Ch21-Fundamentals-of-cutting tool manuf.ppt

Chapter 21
Fundamentals of Machining

Introduction to Cutting - Common
Introduction to Cutting - Common
Machining Operations
Machining Operations
Figure 21.1 Some examples of common
machining operations.
Cutting processes remove material
from the surface of a workpiece by
producing chips.
Turning, in which the workpiece is
rotated and a cutting tool removes a
layer of material as the tool moves to the
left.
Cutting off: in which the cutting tool
moves radially inward and separates the
right piece from the bulk of the blank.
Slab milling: in which a rotating cutting
tool removes a layer of material from the
surface of the workpiece.
End milling: in which a rotating cutter
travels along a certain depth in the
work-
piece and produces a cavity.

Figure 21.2 Schematic illustration of the
turning operation showing various
features.
In the turning process, illustrated
the cutting tool is set at a certain
depth of cut (mm) and travels to
the left with a certain velocity as
the workpiece rotates. The feed,
or feed rate, is the distance the
tool travels horizontally per unit
revolution of the workpiece
(mm/rev). This movement of the
tool produces a chip, which moves
up the face of the tool.
Introduction to Cutting – The Turning
Introduction to Cutting – The Turning
Operation
Operation

Two-Dimensional
Two-Dimensional
Cutting Process
Cutting Process
Figure 21.3 Schematic illustration of a
two-dimensional cutting process, also
called orthogonal cutting: (a) Orthogonal
cutting with a well-defined shear plane,
also known as the Merchant Model. Note
that the tool shape, depth of cut, to, and the
cutting speed, V, are all independent
variables, (b) Orthogonal cutting without a
well-defined shear plane.

Introduction to cutting
Introduction to cutting
• Compare Figs. 20.2 and 20.3,
and note that:
 Feed in turning is equivalent to t0
 Depth of cut in turning is
equivalent to width of cut
(dimension perpendicular to the
page) in the idealized model.
 These relationships can be
visualized by rotating Fig. 20.3
CW by 90o
.

Factors Influencing Machining Operations

• Independent variables in the cutting process:
 Tool material, coatings and tool condition.
 Tool shape, surface finish, and sharpness.
 Workpiece material, condition, and temperature.
 Cutting parameters, such as speed, feed, and depth of cut.
 Cutting fluids.
 The characteristics of the machine tool, such as its stiffness and
damping.
 Workholding and fixturing.
• Dependent variables:
 Type of chip produced.
 Force and energy dissipated in the cutting process.
 Temperature rise in the workpiece, the chip, and the tool.
 Wear and failure of the tool.
 Surface finish produced on the workpiece after machining.

Orthogonal cutting
Orthogonal cutting
Chip Formation by Shearing
Chip Formation by Shearing
Figure 21.4 (a) Schematic illustration of the basic mechanism of
chip formation by shearing. (b) Velocity diagram showing angular
relationships among the three speeds in the cutting zone.
• The tool has a rake
angle of α , and a
relief (clearance)
angle.
• The shearing
process in chip
formation (Fig.
21.4a ) is similar to
the motion of cards
in a deck sliding
against each other.

THE MECHANICS OF CHIP FORMATION-
ORTHOGONAL CUTTING
ORTHOGONAL CUTTING
• The ratio of to/tc is known as the cutting ratio, r, expressed as:
• Chip thickness is always greater than the depth of cut
• Chip compression ratio: reciprocal of r. It is a measure of how
thick the chip has become compared to the depth of cut.
(21.1)
• The cutting ratio is an important and useful parameter for
evaluating cutting conditions. Since the undeformed chip
thickness, to, is a machine setting and is therefore known, the
cutting ratio can be calculated easily by measuring the chip
thickness with a micrometer.

ORTHOGONAL CUTTING
ORTHOGONAL CUTTING
• The shear strain, γ, that the material undergoes can be express as:
(21.2)
• Large shear strains are associated with low shear angles, or low or negative
rake angles.
• Shear strains of 5 or higher in actual cutting operations.
• Deformation in cutting generally takes place within a very narrow
deformation zone; that is, d = OC in Fig. 4.21-a is very small.
• Therefore, the rate at which shearing takes place is high.
• Shear angle influences force and power requirements, chip thickness, and
temperature.
• Consequently, much attention has been focused on determining the
relationships between the shear angle and workpiece material properties
and cutting process variables.

