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ME 1008
Manufacturing Technology
By
S. SAMPATH KUMAR
Assistant Professor
Mechanical Engineering Department
SRM Nagar, Kattankulathur 603 203
Syllabus
Orthogonal and oblique cutting Classification of cutting tools: single,
multipoint Tool signature for single point cutting tool Mechanics of
orthogonal cutting Shear angle and its significance Chip formation
Cutting tool materials Tool wear and tool life Machinability Cutting
Fluids Simple problems.
TEXT BOOKS
1. Sharma, P.C., A textbook of Production Technology Vol I and II, S. Chand &
Company Ltd., New Delhi, 1996.
2. Rao, P.N., Manufacturing Technology, Vol I & II, Tata McGraw Hill Publishing
Co., New Delhi, 1998.
Metal Cutting
Metal cutting or Machining operation is to produce a desired shape, size and
finish of a component by removing excess material in the form of chips.
Chips may constitute more than 50% of initial work piece.
Machining processes are performed on metal cutting machines, using
various types of cutting tools
Metal cutting process in general should be carried out at high speeds and feeds
with least cutting effort at minimum cost.
turning
External
Internal
facing
grooving
forming
threading
Cutting force, heat and abrasive wear are important features in metal cutting.
Orthogonal cutting is also known as two dimensional metal cutting in which the cutting
edge is normal to the work piece. (angle = 90deg)
Oblique cutting is also known as three dimensional cutting in which the cutting action
is inclined with the job by a certain angle called the inclination angle. (angle 90deg)
Single point cutting tool : This type of tool has a effective cutting edge and
removes excess material from the work piece along the cutting edge.
These tools may be left-handed or right-handed.
Again single point cutting tools classified as
A. solid type
B. tipped tool.
C. Brazed tools
are generally known as tool bits and are used in tool holders.
The tipped type of tool is made from a good shank steel on which is mounted a tip
of cutting tool material.
Tip may be made of high speed steel or cemented carbide.
Different types of carbide tips are generally used on tipped tool.
Geometry comprises mainly of nose, rake face of the tool, flank, heel and shank etc.
The nose is shaped as conical with different angles.
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Types of Chips
Chips are separated from the workpiece to impart the required size and shape.
The chips that are formed during metal cutting operations can be classified into four
types:
1. Continuous chips
2. Continuous chips with built-up edge
3. Discontinuous or segmental chips.
4. Non homogenous chips
1. Continuous chips
Chip is produced when there is low friction between the chip and tool face
This chip has the shape of long string or curls into a tight roll
Chip is produced when ductile materials such as Al, Cu, M.S, and wrought Iron are
machined.
Formation of very lengthy chip is hazardous to the machining process and the
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It may wrap up on the cutting tool, work piece and interrupt in the cutting operation.
It becomes necessary to deform or break long continuous chips into small pieces.
It is done by using chip breakers and this can be an integral part of the tool design
or a separate device.
When high friction exists between chip and tool, the chip material welds itself to the
tool face.
Welded material increases friction further which in turn leads to the building up a
layer upon layer of chip material.
Build up edge grows and breaks down when it becomes unstable.
Chips with build up edge result in higher power consumption, poor surface finish and
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large tool wear
4. Non-homogeneous chips
It will be in the form of notches and formed due to non-uniform strain in materal
during chip formation.
Non homogenous chips are developed during machining highly hard alloys like
titanium.
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Chip breaker
There are two types of chip breakers
1. External type, an inclined obstruction clamped to the tool face
2. Integral type, a groove ground into the tool face or bulges formed onto the tool
face
clamped
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Feed
This angle helps in removing the chips away from the work piece.
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Tool Signature
Convenient way to specify tool angles by use of a standardized abbreviated
system is known as tool signature or tool nomenclature.
The seven elements that comprise the signature of a single point cutting tool can
be stated in the following order:
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Straight Tungsten Carbide Cobalt Grade : Cast iron, non ferrous alloys, plastics,
wood, glass etc.
Alloyed Tungsten Carbide Grade: All grades of steel at 3 to 4 times more speeds
than HSS
5. Ceramic Tools:
Aluminium Oxide, Silicon Carbide, Boron Carbide, Titanium Carbide, Titanium
Boride
High speed, longer tool life, superior surface finish, No coolant is required.
6. Diamond Tools:
More abrasion resistance
Used for turning grinding wheels
Used to produce mirror surface finish.
Diamond abrassive belts are used to produce TV screens
Poly crystalline diamond inserts are brazed into cutting edges of circular saws for
cutting construction materials like concrete, refractories, stone etc.
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Tool Life
Properly designed cutting tool is expected to perform the metal cutting operation
in an effective an smooth manner
If a tool is not giving satisfactory performance it is an indicative of tool failure.
Following are the adverse effects observed during operation;
Extremely poor surface finish on the workpiece
Higher consumption of power
Work dimensions are not produced as specified
Overheating of cutting tool
Appearance of burnishing band on the work surface
During operation cutting tool may fail due to following;
Thermal cracking and softening
Mechanical Chipping
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Gradual wear
Tool life is defined as the time interval for which tool works satisfactorily
between two successive grinding or re-sharpening of the tool.
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2. Mechanical Chipping
Mechanical chipping of nose an cutting edge of the tool are commonly observed
causes for tool failure.
Reasons for failure are High cutting pressure, Mechanical impact, Excessive
wear, too high vibrations and weak tip an cutting edge, etc.
This type of failure is pronounced in carbide tipped and diamond tools due to
high brittleness of tool material.
Chipped Tip
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3. Gradual wear
When a tool is in use for some time it is found to have lost some weight or
mass implying that it has lost some material from it due to wear.
Wear locations:
Crater wear location
Flank wear location
Crater wear
Due to pressure of the hot chip sliding
up the face of the tool, crater or a
depression is formed on the face of tool.
(Ductile materials)
By diffusion shape of crater formed
corresponds to the shape of underside
of the chip
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Crater wear
Flank wear
Occurs between tool and workpiece
interface
Due to abrasion between tool flank
and workpiece
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Machinability
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Qualitative measure of
machinability
sharpening
3. The quality of machined surface.
4. The power consumption per unit volume
of material removed.
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material removed.
Maximum metal removal per tool re
sharpening
High quality of surface finish
Good and uniform dimensional accuracy of
successive parts
Easy disposable chips.
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cutting oils
Three categories
Cutting oils
Emulsifiable oils
Chemical (synthetic) cutting fluids
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