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Cutting Temperature
Tool wear
Brittle material
High -ve rake
Low Cutting speed
Inadequate cutting fluid
High feed value
Cutting force measurement
Concept of cutting force
measurement
Resistance based measurement
(Potentiometer)
Capacitance based measurement
Using LVDT
Using Strain Gauges
• HSS
• Cemented Carbide (WC + Co)
• Coated Carbides : WC coated with TiN, TiC
• Ceramics : Al2O3, Si-Al-O-N + Coated ceramics
• Diamond, PCD … brazed to tool shank
• CBN
• Cermets (ceramics (alumina based) + TiC or TiN +
Ni, Fe, Mo)
Cutting Temperature and its effects
Thermocouple method
• Mg alloy: The chips may get fired, so low speeds are preferred. Low
viscosity mineral oils are preferred.
• Adhesion-BUE
• Thermal effects-Diffusion
• Mechanical chipping
• Fracture
Chance of BUE
• Taylor’s equation
VTn=C
n =0.1 HSS tool
n= 0.2 to 0.25 WC
n= 0.4 -0.5 Ceramic tool
Machinability Rating
Machinability will be considered desirably high when
Cutting forces, temperature, surface roughness and tool wear are less,
tool life is long….
Combination of tool geometry, tool materials etc. play a significant role
Addition of lead in low carbon steels and also in aluminium, copper and their
alloys help reduce their shear strength. The dispersed lead particles act as
discontinuity and solid lubricants and thus improve machinability by reducing
friction, cutting forces and temperature, tool wear and BUE formation.