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Introduction
y Success in metal cutting depends on selection of the
proper cutting tool (material and geometry) for a given
work material.
y A wide range
g of cuttingg tool materials is available with
CuttingToolMaterials a variety of properties, performance capabilities, and
cost.
y These include:
y High carbon Steels and low/medium alloy steels,
y Highspeed steels,
y Cast cobalt alloys,
BySKMondal Contd

y Cementedcarbides,
y Castcarbides,
y Coatedcarbides,
y Coatedhighspeedsteels,
y Ceramics,
y Cermets,
y Whiskerreinforcedceramics,
y Sialons,
y Sinteredpolycrystallinecubicboronnitride(CBN),
y Sinteredpolycrystallinediamond,andsinglecrystal
naturaldiamond. FIGURE:Improvementsincuttingtoolmaterialshavereduced
machiningtime.

CarbonSteels
y Limited tool life. Therefore, not suited to mass
production
y Can be formed into complex shapes for small
production runs
y Low
L cost
y Suited to hand tools, and wood working
y Carbon content about 0.9 to 1.35% with a hardness
ABOUT 62 C Rockwell
y Maximum cutting speeds about 26 ft/min. dry
y The hot hardness value is low. This is the major factor
in tool life.
Fig.Productivityraisedbycuttingtoolmaterials

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 9/21/2011

IAS 1997
Assertion (A): Cutting tools made of high carbon
steel have shorter tool life.
Reason(R): During machining, the tip of the cutting
tool is heated to 600/700C which cause the teal tip
to lose its hardness.
hardness
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true Ans. (a)

Highspeedsteel
y These steels are used for cutting metals at a much
higher cutting speed than ordinary carbon tool steels.
y The high speed steels have the valuable property of
retaining their hardness even when heated to red heat.
y Most of the high speed steels contain tungsten as the
chief alloying element, but other elements like cobalt,
chromium, vanadium, etc. may be present in some
proportion.
Contd
y WithtimetheeffectivenessandefficiencyofHSS
(tools)andtheirapplicationrangeweregradually
enhancedbyimprovingitspropertiesandsurface
conditionthrough
y Refinementofmicrostructure
y AdditionoflargeamountofcobaltandVanadiumto
g
increasehothardnessandwearresistance
respectively
y Manufacturebypowdermetallurgicalprocess
y Surfacecoatingwithheatandwearresistive
materialslikeTiC ,TiN ,etcbyChemicalVapour
Deposition(CVD)orPhysicalVapourDeposition
(PVD)

IAS1997 1841Highspeedsteel
Whichofthefollowingprocessescanbeusedfor y This steel contains 18 per cent tungsten, 4 per cent
productionthin,hard,heatresistantcoatingatTiN, chromium and 1 per cent vanadium.
onHSS?
1. Physicalvapour deposition. y It is considered to be one of the best of all purpose tool
2.. S
Sinteringunderreducingatmosphere.
te g u de educ g at osp e e. steels.
3. Chemicalvapour depositionwithposttreatment y It is widely used for drills, lathe, planer and shaper
4. Plasmaspraying. tools, milling cutters, reamers, broaches, threading
Selectthecorrectanswerusingthecodesgivenbelow: dies, punches, etc.
Codes:
(a) 1and3 (b) 2and3
(c) 2and4 (d) 1and4 Ans.(a)

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IES2003 IES2007
Thecorrectsequenceofelementsof1841HSS Cuttingtoolmaterial1841HSShaswhichoneof
toolis thefollowingcompositions?
(a) W,Cr,V (a) 18%W,4%Cr,1%V (b) 18%Cr,4%W,1%V
(b) Mo,Cr,V 4
(c) 18%W,4%Ni,1%V 4
(d) 18%Cr,4%Ni,1%V
(c) Cr,Ni,C
(d) Cu,Zn,Sn Ans.(a)
Ans.(a)

IES1993 Molybdenumhighspeedsteel
Thebladeofapowersawismadeof y This steel contains 6 per cent tungsten, 6 per cent
(a) Boronsteel molybdenum, 4 per cent chromium and 2 per cent
(b) Highspeedsteel vanadium.
y It has excellent toughness and cutting ability.
(c) Stainlesssteel
y The molybdenum high speed steels are better and
(d) Malleablecastiron
cheaper than other types of steels.
Ans.(b)
y It is particularly used for drilling and tapping
operations.

