1d pelt) MACHINING SCIENCE Single point Cutting tool - Lathe Multi point Cutting tool — Dring, Grinding. Machining Conventional Uncenventicnal Machining Machining i i contact hate — Direct contact blu — No Direct con tool & work piece between ‘tool & work piece — We use Mechanical energ Or other forms of energ Single point Matti point Cutting tool Cutting ‘tool ~ lathe operations - Grinding | ? Point Line Gmtact. ~ Driting * Bored on relative motion blw +tool ¥ wp, \ Machining is classified int» two types, © orthogonal proceas @ oblique proceas. ~ Cutting edge and Not perpendicular Cutting velocity vector q ey Ex: Turning, Milling, Qre perpendutar: Grinding . Ex: Shaping & planing, Facing % Amounts of energy we apend for cutting ie not Completely Converted into work. eo... 7 a be oeBecause oF heat generarin srpat_paramotes! Ip tot Lasers ve the, tol Ue decreates, ae ~ Because of 4 Cutting Emditins (v4.4) — the stre: the tol fmateriat decreases ity Ihe Strength oF curing Filss LW) am (oie arattemt oF wpa se in temperature (Meto1) ‘® Retative To? oF work pi chip terval bomen eas influences, the Catting condition Ae the Bame time, ToF Citing toot 4 casting tool is Subjected © wear Sharpness decease > Buatity OF the material i& important Dimentienal accuracy + Surface Fi y + Surface wore piece 4 Goative movin ia prosent between 4 then extemal force > Resisting fi The streas indices | present m™ember"after temo be ving | Force But in a lathe, aa the Tovement of work piece ie heatricted ith clampa,, deformation of ullp takes place “+ Residual streas i important for tool Ue. (xpi # Fite > When applied force > Resintive force, deformation Starts 1. chip. reation Say . 2. Frces —? Strona -1Strain | a. Temperature 4, Tool Wear rae 5, Surface Finish & Dimengional accuracy Se aking teel im at BAarting point, slowly Btresaea inc 6. Hardness ie (clastic region, plastic region) = Reslduat @rveaes Material Failure occurs 8. vib oF up > Shear ions Damages the quality Faiture occurs & Chips Formation bogine aoccurs tq ela "Hn shearing OCHEN takey The deformation ‘ region & hen hen rater, ape OF FE Cary, nding onthe place (Oe plane where ‘material TemoVaL. tikes 2 Shear plane: van taees place im AheOrIng Action Place - chip Reman Region + Elastic & plastic defermation Region @: upte Some pine, Chip 18 Fm COace Uh tay Deformation taxes place due t? fictional force (plastic deFormation) Region ©): Friction force (plantie) WW Region @ is a heat Aource since att the Firelemy work (2hear deformation) “Tres Defermation 1. Primary 2. Secondary in, Berton PAL yeah FI sign erperatten (inde ~ ose) En primary deformation gone, High Yegion bs Shear piace. Geme heat ‘transfer taxes place to chip wp . (Utbove avagtam) oF heat going chip é ‘rnong the above. arroune ‘more (tex ares) © cutting toot (Lene mass) © were piece [More ma9a) um 3 TF the chip has high temp , temporary weld Oces weld goes B Tot cmverted 10 fact 1+ primar) oad aie between chip & cutting tcol » Tnmediately primary Bone - (Not due. to #1) uay From cutting tok fagion @ : Secondary gone \Heat dee to length oF contact 1, Sticking gee ~ Temp. move 2 ; 1 Temporary weld Region @ + Tertiary deformation ame (Heat: duet? #} Sipping one ~ chip moves Quay 5 Fram toot + Tertiary: Very Smalt amounts oF heat: 1% 7B) — hen the Chip moves aulay from the tool, chip + When the tot is Forwarding {maing) , Shear Plame tries to take auny some part of tool 7? Looke particles oF toot Tove auvey From the tool algo forwaras, Lith the chip +000. taser paint) Tha is cated ool wear,citi be ito pareiates: So © weak Wp has Strong parties © A veok partic Cutting toot lay has aéreng # WHO! 2 2 When Up Btrmg particles Comes in Cominet wis, the weax particles oF culting tool, Hol Weay occurs This ia another reason for tool Wear, Toot wear Takes the #00L blurt W® ploughing Force: At the Bbriking paint OF t00l sig wlp, ‘the force to produce Shear is