chuck.

If it is a single piece, it con be mounted centrally on the chuck The table is made to rotate
round
the revolving wheel, both rotating in opposite directions. The vertical feed to the wheel is given by meving the
of the wheel spindle. AShe
wheel-head along a column and the crossfeed by the horizontal movement carry the provision to rais
wheel is used on these machines, which culs on its periphery. Some machines
lower the table also, and also to incline the same.
-WHEEL
WHEEL SPINDLE
DIRECTION OF SPINDLE
WHEEL
ROTATON WHEEL
ROTATION

INFEED.
CROSS
FEED
INFEED
TABLE TABLE

FIG. 1.40. RELATIVE MOVEMENTS OF DIFFERENT PARTS OF A FIG. 1,41. RELATIVE MOVEMENT& OF DIFFERENT PARTs OF A
HORIZONTAL SPINDLE ROTARY TABLE SURFACE GRINDER. VERTICAL SPINDLE ROTARY TABLE SURFACE GRINDER.
Some rotary toble surface grinder are provided with two tables instead of one so that, while the workpieces
are being ground on the table, the other table can be used for loading the fresh batch of workpieces.
Viva-Voce
Q1 What are the various machine tools used in a machine shop?
Ans. (a) Planer (b) Milling machine (c) Lathe machine (d) Shaper (e) Power hack saw ()
(e) Tool and Cutter grinder drilling machine
Q2. Name the various types of lafhes used in a machine shop?
Ans. () Engine lathe (b) Capstan and turret lathe (c) Speed lathe (d)
() Bench lathe (g) Automatic lathe Bench lathe (e) Special purpose lathe
Q3. Name the principal part of a lathe.
Ans. (a) Head stock (b) Bed (c) Feed mechanism (d) Tail
stock
Q4. What is the difference between three jaw chuck
and four jaw chuck ?
Ans. Three jaw chuck isa self-centred chuck. There is no
open and close equally. It is used for cylindrical jobs.need of centring in this chuck because all the jaws
all the jaws are independent to each other. Four-jaw chuck is an independent chuck because
Q5. What are the various opertions Centering is needed. It is used for prismatic parts.
Ans. (a) Drilling performed on a lathe?
(b) Facing (c) Reaming (d) Plain turning (e) Threading
() Step turning (g) Knurling (h) Taper turning
Q6. What is the difference () Boring
between drilling, reaming and boring ?
Ans. Drilling : It is the operation of making
in a chuck and drill is in the a hole in a workpiece with the help of a
tailstock. drill. Workpiece is held
Reaming : It is the operation of
tailstock. finishing the previously drilled hole by reamer.
Reamer is held in
Boring : It is the operation of enlarging of a hole
mounted on arigid bar. already made in a workpiece by a boring tool or a bit

24 Bharat Workshop Technology Pratical Manual

 Q7. What do you mean by cutting speed, feed and depth of cut in
Ans. Cutting speed : The peripheral speed of the work pastthe cuttinglathe ?
tool expressed in meters per minute.
Feed : The distance, which the tool advances for each revolution of the work. It is
millimeters. uSually expressed in
Depth of cut:The depthof penetration of the cutting tool into the workpiece during machining
in millimeters. expressed
Q8. What do you mean by quick return mechanism used in a
shaper ?
Ans. In order to increase the productivity of a shaper, retutn stroke (non-cutting) shosld be
fastly. The mechanism used to accomplish this purpose is known as quick return completed
Q9. Name the quick return mechanism used in a shaper.
mechanism.
Ans. The crank and slotted lever mechanism.
10. What is the material of the cutting tool used for lathe ?
O
Ans. Cutting tool for lathe isgenerally made up of high speed steel. Cutting tool is called single potnt cutting
tool.
Q 11. Name the various lathe accessories.
Ans. (a) Centres () Chucks (c) Carrier (d) Drive plate (e) Face plate () Mandrels (g)
Rests.
Q
12. What is the difference between a shaper and a planer ?
Ans.

Shaper Planer
(a) Work is fixed and the tool moves. (a) Tool is fixed and work moves.
(b) It is a light duty machine tool. (6) It is a heavy duty machine tool.
(c) It is used for small works. (c) It is used for large works.

