METAL CUTTING Cntd….

Dr. P S SUVIN
Department of Mechanical Engineering
Room 511
Types of materials
• Metals
• Steel
• Cast
iron
• Alumin
um
• Copper
• Brass
•…
• Polymers
• Ceramics
• Wood
Changing tool materials

New cutting tool

materials results in a
faster cutting speed in
machine tools.
Changing tool materials

New cutting tool

materials results in a
faster cutting speed in
machine tools.
Cutting tool materials
Plain carbon tool steel
The oldest of the tool materials dating back hundreds of years. In simple terms, it is a high-carbon
steel, which contains about 1.05% C.
This steel has a good hardness, toughness and strength when is hardened and tempered. This
composition of material suitable for lower cutting speed where cutting temperature range is below
200 °C. This material used to made of die, tap, hacksaw blade and reamer.
Cutting tool materials
High Speed Tool Steel (HSS)
The major difference between HSS and plain high carbon steel is the addition of alloying
elements to harden and strengthen the steel and make it more resistant to heat (hot hardness).
Some of the most commonly used alloying elements are manganese, chromium, tungsten,
vanadium, molybdenum, cobalt, and niobium.
While each of these elements will add certain specific desirable characteristics, it can be
generally stated that they add deep hardening capability, high hot hardness, resistance to abrasive
wear, and strength, to HSS.
Its cutting speed can be 2 to 3 times more than carbon steel, moreover it maintain its hardness
up to 900 °C.
Cutting tool materials
High Speed Tool Steel (HSS)
Cutting tool materials
Cemented Carbides
It is made by mixing tungsten powder and carbon at high
temperature. The composition:
Tungsten - 82%
Titanium carbide - 10%
Cobalt - 8%
The cutting tool can withstand higher temperature (1000°C). Its
cutting speed is 6 times higher than that of HSS.
However, it is a brittle material and has low resistance to shock.
Cutting tool materials
Cemented Carbide
Cutting tool materials
Ceramics
The mixture of Boron nitride and Aluminium oxide powder are sintered.
This type of material is very hard with good compressive strength.
The ceramics are used to make tool inserts. They perform at high cutting
speeds up to 2 to 3 times than tungsten carbide.
They can not be used in shock and vibration occur because it is brittle.
Cutting tool materials
Diamond tools
It is the hardest cutting material as compare to other. This material has
high compressive strength, low coefficient of friction and it is extremely wear
resistant.
That is used for machining of very hard material like ceramic and carbides.
The Diamond tool provide good surface finish at high speed with good
dimensional accuracy.
The tool tip is very small and best suited for finishing operations. Diamond
tools can resist temperature up to 1250 °C and can machine material of
hardness up to 3,000 HV.
Comparison of cutting tools construction

VS.
Temperature related hardness
Tool Designation
Wear
Wear in cutting tool
Force measurements