Cutting Tools

Question 1

what is machining

Answer 1

The removal process in the form of chips

Question 2

what are the two principal aspects for cutting tool technology forces and temperatures?

Answer 2

Tool material - developing materials that are able to withstand the high temperatures and forces during machining
Tool Geometry - optimising the geometry for the tool material and for a given operation

Question 3

what are the three possibles modes a cutting tool can fail

Answer 3

Fracture Failure - where the cutting force can be too much for the material to handle
Temperature Failure - temperature being too high causing the tool to soften leading to plastic deformation and loss of shape edge
Gradual Wear - durability of the cutting tool

Question 4

Fracture and temperature failures and considered what type of failure

Answer 4

premature

Question 5

What are the cutting tool materials

Answer 5

▪ Tool Steel / High Speed Steel (HSS)
▪ Cemented Carbides
▪ Cermets
▪ Coated Carbides
▪ Ceramics
▪ Synthetic Diamond
▪ Cubic Boron Nitride

Question 6

advantages of cutting fluids

Answer 6

• helps to remove chips by washing the away
• reduce temperature of work part for easier handling
• reduces thermal distortion
• prolong cutting tool life

Question 7

disadvantages of cutting lfuids

Answer 7

• can be contaminated with oil, small chips, molds

- causes odors and health hazards

Question 8

ways to combat contamination for cutting fluids

Answer 8

• replace cutting fluid and regular and frequent intervals
• use a filtration system
• dry machinig

Question 9

the equation for total production cycle time

Answer 9

Cycle Time = operation processing time * handling time * tool handling or changing time
(All Units in min/pc)

Question 10

total cost per piece equation

Answer 10

Costly per piece = material cost + ((labour cost rate +equipment cost rater)*Cycle Time) + cost of tooling