Superhighspeedsteel IES1995
y This steel is also called cobalt high speed steel Thecompositionsofsomeofthealloysteelsareas
because cobalt is added from 2 to 15 per cent, in order under:
to increase the cutting efficiency especially at high 1. 18W4Cr1V
temperatures. 2. 12Mo1W4Cr1V
y This steel contains 20 per cent tungsten, 4 per cent 3. 6Mo6W4Cr1V
chromium, 2 per cent vanadium and 12 per cent cobalt. 4. 18W8Cr1V
Thecompositionsofcommonlyusedhighspeedsteels
wouldinclude
(a) 1and2 (b) 2and3
(c) 1and4 (d) 1and3 Ans.(d)

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IES2000 IES1992
Percentageofvariousalloyingelementspresent ThemainalloyingelementsinhighspeedSteelin
indifferentsteelmaterialsaregivenbelow: orderofincreasingproportionare
1. 18%W;4%Cr;1%V;5%Co;0.7%C (a) Vanadium,chromium,tungsten
4
2. 8%Mo;4%Cr;2%V;6%W;0.7%C g
(b) Tungsten,titanium,vanadium
3. 27%Cr;3%Ni;5%Mo;0.25%C (c) Chromium,titanium,vanadium
4. 18%Cr;8%Ni;0.15%C (d) Tungsten,chromium,titanium
Whichoftheserelatetothatofhighspeedsteel? Ans.(a)
(a) 1and3 (b) 1and2
(c) 2and3 (d) 2and4 Ans.(b)

IAS2001 IAS1994
Assertion(A):Forhighspeedturningofmagnesium Assertion(A):ThecharacteristicfeatureofHigh
alloys,thecoolantorcuttingfluidpreferrediswater speedSteelisitsredhardness.
misciblemineralfattyoil.
Reason(R):ChromiumandcobaltinHighSpeed
Reason(R):Asarule,waterbasedoilsarerecommended promotemartensite formationwhenthetooliscold
forhighspeedoperationsinwhichhightemperaturesare worked.
generatedduetohighfrictionalheat.Waterbeingagood
generatedduetohighfrictionalheat Waterbeingagood
coolant,theheatdissipationisefficient. (a) BothAandRareindividuallytrueandRisthecorrect
(a) BothAandRareindividuallytrueandRisthecorrect explanationofA
explanationofA (b) BothAandRareindividuallytruebutRisnot the
(b) BothAandRareindividuallytruebutRisnot thecorrect correctexplanationofA
explanationofA (c) AistruebutRisfalse
(c) AistruebutRisfalse (d) AisfalsebutRistrue Ans.(b)
(d) AisfalsebutRistrue Ans.(a)

Castcobaltalloys/Stellite y Other elements added include V, B, Ni, and Ta.

y Tools of cast cobalt alloys are generally cast to shape and
y Cast cobalt alloys are cobaltrich, chromiumtungsten carbon finished to size by grinding.
cast alloys having properties and applications in the
y They are available only in simple shapes, such as single
intermediate range between highspeed steel and cemented
carbides. point tools and saw blades, because of limitations in the
casting process and expense involved in the final shaping
y Although comparable in roomtemperature hardness to high
speedd steell tools,
l cast cobalt
b l alloy
ll tools
l retain
i their
h i hardness
h d to
(grinding). The high cost of fabrication is due primarily to
a much higher temperature. Consequently, they can be used at the high hardness of the material in the ascast condition.
higher cutting speeds (25% higher) than HSS tools. y Materials machinable with this tool material include plain
y Cutting speed of up to 80100 fpm can be used on mild steels. carbon steels, alloy steels, nonferrous alloys, and cast iron.
y Cast cobalt alloys are hard as cast and cannot be softened or y Cast cobalt alloys are currently being phased out for
heat treated. cuttingtool applications because of increasing costs,
y Cast cobalt alloys contain a primary phase of Corich solid shortages of strategic raw materials (Co, W, and Cr), and
solution strengthened by Cr and W and dispersion hardened by the development of other, superior tool materials at lower
complex hard, refractory carbides of W and Cr. cost.
Contd

