TOOL DESIGN (KME-604)
B.Tech Semester VI – Theory Examination (2022–23)
TOOL-DESIGN-KME-604
Tool Design is a core manufacturing subject that deals with the design, selection, and application of cutting tools, machine tools, jigs, fixtures, clamping devices, and tool materials used in production industries. The primary objective of tool design is to improve productivity, accuracy, interchangeability, and economy of manufacturing while ensuring safety and quality. This subject integrates concepts from manufacturing processes, material science, machine tool design, and production engineering. The given question paper evaluates understanding of tool materials, machine tool structures, cutting tool geometry, tool wear, jigs and fixtures, metal forming operations, and machine tool control systems. To score well, answers must be written in clear, descriptive, and logically connected paragraphs, supported by sketches wherever required.
SECTION A – BASIC DEFINITIONS AND FUNDAMENTAL CONCEPTS
Section A focuses on testing the student’s understanding of basic terminology and essential functions related to machine tools and cutting operations.
The control system of a machine tool should be explained as the system responsible for controlling speed, feed, depth of cut, tool movement, and accuracy of operation. It must ensure smooth operation, quick response, reliability, and ease of automation.
The guide ways of a machine tool must be explained as precision surfaces that guide relative motion between machine components such as the table and saddle. Their function is to ensure accurate alignment, rigidity, and smooth motion under load.
Tool chatter should be explained as a self-excited vibration occurring during machining due to improper cutting conditions, lack of rigidity, or tool wear. It adversely affects surface finish, tool life, and dimensional accuracy.
The requirements of machine tool structure should be explained by highlighting rigidity, vibration damping, thermal stability, and accuracy retention under cutting forces.
Materials used for spindles should be explained in terms of strength, toughness, and wear resistance, as spindles transmit power and support cutting tools.
A tool should be defined as a device that removes material from a workpiece to achieve the desired shape and size.
The applications of sliding bearings should be explained by linking them to heavy load applications with smooth motion.
The difference between bending and drawing should be explained in terms of metal forming principles and material flow.
The full form of CNC must be explained along with its relevance in modern manufacturing.
A chip should be explained as the material removed from the workpiece during machining, highlighting its formation during cutting.
SECTION B – CUTTING TOOLS, WEAR, AND MANUFACTURING METHODS
Section B evaluates understanding of cutting mechanics, tool wear, gear manufacturing, and tool design procedures. Answers here must be written as connected explanations.
Tool life should be explained as the duration for which a cutting tool performs satisfactorily before it needs re-sharpening or replacement. Factors affecting tool life include cutting speed, feed rate, depth of cut, tool material, workpiece material, cutting environment, and rigidity of setup.
Different types of tool wear, such as flank wear, crater wear, notch wear, and built-up edge formation, should be explained with reference to cutting temperature and friction.
The gear cutting by milling method should be explained by describing the use of form milling cutters, indexing mechanisms, and the step-by-step process of cutting gear teeth.
The procedures involved in cutting tool design should be explained by discussing selection of tool material, tool geometry, strength analysis, and economic considerations.
The difference between single-point and multi-point cutting tools should be explained by comparing their construction, cutting action, accuracy, and applications.
SECTION C – CLAMPING DEVICES, CUTTING TOOL GEOMETRY & METAL FORMING
Section C tests design understanding and application of tools and fixtures, requiring descriptive answers supported by sketches.
Clamping devices should be explained as mechanisms used to hold the workpiece firmly during machining. Common clamping methods include screw clamps, lever clamps, cam clamps, and hydraulic clamps. Their importance lies in ensuring safety, accuracy, and repeatability.
The single-point cutting tool should be explained by describing its elements such as shank, rake face, flank face, cutting edge, and tool angles like rake angle, clearance angle, and cutting angle. Tool geometry directly influences cutting forces, chip flow, and tool life.
The metal flow during drawing operation should be explained by discussing variables such as die angle, friction, material properties, lubrication, and reduction ratio.
Topics like coated carbide tools, grinding fixtures, and material handling equipment should be explained in terms of their role in improving tool life, precision, and productivity.
JIGS, FIXTURES, AND MACHINE TOOL STRUCTURE
A jig should be explained as a production tool that holds, locates, and guides the cutting tool. The difference between a jig and a fixture should be explained by emphasizing that jigs guide tools while fixtures only hold the workpiece.
The essential elements of a jig should be explained in terms of locating elements, clamping elements, tool guiding elements, and body.
The requirements of tool materials should be explained by highlighting hardness, toughness, hot hardness, wear resistance, and chemical stability. Various cutting tool materials such as high-speed steel, carbides, ceramics, and superhard materials should be explained.
The design criteria for machine tool structures should be explained by discussing rigidity, damping capacity, thermal stability, and ease of manufacturing.
MACHINE TOOL CLASSIFICATION AND CONTROL SYSTEMS
The classification of machine tools should be explained based on function, operation, and control, such as lathes, milling machines, drilling machines, and CNC machines.
The speed and feed changing system should be explained by describing centralized control systems that allow efficient and precise adjustment of machining parameters.
HOW TO WRITE TOOL DESIGN ANSWERS IN THE EXAM
In Tool Design, never write answers in short bullet points. Always begin with a clear definition, followed by detailed explanation of working principles, applications, and significance. Wherever sketches are mentioned, explain them in words along with neat diagrams. Examiners focus on clarity of manufacturing concepts, logical flow, and practical relevance.