O13. What is the difference between down milling and up milling ?

Ans.

Down Milling Up Miling

(a) Use of cutting fluid is easy. (a) Use of cutting fluid is difficult.
(b) The cutter rotates in the same direction (b) The cutter rotates against the direction
in which the work is being fed. in which the work is being fed.
(c) Chip thickness varies from maximum (c) Chip thickness varies from mimimum
to minimum. to maximum.

Q14. What are the various cutting tool materials?

Ans, (a) Tungstun carbide (6) High speed steels (c) Ceramics
(d) Carbon steels (d) Cemernted carbides (e) Stellite (Cobalt-Chromium alloys)
Q15, What do you mean by multipoint count tools?
Ans. Files, twist drill, reamer, knurling tool.
Q16. Name the various types of tool wear.
Ans. (a) Corrosive wear (b) Adhession wear (c) Fatigue wear
(d) Abrasion wear (e) Wear by plastic shear () Diffusion wear
Q17, What is diffusion wear?
Ans. Diffusion wear ocurs because of the diffusion of metal and carbon atoms from the cutting tool surface
in the work material and chip.

Bharat Workshop Technology Practical Manual 25

Q18. What arethe types of sawing machine?
Ans. (a)Circular saw (b) Power Hack saw (c) Band saw
Q19. What do you know about machine tools?
Ans. Amachine which performs the materials removal operation with tools, to produce desired shape a
size of the work-piece is known as machine tools.
Q.20, What do you mean by grinding?
Ans. Grinding is the process of finishing or shaping a work-piece by using an abrasive wheel, rotating a
very high speed, irrespective of the hardness ofthe work. The accuracy that can be obtained
by
varies from 1.27mm-0.25mm.
Q.21. What bonding material is used in a grinding wheel that holds the abrasive grains together?
grinding
Ans. Synthetic resins bond, Rubber bond, Shellac bond, Silicate bond virtrified bond and oxychloride bond
Q.22. For precision grinding how the work feed is given?
Ans, While feeding the work against the rotating grinding wheel for precisioin grinding th work feel may be
obtained wheel.
1. The work is rotating at its axis.
2. The work may be given reciprocating motion.
Q.23. Atwhat speed the grinding wheel should operate to give good result for different type of
operations : grinding
Ans.

Type of grinding operaition Wheel speed in Metre/min

() Internal grinding 625-1825
(i) Surface grinding 1200-1825
(iti) Tool and cutter grinding 1375-1825
(iv) Cylinderical grinding 1675-1975
(v) Cutting off wheels 2750-4875
The speeds give good result for high quality wheel. But in actual
manufacturer's recommended speed. practice one should follow the
Material
M.S. round piece
Results
Job made and self inspected as per drawing.
Satety Precautions
1. Fix and tight the job and tool properly.
2. Tool should be properly ground.
3. Ater load schedding, check the direction of rootion of job. frequired, rectify
4. Use proper speed, feed and depth of cut for efficient, economical and goodwith reversing switch.
5. For taper turning, use hand wheel of compound slide onty. machining.
6. Use safety goggles while machining.
7. Handle hot chips coming from material cutting carefuly. Use cleaning brush or bent rod for this
purpose.
8. After use, clean the machine and hand tools.

Viva-Voee
0.1. What consitute a machine shop?
Ans. A machine shop consists of lathe, shaper, planer, milling, drilling and grinding machines.
Q.2 Give the names of operations that are generally done on the lathe machine.
Ans. Operations done on the lathe machine are facing, turning, taper turning, centering partingof, boring
drilling, threading and knurling etc.
Q.3. What do you understand by facing?
Ans. Facing is a lathe operation which is generally done on the end face of the work piece. In this operation,
the tool tips penetrate about 0.5 mm in the centre of the work piece and feed is given along the radial
direction to finish the end of the work piece or to maintain the length.
Q4. What is taper turning?
Ans. It is an operation of producing an exernal conical surface on a workpiece.
Q.5. What is step turning?
Ans. It is also knowm as shoulder turning. It is a process of plane tuming operation at different lengths with
varied diameters on the same work piece.
Q.6. What do you mean by outside turning or plane turning?
Ans. It is an operation of removing excess amount of material from the surface of the cylindrical work piece
Q.7. What is grooving or parting off?
Ans. It is aprocessing of reducing the diameter of work piece over avery narrow surface.
Q8. State the principles of turning,
Ans. The work piece is rotated between the two centres of the lathe and the tool is moved parallel to the axis
of the work piece, thus producing a cylindrical surface.
Q.9. Define cutting speed on lathe.
Ans. Cutting speed is the distance measured on the circumference of the job that passes the cutting edge of
the tool in one minute.
Q.10. What do you understand by the terms feed and depth of cut?
Ans. (a) Feed : It is a distance along the bed, traversed by the tool in one revolution of the work. It depend
upon the depth of the cut and finish required of the job.

