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1.cutting Tool Materials
1.cutting Tool Materials
Session 5
2
Cutting Tools
• One of most important components in machining
process
• Performance will determine efficiency of operation
• Two basic types (excluding abrasives)
• Single point and multiple point
• Must have rake and clearance angles ground or
formed on them
3
Cutting-Tool Materials
• Toolbits generally made of seven materials
• High-speed steel
• Cast alloys (such as stellite)
• Cemented carbides
• Ceramics
• Cermets
• Cubic Boron Nitride
• Polycrystalline Diamond
4
Cutting Tool Properties
• Hardness
• Cutting tool material must be 1 1/2 times harder than
the material it is being used to machine.
5
Cutting Tool Properties
• Wear Resistance
• Able to maintain sharpened edge throughout the
cutting operation
• Same as abrasive resistance
• Shock Resistance
• Able to take the cutting loads and forces
6
Cutting Tool Properties
7
High-Speed Steel
• May contain combinations of tungsten,
chromium, vanadium, molybdenum, cobalt
• Can take heavy cuts, withstand shock and
maintain sharp cutting edge under red heat
• Generally two types (general purpose)
• Molybdenum-base (Group M)
• Tungsten-base (Group T)
• Cobalt added if more red hardness desired
8
Cast Alloy
• Usually contain 25% to 35% chromium, 4% to 25%
tungsten and 1% to 3% carbon
• Remainder cobalt
• Qualities
• High hardness
• High resistance to wear
• Excellent red-hardness
• Operate 2 ½ times speed of high-speed steel
• Weaker and more brittle than high-speed steel
9
Carbide Cutting Tools
• First used in Germany during WW II as substitute
for diamonds
• Various types of cemented (sintered) carbides
developed to suit different materials and
machining operations
• Good wear resistance
• Operate at speeds ranging 150 to 1200 sf/min
• Can machine metals at speeds that cause cutting
edge to become red hot without loosing harness
10
Manufacture of Cemented Carbides
• Products of powder metallurgy process
• Tantalum, titanium, niobium
• Operations
• Blending
• Compaction
• Presintering
• Sintering
11
Blending
• Five types of powders
• Tungsten carbide, titanium carbide, cobalt, tantalum
carbide, niobium carbide
• One or combination blended in different
proportions depending on grade desired
• Powder mixed in alcohol (24 to 190 h)
• Alcohol drained off
• Paraffin added to simplify pressing operation
12
Compaction
• Must be molded to shape and size
• Five different methods to
compact powder
• Extrusion process
• Hot press
• Isostatic press
• Ingot press
• Pill press
• Green (pressed) compacts soft, must be
presintered to dissolve paraffin
14
Sintering
• Last step in process
• Converts presintered machine blanks into
cemented carbide
• Carried out in either hydrogen atmosphere or
vacuum
• Temperatures between 2550º and 2730º F
• Binder (cobalt) unites and cements carbide
powders into dense structure of extremely hard
carbide crystals
15
Cemented-Carbide Applications
• Used extensively in manufacture of metal-
cutting tools
• Extreme hardness and good wear-resistance
• First used in machining operations as lathe
cutting tools
• Majority are single-point cutting tools used on
lathes and milling machines
16
Types of Carbide Lathe
Cutting Tools
• Blazed-tip type
• Cemented-carbide tips brazed to steel shanks
• Wide variety of styles and sizes
• Indexable insert type
• Throwaway inserts
• Wide variety of shapes: triangular, square, diamond,
and round
• Triangular: has three cutting edges
• Inserts held mechanically in special holder
17
Reasons Indexable Inserts More
Popular than Brazed-Tip Tools
1. Less time required to change cutting edge
2. Amount of machine downtime reduced
considerable thus production increased
3. Time normally spent in regrinding eliminated
4. Faster speeds and feeds can be used
5. Cost of diamond wheels eliminated
6. Indexable inserts cheaper than brazed-tip
18
Cemented-Carbide Insert
Identification
• American Standards Association has developed
system by which indexable inserts can be
