Professional Documents
Culture Documents
Cutting Tools
Unit 29
Objectives
Use the nomenclature of a cuttingtool point Explain the purpose of each type of rake and clearance angle Identify the applications of various types of cutting-tool materials Describe the cutting action of different types of machines
Cutting Tools
One of most important components in machining process Performance will determine efficiency of operation Two basic types (excluding abrasives
!ingle point and multi point
Cutting-Tool Materials
%athe toolbits generally made of five materials
&igh-speed steel 'ast alloys (such as stellite 'emented carbides 'eramics 'ermets
.ble to withstand shoc# during cutting !haped so edge can penetrate wor#
Cemented-Carbide Toolbits
'apable of cutting speeds 3 to $ times highspeed steel toolbits %ow toughness but high hardness and excellent red-hardness 'onsist of tungsten carbide sintered in cobalt matrix !traight tungsten used to machine cast iron and nonferrous materials (crater easily 3ifferent grades for different wor#
Titanium-coated offer wear resistance at low speeds0 ceramic coated for higher speeds
Ceramic Toolbits
Permit higher cutting speeds0 increased tool life and better surface finish than carbide
+ea#er than carbide used in shoc#-free or lowshoc# situation
'eramic
&eat-resistant material produced without metallic bonding agent such as cobalt .luminum oxide most popular additive Titanium oxide or Titanium carbide can be added
iamond Toolbits
9sed mainly to machine nonferrous metals and abrasive nonmetallics !ingle-crystal natural diamonds
&igh-wear but low shoc#-resistant factors
Polycrystalline diamonds
Tiny manufactured diamonds fused together and bonded to suitable carbide substrate
Cutting-Tool !omenclature
'utting edge- leading edge of that does cutting 5ace- surface against which chip bears as it is separated from wor# :ose- Tip of cutting tool formed by ;unction of cutting edge and front face
Copyright The McGraw-Hill Companies, Inc. Permission required or reproduction or display.
Cutting-Tool !omenclature
Point- end of tool that has been ground for cutting purposes
Copyright The McGraw-Hill Companies, Inc. Permission required or reproduction or display.
Cutting-Tool Nomenclature
(ase- (ottom surface of tool shan# 5lan#- surface of tool ad;acent to and below cutting edge !han#- body of toolbit or part held in toolholder
Copyright The McGraw-Hill Companies, Inc. Permission required or reproduction or display.
!egati#e Positi#e ra$e ra$e - -point face of cutting tool contacts and cutting metal edge first contact andmetal chip moves first and chip up moves the face down of the the face toolbit of the toolbit
Copyright The McGraw-Hill Companies, Inc. Permission required or reproduction or display.
Positive
a!e Angle
1enerally used for continuous cuts on ductile materials not too hard or abrasive
%actors &hen Choosing Type and 'a$e "ngle (or Cutting Tool
&ardness of metal to be cut Type of cutting operation
'ontinuous or interrupted
Shape o( Chip
.ltered in number of ways to improve cutting action and reduce amount of power re=uired 'ontinuous straight ribbon chip can be changed to continuous curled ribbon
'hanging angle of the #eeness
>ncluded angle produced by grinding side ra#e
Tool Li"e
Crater wear occurs as result of chips sliding along chip-tool interface, result of built-up edge on cutting tool
Nose wear occurs as result of friction between nose and metal being machined
Occurs on side of cutting edge as result of friction between side of cutting-tool edge and metal being machined
Turning
.ssume cutting machine steel- >f ra#e and relief clearance angles correct and proper speed and feed used0 a continuous chip should be formed<
Copyright The McGraw-Hill Companies, Inc. Permission required or reproduction or display.
