in increasing order of bending
strength of gear teeth is
(a) 1, 2, 3, 4
(b) 1, 2, 4, 3
( ) 2, 1, 4, 3
(c)
(d) 2, 1, 3, 4
IES 2010
IES2010
the code given below the lists:
List I
List II
(Type of work)
(Manufacturing)
A. High rate production of worm Gears and 1. Gear shaving
worm wheel
B. Generating internal gears and Cluster gears 2. Gear milling
C. Finishing of gear tooth profiles
3. Gear hobbing
D. Repair and piece production of gears
4. Gear shaping
A
B
C
D
A
B
C
D
4
3
(b)
3
1
4
2
(a)
2
1
(c)
2
4
1
3
(d)
3
4
1
2
IES 2009
IES
) Gears p
y employing
p y g form
Assertion ((A):
produced by
cutting principle using gearmilling cutter on a milling
machine are not very accurate.
Reason (R): Production of the correct gear tooth profile
employing formcutting principle would require a
separate cutter for cutting different numbers of teeth
even for the same module and also errors are associated
p
of indexing
g mechanism.
with inaccurate operation
(a) Both A and R are true and R is the correct explanation of
A
explanation of A
IES 2006
IES
Which of the following is/are used for cutting
internal gears?
1 Gear hobber
1.
2
2.
Gear shaper
3. Rack cutter
4.
Jig borer
((a)) Onlyy 1 and 2
((b)) Onlyy 2 and 3
(c) Only 1 and 4
(d) Only 2
IES 1996
IES
Gear cutting on a milling machine using an involute
profile cutter is a
(a) Gear forming process
(b) Gear generating process.
(c) Gear shaping process
((d)) Highly
g y accurate g
gear p
producing
gp
process.
IES 1996
IES
Consider the following processes of gear
manufacture:
1 Milling with form cutter
1.
2. Rack type gear shaper (gear planer)
3. Rotary gear shaper (gear shaper)
4. Gear hobbing
4
g
The correct sequence of these processes in increasing
order of accuracy of involute profile of the gear
(a) 3, 2, 4, 1
(b) 2, 3, 4, 1
( ) 3, 2, 1, 4
(c)
(d) 2, 3, 1, 4
Page 102 of 240
IES 2005
IES
In helical milling, the ratio of the circumference of
the gear blank to the lead of the helix determines
the:
(a) Proper speed to use
(b) Proper
P
f d and
feed
d depth
d th off cutt required
i d
(c) Angle setting of the machine table
(d) Gear ratio for table screw and dividing head
IES 2000
2000
IES
Which one of the following processes of gear
manufacture results in best accuracy of the involute
gear tooth profile?
(a) Milling
(b) Hobbing
H bbi
(c) Rotary gear shaper
(d) Rack type gear shaper
IES 2009
IES
By which one of the following machines the teeth of
an internal spur gear can be cut accurately?
(a) Milling machine
(b) Slotting machine
(c) Hobbing machine
((d)) Gearshaping
p g machine
Rev.0
IES 2004
IES
Gear shaping is a process of manufacturing gears.
Which one of the following principles is employed by it?
( ) Form
(a)
F
cutting
tti with
ith cutter
tt
(b) Generating tooth form with a reciprocating cutter
(c) Generating tooth form by a rotating cutter
(d) Generating form with a reciprocating and revolving
cutter
IES 2008
IES
Which machining processes are used for gear
manufacture?
1 Form milling
1.
2
2.
Broaching
3. Roll forming
4.
Hobbing
((a)) 1, 2 and 3
((b)) 1, 3 and 4
(c) 1, 2 and 4
(d) 2, 3 and 4
IES 2007
IES
Which of the following methods are gear generating
processes?
1 Gear shaping
1.
2. Gear hobbing
3. Gear milling
Select the correct answer using
g the code g
given below:
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only
IES 1992
IES
In gear hobbing
(a) Only hob rotates
(b) Only
O l gear blank
bl k rotates
t t
(c) Both hob and gear blank rotate
(d) Neither hob nor gear blank rotates
IES 1999
IES
A 60
teeth gear when hobbed on a differential
60teeth
hobber with a twostart hob, the index change gear
ratio is governed by which one of the following
kinematic balance equations?
(a) 1 revolution of gear blank = 1/60 of hob revolutions
(b) 1 revolution of gear blank = 2/60 of hob revolutions
(c) 1 revolution of hob = 2/60 of blank revolutions
((d)) 1 revolution of hob = 1/60 of blank revolutions
GATE 2007(PI)
2007 (PI)
GATE
Which one of the following gear manufacturing
processes is NOT based on generation principle?
( ) Gear
(a)
G
H bbi
Hobbing
(b) Gear
G
Sh i
Shaping
((c)) Gear Milling
g
((d)) Gear Shaving
g
Page 103 of 240
IES 2003
IES
A spur gear of 40 teeth is machined in a gear
hobbing machine using a double start hob cutter.
The speed ratio between the hob and the blank is
(a) 1:20 (b) 1:40
( ) 40: 1 (d) 20: 1
(c)
IES 1997
IES
Which of the following motions are not needed for
spur gear cutting with a hob?
1 Rotary motion of hob
1.
2. Linear axial reciprocator motion of hob
3. Rotary motion of gear blank
4. Radial advancement of hob.
4
(a) 1,
1 2 and 3 (b) 1,
1 3 and 4
(c) 1, 2 and 4 (d) 2, 3 and 4
IES 1993
1993
IES
Internal gear cutting operation can be performed by
(a) Milling
(b) Shaping
Sh i with
ith rack
k cutter
tt
(c) Shaping with pinion cutter
(d) Hobbing
Rev.0
IAS 1998
IAS
Assertion (A): Internal gears are cut on a gear
shaper.
Reason (R): Hobbing is not suitable for cutting
internal gear.
( ) Both
(a)
B th A and
i di id ll true
t
and
d R is
i the
th
IES 1995
IES
While cutting helical gears on a non
differential
nondifferential
gear hobber, the feed change gear ratio is
(a) Independent of index change gear ratio
(b) dependent on speed change gear ratio
(c) Interrelated to index change gear ratio
((d)) Independent
p
of speed
p
and index change
g g
gear ratio.
IAS 2001
IAS
Consider the following motions and setting in a
hobbing machine:
1 Hob rotation
1.
2. Job rotation
3. Axial reciprocating hob rotation
4. Tilting
4
g of hob to its helix angle
g
Which of these motions and setting in a hobbing
machine are required to machine a spur gear?
(a) 1, 2 and 3 (b) 2, 3 and 4
( ) 1, 2 and
(c)
d 4 (d) 1, 3 and
d4
IES 2006
IES
Which of the following cannot be cut by hobbing
process?
(a) Helical gears
(b) Bevel gears
(c) Worm gears
(d) Spur gears
IES 1992
IES
Gear burnishing process for
(a) Removing residual stresses from teeth roots
(b) Surface
S f
fi i hi
finishing
(c) Undercut gears
(d) Cycloidal gears
IES 1996
IES
For the manufacture of full depth spur gear by
hobbing process, the number of teeth to be cut = 30,
module = 3 mm and pressure angle = 20
20.. The radial
depth of cut to be employed should be equal to
(a) 3.75
3 75 mm
(b) 4.50
4 50 mm
(c) 6.00 mm
(d) 6.75 mm
IAS 2003
IAS
Which one of the following is not a feature of gear
hobbing process?
(a) High rate of production
(b) Generation of helical gears
(c) Very accurate tooth profile
((d)) Generation of internal g
gears
IES 1994
IES
Consider the following machine tools:
1. Hobbing machine
2. Gear
G
shaping
h i machine
hi
3. Broaching machine.
The teeth of internal spur gears can be cut in
(a) 1, 2 and 3 (b) 1 and 2
(c) 1and 3
(d) 2 and 3
Page 104 of 240
ScrewThread
S
Th d
Manufacturing
f
i
Rev.0
BySKMondal
Processes,MachinesandTools
UsedForProducingScrewThreads
(a)Machining
(b)Rolling
( )G i di
(c)Grinding
Thread Cutting
ThreadCutting
Internal
y Can cut both external and
Threading on a lathe
g on a NC lathe
Threading
With a die held in a stock
((manual))
With an automatic die
((turret lathe or screw
machine) or NC lathe
y milling
g
By
By Grinding
Threading (on a lathe or

NC lathe))
With a tap and holder
((manual NC,, machine,,
semiautomatic,
or
automatic))
With a collapsible tap
((turret
lathe,,
screw
machine,
or
special
g machine))
threading
By milling
Internal thread
y Thread cutting
g is a form
cutting operation an
p tool is
accuratelyy shaped
used (with zero rake)
y The lead screw and the
split nut, which provide
positive motion of the
carriage relative to the
rotation of the spindle.
spindle
C i
h d ih i
CuttingThreadswithDies
Th d T i
ThreadTapping
g and tapered
p
y Straight
external threads can be cut q
quicklyy
g internal thread byy a multiplepoint

p p
y Cutting
tool is called
manually by means of threading dies.

y Dies are made of carbon or high
highspeed
speed tool steel
thread tapping, and the tool is called a tap.

y A hole of diameter slightly larger than the minor
diameter of the thread must already exist.
(a)Solidthreadingdie;(b)solidadjustablethreadingdie
y Grinding
Th d G i di
ThreadGrinding
can produce
very accurate threads,
h d and
d
it also permits threads to
be produced in hardened
materials.
y A singleribbed
single ribbed grinding
wheel is employed, but
multipleribbed
multiple
ribbed
wheels
are used occasionally.
y Centerless
thread
grinding is used for
g headless sets
making
screws.
Thread Cutting on Lathe

ThreadCuttingonLathe
External
The
Th flutes
fl t on tap
t create
t cutting
tti
edges on the thread profile and
provide
d space for
f the
h chips
h
and
d
the passage of cutting fluid.
Taps are made of either carbon
g p
steel and coated
or highspeed
with TiN.
Th d R lli
ThreadRolling
g is used to p
y Thread rolling
produce threads in substantial
quantities.
y Cold
Coldforming
forming process operation in which the threads are
formed by rolling a thread blank between hardened dies
that cause the metal to flow radially into the desired
shape.
y Chip less process,
process
fast and economical.
y Mechanical properties
are good.
g
Page 105 of 240
Thread Milling
ThreadMilling
y Highly accurate threads,
particularly in larger
sizes, are often form
milled Either a single or
milled.
a multipleform Cutter
may be used.
used
y The milling cutter is
tilted
il d at an angle
l equall
to the helix angle of the
thread
h d and
d is
i fed
f d inward
i
d
radially to full depth
while
hil
the
h
work
k is
i
stationary.
GATE 2003
GATE
Qualityscrewthreadsareproducedby
(a) Threadmilling
(b) Threadchasing
Th d h i
(c) Threadcuttingwithsinglepointtool
(d) Threadcasting
Rev.0
IES2011
External threads can be produced by :
1. Rolling
2. Grinding
33. Milling
g
(a) 1 and 3 only
(b) 1 and 2 only
(c) 2 and 3only
( ) 1, 2 and 3
(d)
IES 2010
IES2010
For producing both internal and external
screw threads, the method used is
( ) Thread
(a)
Th d chasing
h i with
ith multiplerib
lti l ib chasers
h
((b)) Thread milling
g and multiplethread
p
cutters
(c) Thread tapping with taps
(d) Die
Di threading
h di with
i h selfopening
lf
i die
di heads
h d
ISRO2011
ISRO2010
Whichofthefollowingscrewthreadisadaptedfor
Internal and external threads can be produced
powertransmissioninonedirection
on tapered surfaces conveniently by
(a)Acmethreads
(a) Universal milling machine
( )
(b)Buttressthreads
(b) Plano
l
miller
ll
(c)Squarethreads
(c) Planetary milling machine
(d)Multiplethreads
(d) lathe
IES 2012
IES
Multistart threads are used to get
(a) Smaller linear displacement
(b) Larger
L
li
linear
di l
displacement
t with
ith assured
d self
lf locking
l ki
(c) Larger linear displacement with no guarantee of self
locking
IES 2007
IES
Screw threads are produced on solid rods by using
which of the following?
(a) Dies
(b) Punch
(c) Mandrel (d) Boring bar
IES 2012
IES
The differential screw is used in a
(a) Turnbuckle
(b) Micrometer
Mi
t
(c) Vernier Caliper
(d) Coupler
IES 2012
IES
Which of the following screw threads is adopted for
power transmission in either direction
(a) ACME threads
(b) Square threads
(c) Buttress threads
((d)) Multiple
p threads
Shaper,Planner,Slotter
B SKM d l
BySKMondal
Page 106 of 240
Rev.0
Sh
Shaper
Quick return motion Mechanism

QuickreturnmotionMechanism
RamDrive
FeedMechanism
y Themechanicalramdriveisaslottedarmquickreturn
y Table feed is intermittent and is accomplished on the
Sh
Shaper
y The relative motions between the tool and the workpiece,
shaping and planing use a straightline cutting motion with a

singlepoint
g p
cutting
g tool to g
generate a flat surface.
y In shaping, the workpiece is fed at right angles to the cutting
motion between successive strokes of the tool.
y For either shaping or planing, the tool is held in a clapper box
which p
prevents the cutting
g edge
g from being
g damaged
g on the
return stroke of the tool.
y Relatively
y skilled workers are required
q
to operate
p
shapers
p and
planers, and most of the shapes that can be produced on
them also can be made byy much more p
productive p
processes,
such as milling, broaching, or grinding.
Q i k t
ti M h i
QuickreturnmotionMechanism
y In shaping, the cutting tool is held in the tool post
located in the ram, which reciprocates over the work

with a forward stroke, cutting at velocity V and a quick
return stroke at velocity VR.
y The rpm rate of the drive crank (Ns) drives the ram and
determines the velocity of the operation.
y The stroke ratio, Rs
motionmechanism,
motionmechanism
return (non cutting) stroke when the tool has cleared

th workpiece.
the
k i
y The cross feed is given to the table with the help of a
cutting stroke angle

=
3600
cross feed screw which is actuated by a pawl which

engages a notched wheel (ratchet) keyed to the screw.
Cl ifi ti
f Sh
M hi
ClassificationofShaperMachine
Shapers,asmachinetoolsusuallyareclassified
accordingtotheirgeneraldesignfeaturesasfollows,
1 Horizontal
1.
a.
Pushcut
b.
Pullcutordrawcutshaper
2. Vertical
a.
Regularorslotters
b
b.
Keyseaters
3. Specialpurpose
F
l
Formula
HydraulicShaper
NL(1 + m)
1000
w
y Numberofstrokes, N s =
f
y Cuttingspeed, V =
y Timeofonestroke, t =
y Totaltime,T =
L(1 + m)
min
1000V
L(1 + m)
Lw(1 + m)
Ns =
min
1000v
1000vf
Page 107 of 240
Rev.0
Advantagesofhydraulicshaping
y 1. Cutting speed remains constant throughout most of the cutting
stroke, unlike the crank shaper where the speed changes continuously.
y 2. Since the power available remains constant throughout, it is possible
to utilise the full capacity of the cutting tool during the cutting stroke.
y 3. The ram reverses quickly without any shock due the hydraulic
cylinder utilised. The inertia of the moving parts is relatively small.
y 4. The range and number of cutting strokes possible are relatively large
in hydraulic shaper.
y 5. More strokes per minute can be achieved by consuming less time for
Planer
Slotter
y Planing can be used to produce horizontal, vertical, or
y Slotting machine is basically a vertical axis shaper.

shaper Thus
inclined flat surfaces on workpieces that are too large to

be accommodated on shapers.
y Planing is much less efficient than other basic
machining processes,
processes such as milling,
milling that will produce
such surfaces.
y Planing
Pl i and
d planers
l
h
have
l
largely
l been
b
replaced
l d by
b planer
l
milling machines or machines that can do both milling
and
d planing.
l i
the workpieces, which cannot be conveniently held in

shaper, can be machined in a slotter.
y Generally, keyways, splines, serrations, rectangular
grooves and similar shapes are machined in a slotting
machine.
y The
Th stroke
t k off the
th ram is
i smaller
ll in
i slotting
l tti
machines
hi
than in shapers to account for the type of the work that
i handled
is
h dl d in
i them.
th
Sl tt
Slotter
Sl tt
Slotter
reversal and return strokes.
y The types of tools used in a slotter are very similar to
those in a shaper, except that the cutting actually takes

place in the direction of cutting.
y However, in view of the type of surfaces that are possible
in the case of slotter,
slotter a large variety of boring bars or
singlepoint tools with long shanks are used.
GATE 2012 (PI)

GATE2012(PI)
IAS 1994
IAS
Stroke of a shaping machine is 250 mm. It makes 30
double strokes per minute. Overall average speed of
operation is
(a) 3.75 m/min
(b) 5.0 m/min
( ) 7.5 m/min
(c)
/ i
(d) 15 m/min
/ i
In
I a shaping
h i process, the
th number
b off double
d bl strokes
t k per
minute is 330 and the q
quick return ratio is 0.6. If the
length of the stroke is 250 mm, the average cutting
velocity in m/min is
( ) 3.0
(a)
GATE 2005
GATE
(b) 4.5
( ) 7.5
(c)
Page 108 of 240
(d) 12.0
A 600 mm x 30 mm flat surface of a plate is to be

finish machined on a shaper. The plate has been
fixed with the 600 mm side along the tool travel
direction. If the tool overtravel at each end of the
plate is 20 mm, average cutting speed is 8 m/min,
feed rate is 0.3 mm/stroke and the ratio of return
time to cutting time of the tool is 1:2, the time
required for machining will be
(a) 8 minutes (b) 12 minutes
(c) 16 minutes (d) 20 minutes
Rev.0
IES 1994,ISRO2008
1994 ISRO 2008
IES
Given that, average cutting speed = 9 m/min, the
return time to cutting time ratio is = 1 : 2, the feed
rate = 0.3 mm/stroke, the clearance at each end of
cut = 25 mm and that the plate is fixed with 700 mm
side along the direction of tool travel, the time
required for finishing one flat surface of a plate of
size 700 x 30 mm in a shaper, will be
(a) 10 min
(b) 12.5 min
( ) 15 min
(c)
i
(d) 20 min
i
GATE 2014
GATE2014
A castt iron
block
i
bl k off 200 mm length
l
th is
i being
b i shaped
h
d in
i a
shaping
p g machine with a depth
p of cut of 4 mm,, feed of
0.25 mm/stroke and the tool principal cutting edge angle
of 30o. Number of cutting strokes per minute is 60.
Ui
Using
specific
ifi energy for
f cutting
tti
as 1.49 J/
J/mm3 the
th
average
g p
power consumption
p
((in watt)) is .
IES 2001
IES
In
machine,
the
for
I a shaper
h
hi
th mechanism
h i
f tool
t l feed
f d is
i
(a) Geneva mechanism
(b) Whitworth mechanism
(c) Ratchet and Pawl mechanism
(d) Ward Leonard system
IES 2010
IES2010
Consider the following alignment tests on machine

tools
1 Straightness
1.
2
2.
Flatness
3. Run out
4.
Parallelism
Which of the above alignment tests on machine tools are
common to both lathe and shaper?
(a) 1 and 2
(b) 2 and 3
(c) 3 and 4
(d) 1 and 4
IES 1997
IES
) Longitudinal
g
g motion of the
Assertion ((A):
cutting
tool and crosswise feed motion of the job generates
planning
gp
process.
flat surfaces in p
Reason (R): Jobs used in planning machines are
generally long and heavy compared to shaping.
l
ti off A
IES 1995
IES
In a mechanical shaper, the length of stroke is
increased by
(a) Increasing the centre distance of bull gear and crank
pin
(b) Decreasing
D
i
th centre
the
t distance
di t
off bull
b ll gear and
d
crank pin
(c) Increasing the length of the ram
((d)) Decreasing
g the length
g of the slot in the slotted lever
IES 2004
IES
IAS 1995
IAS
ISRO2010
Size
is
by
Si off a shaper
h
i given
i
b
(a) Stroke length
(b)
Motor power
(c) Weight
g of the machine
(d)
Table size.
Page 109 of 240
Which of the following are the advantages of a

hydraulic shaper over a mechanically driven shaper?
1 More strokes per minute can be obtained at a given
1.
cutting speed.
2. The
Th cutting
tti stroke
t k has
h a definite
d fi it stopping
t
i point.
i t
3. It is simpler in construction.
4. Cutting speed is constant throughout most of the
g stroke.
cutting
(a) 1 and 2
(b) 1 and 4
(c) 2 and 4
(d) 1, 3 and 4
The cutting speed of the tool in a mechanical

shaper
h
i
is
(a) Maximum at the beginning of the cutting stroke
(b) Maximum at the end of the cutting stroke
((c)) Maximum at the middle of the cutting
g stroke
(d) Minimum at the middle of the cutting stroke
Rev.0
AbrasiveMachiningProcesses
GATE2014 (PI)
GATE2014(PI)
Matchthefollowing
GroupI(Mechanism)
PQuickreturn
QApron
RIntermittentindexing
SDifferentialmechanism
S
e e t a ec a s
(a)P1 Q2 R4 S3
(a)P1Q2R4S3
(c)P4Q1R2S3
GroupII(Machines)
1Lathe
2Shaping
3Gearhobbing
4Milling
4
g
Grinding&Finishing
(b)P2 Q1 R4 S3
(b)P2Q1R4S3
(d)P2Q3R1S4
BySKMondal
Process
Features
Grinding
Useswheels,accuratesizing,finishing,lowMRR;
canbedoneathighspeeds.
Creepfeed
grinding
d
Useswheelswithlongcuttingarc,veryslowfeed
rateandlargedepthofcut
dl
d h f
Abrasive
machining
Abrasivewater
jetMachining
Honing
HighMRR,toobtaindesiredshapesand
approximatesizes
Waterjetswithvelocitiesupto1000m/seccarry
abrasiveparticles(silicaandgarnet)
"Stones"containingfineabrasives;primarilya
h l finishingprocess
hole
fi i hi
Fineparticlesembeddedinsoftmetalorcloth;
primarilyasurfacefinishingprocess
i
il f
fi i hi
Lapping
Grinding
Whyishighvelocitydesiredingrinding?
g is the most common form of abrasive

yG
Grinding
y It is desired to off set the adverse effect of very high

negative rake angle of the working grit, to reduce the
force per grit as well as the overall grinding force.
machining.
y It is a material cutting
gp
process which engages
g g an abrasive
tool whose cutting elements are grains of abrasive

material known as grit.
y These grits are characterized by sharp cutting points,
high hot hardness, and chemical stability and wear
resistance.
y The grits are held together by a suitable bonding
material to give shape of an abrasive tool.
y Grinding can be compared with milling with an infinite
number of cutting edge.
Fig- cutting action of abrasive grains
Advantages of Grinding
AdvantagesofGrinding
Applications of Grinding
ApplicationsofGrinding
y Dimensionalaccuracy
Di
i
l
y Surfacefinishing
S f fi i hi
y Goodsurfacefinish
y Slittingandparting
y Goodformandlocational accuracy
y
y Descaling,deburring
g
g
y Applicabletobothhardenedandunhardenedmaterial
y Stockremoval(abrasivemilling)
Onwhichfactorsdoesthetransverseroughness
p
p
gg
g
ofworkpiecedependduringgrinding?
y It mainly depends on the shape of the grits and overlap
cuts made by the grits in the transverse direction. Lateral

plastic flow of the material as a result of ploughing also
influences the surface roughness.
y Finishingofflataswellascylindricalsurface
y Grindingoftoolsandcuttersandresharpening ofthe
same
Page 110 of 240
Rev.0
G i di
Grinding
y If each abrasive grain is viewed as a cutting tool then in
grinding operation.
High
y Rake angle can be positive, zero, or negative ranging from
Interactionofthegritwiththeworkpiece
Interactionofthegritwiththeworkpiece
y Shape of grit is very important because it determines the
y Grit with favourable geometry can produce chip in shear
grit geometry e.g. rake and clearance angle.

y The grits do not have definite geometry unlike a cutting
tool.
y However,
However grits having large negative rake angle or
+45o to 60
60o, dull,
dull rounded grits has large negative rake angle
y Cutting speed is very high
y Very
V
hi h specific
high
ifi energy off cutting
i
mode.
rounded cutting edge do not form chips but may rub or
make a groove by ploughing leading to lateral flow of the
workpiece material.
Low
y Low shear angle
y Low feed rate
Fig Grits engage shearing, ploughing and rubbing
y Low depth of cut
Howischipaccommodationvolumeis
relatedtomaterialremovalrate?
related to material removal rate?
Specificenergyconsumptioningrinding
Howmaythespecificgrindingenergyvary
withmaterialremovalrateingrinding?
with material removal rate in grinding?
y Volume of chip accommodation space ahead of each grit
y Specific grinding energy will start decreasing with
must be greater than the chip volume produced by each

grit to facilitate easy evacuation of the chip from the
grinding wheel.
material removal rate because rake angle of the grit

becomes more favourable with increase of grit depth of
cut. However, if increase of material removal rate causes
chip accommodation problem in the available inter
intergrit
grit
space then specific energy may increase.
GRatio
( )
GATE2011(PI)
y The grinding ratio or G ratio is defined as thee cubic mm
of stock removed divided by the cubic mm of wheel lost.

y In conventional grinding, the G ratio is in the range 20: 1
to 80: 1.
1
y The G ratio is a measure of grinding production and
reflects the amount of work a wheel can do during its

useful life.
life
y As the wheel losses material,
material it must be reset or
repositionedFor-2015
to maintain
workpiece
size.
(IES,
GATE & PSUs)
Grindingratioisdefinedas
volume of wheel wear
volume of work material removed
volume of work material removed
(b)
volume of wheel wear
cutting speed
(c)
feed
longitudinal feed
(d)
transverse feed
(a)
Page 111 of 240
Parametersforspecifyagrindingwheel
1) The type of grit material
2) The grit size
3)) The
Th bond
b d strength
t
th off the
th wheel,
h l commonly
l known
k
as wheel hardness
4) The structure of the wheel denoting the porosity i.e.
the amount of inter grit spacing
5) The type of bond material
6) Other than these parameters, the wheel
manufacturer may add their own identification code
prefixing or suffixing (or both) the standard code.
Rev.0
Abrasive
Material
CommentsandUses
Aluminium oxide
Softer and tougher than silicon

carbide; use on steel,
steel iron,
iron brass
Siliconcarbide
Used
for
brass,,
bronze,,
aluminum, stainless steel and
cast iron
For grinding hard, tough tool
steels, stainless steel, cobalt and
nickel based superalloys, and
hard coatings
Used
to
grind
nonferrous
materials tungsten carbide and
materials,
ceramics
cBN (cubicboron
nitride))
Diamond
Whyisaluminium oxidepreferredto
siliconcarbideingrindingsteel?
silicon carbide in grinding steel?
y Al2O3 is tougher than SiC.
SiC Therefore it is
preferred to grind material having high tensile

strength like steel.
steel Moreover,
Moreover Al2O3 shows higher
chemical inertness than SiC towards steel leading
to much improved wear resistance during
g
grinding.
g
Grit size
Gritsize
y The grain size affects material removal rate and the
surface quality of workpiece in grinding.

y Large grit
grit big grinding capacity,
capacity rough workpiece
surface
y Fine
Fi
grit
it small
ll grinding
i di
capacity,
it smooth
th workpiece
k i
surface
Grade
Structure / concentration
Structure/concentration
y The worn out grit must pull out from the bond and make
y The structure should be open for grinding wheels
room for fresh sharp grit in order to avoid excessive rise

of grinding force and temperature.
y A soft wheel should be chosen for grinding hard
material.
material
y A hard wheel should be chosen for grinding soft
material.
t i l
engaged in high material removal to provide chip

accommodation space.
y The space between the grits also serves as pocket for
holding grinding fluid.
fluid
y Dense structured wheels are used for longer wheel life,
f holding
for
h ldi precision
i i forms
f
and
d profiles.
fil
Page 112 of 240
IES2009
y 2marks
Whydoessinglelayergrindingwheelshowprogressive
riseofforceduringgrindingofhighspeedsteel?
y The geometry of grit undergoes irreversible change in
the form of rounding or flattening due to wear caused by

rubbing action of hard carbides present in high speed
steel.
Whyiscoarsegrainandopenstructuredwheel
ispreferredforstockremovalgrinding?
is preferred for stock removal grinding?
y Coarse grit allows large grit protrusion and open
structure provides large inter grit chip space. Thus in

combination those two provide large space for chip
accommodation during stock removal grinding and risk
of wheel loading is minimized.
Rev.0
B di M
i l f G i di
h l
BondingMaterialsforGrindingwheels
Type of Bond
Attributes
Vitrified bonds Composed of clays and other ceramic

substances, porous, strong, rigid, and
unaffected
by
oils,
water,
or
temperature. Brittle and can not be used
for high wheel speed.
Resinoid,
or Plastic bond, replaced shellac and
phenolic
p
rubber wheels,, not with alkaline
resins
grinding fluid.
Shellac bond
For flexible cut off wheels, replaced by
resin bond.
Bonding Materials for Grinding wheels

Type of Bond
Attributes
Rubber bond
For use in thin wheels, replaced by resin

bond.
bond
Limited use.
Oxychloride
b d
bond
Metal bond
Electroplated
bond
Extensively used with super abrasive

wheels, high toughness, high accuracy,
large stock removal.
Used for small wheel, form wheel and
p abrasive wheels,, for abrasive
thin super
milling and ultra high speed grinding.
Replace by electroplated bond
B di M
i l f G i di
h l
Vitrified bonds
y They are composed of clays and other ceramic
substances.
y Vitrified wheels are p
porous,, strong,
g, rigid,
g , and unaffected
by oils, water, or temperature over the ranges usually
g
encountered in metal cutting.
y The operating speed range in most cases is 1500 to 5000
m/min.
Resinoid or phenolic resins

Resinoid,orphenolic
Shellac bond
Shellacbond
y Because plastics can be compounded to have a wide
y At one time this bond was used for flexible cut off
range of properties, such wheels can be obtained to cover

a variety of work conditions.
y They have, to a considerable extent, replaced shellac and
rubber wheels.
wheels
y Resin bond is not recommended with alkaline grinding
fl id for
fluid
f a possible
ibl chemical
h i l attack
tt k leading
l di
t bond
to
b d
weakening.
wheels.
y At present use of shellac bond is limited to grinding
wheels engaged in fine finish of rolls.
Rubber bond
Rubberbond
Oxychloride bond
Metal bond
Metalbond
off
y Its principal use is in thin wheels for wet cut
cutoff
y Itislesscommontypebond,butstillcanbeusedindisc
y Metal bond is extensively used with super abrasive
Whatisthemainshortcomingofvitrified
bond?
Vitrified bond is brittle and can not with stand high
impact loads. This bond can not be used for high wheel
speed due to risk of wheel breakage under centrifugal
force.
operation.
y Rubber bond was once popular for finish grinding on
bearings and cutting tools.
grindingoperation.Itisusedunderdrycondition.
Page 113 of 240
wheels. Extremely high toughness of metal bonded

wheels makes these very effective in those applications
where form accuracy as well as large stock removal is
desired.
Rev.0
Electroplated bond
Electroplatedbond
Brazed bond
Brazedbond
Gl i
Glazing
y This
large
(3040%)
Thi bond
b d allows
ll
l
(
%) crystal
t l exposure above
b
y This
crystal
Thi is
i relatively
l ti l a recentt development,
d l
t allows
ll
t l
y With continuous
use a grinding
dull
ti
i di wheel
h l becomes
b
d ll with
ith
the bond without need of anyy truing

g or dressing.
g This
exposure
p
as high
g 6080%. In addition g
grit spacing
p
g can be
bond is specially used for making small diameter wheel,
precisely controlled. This bond is particularly suitable for
form wheel and thin super abrasive wheels. Presently it is
very high material removal either with diamond or cBN
th only
the
l bond
b d for
f making
ki wheels
h l for
f abrasive
b i milling
illi and
d
wheel.
h l The
Th bond
b d strength
t
th is
i much
h greater
t than
th provided
id d
ultra high
g speed
p
grinding.
g
g
byy electroplated
p
bond. This bond is expected
p
to replace
p
the sharp
p abrasive g
grains becoming
g rounded.
y This condition of a dull grinding wheel with worn out
grains is termed as glazing.
electroplated bond in many applications.
L di
Loading
Dressing
y Some
grinding
S
i di chips
hi gett lodged
l d d into
i t the
th spaces between
b t
y Dressing is the conditioning of the wheel surface which

ensures that grit cutting edges are exposed from the
bond and thus able to penetrate into the workpiece
material.
y In dressing attempts are made to splinter the abrasive
grains to make them sharp and free cutting and also to
remove any residue left by material being ground.
ground
y Dressing therefore produces microgeometry.
the g
grits resulting
g in a condition known as loaded wheel.
y Loading is generally caused during the grinding of soft
and ductile materials.

y A loaded grinding wheel cannot cut properly and need
dressing.
dressing
G
20
GATE2014
Match the Machine Tools (Group A) with the probable
Operations (Group B):
Group A
G
P:CenterLathe
Q:Milling
R:Grinding
S:Drilling
P
( ) 1
(a)
(c) 3
CanaresinbondedcBN wheelbe
electrochemicallydressed?
electrochemically dressed?
Isdressingnecessaryforsinglelayer
wheel?
y Electrochemical dressing is not possible with resin
y Conventional macro level dressing is not required
bonded wheel because it is not electrically conducting.
because the wheel inherently has an open structure.

However, touch dressing is carried out to obtain better
uniformity in grit height in order to improve surface
finish of the workpiece.
Page 114 of 240
Q
2
1
R
4
4
GroupB
G
B
1:Slotting
2:Counterboring
3:Knurling
4:Dressing
S
3
2
( )
(b)
(d)
P
2
3
Q
1
4
R
4
2
S
3
1
Truing
y Truing is the act of regenerating the required geometry
on the grinding wheel.

y Truing is also required on a new conventional wheel to
ensure concentricity with specific mounting system.
y Truing
T i and
d dressing
d
i are commonly
l combined
bi d into
i t one
operation for conventional abrasive grinding wheels, but
are usually
ll two
t
di ti tl separate
distinctly
t operation
ti
f super
for
abrasive wheel.
Rev.0
BalancingGrindingWheels
y Because of the high rotation speeds involved,
involved grinding
wheels must never be used unless they are in good

balance.
balance
y Grinding wheel must be balanced Statically and
D
Dynamically.
i ll
y A slight imbalance will produce vibrations that will cause
waviness in the work surface. It may cause a wheel to
break, with the probability of serious damage and injury.
IES2011Conventional
What is creep feed grinding? Discuss its salient
f t
features,
advantages,
d
t
and
d application.
li ti
[10 marks]
Whatarethecharacteristicfeaturesofa
universalcylindricalgrinder?
universal cylindrical grinder?
y Characteristicfeaturesofauniversalcylindricalgrinder
notpossessedbyplaincylindricalgrinderare:
Swivelling wheelhead
Swivelling wheelheadslide
Swivelling headstock
Creep feed grinding

Creepfeedgrinding
y Thismachineenablessinglepassgrindingofasurface
withalargerdownfeedbutslowertablespeedthanthat
adoptedformulti passconventionalsurfacegrinding.
adoptedformultipassconventionalsurfacegrinding.
y Increepfeedgrinding,theentiredepthofcutis
completedinonepassonlyusingverysmallin feed
completedinonepassonlyusingverysmallinfeed
rates.
Statethebasicadvantageofacreepfeed
grinderoveraconventionalsurface
grinder over a conventional surface
y Productivityisenhancedandlifeofthegrindingwheelis
extended.
C li d i l G i di
CylindricalGrinding
type cylindrical grinding is commonly used far
y Center
Centertype
producing external cylindrical surfaces.
y The grinding wheel revolves at an ordinary cutting
speed, and the workpiece rotates on centers at a much
slower speed.
speed
y Grinding machines are available in which the workpiece
i held
is
h ld in
i a chuck
h k for
f grinding
i di both
b th external
t
l and
d internal
i t
l
cylindrical surfaces.
C t l
G i di
Centerless
Grinding
y Centerless grinding makes it possible to grind both
external and internal cylindrical surfaces without

requiring the workpiece to be mounted between centers
or in a chuck.
y This eliminates the requirement of center holes in some
workpieces and the necessity for mounting the
workpiece thereby reducing the cycle time.
workpiece,
time
y Two wheels are used. The larger one operates at regular
grinding
i di
speeds
d and
d does
d
th actual
the
t l grinding.
i di
Th
The
smaller wheel is the regulating wheel. It is mounted at
an angle
l to
t the
th plane
l
off the
th grinding
i di wheel.
h l
Page 115 of 240
C t l
G i di
Centerless
Grinding
y The regulating
wheel controls the rotation and

longitudinal motion of the workpiece and usually is a
plastic or rubber
plastic
rubberbonded
bonded wheel with a fairly wide face.
y Theworkpieceisheldagainsttheworkrestbladebythe
cuttingforcesexertedbythegrindingwheelandrotates
atapproximatelythesamesurfacespeedasthatofthe
regulatingwheel.
regulatingwheel
Rev.0
Centerless Grinding
C t l
G i di
Centerless
Grinding
The axial feed is calculated by the equation
F = dN sin
where
F = feed (mm/min)
d = diameter of the regulating wheel (mm)
N = revolutions per minute of the regulating wheel
C t l
i t
l G i di
Centreless
internalGrinding
y This machine is used for grinding cylindrical and
tapered holes in cylindrical parts (e.g. cylindrical liners,

various bushings etc).
y The workpiece is rotated between supporting roll,
pressure roll and regulating wheel and is ground by the
grinding wheel.
= angle
g of inclination of the regulating
g
g wheel
Statethedisadvantagesofcentreless
cylindricalgrindingmachine?
cylindrical grinding machine?
Itdoesnotgrindconcentricallywithcentres.
Largediametershortworkpiecearedifficultto
controlintheprocess
Itmaynotimproveworkpieceperpendicularity.
Istransversefeedprovidedinvertical
spindlereciprocatingtablesurfacegrinder?
spindle reciprocating table surface grinder?
y Usually no transverse feed is provided in such machine.
The wheel diameter is kept larger than the width of the

workpiece surface to be ground.
S f
G i di
hi
SurfaceGrindingMachines
y Surface grinding machines are used primarily to
grind flat surfaces.

formed irregular surfaces can be
formed,
produced on some types of surface grinders by use
of a formed wheel.
wheel
Four basic types of surface grinding machines are:
1 Horizontal spindle and reciprocating table
1.
2. Vertical spindle and reciprocating table
3. Horizontal
H i
l spindle
i dl and
d rotary table
bl
4. Vertical spindle and rotary table
y However
L
i
Lapping
Ch
t i ti
fl
i
Characteristicsoflappingprocess
y Lappingisbasicallyanabrasiveprocessinwhichloose
y Useoflooseabrasivebetweenlapandtheworkpiece
abrasivesfunctionascuttingpointsfindingmomentary
supportfromthelaps.
y Materialremovalinlappingusuallyrangesfrom.003to
.03mmbutmanyreach0.08to0.1mmincertaincases.
03mmbutmanyreach0 08to0 1mmincertaincases
y Usuallylapandworkpiecearenotpositivelydrivenbut
Page 116 of 240
areguidedincontactwitheachother
y Relativemotionbetweenthelapandtheworkshould
changecontinuouslysothatpathoftheabrasivegrains
h
ti
l th t th fth b i i
ofthelapisnotrepeatedontheworkpiece.
y Castironisthemostlyusedlapmaterial.However,soft
steel,copper,brass,hardwoodaswellashardenedsteel
andglassarealsoused.
Rev.0
Ab i
fl
i
Abrasivesoflapping
V hi l
t i l f l
i
Vehiclematerialsforlapping
Technicalparametersaffectinglappingprocessesare
y Al2O3 andSiC,grainsize5~100m
dSiC i i
y Machineoil
M hi il
y unitpressure
it
y Cr2O3,grainsize1
grainsize1~2m
2m
y Rapeside oil
y thegrainsizeofabrasive
y B4C3,grainsize5
g
5 60m
y grease
g
y concentrationofabrasiveinthevehicle
y Diamond,grainsize0.5~5m
y lappingspeed
H i
Honing
y Honing is a finishing process, in which a tool called hone
carries out a combined rotary and reciprocating motion

while the workpiece does not perform any working
motion.
y Most honing is done on internal cylindrical surface,
surface such
as automobile cylindrical walls. The honing stones are
held against the workpiece with controlled light
pressure. The honing head is not guided externally but,
instead floats in the hole,
instead,
hole being guided by the work
surface.
H i
Honing
y It is desired that
1. Honing stones should not leave the work surface

2. Stroke
St k length
l
th mustt cover the
th entire
ti work
k length.
l
th
3. In honing rotary and oscillatory motions are
combined to produce a cross hatched lay pattern.
The honing stones are given a complex motion so as

to prevent every single grit from repeating its path
over the work surface.
surface
Fig.Honingtool
Fig.Laypatternproducedbycombinationofrotaryand
oscillatorymotion
ill
Buffing
Th
iti l
t
Thecriticalprocessparametersare
g is a p
g operation
p
p
y Buffing
polishing
in which the workpiece
y 1.rotationspeed
t ti
d
y 2.oscillationspeed
2 oscillationspeed
y 3.lengthandpositionofthestroke
3
g
p
y 4.honingstickpressure
H i
Honing
Page 117 of 240
is brought into contact with a revolving cloth wheel that

has been charged with a fine abrasive, such as polishing
rough.
y The wheels are made of disks of linen, cotton,
broadcloth, or canvas, and achieve the desired degree of
firmness through the amount of stitching used to fasten
th layers
the
l
off cloth
l th together.
t th
y Negligible amount of material is removed in buffing
while
hil a very high
hi h luster
l t is
i generated
t d on the
th buffed
b ff d
surface.
y The
Th dimensional
di
i
l accuracy off the
th parts
t is
i nott affected
ff t d by
b
Rev.0
the buffing operation.
SuperFinishing
S
Fi i hi
SuperFinishing
Statethespecificapplicationofaplanetary
internalgrinder.
internal grinder
y Planetary internal grinders find application for grinding
holes in workpieces of irregular shape or large heavy

workpieces.
Fig. super finishing of end face
of a cylindrical work piece in radial mode
In this both feeding and oscillation of the super

finishing stone is given in the radial direction.
GATE 1995
GATE
Among the conventional machining processes,
maximum specific energy is consumed in
(a) Turning
(b) Drilling
(c) Planning (d) Grinding
GATE 2000
GATE
Abrasive material used in grinding wheel selected
for grinding ferrous alloys is
(a) Silicon carbide
(b) Diamond
(c) Aluminium oxide
(d) Boron carbide
Fig. super finishing operation in plunge mode
IIn this
hi case the
h abrasive
b i stone covers the
h section
i
off the
h
workpiece requiring super finish. The abrasive stone is
slowly
l l fed
f d in
i radial
di l direction
di
i
while
hil its
i oscillation
ill i
i
is
imparted in the axial direction. It reduce surface
roughness
h
and
d increase
i
b i load
bearing
l d capacity.
it
GATE 1998
GATE
Ideal surface roughness, as measured by the
maximum height of unevenness, is best achieved
when, the material is removed by
(a) An end mill
(b) A grinding
i di wheel
h l
(c) A tool with zero nose radius
(d) A ball mill.
GATE 2002
GATE
The hardness of a grinding wheel is determined by
the
(a) Hardness of abrasive grains
(b) Ability of the bond to retain abrasives
(c) Hardness of the bond
((d)) Abilityy of the g
grinding
g wheel to p
penetrate the work
piece
Page 118 of 240
GATE 1998
GATE
In machining using abrasive material, increasing
abrasive grain size
(a) Increases the material removal rate
(b) Decreases the material removal rate
(c) First decreases and then increases the material
removal rate
(d) First increases and then decreases the material
removal rate
GATE 2006
GATE
If each abrasive grain is viewed as a cutting tool,
then which of the following represents the cutting
parameters in common grinding operations?
(a) Large negative rake angle, low shear angle and high
cutting speed
(b) Large positive rake angle, low shear angle and high
cutting
tti speed
d
(c) Large negative rake angle, high shear angle and low
cutting speed
(d) Zero rake angle,
g high
g shear angle
g and high
g cutting
g
speed
Rev.0
GATE 1997
GATE
List I
(A) Grinding
(B) Honing
H i
(C) Superfinishing
D)) Burnishing
g
1.
2.
3.
4.
4
5.
6
6.
List II
Surface for oil retention
S f
Surface
f max. load
for
l d
capacity
Surface of limiting friction
Surface of matte finish
Surface for pressure sealing
Surface for interference fit.
fit
IES 1997
IES
Which one of the following materials is used as the
bonding material for grinding wheels?
(a) Silicon carbide
(b) Sodium silicate
(c) Boron carbide
((d)) Aluminum oxide
IES 1996
IES
Specific energy requirements in a grinding process
are more than those in turning for the same metal
removal rate because of the
(a) Specific pressures between wheel and work being
high.
high
(b) Size effect of the larger contact areas between wheel
and
d work.
k
(c) High cutting velocities
(d) High heat produced during grinding.
IES 2005
IES
Consider the following statements in respect of
grinding?
1 The pitch of the grit cutting edges is larger than the
1.
pitch of the milling cutter.
2. The
Th cutting
tti
angles
l
off the
th grits
it have
h
a random
d
geometry.
3. The size of the chip cuts is very small for grinding.
Which of the statements g
given above are correct?
(a) 1 and 2
(b) 2 and 3
(c) 1 and 3
(d) 1,
1 2 and 3
IES 1996
IES
Grinding wheel is said to be loaded when the
(a) Metal particles get embedded in the wheel surface
blocking the interspaces between cutting grains.
grains
(b) Bonding material comes on the surface and the
wheel
h l becomes
b
bl t
blunt.
(c) Work piece being ground comes to a stop in
cylindrical grinding.
((d)) Grinding
g wheel stops
p because of veryy large
g depth
p of
cut
IES 1994
IES
The ratio of thrust force to cutting force is nearly 2.5
in
(a) Turning
(b) Broaching
(c) Grinding (d) Plain milling
Page 119 of 240
IES 2009
IES
Which one of the following is NOT used as abrasive
material in grinding wheels?
(a) Aluminium oxide
(b) Silicon carbide
(c) Cubic boron nitride
((d)) Manganese
g
oxide
IES 2001
IES
Specific cutting energy is more in grinding process
compared to turning because
(a) Grinding (cutting) speed is higher
(b) The wheel has multiple cutting edges (grains)
(c) Plaguing force is significant due to small chip size
((d)) Grinding
g wheel undergoes
g
continuous wear
IES 1992
IES
Assertion (A): Vitrified bond is preferred for thin
grinding wheels.
Reason (R): Vitrified bond is hard brittle.
brittle
l
ti off A
Rev.0
IES 2000
IES
) The ratio of cutting
g force to thrust force is
Assertion ((A):
very high in grinding process as compared to other
machining processes.
Reason (R): Random orientation and effective negative
rake angles of abrasive grains increase the cutting force
and adversely affect the cutting action and promote
rubbing action.
explanation of A
IES 2009
IES
Given that the peripheral speed of the grinding
wheel of 100 mm diameter for cylindrical grinding
of a steel work piece is 30 m/s, what will be the
estimated rotational speed of the grinding wheel in
revolution per minute (r.p.m.)?
(a) 11460
(b) 5730
( ) 2865
(c)
86
(d) 95
IES 2000
IES
The sequence of markings "S
S 14 K 14 S
S" on a grinding
wheel represents respectively
(a) Bond type,
type structure,
structure grade,
grade grain size and abrasive
type
(b) Abrasive
Ab i type,
t
grain
i size,
i
grade,
d structure
t t
and
d bond
b d
type
(c) Bond type, grade, structure, grain size and abrasive
type
(d) Abrasive type, structure, grade, grain size and bond
yp
type
IES 1995
IES
IES 2010
IES2010
Soft materials cannot be economically grind due to

(a) The high temperatures involved
(b) Frequent
F
t wheel
h l clogging
l
i
(c) Rapid wheel wear
(d) Low work piece stiffness
In relation to the peripheral or surface

speeds of the grinding wheel and that of the
workpiece in cylindrical grinding of alloy
steel workpieces, the grinding wheel speed is
(a) Less than the speed of the workpiece
(b) Same as the speed of the workpiece
(c) Double the speed of the workpiece
(d) 65 to 75 times the speed of the workpiece.
IES 2002
IES
IES 2001,ISRO2009
2001 ISRO 2009
IES
Which of the following materials are used in

grinding wheel?
1 Aluminium oxide
1.
2. Cubic boron nitride
3. Silicon carbide
g the codes g
given below:
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3
(d) 1 and 3
The marking on a grinding wheel is '51

51 A 36 L 5 V 93
93'..
The code '36' represents the
(a) Structure
(b) Grade
(c) Grain size
((d)) Manufacturer's number
IES 1995
IES
IES 1993
IES
In the grinding wheel of A 60 G 7 B 23, B stands for

(a) Resinoid bond
(b) Rubber bond
( ) Shellac
(c)
Sh ll bond
b d
(d) Silicate
Sili t bond.
b d
Tool life in the case of a grinding wheel is the time

(a) Between two successive regrinds of the wheel
(b) Taken
T k for
f the
th wheel
h l to
t be
b balanced
b l
d
(c) Taken between two successive wheel dressings
(d) Taken for a wear of 1mm on its diameter
Page 120 of 240
Rev.0
IES 2001
IES
Assertion (A): Hard wheels are chosen for grinding
hard metals.
Reason (R): In hard wheels only the abrasive grains
are retained for long time.
( ) Both
(a)
B th A and
i di id ll true
t
and
d R is
i the
th
IES 2001
IES
Dry and compressed air is used as cutting fluid for
machining
(a) Steel
(b) Aluminium
(c) Cast iron (d) Brass
IES 1996
IES
A grinding wheel of 150 mm diameter is rotating at
3000 rpm. The grinding speed is
IES 1994
IES
grinding of high carbon steel:
1 Grinding at high speed results in the reduction of
1.
chip thickness and cutting forces per grit.
2. Aluminium
Al i i
oxide
id wheels
h l are employed.
l d
3. The grinding wheel has to be of open structure.
Of these statements
(a) 1, 2 and 3 are correct
(b) 1 and 2 are correct
(c) 1 and 3 are correct
(d) 2 and 3 are correct
IES 1993
IES
In centre less grinding, the work piece centre will be
(a) Above the line joining the two wheel centres
(b) Below
B l the
th line
li joining
j i i the
th two
t wheel
h l centres
t
(c) On the line joining the two wheel centres
(d) At the intersection of the line joining the wheel
plate p
plane.
centres with the work p
IES 1993
IES
Consider the following parameters:
1. Grinding wheel diameter.
2. Regulating
R
l ti wheel
h l diameter.
di
t
3. Speed of the grinding wheel.
4. Speed of the regulating wheel.
5. Angle between the axes of grinding and regulating
wheels.
Among these parameters,
parameters those which influence the
axial feed rate in centreless grinding would include
( ) 2, 4 and
(a)
d 5 (b) 1, 2 and
d3
(c) 1, 4 and 5 (d) Page
3, 4121
andof5 240
IES 1999
IES
Consider the following reasons:
1. Grinding wheel is soft
2. RPM off grinding
i di wheel
h l is
i too
t low
l
3. Cut is very fine
4. An improper cutting fluid is used
A grinding wheel may become loaded due to reasons
stated at
(a) 1 and 4
(b) 1 and 3
(c) 2 and 4
(d) 2 and 3
IES 2000
IES
Consider the following advantages:
1. Rapid process
2. Work
W k with
ith keyways
k
can be
b ground
d
3. No work holding device is required.
Which of these are the advantages of centre less
g
grinding?
g
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3
(d) 1 and 3
IES 2007
IES
Honing Process gives surface finish of what order?
(a) 10 m (CLA)
(b) 1.0 m (CLA)
( ) 0.1 m (CLA)
(c)
(d) 0.01 m (CLA)
Rev.0
IES 1992
IES
CLA value for Honing process is
(a) 6
(b) 0.05 3.0
( ) 0.05 1.0 (d) 0.025 0.1
(c)
IES 1992
IES
A surface finish of 0.025 0.1 micrometer CLA values
is to by produced. Which machining process would
you recommend?
(a) Grinding (b) Rough turning
( ) Lapping
(c)
L
i
(d) Honing
H i
IAS 2000
IAS
Consider the following statements in respect of a
grinding wheel of specification, 51A 36L7R23,
using the standard alphanumeric codification:
1. Abrasive used in the wheel is aluminum oxide
2. The
Th grain
i size
i off abrasive
b i is
i medium
di
3. The wheel grade is medium hard
4. It has an open structure
5. It has resinoid as bonding agent
Which (If these statements are correct?
( ) 1, 2 and
(a)
d 3 (b) 1, 3 and
d4
GATE & PSUs)
(c) 2, 3 and For-2015
5 (d) (IES,
1, 4 and
5
IES 2012
IES
()
g
gp
Statement(I):Honingisanabradingprocesstoremove
stockfrommetallicsurfaces.
( )
g
y
Statement(II):Honingiscommonlydoneoninternal
surfaces.
IES 1992
IES
Buffing wheels are mode of
(a) Softer metals
(b) Cotton fabric
( ) Carbon
(c)
C b
(d) Graphite
G hit
IAS 1999
IAS
Assertion (A): The grade of a grinding wheel is a
measure of hardness of the abrasive used for the
wheel.
Reason (R): Grading is necessary for making right
selection of the wheel for a particular work.
work
l
ti off A
(d) A is false but R is
true122 of 240
Page
IES 2001
IES
(
g Tools)) with ListII ((Applications)
pp
)
Match ListI (Cutting
and select the correct answer using the codes given
below the lists:
List I
List II
A. Trepanning tool 1.
For surface finishing by
h i
honing
B. Side milling cutter 2.
For machining gears
C Hob
C.
H b cutter
3.
F cutting
For
i keyways
k
i shafts
in
h f
D. Abrasive sticks
4.
For drilling large diameter
holes
Codes:A
B
C
D
A
B
C
D
( ) 1
(a)
3
2
4
(b) 4
3
2
1
(c) 1
2
3
4
(d) 4
2
3
1
IAS 2004
IAS
The size effect refers to the increase in specific
cutting energy at low values of under formed chip
thickness. It is due to which one of the following?
(a) Existence of ploughing force
(b) Work
W k hardening
h d i
(c) High strain rate
(d) Presence of high friction at chiptool interface.
IAS 2001
IAS
The setup for internal centreless grinding consists of a
regulating wheel, a pressure roll and a support roll, between
which the tubular workpiece is supported with the grinding
wheel within the tube, wherein
1.The grinding wheel, workpiece and regulating wheel centers
must lie on one line
2.The directions of rotation of workpiece and grinding wheel are
same
3.The directions of rotation of pressure roll, support roll and
regulating wheel are same
4 The directions of rotation of grinding wheel and regulating
4.The
wheel are same
(a) 1, 2 and 3
(b)
1, 3 and 4
Rev.0
(c) 2 and 3
(d)
3 and 4
IAS 1997
IAS
IAS 2007
2007
IAS
Which of the following pairs are correctly matched?