Called ploughy Force: * Guiting Force: once the Seperation Starts, the fore fequired to Continue cutting decreases (due t» Tt 4\ strengin of tool 4) This force th kenoun a Guiting Pores Ploughing Foce > Citing force Static friction > dynamic friction * “> Gating edge & casing ~ The cutting edge clears Hwy chip femation sdy & Fmportant 2 = Nazure & behaviour oF wp ONE ie energy requirement: (Amount oF energy required & Femow Unit Volume OF work piece material) ~ Nature & degree of interac mm act the chip-toal , inter Faces, lLuprication £ coefticiont oF Fricaon) 4 Factors influen: ng chip Formation + + lone ‘tmateriaL + Materia & geometny OF the cating. toot angles £1 none rads (7 parameter + Prcens parameters “cating Pui _orthogena ve Oblique cuit + dy They are oblique. Velocity are ath i > cutting edge may the with oF wp on The chip curt & Flows Straight up the toot & chip Flows sideways, Tot Fide ways_+ Thee Companents, op ’ rent OF Q force { Tuo. campor cutting fee (mateo, cating. Foes 2) > Heat devetoped per eee nie nea ue t2 Frltin long took wp imrberFace 38 breaching —E AMIBE ALM tet, ~) Partingin Lathe, Frequently, More thay © stoting ne Casting edge ig Im actien | ® Types of chips: 1. Dibamtinuous chips 2. Gmtimeus, chips with BUE 3. Continuous chips without eve Serrated chips (nen hemogencas chips) L.oicontinuows Chips, De Brittle wip at oF =) (ow cutting speeds — Tine fr next port oF OP, ae eming tn tegy2 More nest Large uncut chip thickners > low axe angies lack oF ePhective clking Fuel + MOTE ng A Low mje toot rigisey Duet Merit Serena 9 Next Op OE High tool -chip Friction leads to breaking of cup, Disadvantager + cutting Force Centinuaily Varies during cus + Surface Finish, Bdimerpional accuracy te OF fected + Damage oF ating toot. OF the 2ot. holder: oF the machine to, + Low atiFFrean, 7 Bus allowing vibration % chaser to occur Continuous chips — Ductite dip > High cutting speeda, 1 > High Foxe angle | Low chip-toat > Smaut Feeds, r | Friction Small uncut: chip thicerieoa ~ Sharp cating edge Steady tate process Surface, Finan i goed. % Amooth cutng, * Higher tat Ufe % ler power consurnption "Chip disposal. is @ problemover the FOX! fag cantimuoudls ve Dinadamtnges: «Bue may tax porttlen Fem cating toot + chip Pewing toot 12 dittipate pS : a oF toot devant now 90 Pate ew, Toot Ufe decreanes ° rate tien «citing tool tempera + Toot wear occua we Fuctuatins in cutting Forces ‘ontinuous Chip with QUE i 3. Gone chip with Bue * Poor furFace finan — How to teduce ave 2 “the chip are Sticking to 4 — particles Fi They form Arma Prajec + Imeeare Cutting Speeds Fake face oF tool “Apter some time , it B Called Build-Up-edy, + Decrease depth oF cut Lore goes out: + Increase take angle n causes adhesion + une a sharp tool + Plastic deforma + use Cutting Fluid > Bu becomes unptabi, a8 He Sfous Longer & + Une tool which hay leas chemical afFinity eventuaty breaks apart. This Cyclo repeats with, ullp moserials Le part of B08 b caried aud with Os Part i deposited: on the up / 7) due > High interface Fiction UL ™ depositions. Continupus + Low apeed ip With Boe + High Feed [Depth oF aut ue Need fer chip. breaking a (continuous chips) Brame * Ductile materials ane * Longe uncit chip thickness soa More accumuation of chips in Working area. Temp mcranal cating Speed atta EFfectie fers bited range of Apeed 4 feed Tce boning on ob A camped type ¢ Se eat lane od 7 SoC hip braking by W) various saath a. Red OP b) varie sod eitinas teal geometrical, features ae FRAN ceratd chipn + Somi-treowa Continuous chip® ith Large amen ef Low H principle of fotced chip braking: shear strain & Small temeh oF high hear strain + Sau) tooth -Like appearance me metals with + Associated with difFicule-ste low Yrrmat conductsity (EqTitaniam) at hah Peed Ht Tynos ot forces chip beaters efit ter einane Us Neismatys (a) Paral miep a) pea ©) parel & curved dj fh aa: + Density i high low