cutter in Interview Questions and Answers

1. What is a cutter?

   • Answer: A cutter is a cutting tool used to shape or cut material, typically in machining or woodworking. This can range from simple hand tools like chisels and knives to complex CNC-controlled milling cutters.

2. What are the different types of cutters?

   • Answer: Types of cutters vary greatly depending on the application. Examples include end mills, drills, reamers, taps, saws (circular, band, hacksaw), routers, chisels, plane blades, and many more specialized tools.

3. Explain the difference between a roughing and finishing cutter.

   • Answer: Roughing cutters remove large amounts of material quickly, prioritizing speed over precision. Finishing cutters remove small amounts of material to achieve a high degree of accuracy and surface finish.

4. What is a carbide cutter?

   • Answer: A carbide cutter is a cutting tool made with tungsten carbide, a very hard material. This makes carbide cutters extremely durable and suitable for cutting hard materials like steel and other metals.

5. What is a high-speed steel (HSS) cutter?

   • Answer: High-speed steel (HSS) cutters are made from a type of steel alloy that retains its hardness at high temperatures, allowing for faster cutting speeds compared to other steel cutters.

6. How do you choose the right cutter for a specific job?

   • Answer: Selecting the right cutter depends on several factors: the material being cut, the desired surface finish, the depth of cut, the cutting speed, the required accuracy, and the available machine.

7. What are the safety precautions when using a cutter?

   • Answer: Always wear appropriate safety equipment (eye protection, hearing protection, gloves), use the cutter at the correct speed and feed rate, ensure the workpiece is securely clamped, and never reach over a running cutter.

8. Explain the concept of cutter geometry.

   • Answer: Cutter geometry refers to the shape and angles of the cutting edges of a tool. These angles (e.g., rake angle, clearance angle, lip angle) significantly influence cutting efficiency, surface finish, and tool life.

9. What is the difference between a single-point and a multi-point cutter?

   • Answer: A single-point cutter has one cutting edge (e.g., a lathe tool), while a multi-point cutter has multiple cutting edges (e.g., an end mill). Multi-point cutters are generally more productive.

10. How does cutter wear affect cutting performance?

    • Answer: Cutter wear leads to reduced cutting efficiency, increased surface roughness, decreased accuracy, and ultimately, tool failure. Regular inspection and replacement are crucial.

11. What is a milling cutter?

    • Answer: A milling cutter is a rotating cutting tool used in milling machines to remove material from a workpiece. They come in various shapes and sizes.

12. What is a face milling cutter?

    • Answer: A face milling cutter is designed to machine flat surfaces. It has multiple cutting edges arranged around its periphery.

13. What is an end mill?

    • Answer: An end mill is a type of milling cutter that cuts both on its periphery and its end, allowing for both facing and slotting operations.

14. What is a drill bit?

    • Answer: A drill bit is a rotary cutting tool used to create holes in materials.

15. What is a reamer?

    • Answer: A reamer is a multi-point cutting tool used to enlarge and accurately size existing holes.

16. What is a tap?

    • Answer: A tap is a cutting tool used to create internal threads in a hole.

17. What is a die?

    • Answer: A die is a cutting tool used to create external threads on a workpiece.

18. What is a saw blade?

    • Answer: A saw blade is a cutting tool with a series of teeth designed to cut materials.

19. What is a router bit?

    • Answer: A router bit is a cutting tool used in a router to shape wood or other materials.

20. What is a chisel?

    • Answer: A chisel is a hand tool with a sharp, beveled edge used for shaping and cutting materials.

21. What is a plane blade?

    • Answer: A plane blade is a cutting tool used in a hand plane to smooth and flatten wood surfaces.

22. How do you sharpen a cutter?

    • Answer: Sharpening methods depend on the type of cutter and material. Common methods include using grinding wheels, honing stones, or specialized sharpening jigs.

23. What is the importance of cutter lubrication?

    • Answer: Lubrication reduces friction, heat, and wear, extending cutter life and improving cutting performance.

24. What is coolant used for in cutting operations?

    • Answer: Coolant helps to remove heat generated during cutting, prevent cutter wear, and improve surface finish.

25. What is the significance of spindle speed in machining?

    • Answer: Spindle speed directly affects the cutting speed and influences surface finish, tool life, and the overall machining process.

26. What is feed rate in machining?

    • Answer: Feed rate is the speed at which the cutter advances into the workpiece. It impacts productivity and surface finish.

27. What is depth of cut?

    • Answer: Depth of cut refers to the amount of material removed in a single pass of the cutter.

28. Explain the concept of chip formation.

    • Answer: Chip formation is the process by which material is removed from the workpiece during cutting. Different cutting conditions produce different chip types (continuous, discontinuous, built-up edge).

