⚙️ Mechanics of Chip Formation

1. Metal cutting involves removal of material in the form of:

a. A. Powder
b. B. Vapour
c. C. Chips
d. D. Granules
e. Ans: C
2. The main mechanism involved in chip formation is:
a. A. Elastic deformation
b. B. Brittle fracture
c. C. Plastic deformation
d. D. Magnetic attraction
e. Ans: C
3. Which of the following materials will typically produce continuous chips?
a. A. Cast iron
b. B. Bronze
c. C. Mild steel
d. D. Glass
e. Ans: C
4. Discontinuous chips are usually formed when machining:
a. A. Ductile materials
b. B. Brittle materials
c. C. Polymers
d. D. Non-metals
e. Ans: B
5. Built-up edge is associated with:
a. A. High cutting speed
b. B. High rake angle
c. C. Excessive feed and low cutting speed
d. D. Low friction
e. Ans: C
6. In orthogonal cutting, the cutting edge is:
a. A. Parallel to feed direction
b. B. Perpendicular to feed direction
c. C. At an angle to feed direction
d. D. Curved
 e. Ans: B
7. Oblique cutting differs from orthogonal cutting mainly in:
a. A. Tool shape
b. B. Cutting speed
c. C. Inclination of cutting edge
d. D. Material type
e. Ans: C

🧰 Cutting Forces & Merchant's Force Diagram

8. In Merchant's circle, the shear force acts:

a. A. Along rake face
b. B. Normal to shear plane
c. C. Along shear plane
d. D. Perpendicular to cutting direction
e. Ans: C
9. Cutting force acts in the direction of:
a. A. Perpendicular to tool face
b. B. Tool feed
c. C. Tool motion
d. D. Chip flow
e. Ans: C
10. Merchant’s circle is used to analyze:
a. A. Vibration
b. B. Heat transfer
c. C. Cutting forces
d. D. Lubrication
e. Ans: C

🔧 Tool Geometry & Nomenclature

11. The side relief angle helps in:

a. A. Improving strength
b. B. Reducing tool wear
 c. C. Preventing rubbing
d. D. Increasing surface finish
e. Ans: C
12. Back rake angle is measured in the:
a. A. Orthogonal plane
b. B. Side cutting plane
c. C. Longitudinal plane
d. D. Cutting plane
e. Ans: D
13. Nose radius affects:
a. A. Tool strength only
b. B. Chip flow only
c. C. Surface finish and tool life
d. D. Rake angle
e. Ans: C
14. Single point cutting tools are used in:
a. A. Milling
b. B. Grinding
c. C. Turning
d. D. Drilling
e. Ans: C

🔥 Thermal Aspects

15. The highest temperature in metal cutting is found at:

a. A. Tool flank
b. B. Tool-chip interface
c. C. Workpiece surface
d. D. Tool holder
e. Ans: B
16. Heat is generated in metal cutting due to:
a. A. Combustion
b. B. Plastic deformation and friction
c. C. Electromagnetic induction
d. D. Radiation
e. Ans: B
 17. Among the three heat zones in cutting, most heat is produced at:
a. A. Tool–work interface
b. B. Shear zone
c. C. Tool–chip interface
d. D. Flank face
e. Ans: C

🛠️ Tool Materials

18. Which tool material is hardest?

a. A. HSS
b. B. Cermet
c. C. Diamond
d. D. Carbide
e. Ans: C
19. Tool materials should have high:
a. A. Ductility
b. B. Melting point
c. C. Electrical conductivity
d. D. Plasticity
e. Ans: B

🧪 Tool Wear and Tool Life

20. Flank wear occurs on:

a. A. Top surface of tool
b. B. Bottom surface of tool
c. C. Flank face
d. D. Nose radius
e. Ans: C
21. Crater wear is associated with:
a. A. Flank surface
b. B. Tool shank
c. C. Tool face near cutting edge
 d. D. Nose
e. Ans: C
22. Tool life is the time for which a tool performs:
a. A. Before purchasing
b. B. Between sharpening
c. C. Without feed
d. D. In storage
e. Ans: B
23. The most common criterion for tool life is:
a. A. Surface finish
b. B. Flank wear
c. C. Cutting force
d. D. Temperature rise
e. Ans: B

💦 Cutting Fluids

24. Cutting fluids are primarily used to:

a. A. Increase vibration
b. B. Increase friction
c. C. Reduce heat and friction
d. D. Improve power consumption
e. Ans: C
25. Cutting fluids help improve:
a. A. Tool life
b. B. Tool wear
c. C. Surface finish
d. D. All of the above
e. Ans: D

⚙️ Machinability

26. Machinability refers to:

a. A. Ease of melting
 b. B. Ease of casting
c. C. Ease of machining
d. D. Cost of machining
e. Ans: C
27. Good machinability is indicated by:
a. A. High tool wear
b. B. High cutting forces
c. C. Good surface finish
d. D. Low tool life
e. Ans: C

🔧 Tool Wear and Tool Life (continued)

