Machining Processes Important Questions | Unit-wise R23 Exam Guide
Machine Tools play a major role in modern manufacturing. Understanding how lathes, milling machines, drilling machines, shaping machines, grinding machines, and CNC systems work helps students gain clarity in real-world production processes.
This blog presents Machine Tools important questions in a clean, student-friendly format to support exam preparation.
Machining Processes Important Questions for R23 JNTU Students (Unit-Wise)
Unit 1: Basics of Machining
Key Theory Questions
What are Machining Processes? Explain their significance in manufacturing.
Define metal cutting and explain shear plane theory.
What are the assumptions made in orthogonal cutting?
Explain chip formation and classify different types of chips.
Describe the role of rake angle and clearance angle in machining.
What are the cutting parameters? Explain cutting speed, feed, and depth of cut.
What is machinability? What factors influence machinability?
Describe tool wear mechanisms.
What is tool life? Discuss the tool life characteristics.
Explain the functions of cutting fluids.
What is Merchant’s diagram?
Discuss heat generation in Machining Processes.
What is single-point cutting?
Explain oblique and orthogonal cutting.
Describe chip breakers and their necessity.
What are built-up edges?
What are cutting tool materials? Explain HSS, carbide, ceramic.
Explain the principles of metal removal.
What is surface finish?
Explain the need for high-speed machining.
Numerical Focus Question
Calculate machining time for a given cutting operation.
Determine cutting force using given shear force data.
Evaluate chip thickness ratio.
Compute cutting speed based on workpiece diameter.
Find shear angle using cutting parameters.
Calculate heat distribution in machining.
Determine tool life using Taylor’s relation.
Evaluate metal removal rate.
Compute feed rate based on speed & depth.
Calculate power consumption in machining.
Unit 2: Turning, Drilling & Boring
Key Theory Questions
Explain the principle of turning operation.
Describe various turning operations used in Machining Processes.
What is facing? Explain its purpose.
Describe drilling operations and types of drill bits.
Explain reaming, tapping, and boring.
What are work holding devices used in turning and drilling?
Explain lathe tool signature.
What is taper turning?
Describe thread cutting process.
What is the difference between drilling and boring?
Explain the concept of drilling speeds and feeds.
What are the advantages of CNC turning?
Explain run-out in drilling.
Describe the causes of drill wear.
What factors improve drilling accuracy?
Numerical Focus Question
Calculate RPM for turning based on diameter & speed.
Find machining time for turning operation.
Determine drilling time for a given depth.
Compute feed rate for boring.
Calculate material removal rate in turning.
Find taper angle for taper turning.
Compute thread pitch via gear ratio.
Evaluate drilling power requirement.
Calculate feed per revolution.
Determine tool approach distance.
Unit 3: Milling, Shaping & Planing
Key Theory Questions
What is milling? Explain its working.
Differentiate between up-milling and down-milling.
Explain various milling cutters.
Describe face milling, end milling, and slot milling.
What is a shaping machine? Explain quick-return mechanism.
Explain planing and its applications.
What is indexing? Explain indexing methods.
Describe the principle of operation of horizontal milling machine.
What are feed and speed in milling?
Explain chip load and feed per tooth.
What is climb milling?
State the advantages of milling over shaping.
Explain table drive mechanism in shaping.
What is form milling?
What are tool holding devices in milling?
Numerical Focus Question
Calculate feed per tooth in milling.
Determine cutting speed for milling cutter.
Find machining time for shaping.
Compute table feed rate.
Calculate metal removal rate in milling.
Determine strokes per minute in shaping.
Find cutter RPM.
Compute cutting forces in milling.
Find indexing movement.
Calculate chip load.
Unit 4: Grinding & Superfinishing
Key Theory Questions
What is grinding? Explain its importance in Machining Processes.
Describe types of grinding machines.
What are grinding wheel specifications?
Explain truing and dressing of grinding wheels.
Describe hone, lap, and superfinishing processes.
What is centerless grinding?
What is the significance of grit size?
Explain glazing and loading in grinding wheels.
What factors affect grinding performance?
What is abrasive machining?
Explain surface grinding mechanism.
What is the purpose of coolant in grinding?
Describe cylindrical grinding operation.
What is bond strength in grinding wheels?
Explain friction and heat generation.
Numerical Focus Question
Compute grinding wheel speed.
Calculate material removal rate.
Determine feed rate in surface grinding.
Evaluate time required for grinding.
Compute depth of cut for grinding.
Find power required for grinding.
Calculate work speed.
Determine chip thickness in grinding.
Compute finish accuracy.
Find wheel life.
Unit 5: Advanced Machining Processes
Key Theory Questions
What are non-traditional Machining Processes?
Explain Electrochemical Machining (ECM).
Describe Electric Discharge Machining (EDM).
What is Laser Beam Machining?
Explain water jet machining and its benefits.
Describe abrasive jet machining.
What is Plasma Arc Machining?
Explain USM (Ultrasonic Machining).
What are the limitations of advanced machining methods?
Compare conventional vs non-conventional processes.
Describe tool wear in EDM.
What is thermal conductivity effect in LBM?
State the applications of ECM.
Explain spark erosion in EDM.
What are hybrid machining processes?
Numerical Focus Question
Calculate material removal rate in EDM.
Determine machining time in ECM.
Find power requirement in laser cutting.
Calculate jet velocity in AJM.
Evaluate spark energy.
Compute heat generation in LBM.
Find discharge time in EDM.
Determine removal depth in WJM.
Calculate machining rate in ECM.
Evaluate tool feed rate.
Preparation Tips for Machining Processes
Focus on chip formation, tool geometry, and machining parameters.
Practice numerical problems daily from each unit.
Draw diagrams neatly for turning, milling, drilling, shaping, grinding.
Understand non-traditional processes conceptually.
Revise cutting speeds, feeds, tool life relations.
Solve previous year university question papers.
Concentrate on Units 1, 2, and 5 for higher scoring potential.
Conclusion
Machining Processes is a vital subject for any mechanical engineering student, and mastering its concepts ensures strong manufacturing knowledge. This blog provided a unit-wise list of Machining Processes important questions with numerical practice, preparation tips, and a clear exam-oriented structure. Follow this guide consistently to strengthen your exam preparation.