1. Drill press :
Trepanning
2. Centreless
C t l grinding:
i di
Th
Through
h feeding
f di
3. Capstan lathe:
Ram type turret
Codes:
(a) 1 and 2
(b) 1, 2 and 3
( ) 1 and
(c)
d3
(d) 2 and
d3
Match List I with List II and select the correct answer

using the code given below the Lists:
List I
List II
(Machine Tool/ Cutting Tool)
(Part/ Characteristics)
A. Screw cutting
g lathe1.
Self locking
g taper
p
B. Drill
2.
Chasing dial
33.
Wiper
p insert
C. End mill
D. Grinding wheel
4.
Self releasing taper
55.
Balance weights
g
Code:A
B
C
D
A
B
C
D
((a)) 4
5
3
1
((b)) 2
1
4
5
(c) 4
1
3
5
(d) 2
5
4
1
IAS 2001
IAS
IAS 1999
IAS
Which one of the following processing sequences
will give the best accuracy as well as surface finish?
(a) Drilling,
Drilling reaming and grinding
(b) Drilling, boring and grinding
(c) Drilling, reaming and lapping
((d)) Drilling,
g reaming
g and electroplating
p
g
NC,CNC&Robotics
Which one of the following grinding wheels (with

Grade, Grit and Bond) is suitable for cutter
grinding?
(a) K 60 vitrified
(b) K 320 vitrified
( ) T 60
(c)
6 resinoid
i id
(d) T 320 resinoid
i id
Wh t i NC/CNC?
WhatisNC/CNC?
y NC is
i an acronym for
f Numerical
N
i l Control
C t l and
d CNC is
i an
acronym
y for Computer
p
Numerical Control.
B SKM d l
BySKMondal
WhatisthedifferencebetweenNCandCNC?
WhatisthedifferencebetweenNCandCNC?
Wh
did CNC t t t d?
WheredidCNCgetstarted?
y The difference between NC and CNC is one of age and
y Some
off the
with
S
th enhancements
h
t that
th t came along
l
ith CNC
y 1940 Jhon
Parson
developed
Jh
P
d l
d first
fi t machine
hi able
bl to
t drill
d ill
include: Canned Cycles,

y
, Sub Programming,
g
g, Cutter
holes at specific
p
coordinates p
programmed
g
on p
punch
Compensation, Work coordinates, Coordinate system
cards.
capability.
y The earliest NC machines performed limited functions
and movements controlled by punched tape or punch
cards.
cards
y As the technology evolved, the machines were equiped
with
ith increasingly
i
i l powerful
f l microprocessors
i
(
(computers)
t )
with the addition of these computers, NC machines
b
become
CNC machines.
hi
y CNC machines have far more capability than their
predecessor.
contd..
rotation, automatic corner rounding, chamfering, and B
y 1951 MIT developed servomechanism
spline
li interpolation.
i t
l ti
y 1952 MIT developed first NC machines for milling.

y 1970 First
Fi CNC machines
hi
came into
i
picture
i
Nowadayss modified 1970

Nowaday
1970ss machines are used.
used
Page 123 of 240
Rev.0
IAS 1996
IAS
Assertion (A): The temperature control of an
electric iron is an example of servomechanism.
Reason (R): It is an automatic control system.
system
l
ti off A
Do all machines speak the same CNC

DoallmachinesspeakthesameCNC
language
y CNC machine
tool
offer
what
hi
t l builders
b ild
ff an option
ti
h t is
i
y No, while there is fairly standard set of G and M codes,
known as the conversational control. This control lets
Wh t i C
ti
l C t l
WhatisaConversationalControl
there is some variation in their application. For example
the
operator/programmer
use
simple
descriptive
a G0 or G00 command is universally regarded as the
language to program the part. The control then
command
d for
f rapid
id travel.
l Some
S
older
ld machines
hi
d not
do
di l d a graphical
displayed
hi l representation
t ti off the
th instructions
i t ti
have a G00 command. On these machines, rapid travel is
so the operator/programmer
p
p g
can verifyy the tool p
path.
commanded by using the F (feed) word address.
C C
hi
f
h
AreCNCmachinesfasterthan
conventionalmachines?
conventional machines?
C C
hi
AreCNCmachinesmoreaccurate
thanconventionalmachines?
than conventional machines?
y Yes, No, Sometimes. When it comes to making a single,
y Yes, they can be. But like anything else it depends on
simple part it is hard to beat a conventional mill or lathe.

lathe
who
h is
i running
i the
th machine,
hi
h
how
well
ll the
th machines
hi
h
has
CNC machines move faster in rapid travel than
been maintained,, q
qualityy of setup
p and so on.
GATE 1994
GATE
CNC machines are more accurate than conventional
machines because they have a high resolution
encoder and digital read
readouts
outs for positioning.
T
True
or false?
f l ?
conventional machines.
NC/CNCMachinesAdvantages
y High
Hi h Repeatability
R
t bilit and
d Precision
P i i e.g. Aircraft
Ai
ft parts
t
y Volume of production is very high
NC/CNCMachinesDisadvantages
y Costlysetup,skilledoperators
y Complex contours/surfaces need to be machined. E.g.
y Computers,programmingknowledgerequired
C
t
i k
l d
i d
Turbines
y Flexibility in job change, automatic tool settings, less
scrap
y More safe, higher productivity, better quality
y Less
L
paper work,
k faster
f t prototype
t t
production,
d ti
reduction
d ti
in lead times
y Maintenanceisdifficult
Page 124 of 240
IES 1999
IES
Consider the following statements
numerically controlled machine tools:
1 They reduce nonproductive
1.
non productive time
2. They reduce fixturing
3. They reduce maintenance cost
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3
(d) 1 and 3
Rev.0
regarding
IES 1995
IES
Consider
the
following
characteristics
of
production jobs:
1 Processing of parts frequently in small lots
1.
2. Need to accommodate design changes of products.
3. Low rate of metal removal
4. Need for holding
4
g close tolerances
The characteristics which favour the choice of
numerically controlled machines would include
(a) 1, 2 and 3
(b) 2, 3 and 4
( ) 1, 3 and
(c)
d 4 (d) 1, 2 and
d4
NC/CNC/DNC
y Direct Numerical Control is a system that uses a
Directnumericalcontrol
central computer to control several machines at the same

time
y Distributed Numerical Control (DNC): the central
computer
t downloads
d
l d complete
l t programs to
t the
th CNC
machines, which can be workstations or PCs, and can get
th information
the
i f
ti for
f the
th machine
hi operations.
ti
y The speed of the system is increased, large files can be
handled and the number of machine tools used is
expanded.
497
IES 2009
IES
DNC
In which of the following machining manual part

programming is done?
(a) CNC machining
(b) NC machining
(c) DNC machining
(d) FMS machining
498
GATE 1993
GATE
With reference to NC machine, which of the
following statement is wrong?
(a) Both closedloop
closed loop and openloop
open loop control systems are
used
(b) Paper
P
t
tapes,
fl
floppy
t
tapes
and
d cassettes
tt are used
d for
f
data storage
(c) Digitizers may be used as interactive input devices
((d)) Post p
processor is an item of hardware
499
IES 2007
IES
What are the main components of an NC machine?
1. Part program
2. Machine
M hi Control
C t l Unit
U it
3. Servo motor
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only
20 0
JWM2010
g components
p
g
g numerical
regarding
control system :
1 Programme of instructions
1.
2. Machine control unit
3. Processing
P
i equipment
i
Which of these are correct ?
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only (d) 1 and 3 only
Page 125 of 240
IES 2009
IES
What is the purpose of satellite computers in
Distributed Numerical Control machines?
(a) To act as standby
stand by systems
(b) To share the processing of largesize NC programs
(c) To serve a group of NC machines
((d)) To network with another DNC setup
p
Rev.0
IES 1999
IES
Consider the following components:
1. A dedicated computer
2. Bulk
B lk memory
3. Telecommunication lines
Which of these components are required for a DNC
y
system?
(a) 2 and 3
(b) 1 and 2
(c) 1,
1 2 and 3 (d) 1 and 3
IES 2002Contd..FromS1
2002 C td F
S1
IES
C.
y
DNC system
33.
D. Machining centre 4.
Codes:A
( ) 4
(a)
(c) 4
B
2
3
C
3
2
D
1
1
IES 2002S1
2002
S1
IES
20 0
JWM2010
The controller consists of

softwired computer and
hard wired logic Graphic
display of tool path is
also possible
The instructions on tape is
prepared in binary
d i l form
decimal
f
and
d operated
d by
b
a series of coded
instructions
A
B
C
D
(b) 1
3
2
4
(d) 1
2
3
4
g
g
y
ConsiderthefollowingadvantagesofDNCsystems:
1.Timesharing
2 Greatercomputationalcapability
2.Greatercomputationalcapability
3.Remotecomputerlocation
Whichoftheaboveis/arecorrect?
(a)1and2only
(b)2and3only
(c)2only
(d)1 2and3
(d)1,2and3
Match List I with List II and select the correct

answer:
List I
List II
(NC machine tool systems)
(Features)
A NC system 1.
A.
1
It has an integrated automatic tool
changing unit and a component
g device
indexing
B. CNC system 2.
A number of machine tools are
p
No tape
p
controlled byy a computer.
reader, the part program is
transmitted directly to the
machine tool from the
computer memory
St
M t
StepperMotor
IAS2011main
y The
motor
off synchronous
motor
Th stepper
t
t is
i special
i l type
t
h
t
Explain, at least two, characteristics each of NC,
which is designed
g
to rotate through
g a specific
p
angle
g
CNC and DNC.
(Called step) for each electrical pulse received from the

[10Marks]
control unit.
BasicCNCPrinciples
IAS2010Main
IAS2009main
Illustratewiththehelpofneatsketchesthedifferences
What is the function of stepper motor?
betweenopen loopandclosed loopcontrolinNC

betweenopenloopandclosedloopcontrolinNC
[2 marks]
system.Whyisfeedbacknotpossibleinopenloop
controlsystem?
[22 Marks]
Page 126 of 240
Rev.0
GATE 2007
GATE
WhichtypeofmotorisNOTusedinaxisorspindle
drivesofCNCmachinetools?
(a) Inductionmotor
(b) DCservomotor
(c) Steppermotor
(d) Linearservomotor
IES 1994
IES
IES 2002
IES
Feed drives in CNC milling machines are provided

by
(a) Synchronous motors
(b) Induction motors
(c) Stepper motors
((d)) Servomotors.
In a CNC machine tool, encoder is used to sense and

control
(a) Table position
(b) Table velocity
(c) Spindle speed
((d)) Coolant flow
B i L
th U it (BLU)
BasicLengthUnit(BLU)
GATE 1997
GATE
y In NC machine, the displacement length per one pulse
In a point to point control NC machine, the slides

are positioned by an integrally mounted stepper
motor drive. If the specification of the motor is
1o/pulse, and the pitch of the lead screw is 3.6 mm,
what is the expected positioning accuracy?
output from machine is defined as a Basic Length Unit

(BLU).
y In the CNC computer each bit (binary digit) represents 1
BLU.
BLU
Bit = BLU
y Example: If one pulse makes a servo motor rotate by one
degree and the servo motor moves the table by 0.0001
mm, one BLU will be 0.0001 mm.
y The lead of a ball screw is related to the displacement
p
unit of the machine tool table.
( a ) 1 m
(c ) 50 m
GATE 2007(PI)
2007 (PI)
GATE
In a CNC machine feed drive, a stepper motor
with step angle of 1.8o drives a lead screw with
pitch of 2 mm.
mm The Basic Length Unit (BLU) for
this drive is
(a) 10 microns
(b) 20 microns
(c) 40 microns
(d) 100 microns
GATE 2008(PI)
A stepper
motor
The
t
t has
h 150 steps.
t
Th output
t t shaft
h ft off the
th
motor is directlyy coupled
p
to a lead screw of p
pitch 4 mm,,
which drives a table. If the frequency of pulse supply to
the motor is 200 Hz, the speed of the table (in mm/min)
is
(a) 400
(b) 320
(c) 300
Page 127 of 240
(d) 280
(b) 10 m
(d ) 100 m
l
Example
y A DC servomotor is coupled directly to a leadscrew
which drives the table of an NC machine tool. A

digital encoder,
encoder which emits 500 pulses per
revolution, is mounted on the other end of the
leadscrew If the leadscrew pitch is 5 mm and the
leadscrew.
motor rotates at 600 rpm, calculate
( ) The
(a)
Th linear
li
velocity
l it off the
th table
t bl
(b) The BLU of the NC system
(c) The frequency of pulses transmitted by the encoder.
Rev.0
GATE 2014(PI)
IES 2011 C
ti
l
IES2011Conventional
G
20 0 ( )
GATE
2010(PI)
y The table of a CNC machine is driven by a Lead screw which
is rotated by a DC servomotor. A digital encoder which emits

1000 pulses per second is mounted on the lead screw as a
feedback device. If the lead screw p
pitch is 6 mm and motor
rotates at 500 rpm, find
1.
Basic length Units of the system
2
2.
Linear velocity of the table.

table
3.
Frequency of pulses generated by the feedback device.
For a 3 axes
axes CNC table, the slide along the vertical axis
of the table is driven by a DC servo motor via a lead
screw nut mechanism. The lead screw has a pitch of 5
screw
mm. This lead screw is fitted with a relative
(incremental) circular encoder. The basic length unit
(BLU) of the slide along the vertical axis of the table is
0.005 mm. When the table moves along the vertical axis
by 9 mm, the corresponding number of pulses generated
by the encoder is
(a) 1400
(b) 1800
(c) 4200
(d) 9000
[5 Marks]
StatementforLinkedAnswersquestions:S1
In the feed drive of a Point
to Point open loop CNC
PointtoPoint
drive, a stepper motor rotating at 200 steps/rev drives a
table through a gear box and lead screw
screwnut
nut mechanism
(pitch = 4 mm, number of starts = 1).
Output rotational speed
The gear ratio = Input rotational speed is given by U = 14
The stepper motor (driven by voltage pulses from a pulse
generator)
t ) executes
t 1 step/pulse
t / l off the
th pulse
l generator.
t
The frequency of the pulse train from the pulse
generator
t is
i f = 10,000 pulses
l
per minute.
i t
GATE 2009(PI)
with a pitch of 5.0
5 0 mm to drive the work
worktable
table by a
distance of 200 mm in a NC machine is
(a) 14400
(b) 28800
(c) 57600
(d) 72000
((a)) become
b
d bl off previous
double
i
value
l
(b) become half of previous value
(c) remain the same
(d) become zero
GATE 2008Q1
2008 Q 1 (StatementinS2)
(St t
t i S 2)
GATE
GATE 2008Q2
2008 Q 2 (StatementinS3)
(St t
t i S 3)
GATE
The Basic Length Unit (BLU), i.e., the table

movement corresponding to 1 pulse of the pulse
generator, is
(a) 0.5 microns
(b) 5 microns
( ) 50 microns
(c)
i
(d) 500 microns
i
A customer insists on a modification to change the BLU

of the CNC drive to 10 microns without changing the
table speed. The modification can be accomplished by
GATE2014(PI)
The
h totall angular
l movement (in
( degrees)
d
) off a leadscrew
l d
loop pointtopoint
point to point controlled CNC drilling
In an open loop,
machine, a stepper motor, producing 200 angular steps per
revolution,
revolution drives the table of a drilling machine by one
angular step per each pulse generated by a pulse generator
(shown in figure).
figure) Each angular step moves the table by
one Basic Length Unit (BLU) along X axis with a lead screw
having a pitch of 4 mm. If the frequency of pulse generator
is doubled, the BLU will
Each
driven
by a stepper
motor
E h axis
i off NC machine
hi iis d
i
b
t
t
drive with a lead screw. The pitch of lead screw is p mm.
Th step
The
t angle
l off stepper
t
motor
t per pulse
l input
i
t is
i
degrees/pulse. The ratio of gear drive in stepper motor
d i is
drive
i g(number
(
b off turns
t
off the
th motor
t for
f each
h single
i l
turn of the lead screw). The number of pulses required
t achieve
to
hi
a linear
li
movementt off x mm is
i
g
360 g
g
360 g
x
x
x
x
(a)
(b)
(c )
(d )
360 p
p
360 p
p
Page 128 of 240
IAS2010
Main
IAS
2010Main
In openloop NC system the shaft of a stepping motor is
connected directly to the lead screw xaxis
x axis of the
machine table. The pitch of the lead screw is 3.0 mm.
The number of step angles on the stepping motor is 200.
200
Determine how closelyy the p
position of the table can be
controlled, assuming that there are no mechanical errors
positioning
g system.
y
in the p
Also, what is the required frequency of the pulse train
and
d the
h corresponding
d
rotationall speed
d off the
h stepping
motor in order to drive the table at a travel rate of 100
mm/min?
[ Marks]
[8
k ]
Rev.0
ControlSystemspossibleinCNCMachine
y Point to point mode:
GATE 1992
GATE
P i tt
i t t i ht li
d
Pointtopointstraightlinemode
In a point
to point type of NC system
pointtopoint
(a) Control of position and velocity of the tool is
essential
(b) Control of only position of the tool is sufficient
(c) Control of only velocity of the tool is sufficient
((d)) Neither p
position nor velocityy need be controlled
GATE 2006
GATE
NC contouring is an example of
(a) Continuous path positioning
(b) Pointtopoint
P i tt
i t positioning
iti i
(c) Absolute positioning
(d) Incremental positioning
GATE2005
WhichamongtheNCoperationsgivenbeloware
continuouspathoperations?
ArcWelding(AW)
Milling(M)
Drilling(D)
g
PunchingisSheetMetal(P)
g
LaserCuttingofSheetMetal(LC)SpotWelding(SW)
(a) AW,LCandM
(c) D,LC,PandSW
C
di t
t
Coordinatesystem
ordinate system.
y All the machine tool use Cartesian Co
Coordinate
system
y The first axis to be identified is the Z axis, This is
followed by X and Y axes respectively.

respectively
(b)AW,D,LCandM
(d)D,LC,andSW
Righthandcoordinatesystems
Page 129 of 240
Rev.0
IES 2000
IES
Assertion (A): The axis of an NC drilling machine
spindle is denoted as zaxis.
Reason (R): In NC machine tool,
tool the axis
perpendicular to both x and yaxis is designated as
z axis
zaxis
l
ti off A
IES 1996
IES
Assertion (A): Numerically controlled machines
having more than three axes do not exist.
Reason (R): There are only three Cartesian
coordinates namely xyz.
( ) Both
(a)
B th A and
i di id ll true
t
and
d R is
i the
th
5axesCNCverticalaxismachiningcentreconfiguration
Absolute and Incremental Coordinate System
For-2015 (IES, GATE &

PSUs)
Incremental Coordinate System
Absolute Coordinate System
Page 130 of 240
Rev.0
IES 2003S1
2003
S1
IES
While part programming
in CNC machines, the
input
of
dimensional
information for the tool
path can be given in the
absolute
coordinate
system or in incremental
coordinate system. The
above figure shows the
route to be followed by the
tool from O to C, i.e., O A
B C.
IES 2003Contd..FromS1
2003 C td F
S1
IES
Q
( )
If incremental co
ordinates system is used, the co
coordinates
co
ordinates of each point A, B and C are
(a) A: X 5.0,
5 0 Y 10.0
10 0
(b) A: X 5.0,
5 0 Y 10.0
10 0
B: X 20.0, Y5.0
B: X 25, Y 15.0
C: X 10.0, Y 10.0
C: X 35, Y 5.0
((c)) A: X 10.0, Y 55.0
((d)) A: X 10.0, Y 55.0
B: X 15.0, Y 25.0
B: X 5.0, Y 20.0
C: X 15.0,
15 0 Y 35.0
35 0
C: X 10.0,
10 0 Y 10
10.0
0
A CNC vertical milling machine has to cut a

straight
t i ht slot
l t off 10 mm width
idth and
d 2 mm depth
d th by
b a
cutter of 10 mm diameter between points (0, 0)
and
d (100,
(
100)) on the
th XY plane
l
(di
(dimensions
i
i
in
mm). The feed rate used for milling is 50 mm/min.
Milling time for the slot (in seconds) is
(a) 120
(b) 170
(c) 180
(d) 240
P tP
i
PartProgramming
Th f ll i
th t
t b f ll
d
Thefollowingarethestepstobefollowed
whiledevelopingtheCNCpartprograms.
y FANUCCONTROLL
y Processplanning
y SIEMENSCONTROLL
y Axesselection
y Toolselection
y Cuttingprocessparametersplanning
y Jobandtoolsetupplanning
J
pp
g
y Machiningpathplanning
y Partprogramwriting
y Partprogramproving
CNC programming
CNCprogramming
Importantthingstoknow:
y For a CNC machine control unit (MCU) decides cutting
speed, feed,
speed
feed depth of cut,
cut tool selection , coolant on off
and tool paths. The MCU issues commands in form of
numeric data to motors that position slides and tool
accordingly.
TableofImportantGcodes
ProgrammingKeyLetters
y O Programnumber(Usedforprogramidentification)
CoordinateSystem
Units,incrementalorabsolutepositioning
G01
LinearInterpolation
N__G01X___Y___Z___F___
G02
CircularInterpolation,
CircularInterpolation
CW
N G02X Y Z
N__G02X__Y__Z___R___F___
R
F
G
G03
CircularInterpolation,
C
l
l
CCW
N G X___Y___Z__R__F___
N__G03
X
Y
Z R F
G04
G17
Dwell
XY Plane
N__G04P___
G18
G19
9
XZPlane
y X Xaxisdesignation
y Z Zaxisdesignation
y F Feedratedesignation
y S Spindlespeeddesignation
CoolantControl:On/Off,Flood,Mist
C l C
l O /Off Fl d Mi
ToolControl:Toolandtoolparameters
T lC
l T l d l
Format
N__G00X___Y___Z___
N G00X
Y Z
y G
G Preparatoryfunction
y R Radiusdesignation
Feedrateandspindlespeed
F d
d i dl
d
Meaning
RapidTransverse
y N Sequencenumber(Usedforlineidentification)
y Y Yaxisdesignation
g
Coordinates:X,Y,Z,RX,RY,RZ
Code
G00
y H
H Toollengthoffsetdesignation
y D Toolradiusoffsetdesignation
y T ToolDesignation
g
y M Miscellaneousfunction
Page 131 of 240
N__G02X___Y__Z__I___J__K__F__
N__G03 X__Y__Z__I__J__K__F__
YZPlane
Rev.0
Code
Meaning
G20/G70 InchUnit
G21/G71 MetricUnit
Rapidtraverse:G00
G28
AutomaticReturntoReference
Point
Code Meaning
Format
G44 Toollengthcompensation N__G44H__
N G44H
(minus)
G49 Toollengthcompensation
cancel
G40
Cuttercompensationcancel
G80
Cancelcannedcycles
Ca
ce ca ed cyc es
G41
G
G42
Cuttercompensationleft
C tt
Cuttercompensationright
ti i ht
G81
Drillingcycle
G90
G91
Absolutepositioning
Incrementalpositioning
G92
Absolutepreset,changethe
Absolutepreset
changethe N__G92X__Y__Z__
N G92X Y Z
datumposition
G43
Format
N__G41D__
N G D
N__G42D__
Toollengthcompensation
(plus)
N G43H
N__G43H__
Linearinterpolation:G01
y Itisusedforpositioningmotion.
G90G00X20 0Y10 0
G90G00X20.0Y10.0
N__G81Z__R__F__
End
G90:
9
absolute
coordinates
Start
Circularinterpolation:G02,G03
y Forcircularinterpolation,thetooldestinationandthecircle
y linearinterpolationatfeedspeed.
p
p
centerareprogrammedinoneblock
y G02isclockwiseinterpolation,G03iscounterclockwise
interpolation
G91G0lX200.0Y100.0F200.0
Y
End
100.0
200 0
200.0
Start
p
,
Y
y tomakethemachinemoveatmaximumspeed.
t k th
hi
t
i
(
(20,10)
)
(10,10)
(0,0)
y G02,G03:
y G01:
G91:
incremental
coordinates
y G00:
y I,J,Karetheincremental
distancefromthestartof
thearc;
h
X
Start
j
Center
y Viewingthestartofarcas
theorigin,I,J,Khave
th
i i I J Kh
positiveornegativesigns.
F __;
J __
F __;
K __
G 02
R
G19
Y __ Z __
G 03
J __
F __;
K __
End
point
Start
N0010G92X200.0Y40.0Z0;
N0020G90G03X140.0Y100.0I60.0F300
N0030G02X120.0Y60.0I 50.0
N0010G92X200.0Y40.0Z0
N0010G92X200
0Y40 0Z0
N0020G90G03X140.0Y100.0R60.0F300
N0030G02X120.0Y60.0R50.0
Y
100
60
40
SpecifyRwith
signbeforeit:
>180
R
R=50mm
AnnotationforCircularInterpolation
G92:
Todefineworking
coordinate
G90:
absolute
coordinates
di t
End
G91G02X60.0Y20.0R50.0 F300.0
9
5
F300.0
3
G91G02X60.0Y20.0R50.0
Circlecenter radius
Circlecenter,radius
Or
R=-50mm
180 +R
y SpecifyCenterwithI,J,K
End
G 02
R
G17
X __ Y __
G 03
I __
G 02
R
G18
X __ Z __
G 03
I __
y I0.0,J0.0,andK0.0canbeomitted.
I
J
dK b itt d
y IfX,Y,Zareallomittedintheprogram,thatmeans
startandendofarcaresamepoints
startandendofarcaresamepoints.
N0020G02I20.0(afullcircle)
y IfI,J,K,andRallappearsincircularinterpolation
IfI J K andRallappearsincircularinterpolation
instruction,RisvalidandI,J,andKareinvalid
R50
R60
X
Page 132 of 240
90 120 140
200
Rev.0
GATE 2014
GATE2014
FortheCNCpartprogramming,matchGroupAwith
GroupB:
GroupA
Group B
P:circularinterpolation,counter
clockwise
Q:dwell
R:circularinterpolation clockwise
R:circularinterpolation,clockwise
S:pointtopointcountering
P
( ) II
(a)
(c) I
Q
III
IV
R
I
II
S
IV
III
( )
(b)
(d)
P
I
II
I:G02
GATE 2007(PI)
2007 (PI)
GATE
The interpolator in a CNC machine controls
(a) Spindle Speed
(b) Coolant flow
(c) Feed rate
(d) Tool change
II:G03
III:G04
IV:G00
Q
III
I
R
II
III
During the execution of a CNC part program block

N020 G02 X45.0 Y25.0 R5.0 the type of tool motion will
be
(a) Circular Interpolation clockwise
(b) Circular Interpolation counter clockwise
((c)) Linear Interpolation
p
(d) Rapid feed
S
IV
IV
GATE 2010
GATE
In a CNC program block, N002 G02 G91 X40 Z40,
G02 and G91 refer to
(a) Circular interpolation in counterclockwise direction
and incremental dimension
(b) Circular
Ci l interpolation
i t
l ti in
i counterclockwise
t l k i direction
di ti
and absolute dimension
(c) Circular interpolation in clockwise direction and
incremental dimension
(d) Circular interpolation in clockwise direction and
absolute dimension
GATE 2005
GATE
The tool of an NC machine has to move along a
circular arc from (5, 5) to (10,10) while performing an
operation. The centre of the arc is at (10, 5). Which
one of the following NC tool path commands
performs the above mentioned operation?
(a) N010G02 X10 Y10 X5 Y5 R5
(b) N010G03
N G X10
X Y10
Y X5
X Y5
Y R5
R
(c) N010G01 X5 Y5 X10 Y10 R5
(d) N010G02 X5 Y5 X10 Y10 R5
GATE 2004
GATE
IES 2009
IES
Interpolation
in
to
I t
l ti
i the
th controller
t ll refers
f
t control
t l off
which one of the following
g in a CNC machine?
(a) Loading/unloading of jobs on machine
(b) Loading/unloading of tools from the tool changer
(c) Axes of machine for contouring
(d) Coolant and miscellaneous functions on machine
GATE2014(PI)
A CNC instruction G91G01X30Y40F100 commands the
GATE 2001
GATE
In an NC machining operation, the tool has to be
moved from point (5, 4) to point (7, 2) along a
circular path with centre at (5, 2). Before starting the
operation, the tool is at (5, 4). The correct G and M
code for this motion is
(a) N010 G03 X7.0 Y2.0 I5.0 J2.0
(b) N010
N
G X7.0
G02
X
Y
Y2.0
I
I5.0
J
J2.0
(c) N010 G01 X7.0 Y2.0 I5.0 J2.0
(d) N010 G00 X7.0 Y2.0 I5.0 J2.0
ToolCompensation
y ToolRadiusCompensation
movement of tool along the path at a feed rate of 100
y LefthandG41
L fth dG
mm/min (G91 incremental format and G01 linear
y RighthandG42
interpolation). The feed rate of the tool (in mm/min)

along the X axis will be _______
y CanceltoolradiuscompensationG40
C
l l di
i G
y ToolHeightCompensation
y PositiveG43
y NegativeG44
y CanceltoolheightcompensationG49
Page 133 of 240
Rev.0
ToolRadiusCompensation
y Toolradiuscompensationsmakeitpossibleto
programdirectlyfromthedrawing,andthuseliminate
thetooloffsetcalculation
th
t l ff t l l ti
G41(G42)D
CancelToolCompensation:G40
y Notethedifferencebetweentwoways
N0060G40G01 X2.000Y1.700M02
y D:theradiusoftooltocompensateissavedinamemoryunitthat
D th di ft lt
t i
di
itth t
N0060G01 X2.000Y1.700
N0070G40
7
4 M02
isnamedD
y G41/G42isdirectlyrelatedwithdirectionoftoolmovementand
whichsideofpartiscut
whichsideofpartiscut.
rampoffblock
GATE 2014
GATE
For machining a rectangular island represented by
coordinates P(0, 0), Q(100, 0), R(100, 50) and S(0, 50) on
a casting using CNC milling machine, an end mill with a
diameter of 16 mm is used. The trajectory of the cutter
center to machine the island PQRS is
(a) (8, 8), (108, 8), (108, 58), (8, 58), (8, 8)
(b) (8,
(8 8),
8) (94,
(94 8),
8) (94,
(94 44),
44) (8,
(8 44),
44) (8,
(8 8)
(c) (8, 8), (94, 0), (94, 44), (8, 44), (8, 8)
(d) (0,
( 0),
) (100,
(
0),
) (100,
(
50),
) (50,
(
0),
) (0,
( 0))
TableofImportantMcodes
effectivetotheendpoint
ToolHeightCompensation
G43(G44)H
y H:specifiedmemoryunitusedtosaveheight
compensationoftool.
y Positivecompensation(G43):
realposition=specifiedposition+valuesavedinH
y Negativecompensation(G44):
realposition=specifiedposition
l iti
ifi d iti valuesavedinH
l
di H
g
p
ToolHeightCompensation
y Example:
y N0010G91G00X12.0Y80.0
G G
y N0020G44Z32.0H02
G91:
incremental
coordinates
y Ifweput0.5mmintoH02,
y realposition=32.0 0.5=32.5
y Canceltoolheightcompensation:G49
p g
g
Rulesforprogramming
Block Format
y M01Optionalprogramstop
N135 G01 X1.0

X1 0 Y1.0
Y1 0 Z0.125
Z0 125 F5
y M03Spindleonclockwise
S i dl l k i
y M04Spindleoncounterclockwise
Sample Block
Restrictions on CNC blocks
Each may contain only one tool move
Each may contain any number of non-tool move G-codes
Each may contain only one feed rate
Each may contain only one specified tool or spindle speed
The block numbers should be sequential
Both the program start flag and the program number must be
independent of all other commands (on separate lines)
The data within a block should follow the sequence shown
in the above sample
p block
y M05Spindlestop
y M06Toolchange
y M08Coolanton
y M09Coolantoff
y M10Clampson
y M11Clampsoff
In finish machining of an island on a casting with

CNC milling machine, an end mill with 10 mm
diameter is employed. The corner points of the
island are represented by (0, 0), (0, 30), (50, 30), and
(50, 0). By applying cutter radius right
compensation, the trajectory of the cutter will be
(a) (5,
( 5 0),
0) (5,
( 5 35),
35) (55,
(55 35),
35) (55,
(55 5),
5) (5,
( 5 5)
5)
(b) (0, 5), (55, 5), (55, 35), (5, 35), (5, 5)
(c) (5, 5), (5, 25), (45, 25), (45, 5), (5, 5)
(d) (5,
5 55), (45,
45 55), (45,
45 25),
5 (5,
5 25),
5 (5,
5 55)
GATE 2009
2009
GATE
y M00Programstop
M P
y M02orM30Programstop,resettostart
GATE 2000
GATE
Page 134 of 240
Rev.0
IES 1993
1993
IES
A 'block'
block of information in N.C. machine program
means
(a) One row on tape
(b) A word comprising several rows on tape
(c) One complete instruction
((d)) One complete
p
program
p
g
for a jjob
ToolHome
IES 1996
IES
In manual programming and tape preparation for a
NC drilling machine, the spindle speed was coded
as S 684 (using the magic
magicthree
three code). The spindle
speed in rpm will be
(a) 684
(b) 68.4
(c) 840
((d)) 6840
4
Top
p
View
Top
View
2.)ZAxisRapidMove
JustAboveHole
3.)TurnOnCoolant
)
ExampleofCNCProgramming
Example of CNC Programming
y WhatMustBeDoneToDrillAHoleOnACNC
VerticalMillingMachine
g
Top
View
55.)ZAxisFeedMoveto
DrillHole
4.)TurnOnSpindle
)
O S i dl
1 )X&YRapidToHolePosition
1.)X&YRapidToHolePosition
Front
View
.100
Front
View
Front
View
HeresTheCNCProgram!
Top
View
6.)RapidZAxisMove
6
)RapidZAxisMove
OutOfHole
Front
View
Top
View
Top
View
8.)TurnOffCoolant
Front
View
7.)TurnOffSpindle
9.)X&YAxisRapid
MoveHome
Page 135 of 240
Front
View
ToolAtHome
O0001
O
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
N025G00Z 1M09
N025G00Z.1M09
N030G91G28X0Y0Z0
N035M30
Rev.0
ToolAtHome
Top
View
O0001
O
O0001
N
NumberAssignedtothisprogram
b A i
d hi
Front
View
Top
View
Front
View
Top
View
Front
View
ToolAtHome
Top
View
O0001
O
N005G54G90S600M03
N005
G54
G90
S600
M03
SequenceNumber
FixtureOffset
AbsoluteProgrammingMode
SpindleSpeedsetto600RPM
SpindleoninaClockwiseDirection
Front
View
O0001
O
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
G43
H01
Z.1
M08
ToolLengthCompensation
SpecifiesToollengthcompensation
ZCoordinate.1in.fromZero
FloodCoolantOn
O0001
N005G54G90S600M03
N
G G S6 M
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
75 3 5
N025G00Z.1M09
N030G91G28X0Y0Z0
G91
IncrementalProgrammingMode
G28
ZeroReturnCommand
X0,Y0,Z0
X,Y,&ZCoordinatesatZero
Top
View
Front
View
p
Top
View
Front
F
View
Top
View
O0001
O
N005G54G90S600M03
N010G00X1.0Y1.0
G
G00
X1.0
Y1.0
R idM i
RapidMotion
XCoordinate1.0in.fromZero
YCoordinate1.0in.fromZero
Front
View
O0001
O
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
G01
Z.75
35
F3.5
StraightLineCuttingMotion
ZCoordinate.75 in.fromZero
FeedRatesetto3.5in/min.
35 /
O0001
N005G54G90S600M03
N
G G S6 M
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
N020G01Z
.75F3.5
N025G00Z.1M09
N030G91G28X0Y0Z0
N035M30
M30
Page 136 of 240
EndofProgram
Top
View
Front
View
O0001
O
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
N025G00Z 1M09
N025G00Z.1M09
G00
Z
Z.1
M09
RapidMotion
ZCoordinate.1in.fromZero
ZC
di
i f
Z
CoolantOff
IES 1995
1995
IES
Match List I with List II and select the correct answer
List I
List II
(A function
f
i connected
d
(A
(Associated
i d parameter))
with NC m/c tool)
A Interpolation
A.
1 Tape preparation
1.
B. Parity check
2. Canned cycle
C Preparatory function
C.
3 Drilling
3.
D. Point to point control
4. Contouring
5. Turning
Code:A
B
C
D
A
B
C
D
(a) 4
1
2
3
(b) 4
1
2
5
(c) 5
1
3
2
(d) 1
4
3
2
Rev.0
IAS 2011 M i
IAS2011Main
g operation,
p
, the tool tip
p is at location (
(
In an NC drilling
100, 0, 100). The datum (0, 0, 0) is left hand lower corner
p surface of the workpiece,
p
, which is rectangular
g
on top
(300 mm x 300 mm x 1.5 mm thick). A thru' hole of 10
mm diameter is t o be drilled in the centre of the
workpiece. Using only rapid positioning and linear
p
functions,, write the p
program
g
blocks,, in
interpolation
absolute mode.
Assume permitted cutting speed = 32 m/min and feed
rate = 150 mm/min.
[10Marks]
IFS2011
one to six letters or numerals with the first one being

ga
letter. No special character is allowed in the words.
check ? What is the function of Data Processing

Unit (DPU) and Control Loop Unit (CLU) of MCU.
How is Feed Rate Number (FRN) expressed ? What
is indirect feedback ?
[10marks]
IES 1998
IES
Which of the following are the rules of
programming NC machine tools in APT language?
1 Only capital letters are used
1.
2. A period is placed at the end of each statement
3. Insertion of space does not affect the APT word
g the codes g
given below:
(a) 1 and 2
(b) 2 and 3
(c) 1 and 3
(d) 1 alone
OtherPartProgrammingLanguages
programming system for smaller computers
d l
developed
d by
b IBM and
d first
fi t introduced
i t d d in
i 1962
6
y EXAPT (EXtended subset of APT) was developed jointly in
German in about 1964 by several universities to adapt APT for

European use. It is compatible with APT and thus can use the
same processor as APT
y COMPACT was developed
d l
d by
b Manufacturing
f
Data Systems, Inc.
(MDSI)
y SPLIT (Sundstrand Processing Language Internally Translated)
was developed by Sundstrand Corporation, intended for its own
machine tools
y MAPT (MicroAPT) is a subset of APT, to be run on the
microcomputers
61
Th
l t APT
t
it f
ThecompleteAPTpartprogramconsistsof
thefollowingfourtypesofstatements
y Geometry
y Motion
y Postprocessor
y Compilationcontrol
P0 = POINT/0.0, 0.3, 0.1

FROM/P0
CALL/DRILL,
/
X=1.0,
1 0 Y=1.0,
1 0 Z=0.1,
0 1 DEPTH=0.7
0
CALL/DRILL, X=2.0, Y=1.0, Z=0.1, DEPTH=0.7
GOTO/P0
MACHIN/DRILL,
MACHIN/DRILL 2
COOLNT/
COOLNT/FLOOD
statements made up of the following valid letters, numerals

and punctuation marks.
y Letters:
ABCDEFGHIJKLMNOPQRSTUVWXYZ
y Numerals: 0123456789
/
Aslashdividesastatementintotwosections eg
Aslashdividesastatementintotwosections.eg.,
GO/PAST,
, Acommaisusedasaseparatorbetweentheelementsin
Acommaisusedasaseparatorbet eentheelementsin
astatementgenerallytotherightoftheslash.
= Anequalsisusedforassigninganentitytoasymbolic
A
l i df i i tit t
b li
name,e.g.,P1=POINT/25,50,30.
OthercapabilitiesofAPT,themacrofacility,withusevariableargumentasina
FORTRANsubroutine,forexample:
FORTRAN b
i f
l
Additionalstatements:
Forexample: COOLNT/MIST
y The APT language consists of many different types of
APTLanguage
g g
APTLanguage
D
((ADaptation
Daptat o APT)) was tthee first
st atte
pt to adapt APT
y ADAPT
attempt
y AUTOSPOT (AUTOmatic Sytem for POsitioning Tools) was
y APT (Automatically Programmed Tools)
In NC machine, what is the purpose of the parity
Words
y The
Th words
d to
t be
b used
d in
i the
th statements
t t
t are built
b ilt up from
f
APT L
APTLanguage
COOLNT/OFF
FEDRAT/
whenthedefinitionofthemacroDRILLis:
SPINDL/
Forexample:
l SPINDL/ON
/
TOOLNO/
TURRET/
END
DRILL = MACRO/X, Y, Z, DEPTH

GOTO/X,Y,Z
GODLTA/0,0, -DEPTH
, , DEPTH
GODLTA/0,0,
TARMAC
SPINDL/1250,
/
CCLW
Page 137 of 240
62
Rev.0
63
Point (POINT)
Point (POINT)
(
)
PTA = POINT/ 33,4,5
45
Point (POINT)
PTB = POINT/ INTOF

INTOF, LIN1
LIN1, LIN2
PTD = POINT/ YSMALL, INTOF, LIN3, C1

PTD = POINT/ XSMALL, INTOF, LIN3, C1
PTC = POINT/ YLARGE, INTOF, LIN3, C1
PTC = POINT/ XLARGE, INTOF, LIN3, C1
PTC
(3, 4, 5)
LIN2
PTA
z
LIN3
PTB
C1
LIN1
PTD
Point (POINT)
PTE = POINT/ YLARGE,
YLARGE INTOF,
INTOF C1,
C1 C2
PTE = POINT/ XLARGE, INTOF, C1, C2
PTF = POINT/ YSMALL,, INTOF,, C1,, C2
PTF = POINT/ XSMALL, INTOF, C1, C2
Point (POINT)
(
)
Line (LINE)
(
)
PT7 = POINT/ CENTER,

CENTER C6
LIN1 = LINE/ P1, P2
y
y
C1
y
C6
PTE
P2
PT7
PTF
P1
C2
LIN1
Line (LINE)
Line (LINE)
(
)
Line (LINE)
L12 = LINE/ PT4, ATANGL, 20, XAXIS

L14 = LINE/ PT1,
PT1 ATANGL,
ATANGL 40
L15 = LINE/ 32, -3, 2, ATANGL, -15, XAXIS
L16 = LINE/ PT3, ATANGL, 40, YAXIS
LIN4 = LINE/ PT6,

PT6 15,
15 -30,
30 3
LIN = LINE/ POINT, ATANGL, ANGLE (in degrees), LINE

y
LINE2
PT6
PT3
L
L14
P1
40
L4
L12
PT1
L16
30
PT4
LINE1
LINE
(15,30,3)
LINE LINE/P ATANGL LINE

LINE2=LINE/P1,ATANGL,30,LINE1
40
L15
20
15
Page 138 (32,3,2)

of 240
Rev.0
Line (LINE)
Line (LINE)
Line (LINE)
LIN = LINE/ SLOPE, SLOPE VALUE, INTERC, MODIFIER, d

where the slope value is y/x. The modifier options are [XAXIS,
YAXIS], and d is the corresponding intercept value on the selected
axis
i (i.e.,
(i modifier).
difi )
N = LINE/
N / ATANGL,
NG , DEGREES,
G
S, INTERC,
N
C, MODIFIER,
O
,d
LIN
The modifier options are [XAXIS, YAXIS], and d is the
corresponding
p
g intercept
p value on the selected axis ((i.e., modifier).
)
The LEFT & RIGHT modifier indicates whether the line

is at the left or right tangent point, depending on how
one looks at the circle from the point.
point
L1 = LINE/ PT51, LEFT, TANTO, C11
LINE1
L1
LINE1
LINE1=LINE/SLOPE 1 INTERC XAXIS 6

LINE1=LINE/SLOPE,1,INTERC,XAXIS,6
C11
LINE1=LINE/ATANGL 30 INTERC d
LINE1=LINE/ATANGL,30,INTERC,d
PT51
=30
x
(6 )P i t fX I t
(6,0)PointofXIntercept
t
Line (LINE)
Line (LINE)
Line (LINE)
L6 = LINE/ LEFT, TANTO, C3, LEFT, TANTO, C4

L2 = LINE/ PT51, RIGHT, TANTO, C11
L3 = LINE/ PT40, RIGHT, TANTO, C11
L4 = LINE/ PT40, LEFT, TANTO, C11
L6
L6 = LINE/ RIGHT, TANTO, C4, RIGHT, TANTO, C3

C4
Left
L3
C3
Right
L6
Right
Right
PT40
L1
L8
L9
Left
f
Left
Left
The descriptive words LEFT and RIGHT are used by

g from the first circle written towards the
looking
second circle.
PT51
Right
C3
L7
L4
L
L2
Line (LINE)
L8
L9
L77
Plane (PLANE)
Line
LN5 = LINE/ INTOF,
INTOF PLAN1,
PLAN1 PLAN2
LN3 = LINE/ PNT6, PARLEL, LN15

LN4 = LINE/ PNT5, PERPTO, LN13
PLAN10 = PLANE/ PT6

PT6, PT12,
PT12 PT15
LN5
PLAN10
PT15
y
PNT6
PNT5
LN3
PT6
LN15
LN13
3.0
PLAN1
PT4
PLAN2
PT12
LN4
4
Page 139 of 240
z
PLAN14
Rev.0
C4
Plane (PLANE)
Circle (CIRCLE)
(
)
PLAN14 = PLANE/ PT4,

PT4 PARLEL,
PARLEL PLAN10
PLAN14 = PLANE/ PARLEL, PLAN10, YSMALL, 3.0
Circle (CIRCLE)
(
)
C3 = CIRCLE/ CENTER, PT6, TANTO, LN4
C7 = CIRCLE/ CENTER
CENTER, PT8,
PT8 PT5
C1 = CIRCLE/ 3, 6, 5, 4.3
C1 = CIRCLE/
C C / CENTER,
C
PT3,
3 RADIUS,
A
S 4.3
43
PLAN10
PT15
C1
y
PT6
LN4
PT12
PT5
43
4.3
3.0
PT3
PT4
PT6
PT8
(3,6,5)
C7
C3
z
PLAN14
x
The Machining
g Plan
Contouring:
The Machining Plan
The Machiningg Plan
y Part surface: the surface on which the end of the
CS
CS
CS
tool is riding.
y Drive surface: the surface against which the edge of
the tool rides.
Checksurface
Drivesurface
cutter
Directionof
cuttermotion
DS
DS
DS
y Check surface: a surface at which the current tool
motion
i is
i to stop.
GOUP
The Machining
g Plan
Motion
i commands:
GOLFT/
: Move left alongg the drive surface
GORGT/
: Move right along the drive surface
GOUP/
: Move up along the drive surface
GOBACK
ON
PAST
FROM/PTARG
GO/TO,L1,TO,PL2,TOL3
GORGT/L3,PAST,L4
GORGT/L3 PAST L4
GOLFT
GODOWN/ : Move down along the drive surface

GOFWD/
TO
Partsurface
GOFWD
Present tool
position
GORGT
: Move forward from a tangent position
GODOWN
GOBACK/ : Move backward from a tangent position

Previous
Page 140 of 240
tool position
Rev.0
M hi i Specifications
S ifi i
Machining
Postprocessor
commands
P
d for
f a particular
i l machine
hi tooll are:
MACHIN/ : used to specify the machine tool and call the
postprocessor for that tool:
MACHIN/ DRILL,, 3
COOLNT/ : allows the coolant fluid to be turned on or off:
Machining Specifications
FEDRAT/ : specifies the feed rate for moving the tool along the
part surface in inches per minute:
FEDRAT/ 4.5
SPINDL/ : gives the spindle rotation speed in revolutions per
minute:
COOLNT/ MIST
SPINDL/ 850
COOLNT/ FLOOD
TURRET/ : can be used to call a specific tool from an automatic

tool changer:
COOLNT/ OFF
TOLERANCE SETTING:
motion
is
SETTING Nonlinear
N li
i
i accomplished
li h d in
i
straight-line segments, and INTOL/ and OUTTOL/ statements
di
dictate
the
h number
b off straight-line
i h li segments to be
b generated.
d
INTOL/ 0.0015
OUTTOL/ 0.001
TURRET/ 11
M hi i Specifications
S ifi i
Machining
PARTNO:
PARTNO identifies
id ifi the
h part program andd is
i inserted
i
d at the
h start off
the program.
FINI:
FINI specifies
ifi the
h endd off the
h program.
g g
APTLanguage
OtherMotionstatements:
GO/{TO}, Drive surface, {TO} Part surface, {TO},
Ch k surface
Check
f
Or
GO/{TO}, Drive surface, {TO} Part surface, {TANTO},
Check surface
AndthesamewithPASTorONinsteadofTO
GOLFT/
GORGT/
GOUP/
GODOWN/
GOFWD/
/
GOBACK/
Forexample:
GO/TO, L1, TO, PS, TANTO, C1
GO/PAST, L1, TO, PS, TANTO, C1
CLPRNT: indicates that a cutter location printout is desired.

