lecture 4

J.RamkumarDept of Mechanical Engineering

Cutting tool materials

Fundamentals of Modern Manufacturing M.P.Groover

CUTTING TOOL TECHNOLOGY

Tool Life Tool Materials Tool Geometry Cutting Fluids


Cutting Tool TechnologyTwo principal aspects: 1. Tool material 2. Tool geometry

Three Modes of Tool Failure•Fracture failure

Cutting force becomes excessive and/or dynamic, leading to brittle fracture

•Temperature failureCutting temperature is too high for the tool material

•Gradual wearGradual wearing of the cutting tool


Preferred Mode of Tool Failure Gradual Wear

Fracture and temperature failures are premature failures Gradual wear is preferred because it leads to the longest

possible use of the tool Gradual wear occurs at two locations on a tool:

Crater wear –occurs on top rake face

Flank wear –occurs on flank (side of tool)

Diagram of worn cutting tool


Tool wear as a function of cutting time


Effect of cutting speed on tool life


Taylor Tool Life Equation


This relationship is credited to F. W. Taylor (~1900)

where v = cutting speed; T = tool life; and n and C are parameters that depend on feed, depth of cut,work material, tooling material, and the tool life

criterion used n is the slope of the plot

C is the intercept on the speed axis

Tool Life Criteria in Production


Complete failure of cutting edge Visual inspection of flank wear (or crater wear) by the machine

operator Fingernail test across cutting edge Changes in sound emitted from operation Chips become ribbony, stringy, and difficult to dispose of Degradation of surface finish Increased power Workpiece count Cumulative cutting time


Lathe Toolbit Angles and Clearances7 elements of a single point tool geometry

Cutting-Tool Materials


Generally made of seven materials High-speed steel Cast alloys (such as stellite) Cemented carbides Ceramics Cermets Cubic Boron Nitride Polycrystalline Diamond

Tool spectrum

http://www.mitsubishicarbide.net/contents/mmus/enus/html/product/technical_information/information/sessaku.html

High-Speed Steel Tool bits


May contain combinations of tungsten, chromium, vanadium, molybdenum, cobalt

Can take heavy cuts, withstand shock and maintain sharp cutting edge under red heat

Generally two types (general purpose) Molybdenum-base (Group M) Tungsten-base (Group T)

Cobalt added if more red hardness desired


Cemented-Carbide Tool bits Capable of cutting speeds 3 to 4 times high-speed steel

toolbits Low toughness but high hardness and excellent red-hardness Consist of tungsten carbide sintered in cobalt matrix Straight tungsten used to machine cast iron and nonferrous

materials (crater easily) Different grades for different work

(WC) using powder metallurgy techniques withcobalt (Co) as the binder• Two basic types:1. Non-steel cutting grades - only WC-Co2. Steel cutting grades -TiC and TaC added to WC-Co

Cemented Carbides –General Properties


•High compressive strength but low-to-moderatetensile strength•High hardness (90 to 95 HRA)•Good hot hardness•Good wear resistance•High thermal conductivity•High elastic modulus - 600 x 103 MPa•Toughness lower than high speed steel


Coated Carbide Tool bits Made by depositing thin layer of wear-resistant titanium nitride,

titanium carbide or aluminum oxide on cutting edge of tool Fused layer increases lubricity, improves cutting edge wear resistance

by 200%-500% Lowers breakage resistance up to 20% Provides longer life and increased cutting speeds

Titanium-coated offer wear resistance at low speeds, ceramic coated for higher speeds


Ceramic Tool bits Permit higher cutting speeds, increased tool life and better

surface finish than carbide Weaker than carbide used in shock-free or low-shock situation

Ceramic Heat-resistant material produced without metallic bonding agent

such as cobalt Aluminum oxide most popular additive Titanium oxide or Titanium carbide can be added

Synthetic Diamonds Sintered polycrystalline diamond (SPD) - fabricated by sintering

very fine-grained diamond crystals under high temperatures and pressures into desired shape with little or no binder

Usually applied as coating (0.5 mm thick) on WC-Co insert Applications: high speed machining of nonferrous metals and

abrasive nonmetals such as fiberglass, graphite, and wood Not for steel cutting


Milling Cutters


Principal types:•Plain milling cutter•Form milling cutter•Face milling cutter•End milling cutter

Milling & Drilling tool geometry

Face cutter

Chamfering cutter


Any liquid or gas applied directly to machining operation to improve cutting performance

Two main problems addressed by cutting fluids:1. Heat generation at shear zone and friction zone2. Friction at the tool-chip and tool-work interfaces

Other functions and benefits:•Wash away chips (e.g., grinding and milling)•Reduce temperature of workpart for easier•handling•Improve dimensional stability of workpart

Cutting Fluids


•Cutting fluids can be classified according to function•Coolants - designed to reduce effects of heat in machining•Lubricants - designed to reduce tool-chip and tool-work friction

Cutting Fluid Functions

CoolantsWater used as base in coolant-type cutting fluids•Most effective at high cutting speeds where heatgeneration and high temperatures are problems•Most effective on tool materials that are mostsusceptible to temperature failures (e.g., HSS)

Lubricants•Usually oil-based fluids•Most effective at lower cutting speeds•Also reduces temperature in the operation

lecture 4

Documents

steel cutting grades

cutting fluids

cutting edge

heat generation

titanium carbide

high temperatures

modern manufacturing

temperature failures