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IES2011 CementedCarbide
Stellite is a nonferrous cast alloy composed of: y Carbides, which are nonferrous alloys, are also called,
(a) Cobalt, chromium and tungsten sintered (or cemented) carbides because they are
manufactured by powder metallurgy techniques.
(b) Tungsten, vanadium and chromium
y Most carbide tools in use today are either straight
((c)) Molybdenum,
y g
tungsten and chromium tungsten
g carbide ((WC)
C) or multicarbides of WTi or W
(d)Tungsten, molybdenum, chromium and vanadium TiTa, depending on the work material to be machined.
y Cobalt is the binder.
Ans. (a)
y These tool materials are much harder, are chemically more
stable, have better hot hardness, high stiffness, and lower
friction, and operate at higher cutting speeds than do HSS.
y They are more brittle and more expensive and use strategic
metals (W, Ta, Co) more extensively.
Contd

y Cemented carbide tool materials based on TiC have

been developed, primarily for auto industry y Speeds up to 300 fpm are common on mild steels
applications using predominantly Ni and Mo as a y Hot hardness properties are very good
binder. These are used for higherspeed (> 1000
ft/min) finish machining of steels and some malleable y Coolants and lubricants can be used to increase tool
cast irons. life, but are not required.
y Cemented carbide tools are available in insert form in y Special alloys are needed to cut steel
many different shapes; squares, triangles, diamonds,
and rounds.
y Compressive strength is high compared to tensile
strength, therefore the bits are often brazed to steel
shanks, or used as inserts in holders.
y These inserts may often have negative rake angles.
Contd Contd

IES1995
Thestraightgradesofcementedcarbidecutting
toolmaterialscontain
(a) Tungstencarbideonly
(b) Tungstencarbideandtitaniumcarbide
(c) Tungstencarbideandcobalt
(d) Tungstencarbideandcobaltcarbide

Ans.(c)

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IAS 1994 ThestandardsdevelopedbyISOforgroupingofcarbidetools

andtheirapplicationrangesaregiveninTablebelow.
Assertion (A): Cemented carbide tool tips are
produced by powder metallurgy. ISO Code Colour Code Application
Reason (R): Carbides cannot be melted and cast.
P For machining long chip forming
(a) Both A and R are individually true and R is the common materials like plain carbon
correctt explanation
l ti off A and low alloy steels
(b) Both A and R are individually true but R is not the M For machining long or short chip
correct explanation of A forming ferrous materials like
Stainless steel
(c) A is true but R is false
K For machining short chipping,
(d) A is false but R is true Ans. (a)
ferrous and non- ferrous material
and non metals like Cast Iron,
Brass etc.

Tablebelowshowsdetailgroupingofcementedcarbidetools
K01 Hard grey C.l., chilled casting, Turning, precision turning and boring, milling,
ISO Material Process Al. alloys with high silicon scraping
Application K10 Grey C.l. hardness > 220 HB. Turning, milling, boring, reaming, broaching,
Malleable C.l., Al. alloys scraping
group
containing Si
P01 Steel, Steel castings Precision and finish machining, high speed K20 Grey C.l. hardness up to 220 Turning, milling, broaching, requiring high
HB toughness
P10 Steel, Steel castings Turning, threading, and milling high speed, K30 Soft grey C.l. Low tensile Turning, reaming under favourable conditions
ssmall
a cchips
ps strength steel
P20 Steel, steel castings, Turning, milling, medium speed with small chip K40 Soft non-ferrous metals Turning milling etc.
M10 Steel, steel castings, Turning, milling, medium cutting speed and medium
malleable cast iron section
manganese steel, grey C.l. chip section
P30 Steel, steel castings, Turning, milling, medium speed with small chip M20 Steel casting, austentic steel, Turning, milling, medium cutting speed and medium
manganese steel, chip section
malleable cast iron section
spherodized C.l., Malleable
P40 Steel and steel casting Turning, planning, low cutting speed, large chip C.l.
with sand inclusions section M30 Steel, austenitic steel, Turning, milling, planning, medium cutting speed,
spherodized C.l. heat medium or large chip section
P50 Steel and steel castings Operations requiring high toughness turning, resisting alloys
of medium or low tensile planning, shaping at low cutting speeds M40 Free cutting steel, low tensile Turning, profile turning, specially in automatic
strength strength steel, brass and light machines.
alloy