CUTTER: specifies a cutter diameter for offset (rough versus finish
cutting). If a milling cutter is 0.5 in. in diameter and we have
CUTTER/ 0.6
then the tool will be offset from the finish cut by 0.05 in.
96
IES 2008
IES2008
Name the four types of statements in a complete APT
part program.
program Prepare part program for geometry
description of the contour shown in the figure below:
Y
[15Marks]
[15
Marks]
40
30
20
L2
L3
135
80
20
C1
L4
L1
C2
L5
P2
20
20
P1

X
Answer:
Contd.
PARTNO CONTOUR
MACHIN/MILL, 1
CLPRNT
UNITS/MM
P0 = POINT/0.0, 0.0, 0.0
P1 = POINT/110.0,
POINT/110 0 20.0,
20 0 0.0
00
P2 = POINT/20.0, 20.0, 0.0
P3 = POINT/90.0, 110.0, 0.0
P4 = POINT/20.0, 100.0, 0.0
P5 = POINT/50.0, 130.0, 0.0
L1 = LINE/P2, ATANGL, 90, XAXIS
L2 = LINE/P4, ANTNGL, 45, XAXIS
L3 = LINE/P5, ATANGL, 135, L2
L4 = LINE/P1,, PERPTO,, L3
L5 = LINE/P1, PERPTO, L4
C1=CIRCLE/CENTER, P3, RADIUS, 20.0
C2=CIRCLE/CENTER,
C2
CIRCLE/CENTER, P1, RADIUS, 20.0
PL1=PLANE/P1, P2, P3
Page 141 of 240
CUTTER/25.0
TOLER/0.1
INTOL/0.05
INTOL/0 05
OUTTOL/0.05
FEDRAT/200
SPINDL/500, CLW
COOLNT/ON
FROM/P0
GO/TO, L1, TO, PL1, TO, L5
GOLFT/L1, PAST, L2
GORGT/L2 PAST,
GORGT/L2,
PAST L3
GORGT/L3, TANTO, C1
GOFWD/C1, PAST, L4
GOFWD/L4, PAST, C2
GORGT/C2, PAST, L5
GORGT/L5 PAST,
GORGT/L5,
PAST L1
Rev.0
Contd.
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
IES 2007
IES2007
Prepare part using APT language for milling the contour

shown in Fig.
[20Marks]
Fig in a single pass.
pass D
[20 Marks]
110
R30
Q
110
120
E
R40
40
+ 40
P
Material : M S.
100
8 mm
Answer:
Contd.
Contd.
CUTTER/25.0
TOLER/0.1
INTOL/0.05
INTOL/0 05
OUTTOL/0.05
FEDRAT/200
SPINDL/500, CLW
COOLNT/ON
FROM/P0
GO/TO, LAB, TO, PL1, TO, LAF
GOLFT/LAB, TANTO, CBC
GOFWD/CBC PAST
GOFWD/CBC,
PAST, LCD
GORGT/LCD, PAST, LDE
GORGT/LDE, PAST, CEF
GORGT/CEF, PAST, LAF
GORGT/LAF, PAST, LAB
PARTNO CONTOUR
MACHIN/MILL, 2
CLPRNT
UNITS/MM
P0 = POINT/0.0, 0.0, 10.0
PTA = POINT/0.0, 0.0, 0.0
PTB = POINT/0.0, 120.0, 0.0
PTC = POINT/30.0, 150.0, 0.0
PTD = POINT/140.0, 150.0, 0.0
PTE = POINT/140.0, 40.0, 0.0
PTF = POINT/100.0, 0.0, 0.0
PTQ = POINT/30.0, 120.0, 0.0
PTP = POINT/140.0, 0.0, 0.0
LAB = LINE/PTA, PTB
LCD
C = LINE/PTC,
/ C, PTD
LDE = LINE/PTD, PTE
LAF = LINE/PTA, PTF
CBC = CIRCLE/CENTRE,, PTQ,
Q, RADIUS,, 30.0
CEF = CIRCLE/CENTRE, PTP, RADIUS, 40.0
PL1=PLANE/PTA, PTB, PTC
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
R30
L2
Y
C1
IES 2006
IES2006
Prepare part program to machine the contour shown in
C2
Answer:
P2
the figure using APT on CNC milling machine.

machine
[15Marks]
R30
L3
100 mm
80
L1
R20
X
100 mm
P1
60
80
50
60
200 mm
Material: MS
Thickness: 8.0 mm
Page 142 of 240
L4
200 mm
50
P4
C2
P3
C1
R20
R30
L2
P3
R20
P2
PARTNO CONTOUR
MACHIN/MILL, 3
CLPRNT
80 L1
UNITS/MM
P0 = POINT/0.0, 0.0, 10.0
P1 = POINT/0.0, 0.0, 0.0
P2 = POINT/60.0, 80.0, 0.0
P3 = POINT/150.0, 100.0, 0.0
60
P1
P4 = POINT/200.0,
POINT/200 0 0.0,
0 0 0.0
00
C1 = CIRCLE/ CENTER, P2, RADIUS, 20
C2 = CIRCLE/CENTER, P3, RADIUS, 30
L1 = LINE/P1, LEFT, TANTO, C1
L2 = LINE/LEFT, TANTO, C1, LEFT, TANTO, C2
L3 = LINE/P4
LINE/P4, RIGHT,
RIGHT TANTO
TANTO, C2
L4 = LINE/P1, P4
PL1=PLANE/P1, P2, P3
L3
100 mm
X
L4
200 mm
Rev.0
50
P4
Contd.
CUTTER/25.0
TOLER/0.1
INTOL/0.05
INTOL/0 05
OUTTOL/0.05
COOLNT/ON
SPINDL/500, CLW
FEDRAT/200
FROM/P0
GO/TO, L1, TO, PL1, TO, L4
GOLFT/L1, TANTO, C1
GOFWD/C1 PAST,
GOFWD/C1,
PAST L2
GOFWD/L2, TANTO, C2
GOFWD/C2, PAST, L3
GOFWD/L3, PAST, L4
GORGT/L4, PAST, L1
IES 2011 C
ti
l
IES2011Conventional
State the method of defining line segment of
cutter motion using APT program format.
[5 Marks]
H
W k
HomeWork
p
p
p g
g
Write a complete
part
program
in APT for machining
the product which is given in the diagram. Thickness of
the workpiece is 6 mm. All dimensions are in mm.
[15]
L1 LINE/RIGHT TANTO C1 RIGHT TANTO C3

L1=LINE/RIGHT,TANTO,C1,RIGHT,TANTO,C3
L2=LINE/LEFT,TANTO,C1,LEFT,TANTO,C2
C4=CIRCLE/XLARGE,OUT,C2,OUT,C3,RADIUS,62
C CIRCLE/XLARGE OUT C OUT C RADIUS 6
PL1=PLANE/P1,P2,P3
REMARKPOSTPROCESSORSTATEMENTFOLLOW
CUTTER/50.0
TOLER/0.01
TOLER/
INTOL/0.05
OUTTOL/0.05
OUTTOL/
FEDRAT/200
SPINDL/
SPINDL/1000,CLW
CLW
COOLNT/ON
PARTNOCONTOUR
MACHIN/MILL,1
CLPRNT
UNITS/MM
P0=POINT/25.0,25.0,25.0
P1=POINT/0.0,0.0,6.0
/ ,
,
P2=POINT/117.0,32.0,6.0
P3=POINT/117 0 32 0 6 0
P3=POINT/117.0,32.0,6.0
C1=CIRCLE/CENTER,P1,RADIUS,10.0
C CIRCLE/CENTER P RADIUS
Contd.
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
IES 1997
IES
Which of the following are valid statements for
point to point motion of the tool in APT language?
1 GO/TO/............
1.
GO/TO/
2. GO DLTA/............
3. GO/TO, .
g the codes g
given below:
(a) 1 and 2
(b) 2 and 3
(c) 1 and 3
(d) 1,
1 2 and 3
Page 143 of 240
REMARKMOTIONSTATEMENTFOLLOW
FROM/P0
GO/TO,L1,TO,PL1,TANTO,C1
GORGT/L1,TANTO,C3
GOFWD/C3,TANTO,C4
GOFWD/C4 TANTO C2
GOFWD/C4,TANTO,C2
GOFWD/C2,PAST,L2
GOFWD/L2 TANTO C1
GOFWD/L2,TANTO,C1
GOFWD/C1,PAST,L1
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
IES 1995
IES
In APT language, the cutter motion in incremental
coordinate mode is addressed as
(a) GO/TO/.....
GO/TO/
(b) GO/TO.....
(c) GO DLTA/....
((d)) GO FWD/...
Rev.0
GATE 2008 (PI)

GATE2008(PI)
Robotics
Suppose point P1 in APT programming is coded by statement

P1 = POINT/XSMALL, INTOF, LN1, CR1
The coded g
geometric situation without causing
g error is
Advantages of Robots
AdvantagesofRobots
y Robotics and automation can, in many situation, increase

y
y
y
y
y
y
y
y
p
y, safety,
y, efficiency,
y, q
y, and consistencyy of
productivity,
quality,
products
Robots can work in hazardous environments
R b t need
Robots
d no environmental
i
t l comfort
f t
Robots work continuously without any humanity needs and
illnesses
Robots have repetable precision at all times
Robots can be much more accurate than humans, they may have
mili or micro inch accuracy.
accuracy
Robots and their sensors can have capabilities beyond that of
humans
Robots can process multiple stimuli or tasks simultaneously,
humans can only one.
Robots replace human workers who can create economic
problems
Asimov's three laws of robotics

Asimov'sthreelawsofrobotics
First law (Human safety):
y A robot may not injure a human being, or, through
i
inaction,
ti
allow
ll a human
h
b i to
being
t come to
t harm.
h
Second law (Robots are slaves):
y A robot must obey orders given it by human beings,
p where such orders would conflict with the First
except
Law.
Third law (Robot survival):
y A robot must protect its own existence as long as such
protection does not conflict with the First or Second
Law.
Disadvantages of Robots
DisadvantagesofRobots
y Robots lack capability to respond in emergencies, this can cause:

pp p
g responses
p
Inappropriate
and wrong
A lack of decisionmaking power
A loss of power
Damage to the robot and other devices
Human injuries
y Robots may have limited capabilities in
Degrees
D
off Freedom
F d
Dexterity
Sensors
Vision systems
Realtime Response
y Robots are costly,
y, due to
Initial cost of equipment
Installation Costs
Need for peripherals
Need for training
Need for Programming
All robots have the following basic components:

Allrobotshavethefollowingbasiccomponents:
1. Manipulators: the mechanical unit, often called the
2.
3.
4.
5.
"arm,"
the
the robot.
"
" that
th t does
d
th actual
t l work
k off th
b t It iis
composed of mechanical linkages and joints with actuators
to drive the mechanism directly or indirectly through gears,
chains, or ball screws.
Feedback devices: transducers that sense the p
positions of
various linkages and joints and transmit this information to
the controllers in either digital or analog Form.
End effectors: the "hand" or "gripper" portion of the
robot, which attaches the end of the arm and perform the
operations of the robot.
robot
Controller: the brains of the system that direct the
movements of the manipulator.
manipulator
Power supply
Page 144 of 240
Wh t i
Whatisanindustrialrobot?
i d t i l b t?
A robot is a reprogrammable,
reprogrammable multifunctional
manipulator designed to handle material, parts, tools or
specialized devices through variable programmed
motions for the performance of a variety of tasks.
WhatCanRobotsDo?
IndustrialRobots
d
l b
Material
Material handling
Material transfer
Machine loading and/or unloading
Spot welding
Continuous arc welding
Spray
p y coating
g
Assembly
Inspection
MaterialHandling
Manipulator
A
Assembly
bl
Manipulator
SpotWelding
Manipulator
WristConfigurations
y Wristassemblyisattachedtoendofarm
y Endeffector
E d ff
i
isattachedtowristassembly
h d i
bl
y Functionofwristassemblyistoorientendeffector
y Bodyandarmdeterminesglobalpositionofend
effector
y Twoorthreedegreesoffreedom:
h
d
ff d
y Roll
y Pitch
y Yaw
Rev.0
End Effectors
EndEffectors
y Thespecialtoolingforarobotthatenablesitto
DegreesofFreedom
g
pp
GrippersandTools
y The degree of freedom or grip of a robotic system can be
compared to the way in which the human body moves.
performaspecifictask
y Twotypes:
y For
F each
h degree
d
off freedom
f d
a joint
j i is
i required.
i d
y Grippers tograspandmanipulateobjects(e.g.,
y The degrees of freedom located in the arm define the
parts)duringworkcycle
y Tools toperformaprocess,e.g.,spotwelding,spray
configuration.
painting
y Each of the five basic motion configurations utilizes three
degrees of freedom in the arm.

y Three degrees of freedom located in the wrist give the end
effector all the flexibility.
Degrees of Freedom (contd )

DegreesofFreedom(contd.)
y A total of six degrees of freedom is needed to locate a
robot
robotss hand at any point in its work space.
space
y Although six degrees of freedom are needed for
maximum flexibility,
flexibility most robot employee only three to
five degrees of freedom.
y The more the degrees of freedom,
freedom the greater is the
complexity of motions encountered.
y The three degrees of freedom located in the arm of
a robotic system are:
The
Th rotational
t ti
l reverse: is
i the
th movementt off the
th arm
assembly about a rotary axis, such as leftandright
swivel
i l off the
th robots
b t arm about
b t a base.
b
T
fR b t
TypesofRobot
y Cartesian
or
y
Gantry
robot:
y It's a robot whose arm
has
three
prismatic
joints, whose axes are
coincident
with
a
Cartesian coordinator.
y Used for pick and place
work, application of
sealant,
assembly
operations,
handling
machine tools and arc
welding.
welding
Degrees of Freedom (contd )

DegreesofFreedom(contd.)
The radial traverse: is the extension and retraction
of the arm or the inandout

in and out motion relative to the
base.
The
Th vertical
i l traverse: provides
id the
h upanddown
dd
motion of the arm of the robotic system.
y The three degrees of freedom located in the wrist,
which bear the names of aeronautical terms, are
Pitch or bend: is the upanddown movement of the
wrist.
Yaw: is the rightandleft movement of the wrist.
Roll or swivel: is the rotation of the hand.
hand
T
fR b t
TypesofRobot
T
fR b t
TypesofRobot
y Cylindrical robot:
p
y Spherical
or
y It's a robot whose axes
Polar robot:
y It
It'ss a robot whose axes
form a polar coordinate
y
system.
y Used for handling at
p
machine tools,, spot
welding,
diecasting,
fettling machines, gas
welding
and
arc
welding.
form a cylindrical
coordinate system.
y Used
U d for
f
assembly
bl
operations, handling at
machine
hi
t l
tools,
spott
welding, and handling
att
di
die
casting
ti
machines.
Page 145 of 240
Rev.0
Types of Robot
TypesofRobot
T
fR b t
TypesofRobot
y SCARA robot
y Articulated
or
Revolute Robot:
y It
It'ss a robot whose arm
has at least three rotary
joints.
joints
y Used for assembly
operations,
ti
di casting,
die
ti
fettling machines, gas
welding,
ldi
arc welding
ldi
and spray painting.
y The
SCARA
acronym
stands
for Selective Compliant Assembly
Robot Arm or Selective Compliant
Articulated Robot Arm.
y It's a robot which has two parallel
provide compliance
p
rotaryy jjoints to p
in a plane
y Used for pick and place work,
work
application of sealant, assembly
operations and handling machine
tools
Theconfigurationofarobotusingatelescopingarmthat
canberaisedorloweredonahorizontalpivotmounted
onarotatingbaseiscalled
(a)Polar
(b)C li d i l
(b)Cylindrical
(c)Cartesiancoordinate
(d)Jointedarm
y
JointDriveSystems
y Electric
y Useselectricmotorstoactuateindividualjoints
y Preferreddrivesystemintoday'srobots
y Hydraulic
y Useshydraulicpistonsandrotaryvaneactuators
y Notedfortheirhighpowerandliftcapacity
y Pneumatic
y Typicallylimitedtosmallerrobotsandsimplematerial
T i ll li it dt
ll b t d i l t i l
transferapplications
Working Envelope
WorkingEnvelope
y
RobotControlSystem
Joint2
Level2
Controller
&Program
Level1
Joint4
Joint5
One use is a mobile

platform
handling
cockpit
flight
simulators It
simulators.
It'ss a robot
whose
arms
have
concurrent prismatic
or rotary joints.
Joint6
Sensors
y Limitedsequencecontrol pickandplace
operationsusingmechanicalstopstosetpositions
i
i
h i l
ii
y Playbackwithpointtopointcontrol records
workcycleasasequenceofpoints,thenplaysback
thesequenceduringprogramexecution
y Playbackwithcontinuouspathcontrol
greatermemorycapacityand/orinterpolation
capabilitytoexecutepaths(inadditiontopoints)
y Intelligentcontrol exhibitsbehaviorthatmakes
itseemintelligent,e.g.,respondstosensorinputs,
makesdecisions,communicateswithhumans
Robotic Arc Welding Cell

RoboticArcWeldingCell
y Robotperforms
Cell
C
ll
Supervisor
Joint3
y Parallel robot
Robot Control Systems

RobotControlSystems
IES 2012
IES
Joint1
T
fR b t
TypesofRobot
fluxcoredarc
welding(FCAW)
operationatone
workstation
k
i
whilefitter
changespartsat
theother
workstation
Level0
Page 146 of 240
Rev.0
Robot Programming
RobotProgramming
Leadthrough Programming
y Leadthrough programming
y Work cycle is taught to robot by moving the
manipulator through the required motion cycle and

simultaneously entering the program into controller
memory for later playback
y Robot programming languages
y Textual programming language to enter commands
into robot controller
y Simulation and offline
off line programming
y Program is prepared at a remote computer terminal
and
d downloaded
d
l d d to robot
b controller
ll for
f execution
i
without need for leadthrough methods
IES2011
Trajectoryofarobotmean:
(a)Pathtracedbytheendeffectors
(b)KinematicsofRobot
( )
(c)Robotjoints
j
(d)Robotprogramming
1. Poweredleadthrough
y Commonforpointto
pointrobots
y Usesteachpendant
2. Manualleadthrough
y Convenientfor
continuouspath
controlrobots
y Humanprogrammer
physicalmoves
manipulator
y Easilylearnedbyshoppersonnel
y Logicalwaytoteacharobot
y Nocomputerprogramming
y Disadvantages:
y Downtimeduringprogramming
y Limitedprogramminglogiccapability
Li i d
i l i
bili
y Notcompatiblewithsupervisorycontrol
IES 2010
IES2010
g statements:
Good dynamic performance is usually difficult to achieve
in robots which contain a rotary base because
1. Position, speed and acceleration of the other joints cause
variations in the reflected torque and moment of inertia.
2. The moment of inertia reflected at the base depends upon the
weight of the object being carried.
3. The moment of inertia reflected at the base also depends upon
the distance between the base axis and the manipulated object.
Which of the above statements is/are correct?
(a) 1, 2 and 3
(b) 2 and 3 only
(c) 1 only
(d) 1 and 3 only
IES 2000
IES
Consider the following characteristics of a robot:
1. The tip of the robot arm moves from one point to
another with its in
inbetween
between path not being defined.
2. It can be used for drilling holes at difference points in a
workpiece.
workpiece
3. It can be used for V butt joint welding between two
points.
points
4. The memory capacity required for its control unit is low.
Which of these are the characteristics associated with
ith a point
to point robot?
( ) 1 and
(a)
d2
(b) 1, 3 and
d4
GATE
(c) 1, 2 and 4For-2015
(d) (IES,
2, 3 and
4 & PSUs)
L dh
h ProgrammingAdvantages
P
i Ad
Leadthrough
g
y Advantages:
IES 2006
IES
Which one of the following is the third basic
component of robots besides power supply and
control (memory) console?
(a) Software
(b) Coaxial cable
( ) Mechanical
(c)
M h i l unit
it arm (d) Microcomputer
Mi
t
GATE 2013
GATE2013
CAD
Computer Aided
d d Design (CAD):
(
) Used
d for
f creating the
h
In
mirror
image
off a 2D
I a CAD package,
k
i
i
D point
i t
product database
P(5,10)
(5, ) is to be obtained about a line which p
passes
Geometric Modeling
Engineering Analysis
Design Review and Evaluation
Automated Drafting
Page 147 of 240
through the origin and makes an angle of 45o

counterclockwise with the Xaxis. The coordinates
off the
th transformed
t
f
d point
i t will
ill be
b
(a) (7.5,
(7 5 5)
(b) (10,
(10 5)
(c) (7.5,
(7 5 5)
5)
Rev.0
(d) (10,
(10 5)
5)
GATE 2014
GATE2014
ArobotarmPQwithendcoordinatesP(0,0)andQ(2,5)
A b t
PQ ith d
di t P( ) dQ( )
rotatescounterclockwiseaboutPintheXYplaneby90
p
y 9 o.
ThenewcoordinatepairoftheendpointQis
(a)(2,5)
(b)(5,2)
(c)(5,2)
(d)(2,5)
CAM
ComputerAidedManufacturing(CAM):
y ComputerAidedProcessPlanning(CAPP)
y ComputerizedmaterialResourcePlanning(MRP)
IES 2006
IES
Which item best describes a CAM technology?
(a) Geometric modeling (b) Documentation
( ) Drafting
(c)
D fti
(d) Numerical
N
i l control
t l
y NCpartprogramming
y RobotProgramming
R b P
i
y ComputerizedScheduling
y Computerizedprocesscontrol
y ComputerizedManufacturingControlbyFMS
y Shopfloorcontrol
y ComputerAidedQualityControl(CAQC)
p
Q
y
( Q )
y ComputerAidedInspection
Automation
ISRO2011
In CAM, " Part programming" refers to
(a) Generation of cutter location data
(b) Online Inspection
(c) Machine Selection
(d) Tool
T l Selection
S l i
y Automation is the process of following a predetermined
sequence of operations with little or no human intervention,

using
specialized
and
that
and
i
i li d equipment
i
d devices
d i
h perform
f
d
control the manufacturing process.
Why go for Automation?
1. Increased productivity
2. Reduced cost of labour
3. Improved quality
4. Reduced inprocess
p
inventoryy
5. Reduce Manufacturing time
6. Increased safety
There are three types of Automation
1. Fixed Automation
2. Programmable
P
bl Automation
A t
ti
3. Flexible Automation
Automation
Automation
Programmable Automation
Flexible Automation
y Can change the design of the product or even change the
y If is also known as FMS, and uses CAD/CAM
product by changing the program.

y Used
U d for
f the
th low
l
quantity
tit production
d ti off large
l
number
b off
y Produce different products on the same equipment in
Automation
Fixed Automation
y It
as hard
I is
i also
l known
k
h d automation.
i
y Used to produce a standardized product.
product
y Used for very large quantity production of one or few
marginally different components.

y Highly specialized tools, devices, equipment, special
purpose machine tools,

tools are utilized to produce a
product.
y Very efficient, high production rate , low unit cost.
IES 2012
IES
Programmableautomationissuitablefor
P
bl t
ti i it bl f
(a)Lowproductionvolumeandlargevarietiesofparts
(b)Lowproductionvolumeandsmallvarietiesofparts
p
p
any order
d or mix.
i
(c)Highproductionvolumeandsmallvarietiesofparts
different components.
p
(d)Highproductionvolumeandlargevarietiesofparts
y Equipment are designed to be flexible or programmable.

y Used for batch production.
Page 148 of 240
Rev.0
Wh t i
FMS?
WhatisanFMS?
f
g system
y
((FMS)) is a
y A fflexible manufacturing
manufacturing system in which there is some
amount of flexibilityy that allows the system
y
to
react in the case of changes.
y Two categories of flexibility
y Machine flexibility, covers the system's ability to be
changed to produce new product types,

types and ability to
change the order of operations executed on a part.
y Routing flexibility,
flexibility which consists of the ability to
use multiple machines to perform the same operation
on a part, as well as the system
system'ss ability to absorb
largescale changes, such as in volume, capacity, or
capability.
FMSComponents
y
Most FMS systems comprise of three main

systems
y Work
W k machines
hi
(t i ll automated
(typically
t
t d CNC
machines) that perform a series of operations;
y An integrated material transport system and a
computer that controls the flow of materials,
tools, and information (e.g. machining data
and machine malfunctions) throughout the
system;
y Auxiliary
y work stations for loading
g and
unloading, cleaning, inspection, etc.
FMS G l
FMSGoals
y Reduction in manufacturing cost by lowering direct
labor cost and minimizing scrap, rework, and material

wastage.
y Less skilled labor required.
y Reduction in work
workinprocess
in process inventory by eliminating
the need for batch processing.
y Reduction in production lead time permitting
manufacturers to respond more quickly to the variability
of market demand.
demand
y Better process control resulting in consistent quality.
f
AdvantagesofFMS
Di d t
f FMS
DisadvantagesofFMS
IES 1996
IES
g from one p
y Faster,, lower cost changes
part to another
y Limited ability to adapt to changes in product or product
1. CNCmachinePostprocessor
2. Machiningcentre.Toolmagazine
M hi i t
T l
i
3. DNC.FMS
(a) 1,2and3 (b) 1and2
(c) 1and3
(d)2and3
which will improve capital utilization

y Lower direct labor cost,, due to the reduction in number
of workers
y Reduced inventory,
y, due to the p
planning
g and
programming precision
y Consistent and better q
quality,
y, due to the automated
control
y Lower cost/unit
/
of output,
p , due to the g
greater
productivity using the same number of workers
y Savings
g from the indirect labor,, from reduced errors,,
rework, repairs and rejects
IES 2006
2006
IES
Flexible manufacturing allows for:
(a) Tool design and production
(b) Automated
A t
t d design
d i
(c) Quick and inexpensive product change
(d) Quality control
mix (e.g., machines are of limited capacity and the

tooling necessary for products, even of the same family,
is not always feasible in a given FMS)
y Substantial preplanning
pre planning activity
y Expensive, costing millions of dollars
y Technological problems of exact component positioning
and precise timing necessary to process a component
y Sophisticated manufacturing systems
IES 2004
IES
Consider the following characteristics:
1. Single machine tool
2. Manual
M
l materials
t i l handling
h dli system
t
3. Computer control
4. Random sequencing of parts to machines
Which of the above characteristics are associated with
flexible manufacturing system?
(a) 1,
1 2 and 3 (b) 1 and 2
(c) 3 and 4
(d) 2, 3 and 4
Page 149 of 240
IES 2012
IES
Rankorderclusteringasappliedtomanufacturing
automationis
(a)Atechniqueofidentifyingprocesssequencein
productionofacomponent
(b)Aj ti ti (JIT) th d
(b)Ajustintime(JIT)method
(c)Anapproachofgroupingthemachinesintocellsin
anFMSsystem
( )
(d)Atooltogeneratebillofmaterials
g
Rev.0
ReferenceBook
IFS2011
y CAD/CAM:ComputerAidedDesignand
ManufacturingByGroover
y CNCMachines ByB.S.Pabla,M.Adithan
ByB S Pabla M Adithan
y Machinetooldesignandnumericalcontrol By
Mehta
y ComputerControlOfManu.Systems ByKoren
N df U
ti
lP
NeedforUnconventionalProcesses
y New materials having high strength and hardness,
hardness such as
Prepare a flow diagram for writing the computer
nimonic alloys and alloys with alloying elements such as
programme in FORTRAN for Pulse MIG welding
tungsten, molybdenum, and columbium are difficult to

machine by the traditional methods.
methods
process.
[
[10marks]
k ]
y By conventional machining the MRR reduces with an
increase in the work material hardness.

y Need
N d
f
for
d l
development
t off
processes
which
utilize
nontraditional
t diti
l
other
machining
hi i
methods
such
as
electrochemical processes for the material removal.
N df U
ti
lP
NeedforUnconventionalProcesses
y Complex
C
l shapes.
h
y A very high accuracy is desired besides the complexity of
the surface to be machined.
1 Th
lE
M th d
1.ThermalEnergyMethods
I U
ti
l M hi i
InUnconventionalMachining
y Different forms of energy directly applied to the
workpiece to have shape transformation or material

removal from work surface.
y No chips, No lay pattern on work surface, no direct
physical contact between the tool and the workpiece .
y The tool material does not have to be harder than the
work
k material.
t i l
y Tool forces do not increase as the work material gets
harder.
y Economic metal removal rate does not decrease as the
work material gets harder.
2 El
Ch i l E
M h d
2.Electro
ChemicalEnergyMethod
y Electricaldischargemachining(EDM)
El t i ldi h
hi i (EDM)
y ElectroChemicalMachining(ECM)
El
Ch i lM hi i (ECM)
y LaserbeamMachining(LBM)
y ElectroChemicalgrinding(ECG)
El t Ch i l i di (ECG)
y PlasmaArcMachining(PAM)
g
y ElectronBeamMachining(EBM)
y IonBeamMachining(IBM)
Cl ifi ti
f NTMM
ClassificationofNTMM
The Non
traditional Machining Methods are classified
Nontraditional
according to the major energy sources employed in
machining.
1.ThermalEnergyMethods
2.Electro ChemicalEnergyMethod
3.ChemicalEnergyMethods
4.MechanicalEnergyMethods
3 ChemicalEnergyMethods
Ch i l E
M th d
3.
These methods involve controlled etching of the
workpiece material in contact with a chemical solution.
y Chemical Machining Method (CHM).
y ElectroChemicalHoning(ECH)
El t Ch i lH i (ECH)
y ElectroChemicalDeburring
Electro ChemicalDeburring (ECD)
Page 150 of 240
Rev.0
GATE 2014
GATE2014
4 MechanicalEnergyMethods
M h i lE
M th d
4.
S
Ob
ti
SomeObservations
y UltraSonicMachining(USM)
Ult S i M hi i (USM)
The process utilizing mainly thermal energy for
p
p
q
y EDM has the lowest specific
power requirement
and can
y AbrasiveJetMachining(AJM)
removing material is
y WaterJetMachining(WJM)
g
(a) Ultrasonic Machining
y ECM has the highest

g
metal removal rate,, MRR.
y USM and AJM have low MRR and combined with high
(b) Electrochemical Machining
y LBM and EBM have high penetration rates with low
(c) Abrasive Jet Machining

(d) Laser
L
B
Beam
M hi i
Machining
Sh
C tti C
bilit
ShapesCuttingCapability
The various NTMM have some special shape cutting
capability as given below:
1. Micromachining and Drilling : LBM and EBM
2 Cavity sinking and standard Hole Drilling: EDM and
2.
USM
GATE2014
4. Clean, rapid Cuts and Profiles: PAM

5. Shallow Pocketing: AJM
IES 2012
IES
Whichofthefollowingprocesseshasveryhighmaterial
removalrateefficiency?
(a)Electronbeammachining
(b)Electrochemicalmachining
(c)Electrodischargemachining
( )
(d)Plasmaarcmachining
g
g
tool wear,, are used for nonmetal cutting.
MRR and,, therefore,, are commonlyy used for micro
drilling, sheet cutting, and welding.
y CHM is used for manufacturing
g PCB and other shallow
components.
y PAM can be used for clean,, rapid
p cuts and p
profiles in
almost all plates upto 20 cm thick with 5o to 10o taper.
Li it ti
f NTMM
LimitationsofNTMM
The
unconventional
Th following
f ll i four
f
ti
l machining
hi i processes
y Expensive
required.
E
i sett up, low
l MRR and
d skilled
kill d labour
l b
i d
are available in a shop

p floor. The most appropriate
pp p
one to
y The limitation of electrical machining methods is that
drill a hole of square cross section of 6 mm 6 mm and
the work material must be an electrical conductor. Also,
25 mm deep is
consumption of electrical energy is very large.
( ) Abrasive
(a)
b
Jet Machining
h
3. Fine hole drilling and Contour Machining: ECM
achieve sufficient accuracy.
(b) Plasma Arc Machining
y The NTMM which have not been proved commercially
economical are: USM,

USM AJM,
AJM CHM,
CHM EBM and PAM.
PAM
((c)) Laser
ase Beam
ea Machining
ac
g
(d) Electro Discharge Machining
GATE 2006
GATE
g the p
g order of
Arrange
processes in the increasing
their maximum material removal rate.
g ((ECM))
Electrochemical Machining
Ultrasonic Machining (USM)
Electron Beam Machining (EBM)
Laser Beam Machining (LBM) and
Electric Discharge Machining (EDM)
(a) USM, LBM, EBM, EDM, ECM
(b) EBM,
EBM LBM,
LBM USM,
USM ECM,
ECM EDM
(c) LBM, EBM, USM, ECM, EDM
(d) LBM, EBM, USM, EDM, ECM
Page 151 of 240
IES 2007
IES
Consider the following statements in relation to the
unconventional machining processes:
1 Different forms of energy directly applied to the
1.
piece to have shape transformation or material removal
from work surface.
surface
2. Relative motion between the work and the tool is
essential.
ti l
3. Cutting tool is not in physical contact with work
piece.
(b) 1, 2 and 3 onlyy
(a) 1 and 2 onlyy
(c) 2 and 3 only
(d) 1 and 3 only
Rev.0
IES 2009
2009
IES
IAS 2002
IAS
Which one of the following statements is correct in

respect of unconventional machining processes?
(a) The cutting tool is in direct contact with the job
(b) The tool material needs to be harder than the job
material
t i l
(c) The tool is never in contact with the job
(d) There has to be a relative motion between the tool
j
and the job
(
) with List II (Tolerances
(
Match List I (Processes)
obtained) and select the correct answer using the codes
List I
List II
(Processes)
(Tolerances obtained)
A. Plasma Arc machining 1.
75 microns
B. Laser Beam machining 2.
25 microns
C. Abrasive Jet machining 3.
50 microns
D. Ultrasonic machining
4.
125 microns
Codes:A
B
C
D
A
B
C
D
(a) 4
1
3
2
(b) 3
2
4
1
(c) 4
2
3
1
(d) 3
1
4
2
ECM
B SKM d l
BySKMondal
El t h i l M hi i
ElectrochemicalMachining
El t h i l M hi i
y Electrochemical machining is the reverse of electro
y Variation in the current density will result in work
plating
y The workpiece
work piece is made the anode,
anode which is placed in
close proximity to an electrode (cathode), and a high
amperage direct current is passed between them through
an electrolyte, such as salt water, flowing in the anode
cathode gap.
gap
y Metal is removed by anodic dissolution and is carried
away in
i the
th form
f
off a hydroxide
h d id in
i the
th electrolyte
l t l t for
f
recycling or recovery.
y MRR in ECM depends on atomic weight of work material
taking the electrodes shape.

y The electrode is fed with a constant velocity,
velocity and the
electrolyte is fed through the tool.
ECM E i
t
ECMEquipment
Fig- Electrochemical Machining process
ECM E i
t
ECMEquipment
ECM E i
t
ECMEquipment
y Supply Voltage 2 to 35 V DC and Current 500 to 40,000 A
y The electrolyte consists of the metal debris removed
y The tooltowork gap needs to be maintained at a very
from the anode, which will have to be filtered before it is

repumped
re
pumped into the system.
y Also a large amount of heat is generated during the
electrolysis which heats up the electrolyte,
electrolysis,
electrolyte and hence it
needs to be cooled.
small value 0.1

0 1 to 0.25
0 25 mm.
mm A servo drive is provided on
the tool axis for this purpose.
y The
Th electrolyte
l t l t needs
d to
t be
b pumped
d through
th
h this
thi gap att
high pressures ranging from 0.70 to 3.00 MPa. This
i t d
introduces
a large
l
amountt off load
l d on the
th machine,
hi
because of the large working areas involved. Hence the
machine
hi
structure
t t
will
ill have
h
t be
to
b made
d rigid
i id to
t a
withstand such forces.
Page 152 of 240
Rev.0
Tool
El t l t
Electrolyte
y is so chosen that the anode (workpiece)
(
p
)
The electrolyte
is dissolved but no deposition takes place on the cathode
(tool).
Properties electrolyte should be
1. High
g electrical conductivityy
2. Low viscosity
3 High specific heat
3.
4. Chemical stability
5 Resistance to formation of passivating film on
5.
workpiece surface
6 Noncorrosive
6.
Non corrosive and nontoxic
non toxic
7. Inexpensive and readily available
p
The p
properties
of tool materials should be:
ForECMofsteelNaCl isusedastheelectrolyte.
accurately. Good for low machinability or complicated

shapes.
shapes
2. As ECM leads to atomic level dissolution, the surface
fi i h is
finish
i excellent
ll t (Ra 0.2 to
t 0.6
6 m)) with
ith almost
l
t stress
t
free machined surface and without any thermal
damage.
3. The tool wear is practically nil which results in a large
number of components produced per tool.
4. MRR is highest
g
(1600 mm3/min) among
g NTMM and
comparable with conventional machining.
ISRO2009
The machining process in which the work picce is
di l d into
dissolved
i t an electrolyte
l t l t solution
l ti is
i called
ll d
(a) Electro
Electrochemical
chemical machining
(b) Ultrasonic machining
g
High electrical and thermal comductivity
2.
Easy machinability
3.
Good shiffness
4.
High corrosion resistance
y Tool materials: Copper, brass, bronze, Al, Stainless
Steel Cupro nickel,

Steel,
nickel etc.
etc
y Material wear / Tool wear: Infinite
d
Advantages
1.
1 Complex threedimensional
three dimensional surfaces can be machined
1.
i d
Disadvantages
1.
2.
3.
4.
5.
6
6.
7
7.
y
Use of corrosive media as electrolytes
makes it difficult to
handle.
Sharp interior edges and corners (< 0.2 mm radius) are
difficult to produce.
Very expensive machine.
Forces are large with this method because of fluid pumping
forces.
V
Very
hi h specific
high
ifi energy consumption
i
( b
(about
150 times
i
that required for conventional processes),
Not applicable with
ith electrically
electricall nonconducting
non conducting materials
and jobs with very small dimensions
Lower fatigue strength
PSU
ECMcannotbeundertakenfor
ECM
tb d t k f
(a)steel
(b)Nickelbasedsuperalloy
(c)Al2O3
(d)Titaniumalloy
(c) Electrodischarge machining
A li ti
Applications
y Any electrically conductive work material irrespective
of their hardness, strength or even thermal properties.

y The machining surface can be situated at any
i
inaccessible.
ibl
y Shape application blind complex cavities, curved
y
y
y
y
y
y
y
surfaces, through cutting,

surfaces
cutting large through cavities.
cavities
It is used for the machining of the gas turbine blades.
Die sinking
Profiling and contouring
T
Trepanning
i
Grinding
D illi
Drilling
Micromachining
PSU
Commercial ECM is carried out at a combination
off
(a) low voltage high current
(b) low current low voltage
((c)) high
g current high
g voltage
g
(d) low current low voltage
(d) Laser machining

Page 153 of 240
Rev.0
IAS2011Main
What is the principle of electrochemical
machining
hi i (ECM)?
What are the advantages and disadvantages of
ECM over conventionall drilling?
d ll
Comment on the surface finish and the accuracy of
the ECM.
[
[20Marks]
]
ECM C l l ti
ECMCalculations
y laws state that,,
Faradays
m=
It E
F
Where
m
I
t
E
F
ECM C l l ti
ECMCalculations
yMRR =
=weight(g)ofamaterial
=current(A)
=time(sec)
=gramequivalentweightofthe
gramequivalentweightofthe
material
co sta t o p opo t o a ty
=constantofproportionality
Faraday(96,500coulombs)
y MRR for Alloy
Eeq I cm
eq F sec
100
x
= i
eq
i i
Atomicweightofiron56,density7.8g/cm3 valency,2
g/s
IfyouputE=equivalentweightinCGSi.e.g/mole
IfyouputE=equivalentweightinCGSi
e g/mole
IinAmpere(A)
F=96500columb/molei.e.As/mole
l b
l
l
TheMRRwillbeing/s
GATE 2014
GATE2014
chemical machining is
(a)Ficks law
and
( )Ki hh ff l
(c)Kirchhoffslaws
(d)Ohm slaw
(d)Ohmslaw
100
x v
= i i
Eeq
i Ai
GATE 2011(PI)
2011 (PI)
GATE
GATE2008(PI)
In an electro chemical machining (ECM) operation,
operation a
square hole of dimensions 5 mm x 5 mm is drilled in a
block of copper. The current used is 5000 A. Atomic
weight
g of cupper
pp is 633 and valencyy of dissolution is 1.
Faradays constant is 96500 coulomb. The material
removal rate (in g/s) is
(a) 0.326
AI
F V
F.
(b)Faradayslaws
3
E
l
Example
g/s =
p
The p
principle
of material removal in Electro
AI cm3 EI cm3
vF sec F sec
whatcurrentisrequired?
q
EI
F
ECM C l l ti
ECMCalculations
y MRR for pure metal
UsingECMremove5cm
U i ECM
3/minfromanironworkpiece,
/ i f
i
k i
ECM C l l ti
ECMCalculations
(b) 3.260
(c) 3.15 x 103
Page 154 of 240
While removing material from iron (atomic weight = 56,

valency = 2 and density = 7.8 g/cc) by electrochemical
machining, a metal removal rate of 2 cc/min is desired.
The current (in A) required for achieving this material
removal rate is
(a) 896.07
(b) 14.93
( ) 448.03
(c)
8
(d) 53764.29
6
(d) 3.15 x 105
Rev.0
E
l
Example
Calculate the material removal rate and the
electrode feed rate in the electrochemical
machining of an iron surface that is 25 mm 25 mm
in crosssection using NaCl in water as electrolyte.
The gap between the tool and the workpiece is 0.25
mm. The supply voltage is 12 V DC. The specific
resistance of the electrolyte is 3 c m
For iron, Valency, Z = 2
At
Atomic
i weight,
i ht A = 55.85
8
Density, = 7860 kg / m3
E
l (GATE 2009)
Example(GATE2009)
Electrochemicalmachiningisperformedtoremove
materialfromanironsurfaceof20mmx20mmunder
thefollowingconditions:
Interelectrodegap
=
0.2mm
S
SupplyVoltage(DC)
l V lt (DC) =
12V
V
Specificresistanceofelectrolyte
=2cm
AtomicweightofIron =
55.85
ValencyofIron =
2
Faraday'sconstant
=
96540Coulombs
Th t i l
Thematerialremovalrate(ing/s)is
l t (i / )i
E
l
Example
p
p
y is as follows:
Composition
of a Nickel superalloy
Ni = 70.0%, Cr = 20.0%, Fe = 5.0% and rest Titanium
Calculate rate of dissolution if the area of the tool is 1500
mm2 and a current of 1000 A is being passed through the
cell Assume dissolution to take place at lowest valancy
cell.
of the elements.
GATE 2013
GATE2013
During the electrochemical machining (ECM) of
iron (atomic weight = 56, valency = 2) at current of
1000 A with 90% current efficiency, the material
removal rate was observed to be 0.26 gm/s. If
Titanium (atomic weight = 48, valency = 3) is
machined by the ECM process at the current of 2000
A with 90% current efficiency, the expected material
removal rate in gm/s will be
(a) 0.1
0 1 1 (b) 0.23
0 23
(c) 0.30
0 30
(d) 0.52
0 52
GATE 2008
GATE
Fl
l i
Flowanalysis
A researcher
h conducts
d t electrochemical
l t
h i l machining
hi i
((ECM)) on a binary
y alloy
y ((density
y 6000 kg/m
g/ 3) of iron
y To calculate the fluid flow required, match the heat
generated to the heat absorbed by the electrolyte.
(atomic weight 56, valency 2) and metal P (atomic

weight 24, valency 4). Faraday's constant = 96500
coulomb/mole.
l
b/
l Volumetric
V l
t i material
t i l removall rate
t off
the alloy
y is 550 mm3/s at a current of 2000 A. The
y Neglecting all the heat losses
percentage of the metal P in the alloy is closest to

(a) 40
(b) 25
E
l
Example
The electrochemical machining of an iron surface that is
25 mm 25 mm in crosssection using NaCl in water as
electrolyte. The gap between the tool and the workpiece
is 0.25 mm. The supply voltage is 12 V DC. The specific
resistance of the electrolyte is 3 cm.
Estimate the electrolyte flow rate. Specific heat of the
electrolyte is given as 0.997
0 997 cal/g
cal/gC
C. The ambient
temperature is 35C and the electrolyte boiling
temperature is 95
temperature,
95C
C.
Density, = 7860 kg/m3
(c) 15
l2R = q e ce (B o )
(d) 79
g
Overvoltage
DynamicsofElectrochemicalMachining
y If the total over voltage at the anode and the cathode is
V and the applied voltage is V,

V the current I is given
by,
I=
V V
R
y Schematic representation of the ECM process with no
feed to the tool

Page 155 of 240
Rev.0
E
l
Example
In
an equilibrium
gap off 2
I ECM operation
ti off pure iron
i
ilib i
mm is to be kept.
p Determine supply
pp y voltage,
g , if the total
overvoltage is 2.5 V. The resistivity of the electrolyte is 50
mm and the set feed rate is 0.25 mm/min.
In an EDM process using RC relaxation circuit,
circuit a 12 mm
diameter through hole is made in a steel plate of 50 mm
thickness using a graphite tool and kerosene as
dielectric. Assume discharge time to be negligible.
Machining is carried out under the following conditions:
Resistance
40
Capacitance
20 F
Supply
pp y voltage
g
220 V
Discharge voltage
110 V
Averagepowerinput(inkW)is
(a)0.373
(b)0.137
(c)0.218 (d)0.500
El t h i l G i di (ECG)
ElectrochemicalGrinding(ECG)
p g and sharpening
p
g
y The p
process is used for shaping
carbide cutting tools, which cause high wear rates on
expensive diamond wheels in normal grinding.
Electrochemical grinding greatly reduces this wheel
wear.
y Fragile parts (honeycomb structures), surgical needles,
and tips of assembled turbine blades have been ECG
processed
d successfully.
f ll
y The lack of heat damage, burrs, and residual stresses is
very beneficial,
b
f
l particularly
l l when
h coupled
l d with
h MRRs
that are competitive with conventional grinding but
with
ith far
f less
l wheel
h l wear.
GATE 2007(PI)
2007 (PI)
GATE
Which one of the following process conditions
leads to higher MRR in ECM process?
( ) higher
(a)
hi h current,
t larger
l
atomic
t i weight
i ht
((b)) higher
g
valency,
y, lower current
(c) lower atomic weight, lower valency
(d) higher
hi h valency,
l
l
lower
atomic
i weight
i h
In an EDM process using RC relaxation circuit,
circuit a 12 mm
diameter through hole is made in a steel plate of 50 mm
thickness using a graphite tool and kerosene as
dielectric. Assume discharge time to be negligible.
Machining is carried out under the following conditions:
Resistance
40
Capacitance
20 F
Supply
pp y voltage
g
220 V
Discharge voltage
110 V
The time for one cycle,
cycle in milliseconds,
milliseconds is
(a) 0.55 (b) 0.32
(c) 0.89
(d) 0.24
l
h i l G i di ( CG)
ElectrochemicalGrinding(ECG)
g, metal bonded,,
y In ECG,, the tool electrode is a rotating,
diamond grit grinding wheel.
y As the electric current flows between the workpiece and the
wheel, through the electrolyte, the surface metal is changed

to a metal oxide, which is ground away by the abrasives. As
the oxide film is removed,
removed new surface metal is oxidized and
removed.
y ECG is a low
lowvoltage
voltage high
highcurrent
current electrical process.
process
y The purpose of the abrasive is to increase the efficiency of the
process and p
permit the continuance of the p
process.
ECG p
y The abrasive particles are always nonconductive material
such as aluminum oxide, diamond, or borazon (CBN). Thus
they act as an insulating spacer maintaining a separation of
from 0.012 to 0.050 mm between the electrodes.
IES 2000
IES
C
g statements:
In electrochemical grinding,
1 A rubber bonded alumina grinding wheel acts as the
1.
cathode and the workplace as the anode.
2 A copper bonded alumina grinding wheel acts as the
2.
cathode and the work piece as the anode.
3 Metal removal takes place due to the pressure
3.
applied by the grinding wheel.
4 Metal removal takes place due to electrolysis.
4.
electrolysis
(a) 1 and 3
(b) 2 and 4
156 of 240
(c) 2 and 3
(d) Page
1 and3
Equipmentsetupandelectricalcircuitforelectrochemicalgrinding.
p
OtherElectrochemicalprocesses
y Electrochemicalpolishing
p
g
y Electrochemicalholedrilling
g
y ElectrochemicalDeburring
g
Rev.0
GATE 2001
GATE
In ECM, the material removal is due to
(a) Corrosion
(b) Erosion
E i
(c) Fusion
(d) Ion displacement
GATE 1997
GATE
Selection electrolyte for ECM is as follows:
(a) Nonpassivating electrolyte for stock removal and
passivating electrolyte for finish control
(b) Passivating electrolyte for stock removal and non
passivating
i ti electrolyte
l t l t for
f finish
fi i h control
t l
(c) Selection of electrolyte is dependent on current
density
((d)) Electrolyte
y
selection is based on tool work
electrodes
GATE 1997
GATE
Inter electrode gap in ECG is controlled by
(a) Controlling the pressure of electrolyte flow
(b) Controlling
C t lli the
th applied
li d static
t ti load
l d
(c) Controlling the size of diamond particle in the wheel
(d) Controlling the texture of the work piece
GATE 1992
GATE
The two main criteria for selecting the electrolyte in
Electrochemical Machining (ECM) is that the
electrolyte should
(a) Be chemically stable
(b) Not
N t allow
ll dissolution
di l ti off cathode
th d material
t i l
(c) Not allow dissolution of anode material
(d) Have high electrical conductivity
IES 2002
IES
Assertion (A): In ECM, the shape of the cavity is the
mirror image of the tool, but unlike EDM, the tool
wear in ECM is less.
Reason (R): The tool in ECM is a cathode.
( ) Both
(a)
B th A and
i di id ll true
t
and
d R is
i the
th
IES 1997
IES
Which one of the following processes does not
cause tool wear?
(a) Ultrasonic machining
(b) Electrochemical machining
(c) Electric discharge machining
((d)) Anode mechanical machining
g
Ph i l P i i l
PhysicalPrinciple
y Basic process
Ph i l P i i l
PhysicalPrinciple
y An arc jumps between two points along the path of least
resistance.
Page 157 of 240
Rev.0
Ph i l P i i l
PhysicalPrinciple
Ph i l P i i l
PhysicalPrinciple
Ph i l P i i l
PhysicalPrinciple
y The energy of the arc is so concentrated that it causes the
y The metal and dielectric fluid is partly vaporized,
y The blast from the expanding vapors knocks some
electrode, and the work to melt. But the electrode

material is chosen so that it melts less.
causing sudden expansion.
molten particles loose, and the remaining molten metal

hardens.
Ch
t i ti
f EDM
CharacteristicsofEDM
Ch
t i ti
f EDM
CharacteristicsofEDM
y Mechanics of material removal melting and
y Uses Voltage of 60 to 300 V to give a transient arc lasting
evaporation aided by cavitation.

y The process is based on melting temperature,
temperature not
hardness, so some very hard materials can be machined
this way.
way
y The arc that jumps heats the metal, and about 1 to 10% of
th molten
the
lt metal
t l goes into
i t the
th fluid.
fl id The
Th melted
lt d metal
t l
then recast layer is about 1 to 30 m thick, and is
generally
ll hard
h d and
d rough.
h
y The electrode workpiece gap is in the range of 10 m to
100 m.
from 0.1 s to 8 ms.

y Typical cycle time is 20 ms or less,
less up to millions of
cycles may be required for completion of the part.
y Rotating
R t ti the
th wire
i in
i an orbital
bit l direction
di ti will,
ill
Increase accuracy in form and surface finish
Decrease electrode wear
EDMTool
W
R ti
WearRatio
S
M h i
ServoMechanism
y One major drawback of EDM is the wear that occurs on
y The
the
a critical
Th gap between
b t
th tool
t l and
d work
k has
h
iti l
Theusualchoicesfortool(electrode)materialsare
y Copper,
y brass,
b
y alloysofzincandtin,
y hardenedplaincarbonsteel,
y coppertungsten,
y silvertungsten,
y tungstencarbide,
t
t bid
y coppergraphite,andgraphite.
y Surface finish obtained 0.25

0 25 m
the electrode at each spark. Tool wear is given in terms of

wear ratio which is defined as,
W
Wear
ratio
ti =
Volume of metal removed work

Volume of metal removed tool
y Wear ratio for brass electrode is 1: 1. For most other
4: 1.
metallic electrodes, it is about 33: 1 or 4
y With graphite (with the highest melting point, 3500C),
the wear ratio may range from 5: 1 up to 50: 1.
Page 158 of 240
EDM T l
EDMTool
Prime requirements EDM tool Material
1. It should be electrically conductive.
2. It should
h ld have
h
good
d machinability,
hi bilit thus
th
allowing
ll i
easy manufacture of complex shapes.
3. It should have low erosion rate or good work to tool
wear ratio.
4. It should have low electrical resistance.
5. It should have high melting point.
6. It should have high electron emission.
importance.
p
As the workpiece
p
is machined,, this g
gap
p
tends to increase. For optimum machining efficiency,
this gap should be maintained constant. This is done by
servo mechanism
h i
which
hi h controls
t l the
th movementt off the
th
electrode.
Rev.0
Di l t i Fl id
DielectricFluid
p carryy awayy
y Fluid is used to act as a dielectric,, and to help
Discuss
the
Di
th effects
ff t off insufficient
i
ffi i t dielectric
di l t i and
d
debris.
y If the fluid is p
pumped
p through
g and out the end of the
electrode, particles will push out, and mainly collect at
the edges. They will lower the dielectric resistance,
resulting in more arcs. As a result the holes will be
conical.
y If fluid is vacuum pumped into the electrode tip, straight
holes will result.
y Quite often kerosenebased oil.
y The dielectric fluid is circulated through the tool at a
pressure of 0.35 N/m2 or less. To free it from eroded
metal particles, it is circulated through a filter.
electrolyte
y circulation in the interelectrode g
gap
p on the
Electric Discharge machining and Electro Chemical
Machining process respectively.
2.
3.
4.
5.
6.
g
Hardness,, toughness
or brittleness of the material p
poses no
problems. Due to this EDM can be used for machining
materials that are too hard or brittle to be machined by
conventional
ti
l methods.
th d
The method does not leave any chips or burrs on the work
piece.
piece
Cutting forces are virtually zero, so very delicate and fine
work can be done.
done
The process dimension repeatability and surface finish
g are extremelyy g
good.
obtained in finishing
The characteristic surface obtained, which is made up of
p in better oil retention. This improves
p
die life.
craters, helps
Because the forces between the tool and the workpiece and
virtually zero, very delicate work can be done.
1. O
Onlyy electricallyy conductive materials can be machined
2.
33.
4.
5.
6.
by EDM. Thus non metallic, such as plastics, ceramics

or glass, cannot be machined by EDM.
Electrode wear and overcut are serious problems.
A rehardened,, highly
g y stressed zone is p
produced on the
work surface by the heat generated during machining.
This brittle layer can cause serious problems when the
part is put into service.
Perfectly square corners cannot be made by EDM.
High specific energy consumption (about 50 times that
in conventional machining)
MRR is quite low
A li ti
Applications
A li ti
Applications
y EDM is
with
i particularly
ti l l useful
f l when
h dealing
d li
ith internal
i t
l
y The method is also employed for blanking parts from sheets,

sheets
cuts that are hard to g

get tools into. Machining
g tends to
cutting off rods of materials, flat or form grinding and
work best with external cuts.

y Almost any geometry (negative of tool geometry) can be
sharpening of tools, cutters and broaches.

y In EDM method,
method small holes,
holes about 0.13
0 13 mm,
mm in
A li ti
Applications
y EDM can be
any material
b used
d for
f machining
hi i
t i l that
th t is
i
electricallyy conductive,, thus including

g metals,, alloys
y and
most carbides.
y EDM is widely used for machining burr free intricate
shapes,
h
narrow slots
l
and
d blind
bl d cavities etc., for
f example,
l
sinking of dies for moulding,
moulding die casting,
casting plastic
moulding, wire drawing, compacting, cold heading,
forging, extrusion and press tools.
IES2009Conventional
What is the principle of metal removal in EDM
process??
ii. Describe the process with the help of sketch.
iii. List advantages and limitations of the system.
i.
diameter and as deep as 20mm diameters can be drilled
generated
d on a workpiece
k
iff a suitable
bl tooll can be
b
with virtually no bending or drifting of hole. Due to this,
fabricated (the use of punch as a tool to machine its own
EDM is particularly useful for machining of small holes,

holes
mating die is commonly employed in EDM method).
orifices or slots in dieselfuel injection nozzles, or in aircraft
Fig Relaxation circuit used for generating the pulses in EDM process
Fig-Relaxation
[5 Marks]
Disadvantages
Ad t
Advantages
1.
R l ti
i it
Relaxationcircuit
S 20 C
i
l
IES2011Conventional
engines, air brake valves and so on.

