Production Engineering I

(MEng 3191)

Lecture on: Tool Wear and Tool

Life

09/23/2021 Tool life and Tool Wear 1

 Tool wear Mechanism
2

Major wear mechanisms

1. Abrasive wear
2. Adhesion wear
3. Diffusion
4. Oxidation
5. Fatigue
6. Chemical decomposing

Tool life and Tool Wear

09/23/2021
 1.Abrasive wear
3

• Softer material sliding over the face of hard material may

contain appreciable concentration of hard particles
• Hard particles act as small cutting edge like grinding wheel
• Hard particles result worn out of tool material
• Particles of hard material are intermittently turn out from the
surface and dragged along the surface

Tool life and Tool Wear 09/23/2021

 1.Abrasive wear cont.
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Tool life and Tool Wear 09/23/2021

 2. Adhesive Wear
5

• When softer metal slide over hard metal , parts of soft metal
adhere high spots on the metal due to:
Friction
High temperature
Pressure
• The spots result irregular flow of chip over the face and build
up of more particles on the tool

Tool life and Tool Wear 09/23/2021

 Adhesive Wear cont.
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• Finally the built up edges will torn from the surface result
uneven
structure on the tool surface

Tool life and Tool Wear 09/23/2021

 3.Diffusion
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• When a metal is in sliding contact with another metal the

temperature at the interface is high
• The high temperature allows the atoms of hard material to
diffuse into softer material matrix

Tool life and Tool Wear 09/23/2021

 Diffusion cont.
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• hence the strength and abrasiveness of the softer material

Increase
• Atoms of the softer metal may also diffuse into harder
medium, thus weakening the surface of harder material
medium
• Diffusion phenomenon is strongly dependent on temperature

Tool life and Tool Wear 09/23/2021

 4.Oxidation
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The high temperatures and clean surfaces at the tool–chip interface in

machining at high speeds can result in chemical reactions on the rake
face of the tool.
Oxidation is the result of reaction between tool face and oxygen
Ex. When machining steel work piece with HSS or cemented
carbide tool , groove formation is greatly accelerated if the cutting
zone is subjected to a jet oxygen.

Tool life and Tool Wear 09/23/2021

 5. Fatigue Wear
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• Will occur when two surfaces slides in contact with other under
high pressure
• Roughness of one surface interlocks with those of other.
• Due to friction , compressive force will be produced in one side
and tensile on other side ,These phenomenon cause surface crack

Tool life and Tool Wear 09/23/2021

 Fatigue Wear cont.
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• The cracks ultimately combines with one another and lead

surface crumble
Tool life and Tool Wear 09/23/2021
 Types of Wear
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• Flank wear(wear land)

• Crater wear
• Chipping

Tool life and Tool Wear 09/23/2021

13

Tool life and Tool Wear 09/23/2021

 Flank Wear
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• It produces wear land on the sides and

end of a flank
• Tool-work piece interface
• Predominant at low speed

Tool life and Tool Wear 09/23/2021

 Flank wear
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• Primary region
breakage of sharp cutting edges
• Secondary zone
The predominant zone caused by abrasion
• Tertiary zone
Very sensitive to temperature ,caused
by diffusion wear
Increment of MRR increases flank wear
Tool life and Tool Wear 09/23/2021
 Crater wear
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• It occurs on the rake face of the tool in

the
form of pit called crater
• Predominant at high speed
• Tool-chip interface

Tool life and Tool Wear 09/23/2021

 Crater Wear
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• Diffusion ,
the lose of hardened atoms at the tool chip inter face is the major
cause of creator wear

Tool life and Tool Wear 09/23/2021

 Chipping (premature wear )
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• It refers the breaking away of small chips from the cutting

edge of tool or an insert on account of impact or excessive
plastid deformation
• Large chipping can be caused by interrupted cutting and
sudden shock.

