Answer For PAST YEAR Question
Answer For PAST YEAR Question
Answer For PAST YEAR Question
CVD PVD
Coating process that uses A thin-film coating process which
thermally induced chemical produces coatings of pure metals,
reactions at the surface of a metallic alloys and ceramics with a
heated substrate, with reagents thickness usually in the range 1 to
supplied in gaseous form. 10µm.
CVD processes run at much higher PVD processes run at lower
temperatures temperatures
Does not require the use of Use of specialized precursor
specialized precursor materials materials which are toxic,
pyrophoric, or corrosive.
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).
1 (c) (i) List down the application of Carbon Boron Nitride (CBN) 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 Milling
- a machining process in which a - is the process of machining using
cutting tool, typically a non-rotary rotary cutters to remove material
tool bit, describes a helix tool path by advancing a cutter into a work
by moving more or less linearly piece. This may be done varying
while the work piece rotate 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.
-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.
- 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.
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
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.