Page 159 of 240
[ 5
[15marks]
]
Rev.0
GATE 1994
GATE
Electric discharge machining is more efficient
process than Electrochemical machining for
producing large non
noncircular
circular holes.
The above statement is
( ) True
(a)
T
(b) False
(c) Cant say
(d) Insufficient data
Wi EDM
WireEDM
y Wire EDM is a special form of EDM wherein the
electrode is a continuously moving conductive wire.

y A thin wire of brass, tungsten, or copper is used as an
electrode.
y The electrode wire is typically made with a 0.05 to 0.25
mm diameter,
diameter which is wire electrode wound between
the two spools.
y Deionized water is used as the dielectric.
GATE 2014 (PI)

GATE2014(PI)
Wi EDM
WireEDM
Find the correct combination of manufacturing processes to

produce
the
in
from
a blank
d
th part,
t shown
h
i figure,
fi
f
bl k (holes
(h l shown
h
are with square and circular crosssections)
y This
Thi process is
i much
h faster
f t than
th electrode
l t d EDM.
EDM
y This process is widely used for the manufacture of
punches, dies, and stripper plates, with modern

machines capable of cutting die relief, intricate
openings, tight
h radius
d contours, and
d corners routinely.
l
y Geometrically accurate but moderately finished straight
toothed metallic spur gears,

gears both external and internal
type, can be produced by wire type Electro discharge
Machining (EDM).
(EDM)
El t i Di h
G i di (EDG)
ElectricDischargeGrinding(EDG)
(a) Drilling and milling on column and knee type universal

milling
g machine
(b) Diesinking and CNC Wirecut EDM process
(c) Die
Diesinking
sinking and CNC drilling
(d) CNC Wirecut EDM process only
El t i Di h
G i di (EDG)
ElectricDischargeGrinding(EDG)
y EDG is similar to EDM except that the electrode is a
y The spark gap is normally held at 0.013

0 013 to 0.076
0 076 mm
rotating wheel (usually graphite).

y Positively charged work pieces are immersed in or
flooded by a dielectric fluid and fed past the negatively
charged wheel by servocontrolled
servo controlled machine table.
table
y Metal is removed by intermittent high frequency
electrical
l t i l discharges
di h
passing
i
th
through
h the
th gap between
b t
wheel and workpiece.
y Each spark discharge melts or vaporizes a small amount
of metal from the workpiece surface, producing a small
crate at the discharge sit, as in EDM.
y The graphite wheel is rotated at 0.5 to 3 m/s
Fig- Electric Discharge

Page 160Grinding
of 240 (EDG)
The method
Th
th d can be
b used
d for
f
1. External cylindrical grinding, internal grinding and
surface grinding.
2. Grinding
g carbide and steel at the same time without
wheel loading.
3. Grinding thin sections where abrasive wheel pressures
might cause distortion.
4 Grinding brittle materials or fragile parts where
4.
abrasive materials might cause fracturing.
Rev.0
IES 2012
IES
Statement (I): In Electro Discharge Machining (EDM)
process, tool is made cathode and work piece anode
Statement (II): In this process if both electrodes are made of
same material, greatest erosion takes place upon anode
Statement (I)
()
p
of
Statement (I)
GATE 1999
GATE
In Electro
Discharge Machining (EDM), the tool is
ElectroDischarge
made of
(a) Copper
(b) High Speed Steel
(c) Cast Iron
(d) Plain Carbon Steel
GATE 2004
GATE
The mechanism of material removal in EDM
process is
(a) Melting and Evaporation
(b) Melting and Corrosion
(c) Erosion and Cavitation
((d)) Cavitation and Evaporation
p
G
20 0 ( )
GATE2010(PI)
Keeping all other parameters unchanged,
unchanged the tool
wear in electrical discharge machining (EDM) would
be less if the tool material has
(a) high thermal conductivity and high specific heat
( ) high thermal conductivity and low specific heat
(b)
GATE 2003
GATE
As tool and work are not in contact in EDM process
(a) No relative motion occurs between them
(b) No
N wear off tool
t l occurs
(c) No power is consumed during metal cutting
(d) No force between tool and work occurs
GATE 2007
GATE
In electro discharge machining (EDM), if the
thermal conductivity of tool is high and the specific
heat of work piece is low, then the tool wear rate
and material removal rate are expected to be
respectively
(a) High and high
(b) Low and low
( ) High
(c)
Hi h and
d low
l
(d) Low
L and
d high
hi h
(c) low thermal conductivity and low specific heat

(d) low thermal conductivity and high specific heat
GATE 2005
GATE
A zigzag cavity in a block of
high strength alloy is to be
finish machined. This can be
carried out by using
(a) Electricdischargemachining
(b) Electrochemicalmachining
(c) Laserbeammachining
((d)) Abrasiveflowmachining
g
IES 2005
IES
Which of the following is/are used as low wearing
tool material(s) in electric discharge machining?
(a) Copper and brass
(b) Aluminium and graphite
(c) Silver tungsten and copper tungsten
((d)) Cast iron
Page 161 of 240
GATE 2000
GATE
Deep hole drilling of small diameter, say 0.2 mm is
done with EDM by selecting the tool material as
(a) Copper wire
(b) Tungsten wire
(c) Brass wire
(d) Tungsten carbide
Rev.0
GATE 2009(PI)
Ult
i M hi i
UltrasonicMachining
UltrasonicMachining
A titanium sheet of 5.0 mm thickness is cut by wire

cut EDM process using a wire of 1.0
1 0 mm diameter.
diameter
A uniform spark gap of 0.5 mm on both sides of the
wire is maintained during cutting operation. If the
feed rate of the wire into the sheet is 20 mm/min,
the material removal rate (in mm3/min) will be
((a)) 150
5
((b)) 200
((c)) 3300
((d)) 4
400
BySKMondal
Ult
i M hi i
UltrasonicMachining
Ult
i M hi i
UltrasonicMachining
Ult
i M hi i
UltrasonicMachining
y In ultrasonic machining, a tool of desired shape vibrates at an
y USM is mainly used for machining brittle materials
y At full indentation, the indentation depth in the work
ultrasonic frequency (19 ~ 25 kHz) with an amplitude of

around 155 550
m over the workpiece.
p
y Generally the tool is pressed downward with a feed force, F.
Between the tool and workpiece,
p
, the machining
g zone is
flooded with hard abrasive particles generally in the form of
water based slurry.
y As the tool vibrates over the workpiece, the abrasive particles
act as the indenters and indent both the work material and
the tool. The abrasive particles, as they indent, the work
material, would remove the same, particularly if the work
material is brittle, due to crack initiation, propagation and
brittle fracture of the material.
{which are poor conductors of electricity and thus

cannot be processed by Electrochemical and Electro
Electro
discharge machining (ECM and EDM)}.
material is characterized by w. Due to the indentation,

as the work material is brittle, brittle fracture takes place
leading to hemispherical fracture of diameter 2x under
the contact zone.
y If at any moment of time, there are an average n of grits
and the tool is vibrating at a frequency f
f then material
removal rate can be expressed as
P
P
t
ProcessParameters
y MRRw
EffectofmachiningparametersonMRR
2
( w db )3/2 nf
3
Ult
i M hi
UltrasonicMachine
Feedforce(F)
Amplitudeofvibration(ao)
averagegritdiameter,dg
Frequencyofvibration(f)
Page 162 of 240
Volumeconcentrationofabrasive
inwaterslurry C
Rev.0
Ult
i M hi
UltrasonicMachine
Ult
i M hi
UltrasonicMachine
y The basic mechanical structure of an USM is very similar
y Feed mechanism to provide a downward feed force on
to a drill press.
SubsystemsofUSM
Subsystemsof
USM
the tool during machining
y It has additional features to carry out USM of brittle
y The transducer,
transducer which generates the ultrasonic vibration
work material.
y The
Th workpiece
k i
i mounted
is
t d on a vice,
i
which
hi h can be
b
located at the desired position under the tool using a 2
axis
i table.
t bl
y The table can further be lowered or raised to
accommodate work of different thickness.
y Slurry
y deliveryy and return system
y
y The horn or concentrator, which mechanically amplifies
T
d
Transducer
GATE2010(PI)
y The
ultrasonic vibrations are produced by the

transducer. The transducer is driven by suitable signal
generator followed by power amplifier. The transducer
for USM works on the following principle
Piezoelectric effect
Magnetostrictive effect
Electrostrictive effect
y Magnetostrictive
g
transducers are most p
popular
p
and
robust amongst all.
the vibration
th
ib ti to
t the
th required
i d amplitude
lit d off 15 50 m and
d
accommodates the tool at its tip.
Ultrasonic
used
l
i machines,
hi
d in
i material
i l removall processes,
q
ultrasonic transducers. The transducers works on
require
different working principles. One of the working principles
of such ultrasonic transducers is based on
(a) eddy current effect
(b) Seebeck effect
(c) p
piezoresistive effect
(d) p
piezoelectric effect
T l h ld
H
ToolholderorHorn
y Its
is
the
amplitude
It function
f
ti
i to
t increase
i
th tool
t l vibration
ib ti
lit d
and to match the vibrator to the acoustic load.

y It must be constructed of a material with good acoustic
properties and be highly resistant to fatigue cracking.

y Monel and titanium have good acoustic properties and
are often used together with stainless steel,

steel which is
cheaper.
Limitations
T l
Tool
y Tools
relatively
T l should
h ld be
b constructed
t t d from
f
l ti l ductile
d til
materials.
y LowMRR
y Used for machining hard and brittle metallic alloys,
y Ratherhightoolwear
semiconductors, glass, ceramics, carbides etc.

y Used for machining round,
round square,
square irregular shaped
holes and surface impressions.
y Machining,
M hi i
wire
i drawing,
d
i
punching
hi
or small
ll blanking
bl ki
dies.
y Lowdepthofhole
L d th fh l
y The harder the tool material, the faster its wear rate will
be.
A li ti
Applications
Page 163 of 240
Rev.0
Note
y The following material is generally machined by USM
(i)
Glass
(ii)
Sili
Silicon
(iii)
Germanium
y Tool in USM is generally made of Steel
GATE 1993
GATE
In ultrasonic machining process, the material
removal rate will be higher for materials with
(a) Higher toughness
(b) Higher ductility
(c) Lower toughness
(d) Higher fracture strain
IES 2006
IES
During ultrasonic machining, the metal removal is
achieved by
(a) High frequency eddy currents
(b) high frequency sound waves
(c) Hammering action of abrasive particles
((d)) Rubbing
g action between tool and workpiece
p
GATE 1994
GATE
Ultrasonic machining is about the best process for
making holes in glass which are comparable in size
with the thickness of the sheet.
The above statement is
( ) True
(a)
T
(b) False
(c) Cant say
(d) Insufficient data
IES2011
USM has good machining performance for :
(a) Al
(b) Steel
((c)) Super
p alloys
y
(d) Refractory material
GATE 1992
1992
GATE
In Ultrasonic Machining (USM) the material
removal rate would
(a) Increase
(b) Decrease
(c) Increase and then decrease
((d)) decrease and then increase
with increasing mean grain diameter of the abrasive
material.
IES 2009
IES
By which one of the following processes the
metering holes in injector nozzles of diesel engines
can be suitably made?
(a) Ultrasonic machining
(b) Abrasive
Ab i jet
j t machining
hi i
(c) Electron beam machining
(d) Chemical machining
Chemical Machining
ChemicalMachining
IAS 1996
IAS
During ultrasonic machining, the metal removal is
affected by the
(a) Hammering action of abrasive particles
(b) Rubbing action between tool and workpiece
(c) High frequency sound waves
((d)) High
g frequency
q
y eddyy currents
y Chemicals
Ch i l are used
d to
t dissolve
di l material
t i l
y Masks are used to control attack
y Most common use is circuit boards and p
plates for
printing.
y Cutting speed of 0.00250.1 mm/minute very slow
Page 164 of 240
Rev.0
Chemical Machining
ChemicalMachining
Photo Chemical Machining

PhotoChemicalMachining
Photo Chemical Machining

PhotoChemicalMachining
y PCM is a material removal process using chemicals
(etchants) to produce high precision parts.

y This process is also known as Photo Etching,
Etching Chemical
Blanking and Photo Chemical Milling.

b th sides
both
id
off the
th plate
l t with
ith photoresist.
h t
i t
(photoresist is a polymer that adheres to the metal when
exposed
d to
t UV light).
li ht)
y Spray metal with etchant or dip it in hot acidic solution
t etch
to
t h all
ll material
t i l other
th than
th
partt covered
d with
ith
photoresist (115 min.).
y Rinse
Ri
th plate
the
l t to
t ensure photoresist
h t
i t and
d etchant
t h t
removal.
y Coat
C t
L
B
M hi i
LaserBeamMachining
L
B
M hi i
LaserBeamMachining
y Direct laser beam against surface of workpiece, as in
LaserBeamMachining
y Produceslargeremelt zone
laser welding
y Canproduceholesassmallas0.0005mmdiameter
C d h l
ll
di
y Successive pulses from laser gun vaporize tiny bits of
y Canproducedeepholes
workpiece
k i
y Usedtoproducecoolingholesinblades/vanesforjet
y Location of laser beam controlled by computer
engines
y Workpiece
p
need not be conductive
y Cuts are tapered
y Gotta trap overshoot from laser beam
310
l
h
ElectronBeamMachining
311
ElectronBeamMachining
IFS2011
y Workpiece placed in vacuum

acuum chamber
y Highvoltage
g
g
electron
beam
directed
312
Writetheadvantages,limitationsandapplicationsof
toward
electronbeammachining.Whatisthesafetyproblem
workpiece
connectedwithEBM?
t d ithEBM?
y Energy of electron beam melts/ vaporizes selected
[5 Marks]
[5Marks]
region of workpiece
y Electron beam moved by
y deflection coils
y Similar process to EB welding
313
Page 165 of 240
314
Rev.0
l
PlasmaArcCutting
h
WaterJetMachining
WaterJetMachining
y Plasma is a stream of ionized gas
y Narrowjetofwaterdirected,athighpressureand
j f
di
d hi h
d
y Typical temperatures are very high
velocity,againstsurfaceofworkpiece
y, g
p
y Same process as plasma welding, without filler metal
y Jetofwatererodessurfaceofworkpiece,thereby
y Torch movement controlled by computer
cuttingworkpiece
y Power requirements depend on material being cut,

cut
y Computercontroltoachieveshape
C
t
t lt hi h
plus depth of cut

y Recast layer is deeper than with other processes
316
317
Abrasive Jet Machining (Dry)

AbrasiveJetMachining(Dry)
GATE 2013 (PI)

GATE2013(PI)
y It is similar to sand blasting, except that a very narrow jet of

y
y
y
y
y
y
y
y
y
g
g
gas and abrasive p
particles achieves localized cutting.
It removes material through the eroding action of a high
velocity stream of abrasiveladen gas.
The gas is first compressed and mixed with the abrasive
powder in a mixing chamber and passed through outlet
nozzle.
l
Computer is used to position the jet.
G Pressure
Gas
P
about
b t 7 atm
t
Velocity of jet about 300 m/s
Jet Diameter 0.12
0 12 mm to 1.25
1 25 mm
Abrasive used: Al2O3 , SiC with particle size 10 to 50 m
Tool (nozzle) material tungsten carbide or sapphire
Tool(nozzle)Life about30hours
318
AbrasiveJetMachining
In
jet
the
jet
I water
t
j t machining,
hi i
th water
t
j t is
i issued
i
d
through
g a 0.33 mm diameter orifice at a p
pressure of
400 MPa. The density of water is 1000 kg/m3. The
coefficient of discharge is 1.0. Neglecting all losses
d i
during
water
t jet
j t formation
f
ti
th
through
h the
th orifice,
ifi
th
the
power of the water jjet in KW is
p
(a) 25.3
(b) 50.6
(c) 75.9
(d) 101.2
319
AdvantagesofAJM
y Can be used in any material, conductive, non
conductive ductile or brittle

conductive,
y Good dimensional accuracy (0.05 mm)
y Good Surface finish 0.25 to 1.25 m
321
DisadvantagesofAJM
y Cutting and drilling on metal foils and thin
y LowMRR
y Possibilityofstraycutting
P ibilit f t tti
y Embeddingofabrasiveparticlesinsoftworkpiece
y Dustcontrolneeded
y Due to cooling action of gas stream no thermal damage
sections of ceramics and glass

y Intricate holes in electronic components such as
resistor paths in insulation

y Engraving of characters on toughened glass
automobile windows
on the work surface
y Cleaning, polishing and deburring the surface
y Due to negligible
g g
force delicate workpiece
p
can be
machined. For-2015 (IES, GATE & PSUs)
ApplicationofAJM
Page 166 of 240
Rev.0
Q
( )
In abrasive jet machining, as the distance between
th nozzle
the
l tip
ti and
d the
th work
k surface
f
i
increases,
th
the
material removal rate
( ) increases continuously.
(a)
l
(b) decreases continuously.
(c) decreases, becomes stable and then increases.
(d) increases,
increases becomes stable and then decreases.
decreases
GATE2014(PI)
A hard
h d ceramic
i marble,
bl having
h i density
d it ()
( ) off 3000 kg/m
k / 3
and diameter (d) of 0.025 m, is dropped accidentally
f
from
a static
t ti weather
th balloon
b ll
att a height
h i ht off 1 km
k above
b
the roof of a greenhouse. The flow stress of roof material
( ) is
()
i 2.5 GPa.
GP
Th marble
The
bl hits
hit and
d creates
t
an
indentation on the roof. Assume that the principle of
creation
ti
off indentation
i d t ti
i the
is
th same as that
th t in
i case off
abrasive jet machining (AJM). The acceleration due to
gravity
it (g)
( ) is
i 10 m/s
/ 2. If V is
i the
th velocity,
l it in
i m/s,
/ off the
th
marble at the time it hits the greenhouse, the
indentation
d
d h = 1000 d V , in mm, is.........
depth
y Used to cut much harder materials
Whatarethedisadvantagesofabrasivejetmachining?
y Water is not used directly to cut material as in Pure,
instead water is used to accelerate abrasive particles which
Writesomeofitsapplications.
[5Marks]
g
do the cutting
y 80mesh garnet (sandpaper) is typically used though 50
and
d 120mesh
h is also
l used
d
y Standoff distance between mixing
g tube and workpart
p
is
typically 0.0100.200 important to keep to a minimum to

keep a good surface finish
GATE 1992
GATE
g components
p
pp p
Match the following
with the appropriate
machining processes:
p
Process
Component
(A) Square hole in a high strength alloy
(1)
Milling
((B)) Square
q
hole in a ceramic component
p
((2))
Drilling
g
(C) Blind holes in a die
(3)
ECM
((D)) Turbine blade p
profile on high
g strength
g alloy(4)
y(4) JJig
g boring
g
(5)
EDM
(6)
USM
Codes:A
B
C
D
A
B
C
D
(a) 4
1
2
3
(b)
5
6
1
3
(c) 4
2 For-2015
1
3
(d) &3 PSUs)
1
2
4
(IES,
GATE
GATE 2011
GATE2011
Match the following non traditional machining

processes with the corresponding material removal
mechanism:
Machiningprocess
gp
Mechanismofmaterialremoval
f
P.Chemicalmachining
1.Erosion
Q.Electro
Q
Electro chemical
machining
R Electro discharge
R.Electro
machining
2 Corrosivereaction
2.Corrosivereaction
S.Ultrasonicmachining
4.Fusionandvaporization
3 Iondisplacement
3.Iondisplacement
(a)P 2,Q 33,R 4,S 1(b)P 2,Q 4,R 33,S 1

(c)P 3,Q 2,R 4,S 1(d)P 2,Q 3,R 1,S 4
Page 167 of 240
Statethemechanismofcuttingbyabrasivejet.
Whataretheadvantagesanddisadvantagesof
AJM?Mentiontwoapplications.
[
[10Marks]
]
b
AbrasiveWJCutting
IFS2011
IAS2011Main
AbrasiveWJCutting
y Evolution
of mixing tube
technology
y Standard Tungsten Carbide
lasts 46
4 6 hours (not used much
anymore)
y Premium Composite Carbide
lasts 100150 hours
y Consumables
C
bl
i l d
include
water,
t
abrasive, orifice and mixing
tube
GATE 2007
GATE
gp
Matchthemostsuitablemanufacturingprocessesfor
thefollowingparts.
g
Parts
ManufacturingProcesses
P. Computerchip 1.
Q Metalformingdiesandmoulds
Q.
2.
UltrasonicMachining
R Turbineblade
R.
3
3.
Electro discharge
Electrodischarge
Machining
S Glass
S.
4
4.
PhotochemicalMachining
Codes:P Q
R
S
P
Q
R
S
( ) 4
(a)
3
1
2
(b) 4
3
2
1
(c) 3
1
4
2
(d) 1 Rev.0
2
4
3
GATE 1998
1998
GATE
IES 2008
IES
IES 1998,ISRO2009
1998 ISRO 2009
IES
Match List
II and select the correct answer
ListII with List
ListII
using the code given below the lists:
ListII
List
ListII
List
II
(Unconventional machining process) (Basic process)
A Electro polishing
A.
1
1.
Thermal
B. Electrochemical machining
2.
Mechanical
C Abrasive
C.
Ab i jet
j machining
hi i
3.
El
Electrochemical
h i l
D. Electrical discharge machining 4.
Chemical
Code:A
B
C
D
A
B
C
D
(a) 4
3
2
1
(b) 2
1
4
3
(c) 4
1
2
3
(d) 2
3
4
1
Match List
II
ListII (Machining process) with List
ListII
(Associated medium) and select the correct answer
ListI
ListII
A Ultrasonic
A.
Ult
i machining
hi i
1.
K
Kerosene
B. EDM
2.
Abrasive slurry
C. ECM
3.
Vacuum
D. EBM
4.
Salt solution
Code:A
B
C
D
A
B
C
D
( ) 2
(a)
3
4
1
(b) 2
1
4
3
(c) 4
1
2
3
(d) 4
3
2
1
IES 2005
2005
IES
IES 2003
IES
IES 2003
IES
g Process)) with List II

Match List I ((Machining
(Application) and select the correct answer using the
code given below the Lists:
List I
List II
A. EDM 1.
Holes & cavities in hard & brittle materials
B LBM 2.
B.
2
Microdrilling
Micro
drilling & micro
microwelding
welding of
materials
C. USM 3.
Shaping of hard metals or reshaping of
cemented
d carbide
bid tools
l
D. ECM 4.
Shaping of cemented carbide dies and
punches
Codes:A
B
C
D
A
B
C
D
(a) 4
1
2
3
(b) 3
2
1
4
(c) 4
2
1
3
(d) 3
1
2
4
(
) with List II ((Machining)
g) and
Match List I (Materials)
select the correct answer using the codes given below
the Lists:
List I
List II
(Materials)
(Machining)
A. Machining of conducting materials
1.
ECM
B. Ruby rod
2.
EDM
C. Electrolyte
3.
USM
D. Abrasive slurry
4.
LBM
Codes:A
B
C
D
A
B
C
D
(a) 4
2
1
3
(b) 4
2
3
1
(c) 2
4
3
1
(d) 2
4
1
3
IAS 2002
IAS
IAS 1999
IAS
IES 2004
IES
Match List I (Unconventional machining process) with

List II (Typical application) and select the correct
answer using
g the codes g
List I
List II
A Electro discharge machining 1.
A.
1 Drilling micro holes in
very hard metals
B Electro chemical machining 2.
B.
2 Drilling holes in glass
C. Ultrasonic machining
3.
Die sinking
D Laser beam machining 4.
D.
4
Machining contours
Codes:A
B
C
D
A
B
C
D
( ) 4
(a)
2
3
1
( ) 3
(b)
4
1
2
Page 168 of 240
(c) 4
3
2
1
(d) 3
4
2
1
(
g p
Match List I (Machining
processes)) with List II
(Operating media) and select the correct answer using
the codes given below the Lists:
List I
List II
A. Abrasive jet machining
1.
Dielectric
B. Electron beam machining
2.
Electrolyte
C. Electrochemical machining
3.
Abrasive slurry
D. Electrodischarge machining 4.
Vacuum
5.
Air
Codes:A
B
C
D
A
B
C
D
(a) 5
4
2
1
(b) 4
5
2
1
(c) 4
2
3
5
(d) 2
5
3
4
Rev.0
List I
(A) ECM
(B) EDM
(C) USM
(D) LBM
Codes:A
C
d A
(a) 4
(c) 4
B
1
2
(1)
( )
(2)
(3)
(4)
(5)
(6)
C
2
1
List II
Plastic shear
E i /B ittl fracture
Erosion/Brittle
f t
Corrosive reaction
Melting and vaporization
Ion displacement
Plastic shear and ion displacement
D
A
B
C
D
3
(b) 5
4
2
4
3
(d) 3
1
2
4
Which one of the following pairs is NOT correctly

matched?
(Unconventional
(Application)
machining method)
(a) Electric discharge : Machining of electrically
conductive materials
(b) Laser beam
: Micromachining
(c) Plasma arc
: Faster cutting of hard materials
(d) Electron beam : Faster metal removal rate
) Water jet
j
g uses high
g
Assertion ((A):
machining
pressure and high velocity water stream which acts
like a saw and cuts a narrow groove in the material.
Reason (R): The force required for cutting is
generated from sudden change in the momentum
of the water stream.
IES 1999
IES
Match ListI with ListII and select the correct answer
using the codes given below the Lists:
ListI
ListII
A. Die sinking
1. Abrasive jet machining
g
2. Laser beam machining
g
B. Debarring
C. Fine hole drilling (thin materials) 3. EDM
D. Cutting/sharpening
g
p
g hard materials
4. Ultrasonic machining
55. Electrochemical g
grinding
g
Code:A
B
C
D
A
B
C
D
((a)) 3
5
4
1
((b)) 2
4
1
3
(c) 3
1
2
5
(d) 4
5
1
3
GATE 2004
GATE
yp
g operations
p
Typical
machining
are to be p
performed on hard
tomachine materials by using the processes listed below.
Choose the best set of OperationProcess combinations
O
Operation
ti
P
Process
P. Debarring (internal surface) 1.
Plasma Arc Machining
Q Die sinking
Q.
2
2.
Abrasive Flow Machining
R. Fine hole drilling in thin sheets 3. Electric Discharge
Machining
g
S. Tool sharpening
4.
Ultrasonic Machining
5.
Laser beam Machining
g
6.
Electrochemical Grinding
(a) P1 Q5 R3 S4
(b)
P1 Q4 R1 S2
(c) P5 Q1 R2 S6
(d)
P2 Q3 R5 S6
Page 169 of 240
Rev.0
C t l St t
f
t i l
CrystalStructureofmaterials
y FCC: Ni,Cu,Ag,Pt,Au,Pb,Al(soft)
y BCC: V,Mo,Ta,W(hardmaterial)
y HCP: Mg,Zn
g
y CobaltHCP<4200C,FCC>4200C
oC
y ChromiumHCP<20oC,BCC>20
,
GATE 2011
GATE2011
Thecrystalstructureofausteniteis
(a)bodycenteredcubic
(b)facecenteredcubic
(c)hexagonalclosedpacked
( )
(d)bodycenteredtetragonal
y
g
y Glass Amorphous
y BCC
BCCFerriteor
Ferriteor iron
ironferriteoriron
& ferriteor iron
y FCC Austeniteoriron
IES 2011
IES2011
ListI
ListII
A.Alphairon
p
1.FCC
B.Zinc
2.BCC
C Glass
C.Glass
3 HCP
3.HCP
D.Copper
4.Amorphous
Codes
A
(a) 1
(c) 1
B
4
3
C
3
4
D
2
2
(b)
(d)
A
2
2
B
4
3
C
3
4
D
1
1
IES2003
MatchList
I(CrystalStructure)withList II(Example)and
MatchListI(CrystalStructure)withListII(Example)and
selectthecorrectanswerusingthecodesgivenbelowthe
Lists:
ListII
List
ListII
List
II
(CrystalStructure)
(Example)
A. SimpleCubic
1.Zinc
B
B.
B d
BodycenteredCubic
t dC bi
2.Copper
C
C. FacecenteredCubic
3.Alphaironatroom
temperature
D HexagonalClosePacked
D.
H
lCl P k d
4.Manganese
M
Codes:A
B
C
D
A
B
C
D
((a)
) 4
3
1
2
((b)
)
4
3
2
1
(c) 3
4
2
1
(d) 3
4
1
2
IES2001
IES2006
MatchListI(NameoftheElement)withListII
(CrystalStructure)andselectthecorrectanswerusing
thecodesgivenbelowthelists:
ListI
ListII
A. Fluorspar
1.Bodycenteredcubic
p
2.Hexagonalclosedpacked
g
p
B. AlphaIron
C. Silver
3.Simplecubic
D. Zinc
4.Facecenteredcubic
Codes A
Codes:A
B
C
D
A
B
C
D
(a) 3
2
4
1
(b) 4
1
3
2
((c)
) 4
4
2
33
1
((d)
) 33
1
4
4
2
MatchListI(Element)withListII(CrystalStructure)
andselectthecorrectanswerusingthecodegiven
belowtheLists:
List I
List
List II
List
A. AlphaIron
1.Hexagonalclosedpacked
pp
2.Bodycentredcubic
y
B. Copper
C. Zinc
3.Amorphous
D. Glass
4.Facecentredcubic
Codes A
Codes:A
B
C
D
A
B
C
D
(a) 2
3
1
4
(b) 1
4
2
3
((c)
) 2
4
4
1
33
((d)
) 1
33
2
4
Page 170 of 240
IES 1998
IES1998
usingthecodesgivenbelowthelists:
h
d
b l
h l
ListI
ListII
(Material)
(Structure)
A. Charcoal
1.
F.C.C
B. Graphite
2.
H.C.P
C. Chromium
3.
Amorphous
D. Copper
4.
B.C.C
Code:A
B
C
D
A
B
C
D
(a) 3
2
1
4
(b) 3
2
4
1
( ) 2
(c)
3
4
1
( ) 2
(d)
3
1
4
Pl ti d f
ti
Plasticdeformation
Following the elastic deformation, material undergoes
plastic deformation.
y Also characterized by relation between stress and
strain at constant strain rate and
d temperature.
y Microscopically, it involves breaking atomic bonds,
moving
i atoms, then
h restoration
i off bonds.
b d
y StressStrain relation here is complex because of
atomic
t i plane
l
movement,
t dislocation
di l ti
movement,
t and
d
the obstacles they encounter.
y Crystalline solids deform by processes slip and
twinning in particular directions.
Contd
Rev.0
y Amorphous solids deform by viscous flow mechanism
without any directionality.

y Because of the complexity involved, theory of plasticity
neglects the following effects:

y Anelastic strain, which is time dependent
recoverable strain.
y Hysteresis behavior resulting from loading and
unloading of material.
y Bauschinger
B
hi
effect
ff
dependence
d
d
off yield
i ld stress on
loading path and direction.
y Equations
E
ti
relating
l ti
stress
t
and
d strain
t i are called
ll d
constitutive equations.
y A true stressstrain curve is called flow curve as it gives
the stress required to cause the material to flow

plastically
l i ll to certain
i strain.
i
y Because of the complexity involved, there have been
many stressstrain relations proposed.
proposed
Slip
y Slip is the prominent mechanism of plastic deformation in
metals.
y It involves sliding of blocks of crystal over one other along
definite crystallographic planes, called slip planes.

y In physical words it is analogous to a deck of cards when it
is pushed from one end.

= fn( ,
, T,
T microstructure)
= K n
= K
.m
= K( 0 + )n
= 0 + K n
Strain hardening exponent, n = 0.1 - 0.5

Strain - rate sensitivity,
sensitivity m = 0
0.4
4-0
0.9
9
Strain from previous work - 0
Yield strength - 0
y Slip occurs when shear stress applied exceeds a critical
value.
y During slip each atom usually moves same integral
number
b off atomic distances
d
along
l
the
h slip
l plane
l
producing
d
a step, but the orientation of the crystal remains the same.
y Steps observable under microscope as straight lines are
called slip lines.
Contd
Twinning
y The second important mechanism of plastic deformation
y
is twinning.
It results when a portion of crystal takes up an orientation
that is related to the orientation of the rest of the untwined
l tti in
lattice
i a definite,
d fi it symmetrical
t i l way.
The twinned portion of the crystal is a mirror image of the
parent crystal.
p
y
The p
plane of symmetry
y
y is called twinning
g
plane.
Each atom in the twinned region moves by a homogeneous
shear
h
a distance
di t
proportional
ti
l to
t its
it distance
di t
f
from
th twin
the
t i
plane.
The lattice strains involved in twinning
g are small,, usuallyy
in order of fraction of interatomic distance, thus resulting
in very small gross plastic deformation.
y The important role of twinning in plastic deformation is
y
y
y
that it causes changes in plane orientation so that further

slip can occur.
Twinning generally occurs when slip is restricted, because
the stress necessary for twinning is usually higher than that
for slip.
Thus some HCP metals with limited number of slip
Thus,
systems may preferably twin.
Also, BCC metals twin at low temperatures
p
because slip
p is
difficult.
Of course, twinning and slip may occur sequentially or
even concurrently
l in
i some cases.
IES2007
Whatisthemovementofblockofatomsalong
Wh ti th
t fbl k f t
l
certaincrystallographicplanesanddirections,
termedas?
(a) Glide
(b) Twinning
(c) Slip
(d) Jog
Contd
IES2005
TheB.C.C.andH.C.P.metalsundergoplastic
Th B C C dH C P t l d
l ti
deformationby:
(a) Slip
(b) Twinning
( ) Edgedislocation
(c)
Ed di l ti
(d) Twinningincombinationwithslip
IES1998
Assertion(A):Plasticdeformationinmetalsand
alloysisapermanentdeformationunderload.This
propertyisusefulinobtainingproductsbycold
rolling.
rolling
Reason(R):Plasticorpermanentdeformationin
metaloralloyiscausedbymovementordislocations.
( ) BothAandRareindividuallytrueandRisthecorrect
(a)
B thA dR i di id ll t dRi th
t
explanationofA
(b) BothAandRareindividuallytruebutRisnotthe
l
f
Page 171 of 240
At i St t
AtomicStructure
y Atoms consist of a relatively dense nucleus composed of
positively charged protons and neutral particles of nearly

identical mass, known as neutrons.
y Surrounding the nucleus are the negatively charged
electrons which have only 1/1839 times the mass of a
electrons,
neutron and appear in numbers equal to the protons, to
maintain a net charge balance.
y The
Th light
li h electrons
l
that
h surround
d the
h nucleus
l
play
l a far
f
more significant role in determining material properties.
y Again,
g
experiments
p
reveal that the electrons are arranged
g
in a characteristic structure consisting of shells and
subshells, each possessing a distinctive energy. Upon
absorbing a small amount of energy, an electron can jump
to a higherenergy
hi h
shell
h ll farther
f h from
f
the
h nucleus.
l
Rev.0
Contd
At i B d
AtomicBonds
y The reverse jump can also occur with the concurrent
release of a distinct amount, or quantum, of energy.

y The number of electrons surrounding the nucleus of a
neutral atom is called the atomic number.
y More
M
i
important,
h
however,
are those
h
electrons
l
i the
in
h
outermost shell or subshell, known as valence
electrons.
electrons
y These are influential in determining chemical
properties electrical conductivity,
properties,
conductivity some mechanical
properties, the nature of interatomic bonding, atom
size, and optical
p
characteristics.
y A third type of primary bond can form when a complete outer
y General characteristics of materials joined by ionic bonds

y
y
y
y
include moderate to high strength,

strength high hardness,
hardness brittleness,
brittleness
high melting point, and low electrical conductivity.
A second type of primary bond is the covalent type.
Like the ionic bond,
bond the covalent bond tends to produce
materials with high strength and high melting point.
Atom movement within the framework material (plastic
deformation) requires the breaking of discrete bonds,
bonds thereby
making the material characteristically brittle.
Electrical conductivity depends on bond strength, ranging from
conductive
tin
(weak
covalent
bonding)
bonding),
through
semiconducting silicon and germanium, to insulating diamond
(carbon).
Engineering materials possessing ionic or covalent bonds tend
to be ceramic (refractories or abrasives) or polymeric in nature.
y
y
shell cannot be formed by either electron transfer or electron

sharing.
sharing This bond is known as the metallic bond.
bond
If there are only a few valence electrons (one, two, or three) in
each of the atoms in an aggregate, these electrons can easily be
removed while the remainder are held firmly to the nucleus.
These highlymobile,"free" electrons account for the high
electrical and thermal conductivity values as well as the opaque
property (free electrons can absorb the discrete energies of light
radiation) observed in metals.
Moreover, they provide the "cement" required for the positive
negativepositive attractions that result in bonding.
Bond strength,
strength and therefore material strength,
strength varies over a
wide range.
Contd
y More significant, however, is the observation that the
p
positive ions can move within the structure without
the breaking of discrete bonds. Materials bonded by
metallic bonds can therefore be deformed by atom
movement mechanisms and produce a deformed
material that is every bit as strong as the original.
y This
h phenomenon
h
is the
h basis
b
off metall plasticity,
l
ductility, and many of the shaping processes used in
the fabrication of metal products.
products
IES 2011
IES2011
Solid material chemical bonds are :
(a) Ionic, molecular and fusion
(b) Covalent, fusion and fission
(c) Ionic, covalent and molecular
((d)) Fission,, molecular and ionic
IES2008
Contd
IES2003
Assertion(A):Elementsareclassifiedintometalsand
nonmetalsonthebasisoftheiratomicweights.
Reason(R):Thevalenceelectronstructures
contributetotheprimarybondingbetweentheatoms
toformaggregates.
(a) BothAandRaretrueandRisthecorrectexplanation
ofA
(b) BothAandRaretruebutRisNOTthecorrect
explanationofA
Ai f l b tRi t
Assertion(A):Unlikeinthecaseofionicbonds,the
Assertion(A):Unlikeinthecaseofionicbonds the
coordinationnumbersforcovalentlybondedatoms
arenotcontrolledbytheradiiratio.
Reason(R):Acovalentbondhasaspecificdirectionof
bondinginspace.
explanationofA
Ai f l b tRi t
D l
f
i
Developmentofagrainstructure
y The small, continuous volumes of solid are known as
y When a metal solidifies, a small particle of solid forms
cristals or grains, and the surfaces that divide them

(i.e.,
the
off crystalline
discontinuity)
(i
th surfaces
f
t lli
di
ti it ) are
known as grain boundaries.
y The process by which a grain structure is produced
Upon solidification is one of nucleation and growth.
y Grains are the smallest of the structural units in a
metal that are observable with ordinary light
microscopy.
py
y The atoms in the grain boundaries are more loosely
bonded and tend to react with the chemical more
readily than those that are part of the grain interior.
from
the
characteristic
f
th liquid
li id with
ith a lattice
l tti structure
t t
h
t i ti off the
th
given material.
y This p
particle then acts like a seed or nucleus and g
grows as
other atoms in the vicinity attach themselves. The basic
crystalline unit is repeated throughout space.
y In actual solidification,
solidification many nuclei form independently at
various locations throughout the liquid and have random
orientations with respect to one another. Each then grows
untill it begins
b
to interfere
f
with
h its neighbours.
hb
y Since adjacent lattice structures have different alignments
or orientations,
orientations growth cannot produce a single continuous
structure.
Page 172 of 240
Contd
Rev.0
Contd
Th number
b and
d size
i off the
h grains
i in
i a metall vary with
i h the
h
y The
rate of nucleation and the rate of growth.

g
y The g
greater the nucleation rate,, the smaller the resulting
grains. Conversely, the greater the rate of growth, the larger
the grain.
y Because the resulting grain structure will influence certain
mechanical and physical properties, it is an important
property for an engineer to both control and specify. One
p
is through
g the ASTM ((American
means of specification
Society for Testing and Materials) grain size number,
defined as:
Fracture of metals
Fractureofmetals
IES2002
y If the plastic deformation of a metal is extended too far, the
Chemicalsattackatomswithingrainboundaries
Ch i l tt k t
ithi i b
d i
preferentiallybecausetheyhave
(a) Lowerenergythanthoseinthegrains
(b) Higherenergythanthoseinthegrains
( ) Highernumberofatomsthaninthegrains
(c)
Hi h
b f t
th i th i
(d) Lowernumberofatomsthaninthegrains
where N is the number of grains per square inch

visible in a prepared specimen at lOOX and n is the ASTM
grainsize number.
number Low ASTM numbers mean a few
massive grains;high numbers refer to materials with many
small grains.
GATE2010
Thematerialpropertywhichdependsonlyonthe
Th t i l
t hi hd
d l th
basiccrystalstructureis
(a) Fatiguestrength
(b) Workhardening
(c) Fracturestrength
(d)
Elasticconstant
IES1992
Whichofthefollowingstatementistrueabout
Whi h fth f ll i t t
ti t
b t
brittlefracture?
(a) Hightemperatureandlowstrainratesfavour
brittlefracture
(b) ManymetalwithHCPcrystalstructurecommonly
showbrittlefracture
(c) Brittlefractureisalwaysprecededbynoise
(d) Cupandconeformationischaracteristicforbrittle
materials
metal mayy ultimatelyy fracture.
y These types of fractures are known as ductile fractures,
noting that the initial response to the applied load was one
plastic deformation.
of p
y Another possibility, however, is where fracture precedes
plastic deformation, occuring in a sudden, catastrophic
manner and propagating rapidly through the material.
manner,
material
These fractures, known as, brittle fractures, are most
common with metals having the bcc or hcp crystal
structures.
y Whether the fracture is ductile or brittle, however, often
depends on the specific conditions of material,
temperature state of stress,
temperature,state
stress and rate of loading.
loading
y Fracture strength depends only on the basic crystal
structure .
Cold working recrystallization and

and
Coldworking,recrystallization
hotworking
y Duringdeformation,aportionofthedeformationenergy
becomesstoredwithinthematerialintheformofadditional
dislocationsandincreasedgrainboundarysurfacearea.Ifa
deformedpolycrystallinemetalissubsequentlyheatedtoa
high enoughtemperature,thematerialwillseektolowerits
highenoughtemperature,thematerialwillseektolowerits
energy.New,equiaxed (sphericalshaped)crystalswillnucleate
andgrowoutoftheoriginalstructure.Thisprocessofreducing
theinternalenergythroughtheformationofnewcrystalsis
knownasrecrysrallization.
y The temperatureatwhichrecrystallization
p
y
takesplaceis
p
differentforeachmetalandalsovarieswiththeamountofprior
deformation.
Contd
y The greater the amount of prior deformation, the more
g and the lower the recrystallization

stored energy,
temperature. However, there is a lower limit below
which recrystallization will not take place in a
reasonable
bl amount off time.
i
y This temperature can often be estimated by taking 0.4
ti
times
th melting
the
lti point
i t off the
th metal
t l when
h the
th melting
lti
point is expressed in an absolute temperature scale.
y This is also the temperature at which atomic diffusion
(atom movement within the solid) becomes
significant, indicating that diffusion is an important
mechanism in recrystallization.
Contd
y When metals are plastically deformed below their
recrystallization temperature, the process is called

cold working.
working
y The metal strain hardens and the structure consists of
distorted grains. If the deformation is continued, the
metal may fracture. Therefore, we find it common
practice to recrystallize material after certain amounts
off cold
ld work.
k
y Ductility is restored, and the material is ready for
further deformation.
deformation
y The heating process is known as a recrystallization
anneal and enables deformation to be carried out to
great lengths without the danger of fracture.
Page 173 of 240
Contd
y Ifmetalsaredeformedattemperaturessufficiently
abovetherecrystallization,theprocessisknownas
hotworking.
y Deformationandrecrystallization cantakeplace
simultaneously,and
i l
l
d largedeformationsarepossible.
l
d f
i

ibl
y Sincearecrystallized grainstructureisconstantly
f
forming,thefinalproductwillnotexhibitstrain
i th fi l d t ill t hibit t i
hardening.
Rev.0
Contd
Plastic deformation in
Plasticdeformationin
polycrystallinemetals
y Slip in polycrystalline material involves generation,
y Gross plastic deformation of a polycrystalline specimen

Fig.Recrystallization
of7030brass:
(a)coldworked33%;
33
(b)heatedat580C
(1075F)for3seconds,
(c)4seconds,and
( )
(d)8seconds
corresponds to the comparable distortion of the individual

grains by means of slip.
slip Although some grains may be oriented
favourably for slip, yielding cannot occur unless the
unfavourably oriented neighbouring grains can also slip.
y Thus in a polycrystalline aggregate, individual grains provide a
mutual geometrical constraint on one other, and this precludes
plastic deformation at low applied stresses.
stresses
y That is to initiate plastic deformation, polycrystalline metals
require higher stresses than for equivalent single crystals, where
stress depends on orientation of the crystal.
y Much of this increase is attributed to geometrical reasons.
g
movement and (re)arrangement
of dislocations.
y The second important mechanism of plastic
deformation is twinning. It results when a portion of
crystal takes up an orientation that is related to the
orientation of the rest of the untwined lattice in a
d fi it symmetrical
definite,
t i l way.
y The twinned portion of the crystal is a mirror image of
the parent crystal.
crystal The plane of symmetry is called
twinning plane.
Contd
Crystalline material and Crystal

CrystallinematerialandCrystal
Structures
Stable crystal structure satisfies
y The crystals are electrically neutral.
y The
Th ionion
i i repulsion
l i is
i minimized.
i i i d
y The ions or atoms in crystals
y
are p
packed as closelyy as
possible under the constrains of specific bonding.

y The free energy of the system becomes minimum
U i ll
Unitcell
Itischaracterizedby:
Mostcommonunitcells Facecenteredcubic,
g
BodycenteredcubicandHexagonal.
y Typeofatomandtheirradii,R
y Celldimensions(Latticespacinga,bandc)intermsof
Celldimensions(Latticespacinga bandc)intermsof
Randanglebetweentheaxis
ya
a*,b*,c*
,b ,c latticedistancesinreciprocallattice,
latticedistancesinreciprocallattice,*,*,
, ,
* anglesinreciprocallattice
y Numberofatomsperunitcell,n
p
,
y Coordinationnumber(CN) closestneighborstoan
atom
y Atomicpackingfactor,APF
Contd
Page 174 of 240
C
lS
CrystalStructures
/
,
y All solid materials are made of atoms/molecules,
which are arranged in specific order in some materials,
called crystalline solids. Otherwise noncrystalline or
amorphous solids.
solids
y Groups of atoms/molecules specifically arranged
crystal.
y Lattice is used to represent a threedimensional
periodic array of points coinciding with atom
positions.
y Unit cell is smallest repeatable entity that can be used
to completely represent a crystal structure.
structure It is the
building block of crystal structure
Common Crystal Structures

CommonCrystalStructures
Unit Cell
Simple
Cubic
BodyCentered
C bi
Cubic
FaceCentered
Cubic
Hexagonal
g
Close
Packed
N
1
CN
6
a/R
2
APF
0.52
4/3
0.68
12
4/2
0.74
12
0.74
Rev.0
C t l St t
f
t i l
CrystalStructureofmaterials
y FCC: Ni,Cu,Ag,Pt,Au,Pb,Al(soft)
IAS2009main
y BCC: V,Mo,Ta,W(hardmaterial)
y HCP: Mg,Zn
g
y CobaltHCP<4200C,FCC>4200C
oC
y ChromiumHCP<20oC,BCC>20
,
y Glass Amorphous
y BCC
BCCFerriteor
Ferriteor iron
ironferriteoriron
& ferriteor iron
y FCC Austeniteoriron
Fig.DifferentUnitCell
IES 2010
IES2010
Assertion(A):Mostofthematerialsexistinsingle
crystal.
crystal
Reason(R):Sugarisasinglecrystalmaterial.
( ) Both
(a)
B th A and
i di id ll true
t
and
d R is
i the
th
GATE2009
The
Th effective
ff ti number
b off lattice
l tti points
i t in
i the
th unit
it
cell of simple cubic, body centered cubic, and face
cantered cubic space lattices, respectively, are
(a) 1, 2, 2
(b) 1,
1 2,
2 4
(c) 2, 3, 4
(d) 2,
2 4,
4 4
IES2008
In
model
I the
th atomic
t i hardsphere
h d h
d l off the
th crystal
t l
structure of Copper, what is the edge length of unit
cell?
IES2004
Assuming
to
what
A
i atoms
t
t be
b perfect
f t spheres,
h
h t is
i the
th
value of the highest possible atomic packing
factor (APF) in metals?
(a) 0.95
(b) 0.74
0 74
(c) 0.66
(d) 0.5
05
Page 175 of 240
IES2003
The
coordination
Th
di ti
structure is
(a) 4
(b) 8
( ) 12
(c)
(d) 16
number
b
for
f
FCC
crystal
t l
IES2000
Atomicpackingfactor(APF)inthecaseofcopper
At
i
ki f t (APF)i th
f
crystalis
(a) 0.52
0 52
(b) 0.68
( ) 0.74
(c)
(d) 1.633
Rev.0
IES1999
MatchList
I(Crystalstructure)withList II(Atomic
MatchListI(Crystalstructure)withListII(Atomic
packingfactor)andselectthecorrectanswerusingthe
codesgivenbelowtheLists:
ListII
List
ListII
List
II
A. Simplecubic
1.
74%
B. Bodycenteredcubic
2.
74%
C Facecenteredcubic
C.
F
t d bi
3.
52%
%
D. Hexagonalclosepacked
4.
68%
Codes:
A
B
C
D
A
B
C
D
(a) 3
4
2
1
(b)
4
3
2
1
(c) 3
4
1
2
(d)
4
3
1
2
IES2007
Which one of the following is the correct ascending
order of packing density for the given crystal
structures of metals?
(a) Simple cubic Face centred cubic Body centred
cubic
(b) Body centred cubic Simple cubic Face centred cubic
(c) Simple cubic Body centred cubic Face centred cubic
(d) Body centred cubic Face centred cubic Simple cubic
F
l f
l i
Formulaforalatticeconstant
nM
a=
Consider the following statements about FCC and

HCP crystal structure:
1. Both have same coordination number and atomic
packing fraction.
2. Both represent closely packed crystal structures.
3. Both structures are generated by stacking of close
packed plants on top of one another, but only the
stacking sequence is different.
different
Which of the statements given above are correct?
(a) 1 and 2
(b) 2 and 3
(c) 1, 2 and 3
(d) 1 and 3
B i L i
d i ll
BravisLatticeandunitcell
IES2004
AmetalhasFCCstructure.Supposeitsatomic
A t lh FCC t
t
S
it t
i
weightandatomicradiusisAandrrespectively.
LetNdenotesAvogadro snumber.Whatisthe
LetNdenotesAvogadro'snumber.Whatisthe
densityofthematerial?
(a)
[Wheren=noofatomspercell,M=Atomicweight,
[Wheren
noofatomspercell M Atomicweight
N=Avogadrosnumber, =DensityofMetal]
IES2005
(c)
(b)
2 2r3 N
A
(d)
8 2r3 N
y Totalsixlatticeparameters a,b, c alongthethree

crystalaxes,and , , three,crystalangles.
c>
A
4 2r3 N
a>
>
y Therearesevenlatticesystems
16 2r 3 N
Note: Total7latticesystembuttotal14Bravice lattice
1 C bi
1.Cubic
2 T
l
2.Tetragonal
b c
y a
a=b=c
b c
y a
a=b
y . = = = 90
y = =
IES2001
1 SimpleCubic(SC)=1atom
1.
Whichoneofthefollowingpairsofaxislengths(a,b,
Whi h
fth f ll i i f i l
th ( b
c)andinteraxialangles(,,)representsthe
tetragonalcrystalsystem?
1.Simpletetragonal(ST)
2. Bodycenteredcubic(BCC)=2atom
c
2.Bodycenteredtetragonal(BCT)
3. Facecenteredcubic(FCC)=4atom
F t d bi (FCC) t
Page 176 of 240
(a)
(b)
(c)
(d)
a = b = c; = = = 900
a = b c; = = = 900
a b c; = = = 900
a = b = c; = = 900
Rev.0
3 O h h bi
3.Orthorhombic
IES2006
In
each
is
I Zinc
Zi Blende
Bl d structure,
t
t
h atom
t
i surrounded
d d
by four atoms of the opposite kind which are
located at the corners of which one of the
following?
(a) Tetrahedron
(b) Hexahedron
(c) Cube
(d) Orthorhombic
4 Rh b h d l
4.Rhombohedral
y abc
b c
y a
a=b=c
y = = =900
y = = 90o
1.Simpleorthorhombic(SO)
a
b
(i)SimpleRhombohedral (Sr)
2.Bodycenteredorthorhombic(BCO)
3
3.Facecenteredorthorhombic(FCO)
(
)
4.Endcenteredorthorhombic(ECO)
5 H
l
5.Hexagonal
IES2007
ForaRhombohedral
F Rh b h d l spacelattice,whichoneofthe
l tti hi h
fth
followingiscorrect?
6 M
li i
6.Monoclinic
bc
y a
a=bc
y abc
y = =900
y = =900
y =1200
1. SimpleMonoclinic(Sm)
()
(i)SimpleHexagonal(Sh)
p
g
( )
c
2. Endcenteredmonoclinic(ECM)
7 T i li i
7.Triclinic
IES 2011
IES2011
y abc
Inatriclinicunitcell:
(a ) = = = 90o (b) = = 90o , = 120o

(c) = = 90o
(d ) 90o
1.SimpleTriclinic(Stri)
c
a
Page 177 of 240
IES2006
Whichoneofthefollowingpairsisnotcorrectly
Whi h
fth f ll i i i t
tl
matched?
SpaceLatticeRelationbetweenAtomicradiusr and
Edgeelementa
(a) Simplecubicstructure:
a2 =4r2
(b) Bodycentred cubicstructure:3a2 =16r2
(c) Triclinic:
2a2 =3r
3r2
2
(d) Facecentred cubicstructure: a =8r2
Rev.0
Mill i di
Millerindices
Mill i di
Di
i
Millerindices
Direction
Mill i di
Pl
Millerindices
Plane
otat o iss required

equ ed to identify
de t y pa
t cu a
y A syste
system o
of notation
particular
y A vector of convenient length is placed parallel to the
y Determine the intercepts of the plane along the
direction(s) or plane(s) to characterize the arrangement of

atoms in a unit cell
y Formulas involving Miller indices are very similar to related
formulas from analytical geometry simple to use
y Use
U off reciprocals
i
l avoids
id the
th complication
li ti
off infinite
i fi it
intercepts
y Specifying dimensions in unit cell terms means that the
same label can be applied to any plane with a similar
stacking pattern, regardless of the crystal class of the
crystal. Plane (111) always steps the same way regardless of
crystal system.
required direction
y The length
g of the vector p
projection
j
on each of three
axes are measured in terms of unit cell dimensions
y These three numbers are made to smallest integer
g
values, known as indices, by multiplying or dividing by
a common factor
y The three indices are enclosed in square brackets,
[uvw]
y A family of directions is represented by <uvw>
crystallographic axes, in terms of unit cell dimensions.