29. What are the common causes of cutter breakage?

    • Answer: Cutter breakage can be caused by excessive cutting forces, improper cutter selection, collisions, dull cutters, or improper clamping of the workpiece.

30. How do you inspect a cutter for damage?

    • Answer: Inspect the cutter for chipping, cracks, wear, and any signs of deformation. Use magnification if necessary.

31. What is the importance of cutter storage and maintenance?

    • Answer: Proper storage (clean, dry, protected from damage) and regular maintenance (sharpening, cleaning) extend the life and performance of cutters.

32. What are some common materials used for making cutters?

    • Answer: Common cutter materials include high-speed steel (HSS), carbide, ceramic, and diamond.

33. What is the difference between brazed and mechanically clamped cutter inserts?

    • Answer: Brazed inserts are permanently bonded, while mechanically clamped inserts can be easily replaced when worn.

34. What is a coated cutter?

    • Answer: A coated cutter has a thin layer of material (e.g., TiN, TiCN, AlTiN) deposited on its surface to enhance wear resistance and cutting performance.

35. How do you troubleshoot a cutter that is producing a poor surface finish?

    • Answer: Check for dull cutters, incorrect cutting parameters (speed, feed, depth), improper lubrication/coolant, workpiece clamping issues, or vibrations.

36. How do you troubleshoot a cutter that is breaking frequently?

    • Answer: Investigate excessive cutting forces, improper cutter selection, dull cutters, workpiece clamping issues, vibrations, or collisions.

37. What are the advantages and disadvantages of using carbide cutters?

    • Answer: Advantages: high hardness, long tool life, high cutting speeds. Disadvantages: brittle, expensive.

38. What are the advantages and disadvantages of using HSS cutters?

    • Answer: Advantages: good toughness, relatively inexpensive. Disadvantages: shorter tool life compared to carbide, lower cutting speeds.

39. What is a solid carbide cutter?

    • Answer: A solid carbide cutter is made entirely from carbide, offering superior strength and wear resistance.

40. What is an indexable insert cutter?

    • Answer: An indexable insert cutter uses replaceable inserts, offering cost savings compared to solid cutters.

41. What is the importance of proper cutter clamping in a machine?

    • Answer: Proper clamping ensures accurate positioning and prevents cutter chatter, vibrations, and potential breakage.

42. What is cutter chatter?

    • Answer: Cutter chatter is a vibration during machining that results in poor surface finish and can damage both the cutter and workpiece.

43. How can you prevent cutter chatter?

    • Answer: Prevent chatter by optimizing cutting parameters, ensuring proper workpiece clamping, using dampening techniques, and selecting appropriate cutters.

44. What are some common cutter materials besides carbide and HSS?

    • Answer: Ceramics, diamonds, and cubic boron nitride (CBN) are also used for specialized applications.

45. What is the role of a cutter in CNC machining?

    • Answer: In CNC machining, the cutter is precisely controlled by the machine's computer to create complex shapes and features according to the programmed design.

46. What factors influence the selection of a CNC cutter?

    • Answer: Factors include material being machined, desired accuracy, surface finish, complexity of the part, and the machine's capabilities.

47. How do you maintain a CNC cutter?

    • Answer: Regularly inspect for wear and damage, properly store when not in use, clean and lubricate as needed, and replace worn inserts or cutters.

48. What are some common problems encountered with CNC cutters?

    • Answer: Problems include tool breakage, poor surface finish, tool wear, and collisions due to programming errors or machine malfunction.

49. How do you select the correct coolant for a specific cutting operation?

    • Answer: Coolant selection depends on the material being cut, the cutting parameters, and the desired results. Water-based coolants, oil-based coolants, and synthetics are common choices.

50. What is the impact of incorrect cutting parameters on cutter life?

    • Answer: Incorrect parameters (speed, feed, depth) can significantly reduce cutter life, leading to premature wear and breakage.

51. Describe different methods for measuring cutter wear.

    • Answer: Methods include visual inspection, measuring flank wear, measuring crater wear, and using specialized wear sensors.

52. What is the difference between a roughing pass and a finishing pass?

    • Answer: A roughing pass removes a substantial amount of material quickly, while a finishing pass removes less material to achieve a fine surface finish and precise dimensions.

53. Explain the importance of workholding in cutter operations.

    • Answer: Secure workholding prevents workpiece movement during cutting, which is crucial for accuracy, safety, and preventing cutter damage.

54. What are some common workholding methods used in machining?

    • Answer: Common methods include vises, clamps, chucks, fixtures, and magnetic holders.

55. How does the material of the workpiece affect cutter selection?

    • Answer: The hardness, toughness, and machinability of the workpiece directly influence the choice of cutter material and cutting parameters.

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