28. Crater wear occurs mainly due to:

A. Friction at tool flank
B. Abrasion by hard particles
C. Diffusion and abrasion at high speed
D. Compressive stress
Ans: C
29. Corner wear is most prominent at the:
A. Back rake
B. Tool shank
C. Tool holder
D. Tool nose
Ans: D
30. Which of the following is not a type of tool wear?
A. Flank wear
B. Crater wear
C. Edge chipping
D. Torsional wear
Ans: D

⚙️ Chip Types and Chip Formation

31. Continuous chips form under which condition?

A. Low speed and high feed
 B. High rake angle and high speed
C. High depth of cut
D. Low rake angle
Ans: B
32. Discontinuous chips are most likely when cutting:
A. Ductile metals at high speed
B. Brittle metals at low speed
C. Ductile metals at low speed
D. Any metal at high feed
Ans: B
33. Built-up edge is minimized by:
A. Decreasing rake angle
B. Increasing friction
C. Using coolant and higher speeds
D. Lowering cutting fluid
Ans: C
34. The chip tool interface experiences:
A. No deformation
B. High friction and temperature
C. Heat dissipation only
D. Elastic strain
Ans: B
35. Which type of chip offers better surface finish?
A. Discontinuous
B. Continuous
C. Serrated
D. Built-up
Ans: B

🧮 Merchant's Circle & Force Components

36. Normal force to shear acts:

A. Along the rake face
B. Perpendicular to shear plane
C. Along cutting direction
 D. Across the flank
Ans: B
37. In metal cutting, friction force acts:
A. At the tool base
B. On tool holder
C. Along rake face due to chip
D. Between chip and work
Ans: C
38. Cutting force increases with:
A. Decreasing feed
B. Decreasing depth of cut
C. Increasing feed or depth
D. Increasing rake angle
Ans: C
39. In orthogonal cutting, shear plane angle increases with:
A. Higher friction
B. Lower rake angle
C. Lower friction and higher rake angle
D. Higher tool wear
Ans: C

🛠️ Cutting Tool Materials

40. The most commonly used cutting tool material for high-speed cutting is:
A. HSS
B. Carbon steel
C. Cast iron
D. Nylon
Ans: A
41. Cemented carbides are known for:
A. High impact resistance
B. High toughness
C. High hot hardness
D. Low cost
Ans: C
 42. Ceramic tools are used mainly for:
A. High-speed machining of soft metals
B. Low-speed operations
C. High-speed machining of hard materials
D. Grinding
Ans: C
43. Diamond tools are ideal for:
A. Steel
B. Cast iron
C. Non-ferrous and abrasive materials
D. Wood
Ans: C

💧 Cutting Fluids

44. Cutting fluids reduce:

A. Temperature and friction
B. Machinability
C. Tool strength
D. Chip thickness
Ans: A
45. Primary functions of cutting fluids include all except:
A. Cooling
B. Lubricating
C. Chip breaking
D. Cleaning
Ans: C
46. Which type of cutting fluid is used for high-speed operations?
A. Water
B. Dry air
C. Soluble oil
D. Emulsion
Ans: D
47. Coolant failure can lead to:
A. Tool sharpening
B. Increase in machinability
 C. Built-up edge formation
D. Reduced rake angle
Ans: C

📏 Surface Finish & Machinability

48. A factor affecting surface finish is:

A. Tool wear
B. Cutting speed
C. Feed rate
D. All of the above
Ans: D
49. Better surface finish is obtained by:
A. High feed rate
B. High tool wear
C. Fine feed and sharp tool
D. High depth of cut
Ans: C
50. Surface finish depends most critically on:
A. Tool hardness
B. Nose radius
C. Coolant type
D. Machine speed
Ans: B
51. Machinability of a material is poor when:
A. Chips are continuous
B. Surface finish is good
C. Tool life is short
D. Cutting forces are low
Ans: C
52. A material with high machinability:
A. Requires more tool changes
B. Produces poor surface finish
C. Can be cut easily with long tool life
D. Is brittle
Ans: C
⚙️ Processes & Operations

53. Turning operation is performed using:

A. Multi-point tools
B. Grinding wheels
C. Single-point cutting tools
D. Drill bits
Ans: C
54. Drilling is used for:
A. Machining cylinders
B. Slotting
C. Creating round holes
D. Gear making
Ans: C
55. Shaping involves:
A. Rotating tool and stationary work
B. Rotating work and tool
C. Reciprocating tool with linear motion
D. Curved tool motion
Ans: C
56. Milling differs from turning as:
A. Tool is stationary
B. Tool rotates and removes material
C. Workpiece moves in all directions
D. Feed is not required
Ans: B
57. Grinding involves:
A. High-speed single-point tool
B. Multi-edge abrasive tool
C. Linear tool motion
D. Cutting oil only
Ans: B
🧱 Advanced Concepts

