This set of Manufacturing Processes Multiple Choice Questions & Answers (MCQs) focuses on “Shaping”.
1. What is a shaping process?
a) A type of casting process
b) A type of grinding process
c) A metal removal process in which reciprocating workpiece is fed against a stationary tool
d) A process in which metal is removed by a reciprocating tool fed against a stationary workpiece
Explanation: It is a process in which cutting motion provided by linear-forward motion of the reciprocating tool and the intermittent feed motion provided by the slow transverse motion of the workpiece resulting in a flat surface by gradual removal of excess material layer by layer.
2. Which of the following is the advantage of shaping process?
a) Large objects can be machined easily
b) Thin or fragile workpiece can also be machined
c) Lower machining time
d) Higher tool life
Explanation: In shaping process very less cutting forces are generated. Therefore thin or fragile jobs can be conveniently machined. Large objects cannot be machined by shaping, for that purpose planning process is used.
3. What is the purpose of the RAM in shaping machine?
a) To hold the tool
b) To hold the tool head
c) To hold the saddle
d) To hold workpiece
Explanation: Ram supports tool head on its front. It reciprocates on accurately horizontal machined guide ways on top of the column.
4. What is the use of clapper block in the shaper?
a) To hold the tool post
b) To hold the feed handle
c) To house the down feed screw
d) To operate the angular graduation scale
Explanation: Tool post is mounted upon the clapper block to prevent the interface between the tools and workpiece on the return stroke.
5. Clapper block is connected to the clapper box by means of hinge pin.
Explanation: The clapper box house the clapper block which is connected to it by means of hinge pin. It prevents the tool cutting edge from dragging and wear. The work surface is also prevented from any damage due to dragging.
6. How many types of shapers are there?
Explanation: Shapers are classified as follows:
(a) As per the type of motion.
• Crank type
• Geared type
• Hydraulic type
(b) As per the position and travel of ram.
• Horizontal type
• Vertical type
• Travelling head type
(c) As per the design of the table
• Standard shaper
• Universal shaper
(d) As per the cutting stroke
• Push type
• Draw type.
7. In draw type shaper, the metal is removed when the ram moves towards the machine.
Explanation: In this type of the shaper, metal is removed when the ram and thus tool moves towards the column of the machine, i.e. draw the workpiece towards the machine. The ram is generally supported by an overhead arm which ensures rigidity and eliminates deflection of the tool.
8. In travelling head type shaper, ram can move only in vertical direction.
Explanation: In travelling head shaper, the ram carrying the tool can move crosswise while it reciprocates to give the required feed. Heavy jobs which are difficult to handle are held static on the basement of the machine while the ram reciprocates and supplies the feeding movement.
9. Which of the following is true about push type shapers?
a) The workpiece moves away from the column machining
b) The ram moves away from the machine column while cutting the metal
c) The ram moves towards the machine column while cutting the metal
d) The ram moves away and the workpiece moves towards the machine column
Explanation: It is the most general type of shaper used in common practice. In this type, the metal is removed when the ram moves away from the column, i.e. it pushes the workpiece. As in shaping process workpiece remains stationary.
10. What will be the cutting time for machining the workpiece of width 1000 mm when the bull wheel is rotating at 150 rpm with the feed of 2 mm per stroke?
a) 90 sec
b) 120 sec
c) 200 sec
d) 500 sec
Explanation: Cutting time is calculated by formula,
CT = W/ (Ns*Fc) where, W is width of the work piece
Ns is the bull wheel rpm
Fc is the feed rate
CT = 1000/ (150*2)
= 3.34 min = 200 sec.
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