Bharat Worksbop Technology Practical Manual 31

 (b) Depth of cut : The depth of cueis the perpendicular distance measured from the machined surface
the uncut surface of the work piece. In a lathe the depth of cut is expressed as follows
to
Depth of cut |(D,- D)/2|
diameter of job after cut.
where D, diameter of jobbefore cut and D,
AXIS
WORKPIECE
GIVEN
DIMENSICON
PEOUIRED
DIMENSION

FEED FOR
DEPTH FACING
OF CUT FEED FOR
FEED TURNING
Q.1. List some design considerations for tapping and drilling.
Ans. (0 Design should allow holes to be drilled on flat surface, perpendicular to drill motion.
(i) Interrupted hole surfaces should be avoided or minimized.
Q.12. How lathe size is specified ?
Ans. The size of lathe is specified by two parameters (i) the swing (ii) the maximum distance between the
centres.
Q.13. What is a steady rest?
Ans. It is also called a centre rest and is used to support the long shafts of smaller dia while turning, boring or
threading. The use of steady rest prevents the slender work from springing away from the cutting tool
Q.14. How is taper usually expressed?
Ans. Taper is usually expressed as 1:8 i.e., taper 1 mm over a length of 8 mm
Q.15. What are the different methods, by which taper can be obtained on awork?
Ans. The following methods are employed to obtain the required taper on the
work:
() By using the taper turning attachment of the lathe.
() By setting the compound slide to an angle and feeding through
Q.16. How the tapering angle is calculated? compound slide.
Ans. The tapering angle may be calculated as :
() Tapering angle, tan = D-d
2L
where, D is the major dia. of the taper
dis the minor dia. of the taper
Lis the length of the taper
(i) Tapering angle in degrees
200
7
This is a workman's method of
calculating taper angle.

32 Bharat Workshop
Technology Practical Manual
 Viva-Voce
01. What do you mean by fitting ?
Ans. lilting is the assembling of parts together by filing, chipping sawing, scrapping, tapping etc., necesar
after the machining operation.
02. How do youclassify the tools used in a fitting shop ?
Ans. A fitting shop tools are classified as follows:
(a) Clamping tools (b) Cutting tools (c) Striking tools
(d) Measuring, & markiny, tools () Drilling tools (9 Threading tools

