Cutting Tools (Pages 832 - 859)

Question 1

Question: What are the various forms used to place cutting edges in convenient positions for different surfaces?

a) Straight, bent, offset, and other forms
b) Straight, circular, triangular, and star-shaped forms
c) Vertical, horizontal, diagonal, and curved forms
d) Rectangular, cylindrical, spherical, and pyramid forms

Answer 1

Answer: a) Straight, bent, offset, and other forms

Question 2

Question: What is the effect of increasing the side cutting-edge angle or nose radius on a roughing tool?

a) It reduces the cutting speed
b) It increases the feed rate
c) It permits higher cutting speeds
d) It has no effect on the tool’s performance

Answer 2

Answer: c) It permits higher cutting speeds

Question 3

Question: What is the main body of a single-point tool called?

a) Insert
b) Nose
c) Shank
d) Base

Answer 3

c) Shank

Question 4

Question: Which surface of the tool bears against the supporting tool holder or block?
Options:
a) Face
b) Flank
c) Base
d) Nose

Answer 4

Answer: c) Base

Question 5

Refer to image from page 832

Answer 5

N/A

Question 6

Question: What is the term applied to tools for turning, planing, boring, etc., which has a cutting edge at one end?

a) Shank
b) Single-Point tool
c) Nose
d) Flank

Answer 6

b) Single-Point tool

Question 7

Question: In the image, which cutting edge is primarily responsible for performing the majority of the cutting?
Options:
a) Nose
b) End Cutting Edge
c) Side Cutting Edge
d) Flank

Answer 7

c) Side Cutting Edge

Question 8

Question: Which cutting edge is primarily employed for tasks such as light plunging and facing cuts?
Options:
a) Nose
b) Side Cutting Edge
c) Flank
d) End Cutting Edge

Answer 8

d) End Cutting Edge

Question 9

Question: What is the term for the surface where chips are severed during turning or planing operations?
Options:
a) Nose
b) Flank
c) Base
d) Face

Answer 9

d) Face

Question 10

Question: Which term refers to the end surface adjacent to the cutting edge and below it when the tool is in a horizontal position for turning?
Options:
a) Nose
b) Flank
c) Base
d) Face

Answer 10

b) Flank

Question 11

Question: What term is sometimes used to designate the rounded tip of the cutting end?
Options:
a) Nose
b) Flank
c) Base
d) Face

Answer 11

a) Nose

Question 12

Question: What is rake in a metal-cutting tool, and how is it measured?
Options:
a) The inclination of the tool face, measured by back rake and side rake angles.
b) The keenness of the cutting edge, measured by relief angles.
c) The angle between the side cutting edge and the base.
d) The radius of the tool’s nose.

Answer 12

a) The inclination of the tool face, measured by back rake and side rake angles.

Question 13

Question: How is positive rake defined in relation to a tool’s face inclination?
Options:
a) It makes the cutting edge keener.
b) It makes the cutting edge blunter.
c) It has no effect on the cutting edge.
d) It only affects the tool’s nose.

Answer 13

Answer: a) It makes the cutting edge keener.

Question 14

Question: What is negative rake?
Options:
a) A type of cutting edge angle.
b) An inclination that makes the cutting edge keener.
c) An inclination that makes the cutting edge blunter.
d) The side cutting edge angle.

Answer 14

Answer: c) An inclination that makes the cutting edge blunter.

Question 15

Question: Define the back rake of a tool.
Options:
a) It’s the inclination of the face toward the end cutting edge.
b) It’s the inclination of the face away from the side cutting edge.
c) It’s the inclination of the face toward the base.
d) It’s the inclination of the face away from the end cutting edge.

Answer 15

Answer: d) It’s the inclination of the face away from the end cutting edge.

Question 16

Question: What does the side rake angle measure?
Options:
a) The angle between the side cutting edge and the base.
b) The inclination of the face toward the side cutting edge.
c) The inclination of the face away from the side cutting edge.
d) The angle of the end cutting edge with respect to the base.

Answer 16

Answer: b) The inclination of the face toward the side cutting edge.

Question 17

Question: What is the purpose of relief in a cutting tool?
Options:
a) To create a smoother finish on the workpiece.
b) To allow the cutting edges to penetrate into the workpiece.
c) To control the tool’s nose radius.
d) To measure the end relief angle.

