ME6402 -MANUFACTURING TECHNOLOGY II

UNIT I THEORY OF METAL CUTTING

Mechanics of chip formation, single point cutting tool, forces in machining, Types of chip,
cutting tools nomenclature, orthogonal metal cutting, thermal aspects, cutting tool materials, tool
wear, tool life, surface finish, cutting fluids and Machinability
1. What is Metal Cutting?
Metal cutting or machining is the process of by which unwanted material from a block of
metal is removed in the form of chips.
2. Define the nose radius.
Joining of side and end cutting edges by means of small radius in order to increase the tool
life and better surface finish on the work piece.
3. What are the important/required characteristics of the tool materials used for cutting
tools?
Hot hardness, high toughness, high wear resistance, low coefficient of friction, and high
thermal conductivity.Resistance to thermal shock ,Easy to grind and sharpen .
Low mechanical and chemical affinity for the work material
4. Define tool life
The time period between two consecutive resharpening, with which the cuts the material
effectively is called as tool life
5. What is tool signature?
The various angles of tools are mentioned in a sequence of numerical number in particular
order is known as tool signature.
6. Define the rake angle.
Ti is the angle between the face of the tool and the line parallel to the base of the tool.
7. What are the types of rake angle?
According to the measurement
i. Back rake angle and ii. Side rake angle.
According to the value of the angle
i.Positive rake angle ii. Zero rake angle and iii. Negative rake angle

8. Explain the effects of rake angles.

positive rake angles:
Make the tool more sharp and pointed. This reduces the strength of the tool, as the small
included angle in the tip may cause it to chip away.
Reduce cutting forces and power requirements.
Helps in the formation of continuous chips in ductile materials.
Can help avoid the formation of a built-up edge.
Negative rake angles, by contrast:
Make the tool more blunt, increasing the strength of the cutting edge.
Increase the cutting forces.
Can increase friction, resulting in higher temperatures.
Can improve surface finish.
A zero rake angle is the easiest to manufacture, but has a larger crater wear when
compared to positive rake angle as the chip slides over the rake face.
9. Explain the nose radius.
It is the joining of side and end cutting edges by means of small radius in order to increase
the tool life and better surface finish on the work piece.
10. Name the factors/parameters that contribute to poor surface finish in cutting?
i.Speed ii. Feed and iii. Depth of cut
11. What is orthogonal cutting and oblique cutting
Orthogonal cutting :-The cutting edge of tool is perpendicular to the work piece axis
Oblique cutting: - The cutting edge is inclined at an acute angle with normal to the cutting
velocity vector is called oblique cutting process.

Orthogonal Cutting: The cutting condition when chip is expected to flow along the orthogonal
plane is known as orthogonal cutting.pure orthogonal cutting is orthogonal cutting when
principle cutting angle is 90 degree.
Oblique Cutting: When the chip does not flow on orthogonal plane i.e chip deviates from
orthogonal plane then it is called oblique cutting.
12. What is chip and mention its different types?
Material sheared from the work in the form of small pieces is called chip.
Chips are mainly classified into three types
a.Continuous chip. b.Discontinuous chip. c.Continuous chip with built up edge.
13. What are the favorable factors/conditions for discontinuous chip formation? B
Maching of brittle materials, Small rake angle , Higher depth of cut , Low cutting speeds
Excess cutting fluid , and Cutting ductile materials with low speed and small rake angle of the
tool .