ORTHOGONAL CUTTING
ORTHOGONAL CUTTING
• Assuming that the shear angle adjusts itself to minimize the cutting force,
or that the shear plane is a plane of maximum shear stress.
(21.3)
β is the friction angle and is related to the coefficient of friction, μ, at the tool
– chip interface (rake face):
o From Eq (21.3), as the rake angle decreases
and / or the friction at the tool – chip interface
increases, the shear angle decreases and the
chip becomes thicker,
o Thicker chips mean more energy dissipation
because the shear strain is higher (Eq. (21.2))
o Because work done during cutting is converted
into heat, temperature rise is also higher.

ORTHOGONAL CUTTING
ORTHOGONAL CUTTING
• Higher shear plane angle means smaller shear plane which means
lower shear force
• Result: lower cutting forces, power, temperature, all of which mean
easier machining
Figure - Effect of shear plane angle Ø: (a) higher Ø with a resulting lower shear
plane area; (b) smaller Ø with a corresponding larger shear plane area. Note that
the rake angle is larger in (a), which tends to increase shear angle according to the
Merchant equation

ORTHOGONAL CUTTING
ORTHOGONAL CUTTING
• From Fig. 20.3, since chip thickness is greater than the depth of cut, the
velocity of the chip, Vc, has to be lower than the cutting speed, V.
• Conservation of mass:
(21.5)
(21.6)
• Vs is the velocity at which shearing
takes place in the shear plane.
• From the velocity diagram (Fig. 20.4b), we obtain the

TYPES OF CHIPS PRODUCED IN METAL-
CUTTING
CUTTING
1. Continuous
2. Built-up Edge
3. Serrated or Segmented
4. Discontinuous
A chip has two surfaces:
1.One that is in contact with the tool face (rake face). This surface is
shiny, or burnished.
2.The other from the original surface of the workpiece. This surface
does not come into contact with any solid body. This surface has a
jagged, rough appearance (Fig. 20.3), which is caused by the
shearing mechanism shown in fig. 20.4a.

Figure 21.5 Basic types of chips produced in orthogonal metal cutting, their schematic representation, and
photomicrographs of the cutting zone: (a) continuous chip with narrow, straight, and primary shear zone; (b)
continuous chip with secondary shear zone at the chip-tool interface; (c) built-up edge; (d) segmented or
nonhomogeneous chip; and (e) discontinuous chip. Source: After M.C. Shaw, P.K. Wright, and S. Kalpakjian.
• Formed with ductile
materials at high cutting
speeds and/or high rake
angles (Fig. 21.5a).
• Deformation of the
material takes place along
a narrow shear zone,
primary shear zone.
• CCs may, because of
friction, develop a
secondary shear zone at
tool–chip interface (Fig.
21.5b).
• The secondary zone
becomes thicker as tool–
chip friction increases.
• In CCs, deformation may
also take place along a
wide primary shear zone
with curved boundaries
(Fig. 21.3b).

TYPES OF CHIPS PRODUCED IN METAL -
TYPES OF CHIPS PRODUCED IN METAL -
CUTTING: CONTINUOUS CHIPS (CC)
CUTTING: CONTINUOUS CHIPS (CC)
• The lower boundary is below the machined surface, subjecting
the machined surface to distortion, as depicted by the distorted
vertical lines.
• This situation occurs particularly in machining soft metals at
low speeds and low rake angles.
• It can produce poor surface finish and induce residual surface
stresses.
• Although they generally produce good surface finish, CCs are
not always desirable.

CUTTING: Built-up-Edge Chips (BUE)
• BUE, consisting of layers of material from the workpiece that
are gradually deposited on the tool, may form at the tip of the
tool during cutting (Fig. 21.5d).
• As it becomes larger, BUE becomes unstable and eventually
breads up.
• Part of BUE material is carried away by the tool side of the chip;
the rest is deposited randomly on the workpiece surface.
• The process of BUE formation and destruction is repeated
continuously during the cutting operation, unless measures are
taken to eliminate it.
• Because of work hardening and deposition of successive layers
of material. BUE hardness increases significantly (Fig. 21.6a).

• BUE is generally undesirable.
• A thin, stable BUE is sometimes desirable because it reduces wear
by protecting the rake face of the tool.
• As cutting speed increases the size of BUE decreases.
• The tendency for a BUE to form is reduced by any of the
following practices:
1. Increase the cutting speeds
2. Decreasing depth of cut
3. Increasing the rake angle
4. Using a sharp tool
5. Using an effective cutting fluid
6. Use a cutting tool that has lower chemical affinity for the
workpiece material.

Built-up Edge
Built-up Edge
Figure 21.6 (a) Hardness distribution with a built-up edge in the cutting zone (material, 3115 steel).
Note that some regions in the built-up edge are as much as three times harder than the bulk metal of
the workpiece. (b) Surface finish produced in turning 5130 steel with a built-up edge. (c) Surface
finish on 1018 steel in face milling. Magnifications: 15x. Source: Courtesy of Metcut Research
Associates, Inc.
(b)
(c)

CUTTING: Serrated Chips
CUTTING: Serrated Chips
• Serrated chips: semi-continuous chips with zones of low and
high shear strain (Fig. 21.5e).
• Metals with low thermal conductivity and strength that
decreases sharply with temperature, such as titanium, exhibit
this behavior.
• The chips have a saw-tooth-like appearance.

CUTTING: Discontinuous Chips (DCs)
• DCs consist of segments that may be firmly or loosely
attached to each other (Fig. 21.5f ).
• DCs usually form under the following conditions:
1. Brittle workpiece materials
2. Workpiece materials that contain hard inclusions and
impurities, or have structures such as the graphite flakes in
gray cast iron.
3. Very low or very high cutting speeds.
4. Large depths of cut.
5. Low rake angles.
6. Lack of an effective cutting fluid.
7. Low stiffness of the machine tool.

• Because of the discontinuous nature of chip formation, forces
continually vary during cutting.
• Hence, the stiffness or rigidity of the cutting-tool holder, the
Workholding devices, and the machine tool are important in
cutting with both DC and serrated-chip formation

Chip Breaker
Chip Breaker
Figure 21.7 (a) Schematic illustration of the action of a chip breaker. Note that the chip
breaker decreases the radius of curvature of the chip and eventually breaks it. (b) Chip
breaker clamped on the rake face of a cutting tool. (c) Grooves in cutting tools acting as
chip breakers. Most cutting toold used now are inserts with built-in chip breaker
features.
CBs increase the effective rake
angle of the tool and,
consequently, increase the
shear angle.
Chips can also be broken by
changing the tool geometry,
thereby controlling chip flow,
as in the turning operations
shown in Fig. 21.8.
Experience has indicated that
the ideal chip is in the shape of
the letter C or the number 9
and fits within a 25 mm square
block.

Chips Produced in Turning
Chips Produced in Turning
Figure 21.8 Chips produced in turning: (a) tightly curled chip; (b) chip hits workpiece and
breaks; (c) continuous chip moving radially away from workpiece; and (d) chip hits tool
shank and breaks off. Source: After G. Boothroyd.

CUTTING: Chips Breakers (CBs)
CUTTING: Chips Breakers (CBs)
• With soft workpiece materials such as pure aluminum or
copper, chip breaking by such means is generally not
effective.
• Common techniques used with such materials, include
machining at small increments and then pausing (so that a chip
is not generated) or reversing the feed by small increments.
• In interrupted cutting operations, such as milling, chip
breakers are generally not necessary, since the chips already
have finite lengths because of the intermittent nature of the
operation.

THE MECHANICS OF OBLIQUE CUTTING
• Chip in Fig. 21.9a f lows up the
rake face of the tool at angle αc
(chip flow angle), which is
measured in the plane of the
tool face.
• Angle αn , the normal rake
angle, is a basic geometric
property of the tool. This is the
angle between the normal oz to
the workpiece surface and the
line oa on the tool face.
• The workpiece material
approaches the tool at a
velocity V and leaves the
surface (as a chip) with a
velocity Vc
Figure 21.9 (a) Schematic illustration of cutting with an
oblique tool. Note the direction of chip movement. (b) Top
view, showing the inclination angle, i,. (c) Types of chips
produced with tools at increasing inclination angles.

• Effective rake angle αe is calculated
in the plane of these two velocities.
• Assuming that the chip f low angle
αc is equal to the inclination angle i,
the effective rake angle αe is
• As i increases, the effective rake
angle increases and the chip
becomes thinner and longer.

Right-hand Cutting Tool and Insert
Right-hand Cutting Tool and Insert
Figure 21.10 (a) Schematic illustration of right-hand cutting tool. The various
angles on these tools and their effects on machining are described in Section
23.3.1 Although these tools traditionally have been produced from solid tool-steel
bars, they have been replaced largely with (b) inserts made of carbides and other
materials of various shapes and sizes.

• Knowledge of the cutting forces and power involved in
machining operations is important for the following reasons:
a. Machine tools can be properly designed to minimize distortion
of the machine components, maintain the desired dimensional
accuracy of the machined part, and help select appropriate tool
holders and work-holding devices.
b. The workpiece is capable of withstanding these forces without
excessive distortion.
c. Power requirements must be known in order to enable the
selection of a machine tool with adequate electric power.
CUTTING FORCES AND POWER

• Cutting force, Fc, acts in the direction of cutting speed, V, and
supplies energy required for cutting.
• Thrust force, Ft , acts in a direction normal to cutting velocity,
perpendicular to WP. The resultant force, R can be resolved into
two components :
 Friction force: F, along the tool-chip interface
 Normal force: N, perpendicular to it.
F = R sin β (21.8a)
N = R cos β (21.8b)
R is balanced by an equal and opposite force along the shear plane and
is resolved into a shear force, Fs, and a normal force, Fn
Fs = Fc cos Ø – Ft sin Ø (21.9)
Fn = Fc sin Ø + Ft cos Ø (21.10)

Cutting Forces
Cutting Forces
Figure 21.11 (a) Forces acting on a cutting tool during two-dimensional cutting. Note
that the resultant force, R, must be collinear to balance the forces. (b) Force circle to
determine various forces acting in the cutting zone.

• The ratio of F to N is the coefficient of friction, μ, at the tool-
chip interface, and the angle β is the friction angle.
(21.11)
• The coefficient of friction in metal cutting generally ranges
from about 0.5 to 2.



tan
tan
friction,
of
t
Coefficien
t
c
c
t
F
F
F
F
N
F





Thrust Force
Thrust Force
• If the thrust force is too high or if the machine tool is not
sufficiently stiff, the tool will be pushed away from the surface
being machined.
• This movement will, in turn, reduce the depth of cut, resulting
in lack of dimensional accuracy in the machined part, As the
rake angle increases and/or friction at the rake face decreases,
this force can act upward.
• This situation can be visualized by noting that when μ = 0
(that is, β = 0), the resultant force, R, coincides with the
normal force, N.
• In this case, R will have a thrust-force component that is
upward.

CUTTING FORCES AND POWER -
CUTTING FORCES AND POWER -
Power
Power

Range of Energy Requirements in Cutting Operations
Range of Energy Requirements in Cutting Operations

• EXAMPLE 21.l Relative Energies in Cutting
In an orthogonal cutting operation, to = 0.13 mm, V = 120
m/min, α = 10° and the width of cut = 6 mm. It is observed
that tc = 0.23 mm, Fc = 500 N and Ft = 200 N. Calculate the
percentage of the total energy that goes into overcoming
friction at the tool-chip interface.
Solution The percentage of the energy can be expressed as:

• EXAMPLE 21.l Relative Energies in Cutting

TEMPERATURE IN CUTTING
• The main sources of heat generation are the primary shear
zone and the tool-chip interface.
• If the tool is dull or worn, heat is also generated when the tool
tip rubs against the machined surface.
• Cutting temperatures increase with:
1. strength of the workpiece material
2. cutting speed
3. depth of cut
• Cutting temperatures decrease with increasing specific heat
and thermal conductivity of workpiece material.