Answer 17

Answer: b) To allow the cutting edges to penetrate into the workpiece.

Question 18

Question: How is the end relief angle defined?
Options:
a) The angle between the side cutting edge and the base.
b) The measure of the relief below the end cutting edge.
c) The inclination of the face away from the side cutting edge.
d) The radius of the tool’s nose.

Answer 18

Answer: b) The measure of the relief below the end cutting edge.

Question 19

Question: How is the side rake angle measured?
Options:
a) In a plane perpendicular to the base.
b) In a plane parallel to the base.
c) In a plane perpendicular to the side cutting edge.
d) In a plane parallel to the side cutting edge.

Answer 19

Answer: a) In a plane perpendicular to the base.

Question 20

What is the back rake angle, and how is it measured?

A) An angle that defines the side cutting edge’s sharpness.
B) An angle that measures the tool’s inclination.
C) An angle measured by the inclination of the side cutting edge with respect to a line or plane parallel to the base.
D) An angle used to determine the tool’s length.

Answer 20

C) An angle measured by the inclination of the side cutting edge with respect to a line or plane parallel to the base.

Question 21

What does the side rake angle measure?

A) The angle between the side cutting edge and a plane parallel to the workpiece.
B) The sharpness of the tool’s nose.
C) The angle of inclination of the face perpendicular to the side cutting edge.
D) The tool’s overall length.

Answer 21

C) The angle of inclination of the face perpendicular to the side cutting edge.

Question 22

Why is the end cutting edge angle provided in a tool?

A) To control the tool’s overall length.
B) To clear the finish-machined surface on the workpiece.
C) To measure the side relief angle.
D) To determine the tool’s back rake angle.

Answer 22

B) To clear the finish-machined surface on the workpiece.

Question 23

What is the purpose of the side cutting edge angle?

A) To measure the tool’s overall length.
B) To determine the lead angle.
C) To measure the angle made by the side cutting edge with a plane parallel to the base.
D) To control the tool’s diameter.

Answer 23

C) To measure the angle made by the side cutting edge with a plane parallel to the base.

Question 24

What is the lead angle, and how does it influence a tool’s performance?

A) An angle that measures the tool’s back rake.
B) An angle that determines the side relief.
C) A tool-setting angle that affects performance, bounded by the side cutting edge and a plane perpendicular to the workpiece surface.
D) An angle used to control the tool’s length.

Answer 24

C) A tool-setting angle that affects performance, bounded by the side cutting edge and a plane perpendicular to the workpiece surface.

Question 25

What is the nose radius of a tool, and why is it important for the tool’s performance?

A) The radius of the tool’s handle.
B) The radius of the tool’s cutting edge.
C) The radius of the tool’s nose, and it has a specific influence on the tool’s performance.
D) The radius of the tool’s shank.

Answer 25

C) The radius of the tool’s nose, and it has a specific influence on the tool’s performance, such as:

Surface Finish: A smaller nose radius results in a finer surface finish on the workpiece. The tool can produce smoother surfaces, which is crucial for precision machining and achieving the desired workpiece quality.

Tool Life: The nose radius affects the tool’s longevity. A larger nose radius tends to distribute cutting forces more evenly across the tool’s cutting edge, which can lead to longer tool life. Conversely, a smaller nose radius concentrates forces on a smaller area, causing quicker wear.

Cutting Speed: The nose radius can impact the cutting speed. Larger nose radii can allow for increased cutting speeds, which can enhance productivity. Smaller nose radii might require reduced cutting speeds to avoid excessive tool wear.

Chatter Resistance: Chatter, or vibrations during cutting, can be influenced by the nose radius. A tool with a large nose radius is less prone to chatter, providing more stable and predictable machining.

Chip Control: The nose radius also plays a role in chip control. A larger nose radius can help in breaking chips into smaller, more manageable pieces, which is crucial for efficient chip evacuation and improved machining.

In summary, the nose radius significantly impacts surface finish, tool life, cutting speed, chatter resistance, and chip control, making it a critical factor in optimizing a cutting tool’s performance for specific machining applications.

Question 26

What is a solid tool?

A) A tool made from one piece of material
B) A tool with multiple interchangeable parts
C) A tool that requires constant sharpening
D) A tool used for non-cutting operations

Answer 26

A) A tool made from one piece of material

A solid tool is a single-piece cutting tool.

