~ Less SUnauyic tan Ingim>pecu steers ur interrupted cutting operations. 5. Carbides ¢ Also known as cemented or sintered carbides. ¢ Produced by powder metallurgy technique. ¢ Basic ingradient of most cemented carbides is tungsten carbide (WC) which is extremely hard. * Most important properties of cemented carbides are their very high heat and wear resistance. Scanned with CamScanner. wee Praca Bg BEAM oS e It is very brittle and low resistance to shock and must be very rigidly supported to prevent cracking. r . © They have the following characteristics: oHigh hardness over a wide range of temperatures, © High elastic modulus, o Versatile, Scanned with CamScannere It is very brittle and low resistance to shock and must be very rigidly supported to prevent cracking. . © They have the following characteristics: oHigh hardness over a wide range of temperatures, o High elastic modulus, o High thermal conductivity, o Versatile, © die materials for a wide range of applications. Scanned with CamScannero Cost-effective tool o die materials for a wide range of applications. Carbides: Tungsten Carbide (WC) O Basic ingradient of most cemented carbides is tungsten carbides (WC) which is extremely hard. O Tungsten carbide (WC) consists of tungsten-carbide particles bonded together in a cobalt matrix. ET Scanned with CamScanner(ae edie Ratan Fal OAs the cobalt content increases, the strength, hardness, and wear resistance of WC decrease. Olts toughness increases because of the higher toughness of cobalt. Carbides: Titanium Carbide (TiC) O Consists of a nickel-molybdenum matrix. O Has higher wear resistance than tungsten carbide D1 Cuitahla far machining hard matariale and far Scanned with CamScannerOAs the cobalt content increases, the strength, hardness, and wear resistance of WC decrease_| Olts toughness increases because of the higher toughness of cobalt. Carbides: Titanium Carbide (TiC) O Consists of a nickel-molybdenum matrix. O Has higher wear resistance than tungsten carbide but is not as tough. Q Suitable for machining hard materials and for Carbides: Inserts Scanned with CamScannerting Too Compa ieroaoR Word oar sesso AaBbCs aanbce AAB but is not as tough. O Suitable for machining hard materials and for cutting at speeds higher than tungsten carbide. Carbides: Inserts e Inserts are individual cutting tools with several cutting points. ¢ Clamping is the preferred method of securing an insert and insert has indexed (rotated in its holder) to make another cutting point available. Scanned with CamScanner¢ Available in a variety of shapes: square, triangle, diamond and round. ¢ The smaller the included angle, the lower the strength of the edge. Scanned with CamScanner7oa1 Water Tt e The smaller the included angle, the lower the strength of the edge. Toolholder Insert. Shenk Clamp, Lockpin. oxsht ¥ ) —<—$§€ Increasing strength aaal 80: aan S Scanned with CamScannerTooter Inson Shank Clare Lodigin lame. ‘Seat orshen @ 6 © Scanned with CamScannerresin stron oSadAs) rein eepng an treakng Chip-breaker features on inserts for the purposes of: 1. Controlling chip flow during machining Scanned with CamScannerAambe. ance Aas aUiIg WOlIg Linps aan 3. Reducing vibration and heat generated 6. Coated Tools * New alloys and engineered materials are being developed to have high strength and toughness, abrasive and chemically reactive with tool materials. Coatings have unique properties: 1. Lower friction 2. Higher adhesion 3. Higher resistance to wear and cracking Scanned with CamScannera name e, abrasive and chemically reactive with tool materials. # Coatings have unique properties: 1. Lower friction 2.Higher adhesion 3, Higher resistance to wear and cracking 4. Acting as a diffusion barrier 5.Higher hot hardness and impact resistance Common coating materials are: ‘Scanned with CamScannerCommon coating materials are: 1. Titanium nitride 2. Titanium carbide 4. Aluminum oxide } | 3. Titanium carbonitride Scanned with CamScanner2. Titanium carbide 3. Titanium carbonitride 4. Aluminum oxide| Coatings are applied on cutting tools and inserts by two techniques: 1. Chemical-vapor deposition (CVD) Scanned with CamScannerCoatings are applied on cutting tools and inserts by two techniques: 1. Chemical-vapor deposition (CVD) 2. Physical-vapor deposition (PvD)| Coatings have the following characteristics: e High hardness ¢ Chemical stability and inertness Low thermal conductivity Compatibility and good bonding Little or no porosity Scanned with CamScannering TST WSRAE [mpRY MGT MCGEE WTS (PSY AC Fall AaBbC: A281 Aab AobCcO AalnCet MallbCeDK AOBOCEDL Andes OHave low friction coefficients, high hardness, resistance to high temperature and good adhesion to the substrate. Olmprove the life of high-speed steel tools and improve the lives of carbide tools, drill bits, and cutters. O Perform well at higher cutting speeds and feeds Tool Cutting direction TIN coated Uncoated Scanned with CamScannertg Tatar [Company Moa METRE Wer (FEL Activation Fale I | Aatbeer AaBbC AaBbcc AAB anne ao0ceo improve the lives of carbide tools, drill bits, and cutters. O Perform well at higher cutting speeds and feeds Rake face, Too! Cutting direction TiN coated Uncoated “Flank wear A thin layer of TiC of 4 to 8 ym thickness and 0.2 um grain size is coated over a tungsten carbide substrate by a vaporiz. inder. The layer is m Scanned with CamScannerG Veporicauon wennque; wit nO Couanemnuer He layer is metallurgically bonded to the substrate. It has micro-hardness of 50% more harder than the basic carbides. ia Ocoati stance in Scanned with CamScannerja Ravan