thermat ke, less heat trans: + For toot © V- grove Fs Heat transfer ia ©) moe for Cutting taal Strength decrease H chwacteriaticn of in-bult Chip be, i. : a es © Lo98 for wp tetanian) ‘emcee '. Outer end of the step oF game acta a% & feet U ~ Relative hardness (decreases To im going to 2 Simple im configuration, easy manufactured Pail Froquentiy inexpenive 4 Germetery oF chip-breaking Features are fio once made+ When Tachining high engl alloys. (High ting force “tp + When there are heavy impact loads BUCH as fn interrupted maching —) For rigid setup A when cutting at high Apeeda, 1 We rae given Lean Strength to cuting © + Tn alt the abere condition , load on tool im high: Left Hand & Right hand tootas y Cutking edge em going from right 40 Lefe H Systema of toot geometry rae’ ington “Machine Referaéystem — ASA Ayntem , (Amencan Stands Aagote, (©) Positive Rake + Tol Reference aystern vor (0) Negative Rote (®) orthogona, Rs (© zero Rave | () Normat RS a Par 7+ Work Reference system = wes When aching low Strengin ferrous & Tem-Feme a 8 y Tmaterials. # work hardening materials ~ then using low power machines i ZX | : Machine mg shafts oF amau diameter ZL, — When the setup Lacks strength Z rigisity .soenco sack clearance angle: (4,) a, Same a debut Sf sn Syren: PANES 0 . Ta pirate 'to base oF Cutting dot ams Pare oy i= -Ateg axis of "asen wy My tm BR and LENG Crome Feed rset 7A de Rane angle (J) + Angie of imelinaton oF ake ; Burface from the reference plane (%) ond Teasurey Approach angie (8), Gide cutting e om machine refrtnce plane . 74 Gs ie ctr edge arate ‘7 Side view ‘Amgle betucon the principal casting edge Kt» projection on Back Rare angie (4) © Angle oF inclination oF the eal Eee ne x) and %y and measured om Me take aurface fiom the reference plane 3 ™Measure on ? aching tramerne plane Sra cusig cigs na (0) ; Age bets nthe end cating edge (te projection ony) From Me and measured on Me Side clearance angle (a) en of bo Angle oF Principar Plank For the ‘machined purface (or) [ and measured on 7% Plane, ~ ~ a Sasuh: (pth + litun of the tol OP a Noe 1 provides aang te the tet roe 4 baer He, Surface Finish a Bey, ese de ortinend> clearance angle ip alto Known a8 FeLet ang, ‘reach angle = Site Cuting edge ang tating & 00 %-‘pabaing tmough principal culting edge any ET Mm Ie plane p098Img thoy ary Cutting edged &R Rake anges fe OF inclination oF rake Surfac Lrthogemak rake (8) angle oF in ination OF Fake surh 7a 4 measured on orthegonal plane. Ne /h measured © ‘Angle of inetina# rake surface ‘Treasured on Principal orthogonal ro af the Principal lank Fiot™ Ke'& Measites on m on Figue © Ausittary orthogonal clearance (42) Orttegmnal clearanc F Ineation oF the quiiuary lank from aut lary Calling plane , x and measured om auxitary Orthegaral. plane , 7! Pal ting edge angle = tf) f and the direction oF anaumed longitusimal feed or Me and tmeasured on Xq Vz | | () Angie between me! Measured on rqNode radius’ (om) + Radius of curvature arate - (int Sigratire) Rare angie <0 Princpal cutng edge matching Rake angle Te eight of the gle ve PrinchpaL calting edge 1% below. Rare ange eve princp Principal Gusting edge ip above 1% Cmverrion oF Rowe Sarece argton ve wes) CE & BeO are Simi lar triangles Be ASA to ORS Convernien (rp vowsSimilarly by Be PGF: (Similar triangle) Be co “w B- Principal citing edge angle in ons * Gr = Beta. 8 Be 2 Ge 4 Ba “to * Be ind = AB eof ail ose Tiana ormatien matriz [ sinc) Lcavto-9) 08 = Teanay 00 = Tandy, Oc = Tamas A= Toefore = oy 08 Tansy 4 200 = oe ancl [o8e = do oc = Tham P [24 =» On te We Le & Wy= We (Assumption) 4 + ae ore de te ‘sr Meaguring Length ip easier ® Gear strain during chip formation : Figure © chip » parautel Phear plates Thickneas of Plate Magnitide of gtvaired materialon shear plane @©on Rake plane ie i resolved" énto tue 9 Component ENE | kK Meaaurement oF forces Forces 0". Dyramemeter Fe> Gutking force Fe = thrust force . 