Question 27

What is a brazed tool?

A) A tool that can be easily disassembled
B) A tool with no cutting edges
C) A tool permanently joined with a steel shank
D) A tool with no shank

Answer 27

C) A tool permanently joined with a steel shank

A brazed tool has a blank of cutting material attached to a steel shank through brazing.

Question 28

What is a blank in the context of cutting tools?

A) A tool with a worn-out cutting edge
B) A tool with multiple cutting edges
C) An unground piece of cutting-tool material
D) A tool used for turning operations

Answer 28

C) An unground piece of cutting-tool material

A blank is an unprocessed piece of material used to create a brazed tool

Question 29

What is the primary intention of a dull tool bit, a relatively small cutting tool?

A) To create complex shapes on workpieces
B) To be periodically replaced with a new bit
C) To be reground
D) To act as an extended shank for the tool holder

Answer 29

C) To be reground

A tool bit is a relatively small cutting tool designed to be clamped to a holder in such a way that it can readily be removed and replaced when it becomes dull, and it is intended to be reground for extended use.

Question 30

What is a tool-bit holder used for?

A) To replace tool bits easily
B) To create complex shapes on workpieces
C) To permanently fix the tool bit
D) To extend the shank and clamp the tool bit

Answer 30

D) To extend the shank and clamp the tool bit

The tool-bit holder holds the tool bit, acts as an extended shank, and provides clamping.

Question 31

What’s the difference between a straight-shank tool-bit holder and an offset-shank tool-bit holder?

A) The material they’re made of
B) The size of the tool bit they hold
C) The angle of the tool bit with respect to the shank
D) The number of cutting edges they have

Answer 31

C) The angle of the tool bit with respect to the shank

A straight-shank holder has a straight shank, while an offset-shank holder has a bent shank.

Question 32

What is a side cutting tool?

A) A tool used exclusively for cutting metal
B) A tool with no cutting edges
C) A tool with a major cutting edge on the side
D) A tool for finishing operations

Answer 32

C) A tool with a major cutting edge on the side

A side cutting tool’s primary cutting edge is on the side of the tool.

Question 33

What are indexable inserts used for?

A) To create complex shapes on workpieces
B) To hold cutting tools
C) To have multiple interchangeable parts
D) To provide sharp cutting edges until dull

Answer 33

D) To provide sharp cutting edges until dull

Indexable inserts have multiple edges and are rotated to use a sharp edge.

Question 34

What is an indexable insert holder used for?

A) To store indexable inserts
B) To create complex shapes on workpieces
C) To hold and firmly clamp indexable inserts
D) To permanently attach inserts

Answer 34

C) To hold and firmly clamp indexable inserts

Indexable insert holders securely hold indexable inserts for machining.

Question 35

What distinguishes a straight-shank indexable insert holder from an offset-shank holder?

A) The size of the indexable insert
B) The number of cutting edges
C) The material they’re made of
D) The orientation of the insert with respect to the holder’s axis

Answer 35

D) The orientation of the insert with respect to the holder’s axis

A straight-shank holder has a straight top view, while an offset-shank holder has the insert pocket offset.

Question 36

What type of tool has its major cutting edge on the end of the cutting part of the tool?

A) Curved Cutting-Edge Tool
B) Right-Hand Tool
C) End Cutting Tool
D) Neutral-Hand Tool

Answer 36

C) End Cutting Tool

(End cutting tools have their major cutting edge on the end of the cutting part.)

Question 37

Which tool features a continuously variable side cutting edge angle, usually in the form of a smooth, continuous curve?

A) Right-Hand Tool
B) Left-Hand Tool
C) End Cutting Tool
D) Curved Cutting-Edge Tool

Answer 37

D) Curved Cutting-Edge Tool

(Curved cutting-edge tools have a continuously variable side cutting edge angle and a smooth, continuous curve along their length.)

Question 38

What is a tool called when its major, or working, cutting edge is on the right-hand side when viewed from the cutting end with the face up, typically used for right-to-left feeding in a lathe?

A) Curved Cutting-Edge Tool
B) Neutral-Hand Tool
C) Right-Hand Tool
D) Left-Hand Tool

Answer 38

C) Right-Hand Tool (Right-hand tools have the major cutting edge on the right side for right-to-left feeding.)

