07 Tool Wear, Life & Machinability

Machining Science
Tool Wear, Life &

Machinability
Tool Wear
Tool Wear, Economy, Part Quality &
Tool Wear, Life & Machinability
Process Reliability
1
Tool Wear
Consequences of Tool Wear:
• Large power consumption
• Affects the dimensional accuracy
• Deteriorated Surface Finish
• Overheating of the tool
• Shortens the tool life
• Generates Chatter vibrations
Why Tool Wears?
Failure of the Cutting Tool may be due to:

a) Plastic deformation of the tool due to high

temperature and large stress Hot Hardness
b) Mechanical breakage of the tool due to large force
and insufficient strength and toughness Toughness
c) Blunting of the cutting tool through a process of
gradual wear. Wear Resistance
2
Three Modes of Tool Wear
 Excessive stress and mechanical chipping
 Cutting force becomes excessive and/or
dynamic, leading to brittle fracture

 Thermal cracking and softening
 Cutting temperature is too high for the tool
material losing its hardness
 Gradual wear
 Sliding of the chip along the rake face
 Sliding of the tool along the newly cut work
surface
Preferred modes of tool failure

 Fracture and temperature failures are

premature failures
 Gradual wear is preferred because it leads
to the longest possible use of the tool
3
Tool Wear, Life & Machinability Sources & Locations of Gradual Wear
Fig.: Sources of heat
 Gradual wear occurs at two locations on a tool:

 Crater wear – on rake face
 Flank wear – on flank (side of the tool)
Locations of Gradual Wear

4
Tool Wear, Life & Machinability Types of Wear
Fig.: Worn Cutting Tool – Principal Locations and Types of

Wear
Crater Wear
Fig.: Crater Wear, as seen through Toolmaker’s Microscope
5
Tool Wear, Life & Machinability Crater Wear
Fig.: Crater Wear, as seen through Toolmaker’s Microscope
Crater Wear
Tool
Failure
Fig.: Tool Wear by Crater Wearing
6
Tool Wear, Life & Machinability Crater Wear
Crater Wear
Fig.: Temperature distribution along tool-chip contact length
7
Tool Wear, Life & Machinability Flank Wear
Fig.: Flank Wear, as seen through a Toolmaker’s Microscope
Flank Wear
Fig.: Flank Wear, as seen through a Toolmaker’s Microscope
8
Allowable Wear Land
• ISO Tool Life Criteria:

1. Average flank wear, 0.3 mm

2. Maximum flank wear, 0.6 mm
3. Depth of crater wear,
KT: 0.06 mm + (0.3 x feed)
4. Catastrophic Failure
Major Mechanisms of Tool Wear

 Abrasive Wear
 Adhesive Wear
 Diffusion Wear
 Fatigue Wear
9
Abrasive Wear: abrasive action of hard
particles of work material
Abrasive Wear
(Dominant cause of flank wear)

Adhesive Wear: high pressure localized fusion
and rupturing
Adhesive Wear
(Causes crater wear)
10
Diffusion Wear: Loss of hardening atoms at tool-
chip boundary
+Fe +W
+Cr
+V
+Fe
(Contributes to crater wear)

Fatigue Wear: loading of asperities between
work and chip
Chip
Tool
(Causes crater wear)
11
Tool Wear, Life & Machinability Temperature vs Crater Wear
Fig.: Relationship between rate of crater wear and average

tool-chip interface temperature
Minor Mechanisms of Tool Wear
 Oxide Wear: oxidation of tool material at the

elevated temperatures
 Plastic deformation due to excessive heat

(contributes to flank wear)
 Chemical decomposition through localized

chemical reactions
12
Total Wear Behavior
Total wear
Rate of wear
4
2
5
Cutting velocity (or) temperature
Fig.: Relative Effects of various causes of tool wear:
(1) abrasive wear;
(2) plastic deformation of cutting edge;
(3) chemical decomposition;
(4) diffusion;
(5) adhesion
Tool Wear vs Cutting Time

Fig.: Tool Wear as a Function of Cutting Time
13
Tool Wear, Life & Machinability Wear Control
Progression of Tool Wear

Indicators of the progression of physical wear:
 Increase in the flank wear size
 Increase in the crater depth, width or other parameter of the

crater, in the rake face.
 Increase in the power consumption, or cutting forces
 Failure to maintain the dimensional quality of the machined
part within a specified tolerance limit.
 Significant increase in the surface roughness of the machined
part.
14
Measurement of Tool Wear
Direct Method:
– Optical method by microscope, etc.
(Tool Maker’s Microscope)

