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
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.
 CUTTING TOOL MATERIALS

HIGH SPEED STEEL (H.S.S)

T-Series M-Series
(Tungsten Type) (Molybdenum Type)
18 - 4 - 1- 0.75 664-2
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, milling
cutters, endmill, reamers, Broach, Single point cutting tool etc.
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.
 CUTTING TOOL MATERIALS

CERAMICS:

Al2O3 + MgO, Cr2O3, SiC, TiO, TiC

90% ________10%____________

High abrasive of wear Resistance Limitation:

Less tendency to weld to metal Poor Toughness
Very high compressive strength Unreliable (Sudden
Very high hot hardness fail)
High rigidity of set up
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
CUTTING TOOL MATERIALS

CEMENTED CARBIDES (TUNGUSTAN CARBIDE):

Plain Tungsten Carbide

W C Co
94% 6% BINDER Drawback is its
Affinity with steel
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
CUTTING TOOL MATERIALS
CEMENTED CARBIDES (TUNGUSTAN CARBIDE):

Steel Grade (Triple) Tungsten Carbide

W TiC TaC Co
15% 10% Drawback is its
Affinity with
steel
High hardness and wear resistance
Maximum limiting Temperature -1200 C
Various Shapes Of Inserts
Cutting Speed -100 m/min VARIOUS SHAPES OF INSERTS
High Tool life
High compressive strength
High production rate
Better surface finish
 CUTTING TOOL MATERIALS

DIMOND:

Hardest substance BHN 7000

High heat conductivity (Twice then steel) Limitation:
High hot hardness 1650 C High rigidity of setup is
High wear resistance required.
Poor shock and impact
Very low co-efficient of friction resistance
High compressive strength Not suitable for ferrous
materials
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
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)
 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.
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
 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 friction

Al2O3 High thermal stability
TiCN 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.
CUTTING TOOL MATERIALS

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.
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)

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.
 CUTTING TOOL MATERIALS

TOOL/WORK CHEMICAL OR ADHESIVE INTERACTION SEVERITIES:

CUTTING TOOL MATERIALS
TOOL MATERIAL OXIDATION AND STRUCTURAL
CHANGE TEMPERATURE RANGES:
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
 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 :
Advertising
Sales (D )
Period(t) t (X )
$(1,00,000)
t
t
$(1,000.000)
2D X t
2 XD
t t

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