Hot-work steel (Ayr howe tog HI-HI9 1120 anid up H40 and up Cokd-work steel D te feasting 2) Tn, Swath Oy Wy Shock-resisting steel Mold steel Special-purpose steel Los vem F /Water-hardening steel Whee t sea, h-speed steel application: Cold Meategory For high abrasion areas Teategory ‘Where high hot harduess is needed Cold-work steel application: tee POY: hot dies, roller bearin, Cutting tools for medium speed mtthyorst Molybdenum content (teu! ium coment E48 en content £&- 9-F 47Molybdenum content "* 7 High carbon and | Oil-hardening steel Medium alloy. air hardening Low earbon content, alloyin; f Vary with type top hat yan th Mein Very low carbon coment @e S464, 2¢ Low-alloy Carbon-tungsten. low-alloy /2% Minimum ot allo ww en content Me yoo pot chromium 4o¢e- elements loo ge E Maeingprtth, Lien Is. and where heat-treatment stability isZh Gy fi MIS FF Bb citing (oth AEBS 19 HAY ibe sp05 #, Deve) ww. aft Witt HBS with high Vo, CoB a ny Chem. Petro-chem . NU & 7950 co polymer industries | ve: Pian caramics, Gyn Diarsond — Ceramics and Cerrnate Jet engines Space programmes | —rL_—__— | Coated carbides, PM ~ Reduction of cost of | manufacturing LS CBN, coated HES, SIALON Defence 700 1 Superalloys at } —_ | 1G | High pertormance ceramics Pe Just-in-time 1990 | Diamond cxated caroides Piatt Fig. 3.3.2 Chronological development of cutting tool materials. (ii) Characteristics And Applications Of The Primary Cutting Tool Materials (a) High Speed Steel (HSS) Advent of HSS in around 1905 made a break through at that time in the history of cutting tool materials though get tater superseded by many other cattsdes and ceramics which could novel tool materials (ike ce machine much faster than the HSS tools. Version 2 ME, IT Kharagpuror inserts were powder and sintering 90 to 95% WC grains are ssary strength and grey cast chips and at culling ch produce shorl 2 see times of thal possible for HSS tools, First the straight oF metallurgically produce we powder wilh coball held by the toughness. St bronze ete velocities wo { « Composite carbides / Is f rapid le for machining steels because © i er wear, by diffusion ‘of Co and oo Pom the tool Hy the chip under the high stress and temperature ul (plastic) contact belween the continuous chip and the tool surfaces = Hor machining stecls Su sesstully, another type called composite cr i ie have been developed by adding (8 to 20%) a gamma phase to an : { TiC, TIN, TaC, NiC etc. which are bility and less Co mix, The gamma phase Is 4 mix of more diffusion resistant (han we due wottabiity by steel to their more sla + Mixed carbides Titanium carbide (TiC) is not only more stable but also much harder than WC. So for machining ferritic steels causing intensive diffusion and adhesion wear a large quantity (5 to 25%) of TIC is added with WC and Co to produce another grade called Mixed carbide, But increase In TiC content reduces the toughness of the tools. Therefore, for finishing with light cut but high speed, the harder grades containing upto 25% TiC are used and for heavy roughing work at lower speeds lesser amount (5 to 40%) of TiC is suitable + Gradation of cemented carbides and their applications The standards developed by ISO for groupi i L up application ranges are given in Table 33 2 ne ee Table 3.3.2 Broad classification of carbide tools. 180 Code _[ Colour Code Application For —machinins i | ig long chi os comet materials ike jain carbon and ; |. ee low alloy foe mec pining long or short ip forming ferrous materi like Stainless steel aterials ' machining short chipping, feyous and non-ferrous aterial and non-metals like Casl Iron, Brass etc K-group Is suit Is suitable fo fanoua iat 1 Machining s\ Ht0u8 metals and also some Tah ae producing ferrous and non- Version 2 ME, IIT KharagpurP.group is suitably used for machining tong chipping ferrous metals be plain carbon and low alloy steels M-group is generally recommended for machining more difficull-to- machine matenals ike strain hardening austenitic steel and manganese steel etc Each group again is divided into some subgroups like Pro, Pzo elc.. a8 shown in Table 3.3 3 depending upon their properties and applications Table 3.3.3 Detail grouping of cemented carbide tools | iso ] | Application Material | Process 4 (group | | Pot | Steel Steel castings | Precision and finish machining, - Mice nears high speed. | P10 | Steal Steet castings | Turning, threading and milling \ L = ~__| high speed. small chips / P20 *Sleel, steel castings, | Turning, milling, medium speed | \ | malleable cast iron with small chip section | P30 T Steel, steel castings, | Turning, milling, low cutting 1 | | malleable cast iron | speed, large chip section | [forming tong chips__| ] ‘P40 Steel and steel| Turning, planning, low cutting ‘casting with sand | speed, large chip section t [inclusions P50 Stecl and. steel| Operations requiring high castings of medium or | toughness turning, _ planning, low tensile strenath__| shaping atlow culling, speeds TKOT Hard grey Cl, chilled | Turning, precision turning and casting, Al. alloys with | boring, milling, scraping high silicon _| K10 Grey C1 hardness > | Turning, milling, boring, reaming, 220 HB. Malleable | broaching, scraping C1, AL alloys containing Si K20 Grey C1 hardness up | Turning, milling, broaching, to 220 HB requiring high toughness K30 Soft grey c.1. Low| Turning, reaming under tensile strength steel, favourable conditions K40 Soft non-ferrous | Turing milling etc. metals 10 Steel steel castings, | Turing at medium or high manganese __ steel, | culling speed, medium chip grey C.l | section M20 Steel Casting, | Turning, milling, medium cutting austentic steel, | speed and medium chip section manganese _ steel, spherodized = li Malleable C.! 2 M30 Steel, austenitic steel, | Turning, milling, planning, spherodized Cheat | medium cutting speed, medium resisting alloys [or large chip section M40 Free cutting steel, low | Turning, profile turning, specially tensile strength steel, | in automatic machines brass and light alloy Version 2 ME, IIT Kharagpur Cf. MA ke eenHARDNESS , HRC oe oe oy 7 6 0 i CUTTING TEMPERATURE x 100°C Fig. 9.3.3 Hol hardness of the different commonly used too! materials (Ref Book by A.Bhattacharya) However, the use of those brittle plain ceramic tools, until their strength and toughness could be substantially improved since 1970, gradually decreased for being restricted to ~S ininterrupted machining of soft cast irons and steels only * felatively.high cutting velocity but only in @ narrow range (200 ~ $00 mimin) «requiring very rigid machine tools Advent of coated carbide capable of machining cast iron and steels at high velocity made the then ceramics almost obsolete Version 2 ME, WT Kharagpur4 Direct coating by TiN instead of Tic 4 Using better coating materiale." | feasible (b) Cermets. he le by combining ‘cer’ froy TiC, TiN orn ( or )TICN and ‘met’ from metal (binder) like NNECe re ae Since around 1980, the Since around 1860, he modern Ceimels providing much better performance porcls. ad uadie. ie i - ‘ith 'S consistently more wear resistant, less : jake The charactenstic fe 2 Contrast to sintered tungsten carbides, ae PUES Of Such cermets, m * The grains are made of T ni ICN (in place of WC! and Ni or Ni-t and Fe as binder (in place of Co) 0 oo * Harder, more chemically stable and hence more wear resistant * More brittle and less thermal shock resistant * Wt% of binder metal varies from 10 to 20% * Cutting edge sharpness is retained unlike in coated carbide inserts * Can machine steels at higher cutting velocity than that used for tungsten carbide, even coated carbides in case of light cuts. Application wise, the modern TICN based cermets with bevelled or slightly founded cutting edges are suitable for finishing and semi-finishing of steels at higher speeds, stainless steels but are not suitable for jerky interrupted machining and machining of aluminium and similar materials. Research and development are still going on for further improvement in the properties and performance of cermets (c) Coronite It is already mentioned earlier that the properties and performance of HSS tools could have been sizeably improved by refinement of microstructure, powder metallurgical process of making and surface coating. Recently 2 unique tool material, namely Coronite has been developed for making the tools like small and medium size drills and milling cutters etc. which were earlier essentially made of HSS. Coronite is made basically by combining HSS for strength and toughness