Indirect Methods:
– Force (dynamometer)
– Power (dynamometer)
– Temperature (thermocouple)
– Surface finish (Talysurf)
– Vibration (Vibration pick-up)
– Acoustic Emission ((Acoustic emission sensor)
Tool Life
Length of cutting time that a tool can be

used before the flank wear reaches the
limiting width of flank wear.
15
Tool Life Equation
Taylor’s Tool Life Equation:
=
V = Cutting Speed, m/min
T = tool life, minutes
C = Taylor’s tool life constant (m/min)
n = Taylor’s exponent
 n = 0.10 to 0.20 for HSS

 n = 0.20 to 0.49 for carbides
 n = 0.60 to 1.00 for ceramics
n & C - Taylor’s Tool Life Equation

Tool Material n C
Plain Carbon tool Steel

Non-steel cutting 0.1 70
Steel cutting 0.1 20
High speed steel
Cemented Carbide
Cermet
Ceramic
for turning at feed = 0.25 mm/rev; depth of cut = 2.5 mm
16
Tool Wear, Life & Machinability log (V) – log (T) plot
Fig.: Natural log-log Plot of Cutting Speed vs. Tool Life
Other tool life equations

Extended Taylor’s Tool Life Equation:
=
Other Tool Life Equation:

=
where
V = cutting speed, m/min; T = tool life, min;
d = depth of cut, mm; f = feed rate, mm/rev
K = a constant
n1 = exponent for feed (0.5 to 0.8)
n2 = exponent for depth of cut (0.2 to 0.4)
n3 = exponent for hardness (1.25)
17
Tool Wear, Life & Machinability Cutting speed vs. Flank wear
Fig.: Effect of Cutting Speed on Tool Flank Wear
Process parameters vs. Tool life

Fig.: Effect of feed and depth of cut on

cutting speed for 90 min tool life.
18
Tool Wear, Life & Machinability Effect of Rake angle
Optimum
Range
Effect of Clearance angle

Optimum
Range
19
Tool Wear, Life & Machinability Concept of Machinability
 It is generally applied to the machining

properties of work material
 It indicates how easily and fast a material
can be machined
Quantifying Machinability
Machinability can be measured or quantified mostly

in terms of :
 TOOL LIFE which substantially influences
productivity and economy in machining
 magnitude of CUTTING FORCES which affects
power consumption and dimensional accuracy
 SURFACE FINISH which plays role on
performance and service life of the product.
20
Tool Wear, Life & Machinability Machinability Rating
Machinability Rating (MR) =
.
. × 100
.
Machinability - Defined
Keeping all such factors and limitations

in view, Machinability can be tentatively
defined as:
“ability of being machined”
and more reasonably as
“ease of machining”
21
Tool Wear, Life & Machinability Machinablity Rating
Fig. Machinability rating in terms of cutting velocity giving 60 min tool life.
Machinability Characteristics
Ease of machining or machinability characteristics of any
tool-work pair is to be judged by:
Good Machinability indicators

 cutting forces (less)
 tool wear (less)
 tool life (long)
 surface finish (good)
 cutting temperature (less)
 chip forms (uniform)
22
Influencing Parameters on Machinability
 properties of the work material

 cutting tool: material and geometry

 levels of the process parameters
 machining environments (cutting fluid, etc.)
 strength, rigidity and stability of the machine
 kind of machining operations done in a given
machine tool
Improving Machinability
 Chemical Composition
 Microstructure
 Treatment given to metal
23
Exercise problems
Pb.: A better surface finish is desired on a workpiece.
Recommend three steps without involving tool

change.
Soln.:
1) Increase cutting speed
2) Decrease feed and
3) Decrease depth of cut.
Exercise problems
Pb.: Following data has been obtained in a tool life test
at two different cutting speeds. If 0.3 mm width of
flank wear land is the selective failure criteria,

Calculate the value of ‘n’ and ‘C’ of the Taylor’s
tool life equation.
Time Width of flank wear land
(min) at 150 m/min at 200 m/min
0 0 0
10 0.10 0.17
20 0.14 0.27
30 0.18 0.37
40 0.22 0.47
50 0.26 0.57
60 0.30 0.72
24
Tool Wear, Life & Machinability Exercise problems
Pb.: A tool life of 100 min is obtained at 25 m/min and 6 min

at 70 m/min.
(a) What is the tool life equation
(b) What is the cutting velocity when tool life = 1 min
(c) What is the cutting velocity for tool life = 60 min.
Exercise problems
Pb.: In a tool life test on turning operation, the
following data has been obtained at a depth of cut,
2 mm
T (min) V (m/min) f (mm/rev)

