cutting-tool presentaion
TRANSCRIPT
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POWERPOINT PRESENTATION
CUTTING TOOL AND MATERIAL
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REASONS FOR DEVELOPMENT OF CUTTING TOOL
GLOBLE COMPETATION
PRODUCTIVITY : Cutting Speed Reduce Machining Time Improve Tool Life
QUALITY AND RELIABILITY: High accuracy & tolerances Better surface finish
Cost: Reduce Unnecessary Cost Reduce non-productive cost
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REASONS FOR DEVELOPMENT OF CUTTING TOOL
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BASIC REQUIREMENT OF A TOOL MATERIALS
HOT HARDNESS
WEAR RESISTANCE
TOUGHNESS AND STRENGTH THERMAL CONDUCTIVITY
CO-EFFICIENT OF FRICTION
CO-EFFICIENT OF THERMAL EXPANSION
MACHINIBILITY AND GRINDABILITY
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CUTTING TOOL MATERIALS
HOT HARDNESS OF SEVERAL TYPES OF TOOLS:
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TYPES OF CUTTING TOOL MATERIALS
CONVENTIONAL CUTTING TOOL MATERIALS
High Carbon Steel
High Speed Steel Cast-Cobalt alloys (Satellite)
Cemented Carbide
Ceramics
CERMET
Diomond
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TYPES OF CUTTING TOOL MATERIALS
ADVANCE CUTTING TOOL MATERIALS
Coated Carbides
CBN
PCD
UCON
Multi Coated
Super Coated Alloy
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CUTTING TOOL MATERIALS
HIGH CARBON STEEL
Carbon percentage -0.8 to 1.5%
Oldest known tool material Low Hot Hardness
Maximum Cutting Speed 10 m/min
Maximum Temperature Limit -250 C
Suitable for Low Cutting
Low Cost Used for taps, dies, hacksaw blades, hand drills, wood working
tools etc.
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CUTTING TOOL MATERIALS
HIGH SPEED STEEL (H.S.S)
T-Series M-Series
(Tungsten Type) (Molybdenum Type)18 - 4 - 1- 0.75 6 6 4 - 2
W Cr Va C W M Cr Va
Cutting speed up to 30 m/min
Maximum Limiting Temperature 560C
Less Costly
Excellent toughness
Widely used in industries as a solid Tool like form tool, drill, millingcutters, endmill, reamers, Broach, Single point cutting tool etc.
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CUTTING TOOL MATERIALS
CAST COBALT ALLOYS (STALLITE):
48-53% 30-33% 10-20% 1.5-2.0%Co Cr W C
Manufacturing Process- Casting Hot hardness- 760C Cutting Speed -45 m/min Higher tool life compare to H.S.S. Hardness -58 to 64 HRC Lower toughness/brittle Limited strength Used for from tool, Machining cast and malleable iron.
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CUTTING TOOL MATERIALSCERAMICS:
Al2O3+ MgO, Cr2O3, SiC, TiO, TiC90% ________10%____________
High abrasive of wear Resistance Less tendency to weld to metal Very high compressive strength Very high hot hardness High refractoriness
1800 C
High Cutting Speed -200 to 400 m/min Longer tool life Used for cutting steel and HSS Used for high speed machining
Limitation:
Poor ToughnessUnreliable (Suddenfail)High rigidity of set up
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CUTTING TOOL MATERIALS
CEMENTED CARBIDES (TUNGUSTAN CARBIDE):
Plain Tungsten Carbide
W C Co
94% 6% BINDER
Manufactured by Powder Metallurgy
Grain size 1 micron to 8 micron
% of Co -3 to 12%Many verity can be produced by controlling
grain size and % of cobalt.
Machining of non-ferrous, non-metallic and C.I
Drawback is itsAffinity with steel
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CUTTING TOOL MATERIALS
CEMENTED CARBIDES (TUNGUSTAN CARBIDE):
Steel Grade (Triple) Tungsten Carbide
W TiC TaC Co15% 10%
High hardness and wear resistance Maximum limiting Temperature -1200 C Various Shapes Of Inserts Cutting Speed -100 m/min High Tool life High compressive strength High production rate
Better surface finish
Drawback is itsAffinity withsteel
VARIOUS SHAPES OF INSERTS
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CUTTING TOOL MATERIALS
DIMOND:
Hardest substance BHN 7000 High heat conductivity (Twice then steel) High hot hardness 1650 C High wear resistance Very low co-efficient of friction High compressive strength
High cutting speed (300 to 1000 m/min) High tool life Used for cutting hard material like glass, plastic
Ceramics and cemented carbides. Used for turning and dressing wheel of grinding wheel
Used for machining non-metallic and non-ferrous alloy
Limitation:
High rigidity of setup isrequired.Poor shock and impactresistance Not suitable for ferrousmaterials
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CUTTING TOOL MATERIALS
COATED CARBIDES:
Coating of micro thin layer insets made of tungsten carbide Most commonly used coating materials are:
Titanium Nitride (TiN) Titanium Carbide (TiC) Titanium CarboNitiride (TiCN) Aluminium Oxide (Al2O3) Zicronium Nitride (ZrN) Titanium Aluminium Nitride (TiAlN)
Methods of Coatings- Chemical Vapor Depositio (CVD)- Physical Vapor Deposition (PVD)
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CUTTING TOOL MATERIALS
SUPER COATED CARBIDES :
UE6020 for steel turning } Development by Mitsubishi Material
UE5015 for C.I Turning } Corporation, Japan in 2000
WC- Higher interior Hardness and toughness
Triple layer coating
Inner layer FCCN (Fibrous Crystalline Carbon Titanium )
Balance between wear resistance and fracture resistance Outer coating Al2O3(Fine Grain)
outer most layer Special laminated Titanium Alloys
Superior high temperature strength.
