Production Process and

Technology
History of cutting tool materials
Cutting tool were used during the industrial revolution in
1800 A.D
First cutting tool was cast using crucible method (1740)
and slight hardened by Heat Treatment.
1868: R. Mushet found by adding Tungsten we can
increase hardness and tool life ( Air Quenching).
F.W.Taylor in Pennsylvania did the most basic
research in metal cutting between 1880-1905
Invented high speed steel (better Heat Treatment process)
Better alloy
Contd…
Tungsten Carbide was first synthesized in 1890.
Took 3 decades before we got Cemented carbide
First used in Germany
Sintering technology was invented
 Cutting Tool Materials
Many types of tool materials, ranging from high carbon
steel to ceramics and diamonds, are used as cutting tools
in today’s metalworking industry.
It is important to be aware that differences do exist among
tool materials, what these differences are, and the correct
application for each type of material.
When a tool change is needed or anticipated, a
performance comparison should be made before selecting
the tool for the job.
Contd…
An ideal tool material is the one which will remove the
largest volume of work material at all speeds.
The tool material which can withstand maximum cutting
temperature without losing it’s principal mechanical
properties (specially hardness) and geometry will ensure
maximum tool life.
Higher the hot hardness and the toughness in the tool
material longer the tool life
Contd…
The best tool is the one that has been carefully chosen to get
the job done quickly, efficiently, and economically.
Selection of cutting tool materials is very important
What properties should cutting tools have
 Hardness — harness and strength of the cutting tool must be
maintained at elevated temperatures, also called hot hardness
 Toughness — toughness of cutting tools is needed so that tools
don’t chip or fracture, especially during interrupted cutting
operations.
 Wear Resistance — wear resistance means the attainment of
acceptable tool life before tools need to be replaced.
Contd…
Tool material must be at least 30 to 50% harder than the
work piece material.
Tool material must have high hot hardness temperature.
High thermal conductivity
Lower coefficient of friction
Easiness in fabrication and cheap
Different elements used in cutting tool materials and their properties
 Types of Tool Materials
High Speed Steel
High Carbon Steel
Cemented Carbides
Stellite
Ceramics
Diamond
 High Speed Steel
Very highly used alloy steel
Can be hardened to various depths
Good wear resistance
High toughness
Good for positive rake angle tools.
Two basic types of HSS
Molybdenum: ( M Series)
Tungsten: (T Series)
Contd…
General use of HSS is 18-4-1.
 18 % - Tungsten is used to increase hot hardness and stability.
 4 %– Chromium is used to increase strength.
 1 % - Vanadium is used to maintain keenness of cutting edge.
 In addition to these 2.5% to 10% cobalt is used to increase red hot
hardness.
It looses hardness above 600°C.
Some times tungsten is completely replaced by Molybdenum.
Molybdenum based H.S.S is cheaper than Tungsten based H.S.S
and also slightly greater toughness but less water resistance.
Widely used tool material for taps, drill, end cutters etc.
 High Carbon Steel
Oldest tool material
containing 0.6 to 1.5 % carbon with small quantity of silicon,
chromium, manganese and vandium to refine grain size
The required hardness is lost as soon as the temperature rises
to about 200°C - 250°C.
They are not highly wear resistant and mainly used for hand
tools
They are less costly, easily forgeable and easy to heat treat.
Low wear resistance and low hot hardness
 Cemented Carbide
Everyday growing demand of higher productivity has
paved path for cemented or sintered carbides.
Formed by the mixture of tungsten, titanium or tantalum
with carbon.
Carbide in powder form is mixed with cobalt which acts
as binder and sintered at high pressure of 1500 kg per sq.
cm to 4000 kg per sq. cm and shaped into desired tip.
Contd…
It posses a very high degree of hardness and wear
resistance
They are capable of operating at speeds 5 to 6 times
higher than HSS
Use for Steel mills, mining and tunneling cutting tools
 Stellite
It consists of cobalt-chromium alloys, tungsten-
molybdenum alloys
Other elements tantalum, molybdenum and boron are
added in varying proportion
Tools made of stellite are capable of operating at speeds
up to 2 times more than HSS
Working temperature is 900°C
Mainly designed for wear resistance
 Ceramics
It is recent development in tool metallurgy as cutting tool
material.
It consist primarily of fine-grained, high purity aluminium
oxide, pressed and sintered with no binder at a
temperature of 1700°C.
Have high wear resistance and are more brittle and
possess low resistance to bending
They cannot be used for rough machining work and in
operation where cut is intermittent
Works about 1200 °C and no coolants are required
 Diamond
It is the hardest material known and used as cutting tool
material
It is brittle and offers a low resistance to shock , but is highly
wear resistant
Low friction, high wear resistance and high hardness
Due to low coefficient of friction they produce a high
grade of surface finish
They are used in the form of bits inserted or held in a
suitable design.
Works up to 1650°C
Relative time required to machine with various tool cutting materials,
indicating the year the cutting tool material were first introduced
Property Carbon HSS Cast Cemente Coated Ceramics Poly Diamond
and low Cobalt d carbide carbide -crystallin
to alloys e
medium CBN
alloy
steels

