UNIT-1
CUTTING TOOL
MATERIALS.
MAHESH SATTIGERI
DESIRED PROPERTIES OF CUTTING TOOL
MATERIALS
27 May 2021
Cutting operation is a metal deformation process. The material
is cut by the application of force through the cutting tool. To
achieve this, cutting tool must provide maximum resistance to
change the geometry and cut the material.
The Desired Properties of the good cutting tool material are:
⚫ Hot Hardness : It is the ability of the material to retain
hardness at high temperature. During machining, very
large amount of heat is produced due to shearing of metal
(which is a plastic deformation) and friction at the chip-tool
interface.
⚫ Wear Resistance : The tool must have good wear
resistance. Because the tool undergoes severe wear
conditions during cutting under the action of abrasive 2
particles like dust, BUE in the work material
DESIRED PROPERTIES OF CUTTING TOOL
MATERIALS
27 May 2021
⚫ Toughness : The material must have sufficient strength,
ductility, sudden impact load and also withstand shocks and
vibrations to prevent breakage.
⚫ Friction : The coefficient of friction at the chip tool
interface must remain low so that less heat is generated due
to friction for this tool rake face must be smooth.
⚫ Thermal characteristics : Lot of heat is generated at the
cutting zone, the tool materials should have higher thermal
conductivity to dissipate this heat in the shortest time
otherwise the life of the tool reduces.
⚫ Lower coefficient of thermal expansion : This means lower
distortion and lower dimensional changes of the tool during
high temperature. 3
DESIRED PROPERTIES OF CUTTING TOOL
MATERIALS
27 May 2021
High specific heat : The amount of heat energy required to
raise the temperature of unit mass by unit degree centigrade.
The higher sp.heat. Implies the tempt rise of the tool material is
lesser due to the heat produced. The lower sp.heat would lead
to higher tempt rise of the tool material which is not desired.
Cost and easiness in fabrication :It should be within
reasonable limits.
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TOOL MATERIALS
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Types of cutting tool materials
⚫ Carbon steel (High carbon steel)
⚫ Medium alloy steels
⚫ HSS
⚫ Carbide
⚫ Ceramics
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CARBON STEEL
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Physical Properties Chemical Composition
Modulus of Elasticity :- 185 - Carbon (0.6% to 1.5%)
210(GPa) Silicon
Poisson’s ratio :- 0.28 Magnesium
Strength Chromium
⚫ Compressive :- 250Mpa
Vanadium
⚫ Tensile :- 490 MPa
in small quantities to refine the
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Density :- 7.85 (Kg/m ) grain size and improve the
Thermal conductivity :- 45 hardness.
(W/m.K)
Specific heat :- 0.49 (J/kg/K.)
Rockwell hardness :- B85-B95
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Melting point:- 1425 to 1540˚C
CARBON STEEL
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APPLICATIONS FEATURES
Turning tools Low heat /wear resistance
Twist drills Suitable for low cutting
Milling cutters speeds.
Hack saw blades Cheap and easily
manufactured.
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MICROSTURCTURE
CARBON STEEL
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MICROSTRUCTURE
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HIGH SPEED STEEL (HSS)
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Physical Properties Chemical Composition
Modulus of Elasticity :- 185 - Carbon (0.9%)
210(GPa) Chromium (4%)
Poisson’s ratio :- 0.28 Tungsten (18%)
Strength Molybdenum (6%)
⚫ Compressive :- 315Mpa
Vanadium (1%)
⚫ Tensile :- 450 MPa
Cobalt ( 5%)
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Density :- 7.6 (Kg/m )
18-4-1 very commonly used
Thermal conductivity :- 20.2 HSS means 18% Tungsten, 4%
(W/m.K) Chromium and 1% Vanadium.
Specific heat :- 0.42 (J/kg/K.)
Rockwell hardness :- 63-65
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Color :- Grey.