6 ren snetion of Fe & Fe Bo ee ae : res are wpresented a% a Function 0 7 v thot they Cam be Measured ok Sm{r0-B-I] sini Singh Combined Forces in orthogonal cutting % Mochant’s Theoy of metal cating =. adn F prietional FCI Chip fone tg a “shear Plame NormaL 10 Frictional fang | M**Hface) Or MA 2a.ideals Ernst &/ Merchant oingram > cost Rinse @Merchare, Bhgrn — aoe ti) i con rnap] ResArea of Shear piane. 9) 8 OR eae Feany -Fesing ten]sing 2 hs rw) Pia dependent om Atrength oF the materal. 1 l Objective: y Fin the shear plane angle corresponding +0 minimum cating energy Aosunption: Shear Béreaa (09) 1b a Materia property Bis casumed 0% anstone 4 eet Ag = Tesh) = Tota ‘simp eS RemEN) Fy hacen (ep-8)fee Bcolped) casera) feeom _ calt-d) a7 Simp Os(fep-4) let Pe sing - co (0+ B-¥) Power consumption Uh be Minimum. for minimum cutting energy, 7 Denominator (P= Sing-ces(g+B-2) ‘ip max 2 Py oo C89 -cs|gep-4) —Sing -Sin[s+ P-A)=d 2 cB (a6 Bed) = 3 6 pd Draw back Metts | Suntnetie Plaatica, F According -to brdgeman, For Metals | % = 7 Liar x, ft Modified Merchants Theory 7 [ikon 4p -a)] = Material property (Bat tie ase eg Feo tow | ao |P) sing * esi +R -4) tke 4K Fil * Kh thee a Fu = Roin(s+B-4) Fe = R ce (8-4) Fue & Sin+p-4) aaip-4) 2 mee 1+ KF SinlseB-A) Ging calpa) tw ne T tow colp-4) Sind“ cale B-a) = [ [re 4 Fesinlaep 4) Sid sing \tows | colt) 7 cB (P-1) tow] Sing }cm (p+ p-t) Fe = Typtold. AUP) 4 Kretan WrP-4) Sind Ga(teP-4) = The tow, cs [BA ‘Simp cae+P-¥) cats) + Fes thy tow °° Sind capap-d) —K sing Sloe) Let Pp. sing coipsp-f) -K Sing-sineP-4) ———-o- oF © Gag cs (4 p-4)- Sing. smiaseD k [cg essing (e9-4) + Siml@)-C8(8+B-¥)] «9 2 (ag +p- 4) =k Sinfag +P-4) 2 cee Berg (ag ppt) = | (29+B-4) - cot F Theory of Lee & Shafter : 1. The material is rigid plastic 7% The behaviour oF Material is imdependent oF rate OF deformation 3. The eFFect OF empmeratire increase diving deloritation fo meguigibte } ‘1 The imertiol effect toouiting ftom acceleration Material duting: deformation ‘oie neque u a (Assunpin) LAB - use b+ Lee -aed a) G+ POT -us® — Required Bhear angle souutis L220 Zero take angle, T Tr pews’ &Ie-0 & 6-0" High Friction and low rake angle leads to formation oF BUE ; (29¢@: Negative ‘rake angle Te Peas” and d=-I0, doo" This Solution ip impractical ~ TE ‘Kim given, apply smoditied merchant theory “IP zero, -ve rake anglon = gen. ren i OPply Lee Shafter Theory rBe. Canaunption power ow daring Machin “Power Sse suring Machin Power at the spindle = R= Fe-Vi hye fe Gora > Power is dishipated mainly in the Shear one. and on the taxe face. Fuer For Shearing, Pa» FoVe Power x tp overcome Friction , Pe= Five > Actual motor power Required = Fe yiq9.e Po Te BHiciendy oF motor) | ® Material Removal tate Mer Volume Removed Time. tv, = Ve Lint Tine 12 move a distancelt) = Ly R= LW VV t amm am Me Seria Ven ty mmf in | | The unit horse Powel), HR, 'e' hp, | wR How much hp for unis amounts of rete spate For Cutting, we = Po. MMs en ~ jacana ik | ® Typical orthogonal Model Violation: le. \Gige-GFFect’'- Latger Btreasen are Fequired ou : | aig for Shearing, Ug= Ps) Fav 1 mae Vint for Friction, up = RL Five Mak” Vite \ au Ue = a+ Ue Louting = Shearing + Friction) Me ur increazen, Bhear angle decreases Lhence Ust # Gusting and thrust forces ate derived 04 follows. %- Shear Strength Be GAs Fox Fy_G80-4)_ serpy Reem! Sinead) weer ~The ther ree, ean be dettmingd em he equation in the previous pages . |. Geometry & Form vibrations Violations (ie, mon-Bere angles of inclination, not sharp-radius, end) Bo a 2. Shear taxep places over a volume (70t o- Une ! i roces 3. Guiting lig never a! purely ‘conbinuol® (cracks in chip; material ‘Tot hemegenoua) igi se8 nen the chip Hs" produced Ploduce deformation UST TSa ee yaterial WeLd® tp the (O) Friction angle | (d) Shear atrain m 5. BUG - Some work plere ot face (oge in THE) ©) Specific cutting energy (8) specific energy of : hear