Depth of Light to Light to Light to Light to Light to Light to Light to Very light
cut medium heavy heavy heavy heavy heavy heavy for single
crystal

Finish Rough Rough Rough Good Good Very good Very good excellent
Obtainable

Method of Wrought Wrought, Cast, HIP Cold CVD Cold High High
processing cast, HIP, and pressing pressing pressure pressure
sintering sintering and and and high and high
sintering sintering temp. temp
sintering sintering

Fabrication Machinin Machinin Grinding Grinding Grinding Grinding Grinding Grinding

g and g and and and
grinding grinding polishing polishing
Property Carbon and H Cast Cemented Coated Ceramics Poly Diamond
low to S Cobalt carbide carbide -crystallin
medium S alloys e
alloy steels CBN
Hot increasing
hardness
increasing
Toughness

Wear increasing
resistance
Chipping increasing
resistance
increasing
Cutting
speed
increasing
Thermal
shock
resistance

increasing
Total material
cost
 CUTTING FLUIDS
Liquids or gases that are applied to the tool and the
material being machined to facilitate the cutting
operation.
Reduce friction and wear to improve tool life and surface
finish.
Cool the cutting zone, thus reducing temp and thermal
distortion.
Wash away the chips.
Protect the machined surface from environmental
corrsion
 DESIRED PROPERTIES
High thermal conductivity for cooling.
Good lubricating qualities.
High flash point, should not entail a fire hazard.
Be stable against oxidation
Must not promote corrosion or dislocation of the work
materials.
Must afford some corrosion protection to newly formed
surfaces.
The components of the lubricant must not become bad
easily.
Contd…
Must not cause skin irritation or contamination.
A viscosity that will permit free from the work and dripping
from the chips.
No pleasant odor must develop from continued use.
Must not produce a gummy or solid precipitate at ordinary
working temperatures.
Act as disposable
heat sink

Too much, work

will expand
 Economic Advantage
Reduction of tool costs
Reduce tool wear, tools last longer
Increased speed of production
Reduce heat and friction so higher cutting speeds
Reduction of labor costs
Tools last longer and require less regrinding, less downtime,
reducing cost per part
Reduction of power costs
Friction reduced so less power required by machining
 Heat Dissipation
Ideally most heat taken off in chips
Indicated by change in chip color as heat causes chips to
oxidize
Cutting fluids assist taking away heat
Can dissipate at least 50% of heat created during machining
 Types of Cutting Fluids
Most commonly used cutting fluids
Either aqueous based solutions or cutting oils
Fall into three categories
Cutting oils
Emulsifiable oils
Chemical (synthetic) cutting fluids
Contd…
Cutting Oils
Two classifications
 Active

 Inactive
Terms relate to oil's chemical activity or ability to react
with metal surface
 Elevated temperatures

 Improve cutting action

 Protect surface
Contd…
 Active Cutting Oils
Those that will darken copper strip immersed for 3
hours at temperature of 212ºF
Dark or transparent
Better for heavy-duty jobs
Three categories
 Sulfurized mineral oils
 Sulfochlorinated mineral oils
 Sulfochlorinated fatty oil blends
Contd…
 Inactive Cutting Oils
Oils will not darken copper strip immersed in them for
3 hours at 212ºF
Contained sulfur is natural
 Termed inactive because sulfur so firmly attached to
oil – very little released
Four general categories
 Straight mineral oils, fatty oils, fatty and mineral oil
blends, sulfurized fatty-mineral oil blend
Contd…
Emulsifiable (Water Soluble) Oils
Mineral oils containing soaplike material that makes
them soluble in water and causes them to adhere to
workpiece
Emulsifiers break oil into minute particles and keep
them separated in water
 Supplied in concentrated form (1-5 /100 water)
Good cooling and lubricating qualities
Used at high cutting speeds, low cutting pressures
Contd…
Chemical Cutting Fluids
Also called synthetic fluids
Introduced about 1945
Stable, preformed emulsions
 Contain very little oil and mix easily with water
Extreme-pressure (EP) lubricants added
 React with freshly machined metal under heat and pressure of a
cut to form solid lubricant
Reduce heat of friction and heat caused by plastic
deformation of metal
Contd…
Advantages of Synthetic Fluids
a) Good rust control
b) Resistance to rancidity for long periods of time
c) Reduction of amount of heat generated during cutting
d) Excellent cooling qualities
e) Longer durability than cutting or soluble oils
f) Nonflammable – nonsmoking
g) Easy separation from work and chips
h) Quick settling of grit and fine chips so they are not recirculated in cooling
system
i) No clogging of machine cooling system due to detergent action of fluid
j) Can leave a residue on parts and tools
Contd…
Chemical cutting fluids widely accepted
and generally used on ferrous metals. They
are not recommended for use on alloys of
magnesium, zinc, cadmium, or lead. They
can mar machine's appearance and dissolve
paint on the surface.
 Functions of a Cutting Fluid
Prime functions
Provide cooling
Provide lubrication
Other functions
Prolong cutting-tool life
Provide rust control
Resist rancidity
Contd…
Cooling
Heat has definite bearing on cutting-tool wear
 Small reduction will greatly extend tool life
Two sources of heat during cutting action
 Plastic deformation of metal
 Occurs immediately ahead of cutting tool
 Accounts for 2/3 to 3/4 of heat

