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cutting-tool PRESENTAION

Jun 04, 2018

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    POWERPOINT PRESENTATION

    CUTTING TOOL AND MATERIAL

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    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

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    REASONS FOR DEVELOPMENT OF CUTTING TOOL

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    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

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    CUTTING TOOL MATERIALS

    HOT HARDNESS OF SEVERAL TYPES OF TOOLS:

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    TYPES OF CUTTING TOOL MATERIALS

    CONVENTIONAL CUTTING TOOL MATERIALS

    High Carbon Steel

    High Speed Steel Cast-Cobalt alloys (Satellite)

    Cemented Carbide

    Ceramics

    CERMET

    Diomond

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    TYPES OF CUTTING TOOL MATERIALS

    ADVANCE CUTTING TOOL MATERIALS

    Coated Carbides

    CBN

    PCD

    UCON

    Multi Coated

    Super Coated Alloy

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    CUTTING TOOL MATERIALS

    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 C

    Suitable for Low Cutting

    Low Cost Used for taps, dies, hacksaw blades, hand drills, wood working

    tools etc.

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    CUTTING TOOL MATERIALS

    HIGH SPEED STEEL (H.S.S)

    T-Series M-Series

    (Tungsten Type) (Molybdenum Type)18 - 4 - 1- 0.75 6 6 4 - 2

    W Cr Va C W M Cr Va

    Cutting speed up to 30 m/min

    Maximum Limiting Temperature 560C

    Less Costly

    Excellent toughness

    Widely used in industries as a solid Tool like form tool, drill, millingcutters, endmill, reamers, Broach, Single point cutting tool etc.

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    CUTTING TOOL MATERIALS

    CAST COBALT ALLOYS (STALLITE):

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

    Manufacturing Process- Casting Hot hardness- 760C 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.

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    CUTTING TOOL MATERIALSCERAMICS:

    Al2O3+ MgO, Cr2O3, SiC, TiO, TiC90% ________10%____________

    High abrasive of wear Resistance Less tendency to weld to metal Very high compressive strength Very high hot hardness High refractoriness

    1800 C

    High Cutting Speed -200 to 400 m/min Longer tool life Used for cutting steel and HSS Used for high speed machining

    Limitation:

    Poor ToughnessUnreliable (Suddenfail)High rigidity of set up

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    CUTTING TOOL MATERIALS

    CEMENTED CARBIDES (TUNGUSTAN CARBIDE):

    Plain Tungsten Carbide

    W C Co

    94% 6% BINDER

    Manufactured by Powder Metallurgy

    Grain 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

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    CUTTING TOOL MATERIALS

    CEMENTED CARBIDES (TUNGUSTAN CARBIDE):

    Steel Grade (Triple) Tungsten Carbide

    W TiC TaC Co15% 10%

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

    Better surface finish

    Drawback is itsAffinity withsteel

    VARIOUS SHAPES OF INSERTS

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    CUTTING TOOL MATERIALS

    DIMOND:

    Hardest substance BHN 7000 High heat conductivity (Twice then steel) High hot hardness 1650 C 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 isrequired.Poor shock and impactresistance Not suitable for ferrousmaterials

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    CUTTING TOOL 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)

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    CUTTING TOOL MATERIALS

    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.

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    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

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    CUTTING TOOL MATERIALS

    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 frictionAl2O3High thermal stabilityTiCN Resistance to flank and crater wear

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    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

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    Application

    Recommend for roughing, semi roughing and finishing cuts inturning, facing and boring.

    Use for steel machining grade.

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    CUTTING TOOL MATERIALS

    CUBIC BORON NITRIDE:

    Sanitized artificially made under high pressure and hightemperature.

    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.

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    CUTTING TOOL 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)

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    CUTTING TOOL MATERIALS

    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.

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    CUTTING TOOL MATERIALS

    TOOL/WORK CHEMICAL OR ADHESIVE INTERACTION SEVERITIES:

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    CUTTING TOOL MATERIALS

    TOOL MATERIAL OXIDATION AND STRUCTURAL

    CHANGE TEMPERATURE RANGES:

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    CUTTING TOOL MATERIALS

    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

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

    electronics devices. The planning department knows that the sales of theirclient goods depends on how much they spend on advertising, on account ofwhich they receive in advance of expenditure. The planning department wish

    to find out the relationship between their clients advertising and sales, so asto 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)

    Dt2 Xt2 XtDt

    1 20 6 36 400 120

    2 25 8 64 625 2003 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 9610 20 8 64 400 120

    211 76 592 4597 1599

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