• Machinability:

• Machinability is the ease with which a given material may be worked with a cutting
tool. The machinability of a material is usually defined in terms of four factors:
• Surface finish
• Tool life.
• Force and power required.
• The level of difficulty in chip control.
Thus, good machinability indicates good surface finish and surface integrity, a long tool
life, low force and power requirements and desired chip control in the cutting zone.

• Machinability Factors:
The machinability is affected by following variables aspects:

(a) Work material Aspects

(b) Cutting tool Aspects
(c) Process parameters Aspects
(d) Machining environments Aspects
• Possible ways of Improving Machinability:

The machinability of the work materials can be more or less

improved, without sacrificing productivity, by the following
ways:
• Favorable change in composition, microstructure and
mechanical properties by mixing suitable type and amount
of additive(s) in the work material and appropriate heat
treatment.
• Proper selection and use of cutting tool material and
geometry depending upon the work material.
• Optimum selection of cutting velocity, feed and depth of
cut based on the tool – work materials.
• Proper selection and appropriate method of application of
cutting fluid depending upon the tool and work materials.
• Cutting tool Technology:
• Cutting tool related terms:

• Single point versus multiple point

• Cratering –wear that forms a concave region on the tool.
• Tool life – length of cutting time that a tool can be used.
• Chip breaker – geometry designed into tool to break stringy chips.
• Cutting fluid – Any liquid/gas applied to improve cutting performance.

•Meaning of Tool Wear:

Cutting tools are subjected to an extremely severe rubbing process. They are in
metal-to-metal contact between the chip and work piece, under high stress and
temperature. The tool wear can be defined as “The change of shape of the tool from
its original shape, during cutting, resulting from the gradual loss of tool material”.

• Tool wear depends upon following parameters:

Tool and work piece material.
Tool shape.
Cutting Speed.
Feed.
Depth of cut.
Cutting fluid used.
• Tool wear affects following items:
• Increased cutting forces and cutting temperature. (fig a)
• Decreased tool life and poor surface finish.

• Failure of Cutting Tools and Tool Wear

• Fracture failure: Cutting force becomes
excessive, leading to brittle fracture.
• Temperature failure: Cutting temperature
is too high for the tool material.
• Gradual wear: Gradual wearing of the
cutting tool.

• Preferred Mode of Tool Failure: Gradual Wear

.
Gradual wear occurs at two locations on a tool:
• Crater wear – occurs on top rake face fig(a)
• Flank wear – occurs on flank (side of tool) fig(b)

(fig b)
• Flank Wear:
• Wear occurs on the flank face (relief or clearance face) of the tool is called flank wear. It
is generally results from high temperatures, which affect tool and work material
properties.
• Reasons of Flank Wear:
• High cutting speed feed and depth of cut causes
flank to wear grow rapidly.
• Remedies for Flank Wear:
• Reduce cutting speed, feed and depth of cut.
• Prevent formation of built-up edge by
using chip breakers.
• Effects of Flank Wear:
• Surface roughness increases and also effects on
dimensional accuracy resulting the change in shape of produced
components.
• Features of Flank Wear:
• Notch wear:
It is a common wear type when machining
stainless steels resulting a damage on both the rake face
and flank. It is caused by adhesion (pressure welding of chips).
• Nose Wear:
Nose wear or edge rounding occurs due to high
cutting speed and increase of negative rake angle.

• Crater Wear:
• Wear on the rake face of the tool
is called crater wear shaped as a bowl. The chips
flows across the rake face develop severe friction
between the chip and rake face. This produces a scar on the rake face due to continuous chip.

• Reasons of Crater Wear:

• High temperature in the tool-chip interface.
• Due to rise of feed, cutting speed and
temperature.

• Remedies for Crater Wear:

• Use of proper lubricants and coolant from
tool-chip interface.
• Reduced cutting speeds and feed rates.
• Causes of Tool Wear:
(i) Abrasive wear (Hard particle wear).
(ii) Adhesive wear.
(iii) Diffusion wear.
(iv) Chemical wear.
(v) Fracture wear.
(i) Abrasive Wear (Hard Particle Wear):
Abrasive wear is basically caused by the impurities within the work piece material, such as
carbon nitride and oxide compounds, as well as the built-up edge fragments. It is a
mechanical type of wear. It is the main cause of the tool wear at low cutting speeds.
(ii) Adhesive Wear:
Due to high pressure and temperature at
tool-chip interface, there is a tendency of
hot chips to weld on to the tool rake face.
This concept leads to subsequently formation
and destruction of welded junctions. When
the weld intermittently breaks away picking
particles of cutting tool.
(iii)Diffusion Wear:
Diffusion wear is usually caused by atomic
transfer between contacting materials under
high pressure and temperature conditions.
This phenomena starts at chip-tool interface.
At such elevated temperatures, some particles
of tool materials diffuse into the chip material.
It can also happen that some particles of work
material also diffuse into the tool materials.
(iv) Chemical Wear:
The chemical wear is caused due to chemical attack of a surface. For example:
Corrosive wear.
(v) Facture Wear:
The facture wear is the most harmful and undesirable type of wear usually caused by
breaking of edge at end.

• Consequences (Effects) of Tool Wear:

(i) Increase in Cutting Forces
(ii) Increase in Surface Roughness
(iii) Increase in Vibration or Chatter
(iv) Decreases in Dimensional Accuracy