cutting-tool presentaion

8/13/2019 cutting-tool PRESENTAION

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POWERPOINT PRESENTATION

CUTTING TOOL AND MATERIAL


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REASONS FOR DEVELOPMENT OF CUTTING TOOL

GLOBLE COMPETATION

PRODUCTIVITY : Cutting Speed Reduce Machining Time Improve Tool Life

QUALITY AND RELIABILITY: High accuracy & tolerances Better surface finish

Cost: Reduce Unnecessary Cost Reduce non-productive cost


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REASONS FOR DEVELOPMENT OF CUTTING TOOL


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BASIC REQUIREMENT OF A TOOL MATERIALS

HOT HARDNESS

WEAR RESISTANCE

TOUGHNESS AND STRENGTH THERMAL CONDUCTIVITY

CO-EFFICIENT OF FRICTION

CO-EFFICIENT OF THERMAL EXPANSION

MACHINIBILITY AND GRINDABILITY


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CUTTING TOOL MATERIALS

HOT HARDNESS OF SEVERAL TYPES OF TOOLS:


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TYPES OF CUTTING TOOL MATERIALS

CONVENTIONAL CUTTING TOOL MATERIALS

High Carbon Steel

High Speed Steel Cast-Cobalt alloys (Satellite)

Cemented Carbide

Ceramics

CERMET

Diomond


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TYPES OF CUTTING TOOL MATERIALS

ADVANCE CUTTING TOOL MATERIALS

Coated Carbides

CBN

PCD

UCON

Multi Coated

Super Coated Alloy


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HIGH CARBON STEEL

Carbon percentage -0.8 to 1.5%

Oldest known tool material Low Hot Hardness

Maximum Cutting Speed 10 m/min

Maximum Temperature Limit -250 C

Suitable for Low Cutting

Low Cost Used for taps, dies, hacksaw blades, hand drills, wood working

tools etc.


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HIGH SPEED STEEL (H.S.S)

T-Series M-Series

(Tungsten Type) (Molybdenum Type)18 - 4 - 1- 0.75 6 6 4 - 2

W Cr Va C W M Cr Va

Cutting speed up to 30 m/min

Maximum Limiting Temperature 560C

Less Costly

Excellent toughness

Widely used in industries as a solid Tool like form tool, drill, millingcutters, endmill, reamers, Broach, Single point cutting tool etc.


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CAST COBALT ALLOYS (STALLITE):

48-53% 30-33% 10-20% 1.5-2.0%Co Cr W C

Manufacturing Process- Casting Hot hardness- 760C Cutting Speed -45 m/min Higher tool life compare to H.S.S. Hardness -58 to 64 HRC Lower toughness/brittle Limited strength Used for from tool, Machining cast and malleable iron.


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CUTTING TOOL MATERIALSCERAMICS:

Al2O3+ MgO, Cr2O3, SiC, TiO, TiC90% ________10%____________

High abrasive of wear Resistance Less tendency to weld to metal Very high compressive strength Very high hot hardness High refractoriness

1800 C

High Cutting Speed -200 to 400 m/min Longer tool life Used for cutting steel and HSS Used for high speed machining

Limitation:

Poor ToughnessUnreliable (Suddenfail)High rigidity of set up


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CEMENTED CARBIDES (TUNGUSTAN CARBIDE):

Plain Tungsten Carbide

W C Co

94% 6% BINDER

Manufactured by Powder Metallurgy

Grain size 1 micron to 8 micron

% of Co -3 to 12%Many verity can be produced by controlling

grain size and % of cobalt.

Machining of non-ferrous, non-metallic and C.I

Drawback is itsAffinity with steel


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CEMENTED CARBIDES (TUNGUSTAN CARBIDE):

Steel Grade (Triple) Tungsten Carbide

W TiC TaC Co15% 10%

High hardness and wear resistance Maximum limiting Temperature -1200 C Various Shapes Of Inserts Cutting Speed -100 m/min High Tool life High compressive strength High production rate

Better surface finish

Drawback is itsAffinity withsteel

VARIOUS SHAPES OF INSERTS


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DIMOND:

Hardest substance BHN 7000 High heat conductivity (Twice then steel) High hot hardness 1650 C High wear resistance Very low co-efficient of friction High compressive strength

High cutting speed (300 to 1000 m/min) High tool life Used for cutting hard material like glass, plastic

Ceramics and cemented carbides. Used for turning and dressing wheel of grinding wheel

Used for machining non-metallic and non-ferrous alloy

Limitation:

High rigidity of setup isrequired.Poor shock and impactresistance Not suitable for ferrousmaterials


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COATED CARBIDES:

Coating of micro thin layer insets made of tungsten carbide Most commonly used coating materials are:

Titanium Nitride (TiN) Titanium Carbide (TiC) Titanium CarboNitiride (TiCN) Aluminium Oxide (Al2O3) Zicronium Nitride (ZrN) Titanium Aluminium Nitride (TiAlN)

Methods of Coatings- Chemical Vapor Depositio (CVD)- Physical Vapor Deposition (PVD)


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SUPER COATED CARBIDES :

UE6020 for steel turning } Development by Mitsubishi Material

UE5015 for C.I Turning } Corporation, Japan in 2000

WC- Higher interior Hardness and toughness

Triple layer coating

Inner layer FCCN (Fibrous Crystalline Carbon Titanium )

Balance between wear resistance and fracture resistance Outer coating Al2O3(Fine Grain)

outer most layer Special laminated Titanium Alloys

Superior high temperature strength.


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COATED CARBIDES:

Advantages:

High hot hardness Chemically stable High cutting speed -150 to 250 m/min High Tool life (2 to 3 times higher than carbide)

Applications:

Widely used for high speed machining Production of turning and milling of steels and C.I Machining of very hard materials

Used as inserts


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MULTI PHASE COTING

Outer most layer specially laminated by titanium alloy Smooth surface structure and high chemical stability Two of three layers of various coating materials to get

desired Properties

High speed, continues cutting Tic/ Al2O3 Heavy duty, continues cutting TiC/Al2O3/ Tin

Light interrupted cutting

TiC / TiC + TiN

TiN - Low frictionAl2O3High thermal stabilityTiCN Resistance to flank and crater wear


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UCON

Nitrided refectory metal alloy developed by Union Carbide, USA. Composition :50% columbium, 30%titanium and 20%tungsten and

contain no carbides. Hardness 2500-3000 vickers. Manufacture by cast into ingots and rolled into sheets and then cut

into strips. Withstand very high temperature. Used as through away inserts. Excellent thermal shock resistance, High hardness and toughness.

Excellent resistance proof to diffusion and adhesion wear. 3-5 times more tool life then conventional carbide. Cutting speed range of 250-500 M/Min on steels of 200 BHN


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Application

Recommend for roughing, semi roughing and finishing cuts inturning, facing and boring.

Use for steel machining grade.


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CUBIC BORON NITRIDE:

Sanitized artificially made under high pressure and hightemperature.

Stable up to 10000C temperature. Manufactures under ultra high pressure and high temperature. Excellent in chemical and thermal stability. Hardness next to natural dimond.

Applications:

Permits high feeds and speeds. Available in large varity of shapes and sizes in insert form. Use to turn bore, face, groove and mill difficult to machine

materials.


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CUBIC BORON NITRIDE :

Material Recommended for cutting with CBN

Alloy Steel (45-68 Rc)

Carbon Tool Steel (45-68 Rc)

Die Steel S (45-68 Rc)

High Speed Steel (45-68 Rc)


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PCD:

Synthetic having diamond matrix structure. Sintered under extremely high temperature and pressure. High in uniform hardness and abrasive resistance in all

direction. Very high tool life compare to carbide tool (50 times). Shock resistance is more than natural dimond. Consistency in wear resistance.

Available in large verity of shapes and sizes. Discs as large as 58 mm in diameter. Better thermal conductivity then natural dimond. Lower cost then natural diamond. Used for machining milling, turning, grooving, facing and

boring.


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TOOL/WORK CHEMICAL OR ADHESIVE INTERACTION SEVERITIES:


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TOOL MATERIAL OXIDATION AND STRUCTURAL

CHANGE TEMPERATURE RANGES:


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REFERANCES:

production Technology- HMT

Theory and Application of Metal Cutting by Thomas Child Production Technology- Kalpak Jain

Production Technology P.C.Sharma

Production Engineering and Sciences By Pandey and Singh

Metal Cutting Milton Saw


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Regression Analysis : Farewell Corporation manufactures Integrated Circuit boards(I.C board) for

electronics devices. The planning department knows that the sales of theirclient goods depends on how much they spend on advertising, on account ofwhich they receive in advance of expenditure. The planning department wish

to find out the relationship between their clients advertising and sales, so asto find demand for I.C board. The money spend by the client on advertising and sales (in dollar) is given for

different periods in following table :Period(t)

Advertising(Xt)

$(1,00,000)

Sales (Dt)$(1,000.000)

Dt2 Xt2 XtDt

1 20 6 36 400 120

2 25 8 64 625 2003 15 7 49 225 105

4 18 7 49 324 126

5 22 8 64 484 176

6 25 9 81 625 225

7 27 10 100 729 270

8 23 7 49 529 161

9 16 6 36 256 9610 20 8 64 400 120

211 76 592 4597 1599

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