identified quickly and accurately
• Adopted by manufacturers
• Table 31.1 in text
19
Grades of Cemented Carbides
• Two main groups of carbides
• Straight tungsten carbide
• Contains only tungsten carbide and cobalt
• Strongest and most wear-resistant
• Used for machining cast iron and nonmetals
• Crater-resistant
• Contain titanium carbide and tantalum carbide in addition
to tungsten carbide and cobalt
• Used for machining most steels
20
Qualities of Tungsten
Carbide Tools
• Determined by size of tungsten carbide
particles and percentage of cobalt
1. Finer the grain particles, lower the tool toughness
2. Finer the grain particles, higher tool hardness
3. Higher the hardness, greater wear resistance
4. Lower cobalt content, lower tool toughness
5. Lower cobalt content, higher hardness
21
Additive Characteristics
• Titanium carbide
• Addition provides resistance to tool cratering
• Content increased
• Toughness of tool decreased
• Abrasive wear resistance at cutting edge lowered
• Tantalum carbide
• Addition provides resistance to tool cratering
• Without affecting abrasive wear resistance
• Addition increases tool's resistance to deformation
22
General Rules for Selection of Proper
Cemented-Carbide Grade
1. Use grade with lowest cobalt content and finest
grain size
2. Use straight tungsten carbide grades to combat
abrasive wear
3. To combat cratering, seizing, welding, and galling,
use titanium carbide grades
4. For crater and abrasive wear resistance, use
tantalum carbide grades
5. Use tantalum carbide grades for heavy cuts in
steel, when heat and pressure might deform
cutting edge
23
Coated Carbide Inserts
• Give longer tool life, greater productivity and freer-
flowing chips
• Coating acts as permanent lubricant
• Permits higher speed, reduced heat and stress
• Two or three materials in coating give tool special
qualities
• Innermost layer of titanium carbide
• Thick layer of aluminum oxide
• Third, very thin layer titanium nitride
24
Coatings
• Titanium carbide
• High wear and abrasion resistance
(moderate speed)
• Used for roughing and finishing
• Titanium nitride
• Extremely hard, good crater resistance
• Excellent lubricating properties
• Aluminum oxide
• Provides chemical stability
• Maintains hardness at high temperatures
25
Tool
Geometry
Terms adopted
by ASME
SIDE RELIEF
SIDE CLEARANCE
28
Side Rake
• Large as possible to allow
chips to escape
• Amount determined
• Type and grade of cutting tool
• Type of material being cut
• Feed per revolution
• Angle of keenness
• Formed by side rake and side
clearance
31
Cutting Speeds and Feeds
• Important factors that influence speeds, feeds, and
depth of cut
• Type and hardness of work material
• Grade and shape of cutting tool
• Rigidity of cutting tool
• Rigidity of work and machine
• Power rating of machine
32
Machining with Carbide Tools
• To obtain maximum efficiency
• Precautions in machine setup
• Rigid and free from vibrations
• Equipped with heat-treated gears
• Sufficient power to maintain constant cutting speed
• Cutting operation
• Cutting tool held as rigidly as possible to avoid chatter
33
Suggestions for Using
Cemented-Carbide Cutting Tools
• Work Setup
• Mount work in chuck or holding device to prevent
slipping and chattering
• Revolving center used in tailstock for turning work
between centers
• Tailstock spindle extended minimum distance and
locked securely
• Tailstock should be clamped firmly to lathe bed
34
Suggestions for Using
Cemented-Carbide Cutting Tools
• Tool Selection
• Use cutting tool with proper rake and clearances
• Hone cutting edge
• Use side cutting edge angle
large enough tool can be
eased into work
• Use largest nose radius
operating conditions permit
38
4. Never continue to use dull cutting tool
5. Dull cutting tool recognized by
• Work produced oversize with glazed finish
• Rough and ragged finish
• Change in shape or color of chips
6. Apply cutting fluid only if
• Can be applied under pressure
• Can be directed at point of cutting and kept there at
all times
39