If plane is passing through origin, there is a need to
construct a plane parallel to original plane
y Take the reciprocals of these intercept numbers
y Clear fractions
y Reduce to set of smallest integers
y The three indices are enclosed in parenthesis, (hkl).
y A family
y of p
planes is represented
p
byy {{hkl}}
Contd
Millerindices UsefulConventions
y If a plane is parallel to an axis, its intercept is at infinity
(
)
MillerIndices(hkl)
StepI:Findtheinterceptsofaplanealongthecrystalaxesa,
Step I:Findtheinterceptsofaplanealongthecrystalaxesa
b,candexpresstheinterceptsinunitsofcrystalparameter
a,b,crespectively.
StepII:Findthereciprocaloftheintercepts.
StepIII:Reduce thereciprocalstothethreesmallestinteger
(h k l)keepingtheratiossame
(h,k,l)keepingtheratiossame.
StepIV:Enclosetheseintegerintosameparameters(h,k,l)
b
b
a
y Multiplying or dividing a Miller index by constant has
no effect on the orientation of the plane
and its Miller index will be zero

y Never alter negative
g
numbers. This implies
p
symmetry
y
y
that the crystal may not have! Use bar over the number
to represent negative numbers.
y A plane or direction of family is not necessarily parallel
to other planes or directions in the same family
y The smaller the Miller index, more nearly parallel the
plane to that axis, and vice versa
y When the integers used in the Miller indices contain
Contd
Contd
Example: Find the miller indices of a plane that

makes intercepts in the units of lattice parameters
of 1 and 2 on a and b respectively.
respectively The plane is
parallel to c axis.
Solution:
a
Intercepts
Take reciprocals
Reduce to reciprocals
more than one digit, the indices must be separated by

commas. E.g.: (3,10,13)
y What is p
planer density:
y The number of lattice p
point
per unit area is defied as planer density.
IAS2009Main
Hence millers Indices are (210)
Page 178 of 240
Rev.0
IES 2010
IES2010
Miller indices (x, y,
z) for the hatched
plane in the above
abo e
unit
cell
are
represented as
(a) (100)
(b) (110)
(c) (111)
(d) (101)
IES1998
Aunitcellofacrystalisshowninthegivenfigure.
A it ll f
t li h
i th i
fi
TheMillerindicesofthedirection(arrow)shown
inthefigureis
(a) [012]
(b) [021]
(c) [210]
(d) [201]
IES2006
IES1999
Whatistheplanardensityof(100)planeinFCC(face
Whatistheplanardensityof(100)planeinFCC(face
centred cubic)crystalwithunitcellsideaequalto?
(a) 1.484
a2
(b)
a2
((c)
)
a2
((d)
)
ThesetofMillerindicesoftheplaneshowninthe
Th t fMill i di fth l
h
i th
givenfigureis
(a) (00)
(b) (100)
1
(c) (101)
(d) (110)
1
2
a2
Useful Conventions for a cubic

UsefulConventionsforacubic
crystal
y [uvw] is normal to (hkl) if u = h, v = k, w = l.
E.g.:(111) [111]
y [uvw] is parallel to (hkl) if hu + kv + lw = 0
y Two planes (h1k1l1) and (h2k2l2) are normal if
h1h2+k1k2+l1l2 = 0
y Two directions (u1v1w1) and (u2v2w2) are normal
u1u2+v1v2+w1w2 = 0
I
Pl
di
b
f il f l
{hkl}
InterPlanardistancebetweenfamilyofplanes{hkl}
d( hkl ) =
a
h2 + k 2 + l 2
Anglesbetweentwoplanesisgivenby
cos =
h1h2 + k1 k2 + l1l2
h12 + k12 + l12 h22 + k22 + l22
Contd
CrystalDefects
y The assumption of perfectly arranged atoms in a
solid may not valid i.e. atomic order must have

b
been
di
disturbed.
b d
y Disordered atomic region is called defect or
i
imperfection.
f ti
y Based on geometry, defects are: Point defects
(zero D) Line defects (1D)
(zeroD),
(1 D) or Dislocations,
Dislocations
Interfacial defects (2D) and Bulk or Volume
defects (3
(3D).
D).
P i d f
Pointdefects
y It is clear from the equation that there is an
y Pointdefectsareofzerodimensionali.e.atomicdisorderis
restrictedtopointlikeregions.
y Thermodynamicallystablecomparedwithotherkindof
defects.
y Fractionofvacancysitescanbegivenasfollows:
act o o vaca cy s tes ca be g ve as o ows:
Q
n
= e kT
N
[WherenisthenumberofvacantsitesinNlatticepositions,k
isgasorBoltzmannsconstant
isgasorBoltzmann
sconstant,Tisabsolutetemperaturein
Tisabsolutetemperaturein
kelvin,andQistheenergyrequiredtomoveanatomfromthe
interiorofacrystaltoitssurface.]
Contd
Page 179 of 240
exponential increase in number of vacancies with

temperature. When the density of vacancies becomes
relatively large, there is a possibility for them to cluster
together and form voids.
voids
y In ionic crystals, defects can form on the condition
of charge neutrality.
neutrality Two possibilities are:
Rev.0
IES1998;1999
IES1992
Assertion(A):Carbonformsinterstitialsolid
solutionwhenaddedtoiron.
Reason(R):Theatomicradiusofcarbonatomis
muchsmallerthanthatofiron.
Li d f
Linedefects
Whichofthefollowingisapointimperfection?
Whi h fth f ll i i i ti
f ti ?
1.Vacancy
2.Interstitialcy
3.Frenkelimperfection
F k li
f i
4.Schottkyimperfection
S h k i
f i
( ) 1and2only
(a)
( )
(b)
2and3only
( ) 2,3and4only
(c)
d l
(d)
1,2,3and4
d
Burgersvector
p change
g in atomic
y Line defects or Dislocations are abrupt
y
IES2009
order along a line.

They occur if an incomplete plane inserted between
perfect planes of atoms or when vacancies are aligned in a
line.
A dislocation is the defect responsible
p
for the
phenomenon of slip, by which most metals deform
plastically.
Dislocations occur in high densities (10810
1010 m22),
) and are
intimately connected to almost all mechanical properties
which are in fact structuresensitive.
Dislocation form during plastic deformation, solidification
or due to thermal stresses arising from rapid cooling.
Whichoneofthefollowingdefectsis
Schottky
Whi h
fth f ll i d f t i 'S
h ttk
defect?
(a) Vacancydefect
(b) Compositionaldefect
( ) Interstitialdefects
(c)
I t titi ld f t
(d) Surfacedefect
Li d f
Ed di l
i
Linedefects
Edgedislocation
y A dislocation is characterized by Burger

Burgerss vector, b.
Orowan dislocation.
y ItisalsocalledasTaylor
ItisalsocalledasTaylorOrowan
y It is unique to a dislocation, and usually have the
y Itwillhaveregionsofcompressiveandtensilestresses
direction of close p
pack lattice direction. It is also the
slip direction of a dislocation.
y It represents
p
the magnitude
g
and direction of distortion
associated with that particular dislocation.
y Two limiting cases of dislocations, edge and screw,
are characterized by Burgers vector perpendicular to
the dislocation line (t) and Burgers vector parallel to
th dislocation
the
di l ti line
li respectively.
ti l Ordinary
O di
di l ti
dislocation
is of mixed character of edge and screw type.
oneithersideoftheplanecontainingdislocation.
p
g
Contd
y A pure edge dislocation can glide or slip in a direction
perpendicular to its length i.e. along its Burgers vector in

the slip plane (made of b and t vectors),
vectors) on which
dislocation moves by slip while conserving number of
atoms in the incomplete plane.
y It may move vertically by a process known as climb, if
diffusion of atoms or vacancies can take place at
appropriate
i
rate.
y Atoms are added to the incomplete plane for negative
climb i.e.
i e the incomplete plane increases in extent
downwards, and vice versa.
y Thus climb motion is considered as nonconservative,, the
movement by climb is controlled by diffusion process.
Contd
Page 180 of 240
Rev.0
Contd
IES2009
Whichoneofthefollowingiscorrectfor
Climb
Whi h
fth f ll i i
tf 'Cli
b'??
(a) Dislocationmovesparalleltotheslipplane
(b) Dislocationmovesperpendiculartotheslipplane
Di l
i
di l h li l
(c) Slidingofoneplaneofatomsovertheotherplane
( ) Dislocationmovesfromaslipplanetoanotherslip
(d)
plane
Li d f
S
di l
i
Linedefects
Screwdislocation
y It is also called as Burger
Burgerss dislocation.
y It will have regions of shear stress around the
dislocation line
positive screw dislocation, dislocation line
direction is p
parallel to Burgers
g
vector, and vice versa.
y For
Contd
Li d f
Di l
i
i
Linedefects
Dislocationmotion
pp
y Dislocations move under applied
stresses,, and thus
causes plastic deformation in solids.
y Dislocations can move in three ways glide/slip, cross
slip
li and
d climb
li b depending
d
di on their
h i character.
h
Sli is
Slip
i
conservative in nature, while the climb is non
conservative, and is diffusion
diffusioncontrolled.
controlled.
y Any dislocation can slip, but in the direction of its
burgers vector.
y Edge dislocation moves by slip or climb.
y Screw dislocation moves by slip / crossslip. Possibility
f crossslip
for
li arises
i
as screw dislocation
di l
i does
d
not have
h
a preferred slip plane as edge dislocation have.
Contd
Linedefects Dislocationcharacteristics
y Dislocationshavedistortionalenergyassociatedwith
them.
y Storedelasticenergyperunitlengthofthedislocation
Gb 2
E=
2
[WhereG shearmodulusandb Burgersvector]
g
IES2003
Ascrewdislocation
1. LiesparalleltoitsBurger'svector
2. LiesperpendiculartoitsBurger
LiesperpendiculartoitsBurger'svector
svector
3. MovesinaperpendiculardirectiontotheBurger's
vector
4. MovesinaninclineddirectiontotheBurger'svector
Codes:
(a) 1and4
(b) 1and3
(c) 2and3
(d) 2and4
Page 181 of 240
IES2009
Whichoneofthefollowingiscorrectfor"Burger's
vector inscrewdislocation?
vector"inscrewdislocation?
(a) Perpendiculartothedislocationline
(b) Inclinedtothedislocationline
I li dt th di l ti li
(c) Paralleltothedislocationline
(d) Oppositetothedislocationline
O
i h di l
i li
Rev.0
IES2008
I
f i ld f
Interfacialdefect
IES2007
Whatistheapproximatestrainenergyexpression
Wh ti th
i t t i
i
foradislocationofunitlength,irrespectiveofits
edgeorscrewcharacter?
(a)
G 2b
2
(b)
(c)
G 2b
4
(d)
Gb2
2
Gb2
4
D imperfection in
y An interfacial defect is a 2
2D
crystalline solids and have different crystallographic
orientations on either side of it.
y They usually arise from clustering of line defects into a
plane..
y E.g.: External surface, Grain boundaries, Stacking
faults, Twin boundaries, Dislocations and Phase
b
boundaries.
d i
Contd
IES 2010
IES2010
Surface imperfections which separate two
orientations
that
image
off one
i
i
h are mirror
i
i
another is called
(a) Stacking fault
((b)) Grain boundaryy
(c) Tilt boundary
(d) Twinned boundary
IES2008
Whatisasurfaceimperfection,whichseparates
Wh ti
f
i
f ti
hi h
t
crystalsofdifferentorientationsinapoly
crystallineaggregate,called?
(a) Edgedislocation
(b) Stackingfault
(c) Grainboundary
(d) Screwdislocation
Stackingfaults
Th planner
l
i
f i produced
d d by
b the
h passage off a
y The
imperfection
partial dislocation is called stacking fault.
y They
planes.
Th are faults
f lt in
i stacking
t ki sequence off atom
t
l
y Stacking sequence in an FCC crystal is ABC ABC ABC
, and the sequence for HCP crystals is AB AB AB.
AB
y Two kinds of stacking faults in FCC crystals are:
y (a)
( ) ABC AC ABCwhere
ABC h
CA CA representt thin
thi HCP
region which is nothing but stacking fault in FCC,
y (b) ABC ACB CABC is called extrinsic
e trinsic or twin
t in stacking
fault. Three layers ACB constitute the twin. Thus
stacking faults in FCC crystal can also be considered as
submicroscopic twins.
Contd
y This is why no microscopic twins appear in FCC
y
g faults is energetically
g
y
crystals
as formation of stacking
favorable.
y The total energy
gy of a p
perfect lattice is lower than one
with a stacking fault. This difference is stacking fault
energy, and varies in range 0.010.1 J/m2.
y Lower the stacking fault energy, wider the stacking
fault, metal strain hardens rapidly and twin easily.
Oh
Otherwise,
i
metals
l off high
hi h stacking
ki
f l energy i.e.
fault
i
narrower stacking faults show a deformation structure
of banded,
banded linear arrays of dislocations.
dislocations
Page 182 of 240
B lk aVolumedefects
V l
d f
Bulkor
y Volume defects are threedimensional in nature.
y These defects are introduced, usually, during
processing and fabrication operations like casting,

f
forming
i etc.
E.g.: Pores, Cracks, Foreign particles
y These
Th
d f t actt like
defects
lik stress
t
raisers,
i
th deleterious
thus
d l t i
t
to
mechanical properties of parent solids.
y In some instances,
instances foreign particles are added to
strengthen the solid dispersion hardening. Particles
added are hindrances to movement of dislocations
which
hi h have
h
to cut through
h
h or bypass
b
the
h particles
i l thus
h
increasing the strength.
Rev.0
IES 2011
IES2011
Assertion (A): Excess defects are created by
hammering the crystalline materials.
Reason (R) : The thermal fluctuations create
the
h point defects
d f
in crystalline
ll
materials.
l
correct explanation
l
i off A
(b) Both A and R are individually true but R is NOT
th correctt explanation
the
l
ti off A
(d) A is
i false
f l but
b R is
i true
IES 2010
IES2010
Assertion (A): Natural crystals always contain
defects.
defects
Reason (R): The defects may affect colour and can
make a crystal a valuable gem.
gem
IES2003
Whichoneofthefollowingpairsisnot
Whi h
fth f ll i i i t correctly
tl
matched?
(a) Pointdefectincrystallattice :Selfinterstitials
(b) Lineardefectincrystallattice:Grainboundary
( ) Planardefectincrystallattice:Externalsurface
(c)
Pl
d f ti
t ll tti E t
l f
(d) Volumedefectincrystallattice:otherphases
IES1997
Whichofthefollowingpropertiesofasolidare
dependentoncrystalimperfections?
1. Yieldstress
2.
Meltingpoint
3. Semiconductivity
4.
Ductility
g
g
(a) 1and3
(b) 1,3and4
3
(c) 2,3and4
(d) 2and4
Page 183 of 240
Rev.0
y Purpose of heat treatment:
H tT t
t
HeatTreatment
y Heating
1.To remove or relieve strains or stresses induced by cold
a metal or alloy to various definite
working
cooling
(for
example
ki or non uniform
if
li
(f
l welding):
ldi )
temperatures, holding these for various time durations
Annealing
and cooling at various rates.
2. To increase strength or hardness of the material for
y Combination of controlled heating and cooling
improved wear resistance: Hardening
determine not only the nature and distribution of
3.To improve machinability: Annealing
microconstituents (which determine the properties of
4.To soften the material: Annealing
a metal or alloy),
alloy) but also the grain size.
size
55. To decrease hardness and increase ductilityy and toughness.

g
(Tempering)
Contd...
Main Processes Include

MainProcessesInclude
6. To improve the cutting properties of tools.
7. To change or modify the physical properties of the
material such as electrical properties,
properties magnetic
IES 1992
IES1992
y Annealing
gg
y
Whichofthefollowinggenerallydecreasesinthe
steelafterquenchhardening?
1. Brittleness
2. Percentageelongation
33. Impactstrength
p
g
(a) 1and2only
(b) 2and3only
((c)) 1and3only
3
y
((d)) 1,2and3
,
3
y Stress
Relieving
S
R li i
y Quench Hardening
g
properties, corrosion resistance and heat resistance
y Tempering
etc.
y Carburizing
8 Elimination of H2 gas dissolved during pickling or

8.
y Carbon Nitriding
electroplating which causes brittleness.
y Age Hardening
Contd...
y Ion Nitriding
Contd...
Fig.TTTdiagramforeutectoidtransformationinFeC
Fig.TransformationsinvolvingausteniteforFeCsystem
Page 184 of 240
Rev.0
CCT di
f F C t
CCTdiagramforFeCsystem
y Critical Rate of Cooling: The minimum rate of cooling at
which the austenite is transformed into martensite alone.
g
y TTT diagram
is less practical since an alloy has to be cooled
y Spheroidite: If pearlite is heated just below the eutectoid
rapidly and then kept at a temperature to allow for

respective transformation to take place.
y Usually
U ll
materials
i l
are cooled
l d continuously,
i
l
thus
h
Continuous Cooling Transformation diagrams are
appropriate.
y For continuous cooling, the time required for a reaction to
begin and end is delayed, thus the isothermal curves are
shifted to longer times and lower temperatures.
y Main difference between TTT and CCT diagrams: no space
f bainite
for
b i i in
i CCT diagram
di
as continuous
i
cooling
li
always
l
results in formation of pearlite.
GATE 2003
GATE2003
Duringheattreatmentofsteel,thehardnessof
variousstructuresinincreasingorderis
(a) Martensite,finepearlite,coarsepearlite,
spherodite
(b) Finepearlite,coarsepearlite,spherodite,
martensite
(c) Martensite,coarsepearlite,finepearlite,
spherodite
(d) Spherodite,coarsepearlite,finepearlite,
martensite
IES 1998
IES1998
g curves A and B for a eutectoid iron
Two cooling
carbon alloy are superimposed on a continuous
cooling transformation diagram as shown in the
given
i
fi
figure.
Fine
i
pearlite
li
microstructure
i
i
is
represented by the points labelled
( ) I and
(a)
d III
(b) II
( ) IV
(c)
(d) I
temperature (say 700C) and held at this temperature for a

day or so,
so the cementite lamelle in pearlite get
transformed to spherical shape. The structure is called
"spheroidite".
y This structure is less conducive to stress concentration
because of spherical grains, as compared to cementite
(l
(lamelle
ll structure).
t t )
y This, spheroidite is more tough but less hard as compared
to pearlite.
pearlite
GATE 1996
GATE1996
g
The ironcarbon diagram
and the TTT curves are
determined under
(a) Equilibrium and nonequilibrium conditions
respectively
(b) Nonequilibrium and equilibrium conditions
respectively
(c) Equilibrium conditions for both
(d) Nonequilibrium conditions for both
IAS2002
Two plain carbon steel specimens having 08%
carbon content are welded. If we observe the
weldment under Metallurgical Microscope from
centre towards either side, the following
structures are observed at different zones:
1. Fine Pearlite
2. Coarse Pearlite
3. Martensite
Select the correct sequence using the codes given
b l
below:
Codes:
( ) 1, 2, 3
(a)
(b) 1, 3, 2
(c) 2, 1, 3
(d) 3, 1, 2
Page 185 of 240
IES 2002
IES2002
g
p
TTTdiagramindicatestimeandtemperature
transformationof
(a) Cementite
(b) Pearlite
(c) Ferrite
(d) Austenite
GATE 1997
GATE1997
p
,
g
Oncompletionofheattreatment,theresulting
structurewillhaveretainedAusteniteif
(a) Rateofcoolingisgreaterthanthecriticalcooling
rate
(b) Rateofcoolingislessthanthecriticalcoolingrate
(c) Martensite formationstartingtemperatureis
abovetheroomtemperature
(d) Martensite formationfinishtemperatureisbelow
theroomtemperature
Rev.0
A
li
Annealingprocesses
F ll
li
Fullannealing
y Annealing is a heat treatment process in which the
y Benefits of annealing are:
y Metal is heated above the upper critical temperature &
material is taken to a high temp. kept there for some
relieve stresses
held there until the temperature of the work piece is
time and then cooled in furnace.
increase softness, ductility and toughness
uniform throughout, and finally cooling the work
produce a specific microstructure
piece at a slowly controlled rate in furnace so that the
y Cooling is done slowly to avoid the distortion.

distortion
y Depending on the specific purpose, annealing is
classified into various types: process annealing, stress
temperature of the surface and that of the centre of the

workpiece is approximately the same.
relief full annealing and normalizing.

relief,
normalizing
Contd...
IES 2010
IES2010
Consider the following statements regarding annealing
process:
1. All structural imperfections are removed
2 The hypoeutectoid steel is heated to about 50 70
2.
70 C below
upper critical temperature.
33. Cooling
g can be done in heat treating
g furnace,, byy heating
g it,,
keeping the metal in it and turning off furnace till it cools to
room temperature.
4. Uniform
f
grain structure is resulted.
l d
( ) 1, 2 and
(a)
d 3 only
l
(b) 2, 3 and
d 4 only
l
(c) 1, 3 and 4 only
(d) 1, 2, 3 and 4
IES 1992
IES1992
p
q
g
yp
Temperaturerequiredforfullannealinginhyper
eutectoidsteelis
(a) 50Caboveuppercriticaltemperature(AC3)
(b) 50Cbelowuppercriticaltemperate(AC3)
((c)) 550Cabovelowercriticaltemperature(AC
p
( 1)
(d) 50Cbelowlowercriticaltemperature(AC1)
IES 1999
IES1999
g the hypoeutectoid
yp
Heating
steels to 330oC above
the upper critical temperature line, soaking at
that temperature and then cooling slowly to room
temperature to form
f
a pearlite
li
and
d ferrite
f i
structure, is known as
( ) Hardening
(a)
H d i
(b) Normalizing
N
li i
(c) Tempering
(d) Annealing
IES 1993
IES1993
Whichofthefollowingstatementsaretrueof
annealingofsteels?
1. Steelsareheatedto500to700C.
2. Coolingisdoneslowlyandsteadily.
C li i d
l l d
dil
3. Internalstressesarerelieved.
4. Ductilityofsteelisincreased.
D tilit f t li i
d
Codes:
Codes
(a) 2,3and4
(b) 1,3and4
(c) 1,2and4
1 2and4
(d) 1,2and3
1 2and3
IES 2003
IES
Primaryobjectoffullannealingisto
(a) Increasetoughnessandyieldpoint
(b) Reduceductilityandresilience
(c) Removeforeignimpuritiesandimprovesurface
finish
(d) Increaseductilityandmachinability
Page 186 of 240
P
li
Processannealing
y After cold working the metal can be softened by
process annealing or "recrystallization to reduce the

distortions of the crystal lattice produced by cold
working.
working
Rev.0
Contd...
Isothermalannealingg
IES 2005
IES2005
IES 2010
IES2010
y Increases the machinability.
The complete phase recrystallization and fine

grain structure is obtained in casting, forging and
rolled parts by:
y Heat above the upper critical point and held for some
time, then rapidly cool to a temp. 600 700

700C,
C, and is
held at this new temperature until the austenite is
(a) Recrystallization annealing
(b)
Normalizing
(c) Spheroidizing
(d)
Austenising
completely decomposed to form pearlite.
Isothermalannealingismainlyusedinalloy
steelstoimprove
l i
(a)Machinability
(b)Toughness
(c)Ductility
(d)Weldability
y Finally cooled in still air.

air
Contd...
Stressreliefannealingg
y Stress relief annealing process consists of three steps.
p is heating
g the cold worked steel to a
y The ffirst step
5000
550oC
temperature between
C and
C i.e. below its
recrystallization temperature.
y The
h second
d step involves
l
h ld
holding
the
h steell component at this
h
temperature for 12 hours.
y The final step is to cool the steel component to room
temperature in air.
y It partly relieves the internal stress in cold worked steels
without loss of strength and hardness i.e. without change in
the microstructure. Since only low carbon steels can be cold
worked,
k d the
h process is
i applicable
li bl to hypoeutectoid
h
id steels
l
containing less than 0.4% carbon.
GATE 2014
GATE2014
The process of reheating the reduce its brittleness
without any significant loss in its hardness is
(a) normalizing
(b) annealing
(c) quenching
(d) tempering
GATE2014(PI)
( )
For a metal alloy, which one of the following descriptions

relates to the stressrelief annealing process?
(a) Heating the workpiece material above its
recrystallization temperature, soaking and then cooling
in still air
(b) Heating the workpiece material below its
recrystallization temperature,
temperature holding for some time and
then furnace cooling
(c) Heating the workpiece material up to its
recrystallization temperature and then rapid cooling
(d) Heating the workpiece up to its recrystallization
temperature and cooling to room temperature
alternately for a few cycles
IES 2011
IES2011
Which one of the following statements is NOT
correct for normalizing?
(a) It is often applied to casting to relieve stresses
(b) It increases strength of medium carbon steel to
some extent
(c) Better surface finish can be obtained in
machining
(d) It increases grain size
Page 187 of 240
Normalizing
M i objective
bj ti
Main
1. Refine grain, improve machinability, tensile strength and
structure of weld.
weld
2. Remove cold worked stess.
3. Remove
R
di l ti
dislocations
d to
due
t hot
h t working.
ki
Process
y Heat the
h steell from
f
30C to 50C above
b
its upper criticall
temp, held about fifteen minutes and then allowed to cool

down in still air.
air
y Homogeneous structure provides a higher yield point,
ultimate tensile strength and impact strength with lower

ductility to steels.
Contd...
IES 2000
IES2000
Assertion (A): Normalized steel will have lower
hardness than annealed steel.
Reason (R): The pearlite of normalized steel is
finer and has lower intermolecular space.
space
Rev.0
S h idi i
Spheroidizing
y Heat them to slightly above the critical temperature,
temperature
hold them at this temp for a period of time, and then

letting them cool in the furnace.
y Spheroidizing produces a rounded or globular form of
GATE 2006
GATE2006
Themainpurposeofspheroidising treatmentisto
improve
(a)Hardenabilityoflowcarbonsteel
( )
(b)Machinabilityoflowcarbonsteels
(c)Hardenabilityofhighcarbonsteels
(d)Machinabilityofhighcarbonsteels
carbide.
IES 2003
IES2003
Globular form of cementite in the structure of
steel is obtained through
(a) Normalizing
(b) Malleabilising
((c)) Spheroidizing
p
g
(d) Carbonizing
y It improve abrasion resistance.
The difference between the different annealing processes is

made clear in Fig., a diagram between temperature and time.
Quenching
Tempering
y Quenching isheattreatmentprocesswherematerialis
cooledatarapidratefromelevatedtemperatureto
l d t id t f
l t dt
t t
p
g is the p
g martensitic steel at
y Tempering
process of heating
a temperature below the eutectoid transformation
produceMartensitephase.
temperature to make
k it
i softer
f and
d more ductile.
d il
Comparative coolingratesofQuenchMedia
Brine
Water
Water + NaOH
or KOH
Oil
Forced air
Still air
1.20 to 1.30
1
<1
0.40 to 0.50
0.03
0.02
y During
g the tempering
p
gp
process,, Martensite transforms to
a structure containing iron carbide particles in a matrix

of ferrite.
y Brinehasfastestcoolingrateofsteelquenchingandis
B i h f
li
f
l
hi di
alsousedassecondaryrefrigerant.
IES 2010
IES2010
answer using the code given below the lists:
List I
List II
(Q
(Quenching
hi media)
di )
(St
(Structure
t
produced)
d
d)
A. Water
1. Coarse pearlite
B Oil
B.
2. Martensite
M
i
C. Air
3. Very fine pearlite
D. Furnace cools
4. Fine pearlite
A
B
C
D
A
B
C
D
(a) 1
3
4
2
(b) 2
3
4
1
(c) 1
4For-2015
3
2
(d) 2& PSUs)
4
3
1
(IES,
GATE
IES 2001
IES2001
gq
g
Considerthefollowingquenchingmedia:
1. Oil
2.Water
33. Water+NaOH 4
4.Brine
Thecorrectsequenceofthesemediainorderof
increasinghardnessofsteelundergoingheat
g
g g
treatmentis
(a) 1,3,2,4
(b) 2,1,3,4
(c) 1,2,3,4
(d) 4,3,2,1
Page 188 of 240
IES 2009
IES2009
g
Whichoneofthefollowingmediumsisusedfor
thefastestcoolingrateofsteelquenching?
(a) Air
(b) Oil
(c) Water
(d) Brine
Rev.0
IES 2006
IES2006
MatchListI(EffectofCooling)withListII(Cooling
Medium)andselectthecorrectanswerusingthecode
d
) d l
h
h
d
givenbelow:
ListI
List
I
List II
List
A. Martensite
1.
Waterquenched
B. Veryfinepearlite
y
p
2.
Aircooled
C. Finepearlite
3.
Furnacecooled
D. Coarsepearlite
4.
Oilquenched
A
B
C
D
A
B
C
D
(a) 1
4
2
3
(b) 2
3
1
4
( ) 2
(c)
3
4
1
(d) 1
2
3
4
M t
i
Martempering
y Quench steel from the austenizing temperature to a
bath just above Ms.

y Since,
austenite
transforms
to
simultaneously throughout the steel,

steel the distortion in
quenching is minimized.
y This induces greater toughness in the steel.
A t
i
Austempering
GATE 2004
GATE2004
Fromthelistsgivenbelow,choosethemostappropriatesetof
heattreatmentprocessandthecorrespondingprocess
characteristics
Process
Characteristics
P
P.
Tempering
1
1.
Austeniteisconvertedinto
bainite
Q. Austempering
2.
Austeniteisconvertedinto
martensite
R. Martempering
3.
Cementite isconvertedinto
globularstructure
4.
Bothhardnessandbrittlenessare
reduced
d d
5.
Carbonisabsorbedintothemetal
(a) P3Q1R5
(b)
P4Q3R2
( ) P4Q1R2
(c)
P Q R
(d)
P Q R
P1Q5R4
y This hardening process is basically the same as the
martempering, but has a longer holding time above

the martensitic transformation temperature.
IES 1994
IES1994
g
Considerthefollowingtreatments:
1. Normalizing
2.
Hardening
33. Martempering
p
g
4.
4
Coldworking
g
Hardnessandtensilestrengthinausteniticstainless
steelcanbeincreasedbyy
(a) 1,2and3
(b) 1and3
((c)) 2and4
4
((d)) 4
4alone
martensite
IES 2006
IES2006
p
g
p
g
Temperingisaprocessofannealing
(a) Martensite atlowtemperatures
((b)) Martensite athighertemperatures
g
p
(c) Bainite atlowtemperatures
(d) Bainite athighertemperatures
Page 189 of 240
IES 2005
IES2005
p
g isemployedtoobtain:
p y
Austempering
(a) 100%martensitic structure
((b)) 100%bainitic structure
(c) 50%martensitic and50%bainitic structure
(d) 100%pearlitic structure
Rev.0
IES 2004
IES2004
IES 2001
IES2001
gp
Considerthefollowingpairs:
Heattreatment
Effectonmediumcarbonsteel
g
:Grainrefinement
1. Normalizing
2. Fullannealing
:Uniformgrainstructure
3. Martempering
:Decreasedductility
4. Spheroidizing
:Maximumsoftness
Whichofthepairsgivenabovearecorrectlymatched?
(a) 1and2
(b) 2and3
(c) 3and4
(d) 1,2,3and4
1 2 3and4
GATE2014
G
0
Match the heat treatment processes (Group A) and their

associated effects on properties (Group B) of medium
carbon
b steel
t l
GroupA
GroupB
P T
P:Tempering
i
I St
I.Strengtheningandgrainrefinement
th i d i fi
t
Q:Quenching II.Inducingtoughness
R A
R:Annealing
li
III H d i
III.Hardening
S:Normalizing IV.Softening
(a)
(c)
P
III
III
Q
IV
II
R
II
IV
S
I
I
(b)
(d)
P
II
II
Q
III
III
R
IV
I
p
g
q
'Tempering'ofquenchedmartensitic
steelis
necessarytoimprovethe
(a) Hardnessofthemetal
(b) Surfacetextureorthemetal
((c)) Corrosionresistanceofthemetal
(d) Ductilityorthemetal
A i
Aging
g ((solution heat treatment),

) where the
y Solutionizing
g g finelyy dispersed
p
p
p
p
y Aging
precipitate
particle will form.
alloy is heated to a temperature between solvus and
Aging the alloy at room temperature is called natural
solidus
lid temperatures and
d kept
k
there
h
till
ill a uniform
if
solid
lid
aging,
i
whereas
h
at elevated
l
d temperatures is
i called
ll d
solution structure is produced.
artificial aging. Most alloys require artificial aging, and

aging temperature is usually between 1525% of
t
temperature
t
diff
difference
b t
between
room temperature
t
t
and
d
solution heat treatment temperature.
Induction hardening
Inductionhardening
y Alternating current of high frequency passes for few
y In case hardening, the surface of the steel is made hard
and wear resistant,

resistant but the core remains soft and
tough.
p
ThepatternknownasWidmanstatten
structureis
encounteredin:
(a) Tempering
(b) Normalizing
(c) Spheroidizing
(d) Annealing
Solutionizing
S
I
IV
C
H d i
CaseHardening
IES 2006
IES2006
second through an induction coil enclosing the steel

part to be heat treated.
treated
GATE 2000
GATE2000
y
Caststeelcrankshaftsurfaceishardenedby
(a) Nitriding
(b) Normalising
((c)) Carburising
g
((d)) Inductionheating
g
y Immediately after heating, water jets are activated to
quench the surface.

y Martensite is produced at the surface, making it hard
and wear resistant.
Page 190 of 240
Rev.0
IES 1992
IES1992
g
y
Inductionhardeningisbasicallya
(a) Carburising process
((b)) Surfacehardeningprocess
gp
(c) Corehardeningprocess
(d) Noneoftheabove
Laser hardening
Laserhardening
y Laser beams are of high intensity, a lens is used to
reduce the intensity by producing a defocused spot of

si e ranging from 0.5
size
0 to 25
2 mm.
mm
Fl
h d i
Flamehardening
IES 1996 1997

IES1996;1997
y For large work pieces flame hardening is done by
means of an oxyacetylene torch.

y Heating should be done rapidly by the torch and the
surface quenched.
quenched
y oflathebedsarehardenedby
y
Guideways
(a) Carburising
((b)) Cyaniding
y
g
(c) Nitriding
(d) Flamehardening
C b ii
Carburizing
y Carburizing is the most widely used method of surface
hardening.
y Here,
Here the surface layers of low carbon steel are
enriched with carbon up to 0.81.0%. The source of
carbon mayy be a solid medium, a liquid
q
or a g
gas.
y In all cases, the carbon enters the steel at the surface
and diffuses into the steel as a function of time at an
elevated temperature.
y Carburizing is done at 920950oC.
y austenitic state is essential. If carburizing

g
y There is fully
is done in the ferritic region, the carbon, with very
limited solubility in ferrite, tends to form massive
cementite
i
particles
i l
near the
h surface,
f
making
ki
the
h
subsequent heat treatment difficult.
y For
F this
thi reason, carburizing
b i i
i always
is
l
d
done
i the
in
th
austenitic state, even though longer times are required
due to the diffusion rate of carbon in austenite being
less that in ferrite at such temperatures.
Contd...
IES 2011
IES2011
Assertion (A): Carburizing is used for machine
elements
which
to have
a wear resistant
l
hi h have
h
h
i
working surface.
Reason (R) : The composition of surface layers
are changed in carburizing.
( )
(a)BothAandRareindividuallytrueandRisthe
y
(b)BothAandRareindividuallytruebutRisNOT
thecorrectexplanationofA
h
l
i fA
(c)AistruebutRisfalse
(d)Ai f l b tRi t
(d)AisfalsebutRistrue
GATE 1992
GATE1992
p
g
Carburized machine components
have high
endurance limit because carburization
(a) Raises the yield point of the material
(b) Produces a better surface finish
((c)) Introduces a compressive
p
layer
y on the surface
(d) Suppresses any stresss, concentration produced in
the component.
Page 191 of 240
IES 1992
IES1992
g Carbon is introduced to form a
In case carburising
high carbon layer at the surface. The carbon is
introduce in the form of
(a) Graphite flakes
(b) Pearlite
(c) Cementite
(d) Free carbon
Rev.0
IES 2005
IES2005
p
y stressed
If the surface of a component
is heavily
while the stresses in the core are of comparative
small magnitude, which one of the following heat
treatment methods
h d is
i employed?
l
d
(a) Annealing
(b) Tempering
(c) Quenching
(d) Case hardening
C aniding
Cyaniding
GATE 2003
GATE2003
g
y p
Hardnessofsteelgreatlyimproveswith
(a) Annealing
(b) Cyaniding
((c)) Normalising
g
((d)) Tempering
p
g
y Cyaniding is done in a liquid bath of NaCN, with the
concentration varying between 30 and 97%.

y The temperature used for cyaniding is lower than that
for carburizing and is in the range of 800

800870
870oC.
C
y The time of cyaniding is 13 hr to produce a case depth
of 0.25 mm or less.
Nitriding
IES 1992
IES1992
IES 1995
IES1995
y During nitriding, pure ammonia decomposes to yield
Q
g
y
g
Quenchinginnotnecessarywhenhardeningis
doneby
(a) Casecarburizing
(b) Flamehardening
((c)) Nitriding
g
(d) Anyoftheaboveprocesses
i th d i
b l th li t
ListI(Heattreatment)
ListII(Effectonthe
properties)
A. Annealing
1.
Refinedgrainstructure
B. Nitriding
2.
Improvesthehardnessof
thewholemass
C. Martempering
3.
Increasessurfacehardness
D. Normalising
4.
Improvesductility
Codes:A
d
B
C
D
A
B
C
D
(a) 4
3
2
1
(b) 1
3
4
2
c) 4
2
1
3
(d) 2
1
3
4
nitrogen which enters the steel.

y The temperature of nitriding is 500590oC. The time
for a case depth of 0.02

0 02 mm is about 2 hr.
hr
y Most of the nitrogen, that enters the steel, forms hard
nitrides (e.g., Fe3N).

y No
N phase
h
change
h
occurs after
ft nitriding.
it idi
IES 2004
IES2004
Match List I (Name of treatment) with List II (Media
used)
the
d) and
d select
l t the
th correctt answer using
i
th codes
d
given below the Lists
List I
List II
A. Pack carburizing
1.
Ammonia gas
B. Gas carburizing
2.
Sodium cyanide
C Cyaniding
C.
3
3.
Carburizing
compound
D. Nitriding
4.
Ethane
Codes:A
d
B
C
D
A
B
C
D
(a) 3
4
2
1
(b) 2
1
3
4
(c) 3
1
2
4
(d) 2
4
3
1
IAS2009Main
Precipitation & Dispersion hardening

Precipitation&Dispersionhardening
y Foreign
y
y
y
y
y
y
Page 192 of 240
particles can also obstructs movement of

dislocations
i.e.
the
di l ti
i increases
i
th strength
t
th off the
th material.
t i l
Foreign particles can be introduced in two ways
precipitation
p
p
and mixingandconsolidation
g
technique.
q
Precipitation hardening is also called age hardening
because strength increases with time.
R
Requisite
i i for
f precipitation
i i i hardening
h d i is
i that
h second
d phase
h
must be soluble at an elevated temperature but precipitates
p q
quenching
g and aging
g g at a lower temperature.
p
upon
E.g.: Alalloys, CuBe alloys, MgAl alloys, CuSn alloys
If aging occurs at room temperature Natural aging
If material need to be heated during aging Artificial
aging.
Rev.0
Contd...
IES 2009
IES2009
y In dispersion hardening, fine second particles are
mixed with matrix powder, consolidated, and pressed

in powder metallurgy techniques.
techniques
y For dispersion hardening, second phase need to have
veryy low solubilityy at all temperatures.
p
y E.g.: oxides, carbides, nitrides, borides, etc.
y Dislocation moving through matrix embedded with
foreign particles can either cut through the particles or
bend around and bypass them.
y Cutting of particles is easier for small particles which
can be considered as segregated solute atoms. Effective
strengthening
g
g is achieved in the bending
g p
process,
when the particles are submicroscopic in size.
Contd...
IES 1994 2005

IES1994;2005
Assertion (A): Carburizing is done on nonferrous
alloys to increase the surface hardness.
Reason (R): Precipitation hardening of non
ferrous alloys involves solution heat treatment
followed by precipitation heat treatment.
(d) A is false
f l but
b R is true
Grain gro th
Graingrowth
y Grain growth follows complete crystallization if the
material
t i l is
i left
l ft att elevated
l t d temperatures.
t
t
y Grain growth does not need to be preceded by recovery
y
y
y
y
y
y
; it mayy occur in all p
polycrystalline
y y
and recrystallization;
materials.
In contrary to recovery and recrystallization, driving force
for this process is reduction in grain boundary energy.
energy
Tendency for larger grains to grow at the expense of smaller
grains is based on p
g
physics.
y
In practical applications, grain growth is not desirable.
Incorporation of impurity atoms and insoluble second
phase
h
particles
i l are effective
ff i in
i retarding
di grain
i growth.
h
Grain growth is very strongly dependent on temperature.
y Optimumstrengtheningoccursduringagingoncetheright
g materials can be
Which one of the following
subjected to an age hardening process?
(a) HSS
(b) Aluminium
((c)) Pure iron
(d) Stellite
iinterspacingofparticlesisachieved.
t
i f ti l i hi d
y Smallertheparticles,dislocationscancutthroughthemat
y lowerstresses
y largertheparticlestheywillbedistributedatwider
distances.
IES 2007
IES2007
g the following
g is the most
Which one among
effective strengthening mechanism of non
ferrous metal?
(a) Solid solution hardening
(b) Strain hardening
(c) Grain size refinement
(d) Precipitation hardening
S
ki
t
i
Seasoncrackingorstresscorrosion
g
cracking.
y Brasses with more than 15% zinc often experience
season cracking or stresscorrosion cracking.
IES 2001
IES2001
Whichoneofthefollowingpairsiscorrectly
matched?
h d
(a) SolidsolutionstrengtheningIncreasingdensity
ofdislocations
(b) Dispersionhardening..Creatingstrained
regioninthecrystal
(c) Strainhardening....Creatingparticlesto
resistthemovement
ofdislocations
(d) Precipitationhardening..Creatingparticlesby
decreasingsolubilityofone
phaseinanother
h i
h
IES 2007
IES2007
g elements/ alloy
y
exhibits season cracking?
(a) Iron
(b) Brass
(c) Aluminium
(d) Steel
y Both stress and exposure to corrosive media are
required for this failure to occur (but

(
residual stresses
and atmospheric moisture may be sufficient!).
y As
A a result,
l coldworked
ld
k d brass
b
i usually
is
ll stress relieved
li d
(to remove the residual stresses) before being placed in
service.
service
Page 193 of 240
Rev.0
IAS 1994
IAS1994
IES 2011
IES2011
j
p
Majoroperationsinthemanufactureofsteelballs
usedforBallbearingsaregivenbelow
1. Oillapping
2.
Coldheading
3. Annealing
4.
Hardening
55. Roughgrinding
g g
g
Thecorrectsequenceoftheseoperationsis
(a) 3,2,4,1,5
((c)) 2,3,4,5,1
,3,4,5,
(b)
( )
(d)
3,2,1,4,5
2,3,5,4,1
,3,5,4,
Strengthening by Grain Size

StrengtheningbyGrainSize
Reduction
Assertion (A) : The steel when heated above a

certain
temperature and
i
d cooled
l d to room
temperature, structure adjustment stabilizes.
Reason (R) : The modification is mainly based
on cooling rate.
((a)) Both A and R are individuallyy true and R is the
the
l
i off A
(d) A is
i false
f l but
b t R is
i true
t
Strengthening mechanisms in
Strengtheningmechanismsin
Metals
y Ability of a metal to deform plastically depends on ease of
dislocation motion under applied external stresses.

y As
A strengthening
h i off a metall consist
i hindering
hi d i dislocation
di l
i
motion. Dislocation motion can be hindered in many

ways, thus are strengthening mechanisms in metals.
y Strengthening by methods of grainsize reduction, solid
solution alloying and strain hardening applies for single
phase metals.
y Precipitation hardening, dispersion hardening, fiber
strengthening
t
th i and
d Martensite
M t it strengthening
t
th i are applicable
li bl
to multiphase metallic materials.
IES1998
y Thisstrengtheningmechanismisbasedonthefact
thatcrystallographicorientationchangesabruptlyin
passingfromonegraintothenextacrossthegrain
boundary.
y Thusitisdifficultforadislocationmovingona
commonslipplaneinonecrystaltopassovertoa
similarslipplaneinanothergrain,especiallyifthe
orientationisverymisaligned.
i t ti i
i li
d
y Inaddition,thecrystalsareseparatedbyathinnon
crystallineregion whichisthecharacteristicstructure
crystallineregion,whichisthecharacteristicstructure
ofalargeanglegrainboundary.
y Withdecreaseingrainsize,themeandistanceofa
dislocationcantraveldecreases,andsoonstartspile
upofdislocationsatgrainboundaries.Thisleadsto
increaseinyieldstrengthofthematerial.
y Grainsizereductionimprovesnotonlystrength,but
alsothetoughnessofmanyalloys.
y Grainsizecanbecontrolledbyrateofcooling,andalso
b l i d f
byplasticdeformationfollowedbyappropriateheat
i f ll
db
i h
treatment.
Assertion(A):Refiningthegrainsizeofa
polycrystallinematerialrendersitharderand
stronger.
Reason(R):Grainboundariesprovideeasypathsto
dislocationmotion.
explanationofA
Ai f l b tRi t
Contd
GATE1998
Decreasing
D
i grain
i size
i in
i a polycrystalline
l
t lli material
t i l
(a) Increases yield strength and corrosion resistance.
(b) Decreases
D
yield
i ld strength
h and
d corrosion
i resistance
i
(c) Decreases yield strength but increases corrosion
resistance
i t
(d) Increases yield strength but decreases corrosion
resistance.
resistance
IES 2010
IES2010
Assertion(A):Polycrystallinematerialisstronger
thanordinaryone.
thanordinaryone
Reason(R):Crystalsinpolycrystallinematerial
havedifferentorientationswithrespecttoeach
other.
Page 194 of 240
Solid Solution
SolidSolution
y A solid solution is formed when two metals are
completely soluble in liquid state and also completely

soluble in solid state. In other words, when
homogeneous
g
mixtures of two or more kinds of atoms
(of metals) occur in the solid state, they are known as
solid solutions.
y The
Th more abundant
b d t atomic
t i form
f
i referred
is
f
d as solvent
l
t
and the less abundant atomic form is referred as
solute.
y Example is brass. Brass is a solid solution of copper (64
percent) and zinc (36 percent). In this case copper
atoms are solvent
l
atoms whereas
h
zinc
i atoms are solute
l
atoms.
Rev.0
TYPES OF SOLID SOLUTIONS

