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Chip sliding
along rake
face
Rubbing along
Localized workpiece
stress at tip
Effects of elevated temperatures
2. Crater wear
– Due to: high temp and chemical affinity with workpiece
Tool wear and tool failure
Equation for tool wear:
Tool life curves
VT d f = C
n x y
1
Vα n
T
The recommended cutting speed
for a high-speed steel tool is
generally the one that yields a tool
life of 60 to 120 min, and for a
carbide tool, it is 30 to 60 min.
Tool wear and tool failure
3. Nose wear is the rounding of a sharp tool,
due to mechanical and thermal effects. It
dulls the tool, affects chip formation, and
causes rubbing of the tool over the
workpiece, raising its temperature and
possibly inducing residual stresses on the
machined surface.
4. Notching.
Scale and oxide layers on a workpiece
surface contribute to notch wear, because
these layers are hard and abrasive.
Tool wear and tool failure
6. Chipping, and gross fracture
-A small fragment from the cutting edge of
the tool breaks away.
• Small: Microchipping/macrochipping
• Large: Gross chipping/fracture and
catastrophic failure
-Due to : mechanical shock, thermal
fatigue*
Machinability of materials
Factors that affect machinability of materials:
1. Surface finish and surface integrity of part
Geometric feature Material properties:
eg: Fatigue life,
Corrosion resistance
2. Tool life – most important factor
3. Force and power requirements
4. Chip control
Machinability of materials
How is tool life rating determined?
Tool wear
Need to change
tool
Use insert instead:
-Multiple cutting
Take tool from points
Carbon steel & tool room
-Can easily change
HSS tools to a different
machined to cutting point
desired shape Time consuming
Inserts
Insert shapes
The figure below shows the relative edge strength and tendency for
chipping of inserts with various shapes. Strength refers to the cutting
edge indicated by the included angles.
The figure below shows the edge preparation for inserts to improve
edge strength.
Coated tools
Advantages of coatings:
1. Lower friction
2. Higher adhesion
3. Higher resistance to wear and cracking
4. Acting as a diffusion barrier
5. Higher hot hardness and impact resistance
Types of coatings:
1. Titanium nitride
2. Titanium carbide
3. Ceramics
4. Multiphase coatings
5. Diamond coatings
6. Etc.
Cutting Fluids
Advantages:
1. Reduce friction and wear, thus improving tool life and
the surface finish of the workpiece.
2. Cool the cutting zone, thus improving tool life and
reducing the temperature and thermal distortion of the
workpiece.
3. Reduce forces and energy consumption.
4. Flush away the chips from the cutting zone, and thus
prevent the chips from interfering with the cutting
process, particularly in operations such as drilling and
tapping.
5. Protect the machined surface from environmental
corrosion.
Cutting Fluids
Types of cutting fluids:
1. Oils (also called straight oils) including mineral, animal, vegetable,
compounded, and synthetic oils typically are used for low-speed
operations where temperature rise is not significant.
2. Emulsions (also called soluble oils) are a mixture of oil and water
and additives, generally are used for high-speed operations because
temperature rise is significant. The presence of water makes
emulsions very effective coolants.
3. Semisynthetics are chemical emulsions containing little mineral oil,
diluted in water, and with additives that reduce the size of oil
particles, making them more effective.
4. Synthetics are chemicals with additives, diluted in water, and
contain no oil.
Methods of cutting fluid
applications
Conventional Lathe