PowerPoint to accompany
Objectives
Describe the effect of cutting conditions on cutting-tool life Explain the effect of cutting conditions on metal-removal rates State the advantages of ne cutting-tool materials !alculate the economic performance and cost analysis for a machining operation
*perating Conditions
Three operating variables influence metalremoval rate and tool life
'utting speed 5eed rate 3epth of cut
1/0
2/0
3.0
Optimum cutting speed should balance metal-removal rate and cutting-tool life 'hoose heaviest depth of cut and feed rate possible
PowerPoint to accompany
Objectives
Identify and state the purpose of the t o main types of carbide grades Select the proper grade of carbide for various orkpiece materials Select the proper speeds and feeds for carbide#tools
'an machine metals at speeds that cause cutting edge to become red hot without loosing harness
4lending
5ive types of powders
Tungsten carbide0 titanium carbide0 cobalt0 tantalum carbide0 niobium carbide
One or combination blended in different proportions depending on grade desired Powder mixed in alcohol (2$ to 896 h .lcohol drained off Paraffin added to simplify pressing operation
Compaction
"ust be molded to shape and si)e 5ive different methods to compact powder
Axtrusion process &ot press >sostatic press >ngot press Pill press
Presintering
1reen compacts heated to about 8*66B 5 in furnace under protective atmosphere of hydrogen 'arbide blan#s have consistency of chal# "ay be machined to re=uired shape
$67 oversi)e to allow for shrin#age that occurs during final sintering
Sintering
%ast step in process 'onverts presintered machine blan#s into cemented carbide 'arried out in either hydrogen atmosphere or vacuum
Temperatures between 2**6B and 2236B 5
(inder (cobalt unites and cements carbide powders into dense structure of extremely hard carbide crystals
Cemented-Carbide A##lications
9sed extensively in manufacture of metalcutting tools
Axtreme hardness and good wear-resistance
5irst used in machining operations as lathe cutting tools "a;ority are single-point cutting tools used on lathes and milling machines
'rater-resistant
'ontain titanium carbide and tantalum carbide in addition to tungsten carbide and cobalt 9sed for machining most steels
Tool $eometr%
Terms adopted by .!"A
Copyright The McGraw-Hill Companies, nc! "ermission re#uired for reproduction or display!
Cutting-Tool Terms
5ront0 And0 ,elief ('learance
.llows end of cutting tool to enter wor#
Copyright The McGraw-Hill Companies, nc! "ermission re#uired for reproduction or display!
PowerPoint to accompany
Objectives
State the importance and function of cutting fluids Identify three types of cutting fluids and state the purpose of each %pply cutting fluids efficiently for a variety of machining operations
Cutting %luids
Assential in metal-cutting operations to reduce heat and friction 'enturies ago0 water used on grindstones 866 years ago0 tallow used (did not cool %ard oils came later but turned rancid Aarly 26th century saw soap added to water !oluble oils came in 893/ 'hemical cutting fluids introduced in 89$$
Too much0 cutting edge will brea# down rapidly0 reducing tool life
Copyright The McGraw-Hill Companies, Inc. Permission required or reproduction or display.
Heat issipation
>deally most heat ta#en off in chips >ndicated by change in chip color as heat causes chips to oxidi)e 'utting fluids assist ta#ing away heat
'an dissipate at least *67 of heat created during machining
*il Categories
!ulfuri)ed mineral oils
'ontain <*7 to <47 sulfur %ight-colored and transparent !tains copper and alloys
1ood cooling and lubricating =ualities 9sed at high cutting speeds0 low cutting pressures
Other functions
Prolong cutting-tool life Provide rust control ,esist rancidity
Axtreme-pressure lubricants reduce amount of heat-producing friction AP chemicals of synthetic fluids combine chemically with sheared metal of chip to form solid compounds (allow chip to slide
Cutting-Tool Li(e
&eat and friction prime causes of cuttingtool brea#down ,educe temperature by as little as *6B50 life of cutting tool increases fivefold (uilt-up edge
Pieces of metal weld themselves to tool face (ecomes large and flat along tool face0 effective ra#e angle of cutting tool decreased
Milling
5ace milling
,ing-type distributor recommended to flood cutter completely Eeeps each tooth of cutter immersed in cutting fluid at all times
!lab milling
5luid directing to both sides of cutter by fan-shaped no))les D width of cutter
Copyright The McGraw-Hill Companies, Inc. Permission required or reproduction or display.