• The mean temperature in turning on a lathe is proportional to the
cutting speed and feed:
Mean temperature α Va
fb
(21.19)
• a and b are constants that depend on tool and workpiece materials,
V is the cutting speed, and f is the feed of the tool.
• Max temperature is about halfway up the face of the tool.
• As speed increases, the time for heat dissipation decreases and
temperature rises
Tool Material a B
Carbide 0.2 0.125
HSS 0.5 0.375

Temperatures in Cutting Zone
Temperatures in Cutting Zone
Figure 21.12 Typical temperature
distribution in the cutting zone. Note the
severe temperature gradients within the
tool and the chip, and that the workpiece is
relatively cool. Source: After G. Vieregge.
Figure 21.14 Proportion of the heat generated in
cutting transferred into the tool, workpiece, and
chip as a function of the cutting speed. Note
that the chip removes most of the heat.

Temperatures Developed in Turning 52100 Steel
Temperatures Developed in Turning 52100 Steel
Figure 21.13 Temperatures developed in turning 52100 steel: (a) flank temperature
distribution and (b) tool-ship interface temperature distribution. Source: After B. T.
Chao and K. J. Trigger.

TOOL LIFE: WEAR AND FAILURE
• Conditions that would cause tool wear:
1. High localized stresses
2. High temp
3. Sliding of chip along the rack face
4. Sliding of the tool along the machined surface
• The rate of wear depends on:
1. Tool and workpiece materials
2. Tool shape
3. Cutting fluids
4. Process parameters
5. Machine tool characteristics

• The Cutting tool should be replaced when:
1. Surface finish of the workpiece is poor
2. Cutting force increases significantly
3. Temperature increases significantly
4. Poor dimensional accuracies

Wear Patterns on Tools
Wear Patterns on Tools Figure 21.15 (a) Flank
wear and crater wear in a
cutting tool; the tool
moves to the left as in
Fig. 21.3. (b) View of the
rake face of a turning
tool, showing various
wear patterns. (c) View
of the flank face of a
turning tool, showing
various wear patterns.
(d) Types of wear on a
turning tool: 1. flank
wear; 2. crater wear; 3.
chipped cutting edge; 4.
thermal cracking on rake
face; 5. built-up edge; 6.
catastrophic failure. (See
also Fig. 21.18.) Source:
Courtesy of Kennametal,
Inc.

• VTn
= C (Taylor Equation) (21.20)
• T = time required to develop certain flank wear land (fig 21.15c)
• n & C= exponents that depend on tool and workpiece materials
and cutting conditions
• see table 21.3 for n values
• To take into account feed rate and depth of cut effects on wear,
eq (20) is modified:
• V Tn
dx
fy
= C (21.21)
• here it can be seen that for constant values of C, the smaller the
value of n, the lower is the tool life
• Cutting speed is the most important process variable associated
with tool life followed by depth of cut d and feed f.

Taylor Tool Life Equation
Taylor Tool Life Equation

VTn
 C
VTn
dx
f y
 C
Taylor Equation:

Effect of Workpiece Hardness and Microstructure
Effect of Workpiece Hardness and Microstructure
on Tool Life
on Tool Life
Figure 21.16 Effect of workpiece hardness and microstructure on tool life in turning ductile cast iron. Note
the rapid decrease in tool life (approaching zero) as the cutting speed increases. Tool materials have been
developed that resist high temperatures, such as carbides, ceramics, and cubic boron nitride, as will be
described in Chapter 22.

Tool-life Curves
Tool-life Curves
Figure 21.17 Tool-life curves for a
variety of cutting-tool materials.
The negative inverse of the slope
of these curves is the exponent n
in the Taylor tool-life equation and
C is the cutting speed at T = 1
min, ranging from about 200 to
10,000 ft./min in this figure.

Allowable Wear Land
Allowable Wear Land
• VB in fig 21.15c for various machining conditions is given in
table 21.4
• Optimum cutting speed

Allowable Wear Land
Allowable Wear Land

Crater Wear
Crater Wear
• Occurs on the rake face (fig 21.15a, b, and d and fig 21.18)
• Factors influencing crater wear:
1. temp at tool-chip interface
2. chemical Affinity between tool and workpiece materials
3. factors for flank wear
• Diffusion mechanism, movement of atoms across tool-chip
interface.
• Diffusion rate increases with temp, so increasing crater wear
(fig 21.19)

Types of Wear seen in Cutting Tools
Types of Wear seen in Cutting Tools
Figure 21.18 (a) Schematic illustration of types of wear observed on various cutting tools. (b)
Schematic illustrations of catastrophic tool failures. A wide range of parameters influence these wear
and failure patterns. Source: Courtesy of V. C. Venkatesh.

Relationship between Crater-Wear Rate and
Relationship between Crater-Wear Rate and
Average Tool-Chip Interface Temperature
Average Tool-Chip Interface Temperature
Figure 21.19 Relationship between crater-wear rate and average tool-chip interface
temperature: 1) High-speed steel, 2) C-1 carbide, and 3) C-5 carbide (see Table 22.4).
Note how rapidly crater-wear rate increases with an incremental increase in temperature.
Source: After B. T Chao and K. J Trigger.

Cutting Tool Interface and Chip
Cutting Tool Interface and Chip
Figure 21.20 Interface of a cutting
tool (right) and chip (left) in
machining plain-carbon steel. The
discoloration of the tool indicates
the presence of high temperatures.
Compare this figure with the
temperature profiles shown in Fig.
21.12. Source: Courtesy of P. K.
Wright.

Chipping
Chipping
• Chipping: small fragments from the CE breaks away [sudden
loss of material] . Brittle CT like ceramic.
• Two main causes:
1. Mechanical shock: (i.e., impact due to interrupted cutting, as in
turning a splined shaft on a lathe).
2. Thermal fatigue: (i.e., cyclic variations in the temperature of the
tool in interrupted cutting)
• Thermal cracks normal to the cutting edge of the tool (fig 21.18a)
• Chipping may occur in a region in the tool where a small crack or
defect already exists
• High +ve rake angles can contribute to chipping
• It’s possible for crater wear region to progress toward the tool tip,
weakening the tip and causing chipping

General observations on tool wear
General observations on tool wear
• Due to decreasing in yield strength from high temp during cutting, tools may
soften and undergo plastic deform
• This type of deformation generally occurs when machining high-strength
metals and alloys.
• Therefore, tools must be able to maintain their strength and hardness at
elevated temperature.
• Wear groove or notch on cutting tools is due to:
1. This region is the boundary where chip is no longer in contact with the tool
2. This boundary known as DOC line, oscillates because of inherent variations
in the cutting operation and accelerates the wear process
3. This region is in contact with the machined surface from the previous cut
4. Since a machined surface may develop a thin work-hardened layer, this
contact could contribute to the formation of the wear groove
• Light cuts should not be taken on rusted workpieces.

Tool Condition Monitoring
Tool Condition Monitoring
1. Direct techniques
• optical measurement of wear
• done using toolmaker microscope
1. Indirect methods
• correlation of tool condition with process variables: forces,
power, temp rise, surface finish, and vibration
A. Acoustic emission technique (AE)
• Utilizes a piezo-electric transducer attached to tool holder
• The transducer picks up acoustic emissions that result from the
stress waves generated during cutting.
• By analyzing the signals, tool wear and chipping can be
monitored

B. Transducers are installed in original machine tools
• Continually monitor torque and forces during cutting
• Signals are pre-amplified and microprocessor analyses and
interprets their content
• The system is capable of differentiating the signals that come
from tool breakage, tool wear, a missing tool, overloading of
the machine, or colliding machine comp
• The system also auto compensate for tool wear and thus
improve dim accuracy
C. Monitoring by tool-cycle time
• In CNC expected tool life in entered into the machine control
unit, when it is reached, the operator makes the tool change.
Tool Condition Monitoring – Indirect methods
Tool Condition Monitoring – Indirect methods

Lathe Tool Dynamometer
Lathe Tool Dynamometer

SURFACE FINISH AND SURFACE
INTEGRITY
INTEGRITY
• SF: geometric Features of surfaces
• SI: refers to properties such as fatigue life and corrosion
resistance.
• Factors influencing SI:
1. temp
2. residual stresses
3. metallurgical transformations
4. surface plastic deform, tearing and cracking
• BUE has greatest influence on SF

INTEGRITY
INTEGRITY
(a) (b)
Figure 21.21 Machined surfaces produced on steel
(highly magnified), as observed with a scanning electron
microscope: (a) turned surface and (b) surface produced
by shaping. Source: Courtesy of J. T. Black and S.
Ramalingam.
 Rubbing generates heat
and induce residual stresses
causing surface
damage
 DOC should be greater
than the radius of the
cutting edge.
the built-up edge has the
greatest influence on
surface finish. Figure 21.21

Dull Tool in Orthogonal Machining
Dull Tool in Orthogonal Machining
Figure 21.22 Schematic illustration of a dull tool with respect to the depth
of cut in orthogonal machining (exaggerated). Note that the tool has a
positive rake angle, but as the depth of cut decreases, the rake angle
effectively can become negative. The tool then simply rides over the
workpiece (without cutting) and burnishes its surface; this action raises
the workpiece temperature and causes surface residual stresses.

