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TOOL WEAR & TOOL LIFE

By Ankit nayak Vikram singh


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TOOL LIFE

DEFINED AS It may be the actual cutting time before failure . Volume of work material removed before the failure. Number of component produced before failure. The cutting speed at which it is removing the material for specified time . The length of material removed before the failure.

TAYLORS TOOL LIFE EQUATION


VTn = C
Where V= Cutting speed (m/min) T= Time (min) n = Exponent depends on tool material c = constant biased on tool and work material and cutting condition
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TOOL LIFE CURVE


v= cutting speed t= tool life
1= HSS 2=Carbide 3=Ceramic
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Log V
1

log t

VALUES OF EXPONENT n

n = 0.08 to 0.2 for HSS tool =0.1 to 0.15 for cast alloy =0.2 to 0.4 for carbide tool =0.5 to 0.7 for ceramic tool
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EXTENDED OR MODIFIED TALYLORS EQUATION


VTnfadb = C Where: d = depth of cut f = feed rate OR =
1

1/ 1/ 1/

1/n > 1/m > 1/p


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30-7

Reduction in Tool Life


Operating Conditions
CUTTING SPEED + 50% FEED RATE + 50% DEPTH OF CUT + 50%

90%

60%

15%

Factors Affecting the Life of a Cutting Tool

Cutting speed . Tool geometry. Tool material. Work material. Coolants.

CUTTING TOOL
A device with one or more edges used to create chips and remove metal. Cutting tools are either single point or multi-point tools.

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CONDITION DESIDING FOR TOOL FAILURE


MACHINING INDUS.
Excessive current and power consumption Excessive sound and vibration beyond their limit

R&D LAB
Total breakage of cutting tool or tool tip

Excessive rise in cutting forces and vibrations

Flank and crater wear reach their limit


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Rough surface finish

FAILURE OF CUTTING TOOL & TOOL WEAR


Mechanical breakage. Plastic deformation. Gradual wear. 1. Crater wear 2. Flank wear

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FLANK WEAR
It occur on Flank Surface RESIONS* Abrasion by hard particles. * Shearing of micro weld between tool and work material. * At low speed flank wear predominate. * If MRR increase flank wear increase.

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FLANK WEAR

EFFECT* Flank wear directly affect the component dimension. * Decrease tool life. * Rough surface finish.

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FLANK WEAR
Primary wear Secondary wear Tertiary wear

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FLANK WEAR

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CRATER WEAR
Crater wear occurs on the rack surface . More common in ductile materials which produce continuous chip. At very high speed crater wear pre-dominates.

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CRATER WEAR
Crater wear linear increase with time. It increase with MRR. Crater wear has little effect on work piece tolerance or surface finish.

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CRATER WEAR

MRR increasing

C. W.

time

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Crater Wear and Flank Wear


Crater wear

Flank wear
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WEAR MECHANISM
Abrasion wear Adhesion wear Diffusion wear

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REFRANCES

Manufacturing science by GOSH & MALLIK . Production engg. and Science by PANDAY & SINGH. Production engg. By SWADESH KUMAR. Metal cutting by A. BHATTACHARYYA. web.iitd.ac.in/~suniljha/MEL120/Tool%20Life2012.pdf nptel.iitm.ac.in/courses/Webcoursecontents/.../pdf/LM-14.pdf
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Presented by

ANKIT NAYAK ankitnayak@live.com

&
VIKRAM SINGH vikram.mech89@gmail.com
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