Tool Selection and
Application Guide
• Table 31.7 in text lists points to follow to obtain
most efficient metal-removal rates
• Other factors affecting optimum life
• Horsepower available on machine tool
• Rigidity of machine tool and toolholders
• Shape of workpiece and setup
• Speed and feed rates used for machining operation
40
Grinding Wheels
1. 80-grit silicon carbide wheel used for rough
grinding carbides
2. 100-grit silicon carbide wheel used for finish
grinding carbides
3. Diamond grinding wheels (100-grit) excellent
for finish grinding; high finishes use 220-grit
diamond wheel
41
Type of Grinder
• Heavy-duty grinder used for grinding carbides
• Cutting pressures required to remove carbide are 5
to 10 times as great as high-speed steel tools
• Should be equipped with adjustable table and
protractor so necessary tool angles and
clearances may be ground accurately
42
Tool Grinding
1. Regrind cutting tool to angles and clearances
recommend by manufacturer
2. Use silicon carbide wheels for rough grinding
• Use diamond wheels when high surface finishes
required
3. Move carbide tool back and forth over
grinding wheel face to keep amount of head
generated to minimum
4. Never quench carbide tools that become hot
during grinding – allow them to cool gradually
43
Honing
• Remove fine, ragged edge left by grinding wheel
• Fine, nicked edge fragile
• Suggestions for successful honing
• 320-grit silicon carbide or diamond hone
• 45º chamfer .002 to .004 in. wide honed
on cutting edge when cutting steel
• No chamfer if used for aluminum,
magnesium and plastics
45
Cemented-Carbide
• Capable of cutting speeds 3 to 4 times high-speed
steel toolbits
• Low toughness but high hardness and excellent
red-hardness
• Consist of tungsten carbide sintered in cobalt
matrix
• Straight tungsten used to machine cast iron and
nonferrous materials (crater easily)
• Different grades for different work
46
Metal-Cutting
47
Turning
• High proportion of work machined in shop
turned on lathe
• Workpiece held securely in chuck or between lathe
centers
• Turning tool set to given depth of cut, fed parallel to
axis of work (reduces diameter of work)
• Chip forms and slides along cutting tool's upper surface
created by side rake
48
Turning
49
Planing or Shaping
• Workpiece moved back and forth under cutting
tool
• Fed sideways a set amount at end of each table
reversal
• Should have
proper rake
and clearance
angles on cutting
tool
50
Plain Milling
• Multi-tooth tool having several equally spaced
cutting edges around periphery
• Each tooth considered single-point cutting tool
(must have proper rake and clearance angles)
• Workpiece held in vise or fastened to table
• Fed into horizontal revolving cutter
• Each tooth makes successive cuts
• Produces smooth, flat, or profiled surface depending
on shape of cutter
51
Plain Milling
52
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Inserted Blade Face Mill
• Consists of body that holds several equally
spaced inserts
• Required rake angle
• Lower edge of each insert has relief or clearance
angle ground on it
• Cutting action occurs at lower corner of insert
• Corners chamfered to give strength
53
Face Milling
54
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
End Milling
• Multi-fluted cutters held vertically in vertical
milling machine spindle or attachment
• Used primarily for cutting slots or grooves
• Workpiece held in vise and fed into revolving
cutter
• End milling
• Cutting done by periphery of teeth
55
Nomenclature of an
End Mill
56
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Nomenclature of an
End Mill
57
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Drilling
• Multi-edge cutting tool that cuts on the point
• Drill's cutting edges (lips) provided with lip clearance
to permit point to penetrate workpiece as drill
revolves
• Rake angle provided by helical-shaped flutes
• Slope away from cutting edge
• Angle of keeness
• Angle between rake angle and clearance angle
58
Characteristics of a Chip formation
Drill Point of a drill