Question 39

Which type of tool has its major or working cutting edge on the left-hand side when viewed from the cutting end with the face up, typically used for left-to-right feeding in a lathe?

A) Curved Cutting-Edge Tool
B) Neutral-Hand Tool
C) Right-Hand Tool
D) Left-Hand Tool

Answer 39

D) Left-Hand Tool (Left-hand tools have the major cutting edge on the left side for left-to-right feeding.)

Question 40

What kind of tool is designed to cut either from left to right or right to left, or make cuts parallel to the axis of the shank?

A) Right-Hand Tool
B) Neutral-Hand Tool
C) End Cutting Tool
D) Left-Hand Tool

Answer 40

B) Neutral-Hand Tool (Neutral-hand tools can cut in either direction or parallel to the axis of the shank.)

Question 41

What is the purpose of a chipbreaker on a turning tool?

A) To create long, continuous chips
B) To make cutting operations faster
C) To minimize operator safety risks
D) To speed up the feed rate

Answer 41

C) To minimize operator safety risks

(Chipbreakers prevent the formation of long, continuous chips that can be dangerous to the operator.)

Question 42

Why are the size of relief angles crucial in the performance of cutting tools?

A) To minimize material waste
B) To control chip size
C) To strengthen the cutting edge
D) To avoid issues with size control

Answer 42

D) To avoid issues with size control

(Relief angles significantly impact the cutting tool’s performance, affecting issues like rapid wear of the cutting edge and size control.)

Question 43

When cutting hard and tough materials with high-speed steel tools, what is the recommended range for relief angles?

A) 1 to 3 degrees
B) 6 to 8 degrees
C) 8 to 12 degrees
D) 12 to 16 degrees

Answer 43

B) 6 to 8 degrees

(For hard and tough materials, high-speed steel tools should have relief angles in the range of 6 to 8 degrees.)

Question 44

What is the suggested range of relief angles for high-speed steel tools when working with medium steels, mild steels, cast iron, and similar materials?

A) 1 to 3 degrees
B) 6 to 8 degrees
C) 8 to 12 degrees
D) 12 to 16 degrees

Answer 44

C) 8 to 12 degrees

(Medium steels and similar materials require high-speed steel tools with relief angles in the range of 8 to 12 degrees.)

Question 45

For which type of materials should larger relief angles be used when cutting with high-speed steel tools?

A) Hard and tough materials
B) Soft materials
C) Non-ferrous metals
D) Plastics

Answer 45

A) Hard and tough materials
(Larger relief angles are recommended for cutting hard and tough materials with high-speed steel tools.)

Question 46

What advantage do larger relief angles generally provide when machining a finish surface?

A) Smoother surface finish
B) Faster machining speed
C) Reduced tool wear
D) Greater tool life

Answer 46

A) Smoother surface finish (Larger relief angles help produce a smoother finish on the machined surface by reducing the rubbing of the worn tool flank.)

Question 47

Why should relief angles never be smaller than necessary when using cutting tools?

A) To reduce the tool’s cost
B) To simplify tool manufacturing
C) To prevent chip breakage
D) To ensure the tool’s longevity and performance

Answer 47

D) To ensure the tool’s longevity and performance

(Smaller relief angles can lead to problems with tool wear and longevity.)

Question 48

What occurs when the relief angle is too large for a cutting tool?

A) Improved chip control
B) Weakening of the cutting edge
C) Enhanced surface finish
D) Reduced tool wear

Answer 48

B) Weakening of the cutting edge

(Excessive relief angles can weaken the cutting edge, making it more susceptible to breaking under heavy loads.)

Question 49

How should ductile materials be cut, and can you provide an example of such a material?

A) Use smaller relief angles for ductile materials
B) Use larger relief angles for ductile materials
C) Use high-speed steel tools for ductile materials
D) Use carbide tools for ductile materials

Answer 49

B) Use larger relief angles for ductile materials

For example: the relief angles recommended for turning copper, brass, bronze, aluminum

Question 50

What is the recommended range for the relief angle of carbide tools used for hard materials?