Problem: rn an ortragonal cutting ith OHSS tool (Specific energy of Friction, having tate ange", the Min cating Force ip measured a% oon . The cooFficient OF Friction ang the hear angle ar und 10 be O31 Ord o.ag Fimattaneously . Find all other Torce Components, (using merchants cite) \Z4 a ‘% nan orthogonal turing of Ms, a, toot having | Fare angle 0’, the Main Cutting farce’ > theatand OF 12e0N «The force Aang the hear plane 1% Tnd | . § be Godw . Find allother force Camponents Gepuming 26 shear angle : Cut = 2m ; Feed = 0.25 mIpey oy. amin s | Chip hicknens =0.39-mM | Fe-a80Ns F = TON, Calcutate : . | @), Shear 4 Norma, forces om shear plare: ee) reee ccuirna | py evioce of ih eting Temperate ] ge energy im Machining om cutting tool > Approximately, % 4 * Rapid tool Wear, which teducea tol Ufe cqnverted into hebt (Plastic deformation) is + Plastic deformation of the Cutting edgen if 5 The remainaing energy (0Ut 2%) bb Fetaineg the ttol’ ip Tot enough hot—hard as elastic energy in the chip + Thermal Flaxing and fracturing oF Guiting | = Temp, rise is maximum fr Tough-to-Machine Tmeiny) edges due to thermal shocks Primary + BuiLt-up-tdge formation aoe Secendary defirmaim| on the Tob ae “Plastic defrmatig - + Heat generation Lu] Pianeta 8h) + Dimensional inaccuracies of the fob due.to, Ter ttary deformatin. | expansian-Contraction: “este dora + Surface damage by oxidatian, rapid Corrosion & + eas Generation burning ete + Thduction of thermaL teaidual atresmes and | mictoctacks on machined purface & SUb- | surface, Loadings ae latices Leading. (Das t9 Force) ~ lege Part OF the at Gos axing ih the chip | Thermat loading cold ie | Pei 02 wn echonsin orc Heat depends on ruts lent cerends on Atrength oF UP | Average Shear gone temper Secondary pas reo | Tertiary 02, « cole fice co | ee Ge Rate oF ent generation during the machining, | i : . oe = the power Consumption. | al Qi = Rote OF heat generation’ dt the contact | i é between chip & to0l- Gs = Rate oF heat generation in the Primany ‘atting timingT+ Mechanical equivalent oF heat (},2) ore cp ao Ving = Rv [' 1 SinB sing a Fi) (6-4) Let A> Fraction ‘oF Shear energy that is carielted teh = Fraction oF heat that gde# to pec ram the Bhear gone hedge Aq, BY [1 Sin sing C8 (B-4) colo. a ah A varies Fem 6.5 40 4 variea From 0. t0 09 in machining Lew From ‘the principle oF heat: transfer Ge Mmep at “(SHY cote Volume Wy ctrerimental Methods | Most Proquemtiy Wied technique in Ure to0l-chip thermocouple Gotuwein’s Methed using thin ™ethod, ken Trigger determined Ue peed temperature telationAhip to te oF the form Teev™ Principle oF thermecouple Metala + Toabath | Metate, Teol-work “Thermocouple cead-pretion Recorser | x | Thermpcauple end polit Bhould Tot: ouch chip or wor Piece 4 Tngertes Mermocouple | W embedded Thermocouple: Ging w Thermocouple | ~ 7 OePN ~ Radiation method : : recog io nec toe Poser MGI Pa Grea per unit wmelength Wa depends oT the Obsoiy temperature T ANd tavelength Wy = 2mhe” i Chr here, | Uy = Power radiated A = unvelength of mdiation H (PLand constant) = 6.626 407.5 C (Speed oF Light) =2:999.x10%m5"! = Bottamann's constant © 138 x10 7]atemy Endirect Method) W Micro- Hardnes® Method Measure the hardness | Miaw- Hardness Method before & after machsin arenes ‘rp ® Dimensional Analysis Pimenfiona Analysin oaniieneniimeneee Se= Volumetric Specie heat oF the Materia or= fo] Ve ur Aev Pac a 7 ke_Eneray LMC ung Gime temp lenge THE = _bnel MU. Mtrte! So ray Oe Votune XeEmP 5 avout Ks pe © tuted facto (els fed peg Guetee] Garte' Ferro M— ctd+e=0 L a+ab-Cide<=0° P- -a-2c~d=20-0 * oe -dest Amume g=-29 emt cen a-2 | bel 1 TAU KAS 3 ~ Average temperature along chip-toot interfam ® Average chip-Tool interface temperature Gre FIWAS Us kag), ; Ve cating vetorey A= Area oF Undeirmed chi Ue Speci custing energy ¢ Sreay ne “Mee wi K~ Therma, Conductivity OF the ne yeril Amolytical method derived by Nathan Coo