Code No: R05322001 Set No.

1
III B.Tech Supplimentary Examinations, Aug/Sep 2008
TOOL DESIGN
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
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1. (a) Write the application of low carbon steels in metal cutting industry.
(b) What are non metallic tooling material? Explain in detail. [8+8]
2. (a) Explain how the nose radius effects the functioning of single point cutting
tools?
(b) Explain the design features of HSS and carbide tipped tools. [8+8]
3. (a) Describe the left hand offset, right hand offset and straight shank turning tool
holder.
(b) What is quick change tooling? Explain.
(c) What is throwaway insert type tool holder? Discuss. [6+5+5]
4. With the help of suitable diagrams describe the following cutters.
(a) Screw Slotting Cutter
(b) End Mill
(c) Shell End Mill
(d) T ? Slot Cutter. [16]
5. The symmetrical - cup work piece shown in figure 5 is to be made from cold rolled
steel 0.8mm thick. Make the necessary calculations for designing the drawing die
for this part. The shell diameter is 50 mm and radius of bottom corner is 1.6 mm.
[16]

Figure 5
6. (a) What is the maximum percentage reduction for one draw that can be obtained
under production conditions?
(b) A steel cup of height 30 mm and internal diameter 40 mm with a flange width
of 10 mm is to be deep drawn from a sheet 1 mm thick. Determine the
diameter of the blank and the drawing force. What is the draw ratio? Can
the cup be drawn in a single operation? [4+12]

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Code No: R05322001 Set No. 1
7. (a) Explain the methods of construction of drill jigs.
(b) Describe the principles of pin location. [8+8]

8. (a) What is wear allowance? How is it applied in the design of gauges?

(b) Discuss the various materials used for gauge manufacture. [8+8]

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Code No: R05322001 Set No. 2
III B.Tech Supplimentary Examinations, Aug/Sep 2008
TOOL DESIGN
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) What are the main constituents of high speed steel? Explain the importance
of each of its constituents.
(b) What are the special characteristics of cermets which make them suitable for
metal cutting? [8+8]

2. (a) All the materials cannot be machined at same speed. Discuss.

(b) What is a carbide tipped tool? Discuss their applications. [8+8]

3. (a) What happens if the cutting edges of a drill are equal , but lips are not equal?
(b) Explain the letter series and metric series of the drill sizes. [8+8]

4. (a) What is the difference between drilling tool and reamer?

(b) Explain about the adjustable and carbide tipped reamers. [8+8]

5. (a) Differentiate between blanking and piercing. Which tool size decides the blank
size and that of the pierced hole?
(b) A cup 6 cm in diameter and 8 cm deep is to be drawn from 2 mm thick steel
sheet with a tensile strength of 320 N/ mm2 . The corner radius is negligible.
Determine
i. Blank diameter
ii. Least number of drawing operations.
iii. Force and energy for the first draw with 40% reduction. [6+10]

6. (a) Why is mill oxide (scale) on the surface of the work material detrimental to
deep drawing? Explain.
(b) Explain the variables that affect metal flow during drawing.
(c) What is the die clearance of draw die? [4+10+2]

7. Write detailed note on:

(a) Types of jig bushes.

(b) Degrees of freedom of moment in jigs and fixtures. [8+8]

8. (a) What are the limitations of limit gauges?

(b) What is wear allowance? How is it applied in the design of gauges?

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Code No: R05322001 Set No. 2
(c) Find the ‘Go’ and ‘Not Go’ gauge dimensions of a plug gauge using bilateral
and unilateral systems and including wear allowance for gauging 75 ± 0.05
mm diameter holes. [4+6+6]

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Code No: R05322001 Set No. 3
III B.Tech Supplimentary Examinations, Aug/Sep 2008
TOOL DESIGN
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) What are the low melting tooling materials? Explain their characteristics and
applications.
(b) Define and explain shear zone, shear plane and shear angle. [8+8]
2. (a) What is machinability and how it can be evaluated? Explain the factos which
influence machinability of a material.
(b) Carbon steel is machined by a cutting tool. The tool has a life of 100 min
between consecutive grinds when operating at 80 m/min and a life of 33 min
at a speed of 100m/min. Determine the value of n & C. [10+6]
3. (a) What happens if the cutting edges of a drill are equal , but lips are not equal?
(b) Explain the letter series and metric series of the drill sizes. [8+8]
4. What criteria one has to take to find the correct number of teeth on the milling
cutter. Derive an equation for the same. [16]
5. (a) What are the various types of strippers used in metal forming? Explain their
function with the help of suitable sketches.
(b) Find the center of pressure of the following shape as shown in figure 5b.[8+8]

Figure 5b
6. (a) Why is mill oxide (scale) on the surface of the work material detrimental to
deep drawing? Explain.
(b) Explain the variables that affect metal flow during drawing.
(c) What is the die clearance of draw die? [4+10+2]
7. How are jigs classified? Explain briefly with neat sketches. [16]
8. (a) State and explain Taylor’s principle of limiting gauging.

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Code No: R05322001 Set No. 3
(b) Discuss briefly various aspects for deciding the tolerance on limit gauges.[8+8]

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Code No: R05322001 Set No. 4
III B.Tech Supplimentary Examinations, Aug/Sep 2008
TOOL DESIGN
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) What are the non metallic die material? Explain their use in metal cutting.
(b) Explain the criteria taken for the tool material selection. [8+8]

2. (a) Why clearance angle is provided on a singale point cutting tool? Explain.
(b) Discuss the influence of relief angles on the performance of single point cutting
tool?
(c) What is the difference between side rake angle and back rake angle? [6+6+4]

3. (a) How the clearance angle will affect the cutting process.
(b) Explain the fractional series and name the different series of standard drill
size. [8+8]

4. The feed of an 8 ? tooth face mill is 0.033 cm per tooth at 200 rev/min. The
hardness of the material to be cut is 300 BHN. Depth of the cut is 0.32 cm and the
width is 10 cm. Calculate the

(a) horsepower at the cutter

(b) horsepower at the motor if the efficiency of the machine is 60%. Value of K
for alloy steel having 300 - 400 BHN K =8.2. [16]

5. (a) Explain the ?Bending Terminology? with the help of a suitable sketch.
(b) What means should be employed to reduce the loading on the press during
cutting operations?
(c) Find the pressure required to cut a circular blank 30cm in diameter from 3mm
thick strip that has shear strength of 376 N/ mm2 . [5+5+6]

6. (a) What is the die clearance of draw die?

(b) Explain various methods of retaining metal in draw dies.
(c) Explain the variables that affect metal flow during drawing. [2+6+8]

7. (a) What is the six- point location principle? Explain with the aid of suitable
sketches.
(b) Explain with the aid of suitable sketches, the principle of jig and fixture design.
[8+8]

8. (a) Explain the care to be taken on gauges before and after use?

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Code No: R05322001 Set No. 4
(b) Design ‘GO’ and ‘NO GO’ ends of a plug gauge to measure a hole of size 28.00
± 0.014 mm adopting
i. Unilateral system
ii. Bilateral system. [8+8]

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