Feed Marks on a Turned Surface
Feed Marks on a Turned Surface
Figure 21.23 Schematic illustration of feed
marks on a surface being turned (exaggerated).

Ra 
f2
8R
where
f  feed
R  tool - nose radius
Surface roughness:
the higher the feed, and the
smaller the tool-nose radius, R,
the more prominent these
marks will be.
Vibration and chatter adversely
affect surface finish because a
vibrating tool periodically changes
the dimensions of the cut.

MACHINABLITY
MACHINABLITY
• Machinability of a material is defined in terms of 4 factors:
1. SF and SI of the machined part
2. tool life
3. force and power req
4. chip control
• Tool life and SF: most important factors in machinability
• Machinability ratings
 based on a tool life, T = 60min
 standard material is AISI 1112 steel (resulfurized), given a
rating of 100
 for a tool life of 60 min, this steel should be machined at speed
of 100 ft/min

MACHINABLITY
MACHINABLITY
machinability of steels
machinability of steels
• Improved by adding lead and sulfur (free machining steels)
• Resulfurized & Rephosphorized Steels
 S forms manganese sulfide inclusions (2nd phase particles)
 Act as stress raisers in the primary shear zone
 So chips break up easily and are small
• P has 2 major effects:
1. It strengthens ferrite, causing increased hardness, resulting in
better chip formation and SF
2. Increased hardness causes the formation of short chips

MACHINABLITY
MACHINABLITY
leaded steels
leaded steels
• High % of lead in steels solidifies at the tip of manganese sulfide
inclusions
• in non-resulfurized steels, lead takes the form of dispersed fine
particles
• Pb acts as solid lubricant because of low shear strength
• When temp is high, Pb melts in front of the tool, acting as a liquid
lubricant
• Bismuth and tin are possible substitutes for lead in steel
• Calcium-Deoxidized steels
• Oxide flakes of Calcium silicates (CaSO) are formed
• These flakes reduce strength of secondary shear zone, decreasing
tool-chip interface friction and wear
• Temp is reduced, better crater wear

MACHINABLITY
MACHINABLITY
Stainless steels
Stainless steels
• Austentic steels (300 series) are generally difficult to machine
• Chatter can be a problem, need machine tools with high
stiffness
• Ferrite steels have good machinability
• Martensistic steels are abrasive, tend to form BUE, and require
tool material with high hot hardness and crater wear resistance
• Precipitation-hardening steels are strong and abrasive, require
hard and abrasion resistance tool material

MACHINABLITY
MACHINABLITY
Effects of other elements in steel
Effects of other elements in steel
• Al and Si is always harmful because they combine with O to
form aluminium oxide and silicates, which are hard and
abrasive
• C and Mn have various effects on machinability, depending on
their composition.
• Plain low carbon steels (< 0.15% C) can produce poor SF by
forming BUE
• Tool and die steels are very difficult to machine and usually
require annealing prior to machining.
• Machinability of most steels is improved by cold working,
which hardens the material and reduces the tendency to form
BUE.
• Ni, Cr, Molybdenum, Vn generally reduce machinability

MACHINABLITY
MACHINABLITY
Thermally Assisted Machining
Thermally Assisted Machining
• Source of heat is focused to an area just ahead of the cutting
tool
• Advantages are:
1. lower cutting forces
2. increased tool life
3. use of inexpensive cutting tool materials
4. higher material removal rates
5. reduced tendency for vibration and chatter
Homework:
Problems: 40, 41, 45, 52
Due date: 23/4/2013
A quiz will be made at the same day.

Ch21-Fundamentals-of-cutting tool manuf.ppt

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