IES1999 Ceramics
MatchListI(ISOclassificationofcarbidetools)withList y Ceramics are essentially alumina ( Al2O3 ) based high
II(Applications)andselectthecorrectanswerusingthe refractory materials introduced specifically for high
codesgivenbelowtheLists: speed machining of difficult to machine materials and
ListI ListII cast iron.
A. P10 1. Nonferrous,roughingcut
g g
y These can withstand very high temperatures,
temperatures are
B. P50 2. Nonferrous,finishingcut
chemically more stable, and have higher wear
C. K10 3. Ferrousmaterial,roughingcut
resistance than the other cutting tool materials.
D. K50 4. Ferrousmaterial,finishingcut
y In view of their ability to withstand high temperatures,
Code: A B C D A B C D
they can be used for machining at very high speeds of
(a) 4 3 1 2 (b) 3 4 2 1
the order of 10 m/s.
(c) 4 3 2 1 (d) 3 4 1 2
Ans.(c) y Theycanbeoperatedatfromtwotothreetimesthe
cuttingspeedsoftungstencarbide.
Contd

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y It is possible to get mirror finish on cast iron using

ceramic turning.
y The main problems of ceramic tools are their low
strength, poor thermal characteristics, and the
tendency to chipping.
y They are not suitable for intermittent cutting or for low
cutting speeds.
y Very high hot hardness properties
y Often used as inserts in special holders.

Comparisonofimportantpropertiesofceramicandtungstencarbidetools Contd

y Through last few years remarkable improvements in y Introducing nitride ceramic (Si3N4) with proper sintering
technique this material is very tough but prone to builtup
strength and toughness and hence overall performance
edge formation in machining steels
of ceramic tools could have been possible by several
y Developing SIALON deriving beneficial effects of Al2O3
means which include; and Si3N4
y Sinterability, microstructure, strength and y Adding carbide like TiC (5 ~ 15%) in Al2O3 powder to
toughness of Al2O3 ceramics were ere improved
impro ed to i
impartt toughness
t h and
d thermal
th l conductivity
d ti it
some extent by adding TiO2 and MgO, y Reinforcing oxide or nitride ceramics by SiC whiskers, which
y Transformation toughening by adding appropriate enhanced strength, toughness and life of the tool and thus
productivity spectacularly.
amount of partially or fully stabilised zirconia in
y Toughening Al2O3 ceramic by adding suitable metal like
Al2O3 powder,
silver which also impart thermal conductivity and self
y Isostatic and hot isostatic pressing (HIP) these are lubricating property; this novel and inexpensive tool is still
very effective but expensive route. in experimental stage.
Contd Contd

y Cutting fluid, if applied should in flooding with HighPerformanceceramics(HPC)

copious quantity of fluid, to thoroughly wet the entire
machining zone, since ceramics have very poor
thermal shock resistance. Else, it can be machined
with no coolant.
y Ceramic
C i tools
l are used d for
f machining
hi i workk pieces,
i
which have high hardness, such as hard castings, case
hardened and hardened steel.
SiliconNitride Aluminatoughned by
y Typical products can be machined are brake discs,
(i)Plain (i)Zirconia
brake drums, cylinder liners and flywheels.
(ii)SIALON (ii)SiC whiskers
(iii)Whiskertoughened (iii)Metal(Silveretc)

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IES2010 IAS1996
Constituents of ceramics are oxides of MatchListIwithListIIandselectthecorrectanswer
different materials, which are usingthecodesgivenbelowthelists:
ListI(Cuttingtools) ListII(Majorconstituent)
(a) Cold mixed to make ceramic pallets A. Stellite l. Tungsten
((b)) Ground,, sintered and p
palleted to make readyy B. H.S.S. 2. Cobalt
ceramics C. Ceramic 3. Alumina
D. DCON 4. Columbium
(c) Ground, washed with acid, heated and cooled 5. Titanium
(d) Ground, sintered, palleted and after calcining Codes:A B C D A B C D
(a) 5 1 3 4 (b) 2 1 4 3
cooled in oxygen (c) 2 1 3 4 (d) 2 5 3 4
Ans. (b) Ans.(c)