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COATED CARBIDES:
Advantages:
High hot hardness Chemically stable High cutting speed -150 to 250 m/min High Tool life (2 to 3 times higher than carbide)
Applications:
Widely used for high speed machining Production of turning and milling of steels and C.I Machining of very hard materials
Used as inserts
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CUTTING TOOL MATERIALS
MULTI PHASE COTING
Outer most layer specially laminated by titanium alloy Smooth surface structure and high chemical stability Two of three layers of various coating materials to get
desired Properties
High speed, continues cutting Tic/ Al2O3 Heavy duty, continues cutting TiC/Al2O3/ Tin
Light interrupted cutting
TiC / TiC + TiN
TiN - Low frictionAl2O3High thermal stabilityTiCN Resistance to flank and crater wear
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UCON
Nitrided refectory metal alloy developed by Union Carbide, USA. Composition :50% columbium, 30%titanium and 20%tungsten and
contain no carbides. Hardness 2500-3000 vickers. Manufacture by cast into ingots and rolled into sheets and then cut
into strips. Withstand very high temperature. Used as through away inserts. Excellent thermal shock resistance, High hardness and toughness.
Excellent resistance proof to diffusion and adhesion wear. 3-5 times more tool life then conventional carbide. Cutting speed range of 250-500 M/Min on steels of 200 BHN
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Application
Recommend for roughing, semi roughing and finishing cuts inturning, facing and boring.
Use for steel machining grade.
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CUTTING TOOL MATERIALS
CUBIC BORON NITRIDE:
Sanitized artificially made under high pressure and hightemperature.
Stable up to 10000C temperature. Manufactures under ultra high pressure and high temperature. Excellent in chemical and thermal stability. Hardness next to natural dimond.
Applications:
Permits high feeds and speeds. Available in large varity of shapes and sizes in insert form. Use to turn bore, face, groove and mill difficult to machine
materials.
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CUTTING TOOL MATERIALS
CUBIC BORON NITRIDE :
Material Recommended for cutting with CBN
Alloy Steel (45-68 Rc)
Carbon Tool Steel (45-68 Rc)
Die Steel S (45-68 Rc)
High Speed Steel (45-68 Rc)
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CUTTING TOOL MATERIALS
PCD:
Synthetic having diamond matrix structure. Sintered under extremely high temperature and pressure. High in uniform hardness and abrasive resistance in all
direction. Very high tool life compare to carbide tool (50 times). Shock resistance is more than natural dimond. Consistency in wear resistance.
Available in large verity of shapes and sizes. Discs as large as 58 mm in diameter. Better thermal conductivity then natural dimond. Lower cost then natural diamond. Used for machining milling, turning, grooving, facing and
boring.
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CUTTING TOOL MATERIALS
TOOL/WORK CHEMICAL OR ADHESIVE INTERACTION SEVERITIES:
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CUTTING TOOL MATERIALS
TOOL MATERIAL OXIDATION AND STRUCTURAL
CHANGE TEMPERATURE RANGES:
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CUTTING TOOL MATERIALS
REFERANCES:
production Technology- HMT
Theory and Application of Metal Cutting by Thomas Child Production Technology- Kalpak Jain
Production Technology P.C.Sharma
Production Engineering and Sciences By Pandey and Singh
Metal Cutting Milton Saw
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Regression Analysis : Farewell Corporation manufactures Integrated Circuit boards(I.C board) for
electronics devices. The planning department knows that the sales of theirclient goods depends on how much they spend on advertising, on account ofwhich they receive in advance of expenditure. The planning department wish
to find out the relationship between their clients advertising and sales, so asto find demand for I.C board. The money spend by the client on advertising and sales (in dollar) is given for
different periods in following table :Period(t)
Advertising(Xt)
$(1,00,000)
Sales (Dt)$(1,000.000)
Dt2 Xt2 XtDt
1 20 6 36 400 120
2 25 8 64 625 2003 15 7 49 225 105
4 18 7 49 324 126
5 22 8 64 484 176
6 25 9 81 625 225
7 27 10 100 729 270
8 23 7 49 529 161
9 16 6 36 256 9610 20 8 64 400 120
211 76 592 4597 1599