TERM PAPER

TOPIC- CUTTING TOOL TECHNOLOGY

SUMITTED TO SUMITTED BY:

MS. SANDHYA SINGH RAKSHIT SAHU
ROLL NO.-RK4006A03
REG.NO.-11006227
 (ACKNOWLEDGEMENT)

If practical knowledge carves and sharps the carrier of a person, practical experience polishes
it and adds luster and brilliance to it”. Here, we found this golden chance to acknowledge all
those people who had blessed, encouraged and supported us technically and morally through
all the phases of our term paper. We take this opportunity to express our profound sense of
gratitude. We thank all mighty God for giving us this valuable opportunity to express to all
those who helped in successful completion of this term paper.
Before we get into thick of the things I would like to add a few heartfelt words for the
people who were part of this term paper in numerous ways. We reserve heartiest gratitude to
who has been very supportive and encouraging throughout this term paper. He guides us for
having given us an opportunity to undertake the term paper and providing us with feedback
and influenced the development of this term paper. We gratefully acknowledge invaluable
note of our term paper guide MS. SANDHYA SINGH and to all teachers who besides
helping us in this term paper, guided and encouraged us along each step.
We express heartfelt thanks to our friends for their morale and support and kind
corporation during this course of formulation of this project work who directly or indirectly
helps us to complete this term paper. Last but not least, my sincere regards are reserved for
our family and friends who have always encouraged and blessed us with their best. Specially
thanks to my elder brothers who always encourage me to do your best.

RAKSHIT SAHU
CONTENTS:

 Introduction

 Cutting tool technology

 Tool life

 Taylor tool life equation

 Tool material

 Types of tool materials

 Tool geometry

 Cutting tools

 Latest technology

 Safety

 Future scope
INTRODUCTION

Cutting tool technology is evolving rapidly to respond to changing demands and more
challenging work piece materials. Shops today need to look at cutting tools differently. They
need to look at cutting tool suppliers differently as well.
Advanced cutting tools can increase a shop’s capacity in demanding cases like this one--a
hard turning application involving tooling from Diamond Innovations. Cutting tool
technology has advanced dramatically, and the right choice of tooling today can
fundamentally transform the process.

Cutting tools made of advanced ceramics have the potential for high-speed finish machining
as well as for high-removal-rate machining of difficult-to-machine materials. The raw
materials used in these ceramics are abundant, inexpensive, and free from strategic materials.
In spite of this, solid or monolithic ceramic tools are currently used only to a limited extent
partly due to certain limitations of these materials and partly due to the inadequacy of the
machine tools used. The advances in ceramic materials and processing technology, the need
to use materials that are increasingly more difficult to machine, increasing competition, and
the rapidly rising manufacturing costs, have opened new vistas for ceramics in machining
applications. The development of ceramic tool materials can be broadly categorized into three
types: monolithic forms, thin coatings, and whisker-reinforced composites. Such a
classification provides a totally new perspective on ceramic tool materials and broadens their
scope considerably, and is justified on the basis that it is the ceramic addition that makes the
tool material more effective. A brief overview of these materials is presented in this paper.
CUTTING TOOL TECHNOLOGY

1. Tool life
2. Tool Materials
3. Tool Geometry
4. Cutting fluids

1. Tool life
 Three modes of failure

o Premature Failure

o Fracture failure -Cutting force becomes excessive and/or dynamic, leading to

brittle fracture

o Thermal failure -Cutting temperature is too high for the tool material

 Gradual

o Wear Gradual failure

 Tool wear: Gradual failure

o Flank wear -flank (side of tool)

o Crater wear -top rake face

o Notch wear
 o Nose radius wear

Crater and Flank Wear

• Selection of cutting tool materials is very important

• What properties should cutting tools have
– Hardness at elevated temperatures
– Toughness so that impact forces on the tool can be taken
– Wear resistance
– Chemical stability

Types of tool materials

o Carbon + medium alloy steel
o High speed steel (HSS)
o Cast cobalt alloys
o Carbides
o Coated tools
o Ceramics
o Cubic boron nitride
o invented by GE in 1969
o Silicon nitride
o Diamond
CUTTING TOOL TECHNOLOGY

Three possible failure modes of cutting tool

Fracture failure: due to excessive force, failed suddenly in a brittle pattern

Temperature failure: due to high temperature at tool tip, failed gradually in a ductile
pattern

Gradual wear: most commonly seen, similar to temperature effect

Gradual wear occurs at two principal locations: crater wear and flank wear

Crater wear: formed a concave section on the rake face of the tool due to the sliding of the
chips

Flank wear: formed a rough surface on the flank face due to the constant abrasion
between newly created work surface and flank face

WHAT IS TOOL LIFE?

