clearance cutter Interview Questions and Answers

1. What is a clearance cutter?

   • Answer: A clearance cutter is a type of cutting tool used to remove large amounts of material quickly and efficiently. They are characterized by their wide cutting width and often aggressive cutting geometry, making them ideal for roughing operations and stock removal.

2. What are the different types of clearance cutters?

   • Answer: Types include face mills, shell mills, end mills (with large diameter and high feed rates), and slotting cutters. Specific designs vary based on application and material.

3. Explain the importance of proper chip evacuation in clearance cutting.

   • Answer: Proper chip evacuation is crucial to prevent chip re-cutting, which can lead to poor surface finish, tool damage, and reduced tool life. Effective chip evacuation requires appropriate cutter design, coolant application, and machine settings.

4. How do you select the appropriate clearance cutter for a specific application?

   • Answer: Selection depends on factors like material being machined, depth of cut, desired surface finish, machine capabilities, and available tooling. Consider cutter diameter, number of teeth, cutting geometry, and material composition.

5. Describe the relationship between cutting speed, feed rate, and depth of cut in clearance cutting.

   • Answer: These are interdependent. Higher cutting speeds generally require lower feed rates and depths of cut to avoid excessive tool wear and heat generation. Conversely, lower speeds allow for greater feed rates and depths of cut but may reduce efficiency.

6. What are the common problems encountered during clearance cutting and how can they be addressed?

   • Answer: Common problems include chatter, excessive tool wear, poor surface finish, and broken tools. These can be addressed by optimizing cutting parameters, using appropriate cutting fluids, ensuring proper machine setup and rigidity, and selecting the right cutter for the job.

7. What is the role of cutting fluid in clearance cutting?

   • Answer: Cutting fluid lubricates the cutting edges, cools the workpiece and tool, and helps with chip evacuation. The type of fluid depends on the material being machined.

8. How do you inspect a clearance cutter for wear?

   • Answer: Inspection involves checking for chipping, wear on cutting edges, cracks, and overall dimensional changes. Microscopic examination may be necessary for detailed analysis.

9. Explain the concept of "chatter" in machining and how it relates to clearance cutting.

   • Answer: Chatter is a self-excited vibration that occurs during machining, resulting in poor surface finish and reduced tool life. In clearance cutting, it's particularly problematic due to the large amount of material removed and can be mitigated through proper machine setup, cutter selection, and cutting parameter optimization.

10. What safety precautions should be taken when using a clearance cutter?

    • Answer: Safety measures include wearing appropriate PPE (safety glasses, hearing protection, etc.), ensuring the machine is properly guarded, using proper work holding techniques, and following all safety procedures outlined by the manufacturer and company.

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