Tools

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 Objective
 Categories of tools
 Description of cutting tools
 Tools material and selection
 Tool life
 Tool failure

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 What is tool ?

 Tool is a mean by which something is achieved without

being consumed in the process

 It may be an equipment or an application or intelligence

 Protective devices are not tools, like gloves safety glasses

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 Categories of tools

HOLDING TOOLS FORMING TOOLS

STRIKING TOOLS CUTTING TOOLS

MOTION TRANSFERRING
TIGHTENING TOOLS TOOLS
CUTTING TOOLS MEASURING TOOLS
MEASURING TOOLS, etc SOFTWARE TOOLS,
etc

OPERATED BY HAND OPERATED BY MACHINE

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 Hand Tools
HOLDING TOOL

 COMBINATION PLIER

 EXTERNAL CIRCLIP PLIER

 CIRCLIP PLIER

 INTERNAL CIRCLIP PLIER,

etc

STRIKING TOOL
 HAMMER

 MALLET, etc

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 Hand Tools
TIGHTENING TOOL

 SPANNER

 ALLEN KEY

 SCREW DRIVER

 WRENCH, etc

CUTTINING TOOL
 HAND HACK SAW

 CHIESEL

 FILE, etc

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 Hand Tools
MEASURING TOOL

 SCALE

 PROTECTOR

 LEVEL

 COMPASS

 VERNIER

 MIRCOMETER, etc

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 Machine Tools
FORMING TOOLS

 DIE

 MOULD & CASTING

 ROLLERS (THREAD,SHEET)

 FORGING

 STAMPING

 HYDRO-FORMING etc.

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 Machine Tools
CUTTING TOOLS

Single Point cutting tool Multi Point cutting tool

 TURNING/SHAPER TOOL  DRILLS

 BORING TOOL  REAMERS

 FLY TOOL  MILLING CUTTERS

 GRINDING WHEELS

 BROACHES

 HOBS

 TAPS

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 Tools Material
1) High Carbon Steel
- 0.6–0.99% carbon
- resist up to temp 220° C
- cutting speed limit 0.15 m/s
- used for cutting mild steel

2) High Speed Steel (HSS)

- TUNGSTEN : 18%, CHROMIUM : 4%, VANADIUM : 1%
- resist up to temp 600° C
- cutting speed limit 0.8 m/s to 1.8  m/s
- used for cutting mild steel
- Two basic types of HSS
Molybdenum: ( M Series)
Tungsten: (T Series)

3) Cast alloys
- 45% cobalt, 32% chromium, 21% tungsten, and 2% carbon.
- resist up to temp  760° C
- cutting speed 60% higher than HSS
- hot hardness better than HHS
- high abrasion resistance
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 Tools Material
4) Cemented carbides (cermet) (sintered carbide)
- mixture of tungsten carbide, titanium, or tantalum carbide in powder form, sintered in a matrix of
cobalt or nicke
- cutting speed 30 - 150 m/s
- High temp Hardness
- Low thermal expansion
- High modulus of elasticity
- no effective standards for choosing carbide grade specifications
5) Coated Carbides
- thin layer of  titanium carbide fused to a conventional tough grade carbide
- multiple layers of under .001 of an inch thickness
- cutting speed 100 - 250   m/s
- longer tool life than conventional carbide

6) Ceramics
- Two types of ceramic cutting tools are available: the alumina-based and the silicon nitride-based
- resist up to temp  760° C
- operate best at light loads and high speeds. 
- cutting speed 150 – 650 m/s
- brittle and have little resistance to to shock

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 Tools Material
 
7) CUBIC BORON NITRIDE (CBN)
- Second in hardness to diamond
- cutting speed 30 - 310 m/s
- Standard choice for machining steel with a hardness of 50 Rc or higher
- Good chemical inertness
- Excellent wear resistance

8) Polycrystalline diamond (PCD)

- Can not be used for machining steels
- used for non-ferrous machining and for machining abrasive materials such as glass and some plastics
- cutting speed 200-2000 m/s
- Excellent wear resistance

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 Tool Life
WHAT IS TOOL LIFE
  The length of time that a cutting tool can function properly before it begins to fail

Mathematically the tool life can be expressed in the following equation( Taylor equation)

V Tn = C
Where

V = CUTTING SPEED
T = TOOL LIFE
n = COSTANT
C = CONSTANT

The constants n and C may be found for specific workpiece and tool material and feed, f,
either by experiment or from published data.

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 Tool Failure
WHAT IS TOOL FAILURE

The point at which a cutting tool is no longer useful for machining

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