It is defined as the length of cutting time that the tool is performing satisfactorily.
Tool life is a function of time, and the wear-out curve is similar to a creep test curve.
For flank wear: quantitative analysis and qualitative analysis.
TAYLOR TOOL LIFE EQUATION (QUANTITATIVE)

Developed in 1900 by F. W. Taylor

vTn = C
Where v = cutting speed, ft/min
T = tool life, min
n depends on tool material
C depends on workpiece and cutting conditions

A modified tool life equation: vTn = C (Tnref)

= Where Tnref is a reference value for C (1 minute)

In the tool life prediction, one needs to know n and C first.

The entire equation becomes vTconstant = constant [once v is known, then T can be
calculated]

Tool life prediction (qualitative analyses): complete failure of cutting edge, visual
inspection of flank face, fingernail test across cutting edge by operator, change in sound
 emitting during cutting, chip shape change, increased power consumption, longer cutting

time, etc.

TOOL MATERIALS

Three important properties for tool materials

toughness
Hot hardness (Rc > 60)
Wear resistance (including chemical reaction)

Surface treatment on plain carbon steels: hydrogen embrittlement, nitrogen embrittlement,

and carburization

 TYPES OF TOOL MATERIAL

o High-speed steels (HSS): highly alloyed tool steel capable of maintaining

hardness at elevated temperatures.

o two types of HSS: T-grades (12 –20% tungsten) and M-grades (6% tungsten and 5%
molybdenum)
o Cemented carbides: hard tool materials manufactured through powder metallurgy
methods, consists of tungsten carbide (WC) and cobalt (Co), titanium carbide (TiC) and
Co, or tantalum carbide (TaC) and Co.

o Cermets: combinations of titanium carbide (TiC) and titanium nitride (TiN) with
nickel and/or molybdenum as binders.

o Coated carbides: cemented carbides coated with thin layers of wear-resistant material
such as titanium carbide, titanium nitride, and/or aluminum oxide. (including chromium
carbide, zirconium nitride, and diamond)

TOOL GEOMETRY
Single-point tool: end relief angle, side relief angle, side cutting edge angle, nose radius,
end cutting edge angle

Chip breakers: force chip to curl and fracture

Effects of tool material on geometry

Cutting fluids two types: coolants (water base) and lubricants (oil base with S, Cl, P)

Coolants are used for high cutting speeds and heat generation

Lubricants are used for low cutting speeds with high pressure
 Three categories of cutting fluids: cutting oils, emulsified oils, chemical and semi-
chemical fluids

Cutting oils are generated from petroleum , animal, marine, and vegetable origin.

Emulsified oils are mixtures of mineral oil and water (suspension)

Chemical fluids are chemicals in water solution.

CUTTING TOOLS
The proper holder maintained under all of the correct standards is still only as good as the
cutting tool it contains. A quality tool is determined by three primary factors:

1. Materials (substrates)
2. Geometry
3. Coatings

MATERIALS
The best designs and coatings in the world are of little value if they are not applied to the
appropriate substrates. Using an end mill with a subpar substrate is like using a front door
made from cardboard on a new house. From a distance it looks the same, but a closer look
will reveal the obvious flaws that make it unsuitable for its intended purpose.

Carbide Grain Classification Grain Size [microns]

Fine Micro-grain Carbide 1.0 ~ 1.3

extra-fine Micro-grain Carbide 0.5 ~ 0.9

Ultra-fine Micro-grain Carbide 0.3 ~ 0.5

Nano-series Micro-grain Carbide 0.1 ~ 0.3

CUTTING TOOL (MACHINING)