and tungsten carbides for heat and wear resistance. Microfine TiCN particles are uniformly dispersed into the matrix. Unlike a solid carbide, the coronite based tool is made of three layers; + the central HSS or spring steel core : + alayer of coronite of thickness rain) 15% of the tool diameter . in (2 to 5 um) PVD coating of TiCI Such ‘coh tares ot only more productive but also provides better product suey trusion followed by PVD-coatring of TiN or ite tools made by hot ex‘ 2 TIGN outperformed HSS tools in respect of cutting forces, tool life and surface finish. (a) High Performance ceramics (HPC) Ceramic tools as such are much superior to sintered carbides i et ae hardness, chemical stability and resistance to Mee an fracture toughness and strength as indicated in Fig. 3 Version 2 ME, IT KharagpurThe HPC tools can be broadly classified into two groups as HPC Tools Mis Nitride Ceramics Oxide Ceramics Silicon Nitride Alumina toughned by a cn (i) Zirconia it (ii) SiC whiskers (i) Whisker toughened (ii) Metal (Silver ete) Nitride based ceramic tools Plain nitride ceramics tools Compared to plain alumina ceramics, Nitride (SisN«) ceramic tools exhibit more resistance to fracturing by mechanical and thermal shocks due to higher bending strength, toughness and higher conductivity. Hence such tool seems to be more suitable for rough and interrupted cutting of various material excepting steels, which cause rapid diffusional wear and BUE formation. The fracture toughness and wear resistance of nitride ceramic tools could be further increased by adding zirconia and coating the finished tools with high hardness alumina and titanium compound. Nitride ceramics cannot be easily compacted and sintered to high density. Sintering with the aid of ‘reaction bonding’ and ‘hot pressing’ may reduce this problem to some extent / SIALON tools Hot pressing and sintering of an approptiate mix of AlzO3 and SisNs powders yielded an excellent composite ceramic tool called SIALON which are very hot hard, quite tough and wear resistant. These tools can machine steel and cast irons at high speeds (250 - 300 m/min). But machining of steels by such tools at too high speeds reduces the tool life by rapid diffusion. SiC reinforced Nitride tools The toughness, strength and thermal conductivity and hence the overall performance of nitride ceramics could be increased remarkably by adding SiC whiskers or fibers in 5 — 25 volume%. The SiC whsikers add fracture toughness mainly through crack bridging, crack deflection and fiber pull-out Version 2 ME, IIT KharagpurTor Intermittent pperalfon or Hand feed Ns o en, 3 eee AEz \ [n2— 0 Sony 2 ka.0.36 ne ; £ BH Catt BE A ets ot te i cgi A die fm cohich two o more euttin Performed fn ‘the same single gtatfon _—— Knockout Ree | [4-—~ stern Holder i] operations ave amd $n Same frreds Ate _—Knock et plate _-~- Top Golater a Impoct plate Knock, ch plate is coma Blanking Die Shedder -- Piercing punchel- stock Strip a sisipper plate atvippex Blanking punck cum Bott ehercing ol/e <——~ — gprin: Gottom Golster — Flatness of Component obtained — Greometricol relation obtained comrecty Disddvantege ~— —~ wall feetton clisfance too Amall- =cir complementary is incorporated irectlvin line =] Shank Holder Cana oe 70 4] Teb Bolster “ aon | Ca) | |_ Cast Tron a o{ Knock out Rod OHNS a | | a| Knocl< out plate ce pers Hee) i Knock oul Pin paces Hes 4 “I OHNE 50-S9. Hee : of| Impact plate ONS 50-55 Heel a¢| Punch plate Mild stee! — os Pieweing Punch He Hew 60-69 Hee Cc 04\ Blanking Bie HCHer 60-62. Hee | Blanki neh Cum ‘ 03| Oe Ee tie Helier Go-62HRe | 02| Stripper plate Mild), Steet _ or| Botiom Bolster Catt Iron _ §p,|_ Derectpvfon Materials _ [Haak treatment wa Types_of cle -aet = act and _punpore?