52 hha Workshup lnhmulogy latieal Munual

 03. Name the various
clamping tools used in afitting shop.
Ans. Bench vice, Hand vice,
Q4. Name the various cutting Pin vice, Pipe vice.
Ans. Hand hacksaw, files, chisels.tools used in fitting shops.
O5. Name the various
Ans. Ball pean hammer, striking
straight
tools used in a fitting shop.
06. Name the various pean hammer, Cross pean hammer.
measuring
Ans. Try square, Bevel protector, and marking tools used in a fitting shop.
combination
angle plate, V block, steel rule, vernier set, centre square, dot punch, centre punch, surface plate,
gauge, wire gauge, thread gauge and vernier caliper, micrometer, dividers, calipers, feeler
07. What do you mean by least count of height gauge. gauges, radius
Ans. Minimum dimension that can be the measuring instrument?
Q8. How do you classify the files ? measured by the measuring instrument is called the least count.
Ans. (a) Size of file : According to
(b) Cut of teeth:
length of file (100 mm, 150 mm, 200 mm, 450 mm).
() Single cut. (ii) Double cut.
(c) Grade of cut of file:
() Rough (ii) Bastard
(io) Smooth (ii) Second cut
(v) Dead smooth.
() Shape of file :
() Flat file (i) Square file
(io) Round file (ii) Triangular file
(v) Half round file (vi) Knife edge file
(vi) Needle file.
Q9. Give the names of various parts of the files.
Ans. Heel, Tang, Point, Face, Ferrule, Edge, Wooden handle.
Q 10.What do you mean by pitch of file ?
Ans. The number of teeth in one centimeter is called the pitch of
the file.
Q11.What do you mean by grade of file ?
Ans. Teeth per inch: Rough (20 teeth per inch), Bastard (30 teeth per inch),
Smooth file (50-60 teeth per inch), Dead smooth (100 teeth per inch). Second cut (40 teeth per inch),
12. What is the value of cutting angle of a chisel ?
Q
Ans. For hard materials =70° to 75°
For medium hard materials = 60°
For soft materials = 40°
13. Name the various types of chisels used in fitting shop.
Q
Ans. ) Flat chisel (ii) Cross cut chisel (iiü) Half round chisel
(iv) Diamond pointed chisel () Side chisel.
Q14. List any three holding devices in a fitting shop.
Ans. Hand vice, Pin vice, Bench vice
Q15. What are the various types of punches?
Ans. Dot punch, centre punch.
Q 16. What is the point angle of dot punch?
Ans, 60°
Q17. What is the point angle of centre punch?
Ans. 90°

Bharat Workshop Technology Practical Manua! 53

 flutes in drills?
Q 18. What is the main use of
chips are driven out of the drilled holes through flutes.
Ans. The die &c die stock?
Ans. What
Q19. Taps are usedfunction
is the of Taps
for cutting and threads
internal and díes & die stocks are used for cutting external thread,

20. What are the various types of callipers?calliper, odd leg calliper.
Q
Ans. Outside calliper, inside calliper, spring
Q 21. What are the uses of a surface plate?
used for testing a try-square, testing the trueness of a finished surface.
Ans. It is
Q22. Write the specifications of a bench vice. dimensions :
Ans. The bench vices are specified by following main
Clamping size (Width) 75 mm, 100 mm, 125 mm, 150 mm
Weight 2.5 to 29.5 Kg.
Q 23. What is the function of a vice?
etc.
Ans. Avice is used to grip a job during operations such as filing, chíselling
Q 24. Which materials are the files made of?
Ans. The files are made of hardened steel. They are attached to the wooden handle through the tang t.
ensuring safety and easier work ability.
Q 25. For what purposes are the files used?
Ans. Files are used to serve the following functions:
()To smoothen the rough surface by removing small amounts of metals.
(ü) To prepare surfaces having squareness or roundness for a proper fitting.
Q
26. Define the different types of hammers, their weight and applications.
Ans. Hammer is one of the most important striking tools used in fitting shop. The hammer is usually specifie:
by its weight. Most commonly adopted hammers carry weight ranging between 200 grms to 500 grars
Various types of commonly used hammers (i) Ball-Peen Hammer, (ii) Strainght-Peen Hamme:
(iüi)Cross-Peen Hammer.
 Viva-Voce
Q1. Define Welding?
Ans. Welding is a process of joining two or more, same or different materials with the help of heat.
or filler metal may or may not be applied,
Q2. Classify the Welding process ? .Pressure
Ans. Pressure and non-pressure welding. Resistance welding is a pressure welding. Electric Arc weldine .
non-pressure welding.
Q3. What are the types of Electric Arc welding ?
Ans. (a) Carbon Arc welding. (b) Flux shielded metal Arc welding.
(c) Tungsten Inert gas (TIG) welding. (d) Metal Inert gas (MIG) welding.
(e) Submerged Arc welding. () Electroslag welding.
() Electrogas welding.
Q4. What are the types of Resistance welding ?
Ans. (a) Spot welding. (b) Seam welding.
(c) Flash butt welding. (d) Upset butt welding.
(e) Projection welding. (9 Percussion welding.
Q5. Name the gases used in the gas-welding process ?
Ans. Oxygen and acetylene.
Q6. How many types of flames are used in a welding shop ?
Ans. (a) Oxidising flame (oxygen is more than
acetylene)
(b) Reducing flame (Acetylene is more than oxygen)
(c) Neutral flame (Oxygen and acetylene are in equal
Q7. Name different types of welding joints used in a weldingproportionate)
Ans. (a) Butt Joint.
shop.
(b) Lap Joint.
() T Joint. (a) Corner Joint.
(e) Edge Joint.
Q8. Name different welding positions used in welding.
Ans. (a) Flat position. (b) Horizontal position.
(c) Vertical position. (d) Inclined position.
(e) Overhead position.
Q9. Name the equipments used for Arc welding.
Ans. Transformer, Holder, Electrode, Chipping hammer,
Q 10. Name the equipments used for gas (oxy Connectors, Brush, etc.
acetylene) welding.
Ans. Gas cylinders, regulators, hose, torch, tip, goggles, etc.
Q11. What is the function of a flux ?
Ans. Flux prevents oxidation. It reacts with impurities and forms a
Q
12. What is flux on an electrode? slag.
Ans. Covering on the electrode is called flux.
Q13. What o youmean by polarity in welding?
Ans. Polarity means providing electrical terminals to the job and the
is made negative terminal and job is made positive electrode. In straight polarity, the electrode
terminal and job is negative terminal. terminal. In reverse polarity, electrode is positive
Q14. On which termínal more heat is
Ans. Positive terminal (about 2/3 of thegenerated
total heat)
?
Q15. Which type ofwelding is most
Ans. Shíelded Metal Arc welding. commonly used in workshops ?