14. What are the favorable factors for continuous chip formation?
Small rake angle, Low cutting speed , Strong adhesion between chip and tool face, Coarse
feed Insufficient cutting fluid , Large uncut thickness
15. What are the factors responsible for built-up edge in cutting tools?
During cutting process, the interface temperature and pressure are quite high and also high
friction between tool chip interfaces causes the chip material to weld itself to the tool face near
the nose. This is called built up edge
16. Give two examples for orthogonal cutting.
Turning, facing, thread cutting and parting off
17. Describe the conditions for using positive rake angle?
i. To machine the work hardened materials
ii. To machine low strength ferrous and non-ferrous metals.
iii. To machine long shaft of small diameters
iv. To machine the metal blow recommended cutting speeds
v. Using small machine tools with low horsepower
18. Write Taylors tool life equation.
Taylors tool life equation, VTn=C
Where, V= Cutting speed in m/min.
T= Tool life in minute
C= Constant
N= Index depends upon tool and work.
19. What are the factors affecting tool life?
Cutting speed, Feed and depth of cut , Tool geomentry , Tool material, Cutting fluid , Work
material, Rigidity of work, tool and machine
20. Name the various cutting tool materials.
Carbon tool steel ,High speed steel ,Cemented carbides ,Ceramics ,Diamonds
21. What are the functions of cutting fluids?
It is used to cool the cutting tool and work piece.
It lubricates the cutting tool and thus reduces the co-efficient of friction between tool and work.
It improves the surface finish as stated earlier.
It causes the chips to break up into small parts.
It protects the finished surface from corrosion.
It washes away the chips from the tool. It prevents the tool from fouling.
It prevents corrosion of work and machine
22. List the essential characteristics of a cutting fluid.
It should have good lubricating properties to reduce frictional forces and to decrease the
power consumption.
High heat absorbing capacity.
It should have a high specific heat, high heat conductivity and high film co-efficient.
High flash point.
It should be odorless
It should be non corrosive to work and tool
23. What are the causes of wear?
The tool is subjected to three important factors such as force, temperature and sliding action
due tool
24. Define machineability of metal.
Machine ability is defined as the ease with which a material can be satisfactorily machined.

Briefly, differentiate between orthogonal cutting and oblique cutting.

Sl.
No.
1.

Orthogonal cutting

Oblique cutting

The cutting edge of the tool is

The cutting edge is inclined at an acute angle
perpendicular to the cutting velocity
with the normal to the cutting velocity vector
vector.
2.
The chip flows over the tool face and The chip flows on the tool face making an
the direction of chip-flow velocity is
angel with the normal on the cutting edge.
normal to the cutting edge.
3.
The cutting edge clears the width of
The cutting edge may or may not clear the
the work piece on either ends.(i.e No width of the work piece.
side flow)
4.
The maximum chip thickness occurs
The maximum chip thickness may not occur
at its middle.
at the middle.
25. What is shear plane?
The material of work piece is stressed beyond its yield point under the compressive force. This
causes the material to deform plastically and shear off. The plastic flow takes place in a
localized region is called shear plane.
26. Define Side relief and End relief angle.
Side relief angle: It is the angle between the portion of the side flank immediately below the
side cutting edge and a line perpendicular to the base of the tool, and measured at right angle
to the side flank.
End relief angle: It is the angle between the portion of the end flank immediately below the end
cutting edge and a line perpendicular to the base of the tool, and measured at right angle to the
angle.
28. What is chip breaker?
The chip coils in a helix and curl around the work and the tool and may injure the operator in
case of continuous chip. A chip breaker is a metal piece attached to the tool, breaks the chip
and reduces the difficulties.
29. What are the major types of tool wear?
Crater wear, Flank wear and chip breakage
30. What are the variables that affect the tool life?
Cutting conditions, Tool geometry, Tool material, Work material and cutting fluid
31.Name the two systems used in metal cutting to designate the tool shape
American standards Association, Orthogonal rake system
32. Write the criteria commonly used for measuring tool life.
1. Total destruction of the tool when it ceases to cut.
2.A fixed size of wear land on tool flank.
33.What is cutting force?
The sheared material begins to flow along the cutting tool face in the form of small pieces . The
compressive force applied to form the chip is called cutting force
34. What is the function of chip breakers?
The chip breakers are used to break the chips into small pieces for removal, safety and to
prevent both the machine and work damage
35. What are the factors responsible for built-up edge in cutting tools?
During cutting process, the interface temperature and pressure are quite high and also high
friction between tool chip interfaces causes the chip material to weld itself to the tool face near
the nose. This is called built up edge
36. What are the causes of wear?
The tool is subjected to three important factors such as force, temperature and sliding action
due tool.