- 3. Purbats * = (React from BoM 181) Accumacy of setup : Improved! piece: path Qualtly 3. Increased olfe A. tMinimam eteep-time 5. Facilitalian of maintenance +B Alignment of plinch and Die members | 4 phuvitatfon of Storage > Y eI § | © Gack post ctieret @ Center-post diecd @ Diggers! posh cfiegel‘cateta x ( Anitecia 0 i al 4 a tes at to deside earance {n Shsaiting 2 Shar Case A — Annealed Steel 0 Ac thickness T= lm ot Case & - » emmee’ " T= 4 mm Gase C - Hard Cold veld 6 4 fe is Ped wm Cue © - § = ¥ e . T zhrm Recomendathon| _ E teavance fide -mm peat | CaseA Case C Care BY Case 0 Soft, thin | Hard , thin | Soft, thick] Hard , tht cK : 0.06 0-08 0.24 0 30 Die Denn ies osm) | (25%). C134) Bunnbed 0.05 0-08 0 32 unepean (S*) (ay) (8h) Mis aTLAg | OOF | | OD oe} ae Type (65%) (2h) Sh) (oh) nish gc >00S Qer 0 oF 2¢=032\ 9¢-04 he ; @sty Gs) (ws) St. Conclusion oO ae of cvecomendation fer nares clearance. (. Horolneds materials required large clerance. @ percentage of stock thitkned! So “Conilant fer aif thlekness provided “the Condition of yall fe Same. @® Selection Perteutr amount of cleanance debends mately on cul eoge qualey» Plrpgrelion ai Lo darth alare aahte Cca> Cpre) pdaploen mi oa or Ln dural jen flaiti. [Ue 3 as re howscheld eqpriprodt ABs ( he | Compt Inowstngs boda Lema sigere )! hte Donne, btn pu Breossvas, plvsnaditas ‘ 0, hehe we. F c)' Fs fe Lape, PEL YO | Palen chtatedo. pe rte pn CPVe) 0 phi ft | Frock i Cos Ivor ou, ketchon Co fa sass i chutlbars. Jiu: Poltnipouctch Pasi, wrond gbne Abjient avonilale Prspab lec Mar : reg Ase ehida a drow Tan. + elected flee han IeLiran 2 Seo lontt-outl, » bes hick sSustrtos » ~ Yes te ‘ia thea sahil, thy, hewn A bc, Heros in iTharrrnditltveg Plesbe neuro : Spy Adie. Hebb fel | | HA Ger Una teu lelbiphle | OAL tn Phomolee gettin Cakelite ~ Adve Aehtawsal poh ye | Polyurethane | Tetowenfrndutit | ih Py Leal Anterte tahing & uncorabs Fir Praducth oblrer er, bends amet’ loinc ft, sok tables bevy of titi Ea. bef, batho: UEab atte, » 3 Patapon ft Ava Si tt 2K, Lecgror, tad fanp 2th dbee heals piente rte etl stn fad frdub chung fils wordt] made fread be DeStion wtadlepy Costly 4 pb bandh & ectll ? 4 burfes, lctire£ taulltet,| ross oe SCA bed, broth, trhos lta td dette retre sebedat prieg alas ecu oyardirg i Ee vat ‘se i Bond ha Strndoid ae e “pme | : 4 ee On viecletne ani © Pacpacitfon ©. a ft, be vendo feel te old eee ae 4 > Fed) ae pane J Toe gee gOPestle, apse Alls eeciacly, “del land oxy ge PM py qtr oak mold and alse tallouss the ejactee fae Be the wt a hee ae eee of east N ~ ttl polity, & tee ‘phe dused) tw: the toe? : T~ overt! cde. Hine fy Bee & = (at ext) > “tes novof covks we 7 = Working. 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Fracture £ ea AL Push Ahrough 3 see = After fracture piece part deeanot fa easly Ao forme fore” require tp puth the plece tymugh die opening. if Gives the equatton for the Combrestive strets on punch amd the length of_the punch *- > Compressive stress 3 fez Lnfert here fe Combrentive Atrenglé eff puich mateval d f= Shear gtress, t= thickness of Sheet A= hole dia. 3 length of Punch TD /£.9\ 4 her m= 42 Fe NTE y= Olameter ef bunched hele -(s> Sheaq Aven 1s theenes of theel Es Youngs vmedulitt of bunch materi e!Ta Ny ; El) br of e Tt f ohh NAS YA Fothyl ~ Vas The bates ocbiin My ” oSSah ra tbts. \ The tabit GT watste \ \ bur. ivadly es wbfed \ im. wt ell usuras bn FUSE -poLeus- | | Pee poi ten Wd te 4 Gree we % tHe dig ond Vio-vou. 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Drcdoed * sudred de aha ¢ pate Corll Pitre “8 & sont ot Wajited oe. ¢ aa - mee patdetlity lark Cond ab eee folding Lae en mm }J: medion wot @ foe bas ining fob domd = SL mm 4 a Le mox length ¢ (pry itukading HK and « % Shey te ¢ he Imaténat to be forged of 099 top borne : Hosmmman. lopoaity = Genrer )K press Openly Hash Lod formalse Te lio, Yotdns 6 gine bg Yhe vos SE F ate —4 y he ool oD EE-)- = 0 eA Y fe 084g — 001TH F015 UT Whore , Ax plor praytiled asa 9 tle forgiug. ne Bee i te, O dn 9 Q Me above fermmlas OF 6 doesnt fake Complora'on gq Hae forging ©,@ ane unahy goutoy fo doberman, flo, Bama , 0 * heme, (9° pra gir He pots Hfbichneat + faagth Gabe Wel mall Boe SA - Yoh bo rte ae era, length wll be tere whith in ant peptone por forging tebe ao ip pidwaed bere tevarponsl Ley Cl cc frokiniol worked, (bo wet olithiknted along Ubre Ys nar legs, too makvel oF fsled Yn bro celles which ofa fa agente lin's, thus turgform Aeuchin oy pratewals bs ob fain — he pada oll bg dung edger 2 warleg 9 malady avcidedl bn bbb oh, PS forging Coy) cell bray forming CO) peduted roy oy x “Gh Gompthed fo ute Hats eeitana a 1 ferwnel Exh, basket ib lmalond Pg IY ime —T* “are pt, lay Se woe .EXAMPLE 4 (PIN EJECTION mm) to the worked example, then a single mould (1.8 in) should be adopted for be (2) When specifying the steel that these plates are in final part of the closing plate thickness 46 mm oth the fixed and moving mould plates. for the two mould plates, bear in mind a sliding ‘surface to surface’ contact during the movement. 