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Lecture 10 (Cutting Tool Technology)

This document discusses cutting tool technology and tool life modeling. It covers various aspects of tool life including tool materials, geometry, failure modes, wear mechanisms, and the Taylor tool life equation. The Taylor tool life equation models the relationship between cutting speed and tool life, where tool life decreases as cutting speed increases. The document provides an example problem to determine the constants in the Taylor tool life equation based on given cutting speeds and tool lives.

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hashir siddiqui
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97 views

Lecture 10 (Cutting Tool Technology)

This document discusses cutting tool technology and tool life modeling. It covers various aspects of tool life including tool materials, geometry, failure modes, wear mechanisms, and the Taylor tool life equation. The Taylor tool life equation models the relationship between cutting speed and tool life, where tool life decreases as cutting speed increases. The document provides an example problem to determine the constants in the Taylor tool life equation based on given cutting speeds and tool lives.

Uploaded by

hashir siddiqui
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Department of Mechanical Engineering

University of Central Punjab

Cutting Tool Technology

COURSE TITLE: MANUFACTURING PROCESSES II (MEN3143)

Chapter 23 Course Instructor: Umer Hayat


Summary of Last Lecture

Screw Threads Formation

Gear Formation Methods


Content of Chapter
3

 Tool Life
 Tool Materials
 Tool Geometry
 Cutting Fluids
Cutting Tool Technology
4

Two principal aspects:

1. Tool material
– developing materials that can withstand forces, temperature
and wear

2. Tool geometry
– Optimizing the geometry of tool
Three Modes of Tool Failure
5

 Fracture failure
 Cutting force becomes excessive and/or dynamic, leading to brittle
fracture

 Temperature failure
 Cutting temperature is too high for the tool material

 Gradual wear
 Gradual wearing of the cutting tool
Preferred Mode of Tool Failure: Gradual Wear
6

 Fracture and temperature failures are premature failures


 Gradual wear is preferred because it leads to the longest possible
use of the tool

 Gradual wear occurs at two locations on a tool:


 Crater wear
– occurs on top rake face
 Flank wear

– occurs on flank (side of tool)


7

Figure 23.2 -

(a) Crater wear, and

(b) flank wear on a


cemented carbide tool,
as seen through a
toolmaker's microscope

(Courtesy Manufacturing
Technology Laboratory,
Lehigh University, photo
by J. C. Keefe)
Mechanisms Causing Wear
8

 Abrasion
 Mechanical wearing action caused by hard particles in the work, removing
small portions of the tool.
 Occurs in both flank wear and crater wear

 Adhesion
 When two metals are forced into contact under high pressure and
temperature, adhesion or welding occur between them.
 These conditions are present between the chip and the rake face of the
tool.
 Diffusion
 Diffusion at tool–chip boundary, causes tool surface to become depleted
of the atoms responsible for its hardness.
 Tool surface becomes more susceptible to abrasion and adhesion.
 Diffusion is believed to be a principal mechanism of crater wear.
Mechanisms Causing Wear
9

 Chemical reactions
 The high temperatures and clean surfaces at the tool–chip interface can
result in chemical reactions, i-e oxidation, on the rake face of the tool.
 The oxidized layer, being softer than the parent tool material, is sheared
away, exposing new material

 Plastic deformation
 The cutting forces acting on the cutting edge at high temperature cause the
edge to deform plastically, making it more vulnerable to abrasion of the
tool surface.
 Plastic deformation contributes mainly to flank wear
Wear Progression
10

Figure 23.3 - Tool wear as a function of cutting time


Flank wear (FW) is used here as the measure of tool wear
Crater wear follows a similar growth curve
Wear Progression
11

• Harder work materials cause the wear rate to increase.


• Increased speed, feed, and depth of cut have a similar effect
• Speed being the most important of the three

Effect of cutting speed on tool flank wear (FW) for three cutting speeds, using a tool
life criterion of 0.50 mm flank wear
Tool Life
12

 Tool life is defined as the length of cutting time that the tool can be
used
 In production, it is often a disadvantage to use the tool until this failure
occurs
 because of difficulties in resharpening the tool
 problems with work surface quality

 A level of tool wear can be selected as a criterion of tool life, and the
tool is replaced when wear reaches that level
 A convenient tool life criterion is a certain flank wear value, such as
0.5 mm
Taylor Tool Life Equation
13

This relationship is credited to F. W. Taylor (~1900)

where v = cutting speed; T = tool life


n and C are parameters that depend on feed, depth of
cut, work material, tooling material, and the tool life
criterion used

• n is the slope of the plot


• C is the intercept on the speed axis
Tool Life Criteria in Production
14

1. Complete failure of cutting edge


2. Visual inspection of flank wear (or crater wear) by the machine
operator
3. Fingernail test across cutting edge
4. Changes in sound emitted from operation
5. Chips become ribbony, stringy, and difficult to dispose of
6. Degradation of surface finish
7. Increased power
8. Workpiece count
9. Cumulative cutting time
Example 23.1
15

 Determine the values of C and n in the plot of Figure 23.5, using two
of the three points on the curve and solving simultaneous equations of
the form of Eq. (23.1)
Choosing two extreme points: v=160m/min, T=5min; and v=100m/min,
T=41min; we have
16
Problem
17

 A 15.0-in x 2.0-in-workpart is machined in a face milling operation


using a 2.5-in diameter fly cutter with a single carbide insert. The
machine is set for a feed of 0.010 in/tooth and a depth of 0.20 in. If
a cutting speed of 400 ft/min is used, the tool lasts for three pieces. If
a cutting speed of 200 ft/min is used, the tool lasts for 12 parts.
Determine the Taylor tool life equation
18

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