TYPESOFSOLIDSOLUTIONS
1 Substitutional SolidSolutions
Solid Solutions
1.Substitutional
y Solidsolutionsareoftwotypes.
y If the atoms of the solvent or parent metal are replaced
y Theyare:
in
metall then
i the
h crystall lattice
l i by
b atoms off the
h solute
l
h
the solid solution is known as substitutional solid
solution.
solution
y For example, copper atoms may substitute for nickel
atoms without disturbing the F.C.C.
F C C structure of
nickel.
y In the substitutional solid solutions, the substitution
can be either disordered or ordered.
y HumeRothery
y formulatedcertainruleswhichgovern
g
theformationofsubstitutional solidsolutions.
(a)Substitutional solidsolutions.
(b)Interstitialsolidsolutions.
2 Interstitial Solid Solutions

2.InterstitialSolidSolutions
y In interstitial solid solutions, the solute atom does not
displace
a solvent
atom, but
di l
l
b rather
h it
i enters one off the
h
holes or interstices between the solvent atoms.
y An
A excellent
ll t example
l is
i ironcarbon
i
b
system
t
which
hi h is
i
shown in Fig.
y In this system the carbon (solute atom) atom occupies
an interstitial position between iron (solvent atom)

atoms.
y Normally,
Normally atoms which have atomic radii less than one
angstrom are likely to form interstitial solid solutions.
y Examples are atoms of carbon (0.77
(0 77 A
A)), nitrogen (0.71
(0 71
A), hydrogen (0.46 A), Oxygen (0.60 A) etc.
S lid l bili
Solidsolubility
y in a two element system
y
y Extent of solid solubility
can be
predicted based on HumeRuthery conditions.
y If the system obeys these conditions, then complete solid
p
solubilityy can be expected.
HumeRuthery conditions:
y Crystal structure of each element of solid solution must be
the same.
same
y Size of atoms of each two elements must not differ by more
than 15%.
y Elements
l
should
h ld not form
f
compounds
d with
h each
h other
h i.e.
there should be no appreciable difference in the electro
negativities of the two elements.
y Elements should have the same valence.
IES 2011
IES2011
Assertion (A) : Solid solutions of metal are
crystall whose
properties
to those
off
h
i are close
l
h
the solvent.
Reason (R) : They retain the same crystal lattice
and type of bond.
the
l
i off A
(d) A is
i false
f l but
b t R is
i true
t
Contd
INTERMETALLIC COMPOUNDS
INTERMETALLICCOMPOUNDS
y Intermetallic compounds are generally formed when
one metall (for

(f example
l magnesium)
i ) has
h chemical
h i l
properties which are strongly metallic and the other
metal (for example antimony,
antimony tin or bismuth) has
chemical properties which are only weakly metallic.
y Examples of intermetallic compounds are Mg2Sn,
Mg2Sn
Mg2Pb, Mg3Sb2 and Mg3 Bi2.
y These intermetallic compounds have higher melting
point than either of the parent metal.
y This higher
g
melting
gp
point indicates the high
g strength
g
of the chemical bond in intermetallic compounds.
IES2001
Whichofthefollowingfactorsgovernsolubilityof
twononferrousmetalsbothinliquidstate,as
wellasinsolidstate?
1.Crystalstructure
2.Relativesizefactor
3.Chemicalaffinityfactor
4.Relativevalence
factor
C d
Codes:
(a) 1,2and3
(b) 2,3and4
( ) 1and4
(c)
d
(d) 1,2,3and4
d
Page 195 of 240
IES 2010
IES2010
Consider the following:
1. Crystal structure 2. Relative size
33. Chemical affinityy 4
4. Valencyy
Which of these factors govern relative
solubility of two metals in each other in the
solid state?
(a) 1,
1 2 and 3 only
(b) 2, 3 and 4 only
(c) 1, 2 and 4 only
(d) 1, 2, 3 and 4
Rev.0
IES2006
Which
factors
is
Whi h one off the
th following
f ll i
f t
i more
relevant to represent complete solubility of two
metals in each other?
(a) Chemical affinity
(b) Valency factor
(c) Crystal structure factor (d) Relative size factor
Allotropictransformation
y When metals solidify,
solidify they assume a crystalline structure; that
is, the atoms arrange themselves in a geometric lattice.

y Many metals exist in only one lattice form. Some, however, can
exist
i t in
i the
th solid
lid state
t t in
i two
t or more lattice
l tti forms,
f
th particular
the
ti l
form depending on the conditions of temperature and pressure.
Such metals are said to be allotropic or polymorphic, and the
change
h
f
from
one lattice
l i form
f
to another
h is
i called
ll d an allotropic
ll
i
transformation.
y The most notable example
p of such a metal is iron, where the
allotropic change makes it possible for heattreating procedures
to produce a wide range of final properties.
y It is largely because of its allotropy that iron has become the
basis of our most important alloys.
IES 2010
IES2010
An allotropic material has
(a) Fixed structure at all temperatures
((b)) Atoms distributed in random p
pattern
(c)Different crystal structures at different
temperatures
(d) Fixed structure but random atom distribution
Plain Carbon steel

PlainCarbonsteel
y Duetolackoftensilestrengthandhardnesspureiron
isnotused.
i d
y Mostimportantalloyselementiscarbon.
y Maximumamountofcarbonthatcanbealloyedwith
ironis6.67%.
y Alloycontainingupto
All
i i
2%carbonissteelandabove2%
% b i
l d b %
arecausedcostIron.
BH
N
Hardness
Strength
0.02
Low carbonsteel:(lessthan0 3%C)

Lowcarbonsteel:(lessthan0.3%C)
y Goodformabilityandweldabilitybutlackhardenability
y Usedinhotforming,coldformingetc.
y
y
y
y
y
y
y
MediumcarbonsteelorMildsteel(0.3%to0.8%carbon)
hightoughness&ductility
Mostwidelyusedsteel
y
Heattreatable(austenitizing,quenchingandtempering).
Hardenability isincreasedbyaddingNi,Cr,Mo.
Usedinvarioustemperedconditions
Usedinvarioustemperedconditions.
Typicalapplications:gears,railwaytracks,machineparts.
Highcarbonsteel(morethe0.8%C)
Hardness&wearresistancearehighbutToughness&
formabilityisverylow
Note purestformofIroni.e.wroughtironhasleastcarbon
content.
%Carbon
1.4
Reduction area
IES 2005
IES2005
1. Strengthofsteelincreaseswithcarboncontent.
2 Young
2.
Young'sModulusofsteelincreaseswithcarbon
sModulusofsteelincreaseswithcarbon
content.
3. Young
Young'sModulusofsteelremainsunchangedwith
sModulusofsteelremainsunchangedwith
variationofcarboncontent.
g
/
(a) 1only
(b) 2only
(c) 1and2
(d) 1and3
0.02 %Carbon
IES 2005
IES2005
IES 1995
IES1995
g
Considerthefollowingstatementsaboutmedium
carbonsteel:
1. Itcanbequenchhardenedbutnotcasehardened.
2. Itcannotbequenchhardenedbutcasehardening
canbedone.
3. Itexhibitsdistinctyieldpointundertensiontest.
It hibit di ti t i ld i t d t i t t
Whichofthefollowingstatementsgivenaboveare
correct?
(a) 1and2
(b) 2and3
(c) 1and3
(d) 1,2and3
ListI(Alloy)
ListII(Use)
A Lowcarbonsteel
A.
L b
l
1.
B i
Bearing
B. Hadfieldmanganesesteel
2.
Thermocouple
C Constantan
C.
3
3.
Wirenails
Wirenails.
D. Babbittalloy
4.
Bulldozer
blades.
Code:A
B
C
D
A
B
C
D
(a) 1
2
3
4
(b) 3
4
1
2
( ) 3
(c)
2
1
4
(d) 3
4
2
1
Page 196 of 240
Rev.0
IES 2005
IES2005
(
)
( pp
)
MatchListI(Steel)withListII(Application)and
selectthecorrectanswerusingthecodegivenbelow
theLists:
ListI
ListII
A. MildSteel
1.
Ballbearing
B. ToolSteel
2.
Coldchisels
C. HighCarbonSteel
3.
Shaftandaxles
D. MediumCarbonSteel 4.
Rolledsteelsections
Codes:A
B
C
D
A
B
C
D
(a) 2
1
4
3
(b) 4
3
2
1
( ) 2
(c)
3
4
1
(d) 4
(d)
1
2
3
IES 2007
IES2007
Whichofthefollowingfactorsinfluenceinaplain
carbonsteel?
g
1. Percentagecarbon
2. Quenchingmedia
3. Worksize
Selectthecorrectanswerusingthecodegivenbelow
(a) 1and2only
(b) 2and3only
(c) 1and3only
(d) 1,2and3
IAS 2002
IAS2002
MatchListI(Percentageofcarboncontentinplaincarbonsteel)with
ListII(Application)andselectthecorrectanswerusingthecodes
givenbelowthelists:
ListI
ListII
((Percentageofcarboncontent
g
((Application)
pp
)
inplaincarbonsteel)
A.010 020
1.Drophammers
B.030 040
2.Razors
C.060 070
3.Structures
D.110 140
4.Cranehooks
Codes:A
B
C
D
A
B
C
D
( ) 3
(a)
4
2
1
(b)
4
3
1
2
(c) 3
4
1
2
(d)
4
3
2
1
GATE 1992
GATE1992
Thetruestrainforalowcarbonsteelbarwhichis
doubledinlengthbyforgingis
((a)) 0.307
3 7
(b) 0.5
(c) 0.693
(d) 1.0
FigIronCarbonEquilibriumDiagram
Fe C equilibrium diagram
FeCequilibriumdiagram
y The structural form of pure iron at room temperature
is
i called
ll d ferrite
f i or iron.
i
y Ferrite is soft and ductile.

y Since ferrite has a bodycentred cubic structure, the
interatomic spaces are small and pronouncedly

oblate, and cannot readily accommodate even a small
oblate
carbon atom. Therefore, solubility of carbon in ferrite
is very low, of the order of 0.006% at room
temperature.
y The maximum carbon content in ferrite is 0.05%
5 at 77233
C.
FigIronCarbonEquilibriumDiagram
For-2015
(IES, GATE & PSUs)
OrthorhombicFe
Page3C.Ironatomsareblue.
197 of 240
Rev.0
Contd
I addition
dditi
t carbon,
b
t i amountt off silicon,
ili
y In
to
a certain
manganese and phosphorous may be found in ferrite.
y The face
centred modification of iron is called
facecentred
austenite or iron. It is the stable form of pure iron at
temperatures between 910C and 1400C. At its stable
temperature austenite
i
i soft
is
f and
d ductile
d il and
d
consequently, is well suited for manufacturing
processes.
y The facecentred cubic structure of iron has larger
interatomic spacing than in ferrite. Even so, in FCC
structure the interstices are barely large enough to
accommodate carbon atoms, and lattice strains are
produced As a result,
produced.
result not all the interstitial sites can
be filled at any one time.
y The maximum solubility is only 2% of carbon at 11
30C.
y Above 1400C, austenite is no longer the most stable
form of iron, and the crystal structure changes back to
a bodycentred
b d
d cubic
bi phase
h
called
ll d delta
d l iron.
i
Thi is
This
i
iron except for its
the same phase as the
temperature range.
range
y The solubility of carbon in ferrite is small, but it is
appreciably larger than In ferrite
ferrite, because of higher
temperature. The maximum solubility of carbon in
&iron is 0.1% at 1490C.
49
Contd
y In the reaction, the simultaneous formation of ferrite
and cementite from austenite results at the

temperature of 723
C and composition of 0.80%
723C
0 80%
carbon.
y There are nearly
y 12% of iron carbide and slightly
g y more
than 88% of ferrite in the resulting mixture.
y Since the ferrite and cementite are formed
simultaneously,
i lt
l
th
they
are
i ti t l
intimately
mixed.
i d
Characteristically, the mixture is lamellar, i.e., it is
composed
p
of alternate layers
y of ferrite and cementite.
y This microstructure is called pearlite which is very
important in iron and steel technology, because it can
b formed
be
f
d in
i almost
l
all
ll steels
l by
b means off suitable
i bl
heat treatments.
y Thealloycontaining0.80%ofcarboniscalledthe
eutectoidsteel.
y Uponcoolingtheeutectoidsteelbelow723C,allof
theausteniteistransformedintopearlite.
y Alloyswithlessthan0.80%Carecalledhypo
All i hl h 8 %C ll dh
eutectoidsteelsandthosewithhighercompositionare
calledhyper eutectoidsteels
calledhypereutectoidsteels.
Contd
y FeFe3Cphasediagramischaracterizedbyfiveindividual
phases,:ferrite(BCC)FeCsolidsolution,austenite(FCC)
FeCsolidsolution,ferrite(BCC)FeCsolidsolution,Fe
F C lid l ti f it (BCC)F C lid l ti F 3C
(ironcarbide)orcementite anintermetalliccompoundand
liquidFeCsolutionandfourinvariantreactions:
y peritectic reaction at1495oC and0.16%C,ferrite+L
i (
iron(austenite)
i )
y monotectic reaction 1495oC and0.51%C,L L+iron
(austenite)
y eutecticreaction at1147oC and4.3%C,L iron+Fe3C
(cementite)[ledeburite]
y eutectoidreaction at723oC and0.8%C,iron ferrite+
Contd
IES2004
limit must form a second phase, which is called iron

carbide or cementite.
y Iron carbide has the chemical composition of Fe3C . This
does not mean that iron carbide forms molecules of
Fe3C but simply that the crystal lattice contains iron and
carbon atoms in a three to one ratio.
y The compound Fe3C has an orthorhombic unit cell with
twelve iron atoms and four carbon atoms per cell, and thus
has a carbon content of 6.67%.
y As compared to austenite and ferrite,
ferrite cementite being an
intermetallic compound, is very hard and brittle.
y The presence of iron carbide with ferrite in steel greatly
increases the
h strength
h off steel.
l
Contd
Contd
Three
Three phasereactions
y Suffix ic denotesatleastoneliquidphaseisthere
y Suffix
Suffix oid allphasesinvolvearesolid
I ironcarbon
i
b
ll
b
i excess off the
th solubility
l bilit
y In
alloys,
carbon
in
Considerthefollowingtemperatureranges:
C
id th f ll i t
t
1.Roomtemperature
2.0to910C
oC
oCtobelowmelting
3.910Cto1400
C
4.1400
C b l l i
point
I hi h fth b t
Inwhichoftheabovetemperaturerangesferritewith
t
f it ith
bodycenteredcubicstructureisindicatedin,theFe
Fe3Cphasediagram?
(a)1,2and4(b)2,3and4(c)1and3
(d)2and3
Page 198 of 240
Fe3C(cementite)[pearlite]
Contd
IES1992
Themicrostructurecompositionofpearlite fora
Fe3Cdiagramconsistsof
(a) Carbondissolvedinalphaironhavingabody
canteredcubicstructure.
(b) Carbondissolvedingama ironhavingaface
canteredcubicstructure.
(c) Amixtureofbodycanteredalphaironandface
enteredgammairon
(d) Carbondissolvedinbodycanteredalphaironand
anFe,Fe3C.
Rev.0
IES 2011
IES2011
Liquid + solid (1) on cooling converting solid (2)
reaction is known as:
(a) Eutectoid reaction
(b) Eutectic reaction
(c) Peritectic reaction
(d) Peritectioid reaction
IES 2010
IES2010
Ironcarbon equilibrium diagram
(a) Correlates the microstructure and properties of
steel and cast iron
(b) Indicates the phase changes occurring during
g and cooling
g
heating
(c) Is made by plotting carbon percentage along X
axis and temperature along Yaxis.
Yaxis
(d) All of the above
IES 1995
IES1995
IES 2004
IES2004

answer using the codes given below the lists:
List I (Name of Material) List II (% Carbon Range)
A Hypoeutectoid
A.
id steell 1.
4.3 6.67
B. Hypereutectoid steel 2.
2.0 4.3
C Hypoeutectic
C.
H
t ti castt iron
i
3.
0.8
8 2.0
D. Hypereutectic cast iron 4. 0.008 0.8
Codes A B
Codes:A
C
D
A
B
C
D
(a) 4
3
2
1
(b) 1
3
2
4
(c) 4
1
2
3
(d) 1
2
3
4
y
y
5
y
g
Anironcarbonbinaryalloyhas0.5%Cbyweight.
Whatisthisalloycalled?
(a) Eutectoidalloy
(b) Eutecticalloy
((c)) Hypoeutectoidalloy
yp
y
(d) Hypereutectoidalloy
IES 2005
IES2005
The eutectoid of carbon in iron,, above lower
critical temperature, when cooled, results in:
(a) Ferrite and austenite
(b) Ferrite and cementite
((c)) Cementite and austenite
(d) Ferrite, cementite and austenite
IES 2010
IES2010
Pearlite phase in an ironcarbide phase
diagram
is
di
i
(a) Eutectic phase
(b) Hypoeutectic mixture
(c) Eutectoidal mixture
(d) Hypereutectic phase
IES 1995
IES1995
Eutectoidreactionoccursat
(a) 600C
((b)) 7723C
3
(c) 1147C
(d) 1493
1493C
C
GATE 1992
GATE1992
IES 2006
IES2006
Matchthetermsusedinconnectionwithheattreatmentofsteelwith
themicrostructural/physicalcharacteristics:
Terms
Characteristics
(A) Pearlite
(P)Extremelyhardandbrittlephase
(B) Martensite
(Q)Cementite isfinelydispersedinferrite
(C) Austenite
(R)Alternatelayersofcementite andferrite
(D) Eutectoid
(S)Canexistonlyabove723C
( )
(T)Pertainingtostateofequilibriumbetweenthree
g
q
solidphases
(U)Pertainingtostateofequilibriumbetweenone
liquidandtwosolidphase
Codes: A
B
C
D
A
B
C
D
(a) R
P
S
T
(b)
R
S
P
T
(c) T
R
P
S
(d)
T
R
S
P
Match ListI (FeFe3C Phase Diagram Characteristic) with

ListII
the
Li II (Phase)
(Ph
) and
d select
l
h correct answer using
i the
h code
d
ListI
ListII
A. Alpha () iron
1. iron
B. Iron carbide having crystal lattice
2.Eutectic
with
t 3 iron
o aand
d 1 ca
carbon
bo ato
atom
C. BCC pure allotrope of iron is stable
3.Ferrite
between 1388 C and is melting
point at 1535
1535C
C
4 Cementite
4.Cementite
Codes:A
B
C
A
B
C
(a) 4
2
3
(b)
3
4
1
( ) 4
(c)
2
1
( )
(d)
3
1
2
Page 199 of 240
Rev.0
IES 2002
IES2002
IES 1999
IES1999
IES 1993
IES1993
Match List I with List II and select the correct answer:

List I (Phase diagram)
List II (Characteristic)
A. Isomorphous system
1.One liquid decomposes into another
liquid and solid
BE
B.Eutectic
i system
2.One
O liquid
li id and
d another
h solid
lid combine
bi to
form a new solid
C.Peritectic system
3.Two metals are completely soluble in
liquid state And completely insoluble in
solid state
D.Monotectic system
4.Two metals, soluble in solid and liquid
state
Codes: A
B
C
D
A
B
C
D
(a) 2
3
4
1
(b)
4
1
2
3
(c) 2
1
4
3
(d)
4
3
2
1
Inaeutecticsystem,twoelementsarecompletely
(a) Insolubleinsolidandliquidstates
(b) Solubleinliquidstate
(c) Solubleinsolidstate
(d) Insolubleinliquidstate
Eutecticreactionforiron
carbonsystemoccursat
Eutecticreactionforironcarbonsystemoccursat
(a) 600C
(b) 723
723C
C
(c) 1147C
(d) 1493
1493C
C
IES 2000
IES2000
IES 2007
IES2007
IES 2005
IES2005
Duringperitectic solidification,oneliquid
(a) Combineswithonesolidtoformasecondnew
solid
(b) Solidifiesintotwodifferentsolids
(c) Formsonesolid
(d) Formsonesolidandanotherliquid
IES 2005
IES2005
A60C
plaincarbonsteelhas,approximately:
A60Cplaincarbonsteelhas,approximately:
(a) 75%ofpearlite and25%offerrite
(b) 25%ofpearlite and75%offerrite
(c) 75%ofcementite and25%offerrite
(d) 75%ofpearlite and25%ofcementite
g is the correct
statement?
Pearlite in ironcarbon system is a
(a) Phase consisting of ferrite and cementite at room
temperature
(b) Mechanical
M h i l mixture
i t
off ferrite
f it and
d cementite
tit att
room temperature
(c) Eutectic mixture ferrite and cementite at room
temperature
((d)) All the above three are correct
IES 2000
IES2000
Pearlite consistsof
(a) 6.67%Cand93.33%ferrite
(b) 13%Feand87%cementite
(c) 13%Cand87%ferrite
(d) 13%cementite and87%ferrite
Page 200 of 240
Increaseofferritephaseinsteelincreases:
(a) Strength
(b) Hardness
(c) Ductility
(d) Brittleness
IES 1997
IES1997
A given steel test specimen is studied under
metallurgical microscope. Magnification used is
100 X. In that different phases are observed. One
of them is Fe3C. The observed phase Fe3C is also
known as
(a) Ferrite
(b) Cementite
(c) Austenite
(d) Martensite
Rev.0
IES 1995
IES1995
IES 2001
IES2001
Which one of the following sets of constituents is

expected
in
equilibrium
cooling
of
a
hypereutectoid steel from austenitic state?
(a) Ferrite and pearlite
((b)) Cementite and p
pearlite
(c) Ferrite and bainite
((d)) Cementite and martensite
1 E
i ( F C)
1.Eutectic(FeC)
Martensite is a super
saturated solution of carbon
supersaturated
in
((a)) Alpha
p iron
(b) Beta iron
(c) Gamma iron
(d) Delta iron
2 P i
i (FeC)
( F C)
2.Peritectic
3 M
i FeO
F O2SiO
SiO2
3.Monotectic
y (L+S1S2)
y (L1S1+L2)
y One Liquid and another solid combine to form a new
y One Liquid decomposes into another liquid and solid.
y (L1S1+S2)
y Two materials are completely soluble in liquid state
and completely
p
y insoluble in solid state.
+ L
+L
4 S
i NaZn
N Z
4.Syntectic
y (L1+L2S1)
solid.
L
L+
+L
L
+
L1
L1
L 1+L 2
L2
L2
+ L2
L1
L2
L1 L 2
L+
L1+ L2+
5 E
id F C
5.EutectoidFeC
y (S1S2+S3)
6 P i
id CuAl
C Al
6.Peritectoid
y S1 +S2S3
+r
+
complete intersolubility between components in all

phases,
phases the system is isomorphus.
isomorphus
Ex: CuNi, Al2O3Cr2O3, NiOMgO
y Azeotropic system: Some of isomorphus binary
system, the liquidus touches, the solid tangentially at a
minimum temperature which is lower then milting
temperature of either of the two components.
AuCu,AuNi
r
+
I
h system: In
I a binary
bi
h there
h
i
y Isomorphus
system when
is
Page 201 of 240
L
+L
+L
+p
A
B
CompositionBw/o
Rev.0
IES 2007
IES2007
IES 2004
IES2004
MatchListIwithListIIandselectthecorrectanswerusingthe
codegivenbelowtheLists:
d i
b l th Li t
ListI
ListII
(NameoftheInvariant
(InvariantReactionduring
Reaction)
cooling)
A. Monotectic
1.LIQUID.SOLID1+SOLID2
B. Eutectic
2.LIQUID1..LIQUID2+SOLID
C
C.
E t t id
Eutectoid
3.SOLID1..SOLID1+SOLID2
SOLID
SOLID SOLID
D. Peritectic
4.LIQUID+SOLID1..SOLID2
Consider the following lead

tin phase diagram
leadtin
given below:
g alloy
y compositions,
p
,
For which one of the following
the alloy will have the lowest melting point at 185oC
((a)) 20% Sn and 80% Pb byy weight
g
(b) 60% Sn and 40% Pb by weight
((c)) 97
97% Sn and 33% Pb byy weight
g
(d) 40% Sn and 60% Pb byweight
Code: A
(a) 3
(c) 3
B
1
4
C
2
2
D
4
1
(b)
(d)
A
2
2
B
4
1
C
3
3
D
1
4
IES 2008
IES2008
Assertion (A): Lever Rule can be applied to determine
relative
amounts off phases
present at any
l
h
temperature.
Reason (R): Lever Rule is restricted to estimate
relative phases, only if they are solid phases.
(a) Both A and R are true and R is the correct explanation
off A
explanation of A
)
g
p
(
)
p
method)alongwithrelativefractionofphases(leverrule)canbecomputed.
y Relativeamountofliquidandsolidphasesisgivenrespectivelyby:
CL =
cV
UV
CS =
Uc
UV
CL + CS = 1
y Thereforeitisnotrestrictedtosolidphasesonly.
Example
a pe
y In a binary system of A and B, if a liquid of 35% A (65%
B) is coexists with a solid of 75% A (25% B), for an

overall composition of 40% A, the fraction of the liquid
is given by
CL =
75 40
= 0.875
75 35
F C ll
l ifi i
FeCalloyclassification
IES 2003
IES2003
Calloysareclassifiedaccordingtowt.%Cpresent
y Fe
FeCalloysareclassifiedaccordingtowt.%Cpresent
According to Gibbs
Gibbs' phase rule, the number of
degrees of freedom of an eutectic point in a binary
system is
(a) 1
((b)) 2
(c) 0
((d)) 3
inthealloyfortechnologicalconvenienceasfollows:
y Commercialpureirons
p
%C<0.008
y Lowcarbon/mildsteels
0.008 %C 0.3
y Mediumcarbonsteels
0.3 %C
0.3
%C 0.8
y Highcarbonsteels
0.8 %C 2.11
y Castirons
2 11<%C
2.11<%C
L
R l
LeverRule
y Atapointinaphasediagram,phasespresentandtheircomposition(tieline
Page 202 of 240
Rev.0
Cast Iron
CastIron
y remelting
gp
g iron with
y The cast iron is obtained by
pig
coke and limestone in a furnace known as cupola.
y It is primarily an alloy of iron and carbon.
y The properties of cast iron which make it a valuable
material for engineering purposes are its low cost,

good
g
y The carbon content in cast iron varies from more than
2 per cent to 4.5 per cent.

y The carbon in a cast iron is present in either of the
following two forms:
1. Free carbon or graphite, and
2. Combined carbon or cementite.
casting
g
characteristics,
high
g
compressive
p
strength, wear resistance and excellent machinability.

y The
Th compressive
i strength
t
th off castt iron
i
i much
is
h greater
t
than the tensile strength.
Contd
IES 2010
IES2010
Assertion (A): A cast iron specimen shall fail due to
shear when subjected to a compressive load.
load
Reason (R): Shear strength of cast iron in
compression is more than half its compressive
strength.
IES 1998
IES1998
g
y
Assertion(A):Castironisgenerallyhard,brittleand
wearresistant.
Reason(R):Castironcontainsmorethan2%carbon
andassuchthepercentagecementite
d
h h
i initishigher.
i i i hi h
explanationofA
p
IES 2005
IES2005
g
1. CastIronhaspoorabilitytodampvibrations.
g
p
g
2. CastIronhashighercompressivestrength
comparedtothatofsteel.
33. CastIronpartsaresuitablewherepermanent
p
p
deformationispreferredoverfracture.
(a) 1,2and3
(b) 1and3
((c)) 33only
y
((d)) 2onlyy
IES 1997
IES1997
( )
y
Assertion(A):Thenotchsensitivityofcastiron
componentiszero.
Reason(R):Castirondoesnothaveayieldpoint.
Page 203 of 240
IES 1999
IES1999
Castironisusedformachinebedsbecauseofits
high
(a) Tensilestrength
(b) Endurancestrength
((c)) Dampingcapacity
p g p
y
(d) Compressivestrength
IAS 2003
IAS2003
1. Fromdesignconsiderations,itisalways
advantageoustoplacecastironribsonthetension
sideratherthanonthecompressionside.
sideratherthanonthecompressionside
2. Castironisanexcellentchoiceformachinetool
guidesandframes.
3. Castironpartshavelownotchsensitivity.
(a) 1,2and3
(b) 2and3
((c)) 1and3
3
((d)) 1and2
Rev.0
IES 1992
IES1992
g
Whichofthefollowingmetalshrinksmostfrom
moltenstatetosolidstate?
(a) Castiron
(b) Caststeel
(c) Brass
(d) Admiraltymetal
T pes of Cast Iron

TypesofCastIron
1 Gre cast iron

1.Greycastiron
y Cast
irons that were slowlyy cooled to room

temperature consist of cementite, look whitish white
cast iron.
y If it contains graphite, look grayish gray cast iron.
y It is heat treated to have graphite in form of nodules
malleable cast iron.
y If inoculants are used in liquid state to have graphite
nodules
d l spheroidal
h
d l graphite
h (SG)
( ) cast iron.
5 ;
y Carbon = 3 to 33.5%;
y The grey colour is due to the fact that the carbon is
present in the form of free graphite.

y It has a low tensile strength, high compressive strength
and no ductility.
y It can be easily machined.
y A very good property of grey cast iron is that the free
graphite in its structure acts as a lubricant. Due to this
reason, it is very suitable for those parts where sliding
action
i is
i desired.
d i d
Contd
y The grey iron castings are widely used for machine tool
bodies,
bodies automotive cylinder blocks,
blocks heads,
heads housings,
housings
flywheels, pipes and pipe fittings and agricultural
implements.
y The grey cast iron is designated by the alphabets FG
followed byy a figure
g
indicating
g the minimum tensile
strength in MPa or N/mm2. For example, FG 150
means grey cast iron with 150 MPa or N/mm2 as
minimum tensile strength.
GATE 2004
GATE2004
p
g
g y
Thepercentageofcarboningraycastironisinthe
rangeof
(a) 0.25to0.75percent
(b) 1.25to1.75percent
((c)) 33to4percent
4p
(d) 8to10percent
IES 1994
IES1994
Assertion(A):Machinetoolbedsaregenerally
madeofgreycastiron.
Reason(R):Castironpossessesgoodself
lubricatingproperties.
lubricatingproperties
IES 2007
IES2007
p g
y
Vibrationdampinginmachineryisbestachieved
bymeansofbasestructuresmadeofwhichoneof
thefollowingmaterials?
(a) Lowcarbonsteel
(b) Nodulariron
(c) Greycastiron
(d) Whitecastiron
Page 204 of 240
Contd
IES 2005
IES2005
(DesignationofSteel/CastIron)
(Description)
(D i
ti fSt l/C tI
)
(D
i ti )
1.
FeE250
:Minimumtensile
strengthof250
N/mm2
2.
40C8
:Percentageof
Manganeseis0.7%
0.9%
3.
FG200
:Greycastironwith
ultimatetensilestrength
of200N/mm2
S l tth
t
i th d i b l
(a) 1and2
(b)
2and3
(c) 1and3
(d)
1,2and3
IES 2003
IES2003
Machinetoolmanufacturersprefergreycastiron
grade40forproducingmachinecolumnsand
tablesbecausegreycastironis
1 Heavy
1.
2
2.
Easilycastable
3. Easilyweldable
4.
Havinggood
dampingcapacity
C
Codes:
(a) 1and2
(b) 2and4
((c)) 1and33
((d)) 33and4
4
Rev.0
IES 1993
IES1993
Assertion(A):Fracturesurfaceofgreycastironis
dark.
Reason(R):Failuretakesplacealongtheweak
cementite plates.
plates
2 White cast iron

2.Whitecastiron
IES 2005
IES2005
75 to 2.3%.
3
y Carbon = 1.75
g
Whichofthefollowingmaterialsisusedinthe
manufactureofextrusionnozzles?
(a) Greycastiron
(b) Malleablecastiron
((c)) Whitecastiron
(d) Nodularcastiron
y The white colour is due to fact that it has no graphite
and whole of the carbon is in the form of carbide

(known as cementite) which is the hardest constituent
of iron.
y The white cast iron has a high tensile strength and a
low compressive strength.
3 Chilled cast iron

3.Chilledcastiron
4 Mottled cast iron

4.Mottledcastiron
5 Malleable cast iron

5.Malleablecastiron
g of
y It is a white cast iron p
produced byy q
quick cooling
y It is a p
product in between g
greyy and white cast iron in
y which
y The malleable iron is a cast ironcarbon alloy
molten iron.
y The quick cooling is generally called chilling and the
cast iron so produced is called chilled cast iron.
composition, colour and general properties.

y It is obtained in castings where certain wearing
surfaces have been chilled.
y Chills are used on any faces of a casting which are
required to be hard to withstand wear and friction.
solidifies in the ascast condition in a graphite free

structure, i.e. total carbon content is present in its
combined
bi d form
f
as cementite
i (Fe
( 3C).
C)
y It is ductile and may be bent without breaking or
f t i the
fracturing
th section.
ti
y The tensile strength of the malleable cast iron is
usuall higher than that of grey
usually
gre cast iron and has
excellent machining qualities.
Contd
y It is used for machine parts for which the steel forgings
would be too expensive and in which the metal should

have
a fair
off accuracy, e.g. hubs
h
f i degree
d
h b off wagon
wheels, small fittings for railway rolling stock, brake
supports, parts of agricultural machinery, pipe fittings,
door hinges, locks etc.
y In order to obtain malleable iron castings, it is first cast
into moulds
ld off white
h cast iron. Then
h by
b a suitable
bl heat
h
treatment (i.e. annealing), the combined carbon of the
white cast iron is separated into nodules of graphite.
graphite
y There are two process:
1. Black
Blackheart
heart process,
2. Whiteheart process
Contd
1 Blackheart process
1.Blackheartprocess
2 Whiteheart process
2.Whiteheartprocess
y In this process the white iron castings are heated in
y In this process the castings are packed into airtight boxes
airtight boxes out of contact with air at 850

950 deg C for
850950
50170 hours, depending upon the mass and thickness of
the castings.
y The effect of this prolonged heating is to break down the
iron carbide (cementite) of the white cast iron into small
rosettes of graphite.
graphite
y The name 'blackheart' comes from the darkened
appearance of the iron, when fractured, resulting from the
formation of free graphite.
y It is used in the wheel hubs, break drums, conduit fitting
control levers and pedals.
Page 205 of 240
g g
ore.
with iron oxide in the form of highgrade
y They are then heated to about 1000 deg C for between 70
y
y
and 100 hours, depending upon the mass and thickness of

the castings.
castings
The ore oxidises the carbon in the castings and draws it
out, leaving a ferritic structure near the surface and a
pearlitic structure near the centre of the casting.
There will also be some fine rosettes of graphite.
Whit h t castings
Whiteheart
ti
b h
behave
much
h as expected
t d off a mild
ild
steel casting, but with the advantage of a very much lower
melting point and higher fluidity at the time of casting.
It is used in the wheel hubs, bicycle and motor cycle frame
fittings, gas, water and steam pipe fittings.
Rev.0
IES 1992
IES1992
g
p yp p
Whichofthefollowingdisplaypropertiessimilar
tothatofsteel
1. Blackheartcastiron
2. Whiteheartcastiron
33. Graycastiron
y
4. Pigiron
((a)) 1and2onlyy
((b)
) 33and4only
4
y
(c) 2and4only
(d) 1and3only
IES 1992
IES1992
Forthepipefittinglikeelbow,tee,unionetc.
whichofthefollowingispreferred?
((a)) Pigiron
g
(b) Malleableiron
(c) Spheroidal graphitecastiron
(d) Highcarbonsteel
6 Nodular or spheroidal graphite

graphite
6.Nodularorspheroidal
castiron
y The nodular or spheroidal graphite cast iron is also
called ductile cast iron or high

g strength
g cast iron.
y This type of cast iron is obtained by adding small
amounts of magnesium (0.1 to 0.8%) to the molten

grey iron.
y The addition of magnesium causes the graphite to take
form of small nodules or spheroids instead of the
normal angular flakes.
Contd
IES 2001
IES2001
IES 2009
IES2009
g
, wear resistance,, p
g
,
toughness,
pressure tightness,
weldability and machinability.
y It is g
generallyy used for castings
g requiring
q
g shock and
impact resistance along with good machinability, such
as hydraulic cylinders, cylinder heads, rolls for rolling
mill
ll and
d centrifugally
f
ll cast products.
d
y SG 400/15 means spheroidal graphite cast iron with
400 MPa
MP as minimum
i i
tensile
il strength
h and
d 15 percent
elongation.
g y
g y
Nodulargreycastironisobtainedfromthegrey
castironbyaddingasmallamountof
(a) Manganese
(b) Phosphorus
((c)) Magnesium
g
(d) Chromium
g
Whichoneofthefollowingcastironsconsistsof
carboninrosetteform?
(a) Whitecastiron
(b) Graycastiron
((c)) Malleablecastiron
(d) Nodularcastiron
IES 1995
IES1995
Wro ght Iron

WroughtIron
Effect of Imp rities on Cast Iron

EffectofImpuritiesonCastIron
g
Additionofmagnesiumtocastironincreasesits
(a) Hardness
((b)) Ductilityandstrengthintension
y
g
(c) Corrosionresistance
(d) Creepstrength.
5 iron
y It is the p
purest iron which contains at least 99
99.5%
p 4
1. Silicon. It mayy be p
present in cast iron upto
4%. It
provides the formation of free graphite which makes
the iron soft and easily machinable. It also produces
sound
d castings
i
f
free
f
from
bl
blowholes,
h l
b
because
off its
i
high affinity for oxygen.
y It has high fluidity, castability, tensile strength,
but may contain upto 99.9% iron.

y The wrought iron is produced from pig iron by
remelting it in the puddling furnace of reverberatory
type.
y The wrought iron is a tough, malleable and ductile
material.
y It can be
b easily
l forged
f
d or welded.
ld d It is used
d for
f chains,
h
crane hooks, railway couplings, water and steam pipes.
Page 206 of 240
2. Sulphur. It makes the cast iron hard and brittle. Since

too much sulphur gives
gi es unsound casting,
casting therefore,
therefore it
should be kept well below 0.1% for most foundry
purposes.
purposes
Rev.0
Contd
3. Manganese. It makes the cast iron white and hard. It

p below 0.75%.
75
p to exert a
is often kept
It helps
controlling influence over the harmful effect of
sulphur.
4. Phosphorus. It aids fusibility and fluidity in cast
iron, but induces brittleness. It is rarely allowed to
exceed 1%. Phosphoric irons are useful for casting of
i i
intricate
d i
design
and
d for
f
many light
li h engineering
i
i
castings when cheapness is essential.
IES 1995
IES1995
g
Considerthefollowingworkmaterials:
1. Titanium
2.
Mildsteel
33. Stainlesssteel 4
4.
Greycastiron.
y
Thecorrectsequenceofthesematerialsintermsof
increasingorderofdifficultyinmachiningis
g
y
g
(a) 4,2,3,1
(b) 4,2,1,3
((c)) 2,4,3,1
,4,3,
((d)) 2,4,1,3.
, 4, , 3
IES 1995
IES1995
IES 2007
IES2007
g
Additionofsilicontocastiron
g p
1. Promotesgraphitemoduleformation.
2. Promotesgraphiteflakeformation.
3. Increasesthefluidityofthemoltenmetal.
4. Improvestheductilityofcastiron.
(a) 1and4
(b) 2and3
(c) 1and3
(d) 3and4
p
g
Pistoncompressionringsaremadeofwhichone
ofthefollowing
(a) Castiron
(b) Bronze
(c) Aluminium
(d) Whitemetal
IES 1994
IES1994
Whichofthefollowingpairsarecorrectly
matched?
1. LeadscrewnutPhosphorbronze
2. Piston..Castiron.
i
C i
3. Cam..EN31steel
4. Leadscrew..Wroughtiron.
L d
W
hti
Codes:
Codes
(a) 2,3and4
(b) 1,3and4
(c) 1,2and4
1 2and4
(d) 1,2and3
1 2and3
IAS 2002
IAS2002
p
g
Acastironspecimeninatorsiontestgivesa
(a) Cupandconefracture
((b)) Fracturealongaplanenormaltotheaxisofthe
g p
specimen
((c)) Fracturealongahelixofapproximately45
g
pp
y 45
(d) Fracturealongaplaneinclinedat60 totheaxis
Page 207 of 240
Rev.0
All St l
AlloySteel
y Definition:
A steell to which
f
h h one or more alloying
ll
elements other than carbon have been deliberately

added (e.g.
(e g chromium,
chromium nickel,
nickel molybdenum) to
achieve a particular physical property.
1 Ni k l
1.Nickel
y It has proved to be of advantage in the manufacture of
g and toughness
g
y It increases the strength
of the steel.
y These steels contain 2 to 5% nickel and from 0.1 to
0.5% carbon.
y In this range, nickel contributes great strength and
hardness with high elastic limit, good ductility and
good resistance to corrosion.
y An alloy containing 25% nickel possesses maximum
toughness
h
and
d offers
ff
the
h greatest resistance to rusting,
corrosion and burning at high temperature.
p
boiler tubes,, valves for use with superheated
steam,,
valves for I.C. engines and spark plugs for petrol
engines.
y A nickel steel alloy containing 36% of nickel is known
as invar. It has nearly zero coefficient of expansion. So
it is in great demand
d
d for
f measuring instruments and
d
standards of lengths for everyday use.
Contd
IES 1992
IES1992
g p p
y
Invarisusedormeasuringtapesprimarilytheto
its
(a) Nonmagneticproperties
(b) Highnickelcontent
((c)) Lowcoefficientofthermalexpansion
p
(d) Hardenability
IES 2008
IES2008
p
p
y
CoefficientofExpansionispracticallynilina
particularalloy.Whatisthisalloy?
(a) HadfieldManganeseSteel
(b) Invar
((c)) Vitallium
(d) Stellite
2 Ch
i
2.Chromium
3 T
t
3.Tungsten
y It is used in steels as an alloying element to combine
p
y It p
prohibits g
grain g
growth,, increases the depth
of
hardness with high strength and high elastic limit.

y It also imparts corrosionresisting properties to steel.
y The
h most common chrome
h
steels
l contains
i from
f
0.5 to
2% chromium and 0.1 to 1.5% carbon.

y The chrome steel is used for balls,
balls rollers and races for
bearings.
y A nickel chrome steel containing
g 33.25%
5% nickel,, 1.5%
5%
chromium and 0.25% carbon is much used for armour

plates. Chrome nickel steel is extensively used for
motor
t car crankshafts,
k h ft axles
l and
d gears requiring
i i greatt
strength and hardness.
hardening of quenched steel and confers the property

of remaining hard even when heated to red colour.
y It is usually used in conjunction with other elements.
y Steel containing 3 to 18% tungsten and 0.2 to 1.5%
carbon is used for cutting tools.
y The principal uses of tungsten steels are for cutting
tools,
l dies,
d
valves,
l
taps and
d permanent magnets.
Page 208 of 240
IES 2011
IES2011
Which one of the following is the major alloying element
in Invar?
(a) Aluminium
(b) Nickel
(c) Vanadium
(d) Copper
IES 2004
IES2004
p
g
g
Forimprovingthestrengthofsteelatelevated
temperatures,whichoneofthefollowingalloying
elementisused?
(a) Copper
(b) Tungsten
(c) Aluminium
(d) Zinc
Rev.0
4 V di
4.Vanadium
g a fine g
y It aids in obtaining
grain structure in tool steel.
y The addition of a very small amount of vanadium (less
than 0.2%) produces a marked increase in tensile

strength and elastic limit in low and medium carbon
steels without a loss of ductility.
y The chromevanadium steel containing about 0.5 to
1.5% chromium, 0.15 to 0.3% vanadium and 0.13 to 1.1%
carbon have
ha e extremely
e tremel good tensile strength,
strength elastic
limit, endurance limit and ductility.
y These steels are frequently used for parts such as
springs, shafts, gears, pins and many drop forged parts.
5 M
5.Manganese
p
g of the steel in both the hot
y It improves
the strength
rolled and heat treated condition.
y The manganese alloy steels containing over 1.5%
manganese with a carbon range of 0.40 to 0.55% are

used extensively in gears, axles, shafts and other parts
where
h
hi h strength
high
t
th combined
bi d with
ith fair
f i ductility
d tilit is
i
required.
y The principal uses of manganese steel is in machinery
machiner
parts subjected to severe wear. These steels are all cast
and ground to finish.
finish
7 C b lt
7.Cobalt
y It g
gives red hardness byy retention of hard carbides at
high temperatures.
y It tends to decarburise steel during heattreatment.
y It increases hardness and strength and also residual
magnetism and coercive magnetic force in steel for

magnets.
GATE 1997
GATE1997
y g
y
p
Thealloyingelementmainlyusedtoimprovethe
endurancestrengthofsteelmaterialsis
(a) Nickel
(b) Vanadium
((c)) Molybdenum
y
(d) Tungsten
IES
y
Alloysteelwhichisworkhardenable
andwhichis
usedtomakethebladesofbulldozers,bucket
wheelexcavatorsandotherearthmoving
equipmentcontainiron,carbonand
i
i i
b d
(a) Chromium
(b) Silicon
(c) Manganese
(d) Magnesium.
IES 2010
IES2010
Some high speed steels have cobalt (Co)
added
in
from
2%
dd d to them
h
i amounts ranging
i
f
%
to 15%, since this element improves the
(a)Cutting efficiency, especially at high
temperature
(b) Depth hardening ability of the HSS tool
(c) Red hardness of the HSS tool
(d) Grain structure of the HSS tool
Page 209 of 240
IES 2000
IES2000
Additionofvanadiumtosteelresultsin
improvementof
(a) Heattreatabilitybyquenching
(b) Hardenability
((c)) Fatiguestrength
g
g
(d) Resistancetooxidationatelevatedtemperature
6 Sili
6.Silicon
y The silicon steels behave like nickel steels.
y These steels have a high elastic limit as compared to
ordinary carbon steel.

y Silicon steels containing from 1 to 2% silicon and 0.1 to
0.4% carbon and other alloying elements are used for
electrical machinery, valves in I.C. engines, springs and
corrosion resisting materials.
8 M l bd
8.Molybdenum
y small q
3 ) of molybdenum
y
y A very
quantityy ((0.155 to 0.30%)
is generally used with chromium and manganese (0.5
to 0.8%) to make molybdenum steel.
y These steels possess extra tensile strength and are used
for airplane fuselage and automobile parts. It can
replace
l
t
tungsten
t in
i high
hi h speed
d steels.
t l
Rev.0
9 B
9.Boron
y Boron (not exceeding 0.003%) is a very powerful
hardenability
agent, being
from
250 to 750 times as
h d
bl
b
f
effective as nickel, 75 to 125 times as effective as
y
, and about 100 times as p
powerful as
molybdenum,
chromium.
y Only a few thousandths of a percent are sufficient to
produce the desired effect in lowcarbon
low carbon steels,
steels but the
results diminish rapidly with increasing carbon content.
y Since no carbide formation or ferrite strengthening
g
g is
produced, improved machinability and coldforming
capability often result from the use of boron in place of
other hardenability additions.
additions
y It has no effect on tensile strength of steel.
IES 1992
IES1992
for centuries, but only recently has it been used as an

5 ) to
addition to steel ((in amounts from 0.10 to 0.50%)
provide this property.
y Lowcarbon steel sheet and structural steels often contain
a copper addition to enhance corrosion resistance, but
surface quality and hotworking behavior tend to
deteriorate somewhat.
somewhat
p
y
y Itisanundesirableimpurityinsteelbecauseitsforms
p
g
Smallpercentageofboronisaddedtosteelto
(a) Increaseshardenability
((b)) Reducemachinabilityy
(c) Increaseswearresistance
(d) Increaseendurancestrength
ironsulphide,whichcanresultincracking.
y However,inthepresenceofproperamountofMn,it
formsMn Swhichimprovesthemachinability of
steels.
y Itscontentmayveryfrom0.06 0.30%.
All St l t l
AlloySteelataglance
11.Copper
y Copper has been known
kno n to resist atmospheric corrosion
10 l h
10.sulphur
(4)
,
,
Donotformcarbide: nickel,Silicon,Aluminium
Carbideformingorder:Manganese,chromium,
Tungsten,Molybdenum,vanadium,titanium,
niobium.
(1) Manganese:
Toughness&ductility
Machinability withsulphur
(2) Chromium:
Corrosionresistance
Wearresistance
(3) Nickel:
toughness
g
(5)
(6)
(7)
(8)
(9)
Tungsten,Molybdenum,Vanadium: hothardness
Tungsten
wearresistance,
Vanadium:
endurancelimit
V di
d
li i
Molybdenum
creepproperty
Si&Al deoxidizer,restrictgraingrowth
deoxidizer restrictgraingrowth
Si Magneticpermissibility
Cobalt:
hardenability
Impactstrength
Phosphorus:
reducestrengthtoimpact
conductivityofcopper
Copper:
Raisesyieldpoint
Magnesium:
becauselightweightitisused
whereweightisimportant.
Contd
IES 2011
IES2011
Superalloy: Isforhightemperatureuse[jetengine,
gasturbinebladeetc]
Ex: Hastelloy X
C 0.1%
Mn 1%
Cr 21.8%
Si
Si
1%
%
Ni balance
C 2.5%
Co
%
Mo 9%
W 0.6%
W
0 6%
Fe 18.5%
ListI
ListII
A.Copper
pp
1.Corrosion
B.Nickel
2.Demagnetization
C M
C.Manganese
3.NonSparking
N S ki
D.Vanadium
4.Deformationrestriction
Codes
A
(a) 1
(c) 1
B
2
3
C
3
2
D
4
4
(b)
(d)
A
4
4
Page 210 of 240
B
3
2
C
2
3
D
1
1
IES 1996
IES
Whichofthefollowingpairsregardingtheeffectof
alloyingelementsinsteelarecorrectlymatched?
ll i l
t i t l
tl t h d?
1. Molybdenum:Formsabrasionresistingparticles.
2 Phosphorus:Improvesmachinability infreecutting
2.
steels.
3. Cobalt:Contributestoredhardnessbyhardening
ferrite.
4. SiliconReducesoxidationresistance
(a) 2,3and4 (b) 1,3and4
(c) 1,2and4
(d) 1,2and3
Rev.0
IES 1992
IES1992
g
Matchthefollowing:
ListI(Alloyingelementinsteel)
A. Lead
1.
B. Aluminium
2.
C. Copper
3.
D. Phosphorus
Codes:A
d
B
C
(a) 1
2
3
( ) 3
(c)
4
1
4.
D
4
2
(b)
(d)
IAS 1995
IAS1995
ListII(Effect)
Restrictsgraingrowth
Raisesyieldpoint
Reducesstrengthto
impact
Freemachining
A
B
C
D
2
3
4
1
4
1
2
3
St i l
St l
StainlessSteel
y typical
yp
g with other
y They
consists min.12% Cr along
alloying elements, thus highly corrosion resistant
owing to presence of chromium oxide.
y Three kinds ferritic & hardenable Cr steels, austenitic
and precipitation hardenable (martensitic, semi
austenitic)
t iti ) based
b d on presence off prominent
i
t micro
i
structural constituent.
y Typical
T pical applications cutlery,
cutler surgical knives,
kni es storage
tanks, domestic items.
y Ferritic steels are principally FeCrC
Fe Cr C alloys with 1214%
12 14%
Cr. And small additions of Mo, V, Nb, Ni.
WatchListI(Alloyingelementsfortoolsteel)withListII
(Improvedmechanicalproperty)andselectthecorrect
answerusingthecodesgivenbelowtheLists
ListI
ListII
(All i l
(Alloyingelementsfortoolsteel)
t f t l t l)
(I
(Improved
d
mechanicalproperty)
A. Carbon
1.
Hardness
B. Manganese
2.
HotHardness
d
C. Chromium
3.
LowerCritical
Temp
D. Vanadium
4.
Toughness
Codes:A
B
C
D
A
B
C
D
(a) 1
3
4
2
(b)
2
4
3
1
(c) 1
4
3
2
(d) 2
3
4
1
y Austenitic steels contain 18% Cr and 8% Ni plus minor
y Austenitic stainless steels are nonmagnetic and are
alloying elements. Ni stabilizes the austenitic phase

assisted by C and N.
y For, martensitic steels Ms is made to be above the
room temperature. These
Th
alloys
ll
are heat
h
treatable.
bl
Major alloying elements are: Cr, Mn and Mo.
y Ferritic
F iti and
d austenitic
t iti steels
t l are hardened
h d
d and
d
strengthened by cold work because they are not heat
treatable.
treatable
y Austenitic steels are nonmagnetic as against ferritic
and martensitic steels, which are magnetic.
Contd
IES 2002
IES2002
p
Thecorrectcompositionofausteniticstainless
steelusedfordomesticutensilsis
(a) 0.08%C,18%Cr,.8%Ni,2%Mn,1%Si
(b) 0.08%C,24%Cr,12%Ni,2%Mn,1%Si
((c)) 0.15%C,12%Cr,0.5%Ni,1%Mn,1%Si
5
,
, 5
,
,
(d) 0.30%C,12%Cr,0.4%Ni,1%Mn,1%Si
IAS 2002
IAS2002
Assertion(A):Inhighspeedsteels,alloyingelements
tungsten,chromiumandvanadiumareaddedto
t
t h
i
d
di
dd dt
makethemsuitabletoworkathigherspeedsthan
toolsteelorlowalloysteels.
R
Reason(R):Vanadiumaddstothepropertyofred
(R) V
di
dd h
f d
hardnessandtungstenandchromiumaddtohigh
wearresistance.
explanationofA
(b) BothAandRareindividuallytruebutRis not the
highly resistant to corrosion 304 alloy is 188 when 18%

chromium & 8% nickel used costly material.
material
y Austenitic stainless steels usually contain 18% Cr and
8% Ni in addition to other minor alloying elements. Ni
stabilizes the austenitic phase assisted by C and N.
Other alloying additions include Ti, Nb, Mo (prevent
weld
ld decay),
d
) Mn
M and
d Cu
C (helps
(h l
i stabilizing
in
t bili i
austenite).
y These steels are very tough and can be forged and
rolled but offer great difficulty in machining.
y These steels cannot be hardened by
yq
quenching,
g in fact
they are softened by rapid cooling from about 1000C.
Contd
IES 2008
IES2008
g
p
Considerthefollowingstatementsinrespectof
austeniticstainlesssteels:
1. Austeniticstainlesssteelsarehardenedand
strengthenedbycoldworking.
2. Austeniticstainlesssteelscannotbequenchedand
tempered.
(a) 1only
(b) 2only
(c) Both1and2
(d) Neither1nor2
Page 211 of 240
IES 1997
IES1997
Assertion(A):Austeniticstainlesssteelcontains18%
chromiumand8%nickel.Sinceitretainsitsaustenitic
h
i d8% i k l Si it t i it t iti
structureatroomtemperature,itiscalledaustenitic
stainlesssteel.
R
Reason(R):Chromiumpresentinthesteelimprovesits
(R) Ch
i
i h
li
i
corrosionresistancebyformingathinfilmofchromium
oxideonthesurface.
explanationofA
(b) BothAandRareindividuallytruebutRisnotthe
Rev.0
IES 2009
IES2009
g
Whichoneofthefollowingelementsisan
austeniticstabilizer?
(a) Chromium
(b) Tungsten
((c)) Nickel
(d) Molybdenum
IES 2005
IES2005
MatchListI(AlloyingElement)withListII(Effecton
Steel)andselectthecorrectanswerusingthecodegiven
S l) d l h
i h d i
belowtheLists:
ListII
ListI
A. Vanadium
1.
Increasesendurancestrength
B. Molybdenum
2.
Improvescreepproperties
C Silicon
C.
Sili
3.
I
Increaseshardness
h d
D. Chromium
4.
Increasesresistancetohigh
temperatureoxidation
Codes:A
B
C
D
A
B
C
D
(a) 2
1
3
4
(b) 1
3
2
4
( ) 2
(c)
1
4
3
(d) 1
2
3
4
IES 2010
IES2010
Alloying elements are added to
1. Improve hardness and toughness.
2. Corrosion and oxidation resistance improvement.
33. Improve
p
machinabilityy and hardenability.
y
4. Increase weight and volume.
(a) 1, 2 and 3 only
(b) 2, 3 and 4 only
( ) 1, 2 and
(c)
d 4 only
l
(d) 1, 2, 3 and
d4
IES 2009
IES2009
IES 2004
IES2004
g
Whichoneofthefollowingelementsisaferritic
stabilizer?
(a) Nickel
(b) Manganese
((c)) Copper
pp
(d) Chromium
MatchListI(Nameofalloy)withListII(Major
alloyingelements)andselectthecorrectanswerusing
ll i l
t ) d l tth
t
i
thecodesgivenbelowtheLists:
ListI
ListII
A. Invar
1.
Manganese
B. Hadfieldsteel
2.
Chromium
C Stellite
C.
3
3.
Nickel
D. Stainlesssteel
4.
Tungsten
y
5.
Molybdenum
Codes:A
B
C
D
A
B
C
D
(a) 5
1
4
2
(b) 3
2
5
1
(c) 5
2
4
1
(d) 3
1
5
2
IES
IES 2008
IES2008
MatchListI(Alloyingelementinsteel)withListII
(Propertyconferredonsteelbytheelement)and
(P
t
f
d t lb th l
t) d
selectthecorrectanswerusingthecodesgivenbelow
thelists:
Li I
ListI
Li II
ListII
A.Nickel
1.
Corrosionresistance
B.Chromium
2.
Magneticpermeability
C.Tungsten
3.
Heatresistance
D.Silicon
4.
Hardenability
Codes:A
d
B
C
D
A
B
C
D
(a) 4
1
3
2
(b) 4
1
2
3
(c) 1
4
3
2
(d) 1
4
2
3
g
g
Whichofthefollowingelementsgivenbelow
determine(s)themaximumattainablehardness
insteel?
1. Chromium
2.
Manganese
3. Carbon
4.
Molybdenum
electthecorrectanswerusingthecodegivenbelow:
(b) 1and2
a) 1only
(c) 3only
(d) 2and4
DESIGNATION OF STEEL (INDIAN

DESIGNATIONOFSTEEL,(INDIAN
STANDARD)
y Two systems of notation are recommended by IS :
(a) Based on ultimate tensile strength.