 Friction from chip sliding along cutting-tool face

Water most effective for reducing heat but will promote
oxidation (rust)
Decrease the temperature at the chip-tool interface by 50°F,
and it will increase tool life by up to 5 times.
Contd…
Lubrication
Reduces friction between chip and tool face
 Shear plane becomes shorter
 Area where plastic deformation occurs correspondingly
smaller
Extreme-pressure lubricants reduce amount of heat-
producing friction
EP chemicals of synthetic fluids combine chemically
with sheared metal of chip to form solid compounds
(allow chip to slide)
Cutting fluid reduces friction and produces a shorter shear plane.
Cutting fluid reduces friction and produces a shorter shear plane.
 Cutting-Tool Life
Heat and friction prime causes of cutting-tool
breakdown
Reduce temperature by as little as 50ºF, life of cutting
tool increases fivefold
Built-up edge
Pieces of metal weld themselves to tool face
Becomes large and flat along tool face, effective rake
angle of cutting tool decreased
Contd…
Built-up edge
keeps
breaking off and
re-forming
Result is poor
surface finish,
excessive
flankwear, and
cratering
of tool face
 Cutting Fluid's Effect on Cutting Tool Action
Lowers heat created by plastic deformation of metal
Friction at chip-tool interface decreased
Less power is required for machining because of reduced
friction
Prevents built-up edge from forming
Surface finish of work greatly improved
Contd…
Rust Control
Water best and most economical coolant
 Causes parts to rust
Rust is oxidized iron
Chemical cutting fluids contain rust inhibitors
 Polar film
 Passivating film
Contd…
Rancidity Control
Rancidity caused by bacteria and other microscopic
organisms, growing and eventually causing bad odors to
form
Most cutting fluids contain bactericides that control
growth of bacteria and make fluids more resistant to
rancidity
 Heat Generation in Metal Cutting
The heat generated in cutting was one of the first and
the foremost topics investigated in machining.
In 1798, Benjamin Thompson, investigated the heat
generated in the boring of a cannon and developed the
concept of mechanical equivalent of heat.
The exact relationship of which was established by
Joule in 1850.
Contd…
Taylor recognized the importance of heat in accelerating
tool wear.
This lead to development of heat transfer model to predict
tool temperature and the tool life.
A heat resistant material, termed as the high speed steel
(HSS) was specially developed.
Methods to cool the tool and workpiece were introduced.
Thermodynamic Processes for Metal Cutting
Thermodynamic Processes for Metal Cutting
Contd…
90 to 100 % of Mechanical Energy is converted into
Thermal Energy.
Hence, Temperature is of major concern.
The mechanical process and the thermal dynamic process
are tightly coupled together.
Cutting temperatures strongly influence tool wear, tool
life, workpiece surface integrity, chip formation
mechanism and contribute to the thermal deformation of
the cutting tool.
Heat Dissipation in metal cutting
Sources of Heat Generation
 Factors affecting heat generation
Work piece and tool material
Tool geometry
Cutting speed
Cutting fluid
 High Temperature Effect on Tool
Reduces strength of the tool and formation of create wear.
Shortens tool life
Causes thermal distortion
Causes dimensional change in work piece
Temperature on metal cutting and cutting fluids, making
of control dimensional accuracy difficult
 Temperature Control in Metal Cutting
Application of Cutting Fluid (coolant).
Changing the cutting condition by reduction of
cutting speed and/or feed.
Selection of proper cutting Geometry
 Assignment
Explain the properties of tool material with it’s uses
What is cutting fluid and what are it’s desired
properties?
Thank You