A "numerical controlled machining cell machinist" monitors a B-1B aircraft part being
manufactured.
A cutting tool has one or more sharp cutting edges and is made of a material that is harder
than the work material. The cutting edge serves to separate chip from the parent work
material. Connected to the cutting edge are the two surfaces of the tool —
The rake face; and
The flank.
The rake face which directs the flow of newly formed chip, is oriented at a certain angle is
called the rake angle "α". It is measured relative to the plane perpendicular to the work
surface. The rake angle can be positive or negative. The flank of the tool provides a clearance
between the tool and the newly formed work surface, thus protecting the surface from
abrasion, which would degrade the finish. This angle between the work surface and the flank
surface is called the relief angle. There are two basic types of cutting tools —
Single point tool; and
Multiple-cutting-edge tool.
A single point tool has one cutting edge and is used for turning, boreing and planing. During
machining, the point of the tool penetrates below the original work surface of the workpart.
The point is sometimes rounded to a certain radius, called the nose radius.
Multiple-cutting-edge tools have more than one cutting edge and usually achieve their motion
relative to the workpart by rotating. Drilling and milling uses rotating multiple-cutting-edge
tools. Although the shapes of these tools are different from a single-point tool, many elements
of tool geometry are similar.
CUTTING CONDITIONS
Relative motion is required between the tool and work to perform a machining operation. The
primary motion is accomplished at a certain cutting speed. In addition, the tool must be
moved laterally across the work. This is a much slower motion, called the feed. The
remaining dimension of the cut is the penetration of the cutting tool below the original work
surface, called the depth of cut. Collectively, speed, feed, and depth of cut are called the
cutting conditions. They form the three dimensions of the machining process, and for certain
operations, their product can be used to obtain the material removal rate for the process —
where —
— the material removal rate in mm3/s, (in3/s),
— the cutting speed in m/s, (ft/min),
— the feed in mm, (in),
— the depth of cut in mm, (in).

Note: All units must be converted to the corresponding decimal (or USCU) units.
Machining operations usually divide into two categories, distinguished by purpose and
cutting conditions:
Roughing cuts, and
Finishing cuts.
Roughing cuts are used to remove large amount of material from the starting workpart as
rapidly as possible, in order to produce a shape close to the desired form, but leaving some
material on the piece for a subsequent finishing operation. Finishing cuts are used to complete
the part and achieve the final dimension, tolerances, and surface finish. In production
machining jobs, one or more roughing cuts are usually performed on the work, followed by
one or two finishing cuts. Roughing operations are done at high feeds and depths — feeds of .
04-1.25 mm/rev (0.015-0.050 in/rev) and depths of 2.5-20 mm (0.100-0.750 in) are typical.
Finishing operations are carried out at low feeds and depths - feeds of 0.0125-0.04 mm/rev
(0.0005-0.0015 in/rev) and depths of 0.75-2.0 mm (0.030-0.075 in) are typical. Cutting
speeds are lower in roughing than in finishing.
A cutting fluid is often applied to the machining operation to cool and lubricate the cutting
tool. Determining whether a cutting fluid should be used, and, if so, choosing the proper
cutting fluid, is usually included within the scope of cutting condition.

STAGES IN METAL CUTTING

Roughing cuts are used to remove large amount of material from the starting workpart as
quickly as possible, in order to produce a shape close to the desired form, but leaving some
material on the piece for a subsequent finishing operation. Finishing cuts are used to complete
the part and achieve the final dimension, tolerances, and surface finish. In production
machining jobs, one or more roughing cuts are usually performed on the work, followed by
one or two finishing cuts. Roughing operations are done at high feeds and depths — feeds of .
04-1.25 mm/rev (0.015-0.050 in/rev) and depths of 2.5-20 mm (0.100-0.750 in) are typical.
Finishing operations are carried out at low feeds and depths - feeds of 0.125-0.4 mm/rev
(0.005-0.015 in/rev) and depths of 0.75-2.0 mm (0.030-0.075 in) are typical. Cutting speeds
are lower in roughing than in finishing.
A cutting fluid is often applied to the machining operation to cool and lubricate the cutting
tool. Determining whether a cutting fluid should be used, and, if so, choosing the proper
cutting fluid, is usually included within the scope of cutting condition.
Today other forms of metal cutting are becoming increasingly popular. An example of this is
water jet cutting. Water jet cutting involves pressurized water in excess of 90,000 PSI and is
able to cut metal and have a finished product. This process, is called cold cutting, and it
increases efficiency as opposed to laser and plasma cutting.