(b) Based on chemical composition.
(a) Based on Ultimate Tensile Strength: This is
applicable
li bl to
t carbon
b and
d low
l alloy
ll steels.
t l
y The symbol consists of the letter St followed by the
number representing the ultimate tensile strength in
kgf/mm2 , for example, St 32. The new coding consists
of the letter Fe followed by the number representing
the
h ultimate
li
tensile
il strength
h in
i N/mm2
N/
, for
f example,
l
Fe 410.
Contd
Page 212 of 240
(b) Based on Chemical Composition: This type of

designation is preferred if subsequent heat treatment
is carried out.
1. Plain Carbon Steels: These are designated by letter
C followed
f ll
d by
b a number
b representing
i
the
h average
percentage carbon content, for example, C 14 carbon
steel with 0.14%,
0 14% C.
C
y Its new designation is 14 C4. Here, the first figure
indicates 100 times the average of Carbon content,
content
then letter C, and the last figure indicates 10 times the
average
g p
percentage
g of Mn content rounded off to the
next integer.
Rev.0
Contd
2. Alloy Steels: Here the letter C is omitted and the

numbers representing the carbon content are followed by
y
for one or more of the p
predominant
chemical symbols
alloying elements followed by numbers indicating their
average contents, for example, 15 Cr 65 chromium steel
with 0.15
0 15%
%,C
C and 0.65%
0 65% Cr.
Cr
y 20 Cr 18 Ni 2 Nickel chromium steel with 0.2% C, 18%
Cr and 2% Ni.
y The coding of the alloy steels is given below : The average
alloy content upto 1 per cent, Alloy index number will be :
Average alloy content upto two decimal places,
places underlined
by a bar. For average alloy content one per cent and above,
alloy index number will be : rounded to the nearest whole
number upto 0.5
0 5 rounded down and above
abo e rounded up.
up
IES 2001
IES2001
IES 1996
IES1996
y
g
4
y
Thealloysteeldesignatedas40Cr18Ni2by
BureauofIndianStandardscontains
(a) 0.4%C,18%Crand2%Ni
(b) 4.0%C,1.8%Crand0.2%Ni
((c)) 0.4%C,1.8%Crand2%Ni
4
,
(d) 0.4%C,1.8%Crand0.2%Ni
Plastics or pol mer

Plasticsorpolymer
y Definition:
group
of
engineered
18/8stainlesssteelcontains
(a) 18%stainless,8%chromium.
((b)) 18%chromium,8%nickel.
,
(c) 18%tungsten,8%nickel.
(d) 18%tungsten,8%chromium.
Properties of plastics
Propertiesofplastics
materials
characterized by large molecules that are built up by

the joining of smaller molecules.
y They are natural or synthetics resins.
resins
g
g
y Lightweight
y Goodresistancetocorrosion
y Easyoffabricationintocomplexshapes
y Lowelectricalandthermalconductivity
y Goodsurfacefinish
d
f
f
h
y Goodopticalproperties
p
p p
y Goodresistancetoshockandvibration.
IES 2010
IES2010
Consider the following properties for
plastics:
l i
1. Become hard on heating.
2. Increasing plasticity.
3 Ability to deform with rise in temperature.
3.
temperature
4. Long chain structure.
Whi h off these
Which
h
properties
i
f
for
plastics
l i
are
correct?
(a) 1, 2, 3 and 4
(b) 3 and 4 only
(c) 1 and 4For-2015
only (IES,
(d) 2,GATE
3 and&4PSUs)
only
IES 2010
IES2010
Plasticmaterialisusedforthecomponent
whichrequirescharacteristicsof
hi h
i h
i i f
(a)Lowdensity,machinability andhighstrength
(b)Machinability,highstrengthandlargeplastic
deformation
(c)Highstrength,largeplasticdeformationand
lowdensity
(d) Low density, machinability and large plastic
deformation
Page 213 of 240
IAS 2007
IAS2007
g
Considerthefollowing:
Whichofthefollowingpropertiesarepossessedby
plastics?
1. Goodresistancetocorrosiveatmosphere
2. Easeoffabricationintocomplexshapes.
p
p
3. Goodresistancetoshocksandvibrations.
g
g
(a) 1,2and3
(b) 2and3only
(c) 1and3only
(d) 1and2only
Rev.0
Classification Polymers
Pol mers
Classification
IES 2008
IES2008
p y
Structureofapolymeris:
(a) Longchain
(b) Rhombic
((c)) Cubic
((d)) Closedpackhexagonal
p
g
y Classification based on their industrial usage:

(a) plastics and
(b) elastomers.
elastomers
y Classification based on their temperature dependence:
((a)) thermoplasts
th
l t and
d
(b) thermosets
Thermoplasts
Thermoplastics
(
y Fluorocarbons (PTFE
or TFE,Teflon))
y Plastics which softens up on heating and hardens up
y Acrylonitrilebutadienestyrene (ABS):
on cooling where the softening and hardening are

totally reversible processes.
y Hence thermoplasts
h
l
can be
b recycled.
l d
y They consist of linear molecular chains bonded
together
h by
b weak
k secondary
d
b d or by
bonds
b interwinding.
i
i di
y Crosslinking between molecular chains is absent in
th
theromplasts.
l t
y E.g.: Acrylics, PVC, Nylons, Perspex glass, etc.
Characteristics: Outstanding strength and toughness,

resistance to heat distortion; good electrical properties;
flammable and soluble in some organic solvents.
solvents
Application: Refrigerator lining, lawn and garden
equipment, toys, highway safety devices.
y Acrylics (polymethylmethacrylate) PMMA
Characteristics:
C
a acte st cs: Outsta
Outstanding
d g light
g t ttransmission
a s ss o aand
d
resistance to weathering; only fair mechanical properties.
Application: Lenses, transparent aircraft enclosures,
drafting equipment, outdoor signs.
Characteristics: Chemically inert in almost all

environments,
excellent electrical properties; low
environments
coefficient of friction; may be used to 260ooC; relatively
weak and poor coldflow properties.
Application:
l
Anticorrosive seals,
l chemical
h
l pipes and
d
valves, bearings, anti adhesive coatings, high temperature
p
electronic parts.
y Polyamides (nylons)
Characteristics: Good mechanical strength, abrasion
resistance,
i
and
d toughness;
h
l
low
coefficient
ffi i
off friction;
fi i
absorbs water and some other liquids.
Application: Bearings, gears, cams, bushings, handles,
and jacketing for wires and cables.
Contd
Contd
y Polycarbonates
y Polypropylene
Characteristics: Dimensionally stable: low water

absorption; transparent; very good impact resistance
and ductility.
Application: Safety helmets, lenses light globes, base
for photographic film
y Polyethylene
Characteristics: Chemically resistant and electrically
insulating; tough and relatively low coefficient of
friction; low strength and poor resistance to
weathering.
Application: Flexible bottles, toys, tumblers, battery
parts, ice trays, film wrapping materials.
Characteristics: Resistant to heat distortion; excellent

electrical properties and fatigue strength; chemically
inert; relatively inexpensive; poor resistance to UV
light.
g
Application: Sterilizable bottles, packaging film, TV
cabinets, luggage
y Polystyrene
Characteristics: Excellent electrical properties and
optical clarity; good thermal and dimensional stability;
relatively inexpensive
Application: Wall tile, battery cases, toys, indoor
lighting panels, appliance housings.
Page 214 of 240
Contd
Contd
Rev.0
IES 2003
IES2003
IES 2011
IES2011
Windows of aeroplane are made of :
(a) PVC
(b) PTFE
(c) PMMA
((d)) PEEK
IES 1992
IES1992
y
y
Polyamidesarecharacterizedby
(a) Flexiblechain
((b)) Rigidchain
g
(c) Amorphousstructure
(d) Crystallinestructure
IES 2002
IES2002
Thermosets
p y
g
Thestructureofapolymerisshowninthegiven
y Plastics which are set under the application of heat
figure.Thispolymer
g
p y
Findsspecialapplicationin
(a) Packaging
(b) Adhesives
(c) Bearings
(d) Fertilizer
IAS 2000
IAS2000
Polytetrafluoroethene is
1. Athermoplasticmaterial
2 Havinghighfrictioncoefficient
2.
3. Athermosettingmaterial
4. Havinglowfrictioncoefficient
5. Anelectricinsulator
6. Nonstickingtosurfaces
Whichoftheabovestatementsarecorrect?
(a) 1,2and5
(b) 2,3and6
(c) 3,4and5
(d) 3,2and5
IES 1995
IES1995
F F
C C
F F
Teflonisa
(a) Thermosettingfluorocarbonpolymer
((b)) Thermoplasticfluorocarbonpolymer
p
p y
(c) Inorganiccompoundoffluorineandcarbon
(d) Laminatedphenolic material
and/or pressure.
y This process is not reversible, hence thermosets can
not be
b recycled.
l d
y They consist of 3D network structures based on
strong covalent
l
b d to form
bonds
f
rigid
i id solids.
lid linear
li
molecular chains bonded together by weak secondary
bonds or by interwinding.
interwinding
y Characterized by high modulus / rigidity /dimensional
stability when compared with thermoplasts.
thermoplasts
y E.g.: Epoxies, Amino resins, some polyester resins, etc.
Contd
Page 215 of 240
yp p
( )
( )
Weldable typeplastic(s)include(s)
(a) Thermosets alone
((b)) Thermoplasticsalone
p
(c) Boththermosets andthermoplastics
(d) Neitherthermosets andthermoplast
y Thermosets are strengthened by reinforcements .

y Different reinforcements are in use according to the
y
y
y
necessity.
fibers
are mostt commonly
it Glass
Gl
fib
l used
d to
t form
f
structural and molding plastic compounds.
Two most important types of glass fibers are E (electrical)
and
d S (high
(h h strength)
h) glasses.
l
Eglass (limealuminiumborosilicate glass with zero or
potassium levels)) is often used for
low sodium and p
continuous fibers.
Sglass (65%SiO2, 25%Al2O3 and 10% MgO) has higher
strengthtoweight
strength
to weight ratio and is more expansive thus
primary applications include military and aerospace
applications.
Carbon fiber reinforced plastics are also often used in
aerospace applications. However they are very expansive.
Rev.0
Contd
polyamide) fibers.
fibers
y They are popularly known as Kevlar.
Examples Thermosettingpolymers
Thermo setting polymers
Examples
IES 2011
IES2011
y The other classes of reinforcements include aramid (aromatic
KevlarEpoxycompositeiswidelyusedin:
(a)Automobiles
(b)Aerospace
(c)Navy
( )
(d)InteriorDecoration
y Epoxies
Characteristics: Excellent combination of mechanical

properties and corrosion resistance; dimensionally stable;
good adhesion; relatively inexpensive; good electrical
properties.
ti
Application: Electrical moldings, sinks, adhesives,
protective coatings,
p
g , used with fiberglass
g
laminates.
y Phenolics
Characteristics: Excellent thermal stability to over 150o C;
may be
b compounded
d d with
h a large
l
number
b off resins, fillers,
f ll
etc.; inexpensive.
Application:
Motor
housing
housing,
telephones
telephones,
auto
distributors, electrical fixtures.
Contd
y Polyester(PETorPETE)
Chemical
classification
Tradename
characteristics
Typical
application
Epoxy
Aralditeoxiron
Goodtoughness.
Resistantto;acids.
R i
id
alkalies and
solvents.
excellent
adhesiontometal,
glassandwood.
Adhesiveand
coatings,tools
i
l
and
dies,filament
woundvessels,,
laminatesfor
aircraft,patching
compoundfor
metaland
t l d
plastics.
Characteristics:Oneofthetoughestofplasticfilms;
Ch
i i O f h
h f l i fil
excellentfatigueandtearstrength,andresistanceto
humidityacids greases oilsandsolvents
humidityacids,greases,oilsandsolvents
Application:Magneticrecordingtapes,clothing,
automotivetirecords beveragecontainers
automotivetirecords,beveragecontainers.
Melamineformal
dehyde
IES 1997
IES1997
usingthecodesgivenbelowtheLists:
ListI
ListII
A. Neoprene
1.
Electricswitches
B. Bakelite
2.
Adhesive
C. Foamedpolyurethane
3.
Thermalinsulator
D. Araldite
4.
Oilseal
Code:A
d
B
C
D
A
B
C
D
a) 4
1
2
3
(b) 1
4
2
3
c)) 4
1
3
2
(d) 1
4
3
2
Goodfor
application
requiringcycling
betweenwetand
dryconditions.
Hardandabrasion
d d b
resistant.Good
dielectric.
Tablcware,electric
insulation
insulation,
automotIve Ignition
parts,cutlery
handles,jars and
b l
bowls.
IES 1992
IES1992
Assertion (A): Linear polymers are rigid at low
temperatures but soft and mouldable at elevated
temperatures.
Reason (R): Linear polymers are thermosetting.
thermo setting
Page 216 of 240
Phenol
Bakelite
formaldehy Marblette Durez
de
Cataljn
Gooddimensional
stabilityExcellent
insulatingqualities.
Inert
I
t
tomostsolventsand
weakacids.
g
Goodstrengtharound
inserts.
Industrialelectrical
parts.
automotiveelectrical
components,
t
paperimpregnated
battery
p
separators.
Electricalinsulation.
Phenol
Phenol
furfural
Durite
Similarto
Phenolfonnaldehyde.
Electricalinsulation.
Electricalinsulation
Mechanical
parts.Housingsand
containers.
Alkyd
(Modified
polyester)
Glyptal Duraplex
Beckosol Teglac
Rezly
Canbemadeflexible,
resilientorrigid.Can
resistacidsbutnot
alkalies,withglassfibre
reinforcementresistssalt
waterandfungusgrowth.
Boats,Tanks,Trailerand
Tractor
components.Ducts,
shrouds.
Vaultingpoles.
IES
g
Fibre ReinforcedPlasticsare
g
g
1. Madeofthermosettingresinsandglassfibre
2. Madeofthermoplasticresinsandglassfibre
3. Anisotropic
4. isotropic
(a) 1and4
(b) 1and3
(c) 2and3
(d) 2and4
Rev.0
IES 1994
IES1994
IES 2007
IES2007
MatchListI(materials)withListII(applications)and
l tth
t
i th d i
b l
theLists:
ListI
ListII
A. Engineeringceramics
1.
Bearings
B. Fibre reinforcedplastics 2.
Controlrodsin
nuclearreactors
C. Syntheticcarbon
3.
Aerospaceindustry
D. Boron
4.
Electricalinsulator
Codes:A
d
B
C
D
A
B
C
D
(a) 1
2
3
4
(b) 1
4
3
2
(c) 2
3
1
4
(d) 4
3
1
2
usingthecodegivenbelowtheLists:
h
d
b l
h
ListI
ListII
(Material)
(Application)
A. Fibre reinforcedplastics 1.
Automobiletyres
B. Acrylics
2.
Aircraft
C. Phenolics
3.
Lenses
D. Butadienerubber
4.
Electricswitchcover
Code:A
B
C
D
A
B
C
D
(a) 1
4
3
2
(b) 2
3
4
1
( ) 1
(c)
3
4
2
( ) 2
(d)
4
3
1
IES
Thermosettingplasticsare
1. Formedbyadditionpolymerisation.
2. Formedbycondensationpolymerisation.
3. Softenedonheatingandhardenedoncoolingfor
anynumberoftimes
b fti
4. Moulded byheatingandcooling.
Selectthecorrectans erusingthecodesgi enbelo
(a) 1and3
(b) 2and4
(c) 1and4
(d) 2and3
IES 2006
IES2006
y
Phenolformaldehydeisa/an
(a) Thermoplasticpolymer (b)
((c)) Elastomer
((d))
IES 1999
IES1999
gp
p
Considerthefollowingpairsofplasticsandtheir
distinctcharacteristics:
1. Acrylics..............Verygoodtransparencytolight
2. Polycarbonate..Poorimpactresistance
33. PTFE....Lowcoefficientoffriction.
4. Polypropylene..Excellentfatiguestrength
Whichofthesepairsarecorrectlymatched?
p
y
(a) 2and3
(b) 1and3
(c) 1and4
(d) 2and4
Thermoset polymer
Rubber
IES
ListI(Material)
ListII(Natureofproduct)
A. Polyethylene
1.
Adhesive
B. Polyurethane
2.
Film
C. Cyanoacrylate
3.
Wire
D. Nylon
4.
Foam
Codes:A
B
C
D
A
B
C
D
(a) 2
4
3
1
(b) 4
2
3
1
(c) 2
4
1
3
(d) 4
2
1
3
Polymersynthesis
IAS 2003
IAS2003
Elastomers
g
1. Thermoplasticspossessastrongintermolecular
bondingcomparedtothatofthermosettingplastics.
2. Plasticshaveahighcreepundercontinuousloading.
33. Embrittlement occursinplasticsatlowtemperature.
p
p
((a)) 1and2
((b)) 2and33
(c) 1and3
(d) 1,2and3
y These polymers are known for their high elongations,
which are reversible upon release of applied loads.

y They consist of coillike molecular chains, which
straightens
h
up on application
l
off load.
l d
y Characterized by low modulus / rigidity / strength, but
hi h toughness.
high
h
y E.g.: natural and synthetic rubber.
y Processing of polymers primarily limits to synthesis
followed by forming.
y Polymers
are synthesized
by process known as
polymerization.
l
i ti
y Polymerization
y
is p
process in which multifunctional
monomers are attached to form linear/3D macro

molecular
l
l chains.
h
Page 217 of 240
Rev.0
AdditionPolymerization
y This polymerization process involves single kind of
monomers. Resultant macromolecules composition is an

p
p
exact multiplication
of composition
of individual
monomer.
y Process involves three stages
g
namelyy initiation,
propagation and termination.
y Initiation process will be started by an initiator (e.g.
benzoyl peroxide)) which forms an reactive site where
carbon atom of another monomer is attracted, upon which
reaction site transfers to different place leading to
molecular chain growth.
y As molecular chain grows longer, reaction rate decreases.
However the growth process is terminated either by the
combination or disproportionation process.
C d
i P l
i i
CondensationPolymerization
y Formation of a polyester from Ethylene glycol and Adipic
acid
AdditionPolymerization
d
i
l
i i
CondensationPolymerization
E.g.,
polyethylene
y It involves more then one monomer species.

species This process
is also known as step growth polymerization.

y In condensation polymerization,
polymerization smaller macromolecule
byproduct such as water is eliminated.

y No resultant product has the chemical formula of mere
Combination:
one monomer.
y Repeat
p
unit in condensation p
process itself is p
product of
polymerization involving basic constituents.

y Reaction times for condensation p
polymerization
y
is
usually longer than those for additional polymerization.
Disproportionation:
y Polyesters,
phenolformaldehyde,
nylons,
polycarbonates etc are produced by condensation
polymerization.
y Condensation polymerization reactions also occur in
solgel processing of ceramic materials.
y Polymers,
y
, unlike organic/inorganic
g
/
g
compounds,
p
, do
not have a fixed molecular weight. It is specified in
terms of degree of polymerization number of
repeat units in the chain or ratio of average molecular
weight of polymer to molecular weight of repeat unit.
y Average molecular weight is however defined in
y Weight
g
g molecular weight
g
two ways.
average
is
obtained by dividing the chains into size ranges
and determining the fraction of chains having
molecular weights within that range.
y Number average molecular weight is based on
the
h number
b
f
fraction,
rather
h
than
h
the
h weight
h
fraction, of the chains within each size range. It is
always smaller than the weight average molecular
weight.
Contd
IES 2001
IES2001
g
y chloride is 62.5.
5
The molecular weight
of vinyl
Thus the molecular weight of a polyvinyl chloride
with a degree of polymerization of 20000 is
(a)
62.5
20000
62 5
62.5
(b) 20000
(c) 62.5 20000
(d) 20000
C
li ki
Th crosslinking
li ki can occur due
d to
t the
th presence
y Cross
linking:
The
of some elements called vulcanizing agents, e.g. S, Se, Te, and
O2.
y In case of poly isoprene (natural rubber), the sulphur bridges
are formed between two macromolecules during vulcanization.
y In this vulcanization p
process sulphur
p
bridge
g are formed at the
point of opening of double bonds. If the number of crosslinks
is small; the find product is soft and flexible. The stiffness of the
polymeric
p
y
material increases with the densityy of crosslines.
When the sulphur content in rubber is as high as 32 weight
percent, the hard product is called ebonite.
Page 218 of 240
IES 2003
IES2003
,
Inthecaseofrubber,vulcanizationreferstothe
processofproducinga
(a) Linearpolymer
(b) Branchedpolymer
((c)) Crosslinkedpolymer
p y
(d) Networkpolymer
Rev.0
IES 2006
IES2006
IES 2000
IES2000
Assertion (A) In Addition Polymerization method,

polymer
is
l
i produced
d
d by
b adding
ddi a second
d monomer to
t
the first, then a third monomer to this dimmer and so
on.
R
Reason
(R) There
(R):
Th
must exist
i at least
l
one double
d bl bond
b d
in the monomer for Addition Polymerization
reaction.
explanation of A
y
y
Assertion(A):Additionpolymerizationisaprimary
summationofindividualmoleculesintolongchains,
Reason(R):Inadditionpolymerization,thereaction
producesasmallmoleculeasbyproduct.
d

ll
l
l b
d
explanationofA
p
IES 2008
IES2008
IES 2003
IES2003
y which two or more

What is the p
process by
chemically different monomers are polymerised
to form a cross link polymer together with a by
product
d
such
h as water or ammonia,
i known
k
as?
(a) Addition polymerization
(b) Copolymerisation
(c) Linear polymerisation
(d) Condensation polymerization
y
Polyesterscanbedefinedasthecondensation
productsof
(a) Dicarboxylic acidswithdihydroxy alcohols
(b) BisphenolAandepichlorohydrin
((c)) Phenolandformaldehyde
y
(d) Benzeneandtoluene
IES 1994
IES1994
g
Whichofthefollowingpairsofplasticsandtheir
modesofformationarecorrectlymatched?
1. Polythene..Condensationpolymerization.
2. Polycarbonate.............Additionpolymerisation.
3. Polystyrene...Additionpolymerisation.
4. Polyamide.Eitherbyadditionorby
condensationpolymerisation.
S l tth
t
i th d i b l
(a) 1and2
(b) 2and4
(c) 1and4
(d) 3and4
Additi es to Pol mers

AdditivestoPolymers
y The properties of polymers can be further modified by
the addition of agents which are basically of two types.

y Those that enter the molecular structure are usually
called "additives"
additives , whereas those that form a clearly
defined second phase are called "fillers".
Contd
1 Plastici ers
1.Plasticizers
y Plasticizers are liquids of high boiling point and low
molecular weight, which are added to improve the
2 Fillers
2.Fillers
y A filler is used to economize on the quantity of polymer
plastic behaviour of the polymer.

y
y They are essentially oily in nature.

nature Organic solvents,
solvents
resins and even water are used as plasticizers.
required and/or to vary the properties to some extent,

extent for
example, mechanical strength, electrical resistance etc.
A filler, whose function is to increase mechanical strength, is
termed a "reinforcing filler".
A filler is commonly fibrous in nature and is chemically inert
with respect to the polymer with which it is to be used.
used
Common fillers are wood flour, cellulose, cotton flock, and
paper (for improving mechanical strength); mica and asbestos
(for heat resistance); talc (for acid resistance).Other filler
materials are : fabric, chippedwood moulding compound,
wood veneer,, textile or g
glass fibres.
The commonly used "reinforcing filler agents" with plastics are :
fibres/filaments of glass, graphite or boron.
Page 219 of 240
3. Catalysts:
y These are usually added to promote faster and more
complete
polymerization
and
l
l
i i
d as such
h they
h are also
l
called 'accelerators' and 'hardeners' e.g., ester is used
as a catalyst for Urea Formaldehyde.
4. Initiators:
y As the name indicates,, the initiators are used to
initiate the reaction, that is, to allow polymerization to
begin. They stabilize the ends of the reaction sites of
the molecular chains.
chains H2O2 is a common initiator.
initiator
5. Dyes and Pigments:
y These are added,
added in many cases,
cases to impart a desired
colour to the material.
Rev.0
6. Lubricants:
y Lubricants are added to the polymers for the following
purposes : to reduce friction during processing,
processing to prevent
parts from sticking to mould walls, to prevent polymer
films from sticking to each other and to impart an elegant
fi i h to
finish
t the
th final
fi l product.
d t Commonly
C
l used
d lubricants
l bi
t
include : oils, soaps and waxes.
77. Flame retardants:
y Most plastics will ignite at sufficiently high temperatures.
The noninflammability of the plastics can be enhanced
either by producing them from less inflammable raw
materials or by adding "flame retardants". The common
flame retardants are : compounds of chlorine, bromine and
phosphorous.
h
h
8 Solvents:
8.
y Solvents are useful for dissolving certain fillers or
p
p in manufacturing
g byy allowing
g
plasticizers and help
processing in the fluid state, For example, alcohol is
added in cellulose nitrate plastics to dissolve Camphor.
H
However,
subsequently,
b
tl the
th solvents
l
t mustt be
b removed
d
by evaporation.
9. Stabilisers and anti
antioxidants
oxidants are added to retard
the degradation of polymers due to heat, light and
oxidation.
10. Elastomers are added to plastics to enhance their
elastic properties.
N t Above,
Note:
Ab
excepting
ti fillers,
fill
all
ll other
th materials
t i l used,
d
fall under the category of "Additives.
IAS 2007
IAS2007
thecodegivenbelowtheLists:
ListI
ListII
(AdditiveforPolymers)
(Purpose)
A. Plasticizer
1.
Allowspolymerization
tobegin
B. Filler
2.
Colours thematerial
C. Initiator
3.
Actsasinternal
lubricants
4.
4
Improvesstrength
p
g
Code:A
B
C
A
B
C
(a) 1
4
3
(b)
3
2
1
(c) 1
2
3
(d)
3
4
1
IAS 1998
IAS1998
(a)
( )
(c)
3
5
1
3
2
1
5
4
(b)
(d)
3
3
1
5
5
l
2
4
Plastic Process
PlasticProcess
Injection Mo lding
InjectionMoulding
y The common forms of raw materials for processing
y The polymer is melted and than forced into a mould.

y Thermoplastic pellets melted and melt injected under
plastics into products are : pellets, granules, powders,

sheet, plate, rod and tubing.
y Liquid
d plastics
l
are used
d especially
ll in the
h fabrication
f b
off
reinforced plastic parts.
y Thermoplastics
Th
l i can be
b processed
d to their
h i final
fi l shape
h
by moulding and extrusion processes.
y However,
H
extruding
t di
i often
is
ft used
d as an intermediate
i t
di t
process to be followed by other processes, for example,
vacuum forming or machining.
machining
p
Fillersareaddedtoplasticsto
(a) Improveflow
((b)) Reducebrittleness
(c) Facilitateprocessability
(d) Reducecost
IAS 1994
IAS1994
MatchList I(Nameofmoulding compositiontoprepareplastics)

withList
II(Propertyofmoulding composition)andselectthecorrect
withListII(Propertyofmoulding
List I
List II
A.
Binder
1.
Reducecost,shrinkage
B.
Filler
2.
Makethemoulding ofplasticeasier
C. Plasticizer
3.
Cellulosederivatives
D.
Lubricant
4.
Acceleratecondensationand
polymerization
5.
Toughnessandresistanceto
temperature.
Codes: A
IES 1992
IES1992
high pressure (70 MPa) into a mold. Molten plastic

takes the shape of the mold,
mold cools,
cools solidifies,
solidifies shrinks
and is ejected.
y Molds usually
y made in two p
parts ((internal and external
part).
y Use of injection molding machine mainly used for
thermoplastics
h
l i (gears,
(
cams, pistons,
i
rollers,
ll
valves,
l
fan blades, rotors, washing machine agitators, knobs,
handles, camera cases, battery cases, sports helmets
etc)
Page 220 of 240
Contd
p
y
To reduce the consumption
of synthetic
resins,,
the ingredient added is
(a) Accelerator
(b) Elastomer
((c)) Modifier
(d) Filler
Fig.Injectionmoulding
Rev.0
E tr sion
Extrusion
y The process is continuous and provides a cheap and
y Long plastic products with uniform cross sections are
readily
dil produced
d d by
b the
th extrusion
t i process.
y Thermoplastic pellets & powders are fed through a hopper
g
into the barrel chamber of a screw extruder. A rotating
screw propels the material through a preheating section,
where it is heated, homogenized, and compressed, and
then forces it through a heated die and onto a conveyor
belt.
y As the plastic passes onto the belt, it is cooled by jets of air
or sprays off water which
h h harden
h d it sufficiently
ff
l to preserve
its newly imparted shape.
y It continues to cool as it passes along the belt and is then
either cut into lengths or coiled.
Contd
rapid method of moulding.

y Common production shapes include a wide variety of
solid forms, as well as tubes, pipes, and even coated
wires
i and
d cables.
bl
Compression mo lding
Compressionmoulding
y A compression mould is made of two halves with one
each
off the
h being
b i connected
d to the
h platens
l
h press.
y The mould is electrically heated to maintain the
required temperature.
temperature
y Material is placed in the mould, and it is closed with a
hydraulic
y
cylinder,
y
, or toggle
gg clamp.
p
y The pressure maintained on the material is of the
order of 14 to 40 MPa of moulding area.

y As the material comes in contact with the heated
mould surface, it softens and fills the entire cavity and

at the same time initiates the chemical reaction which
cures the part.
Fig.Extrusion
Contd
Transfer Mo lding
TransferMoulding
C
i
i determined
d
i d by
b the
h thickest
hi k
i
y Cure
time
is
cross section,
mould temperature, material type and grade.
y After
the
Aft curing,
i
th mould
ld opens and
d the
th partt is
i ejected.
j t d
y The most widely used plastic is phenol formaldehyde,
commonly known as 'Bakelite
Bakelite.
y Transfer moulding is very similar to compression
moulding and is developed to avoid the disadvantages

found in that process.
y In this
h method,
h d thermosetting
h
charge
h
is heated
h
d and
d
compressed in a separate chamber and then injected
into the closed mould where it is allowed to cool and
solidify.
y Transfer moulding is capable of moulding part shapes
that are more intricate than compression moulding
but not as intricate as injection
j
moulding.
g
Contd
Blo mo lding
Blowmoulding
y Blow moulding is the process of inflating a hot,
hot hollow,
hollow
thermoplastic preform or parison inside a closed mould so

that its shape conforms to that of the mould cavity.
y Typical parts made are bottles, toys, air ducts of automobiles,
chemical and gasoline tanks, and a number of housholds
goods.
d
Page 221 of 240
Contd
Rev.0
Thermoforming
IES 2005
IES2005
p
p
y
Thermoplasticmaterialscannotbeproducedby:
(a) Injectionmoulding process
((b)) Extrusionprocess
p
(c) Blowmoulding process
(d) Both(a)and(b)above
y In this process, a thermoplastic sheet can be formed into a

y
y
y
y
three
three dimensional shape by the application of heat and
differential pressures.
First, the plastic sheet is clamped to a frame and uniformly
heated to make it soft and flowable.
flowable
Then a differential pressure (either vacuum or pressure or
both) is applied to make the sheet conform to the shape of
a mould
ld or die
di positioned
ii
d below
b l the
h frame.
f
It is possible to use most of the thermoplastic materials.
g material is a p
plastic sheet of uniform
The starting
thickness.
It is a relatively simple process and is used for making such
parts as covers,, displays,
p
p y , blister p
packaging,
g g, trays,
y , drinking
g
cups and food packaging.
Contd
Contd
IES 2004
IES2004
MatchListI(Typeofmoulding)ListII(Mechanisminvolved)and
selectthecollectanswerusingthecodesgivenbelowtheLists:
ListI
ListII
A.
Compressionmoulding
1.
Mouldcavitymustbeheated
tocuretheplasticforced
i i
intoit.
B.
Injectedmoulding
2.
SimilartoHydraulic
extrusion
C
C.
Jetmoulding
3
3.
Analogoustothehot
pressingofpoweredmetals
D.
Extrusionmoulding
4.
Analogoustodiecastingof
metals
A
B
C
D
A
B
C
D
(a) 2
4
1
3
(b)
3
1
4
2
(c) 2
1
4
3
(d)
3
4
1
2
IAS 1999
IAS1999
g
p
Whichoneofthefollowingaretheprocessesfor
thermosettingmaterials?
1. Compression
2. Transfermoulding
33. Injectionmoulding
j
g
4. Extrusion
g
g
(a) 1and4
(b) 1and2
(c) 2and3
(d) 2,3and4
IES 2009
IES2009
usingthecodegivenbelowtheLists:
ListI
ListII
(Article)
(ProcessingMethod)
A. Disposablecoffeecups
1.
Rotomoulding
B. Largewatertanks2.
Expandablebead
moulding
C. Plasticsheets
3.
Thermoforming
D. Cushionpads
4.
Blowmoulding
5
5.
Calendering
Code: A
B
C
D
A
B
C
D
(a) 3
5
1
2
(b)
4
5
1
2
( ) 4
(c)
3
2
1
(d)
3
1
5
2
IAS 2007
IAS2007
Whichoneofthefollowingstatementsisnot
correct?
(a) Ininjectiondiemoulding,exactamountof
materialtofillthecylinderisdelivered
(b) Injectiondiemoulding isgenerallylimitedto
formingthermoplasticmaterial
(c) Thermosettingplasticsaremoresuitablefor
extrusionmoulding
(d) Extrusionmoulding processisusedforgiving
shapes,suchasrods,tubes,pipes,ropesetc.
Page 222 of 240
IAS 2004
IAS2004
Whichofthefollowingarethecharacteristicsofthe
injectionmoulding
ofplastics?
ld
f l
1. Itisthemosteconomicalmethodofmassproducinga
singleitem
2. Inmostcasesfinishedproductsareobtained
3.
Thereislotofwasteofthermoplasticsincethe
runnersandsprues cannotbereused.
Selectthecorrectanswerbyusingthefollowingcodes:
(a) 1and2
(b) 2and3
(c) 1and3
(d) 1,2and3
Rev.0
IAS 2003
IAS2003
IAS 1997
IAS1997
g
Considerthefollowingstatementsinrespectof
fabricationofplasticproducts:
1. Compressionmoulding isanalogoustohotpressingof
powderedmetals.
d d
l
2. Jetmoulding isamodificationofcompressionmoulding.
3. Injectionmoulding
I j ti
ldi isanalogoustodiecastingofmetals
i
l
t di ti f t l
4. Transfermoulding issimilartohydraulicextrusion.
Whi h fth t t
t
t?
(a) 1and2
(b) 1and3
(c) 1,2and4
1 2and4
(d) 2,3and4
2 3and4
IES 2004
IES2004
g
g
Whichofthefollowingarefabricatedusing
engineeringplastics?
1. Surfaceplate
2. Gears
33. Guidewaysformachinetools
y
4. Foundrypatterns
g
g
(a) 1,2and3
(b) 1
(c) 2,3and4
(d) 1,2,3and4
IES 2011
IES2011
MatchListI(Material)withListII(Typicaluse)and
thecorrectanswerusingthecodesgivenbelowthe
h
h
d
b l
h
Lists:
ListI
ListII
A. Branchedpolyethylene 1.
Bottles
B. Polyester
y
2.
Textilefibres
C. Polyvinylidene chloride 3.
Filmsforpackaging
D. LinearPolyethylene
4.
Transparentfilm
A
B
C
D
A
B
C
D
(a) 2
3
4
1
(b) 3
2
1
4
( ) 2
(c)
3
1
4
(d) 3
2
4
1
El t
Elastomers
y Elastomers are a special class, of linear polymers that
display an exceptionally large amount of elastic

deformation when a force is applied.
y Many can be stretched to several times their original
length. Upon release of the force, the deformation can
be completely
p
y recovered,, as the material q
quicklyy
returns to its original shape. In addition, the cycle can
be repeated numerous times with identical results, as
with the stretching of a rubber band.
band
y In the elastomeric polymers, the linear chaintype
molecules
o ecu es aaree ttwisted
sted o
or cu
curled,
ed, much
uc likee a co
coil
spring.
IES 2002
IES2002
Whichofthefollowingprocessescanbeusedfor
massproductionofplasticcontainers(withlid)of
5litercapacity?
1 Injectionmoulding
1.
2. Joltmoulding
3 Blowmoulding
3.
Codes:
(a) 1and2
(b) 2and3
(c) 1and3
(d) 1,2and3
Contd
Assertion (A) : The plastic organic materials

can be
b easily
il shaped
h
d or moulded
ld d by
b mechanical
h i l
action.
Reason (R): It is widely in use as it can be
permanently moulded.
the
l
i off A
(d) A is
i false
f l but
b t R is
i true
t
y When a force is applied, the polymer stretches by
y The elasticity or rigidity of the product can be determined
uncoiling. When the load is removed, the molecules recoil

and the material returns to its original size and shape.
shape
y The relationship between force and stretch does not,
however,, follow Hooke's Law.
y In reality, the behaviour of elastomers is a bit more
complex. While the chains indeed uncoil when placed
under load,
load they also tend to slide over one another to
produce a small degree of viscous deformation. When the
load is removed, the molecules recoil, but the viscous
d f
deformation
i
i not recovered
is
d and
d the
h elastomer
l
retains
i
some permanent change in shape.
y By cross
crosslinking
linking the coiled molecules, however, it is
possible to restrict the viscous deformation while retaining
the large elastic response.
Contd
by controlling the number of crosslinks within the

material.
t i l
Small amounts of crosslinking leave the elastomer soft
and flexible,
flexible as in a rubber band.
band
Additional crosslinking restricts some of the uncoiling,
and the material becomes harder,, stiffer,, and more brittle,,
like the rubber used in bowling balls.
If placed under constant strain, however, even highly cross
linked material will exhibit some viscous flow over time.
This phenomenon is known as stress relaxation.
The rate of this relaxation depends on the material,
material the
force, and the temperature.
Page 223 of 240
y
y
Rev.0
R bb
Rubber
IES 2011
IES2011
During tensile testing it has been observed that for
some material the deformation is fully recoverable
and timeindependent, but does not obey Hooks
l
law.
Th material
The
t i l is
i :
(a) Elastomer
(b) Rubber
R bb
(c) Polymer
(d) Aluminium
l
alloy
ll
y Natural rubber compounds are outstanding for their
y Natural rubber, the oldest commercial elastomer, is made
from
the
f
h processed
d sap off a tropicall tree.
y It could be vulcanized (crosslinked) by the addition of
about 30% sulphur followed by heating to a suitable
temperature. The crosslinking restricts the movement of
the molecular chains and imparts strength.
y Properties
P
i could
ld be
b further
f h improved
i
d by
b various
i
additives
ddi i
(e.g., carbon black) which act as stiffeners, tougheners, and
antioxidants.
y Accelerators have been found that speed up the
vulcanization process. These have enabled a reduction in
the amount of sulfur such that most rubber compounds
now contain less than 3% sulphur.
y g
flexibility,
good electrical insulation, low internal
friction, and resistance to most inorganic acids, salts,
and alkalies.
y However, they have poor resistance to petroleum
products, such as oil, gasoline, and naphtha.
y In addition,
dd
they
h
l
lose
their
h
strength
h at elevated
l
d
temperatures, so it is advisable that they not be used at
temperatures above 175
175F
F (80
(80C)
C).
y They also deteriorate fairly rapidly in direct sunlight
unless specially compounded.
compounded
Contd
y Rubber and similar synthetic materials such as
p
pp
y
Neoprene
have a varietyy of application
in machinery.
y Rubber should be protected from high temperature,
oil and sunlight.

g
y It is an excellent material for seats and diaphragms, for
water lubricated bearings, for parts subjected to

vibrations (such as vibration mountings, flexible
couplings and flexible bearing) and for tubes and
hose.
y In industry, hard rubber is used for electric insulation,
switch
it h handles,
h dl bearings,
b i
etc.
t
Contd
IES 1997
IES1997
g materials is used for
car tyres as a standard material?
(a) Styrenebutadiene rubber (SBR)
(b) Butyl rubber
((c)) Nitrile rubber
(d) Any of the above depending upon the need
Differenttypesofrubber
Applications
Naturalrubber
Tires,gaskets,hose
Polyacrylate
Oilhose, Orings
EDPM(ethylenepropylene)
Electricinsulation,footwear,hose,belts
Chlorosulfonated polyethylene
Tanklining,chemicalhose,polyethyleneshoe,
solesandheels
Polychloroprene (neoprene)
Wireinsulation,belts,hose,(neoprene)gaskets,
Wireinsulation
belts hose (neoprene)gaskets
seals,linings
Polybutadiene
Tires,solesandheels,gaskets,seals
Polyisoprene
Sameasnaturalrubber
Polysulfide
Seals,gaskets,diaphragms,valvedisks
SBR(styrenebutadiene)
Mouldedmechanicalgoods,disposable
pharmaceuticalitems tyres
pharmaceuticalitems,tyres
Silicone
Electricinsulation,seals,gaskets,Orings
Epichlorohydrin
Diaphragms,seals,mouldedgoods,low
ttemperatureparts
t t
Urethane
Casterwheels,heels,foampadding
Fluoroelastomers
Orings,seals,gaskets,rollcoverings
IES 2008
IES2008
C
i
Ceramic
Whichmaterialisusedforbushesinthebushed
pintypeofflexiblecoupling?
(a) Gunmetal
(b) Plastic
(c) Rubber
(d) Aluminium
y Most have crystalline structures, but unlike metals, the
y Ceramic materials are compounds of metallic and
nonmetallic elements (often in the form of oxides,

carbides, and nitrides) and exist in a wide variety of
compositions and forms.
forms
y The American Ceramic Society has defined ceramic
products as those manufactured" byy the action of heat
p
on raw materials, most of which are of an earthy
nature (as distinct from metallic, organic etc.) while of
the constituents of these raw materials,
materials the chemical
element silicon, together with its oxide and the
compounds thereof (the silicates), occupies a
predominant position."
Page 224 of 240
Contd
Contd
g electrons are g
g ionic
bonding
generally captive in strong
or covalent bonds. The absence of free electrons makes
the ceramic materials poor electrical conductors and
results
l in
i many being
b i transparent in
i thin
hi sections.
i
y Because of the strength of the primary bonds, most
ceramics
i have
h
hi h melting
high
lti temperatures.
t
t
y Ceramic articles of industry are : Dinner ware,
electrical and chemical porcelain,
porcelain refractory bricks and
tiles, glass, porcelain enamels, abrasives, cutting tools,
bricks and tiles, cements and concretes, whitewares,
mineral Ores, slags and fluxes and insulators etc.
Contd
Rev.0
y Ceramics can be natural or manufactured:
P
ti
fC
i
PropertiesofCeramics
y Ingeneral,ceramicsarehard,brittleandhigh
q
y used,
y Natural Ceramics : The most frequently
g of ceramic materials,, alongwith

g
y The covalent bonding
naturally occuring Ceramics we : Silica (SiO), Silicates

and Clay minerals.
y Manufactured Ceramics : Such ceramics include :
SiC, Al2O3, Silicon Nitride (Si3N4) and many varieties
off Oxides,
O id
C bid
Carbides,
Nit id
Nitrides,
B id
Borides
and
d more
complex ceramics.
their high melting point and relative resistance to

oxidation, make ceramics good candidates for high
temperature applications.
li i
y In addition, they are relatively cheap and abundant
and
d are nott dependent
d
d t on import
i
t for
f supply.
l
y Many ceramics retain strength to much higher
temperatures than metals.
metals
y There being virtual absence of ductility in ceramics, so,
in general,
general they can not be machined or built up from
stock.
meltingpointmaterialswith:
y desirableelectrical,magneticandoptical
desirableelectrical magneticandoptical
properties,i.e.,lowelectricalandthermal
conductivity.
y goodchemicalandthermalstability,thatis,high
hotstrengthandhighcorrosionresistance,and
freedomfromoxidation.
y goodcreepresistance,and
y Highcompressivestrengthandexcellent
g
p
g
resistancetowear.
y Theirlowdensityisalsoanattractivefeatureto
minimisecentrifugalstressesinpartsrotatingat
highspeed.
Contd
IES 2008
IES2008
Considerthefollowingstatementsrelatingto
mechanicalpropertiesofceramics:
h
l
f
1. Tensilestrengthistheoreticallyhighbutinpractice
quitelow.
quitelow
2. Compressivestrengthismanytimeslowerthantensile
strength.
3. Shearstrengthishigh.
4. Transversestrengthiseasytoascertain.
Whi h f h
i b
?
(a) 1and3
(b) 1and4
(c) 2and3
(d) 2and4
M hi i
fC
i
MachiningofCeramics
y Mostceramicsaresinteredtotheirfinish
dimensions.
y However,sometimes,theyaremachinedtogetbetter
dimensionalaccuracyandsurfacefinish.
y MachiningofceramicscanbedonewithDiamond
abrasives,LBM,EBMandCHM.
IES 2002
IES2002
g
Whichoneofthefollowingistrue?
(a) Structureofmetallicmaterialsconsistsofatoms
havingvalenceof5,6or7
(b) Ceramicmaterialshavelongrangeelectronmatrix
bond
(c) Polymersarecomposedoflongchainofrepeating
molecules
(d) Ceramicsareweakerthanmetalsbecauseofweak
electrostaticbond
P
i
fC
i
ProcessingofCeramics
The processing of ceramics,
ceramics except glass,
glass follows the
Powder Metallurgy route, that is, consists of the
following steps :
1 Preparation of powders
1.
2. Mixing and Blending of powders
3. Compacting of powders
4. Firing or Sintering.
PRODUCT APPLICATIONS
PRODUCTAPPLICATIONS
2 R f t i
2.Refractories
y p
1. Clay
products : Clayy bodyy ceramics include
whitewares and stoneware.
y Whitewares includes such families of products as
earthenwares, China and porcelain.
y Whitewares are largely used as tile, sanitary ware, low
and high voltage insulators, and high frequency
applications.
y Stoneware applications
l
are : Glazed
l d pipes, roofing
f
tiles
l
and tableware.
y Refractory ceramics are the materials which are capable of
Page 225 of 240
withstanding
in
situations.
The
ith t di high
hi h temperature
t
t
i various
i
it ti
Th
refractory materials are of three types.
y Acidic refractories are based on aluminasilica
composition,
ii
varying
i
f
from
pure silica
ili
to nearly
l pure
alumina, through a wide range of alumina silicates.
y The basic constituent of basic refractories is magnesia,
g
,
MgO. Basic refractories include chromemagnesite,
dolomite, limestone and magnesite.
y Neutral refractories include substances which do not
combine with either acidic or basic oxides. With increasing
alumina content, silicaalumina refractories may gradually
g from an acidic to neutral type.
yp A typical
yp
neutral
change
character is exhibited by such refractories as Carbon,
graphite, carbide, chromite, bauxite and forsterite.
Rev.0
Contd
y Refractories are used in the construction or lining of
furnaces,
furnaces boilers,
boilers flues,
flues regenerators,
regenerators convertors,
convertors
crucibles, dryers, pyrometer tubes and in many others,
primarly to withstand the high temperature.
Al2O3
y The most widely used oxide refractory ceramic is
alumina
. It is sintered into cutting tool bits,
spark
k plug
l insulators,
l
h h temperature tubes,
high
b melting
l
crucibles, wear components and substrates for
electronic circuits and resistors.
C bid
f t
Carbiderefractory
y Carbides have the highest melting point of all the
substances.
b t
y Silicon carbide, SiC, is difficult to sinter, but pressure
sintered or reactive sintered solid bodies of SiC are used as

hi h
hightemperature
resistanceheating
i
h i
elements,
l
rocket
k
nozzels and sand blast nozzles.
y Ceramics such as UO2,, UC and UC,, are used in nuclear
applications as fuel elements, fuel containers, moderators,
control rods and structural parts.
y Boron carbide, B4C, is extremely hard and is used as a
grinding grit.
y Other carbides (Tungsten Carbide, Tantalum Carbide and
Titanium carbide) are used in the sintered form as cutting
tool materials.
Contd
3 Electrical and Magnetic

3.ElectricalandMagnetic
Applications
y Ceramics find wide applications in electrical and
electronic industries.
y As
A
i
insulators,
l
semiconductors,
i
d
di l
dielectrics,
i
ferroelectrics, piezoelectric crystals.
y Ceramics such as glass,
glass porcelain,
porcelain alumina,
alumina quartz and
mica, are getting heavy demands.
y Ceramics,, such as SiC,, are used as resistors and
heating elements for furnaces.
y Ceramics, having semiconducting properties, are used
f thermistors
for
h
i
and
d rectifiers.
ifi
B i
Barium
titantate,
i
f
for
example, is used in capacitors and transducers.
and is used as cutting tool material.

material Silicon nitride,
nitride Si3N4,
Si3N4 is
used for ceramic engine components, turbine disks and rocket
nozzles.
Sialon (Si Al O N),
N) that is oxynitrides,
o nitrides have
ha e better
oxidation resistance and is used for cutting tools and welding
pins.
Borides
d (of
( f Chromium,
h
Zirconium and
d Titanium)) are used
d as
turbine blades, Rocket nozzles and Combustion chamber
liners.
Cermet is a composition of ceramic and metal. This material
shows better thermal shock resistance than ceramics, but at the
g refractoriness.
same time retains their high
It is used as cutting tool material, as crucibles and as jet engine
nozzles.
4 O ti l A li ti
4.OpticalApplications
5 Ph h
5.Phosphorescence
y useful as a p
g
, because it is
y Ceramics are notably
pigment,
p
g of a characteristic wave
y Ceramic p
phosphors
emit light
exceptionally durable. It is completely oxidised and not

subject to chemical attack and variation.
y Yttralox (a new ceramic material) is useful in optical
appIications, becuase it is as transparent as window
glass
l
and
d can resist
i t very high
hi h temperature.
t
t
Ytt l is
Yttralox
i
completely free from pores.
y Generally,
Generall Ceramics are opaque,
opaque because of the
presence of tiny pores within them that scatter light.
length when excited or pumped by some appropriate

energy source (an electric discharge or electron beam).
y Light tubes, VDT's and colour T.V. rely on this
phenomenon.
y Of increasing interest are Laser materials, The most
widely used Laser is ruby (an Al2O3 , crystal doped with
Cr ions).
ions)
y They are being used for machining, welding and
cutting etc.
etc
IES 2002
IES2002
Gl
Glass
MatchListIwithListIIandselectthecorrectanswer:
ListI(Material)
ListII(Application)
A. Ceramics
1.
Constructionof
chemicalplants
B. Refractory
2.
Columnsandpillars
C. Stones
3.
Liningoffurnaces
D. Highsilicaglass
4.
Tiles
Codes:A
d
B
C
D
A
B
C
D
(a) 4
3
2
1
(b) 2
1
4
3
( ) 4
(c)
1
2
3
(d) 2
3
4
1
y definition,, "Ceramics" because the

y Glasses are,, by
y Nitrides have only slightly lower melting points than carbides.

y Cubic boron nitride, CBN, is the hardest material after diamond
starting materials needed to produce glass are typical

of ceramic materials. However, they are produced by
the
h melt
l processing
i
route, instead
i
d off the
h powder
d
metallurgy route used for other ceramics.
y In
I ceramic
i science,
i
th word
the
d "glass"
" l " signifies
i ifi
any
amorphous component of ceramic mixture.
y However,
Ho e er in general terms,
terms glass is a transparent silica
product which may be amorphous or crystalline,
depending on heat treatment.
treatment
y Glasses may be either inorganic or organic.
Contd
Page 226 of 240
y Vitreous materials or inorganic glasses are the fusion
products which during solidification from a liquid state

failed to crystallise.
crystallise
y During the cooling process, the glasses exhibit no
g at anyy temperature
p
and onlyy a
discontinuous change
progressive increase in viscosity is noticed. In fact, glass is a
hard liquid.
y Glass Forming Constituents : Silica,
Silica which is obtained
from highpurity silica sand is the most widely used glass
forming constituent.
y Other glass forming constituents are the oxides of boron,
vanadium, germanium and phosphorous. Some other
elements and compounds such as tellurium, selenium and
BeF2 can also form glasses.
Rev.0
Contd
y Along with oxides, fluxes are also added to the charge
for a g
glass. Fluxes lower the fusion temperature of the
glass and render the molten glass workable at
reasonable temperature.
y However, fluxes may reduce the resistance of glass to
chemical attack, render it water soluble or make it
subject
bj t to
t partial
ti l or complete
l t devitrification
d it ifi ti
(th t is,
(that
i
crystallisation) uponcooling; Such a glass is
undesirable since the crystalline are extremely weak
and brittle.
y Stabilizers are therefore, added to the glass batch to
overcome these problems.
C
it
Composites
y
y
y
IES 2011
IES2011
What are composites?