rinentat, data, dimrensionar analysis U#ing experirnen tat for Various work materiale - Ye from | rege Ey” T= Temperature rise at the teot chip Interface ‘e)U= Spearic -enerad [Neonat Ve cating apo FP) te = chip thicknea® $e ~ Vouuametnie, specie, Real OF WOM TO (Sr Ks Thermal diffusivity OF work (mnt)s) = Temperature in turning For imple turning To vere (here. velocity (mlmmin) F > feed of the tool (™m{rev) Rr Carbide, a~0.2, b-0.125 Fr 99, +05, 0.375 & Shou that. when cng mest orhogrally with @ feol oF qe fake angle, the: fate OF heat generation, Asin the Shear gone is giveniy, > else) there, Fe ve mere, Fe és Cuttng cay V = Gatting Speed, mln Hs Mean Coetticient of Friction’ on tt fe tee OMe ‘reduction’ cad teisite Fev L ~ ton ing] TanP>H tang < rest rego ‘ersind ema 7 6s. = Fevfi- pr] 6. For the Same Gmditions , caculate the Tein shear gone temperature tise Ap then the metal has a PPeCiFTE Gating energy OF 2.8 Guslm’, Helo, fe=0a and 10% oF the Ahear gone heat ip conducted into the Ulorkpiece « Agsume for the Work Material, rat f= 7200 kgfm? and ,Cpx SOOT] ia-K Sen Gu 7 7 be- AdFe [: "Sins cing Suttocrtr aly F), sae we ae _avwot son [1 tern] 5005 7200 a «” = _asviot ae [is ieee} S00 w1200 48a What woutd be the Uniue DF Ar,’ the cutting speed Were doubled and the proportien oF ghear-gone heat conducted into the Workpiece remained the SamM2 Toot wear, Too Ute ¥ Nucrinabilt compequences Tange pouer amampuen (FW) Vecritang cs The, Range + Atfects dimensional occuracy + Detsicrated surfocs Finish + overheating oP the tol. + Shortens the tol Life + Generates, chatter WoraEion Bint toot + Hove fete Ih Pepuled to GUE 4 Po ey T (@) Plastic defermotion oF the tol due to high temperate and Large strom. , (0) Mechanical breakage oF thi tock ch to large form and insutticents strength d tughress Le toaghneas © Buunting of the caltng te though a process & > Hob hardness oda Hr, eae Resin Modes oF ‘Toot faltute 1. ena tons dm. franc hy sipping 2. Taermat oral a ong gang fone beer uring temperature in Sala ee Gradual Wear L stiding af the chip along take Face L stisng oF the taot lang the’ ely ct see Sure 4 prefered Mede oF Tool failure Fracture & temperature Failures are premative Failue ~ Gradual wear i prefered because it Lead 4 Langent Possible use of the toot > Graduat wear occurs at tule Locators : * Gater wear occurs on top rake Face spear Aatusa- Flane wear eccurs on Plank side ¢f tool sources oF Gradual wear _ Rubbing action Friethen "ty Rank wear, iF Flank wear depth 209 Feplace the toot| Abrasive Wear: Abrasie action 8F hard particles oF Apes ‘ork Material Ke ~ frat Fone ee “yey » KAO ‘KM- Crater cent a coe Ginter src any | Mod potion oF pve Sting sare pre o am Key ~ Cater depay toot Then, tool wear occurs, ae This {9 Colled abtaive Wear 2, Adhesive wear: igh presdure Localized fusion cont emmce forsee and THPEUFITG . (cx: cellotope with paint) ' poeta 1 SS coo I Average Flank wear #037 t 2. Mastimem Flame wear :0.67™m 3. Diffusion Wear: Loas of hardening atoms at tool 2, Depth oF cater Wear Cae kr 006mm + (0.36Feed) eae chip Fe 4 Catmstvophic Faiture resadiLeeiloe are goin chip. to tool ‘ Fe motecuted are going from chir ee W Major Mechamisonp of toot wear Crew,v move From tool 10 WP affinity 1. Abrasive wear >.” \ i Thin reduces the tool Atrength - 2. Adhesive wear, (+ Contributes 40 Crater Wear 4, DiFFusion wear \. Fatigue wear: Loading of aaperities between Wore 4. Fasigue wear oe: * causes crater Wear Da ted= Se, tool wear Occurs gaduaiy Failure region + High temp are present £ tool wear | Occurs tapidly Grater | ee [a 3 #mall Shachamier ip given 10 the cutting odge, 5 | Break-in Period @ can be reduced. : ‘Avcrage tot-chip \ chamfered, Teal) ineor face temperatures \ a Ea | Measurement, of tool wear Minor Mechanisms of 400l WeOr — een a ons OF Direct Method + +1 Onidation oF tool Material at the wesc Neihe 1. Oxide tear 1 Oudatien of ~ Optical