90 Bharat Workshop Technology

Practical Manual
 Q16. What is the difference between TIG and MIG.
Ans. Tungsten Inert gas welding (TIG) Metal Inert Gas welding. (MIG)
(a) Electrode is made of tungsten. (a) Electrode is having similar composition as that of job.
(6) Electrode is non-consumable in (b) Electrode is consumable in the form of wire.
the form of rod.
Q17. Name different Inert gases used in TIG and MIG.
Ans. Argon, Helium.
A.C. and D.C. arc welding.
Q18. Compare
A.C. (Altermating current) welding D.C. (Direct current) Welding
Ans.
(a) In A.C. welding transformer is used (a) In D.C. welding generator is used.
(b) A.C. is more dangerous (b) D.C. is comparatively less dangerous.
(c) Transformer costs less. (c) Generator costs more.

19. Name any five welding defects.

O
Ans. v Spatter
Porosity
¼ Cracks
Slag Incusion
Distortion
20. What is the principle of resistance welding?
Q the
flows through a conductor, heat is generated due to
Ans. It works on the principle that when current
flow of current as
Resistance, T= Welding Time
Heat generated = I'RT, where I = Current, R=
in the joint.
The heat produced is used to melt the metal
Q21. What is the principle of Electric Arc welding ? flowing. When we create the gap between the electrode
starts
Ans. When the electrode touches the job, current because of high resistance in the path and current
can
job, the path between them gets ionized
and the
even pass through the gap. flux-coated electrode ?
the
Q22. What is the effect of moisture on hydrogen and oxygen
Ans. Ata high temperature on the electric arc welding,water gets dissociated into maximum attainable
porosity defect and reduces the
gases. Due to liberation of H, gas it increases the
temperature.
Q23. What is spot-welding? electrodes, applying
or more pieces of metal between two copper
Ans. Spot-welding consists of clamping twocurrent weld.
through the metal to make the
pressure and then passing sufficient
help af a gas-welding torch?
Q24. How much temperature can be achieved with the
Ans. Up to 3000°C.
Q25. What is edge preparation?
are made in a particular shape, it is called
Ans. Before welding the two metal pieces, their adjacent edges
edge preparation.
Q26. What is projection-welding?
current and pressure are localized at
Ans. Projection welding is a modification of spot-welding in which the pieces.
the weld section by the use of embossed, machined or projections on one or both of the

Bharat Workshop Technology Practical Manual 91

 3. Planing should be parallel to the
4. You must be grains of wood.
concentrate on the job.
5. Use sharp edge chisel on the job.