IES1997 IES1996
Assertion(A):Ceramictoolsareusedonlyforlight, Amachinistdesirestoturnaroundsteelstockof
smoothandcontinuouscutsathighspeeds. outsidediameter100mmat1000rpm.The
Reason(R):Ceramicshaveahighwearresistanceand materialhastensilestrengthof75kg/mm2.The
hightemperatureresistance.
depthofcutchosenis3mmatafeedrateof0.3
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
mm/rev.Whichoneofthefollowingtool
h h f h f ll l
materialswillbesuitableformachiningthe
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA componentunderthespecifiedcutting
(c) AistruebutRisfalse conditions?
(d) AisfalsebutRistrue (a) Sinteredcarbides (b) Ceramic
Ans.(b) (c) HSS (d) Diamond
Ans.(b)

IES2007 IAS2000
Whichoneofthefollowingisnotaceramic? Considerthefollowingcuttingtoolmaterialsusedfor
metalcuttingoperationat
(a) Alumina
highspeed:
(b) Porcelain 1. Tungstencarbide
(c) Whisker 2 Cementedtitaniumcarbide
2.
(d) Pyrosil 3. Highspeedsteel
Ans.(d) 4. Ceramic
Thecorrectsequenceinincreasingorderoftherangeof
cuttingspeedsforoptimumuseofthesematerialsis
(a) 3,1,4,2 (b) 1,3,2,4
(c) 3,1,2,4 (d) 1,3,4,2 Ans.(c)

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IAS2003 CoatedCarbideTools
Atroomtemperature,whichoneofthefollowing y Coated tools are becoming the norm in the metalworking
isthecorrectsequenceofincreasinghardnessof industry because coating , can consistently improve, tool
thetoolmaterials? life 200 or 300% or more.
y
(a) CastalloyHSSCeramicCarbide y In cutting tools, material requirements at the surface of the
tooll needd to be
b abrasion
b i resistant,
i h d and
hard, d chemically
h i ll
(b) HHCastalloyCeramicCarbide inert to prevent the tool and the work material from
(c) HSSCastalloyCarbideCeramic interacting chemically with each other during cutting.
(d) CastalloyHSSCarbideCeramic y A thin, chemically stable, hard refractory coating of TiC,
Ans.(d) TiN, or Al2O3 accomplishes this objective.
y The bulk of the tool is a tough, shockresistant carbide that
can withstand hightemperature plastic deformation and
resist breakage.
Contd

y The coatings must be fine grained, & free of binders y The most successful combinations are
and porosity. TiN/TiC/TiCN/TiN and TiN/TiC/ Al2O3 .
y Naturally, the coatings must be metallurgically bonded y Chemical vapour deposition (CVD) is the technique
to the substrate. used to coat carbides.
y Interface coatings are graded to match the properties
of the coating and the substrate.
y The coatings must be thick enough to prolong tool life
but thin enough to prevent brittleness.
y Coatings should have a low coefficient of friction so
that the chips do not adhere to the rake face.
y Multiple coatings are used, with each layer imparting
its own characteristic to the tool. Contd Contd

IAS1999
Thecoatingmaterialsforcoatedcarbidetools,
includes
(a) TiC,TiN andNaCN (b) TiC andTiN
(c) TiN andNaCN (d) TiC andNaCN

Ans.(b)

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TiNCoatedHighSpeedSteel y Physical vapour deposition (PVD) has proved to be the

y Coated highspeed steel (HSS) does not routinely best process for coating HSS, primarily because it is a
provide as dramatic improvements in cutting speeds as relatively low temperature process that does not
do coated carbides, with increases of 10 to 20% being exceed the tempering point of HSS.
typical. y Therefore, no subsequent heat treatment of the
y In addition to hobs, gearshaper cutters, and drills, cutting
i tooll is
i required.
i d
HSS tooling coated by TiN now includes reamers, taps, y The advantage of TiNcoated HSS tooling is reduced
chasers, spadedrill blades, broaches, bandsaw and tool wear.
circular saw blades, insert tooling, form tools, end y Less tool wear results in less stock removal during tool
mills, and an assortment of other milling cutters. regrinding, thus allowing individual tools to be
reground more times.