tMethod by ‘microscope ete elevated temperatures (Woot maxers Tictoscare) 2, Plastic deformation due to Cxcesbive heat (Contribue Indirect Methods. to Flank wear + Farce (dynamometer) 3 Chemicat decomposition through Localined chemical | * Power (dynamometer) teactiane Temperature (Thermocouple) Toot wear vs. culing time + Surface Finiph (Talypur?) SS j¢ SteadyState wear on Vibtetion (vibration Pick-up) oe : : ues * Acoustic Emission (Acoustic emiazion Zenaor) Flank Finot Failue ee sion ) ir) Heasured using diet a Aertaeing Time fase Flaneucer “thn = Co of t- ee | a plank ul Time OF cutting (min) (min SON 0.08 wy owete! Im PHOS TL Lar moe faaune as the 0: woot rote : Phects method) tol 8 Sharp > Tol 0.03 (Direc WE Beda ee eae les emm, _T00N as ting con ato i Bag ot paricly V=80 m/min f201mm/rev d>a.5mm Steady-state Wear petiod + Toot blunt OHer gome tM:replace the tool Weak les Time #2 Lengin oF casting tine thot @ Sok a eng oF Gustin before the Flank wear fe Width oF Rank wear Wol-lite equation + aches the Limiting Taylors Toot Life equatien yr=c V=catting Speed, ™fmin To Tool Ue, min Ce Taylors tool LiFe Constant (m[min) Te Taylor’ exponent T+ 0.10 to 040 fer HSS Ts 0.20 t O49 fer carbides, Ts0.6 to) for ceramicg. We did not cmaider doc, int) the equatign So, the above equation 1% Tot accurate % extended Taylors Toot Uife equation viedo ke. % Other “Tool Fe equation ttmuding Hardrenn oF tt) ke yaema™ 8HN™S isin tin Somiey T= exponent for feed (05 40 05) THs Bpement or doe (0240 ou) Ta + hatdeos tpment: (1.25) 4 effect OF Rake a: owe Rake angle > chip Formation in diPricute: Tool strength i Tore 50, “Load on the taol ig Tore tie axe angie + (6-«, 710" 3 Strength oF the tool i leas 4 Teel wear cccurs easily Optimum Range : -5°to +10" Re ‘| Ure clearance optimurn Range OT fect oF Clearamee angle ingle 10 Rok take angle More power Consumption occurs (sv) Hence, tool Life ip leas, 0) Teal cutting Forces (relay deformatin | Less cA4 More Rubbing 9) action | + Tool wear occur, More crs Tool tength decreases angle ~ Tool wear occurs, |A Machmanivty | me « Rfera tp mutenat (uore) eAperme 12 Tachining casing /—~ Stordars material + nei genwany ape othe M*CMIMG Porgy © | — rtd Pate OF Wore material: , 7 Se a or ante onal ste “Te maicaten haw eangily foot, a MAberiaL | on: Gn be machined Mabchinabitity » “Abitity oF being Tachined” % Machimabitity con be meatured’ by | ee ‘machining (®)Toot'Life + Which substantially influences w Machinabitity characteriaticn Paty 2 eanmgih ombiing Pachiraiuy be Jude by (© wmegritude oF cating Free: which OFects pour] Gang Forces ves Cornunptio' mendinal, aceuacy J eat ar less ©) Surface Finish: whieh plays tole on performance | + Tool Life mal Gnd Service Li® of the product * Surface Fininh Good W Machinaviity _Rasng (un) 4 “Siting temper etn + chip farms = SPeed a machining te wore + i Riv o-min, tool Lire Gore strantat uh: NOY TIRE OF Ming Ra aay *8°°—— Baramatrsnftaentng Machina: Siving Go-min, took Lite “ Properties OF work materia. (Strength) Std, Material + Mild Steet, (rosy) cating tool: Materiol 3 Geometry Level» oF process parameters. “| soe, sys Machining environments . see ye cuiting Fluids ee vean bet H9s—+ Mitdatet Hea Cpbide | Bot opie CarieWidth OF Plane wear Land ee 4 oF the machi stabi > Strength rigidity # 2 ISom{min. at 206m Imm Ls cause virions ° o o = sind ge mochininy operstions come iT give, i. a out © given Tmachine tool 20 oe Ec: Taper Turning Plain turning | - e “ os ee | HO 0.22 OWT ay? | 50 one 0.57 Dec tot usar | @ 0:30 73 Axis. oF machining Ip diFFerent van Ve 150 mi min Va = 88min % improving Machinabibiey ae a Tae23 min ~ chemical. cempositien . . 4. A tool Ute oF 10min. fs obtained at 25%/min Microstructure and émin at 70 ™/min “+ Teatmeame given 10 metal d ! (0) What ip the tool Life equation 8. A beter surface Finish in desired on a work pew | () what ig V at T=Imin Recommend thee ‘tepa without involving tool chant ‘nm: 1 Tnereane Gating Speed —> 9 2 Decrease Feed 4 ,° | v (what ig y at T-6ommn Fotlowing iy the record of 70. 