J - Hand Tools

Question 1

What process requires the use of Tools?

Answer 1

Material Removal Processes
Machining
Subtractive Manufacturing

Question 2

Portable tools that are powered manually (by human muscles)

Answer 2

Hand Tools
Examples: Hacksaw, Files

Question 3

Portable tools that use a supplementary power source like mains electricity, batteries, compressed air, or even fuel.

Answer 3

Power Tools
Examples: Electric Drill, Angle Grinder, Reciprocating Saw

Question 4

Static (non-portable), large, stiff, heavy units usually employed in machine shops. These are usually electrically powered and may use 220VAC or 3-phase supply.

Answer 4

Machine Tools
Examples: Lathe, Vertical Stand Drill

Question 5

This performs the actual cutting of metal and must provide the necessary hardness and geometric configuration to facilitate the cutting action.

Answer 5

Cutting Tool or Tool Bit

Question 6

Tool Bits that have an essentially circular cross-section, must be rotated, and involve a number of individual cutting edges or teeth.

Answer 6

Multi-point cutting tools

Question 7

A tool bit that uses a square cross-section cutter, which doesn’t rotate, and only has one cutting edge. Examples include Lathes, Shapers, Planers, and Boring machines.

Answer 7

Single Point Cutting Tool (SPCT)

Question 8

Cleaving

Answer 8

Wedging

Question 9

The geometry of a SPCT is dominated by _____ angles that stop the tool rubbing on the workpiece and provide clearance for cutting debris, and _____ angles that create the wedge.

Answer 9

Relief; Rake

Question 10

Two examples of the effect tool positioning (at any compound angle) can have on the cutting action.

Answer 10

Orthogonal (cutting edge at 90°) and Oblique (inclined cutting edge) Cutting

Question 11

The cutting debris from the SPCT

Answer 11

Chips (Swarf outside the USA)

Question 12

Optimal cutting (characterized by low tool wear, low energy consumption, low heat, and good surface finish) is indicated by the production of

Answer 12

Continuous Chips

Question 13

Chatter

Answer 13

Vibration

Question 14

Very poor inefficient cutting, even with ductile material, results in _____. These are characteristically short and fragmented, and are associated with noise, heat, and bad surface finish.

Answer 14

Discontinuous Chips

Question 15

These are an intermediate type of chips that are generated in a continuous form but with toothed edges. They produce all the same bad outcomes as discontinuous chips, while being sharp and hazardous.

Answer 15

Serrated chips

Question 16

Continuous chips are desirable, and can be achieved through the manipulation of

Answer 16

Cutting Speed, Feed Rates, SPCT Angles, and Tool Presentation Angle

Question 17

These are employed to achieve the “best of both worlds”, where chips are initially generated as continuous (with all the benefits), but then are subsequently broken up into a discontinuous form for better packing and cleanup.

Answer 17

Chip Breakers

Question 18

The two types of chip breakers.

Answer 18

Obstruction-type and Groove-type

Question 19

This chip breaker type is more popular as it is more rugged, less prone to wear, and won’t fail under high temperature/load/friction.

Answer 19

Groove-type Chip Breaker

Question 20

Adjustments are made to _____, ______, and ______ until continuous chips are generated.

Answer 20

Speed, Feed, and Angles

Question 21

Small particles of workpiece material detach from the chip as it rides the tool face and fuse themselves to the tool due to the high temperatures and pressures involved.

Answer 21

BUE (Built Up Edge)

Question 22

The cure for BUE, which is a mixture of lubricant and coolant that reduces temperature and friction.

Answer 22

Cutting Fluid

Question 23

The most common Cutting Fluid is comprised of what which has a milky-white appearance.

Answer 23

Soluble Oil (lubricant) and Water (coolant)

Question 24

A Cutting Tool Material must be harder than the workpiece material, but must also be able to maintain that hardness at elevated operating temperature. This ability is called

Answer 24

Hot Hardness

Question 25

Cutting Tools are also subject to impact/shock loading and must possess sufficient

Answer 25

Toughness

Question 26

The rule-of-thumb to select a tool material is

Answer 26

Select a tool material that is just slightly harder than the workpiece, but no more, so as to preserve as much toughness as possible.

Question 27

One of the first cutting tool materials developed, which is very poor by today’s standards, and should no longer be used. It has low hardness at room temperature, which drops off dramatically as it heats up.

Answer 27

Carbon Tool Steel

Question 28

An excellent material for general purpose use, and has replaced carbon tool steel. When used for twist drills it usually has a black appearance as a result of the black oxide developed during heat treatment.

Answer 28

High Speed Steel (HSS)

Question 29

A slightly harder cutting tool material than HSS

Answer 29

Cobalt Alloy

Question 30

Twist drills made of cobalt alloy are heat treated to a ____ _____ temper, which gives them their characteristic appearance.

Answer 30

Light-Straw

Question 31

A material with even greater hardness than cobalt alloy. This slate-gray colored material is very easily chipped because of low toughness, and cannot be resharpened.

Answer 31

Tungsten Carbide (WC)

Question 32

The most common type of Coated Cutting Tool. This material combination has a bright gold-colored appearance except on areas such as the shank of drills where the underlying HSS is left exposed.

Answer 32

Titanium Nitride (TiN) on HSS

Question 33

The hardest material known, but is expensive (in large pieces) and very brittle. However it is useful for cutting very hard workpieces such as glass or ceramic.

Answer 33

Diamond

Question 34

Since SPCTs only cut at their nose, any use of harder material need only be applied in that one locality, while the rest of the tool can remain HSS. This locality is called

Answer 34

Cutting Tool Insert

Question 35

Inserts are often constructed of ______ ______ coated in ________ _________ and thus have a gold appearance.

Answer 35

TUNGSTEN CARBIDE; TITANIUM NITRIDE

Question 36

A material that is second only to diamond in hardness. This material can be made and shaped into a form suitable for a SPCT, but is rather expensive. To keep cost manageable, it is offered as a small INSERT on one corner of an INSERT.

Answer 36

Cubic Boron Nitride (CBN)