58. Tool wear is influenced most by:

A. Tool holder design
B. Cutting fluid color
C. Temperature and friction
D. Feed rate only
Ans: C
59. Common failure of tools is due to:
A. Rake angle variation
B. Nose radius increase
C. Excessive wear
D. Tool coating
Ans: C
60. A high nose radius results in:
A. Poor surface finish
B. Reduced feed
C. Improved finish but increased cutting force
D. Crater wear
Ans: C
61. Shear angle in orthogonal cutting is defined between:
A. Tool face and chip
B. Shear plane and cutting direction
C. Tool and rake face
D. Flank and nose
Ans: B
62. Cutting speed refers to:
A. Tool movement per minute
B. Workpiece rotation
C. Speed at tool-work interface
D. Coolant flow rate
Ans: C
63. Depth of cut is measured:
A. Along cutting edge
B. From machined to unmachined surface
C. Radially
D. Axially
Ans: B
64. Feed rate is the:
A. Length of chip
B. Distance tool advances per rev
C. Tool angle
D. Shear zone
Ans: B
65. Higher rake angle:
A. Increases cutting force
B. Reduces shear deformation
C. Promotes built-up edge
D. Worsens finish
Ans: B
66. Excessive tool vibration may cause:
A. Better surface
B. Chatter marks and tool breakage
C. Higher strength
D. Tool cooling
Ans: B
67. The major source of heat in cutting is:
A. Motor
B. Chip deformation and friction
C. Workpiece rotation
D. Coolant flow
Ans: B
68. Higher cutting speed generally:
A. Increases BUE
B. Reduces tool wear
C. Improves finish but increases heat
D. Reduces chip formation
Ans: C
69. Chip thickness is greater than uncut thickness due to:
A. Friction
B. Plastic deformation
C. Thermal strain
D. Coolant
Ans: B
70. Nose radius is important in:
A. Friction control
 B. Cutting force analysis
C. Surface finish and corner strength
D. Tool holding
Ans: C

🔩 Advanced Tool Geometry, Wear, and Machining Aspects

71. In a single point cutting tool, the angle between the side cutting edge and the axis of
the tool is called:
A. Side rake angle
B. Side relief angle
C. Side cutting edge angle
D. Back rake angle
Ans: C
72. The main purpose of the relief angle in a cutting tool is to:
A. Increase tool strength
B. Reduce friction with the workpiece
C. Increase rake angle
D. Improve chip flow
Ans: B
73. A zero rake angle tool is used when:
A. Cutting soft ductile materials
B. High cutting speeds are required
C. Tool strength is critical
D. Surface finish is not important
Ans: C
74. Oblique cutting differs from orthogonal cutting because:
A. Tool is stationary
B. Inclination angle is non-zero
C. Chip flows perpendicular to tool edge
D. Workpiece is brittle
Ans: B
75. Which of the following parameters affects the shear angle in cutting?
A. Rake angle
B. Friction at tool–chip interface
C. Work material properties
D. All of the above
Ans: D
 76. Tool life is expected to increase with:
A. Increase in cutting speed
B. Increase in feed
C. Use of coolant and proper tool geometry
D. Increase in depth of cut
Ans: C
77. The type of wear occurring on the tool face is called:
A. Flank wear
B. Crater wear
C. Nose wear
D. Edge wear
Ans: B
78. Crater wear generally occurs during machining of:
A. Hard brittle materials
B. Soft ductile materials
C. Non-metallic materials
D. Plastics
Ans: B
79. Flank wear can result in:
A. Reduced surface finish
B. Dimensional inaccuracy
C. Tool breakage
D. All of the above
Ans: D
80. Nose radius of a cutting tool helps in:
A. Reducing heat generation
B. Controlling flank wear
C. Improving surface finish and tool strength
D. Increasing friction
Ans: C

🧊 Thermal, Chip, and Force Considerations

81. The temperature at the tool–chip interface increases mainly due to:
A. Shear deformation
B. Friction
 C. Both A and B
D. Coolant application
Ans: C
82. In cutting ductile metals, which chip is most commonly observed?
A. Discontinuous
B. Continuous
C. Serrated
D. Powdery
Ans: B
83. Built-up edge is a result of:
A. Adhesion between tool and chip
B. High rake angle
C. High speed and good coolant
D. Smooth chip flow
Ans: A
84. High cutting speeds generally result in:
A. Larger BUE
B. Smaller BUE or none
C. Reduced surface finish
D. Tool breakage
Ans: B
85. Merchant’s force diagram is valid for:
A. Orthogonal cutting only
B. Oblique cutting
C. Drilling
D. Milling
Ans: A
86. Tool wear can be minimized by:
A. Increasing cutting speed
B. Increasing feed
C. Using proper cutting fluid and tool geometry
D. Reducing nose radius
Ans: C
87. The wear at the extreme tip of a tool is termed:
A. Crater wear
B. Flank wear
C. Corner wear
 D. Edge chipping
Ans: C
88. Tool wear can be best observed and measured using:
A. Lathe scale
B. Optical microscope
C. Thermometer
D. Vernier caliper
Ans: B
89. In cutting, the highest temperature is found:
A. On the tool shank
B. In the workpiece interior
C. At the chip-tool interface
D. On the tool holder
Ans: C
90. Effective chip breaking is desirable because it:
A. Reduces tool life
B. Increases cutting force
C. Improves safety and chip disposal
D. Increases vibration
Ans: C