Contd

Cermets IES2010
y These sintered hard inserts are made by combining cer from
ceramics like TiC, TiN or TiCN and met from metal (binder) The cutting tool material required to
like Ni, NiCo, Fe etc. sustain high temperature is
y Harder, more chemically stable and hence more wear resistant
y More brittle and less thermal shock resistant
(a) High carbon steel alloys
y Wt% off binder
bi d metal t l varies
i from
f 10 to
t 20%.
% (b) Composite of lead and steel
y Cutting edge sharpness is retained unlike in coated carbide
inserts (c) Cermet
y Can machine steels at higher cutting velocity than that used for (d) Alloy of steel, zinc and tungsten
tungsten carbide, even coated carbides in case of light cuts.
y Modern cermets with rounded cutting edges are suitable for Ans. (c)
finishing and semifinishing of steels at higher speeds, stainless
steels but are not suitable for jerky interrupted machining and
machining of aluminium and similar materials.

IES2000 IES 2003

The correct sequence of cutting tools in the
Cermetsare
ascending order of their wear resistance is
(a) Metalsforhightemperatureusewithceramiclike
(a) HSSCast nonferrous alloy (Stellite)Carbide
properties
Nitride
(b) Ceramicswithmetallicstrengthandluster
(b) Cast
C t nonferrous
f alloy
ll (St llit ) HSS C bid
(Stellite)HSSCarbide
(c) Coatedtoolmaterials Nitride
(d) Metalceramiccomposites (c) HSSCast nonferrous alloy (Stellite)Nitride
Ans.(d) Carbide
(d) Cast nonferrous alloy (Stellite)CarbideNitride
HSS Ans. (a)

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Diamonds
y Diamond is the hardest of all the cutting tool materials.
y Diamond has the following properties:
y extreme hardness,
y low thermal expansion,
y high heat conductivity, and
y a very low coefficient of friction.
y This is used when good surface finish and dimensional accuracy
are desired.
y The workmaterials on which diamonds are successfully employed
are the nonferrous one, such as copper, brass, zinc, aluminium
and magnesium alloys.
y On ferrous materials, diamonds are not suitable because of the
diffusion of carbon atoms from diamond to the workpiece
material. Contd
y Diamond tools have the applications in single point turning and
boring tools, milling cutters, reamers, grinding wheels, honing
tools, lapping powder and for grinding wheel dressing.
y Due to their brittle nature, the diamond tools have poor
resistance to shock and so, should be loaded lightly.
y Polycrystalline diamond (PCD) tools consist of a thin layer (0.5
to 1.5 mm) of'fine grain size diamond particles sintered
together and metallurgically bonded to a cemented carbide
substrate.
y The main advantages of sintered polycrystalline tools over
natural singlecrystal tools are better quality, greater toughness,
and improved wear resistance, resulting from the random
orientation of the diamond grains and the lack of large cleavage
planes.
Contd

y Diamondtoolsofferdramaticperformance IES1995
improvementsovercarbides.Toollifeisoftengreatly Assertion(A):Nonferrousmaterialsarebest
improved,asiscontroloverpartsize,finish,and machinedwithdiamondtools.
surfaceintegrity. Reason(R):Diamondtoolsaresuitableforhighspeed
y Positiveraketoolingisrecommendedforthevast machining.
majorityofdiamondtoolingapplications.
majorit ofdiamondtoolingapplications (a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
y IfBUEisaproblem,increasingcuttingspeedandthe
(b) BothAandRareindividuallytruebutRisnot the
useofmorepositiverakeanglesmayeliminateit. correctexplanationofA
y Oxidationofdiamondstartsatabout450oCand (c) AistruebutRisfalse
thereafteritcanevencrack.Forthisreasonthe (d) AisfalsebutRistrue
diamondtooliskeptfloodedbythecoolantduring Ans.(b)
cutting,andlightfeedsareused.