LATEST TECHNOLOGIES

1. Mold making technology:

• Machine tools
• CAD/CAM
• Cutting tools

2. Sarin technology

3. Emerging technology

4. Glass scratch removal technology

SHARP AND CUTTING TOOL SAFETY

Now a days safety drives are organized by companies. They consider it a prime necessity and
utmost goal that all the workers of the company should work in healthy and safe environment.
No compromise is undertaken where safety is concerned. Safe equipments are being used
which follow all the safety norms with authorized guarantee. Manufacturers of quality
equipments are given orders even if there cost is bit high.

Hand-held sharp and cutting tools are frequently used in the workplace. The tools range from
scissors, razors, saws, and knives to pruners, chisels, and snips. While these tools are very
different and can be used for a wide variety of jobs, they have some common hazards and
safety precautions. Horseplay should be forbidden around sharp and cutting tools.
Sharp and cutting tools can cause cuts and puncture wounds, if they’re not handled properly.
Workers should be trained in the tool manufacturer’s directions for proper use, including how
to inspect, maintain, and sharpen the tool. For some tools, workers must wear personal
protective equipment such as safety glasses and well-fitting gloves.

In order to choose the right tool for the job, workers should consider not only the job task but
the type, hardness, and size of the material on which they’ll be working. Substituting the
wrong tool for the job can lead to an accident or injury. Workers should use only quality tools
that are sharp and in good condition. If a tool is broken, dull or damaged, it should be tagged
as such and taken out of service.

The most important rule to remember about using sharp and cutting tools is to ALWAYS cut
away from the body and face. When cutting with one hand, workers should know where their
other hand is. If a sharp tool is dropped, workers should be taught not to try to catch it but
allow it to fall, making sure that their legs and feet are out of the way.

The safe way to work with a sharp or cutting tool is to concentrate on the task at hand,
making straight, even cuts without rocking, prying or twisting the tool. Hammering or
applying excessive force or pressure to sharp and cutting tools can cause them to slip. Keep in
mind, that some materials or outdoor conditions can also make tools slippery.

Workers need to be careful when transporting and storing sharp tools. Workers should be
instructed not to carry a sharp tool in their pocket; to use a sheath, belt or apron; and when
there is a pause in work, to hold the tool at their sides but a safe distance from their body.
When walking with a sharp tool, the tool should be carried with the blade down and away
from the body. When climbing with a sharp tool, tool belts or buckets with hand lines should
be used so workers can have both hands to grip the ladder. When passing a sharp or cutting
tool to another worker, tools should be passed with the hand first and the blade down; they
should never be tossed from one worker to another.
When not in use, sharp or cutting tools should be stored in a sturdy tool box or on a tool rack
with the sharp edges suitably covered. Otherwise, they should be placed near the back of
work benches to keep handles or blades from extending over the edge.

FUTURE SCOPE:-

The technologies that we are using for cutting tools today are already outdated. The
ideas of the next generation of machine tools, cutting tools etc. have already gone
through research and development and are in production.

The technology is even changing rapidly and come at a price that is measurable and
when that measure is justified, it is time to make investment.

With new cutting tool technologies, companies can focus on time, cost, reduction, shortening
lead times and in many instances break even point of their cutting tool investment within
hourstoday, a high proportion of machining processes are conducted with coolants. In this
way, the work piece, tool and machine tool are cooled, friction processes are reduced, and the
manufactured chips are removed from the cutting area. Unfortunately, coolants are dangerous
to the environment and human health. Moreover, the disposal costs for used coolants are set
to soar. Therefore, the movement towards green manufacturing cutting operations will be one
of the most important challenges in the near future. Decreasing the costs of the cutting
process and the associated reduction of environmental pollution by dry machining is the main
key to remain competitive and profitable.
In this contribution, results are presented to introduce dry machining of synchronizing cones
for automotive applications. Different CVD/PVD commercial coatings were investigated in
preliminary investigations for their suitability in dry-machining the specific austenitic steel. It
will be shown that coating systems (like hard/soft double layers) exhibit a great potential for
such operations, even under a minimal lubricant system. Furthermore, several parameter
studies were carried out towards accuracy to size, work piece morphology and process
stability. In a last step, field tests were done performed on these results.

RFERENECES:

1. Manufacturing science, H.P.GROVER,

2. Tool design and technology, P.N RAO

Links and bookmarks:

www.springer.com
www.ctemag.com
kimth2.softarchive.net
www.productionmachining.com
www.macraesbluebook.com