120 100 0.10
50 130 0.10
70 100 0.12
Find out the tool life, when V = 120 m/min;

f = 0.2 mm/rev and C = 2.22
25
Exercise problems
Pb.: Following is the record of number of identical
components produced at different spindle speeds
and feeds between the consecutive tool changes

in a single pass turning operation. Estimate the
number of components that can be produced at
a spindle speed of 350 rpm and a feed of 0.15
mm/rev.
N (rpm) 250 250 300
f (mm/rev) 0.1 0.125 0.125
m (no. of 311 249 144
components)
Exercise problems
Pb.: The following equation was obtained when
machining AISI 2340 steel with HSS tool.

Calculate the tool life using cutting speed = 25
m/min, feed = 0.3 mm/rev, depth of cut = 2.5 mm.
Calculate the effect upon the tool life for a 20%
increase in the cutting speed, feed and depth of
cut, taking each separately. Also calculate the
effect of 20% increase in each of the above
parameters taken together.
. . .
= 2.035
26
Tool Wear, Life & Machinability Machining Example
Pb.: The n and C values from Machining Data book

for machining steel with HSS are 0.125 and 70
whereas for Ceramic are 0.6 and 3000. These are
based on a feed rate of 0.25 mm/rev and a depth
of cut of 2.5 mm. Determine and compare the
cubic mm of steel removed for each of the tool
materials if a 15 minute tool life is required.
References
 Metal Cutting Principles, M.C. Shaw, Oxford Publishers

 Fundamentals of Modern Manufacturing: Materials,

Processes and Systems, Mikell P Groover, John Wiley
 Manufacturing Technology, P.N. Rao, TMH
 Machining & Machine Tools, AB Chattopadhyay, Wiley
 Fundamentals of Machining and Machine Tools,
G. Boothroyd, Int. McGraw Hill
27

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Machining Science

Tool Wear, Life &

• Large power consumption

• Affects the dimensional accuracy

• Deteriorated Surface Finish

• Overheating of the tool

• Shortens the tool life

• Generates Chatter vibrations

Why Tool Wears?

Failure of the Cutting Tool may be due to:

a) Plastic deformation of the tool due to high

dynamic, leading to brittle fracture

Preferred modes of tool failure

 Fracture and temperature failures are

Fig.: Sources of heat

 Gradual wear occurs at two locations on a tool:

Locations of Gradual Wear

Fig.: Worn Cutting Tool – Principal Locations and Types of

Fig.: Crater Wear, as seen through Toolmaker’s Microscope

Fig.: Crater Wear, as seen through Toolmaker’s Microscope

Fig.: Tool Wear by Crater Wearing

Fig.: Temperature distribution along tool-chip contact length

Fig.: Flank Wear, as seen through a Toolmaker’s Microscope

Fig.: Flank Wear, as seen through a Toolmaker’s Microscope

• ISO Tool Life Criteria:

1. Average flank wear, 0.3 mm

Major Mechanisms of Tool Wear

(Dominant cause of flank wear)

Major Mechanisms of Tool Wear

(Causes crater wear)

(Contributes to crater wear)

Major Mechanisms of Tool Wear

work and chip

(Causes crater wear)

Fig.: Relationship between rate of crater wear and average

Minor Mechanisms of Tool Wear

 Oxide Wear: oxidation of tool material at the

 Plastic deformation due to excessive heat

 Chemical decomposition through localized

Tool Wear vs Cutting Time

Fig.: Tool Wear as a Function of Cutting Time

Progression of Tool Wear

 Increase in the crater depth, width or other parameter of the

(Tool Maker’s Microscope)

Length of cutting time that a tool can be

 n = 0.10 to 0.20 for HSS

n & C - Taylor’s Tool Life Equation

Plain Carbon tool Steel

Fig.: Natural log-log Plot of Cutting Speed vs. Tool Life

Other tool life equations

Other Tool Life Equation:

Fig.: Effect of Cutting Speed on Tool Flank Wear

Process parameters vs. Tool life

Fig.: Effect of feed and depth of cut on

Effect of Clearance angle

 It is generally applied to the machining

Machinability can be measured or quantified mostly

Machinability Rating (MR) =

Keeping all such factors and limitations

Good Machinability indicators

 properties of the work material

 cutting tool: material and geometry

Recommend three steps without involving tool