IES2001 IES 1999

Assertion(A):Diamondtoolscanbeusedathigh Considerthefollowingstatements:
speeds. Forprecisionmachiningofnonferrousalloys,diamond
Reason(R):Diamondtoolshaveverylowcoefficient ispreferredbecauseithas
offriction. 1. Lowcoefficientofthermalexpansion
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA 2. Highwearresistance
(b) BothAandRareindividuallytruebutRisnot the 3. Highcompressionstrength
correctexplanationofA 4. Lowfracturetoughness
(c) AistruebutRisfalse Whichofthesestatementsarecorrect?
(d) AisfalsebutRistrue
(a) 1and2 (b) 1and4
Ans.(c)
(c) 2and3 (d) 3and4 Ans.(a)

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IES1992 IAS 1999

Assertion(A):Duringcutting,thediamondtoolis
Whichofthefollowinggiventhecorrectorderof
keptfloodedwithcoolant.
increasinghothardnessofcuttingtoolmaterial?
Reason(R):Theoxidationofdiamondstartsat
(a) Diamond,Carbide,HSS
about4500C
(b) Carbide,Diamond,HSS
(a)
( ) BothAandRareindividuallytrueandRisthe
B thA dR i di id ll t dRi th
(c) HSS,carbide,Diamond correctexplanationofA
(d) HSS,Diamond,Carbide (b) BothAandRareindividuallytruebutRisnot the
Ans.(d) correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue Ans.(a)

Cubicboronnitride/Borazon y The operative speed range for cBN when machining

y Next to diamond, cubic boron nitride is the hardest
material presently available.
y It is made by bonding a 0.5 1 mm layer of
p
polycrystalline
y y cubic boron nitride to cobalt based
carbide substrate at very high temperature and
pressure.
y It remains inert and retains high hardness and fracture
toughness at elevated machining speeds.
y It shows excellent performance in grinding any
material of high hardness and strength.
Contd
grey cast iron is 300 ~400 m/min
y Speed ranges for other materials are as follows:
y Hard cast iron (> 400 BHN) : 80 300 m/min
y Superalloys (> 35 RC) : 80 140 m/min
y Hardened steels (> 45 RC) : 100 300 m/min
y It is best to use cBN tools with a honed or chamfered
edge preparation, especially for interrupted cuts. Like
ceramics, cBN tools are also available only in the form
of indexable inserts.
y The only limitation of it is its high cost.
Contd

IES1994
y CBNislessreactivewithsuchmaterialsashardened Considerthefollowingtoolmaterials:
steels,hardchillcastiron,andnickel andcobalt 1. Carbide 2. Cermet
basedsuperalloys. 3. Ceramic 4. Borazon.
y CBNcanbeusedefficientlyandeconomicallyto
y y Correctsequenceofthesetoolmaterialsinincreasing
machinethesedifficulttomachinematerialsathigher orderoftheirabilitytoretaintheirhothardnessis
speeds(fivefold)andwithahigherremovalrate
(fivefold)thancementedcarbide,andwithsuperior (a) 1,2,3,4 (b) 1,2,4,3
accuracy,finish,andsurfaceintegrity. (c) 2,1,3,4 (d) 2,1,4,3
Ans.(a)

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IES2002 IES1996
Whichoneofthefollowingisthehardestcutting Cubicboronnitride
toolmaterialnextonlytodiamond? (a) Hasaveryhighhardnesswhichiscomparableto
(a) Cementedcarbides thatofdiamond.
(b) Ceramics (b) Hasahardnesswhichisslightlymorethanthatof
(c) Silicon HSS
(d) Cubicboronnitride (c) Isusedformakingcylinderblocksofaircraft
Ans.(d) engines
(d) Isusedformakingopticalglasses.
Ans.(a)

IES1994 IAS1998
Cubicboronnitrideisused Whichofthefollowingtoolmaterialshavecobalt
(a) Asliningmaterialininductionfurnace asaconstituentelement?
(b) Formakingopticalqualityglass. 1. Cementedcarbide 2. CBN
(c) Forheattreatment 3. Stellite 4. UCON
(d) Fornoneoftheabove. Selectthecorrectanswerusingthecodesgivenbelow:
Ans.(d) Codes:
(a) 1and2 (b) 1and3
(c) 1and4 (d) 2and3
Ans.(b)

