Chapter 21 Cutting Tools
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1 MET Manufacturing Processes Chapter 21 Cutting Tools Before you begin: Turn on the sound on your computer. There is audio to accompany this presentation. MET Manufacturing Processes Chapter 21 Cutting Tools Unless otherwise indicated, illustrations in this presentation are taken from the 11 th Edition of Degarmo s Materials and Processes in Manufacturing textbook by J.T. Black and Ronald A. Kohser, 2012, Wiley. Materials Processing Chapters Chapters Chapters Chapters Page 268 Figure 11 1, The Five materials processing families with subgroups and typical processes Chapter
2 Cutting Tools for Machining Success in metal cutting depends on selection of the proper cutting tool (material and geometry) for a given work material. (Quote from text) china.com/myimgs/ _ jpg Chapter 21 4 Basics Increase Cutting Speed MRR Increased Lower Cost Results Chapter 21 5 Basics Chapter
3 Tool Material Selection Variables 1. Work Material: a. Chemistry b. Metallurgical state 2. Part Characteristics: a. Geometry b. Surface Roughness c. Accuracy d. Surface Integrity 3. Machine Characteristics: a. Workholding b. Horsepower c. Speed/Feed Capability 4. Support Systems: a. Operator s Ability b. Sensors and Controls c. Coolant d. Chip Removal Chapter 21 7 Chapter 21 8 Required Tool Characteristics 1. High hardness. 2. Abrasion, wear and chipping resistance. 3. High toughness (impact strength). 4. High hot hardness (1000 C). 5. Resistance to deformation. (continued) Chapter
4 High Hardness Chapter High Hot Hardness Chapter Toughness and Wear Resistance Chapter
5 Required Tool Characteristics (continued) 6. Chemical stability. 7. Adequate thermal properties. 8. High stiffness (elastic modulus). 9. Consistent tool life. 10.Tool geometry and finish. Chapter Tool Coating Processes Chemical Vapor Deposition (CVD) atmosphere controlled process: Higher adhesion. Thicker than PVD (6 9 μm). Uniform coating. Requires heat treating after deposition. Applications: loosely toleranced tooling; solid carbide tooling. Chapter Tool Coating Processes atings An insight into production GB Handou 5t 5.jpg Chapter
6 Tool Coating Processes Physical Vapor Deposition (PVD) physical method: Line of sight process reactive sputtering; reactive ion plating; arc evaporation. Thinner than CVD (1 3 μm). Preserves substrate metallurgy; surface finish; edge condition; geometry. Applications: HSS; solid carbide; carbide tipped. Chapter Tool Coating Processes ngs An insight into production GB Handou 5t 6.jpg Chapter Tool Coating Processes conversiongate02/95/thermal spray coating jpg?cb= Chapter
7 Chapter Cutting Tool Materials 1. Tool Steels Carbon steel and low/medium alloy steel. Low hot hardness (400 F) and limited abrasion resistance. 2. High Speed Steels (HSS) High alloy steel (W, Mo, Co, V and Cr). Better hot hardness (1100 F). Used for drill bits, taps, reamers, end mills. Fabrication methods: cast, wrought, and sintered. Chapter Cutting Tool Materials 3. TiN Coated HSS 10 20% improvement in tool life. Coatings are TiN and are applied by physical vapor deposition. 4. Cast Cobalt Alloys Stellite tools. Excellent hot hardness. Properties between HSS and carbide. Produced by grinding shapes. Very high cost due to shortages of raw materials. Chapter
8 Cutting Tool Materials 5. Carbides Various alloys of tungsten carbide. Made by powdered metallurgy. Binders cobalt, nickel, molybdenum. Cemented or insert styles. 6. Coated Carbides % improvement in tool life. Coatings hard, abrasion resistant, chemically inert. Coatings include: TiC, TiN, Al 2 O 3 and are applied by chemical vapor deposition. Chapter Carbide Tool Manufacturing carbide powder.jpg Chapter Coated Carbide Insert Chapter
9 Coated Carbide Insert Chapter Coated Carbide Insert Kennametal Products, Inc. Chapter Carbide Insert Chip Breaker A chip breaker is a groove on the face of the insert which can cause the chips to curl tightly and break into small, discontinuous chips. Chapter
10 Cutting Tool Materials 7. Ceramics Pure aluminum oxide (Al 2 O 3 ). Typically disposable tip type tools. Excellent hot hardness and abrasion resistance. Poor thermal and mechanical shock resistance. 8. Cermets Essentially cemented carbides using hard particles other than tungsten carbide. Materials include: TiC, TiCN, MoC Binders include: Ni, Co Chapter Cutting Tool Materials Chapter Cermets Chapter
11 Cutting Tool Materials 9. Diamonds Hardest material known. High speed finishing operations. Diamonds react chemically with certain materials. Difficulty in manufacturing expensive tools. 10.Polycrystalline Cubic Boron Nitrides (PCBN) Manmade material. Used for aerospace materials with high nickel and cobalt content. Chapter hardturning tooling cbn inserts.jpg Chapter Cutting Tool Selection 1. Cutting Tool Material 2. Geometric Characteristics 3. Style of Cutting Tool 4. Cutting Fluid Requirements 5. Machining Economics /images/chipping cutting tools2.jpg Chapter
