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Fundamentals of Cutting Fundamentals of Cutting &&
Cutting-Tool Materials Cutting-Tool Materials and Cutting Fluidsand Cutting Fluids
MANUFACTURING MANUFACTURING ENGINEERINGENGINEERING
AND TECHNOLOGYAND TECHNOLOGY
BY KALPAKJIANBY KALPAKJIANTHIRD EDITIONTHIRD EDITION
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IntroductionIntroduction
Cast, formed and shaped products may need further machining operations.
Machining processes remove material from a workpiece.
• CUTTING:
• ABRASIVE:
• NONTRADITIONAL:
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Fundamentals of CuttingFundamentals of Cutting
• Mechanics of Chip Formation.Mechanics of Chip Formation.– RAKE ANGLERAKE ANGLE
– RELIEF ANGLERELIEF ANGLE
– SHEAR ANGLESHEAR ANGLE
• Chip Type.Chip Type.– CONTINUOUSCONTINUOUS
– BUILT-UP EDGEBUILT-UP EDGE
– SERRATEDSERRATED
– DISCONTINUOUS.DISCONTINUOUS.
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Fundamentals of CuttingFundamentals of Cutting
• Oblique Cutting.Oblique Cutting.– THREE DIMENTIONALTHREE DIMENTIONAL
– INCLINATION ANGLEINCLINATION ANGLE
• Cutting Forces and Power.Cutting Forces and Power.– MACHINE TOOL SELECTIONMACHINE TOOL SELECTION
– DYNAMOMETERDYNAMOMETER
– MANY VARIABLESMANY VARIABLES• FRICTIONFRICTION
• CUTTING FLUIDSCUTTING FLUIDS
• TOOL SHARPNESSTOOL SHARPNESS
• PROCESSPROCESS
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Fundamentals of CuttingFundamentals of Cutting
• Temperatures in Cutting.Temperatures in Cutting.– TOOL PROPERTIESTOOL PROPERTIES
– DIMENSIONAL ACCURACYDIMENSIONAL ACCURACY
• Tool Life.Tool Life.– HIGH STRESSES & HIGH STRESSES &
TEMPERATURESTEMPERATURES
– GRADUAL WEARGRADUAL WEAR
– MANY VARIABLESMANY VARIABLES• MATERIALMATERIAL
• CUTTING FLUIDSCUTTING FLUIDS
• TOOL SHAPETOOL SHAPE
• SPEEDS & FEED RATESPEEDS & FEED RATE
– CHIPPINGCHIPPING
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• Surface Finish and IntegritySurface Finish and Integrity– GEOMETRYGEOMETRY
– PROPERTIESPROPERTIES• FATIGUE LIFEFATIGUE LIFE
• CORROSION RESISTANCECORROSION RESISTANCE
• MachinabilityMachinability– RATINGS BASED ON TOOL LIFERATINGS BASED ON TOOL LIFE
– DECREASES AS HARDNESS INCREASESDECREASES AS HARDNESS INCREASES
– ALLOYING ELEMENTSALLOYING ELEMENTS
Fundamentals of CuttingFundamentals of Cutting
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• Cutting Tool Cutting Tool MaterialsMaterials
• ARE SUBJECTED TO...ARE SUBJECTED TO...– HIGH TEMPERATURESHIGH TEMPERATURES– CONTACT STRESSESCONTACT STRESSES– ABRASIONABRASION
• MUST HAVE...MUST HAVE...– HARDNESSHARDNESS– TOUGHNESSTOUGHNESS– WEAR RESISTANCEWEAR RESISTANCE– CHEMICAL STABILITYCHEMICAL STABILITY
Cutting Tool Materials and Cutting Cutting Tool Materials and Cutting FluidsFluids
• Material Material Categories:Categories:
• CARBON AND MEDIUM CARBON AND MEDIUM ALLOY STEELSALLOY STEELS
• HIGH-SPEED STEELSHIGH-SPEED STEELS
• CAST-COLBALT ALLOYSCAST-COLBALT ALLOYS
• CARBIDESCARBIDES
• COATED TOOLSCOATED TOOLS
• ALUMINA-BASED ALUMINA-BASED CERAMICSCERAMICS
• CUBIC BORON NITRIDECUBIC BORON NITRIDE
• SILICON-NITRIDE-BASED SILICON-NITRIDE-BASED CERAMICSCERAMICS
• DIAMONDDIAMOND
• WHISKER-REINFORCED WHISKER-REINFORCED MATERIALSMATERIALS
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• Cutting FluidsCutting Fluids– REDUCE FRICTION AND WEARREDUCE FRICTION AND WEAR
– REDUCE ENERGY CONSUMPTIONREDUCE ENERGY CONSUMPTION
– COOL THE CUTTING ZONECOOL THE CUTTING ZONE
– PROTECT MACHINED SURFACESPROTECT MACHINED SURFACES
• Fluid ActionFluid Action– CAPILLARY ACTIONCAPILLARY ACTION
– SMALL MOLECULAR SIZESMALL MOLECULAR SIZE
– PROPER WETTING CHARACTERISTICSPROPER WETTING CHARACTERISTICS
Cutting Tool Materials and Cutting Cutting Tool Materials and Cutting FluidsFluids
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• Types of Cutting FluidsTypes of Cutting Fluids– OILSOILS
– EMULSIONSEMULSIONS
– SEMI-SYNTHESISSEMI-SYNTHESIS
– SYNTHETICSSYNTHETICS
• Methods of ApplicationMethods of Application– FLOOD COOLINGFLOOD COOLING
– MIST COOLINGMIST COOLING
– HIGH PRESSURE REFRIGERATED SYSTEMSHIGH PRESSURE REFRIGERATED SYSTEMS
Cutting Tool Materials and Cutting Cutting Tool Materials and Cutting FluidsFluids
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• Effects of Cutting Fluids on…Effects of Cutting Fluids on…– WORKPIECE MATERIALSWORKPIECE MATERIALS
– MACHINE TOOLSMACHINE TOOLS
• Biological and Environmental EffectsBiological and Environmental Effects– OPERATOR CONTACTOPERATOR CONTACT
– EXTERNAL ENVIRONMENTEXTERNAL ENVIRONMENT
– DEGREDATION & CHEMICAL CHANGEDEGREDATION & CHEMICAL CHANGE
• Waste ManagementWaste Management– CLARIFICATIONCLARIFICATION
– RECYCLINGRECYCLING
– DISPOSALDISPOSAL
Cutting Tool Materials and Cutting Cutting Tool Materials and Cutting FluidsFluids