Melting point:- 4680˚C
HIGH SPEED STEEL (HSS)
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HSS MICROSTRUCTURE
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HIGH SPEED STEEL (HSS)
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APPLICATIONS PROPERTIES
Single point cutting tool High working hardness
End mill High wear resistance
Broach High retention of hardness and
Taps red hardness
Drills Excellent toughness
Reamers
Milling cutters
Saw blades
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CARBIDES
Physical Properties Chemical Composition
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Modulus of Elasticity:- Carbon
669- 696(GPa) Calcium
Poisson’s ratio:-0.31 Tungsten
Strength Titanium
⚫ Compressive:- 2.7 GPa
⚫ Tensile:-344 MPa
Density:- 5,800 (Kg/m3 )
Thermal conductivity:- 110
(W/m.K)
Specific heat:- 184 (J/kg/K.)
Rockwell hardness:- 90
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Color :- Grey
Melting point: 2800-2870˚C
CARBIDES MICROSTRUCTURE
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CARBIDES
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APPLICATIONS PROPERTIES
car brakes & turbine Hot hardness up to 10000 C
mechanics. Resistance to abrasion
It's used in the military in Hardness at varying
armor-piercing weaponry and temperatures
found on the tips of poles used
Very high cutting speed are
by hikers.
possible.
Tools, the balls of ball point
High compressive strength.
pens, razor blades
Resistance to deflection:
tank armor , sand papers,
grinding wheels and cutting high degree of stability
tools. Corrosion resistant
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fuel cells and solar panels
applications.
CERAMICS
Physical Properties Chemical Composition
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Modulus of Elasticity:- Carbon
7 - 10(GPa) Calcium
Poisson’s ratio:-0.21 Tungsten
Strength Titanium
⚫ Compressive:- 25 GPa
⚫ Tensile:-1.5 - 2.5 MPa
Density:- 6000 (Kg/m3 )
Thermal conductivity:- 5
(W/m.K)
Specific heat:- 850 (J/kg/K.)
Rockwell hardness:- 22
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Color :- white
Melting point:-2800-2870˚C
CERAMICS MICROSTRUCTURE
27 May 2021
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CERAMICS
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APPLICATIONS PROPERTIES
car brakes & turbine Resistance to abrasion
mechanics. Hardness at varying
It's used in the military in temperatures
armor-piercing weaponry and Resistance to deflection:
found on the tips of poles used
high degree of stability
by hikers.
Corrosion resistant
Tools, the balls of ball point
pens, razor blades
tank armor , sand papers,
grinding wheels and cutting
tools.
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fuel cells and solar panels
applications.
HEAT DISTRIBUTION IN TOOL,
WORK PIECE AND CHIP
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HEAT DISTRIBUTION IN TOOL,
WORK PIECE AND CHIP
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The shear zone : Here the energy needed to shear the chip is
the source of heat. In this region about 70% of the heat is
generated. (Primary Zone)
The chip-tool interface :As the chip starts moving the rake
face heat is produced due to friction this is because of
shearing action. The volume is very small. The heat
developed is transferred to the tool rake face and chip
interface. In this region about 15% of the heat is generated.
(Secondary Zone)
Tool work interface : Here also small percent of total work
done is converted in to heat. This energy needed to
overcome frictional rubbing between flank face of the tool
and the work piece. In this region about 15% of the heat is
generated. 19
TOOL WEAR, TOOL FAILURE AND
TOOL LIFE
27 May 2021
Wear can be defined as the loss of weight or mass that
accompanies the contact of sliding surfaces.
Tool wear is usually undesirable and to be minimized.
Wear which is responsible for most tool failures involves
chemical, physical and mechanical process often in
combination.
The wear mechanism associated with gradual wear or
progressive wear include
i) Abrasion wear
ii) Adhesion wear
iii) Diffusion wear
iv) Chemical reaction
v) Plastic deformation 20
TOOL WEAR, TOOL FAILURE AND
TOOL LIFE
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Abrasion wear : It occurs when hard constituents of one
surface rubbing with another surface.
Many steel, CI and nickel based alloys contain hard particles,
oxides and nitrides that may cause abrasive wear.
