Question no. 1:

a- Draw 3 views of the turning tool showing wear zones on all views and name them.

b- While drilling holes in steel plate by a 20 mm diameter HSS drill at a given feed, the tool life decreased from 40 min. to 24 min. when speed was raised from 250 rpm to 320 rpm. At what speed (rpm) the life of that drill under the same condition would be 30 min.?

Question No.2:

a- Compare between conventional and climb milling.

Question No.3

a- If the length of the cut during broaching process was = 200 mm. Calculate I - The Pitch. 2- The number of teeth which are cutting at the same time.

b- On a milling machine it is required to Index 73 divisions, find the gears and the movement of the index handle

c- On a milling machine it is required to Index 171 divisions, find the gears and the movement of the index handle.

d- In a milling operation it was found that: diameter of cutter d = 150 mm, number of teeth = 8, Block to be removed (18r0X150X15 mm), the feed S = 0.06 min/tooth, permitted depth of cut (a = 2.5 mm), width of cutter b = 10 mm and the linear speed v = 20 m/min, while V' = 0.4 cm3/KW.min.

Calculate: 1- The total machining time to remove the block completely.
2- The machine power in KW.
b. While drilling holes in steel plate by a 20 mm diameter IISS drill at a given feed, the tool life decreased from 40 min. to 24 min. when speed was raised from 250 rpm to 320 rpm. At what speed (rpm) the life of that drill under the same condition would be 30 min.?

Question No.4

a- Write down the necessary information for maintenance of the Grinding Wheel

Question NO. 5

a- Draw 3 views of the turning tool showing wear zones on all views and name them.
b- Discuss electron beam welding.

Question NO. 6

a- By drawing only Compare between injections modeling and blow/vacuum modeling in polymer processing

b- By drawing only compare between Surface and cylindrical grinding

Question NO. 7

a- What are the defects in rod and wire drawing ?
b- Mention all types of metal extrusion process and draw a simple section for tube extrusion
c- Estimate the limiting drawing ration(LDR) that you would expect from a sheet that when Stretched by 20 % in length, decrease in thickness by 15 %

Question NO. 8

a- If the length of the cut during broaching process was = 200 mm. calculate:
1- The pitch . 2- The number of teeth which are cutting at the time.
b- 120 mm long, 12 mm diameter stainless steel rod is being machined by turning on a center lathe to 11 mm. The spindle rotates at N = 450 rpm and the feed = 0.3 mm/rev and the specific energy for stainless steel = 4.5 W s/mm3. Calculate:
cutting speed
machining time
material removal rate
Power dissipated

Question no 9

a- What are the physical properties of polymers

b- On a milling machine it is required to Index 171 divisions, find the gears and the movement of the index handle.

c- Draw the pressure gas welding process.

d- A Cylinder specimen made of annealed steel has a diameter of 125 mm and has 80 mm height. If this cylinder has to be upset at room temperature by open die forging with flat dies to a height of 60 mm. If the coefficient of friction is 0.15, calculate the upsetting force required at the ebd of the stroke. Use the strain hardening exponent n= 0.15 and the strength coefficient k = 1000 Mpa.