Coronite IES1993
y Coronite is made basically by combining HSS for strength and
toughness and tungsten carbides for heat and wear resistance. MatchListIwithListITandselectthecorrectanswerusingthe
codesgivenbelowthelists:
y Microfine TiCN particles are uniformly dispersed into the matrix. List I(CuttingtoolMaterial) List II(Major
y Unlikeasolidcarbide,thecoronite basedtoolismadeofthree characteristicconstituent)
layers; A. Highspeedsteel 1. Carbon
B. Stellite 2. Molybdenum
y
y thecentralHSSorspringsteelcore
th t lHSS i t l C. Diamond 3. Nitride
y alayerofcoronite ofthicknessaround15%ofthetool D. Coatedcarbidetool 4. Columbium
diameter 5. Cobalt
y athin(2to5m)PVDcoatingofTiCN Codes: A B C D A B C D
(a) 2 1 3 5 (b) 2 5 1 3
y The coronite tools made by hot extrusion followed by PVD (c) 5 2 4 3 (d) 5 4 2 3
coating of TiN or TiCN outperformed HSS tools in respect of Ans.(b)
cutting forces, tool life and surface finish.

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IES2003 IES2000
Whichoneofthefollowingisnotasynthetic Considerthefollowingtoolmaterials:
abrasivematerial? 1. HSS 2. Cementedcarbide
(a) SiliconCarbide (b) Aluminium Oxide 3. Ceramics 4. Diamond
(c) TitaniumNitride (d) CubicBoronNitride Thecorrectsequenceofthesematerialsindecreasing
Ans.(b) orderoftheircuttingspeedis
(a) 4,3,1,2 (b) 4,3,2,1
(c) 3,4,2,1 (d) 3,4,1,2
Ans.(b)

IES1999 IAS2001
MatchListIwithListIIandselectthecorrectanswer Match.ListI(Cuttingtoolmaterials)withListII
usingthecodesgivenbelowtheLists: (Manufacturingmethods)andselectthecorrectanswer
ListI ListII usingthecodesgivenbelowtheLists:
(Materials) (Applications) ListI ListII
A. Tungstencarbide 1. Abrasivewheels A. HSS 1. Casting
B.
B Siliconnitride
Sili i id 2. Heatingelements
H i l B
B. Stellite 2
2. Forging
C. Aluminium oxide 3. Pipesforconveying C. Cementedcarbide 3. Rolling
liquidmetals D. UCON 4. Extrusion
D. Siliconcarbide 4. Drawingdies 5. Powdermetallurgy
Code: A B C D A B C D Codes:A B C D A B C D
(a) 3 4 1 2 (b) 4 3 2 1 (a) 3 1 5 2 (b) 2 5 4 3
(c) 3 4 2 1 (d) 4 3 1 2 (c) 3 5 4 2 (d) 2 1 5 3
Ans.(d) Ans.(d)

Attritionwear IES1996
y The strong bonding between the chip and tool material at Thelimittothemaximumhardnessofawork
high temperature is conducive for adhesive wear. materialwhichcanbemachinedwithHSStools
y The adhesive wear in the rough region is called attrition
wear . evenatlowspeedsissetbywhichoneofthe
y In the rough region, some parts of the worn surface are still followingtoolfailuremechanisms?
coveredd by
b moltenl chip
hi and
d the
h irregular
i l attrition
ii wear ( ) Attrition
(a)
occurs in this region .
y The irregular attrition wear is due to the intermittent (b) Abrasion
adhesion during interrupted cutting which makes a (c) Diffusion
periodic attachment and detachment of the work material
on the tool surface. (d) Plasticdeformationundercompression.
y Therefore, when the seizure between workpiece to tool is Ans.(a)
broken, the small fragments of tool material are plucked
and brought away by the chip.

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IES2005
Considerthefollowingstatements:Anincreaseinthe
cobaltcontentinthestraightcarbidegradesof
carbidetools

TheEnd
The End
1. Increasesthehardness.
2. Decreasesthehardness.
D h h d
3. Increasesthetransverserupturestrength
4. Lowersthetransverserupturestrength.
Whichofthestatementsgivenabovearecorrect?
(a) 1and3 (b) 2and4
(c) 1and4 (d) 2and3 Ans.(d)

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