Tools

Manufacturing Processes

Outline
Types of Tools Tool Geometry Cutting Fluids
Effects Types

Tool Wear
Forms Causes

Failure Modes Critical Parameters

Horsepower Used Operating Temperature

Feed and Speed Tool Life

Types of Tools

Tool Geometry

Single Point Tools Multiple Point Tools Chip Breakers Effects of Material on Design

Single Point Tools

Multiple Point Tools

Chip Breakers

Important Tool Properties

- High hardness - Resistance to abrasion, wear and chipping of the cutting edge - High toughness/impact strength - High hardness at high temperatures - Resistance to bulk deformation - Chemical stability (does not react or bond strongly with the work material - High modulus of elasticity (stiffness) - Consistent tool life - Proper geometry and surface finish

Tool Materials
- Carbon and medium-alloy steels - High-speed steels - Cast-cobalt alloys - Carbides - Coated tools - Alumina-based ceramics - Cubic boron nitride - Silicon-nitride-base ceramics - Diamond - Whisker-reinforced materials

Cutting Speeds of Tool Materials

Cutting Fluids
Effects
coolant lubricant flushes chips reduces oxidation of heated surfaces

Types
- cutting oils - emulsified oils - chemical fluids

Cutting Fluid Application

Flooding - 3 gallons per minute per tool Misting - atomized fluids - a health hazard (OSHA limit = .2 mg/m3)

High Pressure Systems - often applied through the tool

Tool Wear
Forms
- crater wear - flank wear - chipping

Causes
abrasion adhesion diffusion plastic deformation

Crater Wear and Flank Wear

Crater wear

Flank wear

Failure Modes

Fracture Temperature Failure Gradual Wear

Critical Parameters

Horsepower Used Operating Temperature

Horsepower Used
Values of Unit Horsepower for Various Work Materials
Brinell Hardness 150-200 Carbon Steels 201-250 251-300 125-175 175-250 50-100 Unit Horsepower hpu hp/(in3/min) 0.6 0.8 1.0 0.4 0.6 0.25

Material

Cast Irons

Aluminum

Operating Temperature

Feed and Speed

Speed the rate at which the tool point moves as it rotates (in a lathe, the rate at which the cutting point on the workpiece rotates) Feed the rate at which the tool is fed into/along the workpiece

Feed and Speed

V = DN/12 V = surface cutting speed (ft/min) D = diameter of rotating object (in.) N = rotation rate (RPM)

Feed and speed

Example: Assume a high-speed steel saw with 100 teeth and a diameter of 6 inches is used to cut aluminum. Determine the proper RPM and feed rate. V (HSS, aluminum) = 550-1000 ft/min [in table] N = 12V/(D) = 12(550-1000)/(6) = 350-637 RPM

Feed (aluminum, saw) = .006-.01 in/tooth [in table] (.006-.01)100 teeth = .6-1in (.6-1)350 RPM = 210-350 in/min
Start with the lowest values. They can be increased so long as the finish is acceptable.

Tool Life
F. W. Taylor, 1907 Taylor Tool Life Equation vTn = C vTn = C(Tn ) ref

Cutting Performance
How do we know if cutting parameters are optimal? 1. 2. 3. 4. 5. 6. Surface finish Tool wear Chip shape Sound Cutting time Heat

Summary
Tools fail slowly with gradual wear or suddenly with fracture Cutting fluids help reduce the effects of wear and temperature failure The materials of the tool and the workpiece affect the tool shape and life

Higher cutting speeds increase the operating temperature and decrease tool life
It is necessary to calculate proper feed and speed to prevent excessive tool wear www.mime.eng.utoledo.edu/people/faculty/imarinesc u/2650/

The End