TOOL LIFE

Tool no longer performs desired function failed

Re-sharpen and use it again.
TOOL LIFE:
• Useful life of a tool expressed in terms of time from start
of a cut to termination point (defined by failure criterion).
Sometimes also expressed in terms of no. Of the parts
machined.
• Tool failure criterion depends on
• 1. The requirements of the component being produced.
• 2. Type of Operation: • Roughing: force and power
requirement.
• Finishing : Surface finish & dimensional accuracy.
TAYLOR’S TOOL LIFE EQUATION
TAYLOR’S TOOL LIFE EQUATION
 VARIABLES AFFECTING TOOL LIFE
Cutting Conditions (V, d, f)
• Tool Geometry (all six angles, and nose radius)
• Workpiece Material
• Cutting fluid
• Machine tool and Work piece region
• Tool Material
 MACHINABILITY
Mainly concerned with work piece material properties, not
the tool properties.
It depends on work piece material properties and good
machinability means:
1. Low tool wear
2. 2. Good surface finish produced
3. 3. Low cutting forces
 Tool life
Tool wear is a time dependent process. As cutting proceeds,
the amount of tool wear increases gradually. But tool wear
must not be allowed to go beyond a certain limit in order to
avoid tool failure. The most important wear type from the
process point of view is the flank wear, therefore the
parameter which has to be controlled is the width of flank
wear land, VB. This parameter must not exceed an initially set
safe limit, which is about 0.4 mm for carbide cutting tools.
The safe limit is referred to as allowable wear land (wear
criterion), VBk . The cutting time required for the cutting tool
to develop a flank wear land of width VBk is called tool life, T,
a fundamental parameter in machining. The general
relationship of VB versus cutting time is shown in the figure
(so-called wear curve). Although the wear curve shown is for
flank wear, a similar relationship occur for other wear types.
The figure shows also how to define the tool life T for a given
wear criterion VBk .
• The slope of the wear curve (that is the intensity of
tool wear) depends on the same parameters, which
affect the cutting temperature as the wear of cutting
tool materials is a process extremely temperature
dependent. Parameters, which affect the rate of tool
wear are v cutting conditions (cutting speed V, feed f,
depth of cut d) v cutting tool geometry (tool
orthogonal rake angle) v properties of work material
From these parameters, cutting speed is the most
important one. As cutting speed is increased, wear rate
increases, so the same wear criterion is reached in less
time, i.e., tool life decreases with cutting speed:
• Tool wear describes the gradual failure of cutting tools due to regular operation. It is a term often
associated with tipped tools, tool bits, or drill bits that are used with machine tools.
• Types of wear include:
• flank wear in which the portion of the tool in contact with the finished part erodes. Can be
described using the Tool Life Expectancy equation.
• crater wear in which contact with chips erodes the rake face. This is somewhat normal for tool
wear, and does not seriously degrade the use of a tool until it becomes serious enough to cause a
cutting edge failure.
• Can be caused by spindle speed that is too low or a feed rate that is too high. In orthogonal cutting
this typically occurs where the tool temperature is highest. Crater wear occurs approximately at a
height equaling the cutting depth of the material. Crater wear depth ~ t0 t0= cutting depth
• built-up edge in which material being machined builds up on the cutting edge. Some materials
(notably aluminum and copper) have a tendency to anneal themselves to the cutting edge of a tool.
It occurs most frequently on softer metals, with a lower melting point. It can be prevented by
increasing cutting speeds and using lubricant. When drilling it can be noticed as alternating dark
and shiny rings.
• glazing occurs on grinding wheels, and occurs when the exposed abrasive becomes dulled. It is
noticeable as a shine while the wheel is in motion.
• edge wear, in drills, refers to wear to the outer edge of a drill bit around the cutting face caused by
excessive cutting speed. It extends down the drill flutes, and requires a large volume of material to
be removed from the drill bit before it can be corrected.