12 Cutting Tool Selection Chapter Cutting Tool Selection Chapter Cutting Tool Selection Kennametal Products, Inc. Chapter
13 Cutting Tool Selection Kennametal Products, Inc. Chapter Cutting Tool Selection Kennametal Products, Inc. Chapter Cutting Tool Selection Kennametal Products, Inc. Chapter
14 Cutting Tool Selection 1. Cutting Tool Material 2. Geometric Characteristics 3. Style of Cutting Tool 4. Cutting Fluid Requirements 5. Machining Economics /images/chipping cutting tools2.jpg Chapter Tool Geometry Chapter Tool Geometry 1. Back Rake Angle Affects ability to shear material and form chip. Zero degree back rake places cutting surface plane perpendicular to workpiece surface. 2. Side Rake Angle Affects tool strength, cutting forces, friction and chip configuration. 3. True Rake Angle Compound angle consisting of planes established by back and side rake angles. Affects tool force, friction and chip size. Chapter
15 Tool Geometry Chapter Tool Geometry Positive Back Rake Angle Negative Back Rake Angle Chapter Tool Geometry 4. Side Cutting Edge Angle Affects chip thickness, clearance and tool strength. 5. End Cutting Edge Angle Affects clearance and tool strength. 6. Side Relief Angle Affects clearance and tool strength. Chapter
16 Tool Geometry Chapter Tool Geometry /contents/mhg/ru/html/product/t echnical_information/information /images/t_yokokirehakaku_1.gif contents/mhg/de/html/product/te chnical_information/information/i mages/t_maekirehakaku_1.gif Chapter Tool Geometry 7. End Relief Angle Affects clearance and tool strength. 8. Tool Nose Radius Affects surface finish and tool wear. 9. Chip Breaker Helps break chips into desired short pieces. Chapter
17 Tool Geometry Chapter Tool Geometry MAXIMIZING SURFCAM, S.C. Jonathon Lin and Behrooz Lahidji, Scholars International Publishing Corp., Chapter Cutting Tool Selection 1. Cutting Tool Material 2. Geometric Characteristics 3. Style of Cutting Tool 4. Cutting Fluid Requirements 5. Machining Economics /images/chipping cutting tools2.jpg Chapter
18 Cutting Tool Selection MAXIMIZING SURFCAM, S.C. Jonathon Lin and Behrooz Lahidji, Scholars International Publishing Corp., Chapter Cutting Tool Selection MAXIMIZING SURFCAM, S.C. Jonathon Lin and Behrooz Lahidji, Scholars International Publishing Corp., Chapter Cutting Tool Selection MAXIMIZING SURFCAM, S.C. Jonathon Lin and Behrooz Lahidji, Scholars International Publishing Corp., Chapter
19 Cutting Tool Selection 1. Cutting Tool Material 2. Geometric Characteristics 3. Style of Cutting Tool 4. Cutting Fluid Requirements 5. Machining Economics /images/chipping cutting tools2.jpg Chapter Cutting Fluids Purpose: 1. Coolant Reduces temperature, which extends tool life and reduces thermal distortion. Primary purpose of a cutting fluid. 2. Lubricant Reduces friction at chip/tool interface and any area tool rubs workpiece. 3. Chip Removal Flushes hot chips away from point of machining. Chapter Cutting Fluids Characteristics: 1. Thermal capacity and conductivity 2. Lubricity 3. Stable and non corrosive 4. Nontoxic m/monroe/coolant2.jpg Chapter
20 Cutting Fluids Types: 1. Water 2. Oil 3. Emulsions of water and oil 4. Chemically active compounds 5. Wax 6. Cryogenic liquid nitrogen 0recycling/Coolant/Coolants_and_cutting_fluid.ashx?mw=460 Chapter Cutting Fluids Modern Application News, August 2007 Modern Application News, August oads/2012/11/am1108magairproductscryomachining.gif Chapter Cutting Tool Selection 1. Cutting Tool Material 2. Geometric Characteristics 3. Style of Cutting Tool 4. Cutting Fluid Requirements 5. Machining Economics /images/chipping cutting tools2.jpg Chapter
21 Tool Failure Mechanisms Slow death mechanism Gradual tool wear on edge, flank or top, and Built up Edge (BUE). Changes geometry, which affects power required, surface finish, accuracy and dynamic stability. Predictable. Sudden death mechanism Deformation, chipping, fracture and/or thermal cracking. Less predicable. Chapter Tool Wear Kennametal Products, Inc. Chapter Failure Mechanisms Chapter
22 Tool Wear Chapter Tool Wear Chapter Tool Life and Economics Taylor Tool Life Equation: n V T V = cutting speed (sfpm) T = time (min) n = exponent based on tool material C = constant depending on input parameters = C Chapter
23 Tool Life and Economics n V T = C Chapter Tool Wear Chapter Tool Life and Economics Total Cost/Operation: 1. Machining costs. 2. Tool costs. 3. Tool-changing costs. 4. Handling costs. Chapter
24 Tool Life and Economics Chapter Cutting Tool Selection Chapter Tool Life and Economics Chapter
25 The End See Oncourse for Videos Chapter
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