PROPERTIES OF CUTTING TOOL, CUTTING FLUID, MATERIALS

Properties of Cutting Tool Materials:

1. High Hot Hardness/ Red Hardness: The property of a material by virtue of which it
retains the hardness at higher temperatures.
2. Toughness: Toughness is the property by virtue of which it absorbs energy before the
failure point.
3. Thermal Conductivity: The property of a material by virtue of which it allows the heat to
pass through it.
4. Low coefficient of friction
5. Low coefficient of expansion

Tool Materials:

1. High Carbon Steel: Hardness-750HV @ cutting speed of 5-6m/min. Hardness decreases

at higher cutting speeds. Used in wood working.
2. High Speed Steel: Hardness-850HV @ cutting speed of 5-6 m/min.

T-series symbol Percentage

W Cr V Co
T-1 18 4 1 0
T-4 18 4 1 5
T-7 14 4 2 0
T6 20 4 2 12

3. Cemented Carbide: Tungsten Carbide (WC)- 2000HV, Titanium Carbide (TiC)-

3100HV, Tantalum Carbide(TaC)- 1800 HV.
• P-type : 30%TiC + 60%(WC+TaC) + 10%Co
• M- type: 15% TiC + 75%(WC+TaC) + 10%Co
• K- Type: 90%(WC+TaC) + 10%Co
4. UCON: Niobium based alloy developed by Union Carbide Company. It consists of 50%
columbium, 30%titanium and 20% tungsten.
5. Stellite (Cast Hard Alloys): High hot hardness and very low coefficient of friction.
Stellites are inferior to carbides and superior to HSS. Alloying elements are: 53%Co+
33%Cr + 14%W.
 6. Ceramic: Hardness- 2200HV @ cutting speed of 400m/min. powder metallurgically
produced aluminum oxide tools superior to carbide.
7. Sialon (Si-Al-O-N): This is produced by milling, silicon nitride, aluminium nitride,
alumina, yttrium oxide. It has igher thermal shock resistance than silicon nitride and is
tougher than aluminium. It is recommended for machining cast iron and nickel based
super alloys at intermediate cutting speeds.
8. CBN ( Cubic Boron Nitride): Hardness-4700HV @cutting speed of 600-700 m/min.
CBN tools are primarily to machine stainless steels and high speed steels. The tool life of
CBN is excellent for machining quenched alloy steel for dies.
9. Diamond: Hardness value is 7500HV @ cutting speed 1000 m/min.
10. Coated Tools: Coating of HSS cutting tools with thin layers of about 2-15µ of a metal
carbide or nitride. This can be done by two methods- (a) Physical Vapor Deposition (b)
Chemical Vapor Deposition.

Cutting Fluids

Cutting fluids are used in metal machining for a variety of reasons such as improving tool life,
reducing workpiece thermal deformation, improving surface finish and flushing away chips from
the cutting zone. Practically all cutting fluids presently in use fall into one of four categories:

• Straight oils
• Soluble oils
• Semi synthetic fluids
• Synthetic fluids

Straight oils are non-emulsifiable and are used in machining operations in an undiluted form.
They are composed of a base mineral or petroleum oil and often contains polar lubricants such as
fats, vegetable oils and esters as well as extreme pressure additives such as Chlorine, Sulphur
and Phosphorus. Straight oils provide the best lubrication and the poorest cooling characteristics
among cutting fluids

Synthetic Fluids contain no petroleum or mineral oil base and instead are formulated from
alkaline inorganic and organic compounds along with additives for corrosion inhibition. They are
generally used in a diluted form (usual concent ration = 3 to 10%). Synthetic fluids often provide
the best cooling performance among all cutting fluids.

Soluble Oil Fluids form an emulsion when mixed with water. The concentrate consists of a base
mineral oil and emulsifiers to help produce a stable emulsion. They are used in a diluted form
(usual concentration = 3 to 10%) and provide good lubrication and heat transfer performance.
They are widely used in industry and are the least expensive among all cutting fluids

Semi-synthetic fluids are essentially combination of synthetic and soluble oil fluids and have

characteristics common to both types. The cost and heat transfer performance of semi-synthetic
fluids lie between those of synthetic and soluble oil fluids.

Properties of Cutting Fluids:

1. Higher Conductivity
2. Low Viscosity
3. It should not react with machining components
4. Easily available
5. It should not fume
6. It should not foam
7. It should not give bad odor.
 Conventional Machining: Lathe, Drilling, Milling.

Conventional machining usually involves changing the shape of a work piece using an
implement made of a harder material. Using conventional methods to machine hard metals and
alloys means increased demand of time and energy and therefore increase in cost. Conventional
machining also costs in terms of tool wear and in loss of quality in the product owing to induced
residual stresses during manufacture.

Basic Process:

Conventional Machining Operations:

The three principal machining processes are classified as turning, drilling and milling. Other
operations falling into miscellaneous categories include shaping, planing, boring, broaching and
sawing.

• Turning operations are operations that rotate the workpiece as the primary method of
moving metal against the cutting tool. Lathes are the principal machine tool used in
turning.
 To produce rotational, axis-symmetric parts.
Feed motion
Feed relative to work piece.

Turning Operations:

• Facing
• Parting
• Grooving
• Drilling
• Screw cutting

• Milling operations are operations in which the cutting tool rotates to bring cutting edges
to bear against the workpiece. Milling machines are the principal machine tool used in
milling.
Face Milling and End Milling

• Drilling operations are operations in which holes are produced or refined by bringing a
rotating cutter with cutting edges at the lower extremity into contact with the workpiece.
Drilling operations are done primarily in drill presses but sometimes on lathes or mills.

Drilling Operations:

• Reaming
• Tapping
• Counter boring
• Countersinking
• Centering
• Spot facing
 Lubrication of Machines

The application of some oily or greasy substance in order to diminish friction is defined as
lubrication.

Reducing friction is the key objective of lubrication, but there are many other benefits of this
process. Lubricating
ing films can help prevent corrosion by protecting the surface from water
and other corrosive substances. In addition, they play an important role in controlling
contamination within systems. The lubricant works as conduit in which it transport
contaminantss to filters to be removed. These fluids also aid in temperature control by
absorbing heat from surfaces and transferring it to a point of lower temperature where it can
be dissipated.

Types of Lubrication:

• Boundary Lubrication
• Mixed Lubrication
• Full Film Lubrication

Boundary lubrication is found where there are frequent starts and stops, and where shock-loading
shock
conditions are present. Boundary lubrication occurs when the two surfaces are contacting in such
a way that only the EP or AW layer is all that is protecting them. This is not ideal, as it causes
high friction, heat and other undesirable effects.

Full film lubrication can be broken down into two categories: hydrodynamic and
elastohydrodynamic. Hydrodynamic lubrication occurs when two surfaces in sliding
slid motion are
fully separated by film of fluid. Elastohydrodynamic is similar but occurs when the surfaces are
in a rolling motion. It is called elastohydrodynamic because the film elastically deforms the
rolling surface to lubricate it.

Mixed lubricationn is a cross between boundary and hydrodynamic lubrication.