Composites are the multiphase materials, which can be
defined as any multiphase material that is artificially made
and exhibits a significant proportion of the properties of
the
h constituent
i
phases.
h
The constituent phases of a composite are usually of macro
portions,, differ in form and chemical composition
p
sized p
and essentially insoluble in each other.
Why do we need composites?
Composites are the class of materials with special
properties.
Propertiesofthecompositecanbetailoredtomeetthe
requiredpurposesuchassuperiorpropertieslikehigher
strengthtoweightratio,highmodulusandhigh
temperaturestabilityalongwithgooddampingability.
TYPES OF COMPOSITE MATERIALS

TYPESOFCOMPOSITEMATERIALS
y Composite materials may roughly be classified as :
1. Agglomerated materials or Particulate Composites

2. Reinforced materials
3. Laminates
4. SurfaceCoated materials.
y The particulate composites and reinforced composites
are constituted by just two phases, the matrix phase
and the dispersed phase.
phase
y The matrix phase is continuous and surrounds the
dispersed
p
phase. The aim is to improve
p
p
the strength
g
properties of the matrix material.
IES 2011
IES2011
Structure of common glass is
(a) Amorphous
(b) Partially crystalline
(c) Fully crystalline
Contd
Assertion (A) : A composite is a multiphase

material
t i l which
hi h is
i artificially
tifi i ll made
d as one that
th t
occurs naturally.
Reason ((R):
) Technology
gy of modern age
g requires
q
a
material with unusual combination of properties
that cannot be met by metal or alloys.
((b)) Both A and R are individuallyy true but R is NOT the
(d) A is
i false
f l but
b R is
i true
Th matrix
i material
i l should
h ld be
b : ductile
d il with
i h its
i
y The
modulus of elasticity much lower than that of the
dispersed phase.
phase Also,
Also the bonding forces between the
two phases must be very strong.
y Depending upon the nature of the reinforcing
materials (shape and size), the reinforced composites
can be classified as:
1. Particle reinforced composites or particulate
reinforced composites.
2. Fibre reinforced composites.
y In p
particle reinforced composites,
p
, the dispersed
p
phase
p
is in the form of exiaxed particles, whereas in fibre
reinforced composites,
is inofthe
form of fibres. Contd
Pageit227
240
IES 2008
IES2008
g
Whichoneofthefollowingiscorrect?
When"devitrification"ofinorganicglassesisdone,
((a)) Glasstransformsfromcrystallinetonon
y
crystallinestate
((b)) Glasstransformsintoafullytransparentmaterial
y
p
(c) Glasstransformsfromnoncrystallinestateto
polycrystallinestate
(d) Glassisrelievedofinternalstresses
IES 2009
IES2009
p
g yp
Nano compositematerialsarehighlypreferablein
designconsiderationfortheir
(a) Highresistancetocrackpropagation
(b) Vibrationresistance
((c)) Impactresistance
p
(d) Highresilience
A l
t dM t i l
AgglomeratedMaterials
y Agglomerated materials or particulate composites
consist of discrete particles of one material,

surrounded by a matrix of another material. The
materials are bonded together into an integrated mass.
mass
y Two classic examples of such a composite material are :
Concrete formed byy mixing
gg
gravel,, sand,, cement and
water and agglomeration of asphalt and stone
particles, that is used for paving the highway surfaces.
Other examples of particulate composite materials
include :
1.. G
Grinding
d g aand
d cutt
cutting
g wheels,
ee s, in which
c ab
abrasive
as e
particles ( Al2O3 , SiC, CBN or diamond) are held
together by a vitreous or a resin bond.
Contd
Rev.0
IES 2009
IES2009
C
d carbides,
bid
i which
hi h particles
i l off ceramic
i
2. Cemented
in
materials, such as WC, TaC, TiC and of Cobalt and nickle,
are bonded together via Powder Metallurgy process, to
produce
cutting
d
i tooll materials.
i l Cobalt
C b l acts as the
h binder
bi d for
f
ceramic particles. During sintering, the binder melts and
forms a continuous matrix between the ceramic particles.
Thi method
This
th d is
i called
ll d as "Vitreous
"Vit
sintering",
i t i " that
th t is,
i
sintering with the formation of liquid phase.
3. Cermets (Ceramics + metals). Metals (W, Mo, Ni, Co
act as binders
bi d
and
d the
h product
d
i made
is
d by
b Powder
P d
Metallurgy method.
y The sintering
g temperature
p
is the melting
gp
point of the metal.
y In the resulting composite material, the metal contributes
high toughness and thermal shock resistance, while the
ceramic
ce
a c co
contributes
t butes higher
g e refractoriness
e acto ess aand
d ccreep
eep
resistance, superior chemical stability and abrasion
resistance.
y The toughness of the composite material increases,
g will be needed to break or pull

because extra energy
out a fibre.
y Also, when any crack appears on the surface of a fibre,
only that fibre will fail and the crack will not
propagate catastrophically as in bulk material.
y Woodandbambooaretwonaturallyoccurringfiber
d db b
ll
fb
composites,consistingofcellulosefibers inalignin
matrix.
matrix
y Thecommonlyusedmatrixmaterialsare:Metalsand
polymers suchas Al Cu Nietc andcommercial
polymers,suchas,Al,Cu,Nietc.andcommercial
polymers.
g
p
Whichofthefollowingcompositesare
dispersionstrengthenedcomposites?
((a)) Particulatecomposites
p
(b) Laminarcomposites
(c) Fiberreinforcedcomposites
(d) Shortfiberdiscontinuouscomposites
Reinforced Materials
ReinforcedMaterials
y Reinforced materials form the biggest and most
important group of composite materials.

materials
y The purpose of reinforcing is always to improve the
strength properties.
properties
y Reinforcement may involve the use of a dispersed phase
or strong fibre,
fibre thread or rod.
rod
y The matrix material provides ductility and toughness
and supports and binds the fibres together and

transmits the loads to the fibres.
y The fibres carry
y most of the load.
Contd
y Reinforcing Fibres :A good reinforcing fibre should have :
y
y
high elastic modulus, high strength, low density, reasonable

ductility and should be easily wetted by the matrix.
matrix
Metallic fibres such as patented steel, stainless steel,
tungsten and molybdenum wires are used in a metal matrix
such
h as aluminium
l
and
d titanium.
Carbon fibres and whiskers are also used to produce ultra
high strength composites.
composites
Fibres need not be limited to metals. Glass, ceramic and
polymer fibres are used to produce variety of composites
h i wide
having
id range off properties.
i
The ductile matrix material can be aluminium, magnesium,
nickle or titanium and the reinforcing fibres may be of
boron, graphite, alumina or SiC.
Contd
IES 2007
IES2007
IES 2002
IES2002
p
g
Woodisanaturalcompositeconsistingofwhich
ofthefollowing?
(a) Ligninfibres incollagenmatrix
(b) Ligninfibres inapatitematrix
((c)) Cellulosefibres inapatitematrix
p
(d) Cellulosefibres inligninmatrix
g
Whichofthefollowingfibre
materialsareused
forreinforcementincompositematerials?
1. Glass
2. Boroncarbide
33. Graphite
p
((a)) 1and2
((b)) 1and3
3
(c) 2and3
(d) 1,2and3
Page 228 of 240
IES 2010
IES2010
composite materials:
1. Material is termed as advanced composite, if fibers are
directionally oriented and continuous.
continuous
2. Reinforced fiber glass products are strong and light
weight.
g
3. Concrete is reinforced with steel rebar, the rebar becomes
matrix.
4. Pearlitic steels are composite materials.
(a) 1, 2 and 3 only
(b) 2, 3 and 4 only
(c) 1, 2 and 4 only
(d) 1, 2, 3 and 4
IES 1999
IES1999
g
Thestrengthofthefibre reinforcedplasticproduct
p
p
g
alone
1. Dependsuponthestrengthofthefibre
2. Dependsuponthefibre andplastic
3. Isisotropic
4. Isanisotropic
(a) 1and3
(b) 1and4
(c) 2and3
(d) 2and4
Rev.0
Whi k
Whiskers
g crystals in the form of fine filaments, a
y Whiskers are single
y
y
y
y
few microns in diameter (2050 nm dia.) and short in

length (a few mm).
Th
These
single
i l crystall whiskers
hi k
are the
h strongest known
k
fibres.
Their high strength is due to the high degree of perfection
and the absence of dislocation in their structure.
Their strength
g is manyy times g
greater than that of the
normal metals.
Theyareintroducedintoresinormetallicmatrixforthe
purposeofhighstrengthandhighstiffnessathigh
temperatures.
3. Graphite fibrereinforced epoxy : (Organic or Resin

p
) : This material is being
g used to
matrix composites)
make m y parts of a fighter plane.
4. Automative uses : Bodyy p
4
panels,, drive shafts,, springs
p g
and bumpers, Cab shells and bodies, oil pans, fan
shrouds, instrument panels and engine covers.
5. Sports equipment : Golf club shafts, baseball parts,
fishing rods, tennis rackets, bicycle frames, skis and
pole
l vaults.
l
IES 2011
IES2011
Whiskers are
(a) Very thin metallic particles
g crystals
(b) Very thin single
(c) Very thin polycrystals
((d)) Fiber p
particles of aspect
p ratio less than 10
Hardness
Hardness is the resistance offered by a material
to indentation.
1. Glassfibre reinforced p
plastics : Here,, we have g
glass
fibres in a matrix of unsaturated polyester.
y Glass fibrereinforced plastics are used to make : boat
hulls, Car bodies, truck, cabins and aircraft fittings.
2. CC Composites : These composites have graphite
fibres in a carbon matrix.
y This material is being used to make : Nose cone and
l d
leading
edge
d off the
h missiles
l and
d space shuttles,
h l racing
car disk brakes, aerospace turbine and jet engine
components rocket nozzles and surgical implants.
components,
implants
Contd
IES 2009
IES2009
g
Whichoneofthefollowingmaterialsisnota
composite?
(a) Wood
(b) Concrete
((c)) Plywood
y
(d) Sialon
H d
T
HardnessTest
Definition: Hardness is a very important but hard to
define property of materials.
A li i
f i f
d
i l
Applicationsofreinforcedmaterials
IES 1992
IES1992
Hardnessasafunctionofcarboncontentisshown
in
( ) g
(a)FigA
(b)Fig B
(b)FigB
IAS 2001
IAS2001
With the
off percentage
off carbon
in
th increase
i
t
b
i the
th
steel, which one of the following properties does
increase?
(a) Modulus of elasticity (b) Ductility
(c) Toughness
(d) Hardness
(c)Fig C
(c)FigC
(d)Fig D
(d)FigD
Page 229 of 240
Rev.0
M h ScaleofHardness
S l fH d
Mohs
Material
Talc
Gypsum
Calcite
Fluorite
A tit
Apatite
Orthoclase
Quartz
Topaz
Corundum
Diamond
Mohs hardness
1
2
3
4
5
6
7
8
9
10
Brinell Hardnesstest
y A 10 mm tungsten carbide or hardened steel ball
intended.
y Gradually applied load.
load
y Load applied at right angle to the specimen surface
y Indentation diameter made on the specimen is
measured.
BHN =
Load
oad
=
Surface Areaof Indentation
(D
D d
y Itisbestifthethicknessofthematerialisatleast10
timesthedepth.
y Tensilestrength=kBHN MPa
k =3.296foralloysteel
3 34
=3.342forPlainCarbonsteel.
y Forsteel,flexuralendurancelimit e
e = 1.75 BHN
k f / mm2
kgf
MPa
VHN BHN
P Kgf ; D and d in mm
IES 2010
IES2010
Thehardnessoflathebedmaterialshouldbe
measuredby
db
(a)Rockwelltester
(b)Brinell hardnesstester
(c)ShoreScleroscope
(d)Vickershardnesstester
y Itcannotbeusedonveryhardorverysoftmaterial.
y Most commonly used tests.
Rc
Contd
IES 1992
IES1992
A carbon steel having Brinell Hardness
number 100 should ultimate tensile
strength closer it
(a) 100 N/mm2
(b) 200 N/mm2
2
2
( ) 350 N/mm
(c)
N/
(d) 1000 N/mm
N/
BHN
10
R k ll H d
RockwellHardnesstest
y A sphere conical diamond cone of 120
120 angle and a
spherical apex of radius 0.2 mm is used

y Depth
p of indentation t is measured.
y Gradually applied load,
y Load is applied at right angle to the specimen surface.
y R = 100 500 t
y Depending on the load used a scale A,
A B,
B C,
C etc.
etc used.
used
y Rockwell test should not be used on thin materials
(generally less than 0.16 mm, on rough surface or on

materials that are not homogeneous).
IAS 1999
IAS1999
AmeasureofRockwellhardnessisthe
(a) Depthofpenetrationofindenter
(b) Surfaceareaofindentation
(c) Projectedareaofindentation
(d) Heightofrebound
Vi k h d
Vickershardnesstest
(i) A square based diamond pyramid having 136
136
between the opposite faces is used.
((ii)) Average
g Diagonal
g
of the indention
((D)) is
measured.
VHN =
1.854
1
854 p
,
D2
p in kgf
D in mm.
Th S l
TheScleroscope
(i) Based on the rebound height of a ball from the
specimen.
((ii)) Harder the material,, higher
g
is the height
g to which
the ball rebounds.
((iii)) Scleroscope
p hardness numbers are comparable
p
only among similar materials. A comparison between
steel and rubber would not be valid.
(iii) Even
E
a light
li ht load
l d will
ill produce
d
plastic
l ti deformation
d f
ti
that so why we may use VHT on very hard material
likes Tungsten Carbide.
Carbide
Page 230 of 240
Rev.0
Knoop Test(MicroHardnessTest)
y Various micro hardness tests have been developed for
application where it is necessary to determine the

hardness of a very precise area of material, or where
the material or surface layer is exceptionally thin.
y Special machine have been developed for this purpose.
The location for this test is select in the high
magnification.
y A small
ll diamond
di
d penetrator is
i then
h
l d d with
loaded
ih a
predetermined load ranging fm 25g to 3000g.
IES 1992
IES1992
Herbert cloudburst Hardness test is conducted to
know
((a)) Uniformityy of hardness over a surface
(b) Softness of nonmetallic components
(c) Hardness of non
nonmetallic
metallic components
(d) Hardness at specified depth inside the surface.
Sh
F
bili T
SheetFormabilityTests
y During the various sheet metal forming processes, the
stresses and strains developed in the material are quite

complex. So, any measure of the formability of the
sheet metal on the basis of material properties derived
from a simple tension test( for example, % elongation
as an index
i d off ductility
d tilit off the
th material)
t i l) is
i nott very
accurate.
y So cupping tests have been developed to evaluate the
formability of the sheet metals.
IES 1992
IES1992
Whichofthefollowingwouldyoupreferfor
checkingthehardnessofverythinsections?
((a)) Hebertcloudbursttest
(b) Shore'sScleroscope
(c) Knoop hardnesstest
(d) Vickershardnesstest
Durometer
y When
testing
soft,
Wh
i
f elastic
l i materials,
i l such
h as
rubbers and non rigid plastics, a durometer is
use
Herbert Cloudburst hardness test:
y It is used to know the uniformity of hardness
over a surface.
Charpy andIzod test

y Toughness of a material is measured by means of impact
tests.
y Notched bar prepared as per standard from the test
material, is held in a vice and a weight is allowed to swing
from a known height in such a way that it hits the notched
bar in its path and breaks it.
y Since the material has absorbed some amount of energy
gy
during its fracture, the swinging mass loses part of its
energy and therefore will not be able to reach the same
h i ht from
height
f
where
h
it started.
t t d
y The loss in height (h) multiplied by the weight represents
the energy absorbed by the specimen during fracture,
fracture
which can be directly measured from the indicator on the
Contd
tester.
GATE 2006
GATE2006
MatchtheitemsinColumnIandColumnII.
ColumnI
ColumnII
P. Charpy test
1.
Fluidity
Q. Knoop test
2.
Microhardness
R. Spiraltest
3.
Formability
S Cuppingtest
S.
C
i t t
4.
T
Toughness
h
5.
Permeability
(a) P 4,Q 5,R 3,S 2
((c)) P 2,Q
, Q 4,
4,R 3,
3,S 5
(b)
((d))
P 3,Q 5,R 1,S 4

P 4,
4,Q
Q 2,R
,
1,S
,
3
Page 231 of 240
y In the Charpy impact test, the specimen is held between
two grips whereas in the Izod impact test the specimen is

held at one end like a cantilever .
y The standard test specimens used in the izod and Charpy
impact tests are made of bars with a square cross section of
10 mm.
y The impact resistance is dependent upon the material
composition as well as the heat treatment process given to
it.
y The annealed materials normally would have better
toughness
h
than
h
the
h
corresponding
di
normalized
li d or
quenched specimens. Coarsegrained structure would tend
g
ductilityy compared
p
to fine g
grain structure
to have higher
and consequently better toughness.
IES 2002
IES2002
) The hardness test is a slow,, expensive
p
Assertion ((A):
method of assessing the mechanical properties of
materials.
Reason (R): The hardness is a function of yield stress
and the work hardening rate of material.
((a)) Both A and R are individuallyy true and R is the correct
explanation of A
Rev.0
Duralumin
IES 1993
IES1993
y It is an important and interesting wrought alloy.

y Its composition is as follows:
y Copper = 3.5 4.5%; Manganese = 0.4 0.7%;
y
pp
DuraluminAlloycontainsaluminium
andcopper
intheratioof
%Al
%Cu
(a) 94
4
((b)) 9
90
8
(c) 88
10
((d)) 86
12
M
Magnesium
i
= 0.4 0.7%,
% and
d the
th remainder
i d
i
is
aluminium.
y This alloy possesses maximum tensile strength (upto
400 MPa) after heat treatment and age hardening.
After working, if the metal is allowed to age for 3 or 4
d
days,
i will
it
ill be
b hardened.
h d
d This
Thi phenomenon
h
i known
is
k
as age hardening.
y It is widely used in wrought conditions for forging,
forging
stamping, bars, sheets, tubes and rivets.
Magnalium
IES 1992
IES1992
g
Whichofthefollowingstatementisincorrect
aboutduralumin?
(a) Itispronetoagehardening
(b) Itcanbeforged
((c)) Ithasgoodmachiningproperties
g
gp p
(d) Itislighterthanpurealuminium
y It is made by melting the aluminium with 2 to 10%
magnesium in a vacuum and then cooling it in a

vacuum or under a p
pressure of 100 to 200 atmospheres.
p
y It also contains about 1.75% copper. Due to its light
weight
g and g
good mechanical p
properties,
p
it is mainlyy
used for aircraft and automobile components.
Copper zinc alloys (Brass)

Copperzincalloys(Brass)
y The addition of zinc strengthens the material and
zinc alloy is brass.

y The most widely used copper
copperzinc
y There are various types of brasses, depending upon the
proportions
p
p
of copper
pp and zinc.
y This is fundamentally a binary alloy of copper with
zinc each 50%.

5
y By adding small quantities of other elements, the
properties of brass may be greatly changed.

y ApplicationsofCualloysinclude:costumejewellery,
coins,musicalinstruments,electronics,springs,
bushes,surgicalanddentalinstruments,radiators,etc.
Contd
incidentally changes the colour to a yellow or gold

effect.
ff
y The ratio of copper and zinc can be varied for
advantages and the addition of other elements gives
still more variety of combinations of properties such as
machinability, strength, hardness, ductility (hot or
cold),
ld) conductivity
d
and
d corrosion resistance as well
ll as
many others.
y Leadadditionsareusedtoimprovemachinability.The
Leadadditionsareusedtoimprovemachinability The
leadisinsolubleinthesolidbrassandsegregatesas
smallglobulesthathelptheswarftobreakupinto
g
p
p
smallpiecesandmayalsohelptolubricatethecutting
toolaction.
Page 232 of 240
Hindalium
y Itisanalloyofaluminium andmagnesiumwitha
smallquantityofchromium.
IES 1992
IES1992
g
p
Additionofwhichofthefollowingimproves
machiningofcopper?
(a) Sulphur
(b) Vanadium
((c)) Tin
(d) Zinc
Rev.0
IES 1992
IES1992
g
Cartridgebrasscanbe
(a) Coldrolledintosheets
((b)) Drawnintowires
(c) Formedintotubes
(d) Anyoftheabove.
Copper tin alloys (Bronze)

Coppertinalloys(Bronze)
y The hardness and strength of bronze increase with an
y The alloys of copper and tin are usually termed as
bronzes.
y The useful range of composition is 75 to 95% copper
and
d 5 to 25%
% tin.
y The metal is comparatively hard, resists surface wear
and
d can be
b shaped
h
d or rolled
ll d into
i
wires,
i
rods
d and
d sheets
h
very easily.
y In
I corrosion
i resistant
i t t properties,
ti bronzes
b
are superior
i
to brasses.
increase in tin content.

y The ductility is also reduced with the increase in tin
percentage above 5.
y When aluminium is also added (4 to 11%), the
resulting alloy is termed aluminium bronze, which
h a considerably
has
d bl higher
h h corrosion resistance.
y Bronzes are comparatively costly compared to brasses
d to the
due
h presence off tin
i which
hi h is
i an expensive
i metal.
l
y The colour of aluminium bronze is similar to that of
22 caratt gold
ld and
d it is
i frequently
f
tl called
ll d imitation
i it ti
gold.
Contd
Phosphor bronze
Phosphorbronze
IES 2011
IES2011
Aluminium Bronze is also known as :
(a) Muntz metal
(b) White metal
(c) Duraluminium
((d)) Imitation g
gold
y When bronze contains phosphorus, it is called
phosphor bronze.
y Phosphorus increases the strength, ductility and
soundness
d
off castings.
y This alloy possesses good wearing qualities and high
elasticity.
l i i
y A common type of phosphor bronze has the following
composition
iti
according
di to
t Indian
I di standards
t d d Copper
C
=
8790%, Tin = 910%, and Phosphorus = 0.13%.
y The material is specified for pump parts,
parts gears,
gears
springs, power screw nuts and bearings.
Gun Metal
GunMetal
IES 1992
IES1992
p
g
p
p
p
p
Thepercentageofphosphorousinphosphorbronze
is
(a) 0.1
(b) 1
(c) 11.1
(d) 98
y It is an alloy of copper, tin and zinc.

y It usually contains 88% copper, 10% tin and 2% zinc.
y This metal is also known as Admiralty g
gun metal.
y The zinc is added to clean the metal and to increase its
fluidity.
y It is not suitable for being worked in the cold state but
may be forged when at about 600C.
IES 2006
IES2006
Incaseofpowerscrews,whatisthecombination
ofmaterialsusedforthescrewandthenut?
((a)) Castironscrewandmildsteelnut
(b) Carbonsteelscrewandphosphorbronzenut
(c) Castironscrewandcastironnut
(d) Aluminium screwandalloysteelnut
IES 2003
IES2003
,
j
g ,
Gunmetal,whichisusedinjournalbearings,
contains
(a) 88%Cu,10%Sn,2%Zn
(b) 80%Cu,10%Zn,10%Al
((c)) 85%Cu,5%Mg,10%Al
5
,5
g,
(d) 85%Cu,5%Sn,10%Pb
y It is extensively used for casting boiler fittings, bushes,
bearings, glands, etc.
Page 233 of 240
Rev.0
IES 1994
IES1994
gp
y
Whichofthefollowingpairsarecorrectly
matched?
1. SiliconsteelsTransformerstampings
2. DuraluminCookingutensils.
33. Gunmetal.................Bearings
g
Selectthecorrectanswerusingthecodesgivenbelow.
C
Codes:
(a) 1,2and3
(b) 1and2
(c) 1and3
(d) 2and3
IES 2011
IES2011
thecodegivenbelowthelists:
ListI
1 Wormwheel
1.Wormwheel
B.Phosphorbronze
2.Cylinderblock
C.Graycastiron
3.Piston
D Alallo
D.Alalloy
4 Bushings
4.Bushings
Codes
A
(a) 3
(c) 3
B
1
2
C
2
1
D
4
4
(b)
(d)
A
4
4
B
1
2
y It is an important alloy of nickel and copper.

y It contains 68% nickel, 29% copper and 3% other
ListII
A GunMetal
A.GunMetal
Monel metal
C
2
1
D
3
3
constituents like iron, manganese, silicon and carbon.

It is superior to brass
b
and
d bronze
b
in corrosion resisting
properties.
y It
I is
i used
d for
f
making
ki
propellers,
ll
pump fittings,
fi i
condenser tubes, steam turbine blades, sea water
exposed parts,
parts tanks and chemical and food handling
plants.
IES 2011
IES2011
Admirality Brass is used for
(a) Condenser Tubes
(b) Rivets
(c) Piston rods
((d)) Utensils
IES 2006
IES2006
MatchListI(Composition)withListII(Application)andselect
thecorrectanswerusingthecodegivenbelowtheLists:
List I
ListII
A. Commercialbronze(10%Zn)
1.Radiator
B
B.
Redbrass(15%Zn)
2 Springmetal
2.Springmetal
C. Aluminiumbrass(22%Zn,2%Al)
3.Forgingand
stamping
D
D.
Pbronze(11%tin)smallamountofP)
4 Powerplant
4.Powerplant
andchemical
equipment
Codes: A
B
C
D
A
B
C
D
(a) 2
4
1
3
(b)
3
1
4
2
(c) 2
1
4
3
(d)
3
4
1
2
IES 2003
IES2003
y
Monel metalisanalloyof
(a) Ironandcarbon
((b)) Copperandzinc
pp
(c) Aluminium andcopper
(d) Copperandnickel
Page 234 of 240
IES 2004
IES2004
y
pp
MatchListI(Alloy)withListII(Application)andselect
ListI
ListII
A Siliconsteel
A.
1
1.
Marinebearings
B. Highcarbonsteel
2.
Cuttingtools
C. Highspeedsteel
3.
Springs
D. Monel metal
4.
Transformer
laminations
Codes:A
B
C
D
A
B
C
D
(a) 1
2
3
4
(b) 4
3
2
1
(c) 4
2
3
1
(d) 1
3
2
4
Rev.0
Inconel
y It consists of 80% nickel, 14% chromium, and 6% iron.
y This alloy has excellent mechanical properties at
ordinary and elevated temperatures.

y It can be cast, rolled and cold drawn.
y It is used for making springs which have to withstand
high temperatures and are exposed to corrosive action.
y It is also used for exhaust manifolds of aircraft engines.
Babbit metal
y The tin base and lead base babbits are widely used as a
bearing material, because they satisfy most

requirements for general applications.
y The
h babbit
b bb is generally
ll used
d as a thin
h layer,
l
0.05 mm to
0.15 mm thick, bonded to an insert or steel shell. The
composition of the babbit metals is as follows:
y Tin base babbits : Tin 90% ; Copper 4.5% ; Antimony
5% ; Lead 0.5%.
0 5%
y Lead base babbits : Lead 84% ; Tin 6% ; Anitmony
9 5% ; Copper 0.5%.
9.5%
0 5%
IES 2009
IES2009
y
y
g
Whyarebabbit
alloysusedforbearingmaterial?
(a) Theyhaveexcellentembeddability
((b)) Theyarerelativelystrongerthanotherbearing
y
y
g
g
materials
((c)) Theydonotlosestrengthwithincreasein
y
g
temperature
(d) Theyhavehighfatiguestrength
Nichrome
y It consists of 65% nickel,
nickel 15% chromium and 20% iron.
iron
y It has high heat and oxidation resistance.
y It is used in making electrical resistance wire for
electric furnaces and heating elements.
IES 2011
IES2011
Babbit is an alloy of
(a) Sn, Cu, Sb and Pb
(b) Sn and Cu
(c) Sn, Cu and Pb
((d)) Sn,, Cu and Sb
IES 2008
IES2008
g
Whichoneofthefollowingiscorrect?
Babbittareusedfor
((a)) Gears
((b)) Bearings
g
(c) Bolts
(d) Clutchliners
Page 235 of 240
Nimonic
y It consists of 80% nickel and 20% chromium.
y It has high strength and ability to operate under
intermittent heating and cooling conditions.

y It is widely used in gas turbine engines.
IES 1995
IES1995
g
g
Babbit liningisusedonbrass/bronzebearingsto
(a) Increasebearingresistance
((b)) Increasecompressivestrength
p
g
(c) Provideantifrictionproperties
(d) Increasewearresistance.
IES
g
Tinbasewhitemetalsareusedwherethebearings
aresubjectedto
(a) Largesurfacewear
(b) Elevatedtemperatures.
((c)) Lightloadandpressure
g
p
(d) Highpressureandload.
Rev.0
IES 1998
IES1998
IES 2005
IES2005
MatchListI(Alloys)withListII(Applications)and
l
h
h
d
b l
thelists:
ListII
List
ListII
List
II
A. Chromel
1.
Journalbearing
B. Babbit alloyy
2.
Millingcutter
g
C. Nimonic alloy
3.
Thermocouplewire
D. Highspeedsteel
4.
Gasturbineblades
Code:A
B
C
D
A
B
C
D
(a) 3
1
4
2
(b) 3
4
1
2
( ) 2
(c)
4
1
3
(d) 2
1
4
3
MatchListI(Alloy)withListII(MajorConstituent)
andselectthecorrectanswerusingthecodegiven
d l
h
h
d
belowtheLists:
ListI
ListII
A. Babbitt
1.
Nickel
B. Invar
2.
Tinandlead
C. GunMetal
3.
Aluminium
D. Duralumin
4.
Copper
Code:A
B
C
D
A
B
C
D
(a) 2
4
1
3
(b) 3
1
4
2
( ) 2
(c)
1
4
3
(d) 3
4
1
2
Col mbi m/Niobi m

Columbium/Niobium
IES 2011
IES2011
y Columbium finds much use in largescale applications,
such
The
h as steel
t l for
f automobile
t
bil bodies
b di and
d pipelines.
i li
Th use
that probably will consume most of the columbium is
microalloying.
y Relatively small amount of columbium lend high strength
to steel. The microalloyed, or highstrenght, lowalloy
(HSLA) steels,
steels are used for automobile bodies,
bodies structures
of all kinds, and highpressure pipe, particulary in the oil
and gas industry.
y Columbium
l b
with
h oxygen as dominant
d
substiutitional
b
l
alloying atoms is used in the nuclear fusion reactor.
y Nuclear material refers to the metals uranium,
uranium plutonium,
plutonium
and thorium, in any form, according to the IAEA
Columbiumisa:
(a)Nuclearmaterial
(b)Automobilematerial
(c)Filmmaterial
( )
(d)Foammaterial
y
y
Ferro electricity
Ferroelectricity
Piezo electricity
Piezoelectricity
y Piezoelectricity, or pressure electricity, is defined as
Nimonic 90
y A precipitation hardenable nickelchromiumcobalt alloy,
y Ferroelectricity is defined as the spontaneous alignment
off electric
by
in
l t i dipoles
di l
b their
th i mutual
t l interaction
i t
ti
i the
th
absence of an applied electric field.
y This arises from the fact that the local field increases in
proportion to the polarization. Thus, ferroelectric
materials must posses permanent dipoles. Ex.: BaTiO3,
Rochelle salt (NaKC4H4O6.4H2O), potassium dihydrogen
phosphate (KH2PO4), potassium niobate (KNbO3).
y These
Th
materials
t i l have
h
extremely
t
l high
hi h dielectric
di l t i constants
t t att
relatively low applied field frequencies.
y Thus,
Thus capacitors made from ferro
ferroelectric
electric materials are
smaller than capacitors made of other dielectric materials.
IES 2007
IES2007
MatchListIwithListIIandselectthecorrectanswerusingthecode
givenbelowtheLists:
ListI
ListII
(Component)
(RequiredProperty)
A.
Bladesofbulldozer
1.
Highwearresistanceand
g
hightoughness
B.
Gasturbineblades
2.
LowYoungsmodulusand
highfatiguestrength
C
C.
Drillbit
3
3.
Highwearandabrasion
resistance
D.
Springsofautomobiles
4.
Highcreepstrengthand
goodcorrosionresistance
Code: A
B
C
D
A
B
C
D
(a) 3
2
1
4
(b)
1
4
3
2
(b) 3
4
1
2
(d)
1
2
3
4
polarization induced by the application of external force.
y Hence, by reversing the direction of external force, direction
of the field can be reversed i.e. the application of an

external electric field alters the net dipole length and causes
a dimensional change.
y This property is characteristic of materials having
complicated structures with a low degree of symmetry.
symmetry
y Thus, piezoelectric materials can be used as transducers
devices that convert mechanical stress into electrical energy
and
d vice
i versa.
y Application for these materials includes microphones,
ultrasonic generators, sonar detectors, and mechanical
strain
i gauges. Ex.:
E
B i
Barium
titanate,
i
l d titanate,
lead
i
l d
lead
zirconate (PbZrO3), ammoinium dihydrogen phosphate
(NH4H2PO4), and quartz.
Page 236 of 240
having
strength
att
h i high
hi h stressrupture
t
t
t
th and
d creep resistance
i t
elevated temperatures up to about 950 C.
For springs exposed to lower loads,
loads the material can be used
up to 700 C.
Nimonic 9
90 offers g
good resistance to corrosion and is non
magnetic.
Applications include the aircraft industry, gas turbines,
vehicle
h l components and
d springs in high
h h temperature
environments, and thermal.
Operating temperature: 100
100 + 550 C
IES 1993
IES1993
Q
Quartzisa
(a) Ferroelectricmaterial
((b)) Ferromagneticmaterial
g
(c) Piezoelectricmaterial
(d) Diamagneticmaterial
Rev.0
Welding cracks
Weldingcracks
y Cracksmayoccuratthefollowinglocations:
(i)Intheweld(Fuse)MetalZone
(ii)IntheBasemetalzone
(iii)S
(iii)Sometimes,thecracksoriginateinoneZoneand
ti
th
k i i t i
Z
d
thenspreadtotheotherZone.
y Cracksinthebasemetalusuallyoccuratlow
y Coldcrackingcanoccurdueanytothefollowing
temperatures(around200C)andareknownasCold
cracks.
y Ontheotherhand,thecracksintheweldmetalzone
occurwhilethemetalisstillveryhot.Suchcracksare
hil h
li ill
h S h
k
calledHotcracks.
y Cracksintheweldmaybeduetostructuralstressesin
C k i th ld
b d t t t l t
i
themetal(forexample,theformationofmartensite),
heavyshrinkage extrahighamountofsulphur
heavyshrinkage,extrahighamountofsulphur,
phosphorousorcarboninthemetal,excessivelyrigid
clampingofthepartsbeingweldedorthepresenceof
p g
p
g
p
gasesintheweldmetal.
severalfactors: improperweldingconditions,the
presenceofgasandotherimpuritiesintheweld,
f d h i
i i i h ld
wrongchoiceoffillerrodandmetallurgicalfactors
suchasexcessivecoolingrateresultinginthe
formationofmartensiteandformationofbrittle
phasesintheweldwhencoldortheformationof
phaseswhicharebrittleathightemperatures
h
hi h b ittl thi ht
t
[Allotropictransformations].
y Cracksinthebasemetalcanoccurduetothe
followingreasons: Corrosion,Basemetaldefects,
Basemetalcompositionvariations,hydrogen
embrittlement
bi l
andinternalstressessetupdueto
di
l
d
restrainedshrinkingafterwelding.
Contd
IES 2005
IES2005
ot c ac s occu
t e e d a d us o o e as t e
Hotcracksoccurintheweldandfusionzoneasthe
metalsolidifies.Whichofthefollowingarethecauses
forhotcracks?
1. Presenceofsulphur andphosphorusinthebasemetal
2. Highcarbonoralloycontentofthebasemetal
3. Moistureinthejointorelectrode
4. Jointrestraint
l
h
h
d
b l
(a) 1,2and4
(b) 1,2and3
( ) 3and4
(c)
d
(d) 1,2,3and4
d
Contd
H
bi l
dP i i
Hembrittlement
andPassivity
yd oge e b tt e e t isformoffailurethan
s o o a u et a
y Hydrogenembrittlement
corrosion,but occursasaresultofhydrogenproduced
duringcorrosion.Atomichydrogendiffusesintocrystals
andinhibitsdislocationmotion,causingfailure.
di hibi di l
i
i
i f il
y Countermeasures:heattreatment;removalofhydrogen
source.
source
y Passivity:Itisformprotectionagainstcorrosion.Itresults
,
g
y
fromthin,strongadherentoxidelayerformedoverthe
surface.UsuallyobservedinAl,Cr,Fe,Ni,Tiandtheir
alloys.Passivelayersmaygetdamagedduringmechanical
vibrations,andsothesemetalsarepronetoerosion
ib i
d h
l

i
corrosion.
IES 2006
IES2006
Otherquestions
Incaseofpowerscrews,whatisthecombination
ofmaterialsusedforthescrewandthenut?
((a)) Castironscrewandmildsteelnut
(b) Carbonsteelscrewandphosphorbronzenut
(c) Castironscrewandcastironnut
(d) Aluminium screwandalloysteelnut
Page 237 of 240
IES 1992
IES1992
Presenceofhydrogeninsteelcauses
(a) Reducedneutronabsorptioncrosssection
(b)improvedweldability
(c) Embrittlement
(d)corrosionresistance
IES 1992
IES1992
Forthepipefittinglikeelbow,tee,unionetc.
whichofthefollowingispreferred?
((a)) Pigiron
g
(b) Malleableiron
(c) Spheroidal graphitecastiron
(d) Highcarbonsteel
Rev.0
IES 1992
IES1992
g
p yp p
Whichofthefollowingdisplaypropertiessimilar
tothatofsteel
1. Blackheartcastiron
2. Whiteheartcastiron
33. Graycastiron
y
4. Pigiron
((a)) 1and2onlyy
((b)
) 33and4only
4
y
(c) 2and4only
(d) 1and3only
IES 1992
IES1992
g
p
Additionofwhichofthefollowingimproves
machiningofcopper?
(a) Sulphur
(b) Vanadium
((c)) Tin
(d) Zinc
IES 2006
IES2006
p
g
g
Disruptivestrengthisthemaximumstrengthofa
metal,when
(a) Subjectedto3principaltensilestressesatright
anglestooneanotherandofequalmagnitude
(b) Loadedintension
(c) Loadedincompression
(d) Loadedinshear
IAS 1996
IAS1996
IAS 1998
IAS1998
IES 1996
IES1996
h
d
b l
h l
ListI(Cuttingtools)
ListII(Majorconstituent)
A Stellite
A.
l
l.
Tungsten
B. H.S.S.
2.
Cobalt
C. Ceramic
3.
Alumina
D. DCON
4.
Columbium
5.
Titanium
Codes:A B
C
D
A
B
C
D
(a) 5
1
3
4
(b)
2
1
4
3
( ) 2
(c)
1
3
4
( )
(d)
2
5
3
4
Whichofthefollowingmethodsaresuitablefor
theproductionofsuperalloys?
1. Atomizationfrommoltenstateusinginertgas.
2. Atomizationusingplasmaarcandrotating
A
i i i l
d
i
electrode.
3 Reductionandcrushing.
3.
Reductionandcrushing
Codes:
(a) 1and2
(b) 2and3
(c) 1and3
(d) 1,2and3
Thelimittothemaximumhardnessofawork
materialwhichcanbemachinedwithHSStools
evenatlowspeedsissetbywhichoneofthe
f ll i
followingtoolfailuremechanisms?
lf il
h i
(a) Attrition
(b) Abrasion
(c) Diffusion
(d) Plasticdeformationundercompression.
GATE 2002
GATE2002
y
g
Theductilityofamaterialwithworkhardening
(a) Increases
(b) Decreases
((c)) Remainsunaffected
((d)) Unpredictable
p
IES 2009
IES2009
p
g yp
Nano compositematerialsarehighlypreferablein
designconsiderationfortheir
(a) Highresistancetocrackpropagation
(b) Vibrationresistance
((c)) Impactresistance
p
(d) Highresilience
Page 238 of 240
IES 1992
IES1992
Machinetoolframeshouldhave
(a) Highrigiditytoweightratio
((b)) Graphiteintheformofnodules
p
(c) Lowhardness
(d) Highworkhardness
Rev.0
GATE 1995
GATE1995
g
Machinetoolstructuresaremade..forhigh
processcapability.(tough/strong/rigid)
IES 2011
IES2011
Materialswhichshowdirectiondependentpropertiesare
called:
(a)Homogeneous
(b)Viscoelastic
(c)Isotropic
(d)Anisotropic
IES 2009
IES2009
gp
p p y
Whichoneofthefollowingpossessestheproperty
ofnonsparking character?
(a) Hadfield'smanganesesteel (b) Springsteel
(c) Stellite
(d) Invar
IES 2011
IES2011
Lead is widely used in:
(a) Transformers
g
(b) Switch gear
(c) Galvanized pipes
((d)) Batteries
JWM 2010
JWM2010
Considerthefollowingpropertiesofengineering
materials
1.Density
2.Conductivity
C d ti it
3.Elasticity
4.Hardness
H d
5.Ductility
Whichofthesearemechanicalpropertiesofa
material?
( ) d l (b) d
(a)1,2and4only(b)1,2,3and4
(c)3,4and5(d)2,4and5
IES 2011
IES2011
ListI
A.System
y
1.Freeenergyisaminimum
gy
B.Phase
2.Chemicalelementsorchemical
compounds
3.Consistsofsolids,liquidsorgassesortheir
combination
4.Homogeneousportionofasystemthat
hasuniformphysicalcharacteristics
C
D
A
B
C
D
C.Phase
equilibrium
D.Components
Codes
A
(a) 2
(c) 2
GATE2005
When
off a solid
Wh the
th temperature
t
t
lid metal
t l increases
i
(a) Strength of the metal decreases but ductility
increases
(b) Both strength and ductility of the metal decrease
( ) Both
(c)
B th strength
t
th and
d ductility
d tilit off the
th metal
t l increase
i
(d) Strength of the metal increases but ductility
decreases
ListII
IAS1998
Magnesiumisextrudedandnotrolledbecause
M
i
i t d d d t ll db
(a) Ithasalowmeltingpoint
(b) Ithasalowdensity
I h l d i
(c) Itsreactivitywithrollmaterialishigh
( ) Ithasadosepackedhexagonalstructure
(d)
Page 239 of 240
B
1
4
4
1
3
3
(b)
(d)
3
3
1
4
4
1
2
2
IES 2011
IES2011
ListI
ListII
A.Elasticityy
1.Deformnonelasticallywithoutfracture
y
B.Malleability
2.Undergoplasticdeformationundertensile
load
3.Undergoplasticdeformationunder
compressiveload
4.Returntoitsoriginalshapeonunloading
C.Ductility
D.Plasticity
Codes
A
B
(a) 1
2
(c) 1
3
C
3
2
D
4
4
(b)
(d)
A
4
4
B
2
3
Rev.0
C
3
2
D
1
1
IES 2011
IES2011
Injection moulding process used to produce
thermoplastic matrix composites with fibre
reinforcement normally gives:
( ) Short
(a)
h fibre
f b composites
(b) Two layer structure composites
(c) Continuous fibre composites
(d) Single layer composites
IES 2011
IES2011
Assertion (A) : Solid solutions of metal are
crystall whose
properties
to those
off
h
i are close
l
h
the solvent.
Reason (R) : They retain the same crystal lattice
and type of bond.
the
l
i off A
(d) A is
i false
f l but
b t R is
i true
t
JWM 2010
JWM2010
IES 2010
IES2010
Assertion(A):Electricarcfurnacecanbeusedfor
acidandbasicmethodofsteelmaking.
acidandbasicmethodofsteelmaking
Reason(R):Impuritiesareeliminatedextensively
inacidareprocess.
inacidareprocess
Consider the following:

1. Water
2. Ice
3. Brine solution
4 Oil
4.
Which of these is/are used as quenching
media
di in
i case off Alloy
All steels?
l ?
(a) 1, 2 and 3 only
(b) 2, 3 and 4 only
(c) 1 and 4 only
(d) Only
Page 240 of 240
IES 2010
IES2010
The correct statement is
(a) Characteristic of any series of alloys cannot be
found by phase diagram.
(b) Phase diagram does not give amount of
phases which are a function of composition,
p
p
,
temperature and pressure.
(c) The phase may be liquid or vapour with
ordered crystal structure.
(d) Phase diagram provides the information on
how rapidly equilibrium is reached.
The End
TheEnd
Rev.0

Casting, Welding, Machine Tools, Material SC

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Casting, Welding, Machine Tools, Material SC

Uploaded by

Copyright:

Available Formats

S d

y The molten metal is poured into the sprue hole, flows

through the runners,

y The mold is opened, the pattern board is drawn

segment is separated from the sand, ready for further

y Moulding sand: The freshly prepared refractory

material used for making the mould cavity. It is a

y Parting line: This is the dividing line between the two

y Bottom board: This is a board normally made of wood,

which is used at the start of the mould making.

g basin: A small funnelshaped

from the pouring basin reaches the mould cavity.

y Runner: The passage ways in the parting plane through

y Riser: It is a reservoir of molten metal provided in the

which molten metal flow is regulated before they reach

cavity when there is a reduction in volume of metal due

y Gate: The actual entry point through which molten

(a) To ensure directional solidification

metal enters the mould cavity in a controlled rate. Contd

The main purpose of chaplets is

Suitable placement of chills

Suitable placement of chaplets

Select the correct answer.

are amplified by an increase in temperature.

linear dimensions. Even in case of internal dimensions.

when the metal changes temperature from pouring to

y Gray CI with a carbon equivalent of 4.3% has

negative shrinkage, that is, it actually expands

Which one of the following materials will require

compensated from the riser is

Shrinkage allowance on pattern is provided to

For-2015 (IES, GATE & PSUs)

A cubic casting of 50 mm side undergoes volumetric

cavityy at the time of p

y A metal when it has just solidified is very weak and

y Itt iss a negative

those dimensions, which are parallel to the parting

y This is particularly so for weaker sections such as long

flat portions, V, U sections or in a complicated casting

material provision for reducing the distortion.

Which of the following materials can be used for

Select the correct answer using the codes given below:

very dimensionally stable. Commonly used teak, white

all around the vertical faces to enlarge the mould

Split Pattern or Two Piece Pattern

Gating and runner system are integral with the

This type of pattern is also used when the

For-2015 (IES, GATE & PSUs)

y Cope and Drag Pattern

The pattern adopted for those castings where there

It is used to sweep the complete casting by means

A skeleton of the pattern made of strips of wood

and are therefore subjected to much more severe

d) Carbon content of molten metal

y Permeability: Gases evolving from the molten metal

and generated from the mould may have to go

taken by a 2000 cu cm of air at a pressure typically of

25stopass2000cm3 ofairatapressureof5g/cm2 through

y Friability: The ability to crumble should be a very

unless the core has good collapsibility (ability to decrease

in size) it is likely to provide resistance against shrinkage

important consideration at the time of removal.

and thus can cause hot tears.