TheoryofMetalCutting.pptVIP

* Working temperatures for common tool materials are; Carbon tool steels 200oC - 250oC High speed steel 560oC - 600oC Cemented Carbides 800oC - 1000oC Tool material is subjected to local expansion and contraction due to severe temperature gradient. Gives rise to thermal stresses further leads to thermal cracks. * 2. Mechanical Chipping Mechanical chipping of nose an cutting edge of the tool are commonly observed causes for tool failure. Reasons for failure are High cutting pressure, Mechanical impact, Excessive wear, too high vibrations and weak tip an cutting edge, etc. This type of failure is pronounced in carbide tipped and diamond tools due to high brittleness of tool material. Chipped Tip * 3. Gradual wear When a tool is in use for some time it is found to have lost some weight or mass implying that it has lost some material from it due to wear. Wear locations: Crater wear location Flank wear location Crater wear Due to pressure of the hot chip sliding up the face of the tool, crater or a depression is formed on the face of tool. (Ductile materials) By diffusion shape of crater formed corresponds to the shape of underside of the chip Crater wear * Flank wear Occurs between tool and workpiece interface Due to abrasion between tool flank and workpiece The entire area subjected to flank wear is known as WEAR LAND (VB), occurs on tool nose, front and side relief faces Machinability The major factor involved in metal cutting are, Forces and power absorbed Tool wear and tool life Surface finish Dimensional accuracy Machining cost This factor depend upon a large variables, such as Property of work material Tool geometry Cutting condition Machine tool rigidity * Qualitative measure of machinability The easy with which it could be machined, The life of tool before tool failure or re sharpening The quality of machined surface. The power consumption per unit volume of material removed. * The machinability may be evaluated as given bel