MCE 4321 Manufacturing Processes

Thu, 20 Mar, 2014

7:02:02 AM

Characteristics of cutting tool :

Part 5
Machining Processes:
Cutting tool materials & Cutting fluids

Hot hardness, so that the hardness, strength, and wear resistance of the tool are
maintained at the temperatures encountered in machining operations. This
property ensures that the tool does not undergo any plastic deformation and
thus retains its shape and sharpness.
Toughness and impact strength (or mechanical shock resistance), so that
impact forces on the tool that are encountered repeatedly in interrupted cutting
operations or forces due to vibration and chatter during machining do not chip
or fracture the tool.
Thermal shock resistance, to withstand the rapid temperature cycling
encountered in interrupted cutting.
Wear resistance, so that an acceptable tool life is obtained before replacement
is necessary.
Chemical stability and inertness with respect to the material being machined,
to avoid or minimize any adverse reactions, adhesion, and tool-chip diffusion
that would contribute to tool wear.

Dr. Mohammad Ahsan Habib

Assistant Professor
E-mail: mahabib@iut-dhaka.edu
Department of Mechanical and Chemical Engineering (MCE)
Room: 405, Level 4, First Academic Building

Islamic University of Technology (IUT)

Universit Islamique de Technologie
ORGANISATION OF ISLAMIC COOPERATION (OIC)

MCE 4321 Manufacturing Processes

Dr. Mohammad Ahsan Habib

Thu, 20 Mar, 2014

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MCE 4321 Manufacturing Processes

Thu, 20 Mar, 2014

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Cutting tool materials

1. Carbon and Medium alloy steels :

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Carbon & medium alloy steels

High speed steels
Cast-cobalt alloys
Carbides
Coated tools
Alumina-based ceramics
Cubic boron nitride
Silicon-nitride-base ceramics
Diamond
Whisker-reinforced materials

Dr. Mohammad Ahsan Habib

Oldest of tool materials

Used for drills taps, broaches ,reamers
Inexpensive, easily shaped, sharpened
No sufficient hardness and wear resistance
Limited to low cutting speed operation

2. High speed steels (HSS):

Hardened to various depths, Good wear resistance, Suitable for
high positive rake angle tools
H.S.S. available in wrought, cast & sintered (Powder metallurgy)
Coated for better performance
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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Thu, 20 Mar, 2014

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MCE 4321 Manufacturing Processes

2. High speed steels (HSS): (Cont. )

3. Cast-Cobalt alloys

Two basic types of HSS

Commonly known as Stellite tools

Composition ranges :

Molybdenum ( M-series)
Tungsten ( T-series)

38% - 53 % cobalt
30% - 33% chromium
10% -20%tungsten

M-series: Contains 10% molybdenum, chromium, vanadium,

tungsten, cobalt
Higher, abrasion resistance
H.S.S. are majorly made of M-series

Good wear resistance ( higher hardness)

Less tough than high-speed steels and sensitive to impact forces
Less suitable than high-speed steels for interrupted cutting
operations
Continuous roughing cuts relatively higher feeds & speeds
Finishing cuts are at lower feed and depth of cut

T-series: Contains 12 % - 18 % tungsten, chromium, vanadium &

cobalt
undergoes less distortion during heat treating

Subjected to surface treatments such as case-hardening for

improved hardness and wear resistance or steam treatment at
elevated temperatures
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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Thu, 20 Mar, 2014

9:52:21 AM

Thu, 20 Mar, 2014

9:54:49 AM

5. Coated tools :

These carbides are also known as cemented or sintered carbides

High elastic modulus, thermal conductivity
Low thermal expansion
2-groups of carbides used for machining operations

High strength and toughness but generally abrasive and chemically

reactive with tool materials

Unique Properties :

Tungsten carbide:
Composite material consisting of tungsten-carbide particles bonded together
Alternate name is cemented carbides
Manufactured with powder metallurgy techniques
Amount of cobalt present affects properties of carbide tools
As cobalt content increases strength hardness & wear resistance increases

Lower Friction
High resistance to cracks and wear
High Cutting speeds and low time & costs
Longer tool life

Techniques used :

Titanium carbide:
Titanium carbide has higher wear resistance than tungsten carbide
Nickel-Molybdenum alloy as matrix TiC suitable for machining hard materials
Steels & cast irons
Speeds higher than those for tungsten carbide
Dr. Mohammad Ahsan Habib

Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

4. Carbides :

Thu, 20 Mar, 2014

9:50:20 AM

Chemical vapor deposition (CVD), Plasma assisted CVD

Physical vapor deposition (PVD)
Medium temperature chemical vapor deposition (MTCVD)
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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Thu, 20 Mar, 2014

9:56:01 AM

MCE 4321 Manufacturing Processes

Multiphase Coatings on a Tungsten-Carbide

Substrate

Coating materials

Titanium nitride (TiN)

Titanium carbide (TiC)
Titanium Carbonitride (TiCN)
Aluminum oxide (Al2O3) thickness range: 2-15 m
Titanium Aluminum Nitride(TiAlN)
Chromium Based coatings
Chromium carbide
Zirconium Nitride (ZrN)
Hafnium nitride (HfN)
Recent developments gives nano coating & composite coating

MCE 4321 Manufacturing Processes

Figure: Multiphase coatings on a tungsten-carbide substrate. Three alternating layers of

aluminum oxide are separated by very thin layers of titanium nitride. Inserts with as many
as thirteen layers of coatings have been made. Coating thicknesses are typically in the
range of 2 to 10 m.
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Dr. Mohammad Ahsan Habib