A) 1 to 3 degrees
B) 5 to 7 degrees
C) 8 to 12 degrees
D) 12 to 16 degrees

Answer 50

B) 5 to 7 degrees

(Carbide tools for hard materials should have relief angles in the range of 5 to 7 degrees.)

Question 51

What should be the relief angle for carbide tools used for medium materials?

A) 1 to 3 degrees
B) 5 to 7 degrees
C) 8 to 12 degrees
D) 12 to 16 degrees

Answer 51

B) 5 to 10 degrees

(Carbide tools for medium materials should have relief angles in the range of 5 to 10 degrees.)

Question 52

How are cutting force and temperature affected when the true rake angle is increased in the positive direction along which chips slide?

A) They increase.
B) They decrease.
C) There is no effect.
D) Cutting force increases, but temperature decreases.

Answer 52

B) They decrease.

(An increase in the true rake angle in the positive direction results in decreased cutting force and temperature.)

Question 53

What are the effects of increasing the side rake angle in the positive direction on cutting force, temperature, tool life, and permissible cutting speed?

A) Cutting force and temperature increase, tool life decreases, and permissible cutting speed decreases.
B) Cutting force and temperature decrease, tool life increases, and permissible cutting speed increases.
C) Cutting force and temperature decrease, but tool life and permissible cutting speed also decrease.
D) Cutting force and temperature increase, while tool life and permissible cutting speed increase.

Answer 53

B) Cutting force and temperature decrease, tool life increases, and permissible cutting speed increases.

(Increasing the side rake angle in the positive direction reduces cutting force and temperature, resulting in a longer tool life and a higher permissible cutting speed, up to an optimum value.)

Question 54

What is the approximate change in cutting force per degree increase in side rake angle?

A) About 10%
B) Approximately 1%
C) Around 5%
D) Roughly 20%

Answer 54

B) Approximately 1%

(Roughly, cutting force decreases by about 1% per degree increase in side rake angle.)

Question 55

When is it recommended to use negative rake angles on single-point cutting tools?

A) For turning soft materials
B) For turning hard materials
C) For turning materials with medium hardness
D) For taking light finishing cuts

Answer 55

B) For turning hard materials

(Negative rake angles are typically used for turning very hard materials and for heavy interrupted cuts.)

Question 56

What is the primary effect of the back rake angle on turning tools that cut primarily with the side cutting edge?

A) It increases cutting force and temperature.
B) It decreases cutting force and temperature.
C) It strengthens the nose of the tool.
D) It has no significant effect.

Answer 56

D) It has no significant effect.

(For turning tools that cut primarily with the side cutting edge, the back rake angle has a minimal effect on performance.)

Question 57

How does a negative back rake angle impact end cutting edge tools, like cut-off tools?

A) It has no effect.
B) It strengthens the cutting edge.
C) It increases tool life.
D) It reduces tool life.

Answer 57

B) It strengthens the cutting edge.

(A negative back rake angle on end cutting edge tools strengthens the cutting edge, making it suitable for taking heavy interrupted cuts.)

Question 58

When is the lead angle determined by the side cutting edge, and when are they equal?

A) Lead angle is determined when the shank is perpendicular to the workpiece, and they are equal in this case.
B) Lead angle is determined when the shank is perpendicular to the tool holder, and they are equal in this case.
C) Lead angle is determined by the cutting tool’s shape, and they are equal when the tool is positioned horizontally.
D) Lead angle is always determined by the side cutting edge, and they are equal in all cases.

Answer 58

A) Lead angle is determined when the shank is perpendicular to the workpiece, and they are equal in this case.

(This context helps you understand when the lead angle and side cutting edge are equal.)

Question 59

How does increasing the lead angle affect the chips and tool performance?

A) It makes chips shorter and thicker, reducing tool life.
B) It makes chips longer and thinner, increasing tool life and permitting higher cutting speeds.
C) It has no significant impact on chips or tool performance.
D) It causes the tool to overheat.

Answer 59

B) It makes chips longer and thinner, increasing tool life and permitting higher cutting speeds. (Understanding how the lead angle influences chips and tool performance is important.)

Question 60

What adverse effect can a high lead angle of the side cutting edge have, and what can remedy it?

A) It causes tool wear, and the remedy is to decrease the feed rate.
B) It leads to a smoother finish, and the remedy is to increase the depth of cut.
C) It can cause chatter, and often reducing the lead angle can cure it.
D) It enhances tool life, and the remedy is to maintain a high lead angle.