Q1. What do you mean by seasoning ? Viva-Voco

Ans. The processof removing
Q
2. moisture from the freshly cut down trees is known as
Name the various types of seasoning seasoning
Ans. method.
Natural seasoning, Kiln seasoning, Water
O3. What is the seasoning, Chemical seasoning.
commonly used material for patterns?
Ans. Timber.
O4. What is the
difference
Ans. Wood is available from betweenin wood and timber?
nature the form of trees. Wood,
prepared for Engineering purpose is known obtained fromn fully grown trees, cut ana
Q5. Name the various as timber.
cutting tools used in
Ans. (a) Saws
(b) Chisels pattern-making
(c) Adze.
or carpentary shop.
Q6. Name the various types of
saws used in a
Ans. (a) Rip saw (b) Tenon saw pattern-making shop.
(c) Compass saw
(e) Cross cut saw
() Bow saw. (d) Keyhole saw
Q7. Name the various
planning tools
Ans. (a) Wooden jack plane (6) Iron used in a pattern-making shop.
jack
Q8. Name the various holding tools plane (c) Trying plane (d) Rebate plane
used in a pattern-making shop.
Ans. (a) -Work bench (b) Bench hook
(e) Spoke sheave (c) Clamping vice (d) C- clamp.
() Rasp.
Q9. Name the various measuring tools
used in a
(b) Four fold box wood pattern-making
Ans. (a) Steel rule or a carpentary shop.
rule (c) Inch tape.
Q
10. What is the difference between a
Ans. A marking gauge has one marking pin
marking gauge and a mortise gauge?
wheares the mortise gauge has two marking pins.
Q11. Classify the various
pattern-making (carpentary )tools.
Ans. (a) Measuring tools (b) Marking tools (c) Cutting tools
(e) Drilling and boring tools. () Holding devices (d) Plaring tools
(g) Striking tools (4) sharpening tools.
Q 12. What do you mean by conversion of wood?
Ans. The process of cutting the wood into marketable forms from
Some of the conversion mnethods are :
timber logs is called conversion of wood.
(a) Flat sawing (b) Tangential sawing (c) Quarter sawing.
Q 13. Explain the common defects in wood.
Ans. (i) Knots : It is the central irregular grown part of the tree. The fibers cells of the
tree are wrapped
around it. Presence of a knot causes problemn in processing.
(ii) Shakes : Shakes are the cavities produced by internal and external diseases of the tree.
(iii)Twisted Grains: The grains of the wood are not straight but are at an inclination with respect to axis.
(iv) Distortion : Due to uneven moisture inside the wood, the shape of the wood is distorted.
Q14. Name the various marking tools used in a pattern making or in acarpentary shop.
Ans. (a) Pencil (b) Scriber (c) Marking gauge (d) Mortise gauge
(e) Try square (f) Bevel (g) Compass (h) Dividers.

Bharat Worksbop Technology Practical Manual 107

 Q
15. Name the various type of chisels used in a pattern-making shop.
Ans. (a) Firmir chisels (b) Mortise chisels (c) Gauge chisels.
Q16. Name the various striking tools used in a patern-making shop.
Ans. (a) Cross peen hammer (b) Claw hammer (c) Mallet.
Q17. Name the various drilling and boring tools used in a pattern-making shop.
Ans. (a) Hand drill (b) Ratchet Brace (c) Gimlet drill.
Q
18. What is the carpenter's vice?
Ans. It is used to hold a work-piece.
Q 19, What is the pitch of saw?
Ans. It is the distance between the two adjacent teeth.
Q
20. Name any three wood-working machines.
Ans. Lathe, Planer and Circular saw.
Q
21. What is the function of a rebate plane?
Ans. To make recesses.
Q22. How can youclassify the various saws used in a carpantry shop?
Ans. (a) Tenon saw (b) Bow saw (c) Rip saw (d)Cross cut saw
(e) Compass saw (f) Keyhole saw
Q23. Define the various types of planes used in a carpantry shop.
Ans. (a) Smoothing plane (b) Trying plane () Wooden Jack plane (d) Spoke Sheave
(e) Iron Jack plane (E) Rebate plane
Q24. What are the various types of striking tools used in a carpentry shop?
Ans. (a) Mallet (b) Cross pean hammer (c) Claw hammer
Q 25. What do meant by the various holding devices used in a carpantry shop?
Ans. (a) C-clamp (b) Bench hook () T-Clamp (d) Clamping vice