Thu, 20 Mar, 2014

9:58:47 AM

6. Alumina-Based ceramics:
Cold-Pressed into insert shapes under high pressure and sintered at high
temperature
High Abrasion resistance and hot hardness
Chemically stable than high speed steels & carbides
So less tendency to adhere to metals
Good surface finish obtained in cutting cast iron and steels
Negative rake-angle preferred to avoid chipping due to poor tensile
strength
Cermets, Black or Hot- Pressed :
70% aluminum oxide & 30 % titanium carbide
cermets(ceramics & metal)
Cermets contain molybdenum carbide, niobium carbide and tantalum
carbide.
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Dr. Mohammad Ahsan Habib

Thu, 20 Mar, 2014

9:56:04 AM

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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Thu, 20 Mar, 2014

9:59:56 AM

7. Cubic boron Nitride ( CBN ) :

Made by bonding ( 0.5-1.0 mm) ( 0.02-0.04-in)
Layer of poly crystalline cubic boron nitride to a carbide substrate by
sintering under pressure
While carbide provides shock resistance CBN layer provides high
resistance and cutting edge strength
Cubic boron nitride tools are made in small sizes without substrate

Figure : (a) An insert of polycrystalline cubic boron nitride or a diamond

layer on tungsten carbide. (b) Inserts with polycrystalline cubic boron
nitride tips (top row) and solid polycrystalline CBN inserts (bottom row).
Dr. Mohammad Ahsan Habib

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MCE 4321 Manufacturing Processes

Thu, 20 Mar, 2014

10:00:31 AM

MCE 4321 Manufacturing Processes

8. Silicon-Nitride based ceramics (SiN)

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10:01:49 AM

9. Diamond :

They consists various addition of Aluminum Oxide, Ytthrium

oxide, titanium carbide
SiN have toughness, hot hardened & good thermal shock
resistance

Hardest known substance

Low friction, high wear resistance
Ability to maintain sharp cutting edge
Diamond is brittle , tool shape & sharpened is important
Low rake angle used for string cutting edge

Polycrystalline-Diamond ( PCD ) Tools:

SiN base material is Silicon

High thermal & shock resistance
Recommended for machining cast iron and nickel based super
alloys at intermediate cutting speeds
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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Thu, 20 Mar, 2014

10:02:55 AM

Small synthesis crystal fused by high pressure and temperature

Bonded to a carbide substrate
Diamond tools can be used for any speed
Suitable for light un-interrupted finishing cuts
To avoid tool fracture single crystal diamond is to be re-sharpened
as it becomes dull
Also used as an abrasive in grinding and polishing operations

MCE 4321 Manufacturing Processes

10. Whisker-reinforced tool materials

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Dr. Mohammad Ahsan Habib

Thu, 20 Mar, 2014

10:02:58 AM

Operating Characteristics of Cutting-Tool Materials

New tool materials with enhanced properties :

High fracture toughness
Resistance to thermal shock
Cutting edge strength
Hot hardness
Examples: Silicon-nitride base tools reinforced with siliconcarbide( SiC)
Aluminum oxide based tools reinforced with silicon-carbide
with ferrous metals makes SiC-reinforced tools
Progress in nanomaterial has lead to the development of cutting
tools
Made of fine grained structures as (micro grain) carbides
Dr. Mohammad Ahsan Habib

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Dr. Mohammad Ahsan Habib

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MCE 4321 Manufacturing Processes

Thu, 20 Mar, 2014

10:03:03 AM

MCE 4321 Manufacturing Processes

Ranges of Mechanical Properties for

Groups of Tool Materials

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10:03:04 AM

Inserts

Individual cutting tool with severed cutting points

Clamped on tool shanks with locking mechanisms
Inserts also brazed to the tools
Clamping is preferred method for securing an insert
Carbide Inserts available in various shapes-Square, Triangle,
Diamond and round
Strength depends on the shape
Inserts honed, chamfered or produced with negative land to
improve edge strength

Figure: Ranges of mechanical properties for various groups of tool materials.

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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Thu, 20 Mar, 2014

10:03:35 AM

MCE 4321 Manufacturing Processes

Inserts and Tool holders

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Dr. Mohammad Ahsan Habib

Thu, 20 Mar, 2014

10:05:41 AM

Insert Edge Properties

Figure: Typical carbide inserts with various shapes and chipbreaker features: Round inserts are also available. The holes in
the inserts are standardized for interchangeability in tool holders.

Figure: Relative edge strength and tendency for chipping of inserts with various shapes.
Strength refers to the cutting edge indicated by the included angles.

Figure: Methods of mounting inserts on tool holders: (a) clamping and (b) wing lock pins. (c)
Examples of inserts mounted with threadless lock pins, which are secured with side screws.
Dr. Mohammad Ahsan Habib

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Figure: Edge preparation for inserts to improve edge strength.

Dr. Mohammad Ahsan Habib

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MCE 4321 Manufacturing Processes

Thu, 20 Mar, 2014

10:05:42 AM

MCE 4321 Manufacturing Processes

Cutting Fluids: (Lubricants + Coolants)

Thu, 20 Mar, 2014

10:07:17 AM

Proper Methods of Applying Cutting Fluids

Used in machining as well as abrasive machining processes

Reduces friction wear
Reduce forces and energy consumption
Cools the cutting zone
Wash away the chips
Protect Machined surfaces from environmental corrosion

Dr. Mohammad Ahsan Habib

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Figure: Schematic illustration of the proper methods of applying cutting fluids (flooding) in
various machining operations: (a) turning, (b) milling, (c) thread grinding, and (d) drilling.
Dr. Mohammad Ahsan Habib

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