Answer 60

C) It can cause chatter, and often reducing the lead angle can cure it.

(Understanding the effect of a high lead angle and the remedy for chatter is crucial.)

Question 61

Why can boring bars be susceptible to chatter, and what lead angle is recommended for very long and slender boring bars?

A) They are too short, and zero-degree lead angle is recommended.
B) They are not suitable for machining, and higher lead angles should be used.
C) They are usually long and slender, and a small lead angle is recommended.
D) They are too rigid, and a larger lead angle is recommended.

Answer 61

C) They are usually long and slender, and a small lead angle is recommended.

(Understanding why boring bars are susceptible to chatter and the recommended lead angle is crucial.)

Question 62

What factors should be considered to prevent chatter caused by the lead angle, and why might reducing the lead angle cure it?

A) Part size, workpiece holding, and machine rigidity; reducing lead angle affects chip formation.
B) Tool material, part size, and workpiece holding; reducing lead angle increases tool life.
C) Material hardness, cutting speed, and chip formation; reducing lead angle reduces tool wear.
D) Part size, tool material, and workpiece holding; reducing lead angle avoids tool overheating.

Answer 62

A) Part size, workpiece holding, and machine rigidity; reducing lead angle affects chip formation.

A part that is firmly held is less apt to chatter. A) Yes, because larger lead angles are advantageous for tool life and productivity. Page 837

Question 63

What’s the significance of the end cutting edge angle and its connection to cratering in cutting tools?

A) It affects chip thickness and is crucial during cratering for tool longevity.
B) The angle influences surface aesthetics and minimizes tool wear.
C) It’s primarily for optimizing cutting speed and coolant use.
D) The angle helps reduce chatter and tool maintenance.

Answer 63

A) It affects chip thickness and is crucial during cratering for tool longevity.

Comment: The end cutting edge angle plays a vital role in chip formation and controlling tool wear, particularly during cratering. Understanding its impact is essential for tool longevity.

Question 64

During cratering, why would you reduce the end cutting edge angle, and what’s the recommended range in such cases?

A) To maximize tool life; 1 to 4 degrees.
B) To enhance the surface finish; 30 to 40 degrees.
C) To delay the occurrence of crater breakthrough; 8 to 15 degrees.
D) To achieve higher cutting speed; 50 to 60 degrees.

Answer 64

C) To delay the occurrence of crater breakthrough; 8 to 15 degrees.

Comment: Reducing the end cutting edge angle helps delay the occurrence of crater breakthrough, a common issue during machining. The recommended range offers guidance to mitigate this problem.

Question 65

What role does a nose radius play in cutting tools, and how does it impact surface finish and tool performance?

A) It reduces chatter and extends tool life.
B) It shapes chips, enabling faster feed rates and better finishes.
C) It improves coolant efficiency and tool durability.
D) It influences material hardness and accelerates cutting.

Answer 65

B) It shapes chips, enabling faster feed rates and better finishes.

Comment: The nose radius is integral to shaping chips and, consequently, enhancing surface finish and enabling higher feed rates. It’s a key factor in tool performance and longevity.

Question 66

What factors influence surface finish when utilizing a nose radius, and how does an increased nose radius affect tool behavior?

A) Cutting speed and coolant; a larger nose radius decreases tool wear.
B) Feed rate and nose radius; a larger nose radius improves surface finish and allows higher feed rates.
C) Material hardness and tool material; a large nose radius eliminates the need for coolant.
D) Nose radius and cutting speed; a larger nose radius reduces tool temperature.

Answer 66

B) Feed rate and nose radius; a larger nose radius improves surface finish and allows higher feed rates.

Comment: A nose radius can become too large however, the interaction between feed rate and nose radius is crucial for achieving improved surface finishes. Furthermore, understanding the effects of an increased nose radius on tool behavior is valuable in tool selection and optimization.

Question 67

Why should an excessively large nose radius be avoided, and how does it contribute to chatter during machining?

A) An excessive radius increases tool temperature, and there’s no limit to its size.
B) An excessive radius helps eliminate chatter, and larger is always better.
C) Chatter occurs with a very large radius, and there is a limit to its size.
D) A very large radius reduces tool wear, and there’s no need for a size limit.

