REASONS FOR DEVELOPMENT OF CUTTING TOOL GLOBLE COMPETATION PRODUCTIVITY : Cutting Speed Reduce Machining Time Improve Tool Life QUALITY AND RELIABILITY:

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

REASONS FOR DEVELOPMENT OF CUTTING

TOOL

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

CUTTING TOOL MATERIALS

HOT HARDNESS OF SEVERAL TYPES OF TOOLS:

TYPES OF CUTTING TOOL MATERIALS

CONVENTIONAL CUTTING TOOL MATERIALS

High Carbon Steel High Speed Steel Cast-Cobalt alloys (Satellite) Cemented Carbide Ceramics CERMET Diomond

TYPES OF CUTTING TOOL MATERIALS ADVANCE CUTTING TOOL MATERIALS

Coated Carbides CBN PCD UCON Multi Coated Super Coated Alloy


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 ºC Suitable for Low Cutting Low Cost Used for taps, dies, hacksaw blades, hand drills, wood

working tools etc.


HIGH SPEED STEEL (H.S.S)

T-Series M-Series(Tungsten Type) (Molybdenum Type)18 - 4 - 1- 0.75 6 – 6 – 4 - 2W Cr Va C W M Cr Va

Cutting speed up to 30 m/min Maximum Limiting Temperature 560ºC Less Costly Excellent toughness Widely used in industries as a solid Tool like form tool, drill,

milling cutters, endmill, reamers, Broach, Single point cutting tool etc.


CAST COBALT ALLOYS (STALLITE):

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

Manufacturing Process- Casting Hot hardness- 760ºC 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.


CERAMICS:

Al2O3 + MgO, Cr2O3, SiC, TiO, TiC 90% ________10%____________

High abrasive of wear Resistance Less tendency to weld to metal Very high compressive strength Very high hot hardness High refractoriness – 1800 ºC High Cutting Speed -200 to 400 m/min Longer tool life Used for cutting steel and HSS Used for high speed machining

Limitation:

Poor Toughness Unreliable (Sudden fail) High rigidity of set up


CEMENTED CARBIDES (TUNGUSTAN CARBIDE):

Plain Tungsten Carbide

W C Co94% 6% BINDER

Manufactured by Powder MetallurgyGrain 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


CEMENTED CARBIDES (TUNGUSTAN CARBIDE):

Steel Grade (Triple) Tungsten Carbide

W TiC TaC Co 15% 10%

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

Drawback is itsAffinity with steel

VARIOUS SHAPES OF INSERTS


DIMOND:

Hardest substance BHN 7000 High heat conductivity (Twice then steel) High hot hardness 1650 ºC 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 is required.• Poor shock and impact resistance• Not suitable for ferrous materials


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)


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.

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


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 friction Al2O3 – High thermal stabilityTiCN – Resistance to flank and crater wear

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

Application Recommend for roughing, semi roughing and finishing cuts in turning, facing and boring. Use for steel machining grade.


CUBIC BORON NITRIDE:

Sanitized artificially made under high pressure and high temperature.

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.


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)


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.


TOOL/WORK CHEMICAL OR ADHESIVE INTERACTION SEVERITIES:


TOOL MATERIAL OXIDATION AND STRUCTURAL CHANGE TEMPERATURE RANGES:


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

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

for electronics devices. The planning department knows that the sales of their client goods depends on how much they spend on advertising, on account of which they receive in advance of expenditure. The planning department wish to find out the relationship between their clients advertising and sales, so as to 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)Dt

2 Xt2 XtDt

1 20 6 36 400 120

2 25 8 64 625 200

3 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 96

10 20 8 64 400 120

211 76 592 4597 1599

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REASONS FOR DEVELOPMENT OF CUTTING TOOL GLOBLE COMPETATION PRODUCTIVITY : Cutting Speed Reduce Machining Time Improve Tool Life QUALITY AND RELIABILITY: