1 (a) Differentiate the tool coatings of Chemical Vapour Deposition (CVD) and

Physical Vapour Deposition (PVD).

CVD
Coating process that uses
thermally induced chemical
reactions at the surface of a
heated substrate, with reagents
supplied in gaseous form.
CVD processes run at much higher
temperatures
Does not require the use of
specialized precursor materials
PVD
A thin-film coating process which
produces coatings of pure metals,
metallic alloys and ceramics with a
thickness usually in the range 1 to
10µm.
PVD processes run at lower
temperatures
Use of specialized precursor
materials which are toxic,
pyrophoric, or corrosive.

1 (b) Interpret the classification of cemented carbide cutting tools.

Cemented carbides

Classification

The optimum way in which to select a tool grade is based on ISO standards. Originally.
Cemented carbide was classified into 3 groups based on the chip geometry. These groups
being P (steels), M (stainless steels), and K (cast irons).

Group P Continuous type chips. Main workplace

materials being steel and cast steel.
Group M Shear type chips. Main work piece
materials being stainless steel and high
manganese steel.
Group K Crack type chips. Main work piece
materials being cast Iron.

1 (c) (i) List down the application of Carbon Boron Nitride (CBN) cutting tools

-Grinding of hardened steel, Lead Screw, bores, splines, threads.

-Parts of ball and roller bearing
-Machining chilled cast iron, high strength and heat resistant alloys.
1 (c) (ii) List down the application of both (CBN) and polycrystalline diamond
(PCD) cutting tools

-used in cutting extremely hard materials, such as hardened steels and heat-
resistant steels.

2 (a) Solve the basic machining terminology by using diagrams. Then, explain
only two of the terminologies shown.

Turning
- a machining process in which a
cutting tool, typically a non-rotary
tool bit, describes a helix tool path
by moving more or less linearly
while the work piece rotate
Milling
- is the process of machining using
rotary cutters to remove material
by advancing a cutter into a work
piece. This may be done varying
direction on one or several axes,
cutter head speed, and pressure.
3 (a) Asses the influence and interrelationship between factors and machining
operations for the three types of chips.

Continuous chips Discontinuous chips Continuous chips with

built up edge
Factor Factor Factor
- Work piece should have - The work piece should -Cutting of ductile metal.
ductile in nature. have brittle in nature. -High friction force at the
- Proper use of coolant - Slow speed of cutting face of tool.
and lubricant. - Depth of cut should -High temperature
- Tool should have low large between tool and work
coefficient of friction. - Small rack angle of tool piece.
-Lack of coolant and
lubricant

-From above the influence and interrelationship between factors and machining operations
for the three types of chips are Ductile material are become the influence for Continuous
chips, Discontinuous chips and Continuous chips with built up edge forming. The ductile
material type become same factors for all three types of chips.

3 (b) Recommend a solution to reduce Built-Up-Edge (BUE) chips from

happening.

-Reduce the friction force between tool and work piece.

-Provide the coolant and lubricant during cutting process.
-Use high of cutting speed to prevent the built up edge forming.
-Use high rack angle in cutting process.

3 (c) Discuss the formation of Discontinuous Chips in a turning operation and

the conditions that make it happen.

- This chips form in segment. It is form when machining of brittle material like
cast iron, brass etc. with slow cutting speed. Chips cut into small segment during
cutting.
-This is formed during slow cutting speed with small rack angle. This chips form
in ductile material when the friction between tool and work piece is high.
Discontinuous chips in ductile material give poor surface finish and slow
machine. It is suitable form of chips of machining brittle material.
4 (a) Discuss three major causes and modes of cutting tool failure. Suggest
ONE way to avoid such cause and failure.

- Built-Up Edge Formation:

Built-up edge means the adhesion of work material on the rake face of the
cutting tool near the cutting edge. It occurs frequently while machining softer or
ductile metals at lower cutting speeds. For example, low carbon steel, aluminum
and copper.

- Plastic Deformation of Cutting Edge:

Due to high temperature, the geometry of the cutting edge (nose radius) is
completely changed. This phenomenon is known as plastic deformation of
cutting edge.

-Micro Chipping of Cutting Edge:

The breaking away of a small piece from the cutting edge of the tool is known as
chipping. This phenomenon is similar to breaking the tip of a sharp pencil. The
chipped pieces may be very small (macro-chipping or micro-chipping) or
relatively large (gross chipping or fracture).

The way to avoid such cause and failure are use tougher grade of carbide as tool
material and use proper coolant or lubricant.
4 (b) Suggest three machining conditioning monitoring systems that can be
applied in industries
- Tool Condition monitoring system (TCM)
- Tool Wear Monitoring System
- Machine monitoring with smart sensors system

4 (c) Suggest two sensors that can be used for an indirect tool wear monitoring
technique. Discuss the effectiveness for one of the sensors.

-Dynamometer
-Thermocouple

Dynamometer is a device for measuring force, moment of force (torque), or

power. Used in analyzing, comparing and selecting materials, tools and
machines. Additional areas of application result from defining optimum cutting
conditions, analyzing the breakage behavior of tools and the chip formation
process and their influence on cutting forces.

5 (a) Plot the Taylor’s tool wear curves for three different cutting speed.
Suggest ONE important conclusion that can be drawn from the curve.

From the graph, cutting speed are the important things that will determine the
tool life. This is because the increase in cutting speed will decrease in tool life
and the decrease in cutting speed will increase in tool life.
5 (b) (iii) Suggest in detail one solution that can be used to predict the wear on
cutting tool.

- Use Artificial Neural Networks that detect cutting forces and acceleration of
mechanical vibrations which are used to monitor the tool wear process.

Types of tool:
Strategy for milling thin wall:
 Helical milling to depth.
 Milling is performed at the centre of base, spiraling-down.
 Milling outward in a ‘flattened helical manner’ from that point.