Answer 67

C) Chatter occurs with a very large radius, and there is a limit to its size.

Comment: An excessively large nose radius can lead to chatter during machining, an undesired outcome. Knowing the reasons to avoid it is key to preventing tool instability.

Question 68

What benefits are associated with maximizing the nose radius in cutting tools?

A) A larger radius reduces tool life and accelerates feed rates.
B) A larger radius minimizes cutting speed but optimizes tool wear.
C) A larger radius offers a better surface finish and extends tool life.
D) A larger radius always results in chatter and should be avoided.

Answer 68

Comment: Maximizing the nose radius offers numerous advantages, such as improved surface finish and extended tool life. However, there are considerations, like chatter, that come into play when determining the ideal nose radius.

Question 69

When might larger end cutting edge angles be required?

A) For increasing tool chatter.

B) To optimize tool longevity and reduce cratering.

C) For improved surface finish on all workpieces.

D) To enable profile turning tools to plunge into the work without interference from the end cutting edge.

Answer 69

D) To enable profile turning tools to plunge into the work without interference from the end cutting edge.

Comment: Understanding when larger end cutting edge angles are necessary is essential for specific machining requirements, particularly in cases where profile turning tools need to avoid interference from the end cutting edge.

Question 70

What practice is generally advisable regarding the nose radius in cutting tools?

A) Always use the smallest nose radius.
B) Maximize the nose radius for all operations.
C) Use the largest compatible nose radius.
D) Disregard the nose radius’s influence.

Answer 70

C) Use the largest compatible nose radius.

Comment: The largest you can without hearing chatter

Question 71

What are the consequences of making the tool nose into a sharp point?

A) Improved tool life and heat generation.
B) Acceptable surface finish and reduced tool life.
C) Enhanced chip formation and better feed rates.
D) Reduced chip control and rougher finishes.

Answer 71

B) Acceptable surface finish and reduced tool life.

Comment: Understanding the consequences of having a sharp-pointed tool nose is essential for optimizing tool performance.

Question 72

When the crater enlarges, where does it typically break through?

A) The tool’s middle section.
B) The tool shank.
C) The side of the workpiece.
D) Just behind the tool’s nose.

Answer 72

D) Just behind the tool’s nose.

Comment: Identifying the specific location where craters usually break through provides insights into the wear patterns of cutting tools during machining.

Question 73

What is the primary purpose of chipbreakers on steel turning tools?

A) To enhance surface finish.

B) To twist and reshape chips for easier handling.

C) To prevent the formation of long, continuous chips and improve safety.

D) To increase cutting speed.

Answer 73

C) To prevent the formation of long, continuous chips and improve safety.

Comment: Chipbreakers on steel turning tools serve the crucial function of preventing the formation of long, continuous chips, which is essential for safety and efficient machining.

Question 74

What angle is commonly associated with the Angular Shoulder Type of chipbreaker, and why does it vary?

A) 1 degree, for improved chip control.

B) 30 degrees, for higher feed rates.

C) 8 degrees, dependent on various factors.

D) 90 degrees, to force chips against the work.

Answer 74

C) 8 degrees, dependent on various factors.

Comment: The Angular Shoulder Type chipbreaker typically has an angle of 8 degrees, although it may vary based on factors such as speed, feed, depth of cut, and material. It ranges from 6 to 15 Understanding the variations is essential for effective chip control

Question 75

What width is typical for the end of the tool in the Parallel Shoulder Type of chipbreaker (diagram C Page 838)?

A) 3⁄32 inch (2.4 mm)

B) 7⁄32 inch (5.6 mm)

C) 1⁄16 inch (1.59 mm)

D) 1⁄32 inch (0.79 mm)

Answer 75

C) 1⁄16 inch (1.59 mm).

Comment: For the Parallel Shoulder Type chipbreaker, a typical width at the end of the tool is 1⁄16 inch (1.59 mm). Understanding these dimensions is crucial for effective machining.

Question 76

What finish should be given to chipbearing surfaces in grinding chipbreakers?

A) A coarse finish to improve chip grip.

B) A rough finish for better chip control.

C) A fine finish, similar to honing.

D) A polished finish to resist chip buildup.

Answer 76

C) A fine finish, similar to honing.