Fal It has micro-hardness of 50% more harder than the basic carbides. Titanium-carbide Coatings Ocoatings have high flank-wear resistance in ao : . machining abrasive materials. Ceramic Coatings Ocoatings have low thermal conductivity, resistance Scanned with CamScannerwo 1 6 [eas amc Aas samer AB Se Vw nigh temperaiure, lank anu ciater wear 7. Ceramics © Ceramics are basically introduced for high speed machining of materials and cast iron (~ 10m/s).. © These can withstand very high temp, are | chemically more stable and have higher wear resistance than other cutting tool materials. Scanned with CamScannering Tea ‘oma Foun Word Produc re AaBbec AaBbC Aabbcc AAD o Ceramic tool materials consist of fine-grained and high-purity aluminum oxide (Al203) o Additions of titanium carbide and zirconium oxide improve toughness and thermal shock o Alumina-based ceramic tools have very high Scanned with CamScannero Ceramic tool materials consist of fine-grained and high-purity aluminum oxide (Alz05)| o Additions of titanium carbide and zirconium oxide improve toughness and thermal shock resistance. o Alumina-based ceramic tools have very high abrasion resistance and hot hardness. o Heat conductivity is very low. They are generally Scanned with CamScannero Ceramic tool materials consist of fine-grained and high-purity aluminum oxide (Al2,O3) o Additions of titanium carbide and zirconium oxide improve toughness and thermal shock resistance. o Alumina-based ceramic tools have very high abrasion resistance and hot hardness. o Heat conductivity is very low. They are generally used without a coolant. o The main problems with ceramics tools are their low strength, poor thermal characteristics and Scanned with CamScannero Alumina-based ceramic tools have very high abrasion resistance and hot hardness. © Heat conductivity is very low. They are generally used without a coolant 0 The main problems with ceramics tools are their low strength, poor thermal characteristics and their tendency towards chipping. o Ceramic tools should be used with very high cutting speed on steels. They are not suitable for low cutting speeds «nor for intermittent o It is possible to get a mirror finish on cast iron Scanned with CamScanner8. Cubic Boron Nitride (CBN) Ocubic boron nitride is next in hardness only to diamond. Hilt consist the atoms of Boron and Nitrogen. Olt is not a natural material. It is produced in the laboratory using a high temp/high pressure process similar to the making of artificial diamond. DAt elevated temperatures, it is chemically inert to iron and nickel. ' cutting hardened ferraiucs and hish-temneratiure Scanned with CamScannersimilar to the making of artificial diamond. DAt elevated temperatures, it is chemically inert to iron and nickel, Diits resistance to oxidation is high and suitable for cutting hardened ferrous and high-temperature alloys. Olt is having high hardness, high thermal conductivity and high tensile strength. Scanned with CamScannerOn certain applications a thin layer of CBN is applied on cemented carbide tools to obtain better machining performance. OThis material is traded in the name of “BOROZON”. Tungsten-carbide insert Polyorystalline cubic boron nitride Braze or diamond layer Carbide substrate jam e hardest substance is diamond. Scanned with CamScannerCarbide substrate 9. iamond OThe hardest substance is diamond. OThey have low friction, high wear resistance and the ability to maintain a sharp cutting edge. Qt is used when a good surface finish and dimensional accuracy are required. ; Osynthetic or industrial diamonds are used as natural diamond has flaws and performance can be Scanned with CamScannerDAs diamond is brittle, tool shape and sharpness are important. Olt can be run at cutting speeds about 50 times greater than that of HSS tool and temp upto 1650 °C. al Scanned with CamScanner10. Whisker - reinforced Materials|_and Nano- materials * There is continuous effort of improving the performance and wear resistance of cutting tools. SESE are Scanned with CamScanner9 amc: samen aac, ssnice AAB some 1 10. Whisker - reinforced Materials_and Nano- materials * There is continuous effort of improving the performance and wear resistance of cutting | tools. * New tool materials with enhanced properties | are: | 1. High fracture toughness Scanned with CamScannerseen tc) Aahee AQIS 1. High fracture toughness 2. Resistance to thermal shock 3. Cutting-edge strength 4. Creep resistance 5. Hot hardness * The use of whiskers is for reinforcing fibers in * Nanomaterials are also becoming important in Scanned with CamScannerHardness (Rockwell C) « Nanomaterials are also becoming important in advanced cutting-tool materials| Ceramics 70} fr Cemented carbides 50 7 Cast cobalt alloys 30 20 High-speed steels, Plain carbon steels: Temperature (F) Scanned with CamScannerec AabtbG AaBbCe Aabs General Characteristics of Cutting-tool Materals (These Tool Matertals Have a Wide Range of Compositions and Properties; Overlapping Characteristics Exist in Many Categories of Tool Materials) High-speed Cast-cobalt Uncoated Coated Polycrystalline cubic steels alloys carbides carbides Ceramics boro nitride Diamond Hot ares —— oo ‘Toughness —<——— Ampact strength —— Wear resistance —_— Chipping resistance << _ aa Cutting speed —— ‘Thermal-shock resstance <—_—_—_—__ Tool mater cost ee Depth of cut Lightto Light to Light to. Light to Light to Light to heavy Very light for hey heavy heavy heavy heavy single | side att ange» ee Naee Scanned with CamScanner} tmnutane Ae Nae End reotangie End clearance angie Scanned with CamScanner