Adhesion wear : It occurs when the cold bond between chip
material and tool face occurs.
Diffusion wear : It occurs by solid state mechanism in which
atoms in a metallic crystal lattice move from one lattice point
to another. It depends upon the temperature.
Chemical composition : It occurs because of rise in
temperature between rake face and the tool.
Plastic Deformation : It occurs because of rise in temperature
of cutting forces.
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TOOL WEAR, TOOL FAILURE AND
TOOL LIFE
27 May 2021
Tool Failure :
The tool failure may occur due to the following factors
i) Excessive Temperature
ii) Excessive Stress
iii) Flank wear
iv) Crater wear
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TOOL WEAR, TOOL FAILURE AND
TOOL LIFE
27 May 2021
Tool Failure :
The tool failure may occur due to the following factors
i) Excessive Temperature
ii) Excessive Stress
iii) Flank wear
iv) Crater wear
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TOOL WEAR, TOOL FAILURE AND
TOOL LIFE
27 May 2021
Tool Life :
The tool life is the time period between two consecutive re
sharpening with which the tool cuts the material effectively.
Tool life is important factor in production work since
considerable time is lost whenever a tool is re-sharpened and
reset on the machine.
Tool life is actual machining time which a fresh cutting tool
satisfactorily works after which it needs conditioning or
replacement.
Basically the tool life is based on criteria of the volume of the
material removed and that is derived as follows.
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TOOL WEAR, TOOL FAILURE AND
TOOL LIFE
No2.The tool life equation is given by VTn=C where n & c
27 May 2021
are constants. The values of V and T obtained by experiments
is given below. Calculate n and c. Recommend the cutting
speed for a desired tool life of 50 min.
V- m/min 25 35
T min 90 20
No3.Mild steel bars of 50 mm diameter are to be turned over a
length of 160 mm with a depth of cut of 1.5 mm, feed of 0.2
mm/rev at 250 rpm by HSS tools. If the tool life equation is
given by
V T0.2 f0.3 d0.12 = 50
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TOOL WEAR, TOOL FAILURE AND
TOOL LIFE
27 May 2021
No4. Calculate the cutting speed for a tool to have a tool life of 160
min. The same tool had a life of 9 min when cutting at 250 m/min
Take :n=0.22 in the equation.
No5. A carbide tool with mild steel work piece was found to
give life of 2 hours while cutting at 48 m/min. If Taylor’s
exponent n=0.27, determine
i) The tool life if the same tool is used at a speed of 20%
higher than the previous one.
ii) The value of cutting speed if the tool is required to have tool
life of 3 hours.
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END OF UNIT 1 YOU SHOULD BE ABLE TO
ANSWER THE FOLLOWING QUESTIONS
27 May 2021
How the chips are formed. Explain briefly
Explain the following types of chips with sketch
i) Continuous ii) Discontinuous iii) BUE chips
How are cutting tools are classified.
With sketch explain briefly the tool elements and tool angles
in a single point cutting tool.
Discuss briefly : Side cutting angle, Side relief angle, Back
rake angel, Clearance angle and nose radius.
What do mean by tool signature explain.
Explain briefly with sketch : i) Orthogonal ii) Oblique cutting.
How are cutting forces measured.
Discuss the basic mechanism of chip formation.
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What is chip thickness ratio.
END OF UNIT 1 YOU SHOULD BE ABLE TO ANSWER
THE FOLLOWING QUESTIONS
Derive the following relation for the shear angel (Ø)
27 May 2021
Ø =taqn-1 (r cos. α / 1-r sin.α)
Derive the following velocity relation ship in orthogonal
cutting
Vc = V sin Ø/ cos. (Ø-α)
Vs = V cos α/ cos. (Ø-α)
Explain regions of heat generation in metal cutting
What does the tool failure means.
Explain the term wear.
Explain briefly :i) Abrasion ii) Adhesion iii) Diffusion wear
On what factors tool life depend.
What is Taylors tool life equation
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Numerals.
27 May 2021 TOOL NOMENCLATURE
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THANK YOU