16.9 EXAMPLE 5 (D' PIN EJECTION) 16.9.1 Problem A Design a single-impression injection mould to produce the octagonal- shaped box shown in Figure 16.35. The box is to be manufactured in cellulose acetate, The drawing should 'nclude a pian view of the moving half and a side-sectional view of both mould halves Drawing references: plan view of the moving half (Figure 16.36); side- Sectional vicw of both mould halves (Figure 16.37); isometric view of the m ving half for reference purposes (Figure 16.38). 16.9.2 Design notes (1) General considerations. The component to be moulded is an octag- Onal box with a relatively thin-wall section. D-pin type ejection has been adopted for this design so as to obtain a reasonably large 2° oS . ro | yen eX SECTION Xx 2 3 GENERAL WALL THICKNESS Imm(0.04n) ORAWN /2 FULL SIZE. 50. t2i Figure 16.35— Example 5: octagonal shaped bOx for WhICh 0 Single.impréssion mould is required 57865 cou Jo May8 wend ~9E-OF Bandi x = s = Fd & S 5 z = Zz SATNOW NoLaaten ay a iti peer annie any soaeanis 20°94 dmb (NoNLDatT NMEA) 6 RA YSHO.KT s>I01 on (1 9jdurexg paWORKED EXAM?! the ejector Figure 16.38~lsomaric view of 600 to spark n feature is for octagonal box shown in AMPLE 5 ('D' PIN EJECTION) Four horizontal drillings are incorporated lings are positioned relati ing may be connected external ported by the the core wall design the columa lunin could alterna. ol |se WORKED EXAMPLES OF SIMPLE INIECHON MOULDS tively have been incorporated ay a separate member, fitted in the same position.) The top (front as viewed) of the cen column is slotted in both the vert and horizontal planes as shown by the ‘hidden detail’ dotted fines in Figure 16.36. The slots provide a passage for the coolant fluid into the central chaniber from the central drilling (Figure 16.37). lauter drilling is connected to the coulant entry supply via a vertical hole drilled in the bolster as shown, The coolant circulates within the chamber and leaves by w the top horizontal drilling and second vertical hole machined bolster. By causing the incoming coolant to strike the rear side of the core insert, turbulent flow is created in this region which facilitates the conduction of heat from this, the hottest part of the cor To prevent leakage of coolant from the core insert chamber, O- rings (O-1) must be incorporated. In this design one O-ring is fitted into an annular recess machined into the base of the insert (CLL) Mould alignment. Guide pillars (Ga) are incorporated in the fixed mould half (cavity plate) and guide bushes in the moving mould half (core plate). Very accurate mould alignment is required because the component has a relatively thin wall section thicknes: (10) Sprue pulling. A sprue puller is not required in this design as the sprue gate is directly attached to the moulding, (11) Parting surface relief. The surface contact between the two mould halves is restricted to the area adjacent to the impression plus four rectangular areas situated one at each corner of the moving mould plate. Refer to the isometric view shown in Figure 16.38, (9) 16.9.3 Problem B Design a single-impression injection mould to produce an octagonal- shaped box (Figure 16.35), this time utilising a standard mould unit from the Desoutter range. For details of the minor mould plates and other component part sizes refer to the relevant page of the Desoutter cate logue which are reproduced in Figures 7.11 and 7.12 respectively. Mould data 1. Mould plate size: W = 246 (9,7) 2. Mould plate siz L = 26 (02 3. Mould plate thickness: A = 27 (1.0) 4. Mould plate thickness: Bo = 46 (1.8) 5. Support block (riser) height: C = 56 (2.2) Sa. Ejector stroke: S = 26 (1.6) 6. Stripper plate: SP os NLA. 7. Width of ejector plate (Ref) EW 150 (5,9) Notes: (1) The overall width (W) of the standard mould unit (or kit), which is specified above, is greater than that adopted for the design shown in Figure 16.36. This is because the ejector plate assembly in design A was of a non-rectangular shape. 602