Comment: The chipbearing surfaces in grinding chipbreakers should have a fine finish, similar to honing, to improve their performance and longevity.

Question 77

In the Angular shoulder type, where is the chipbreaking shoulder located?

A) At the nose of the tool.

B) Back of the cutting edge.

C) On the cutting edge.

D) At the tool’s shank.

Answer 77

B) Back of the cutting edge.

Comment: Understanding the location of the chipbreaking shoulder in the Angular shoulder type is essential for effective chip control.

Question 78

For example, in a parallel shoulder, and a design where the chipbreaking shoulder is parallel with the cutting edge, how do the chips come off?

A) In long continuous sections.

B) In short curled sections.

C) They become twisted around the tool.

D) They adhere to the workpiece.

Answer 78

B) In short curled sections.

Comment: The design with a chipbreaking shoulder that is parallel with the cutting edge results in chips coming off in a specific manner. Knowing this helps optimize machining processes.

Question 79

What is the tendency of a parallel shoulder form?

A) To minimize the tendency for chips to damage the work.

B) To force the chips against the work.

C) To encourage the formation of long, continuous chips.

D) To have no effect on chip behavior.

Answer 79

B) To force the chips against the work.

Question 80

Where can the parallel form also be applied?

A) Only on straight tools.

B) On tools with side cutting-edge angles.

C) On all types of turning tools.

D) Only on tapered tools.

Answer 80

On tools with side cutting-edge angles.

Question 81

Where is the groove in the groove type, and how is it produced?

A) It’s parallel to the cutting edge and produced by grinding.

B) It’s located at the nose of the tool and produced through casting.

C) It’s near the tool’s shank and created using heat treatment.

D) There is no groove in the groove type.

Answer 81

A) It’s parallel to the cutting edge and produced by grinding.

Question 82

What influences the amount of rake in planing tools?

A) The tool’s color.

B) The direction of the grinding wheel.

C) The hardness of the material.

D) The tool’s size.

Answer 82

C) The hardness of the material.

Question 83

What is the recommended angle of clearance for planer tools, and how does it compare to lathe tools?

A) About 4 or 5 degrees, which is greater than for lathe tools.

B) About 4 or 5 degrees, which is the same as for lathe tools.

C) About 10 degrees, which is greater than for lathe tools.

D) About 1 or 2 degrees, which is less than for lathe tools.

Answer 83

A) About 4 or 5 degrees, which is greater than for lathe tools.

Question 84

What type of rake is commonly found in carbide tools for planing?

A) Positive rake.

B) Neutral rake.

C) Negative rake.

D) Zero rake.

Answer 84

C) Negative rake.

Question 85

For round-nose and square-nose end-cutting tools, what is the recommended “negative back rake”?

A) 10 degrees.

B) 2 or 3 degrees.

C) 5 degrees.

D) 0 degrees.

Answer 85

B) 2 or 3 degrees.

Question 86

What are the recommended negative rake angles for side cutting tools for planing?

A) Negative back rake of 1 degree, negative side rake of 5 degrees, and a side cutting-edge angle of 10 degrees.

B) Negative back rake of 10 degrees, negative side rake of 5 degrees, and a side cutting-edge angle of 8 degrees.

C) Negative back rake of 5 degrees, negative side rake of 2 degrees, and a side cutting-edge angle of 15 degrees.

D) Negative back rake of 2 degrees, negative side rake of 8 degrees, and a side cutting-edge angle of 5 degrees.

Answer 86

B) Negative back rake of 10 degrees, negative side rake of 5 degrees, and a side cutting-edge angle of 8 degrees.

Question 87

In what direction should the rake face while using a planing tool?

A) Towards the operator.

B) Towards the workpiece.

C) Perpendicular to the workpiece.

D) Away from the workpiece.

Answer 87

D) Away from the workpiece.

Question 88

Why is a small clearance allowable for a planing tool?

A) It allows for faster cutting speeds.

B) Planer tools are larger than lathe tools.

C) Planer tools are held at a constant position.

D) It accommodates different tool sizes.

Answer 88

C) Planer tools are held at a constant position.

Question 89

What is a planing tool used for in machining?

A) Making holes and bores.

B) Producing threads and threads.

C) Shaping flat surfaces.

D) Cutting internal grooves.

Answer 89

C) Shaping flat surfaces.