0F identical components Decrease depth of uxt Produced at ditforent Ppindte Speeds and feeds 8. Following data has been obtained in a toot Life teat between the Consecutive tol changes in a at two different cutting Bpeeds.’ 0,3 mm tidth ingle pas turning Operation Extimate the OF Flamk wear land ip the gelective Failure Criteria, Calculate the. Value of tn’ '¢? of te .n be produced at N=35 70. oF components that C27 tpm and f= 015 mmjev- q toler tool. Life equation 7 Nuewpm) co) Ge outa, Flommper) Os 015 OBS VETER, mie a erase {Conpanent)i sae turning operation, the Ty Qo Ina tt Lie te med ab a doe due t heat gene Following data has been obtained doc am, | # Bree, cating Buide oe opm tan, Tom's) vmimin) —F(omtrer) onto 120 oo oO Y Shean Strength, ad 130 ol ad 100 oun Sing Find out the tool Lie 8. The Ruouing eptiatien toa obtained Wher machining ATSE ayo sine uth HS tool, Calculate the | # Functions oF cutting Fide (ook Ute using cating rede 2# Inn, F203 mo] 1 a Luvcatioy at laity a ion ively tna cutting Speeds doc =2.5mm. Calculate the effect upon the tool Uke fora, 204. iMcreage inthe “iting Speed, Lae| Algo Calculate the ef Feet % Cooling at relatively high cubirig apeeda “1 Heat generation in Secondary deformation gone can be reduced by decreasing coefficient of Friction » AL tow cutting apeeds, Sgp=lens Sq, =More @. The Tand © values ftom machining data, book fr Cutting Fluids Row only in See. (6Upping ame) Machining ateel with H99 are ons 370 Tor But at high Gusting apeeds, S.-More, Sau = Leas Ceramic +06 42000, These are based er feed (0 |e Gauing puta (a8 luicant) 1p MOE eFFecive dp OF 025 mm|tev & doc =1.5 mm. Determine & Oma high aaiting speed the Cubic mm OF Steel remoed for each of tne tool materials Secondary functions: \ cleaning de machining Ame, by Washing away ‘the chip \ Protection oF the adjacent Machined Aurface a rc® Main aim oF the auting Fuld ia to improve ‘™achimabitity ‘traugh 1. Reduction oF autting Forces 2. Reduction oF temperature 3. Improvement ein BurPace integrity 4, Enhancement oF tool Live padvarcages 1. Moy pose Fire hazard 2. May react chemically * 8 May decompose | precipatig 4. May produce toxic Vapours ® Lubricant + oit (eH bonds) High 7 Cooting ation: WHEY (0-4 bends), + High k Conventional Cutting Fuuid: Combination of water + > Surfactant breaks tho into Ht Lor ions intely ater breaking H7 & on” bend with Git Unydrocarbond) & Sarma gouition mmedi + But When Hho breaxs into ute OW jong [t lied 1 Ptabitity % Forms Fangunk bacteria. this dam ce taiid! he © |, Mineral ola euith ep additives the “tard whee itis fund. They may release | A La etre, presure (Fort stanivegy toule vapows, | Meat scams (to bring - ; | ican capacity oF) Tx Age ‘aimntries, Convention, gy epsential characy % Types oF cautting Fucids : teristicn oF cutting Fluids For cooting : '. Spreadin, Preading 2 welking cbivity High Apecific heat, thermat conductivity 4 Film coeFFicient: for heat trans ter: For lubrication : . 1 Wetting & Spreading 2. High Film Bp 3. High lubriedty ithe gumming & foamy Esaential properties oF ailtin whertiee OF aliting Fluids (Non Toxic 2. chemical ptnbitity 3. Easily available ¥ low cont 44. Lease Volatile & high Flash points 5. High repistance 40 bacterial growth 6. cdouriess % algo preferably colourless 7. Non-corropive to meta of FTW System Mineral ois and vegetable o'ta Soluble golutione plantC—O ee '’~ i: Ep additives, Water + EmuLsifying oil + EP Se oe More CooLanta ou Waker+ Rust inhibitors - x Common ty used Cutting Fluida : eee gare eed I. Air blast or Compreazed tr. 2. Water 3. Soluble oilal water baged cutting Fluids 4. Cutting oitg with EP additives . 5. Chernicap Fluuidg . &- Solid o Pemi—gouid lubricant. — Graphite 7 Cryogenic Cutting Fluid orig L Liquid: co, (a4 low rT) \