Tool life and Tool Wear 09/23/2021

 Tool life
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Criteria for tool life

Change of quality of machined surface
Change in magnitude of cutting force
Change in cutting temperature

Tool life and Tool Wear 09/23/2021

 Tool Life Prediction
• Taylor’s tool life equation

VT  C n

where V is the cutting speed,

T is the tool life, n is Taylor
exponent.
n and C are constants depends on
work material, feed, depth of
cut and cutting speed.
• n=0.125 for HSS, n=0.25
for Carbide, n=0.5 for
Coated Carbide/Ceramic
21

Tool life and Tool Wear 09/23/2021

 Tool Life Prediction cont.
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Modified Taylor’s tool life equation

VT d n n1
f n2
C
where V is the cutting speed,
f is the feed
d is depth of cut
T is the tool life,
n, n1 and n2 are Taylor exponent.
n, n1 and n2 and C are constants depends on
work material, feed, depth of cut and cutting
speed.
Tool life and Tool Wear 09/23/2021
 Tool life cont.
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Example
A steel bar of 40mm diameter is to be turned over a length of
200mm with a depth of cut 1.2mm and feed of 0.2mm/rev at
200rpm. If the tool life equation is given by

VT 0.2
d 0.13
f 0.31
 40

Determine the number of components that may be turned before

regrinding the tool.

Tool life and Tool Wear 09/23/2021

 Ex 2
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 In a production turning operation, the work part is

125 mm in diameter and 300 mm long. A feed of
0.225 mm/rev is used in the operation. If cutting
speed = 3.0 m/s, the tool must be changed every 5
work parts; but if cutting speed = 2.0 m/s, the tool
can be used to produce 25 pieces between tool
changes. Determine the Taylor tool life equation for
this job.

Tool life and Tool Wear 09/23/2021

 Surface Quality

 Ideal transverse roughness

 R = f 2
/8R
max
 where R is the tool nose radius and f is the feed.

a b

Surface produced on steel during cutting by SEM, a) turning and b) shaping

 Temperature in metal cutting
26

High temperature
• Reduces strength of the tool and formation of
create wear.
• Shortens tool life
• Causes thermal distortion
• Caused dimensional change in work piece ,
making of control dimensional accuracy difficult

Tool life and Tool Wear 09/23/2021

 Heat generation in metal cutting
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a) Region AB is Primary shear zone-

plastic deformation (Ps )
b) Region BC is Secondary shear
zone friction (Pf )
c) Region BD Between tool &
work piece plowing force (negligible)
 
Pm  FcV Pm Power consumed
Fc Cutting force

Pm  Ps  Pf Pf  F f V
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 Temperature distribution in metal cutting
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Temperature distribution at V  25 m s , HSS

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 Temperature distribution in metal cutting
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Isotherms in temperature distribution

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 Cutting temperature control
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Temperature in metal cutting can be controlled by

• Application of cutting fluid(coolant)
• Changing the cutting condition by reduction of
cutting speed and/or feed.
• Selection of proper cutting Geometry
ex. Positive tool orthogonal rake angle

Tool life and Tool Wear 09/23/2021

 Temperature and Cutting Fluid
 Function of cutting fluids
 Lubrication
 Cooling
 Chip removal
 Cutting temperature as a function of cutting parameters

32

Cutting temperature as a function of cutting speed V, feed f and depth of cut d

Tool life and Tool Wear 09/23/2021

 1. Name and briefly describe the four types of chips that occur in
metal cutting.
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2. What are the two principal locations on a cutting tool

where tool wear occurs?
3. Tool life tests on a lathe have resulted in the following
data: (1) at a cutting speed of 375 ft/min, the tool life
was 5.5 min; (2) at a cutting speed of 275 ft/min, the
tool life was 53 min.
a. Deter-mine the parameters n and C in the Taylor tool life
equation.
b. Using your equation, compute the tool life that corresponds
to a cutting speed of 300 ft/min.
c. Compute the cutting speed that corresponds to a tool life T
=10 min. Tool life and Tool Wear 09/23/2021
1. Identify the mechanisms by which cutting tools
34
wear during machining.

2. Tool life tests in turning yield the following data: (1)

when cutting speed is 100 m/min, tool life is 10min;
(2) when cutting speed is 75m/min, tool life is 30
min.
a) Determine the n and C values in the Taylor tool life
equation. Based on your equation, compute
b) the tool life for a speed of 110 m/min, and
c) the speed corresponding to a tool life of 15 min
3. Identify the three desirable properties of cutting tool materials
or Tool life and Tool Wear 09/23/2021