tools manufacturingprocesses. outline types of tools tool geometry cutting fluids effectstypes tool...
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OutlineOutline
Types of ToolsTypes of ToolsTool GeometryTool GeometryCutting FluidsCutting Fluids
EffectsEffectsTypesTypes
Tool WearTool WearFormsFormsCausesCauses
Failure ModesFailure ModesCritical ParametersCritical Parameters
Horsepower UsedHorsepower UsedOperating TemperatureOperating Temperature
Feed and SpeedFeed and SpeedTool LifeTool Life
Tool GeometryTool Geometry
Single Point ToolsSingle Point Tools
Multiple Point ToolsMultiple Point Tools
Chip BreakersChip Breakers
Effects of Material on DesignEffects of Material on Design
Important Tool Important Tool PropertiesProperties
- High hardnessHigh hardness- Resistance to abrasion, wear and Resistance to abrasion, wear and
chipping of the cutting edgechipping of the cutting edge- High toughness/impact strengthHigh toughness/impact strength- High hardness at high High hardness at high
temperaturestemperatures- Resistance to bulk deformationResistance to bulk deformation- Chemical stability (does not react Chemical stability (does not react
or bond strongly with the work or bond strongly with the work materialmaterial
- High modulus of elasticity High modulus of elasticity (stiffness)(stiffness)
- Consistent tool lifeConsistent tool life- Proper geometry and surface finishProper geometry and surface finish
Tool MaterialsTool Materials
- Carbon and medium-alloy Carbon and medium-alloy steelssteels
- High-speed steelsHigh-speed steels- Cast-cobalt alloysCast-cobalt alloys- CarbidesCarbides- Coated toolsCoated tools- Alumina-based ceramicsAlumina-based ceramics- Cubic boron nitrideCubic boron nitride- Silicon-nitride-base ceramicsSilicon-nitride-base ceramics- DiamondDiamond- Whisker-reinforced materialsWhisker-reinforced materials
Cutting FluidsCutting Fluids
EffectsEffects- coolantcoolant- lubricantlubricant- flushes chipsflushes chips- reduces oxidation of heated reduces oxidation of heated
surfacessurfaces
TypesTypes- cutting oilscutting oils- emulsified oilsemulsified oils- chemical fluidschemical fluids
Cutting Fluid Cutting Fluid ApplicationApplication
FloodingFlooding- ≥ ≥ 3 gallons per minute per tool3 gallons per minute per tool
MistingMisting- atomized fluidsatomized fluids- a health hazard (OSHA limit a health hazard (OSHA limit
= .2 mg/m= .2 mg/m33))
High Pressure SystemsHigh Pressure Systems- often applied through the tooloften applied through the tool
Tool WearTool Wear
FormsForms- crater wearcrater wear- flank wearflank wear- chippingchipping
CausesCauses- abrasionabrasion- adhesionadhesion- diffusiondiffusion- plastic deformationplastic deformation
Failure ModesFailure Modes
FractureFracture
Temperature FailureTemperature Failure
Gradual WearGradual Wear
Critical ParametersCritical Parameters
Horsepower UsedHorsepower Used
Operating TemperatureOperating Temperature
Horsepower UsedHorsepower Used
MaterialMaterialBrinellBrinell
HardnessHardness
Unit HorsepowerUnit Horsepower
hphpuu hp/(in hp/(in33/min)/min)
CarbonCarbon
SteelsSteels
150-200150-200 0.60.6
201-250201-250 0.80.8
251-300251-300 1.01.0
CastCast
IronsIrons
125-175125-175 0.40.4
175-250175-250 0.60.6
AluminumAluminum 50-10050-100 0.250.25
Values of Unit Horsepower forVarious Work Materials
Feed and SpeedFeed and Speed
Speed – the rate at which the Speed – the rate at which the tool point moves as it rotates tool point moves as it rotates (in a lathe, the rate at which (in a lathe, the rate at which the cutting point on the the cutting point on the workpiece rotates)workpiece rotates)
Feed – the rate at which the tool Feed – the rate at which the tool is fed into/along the workpieceis fed into/along the workpiece
Feed and SpeedFeed and Speed
V = V = ππDN/12DN/12
V = surface cutting speed (ft/min)V = surface cutting speed (ft/min)
D = diameter of rotating object (in.)D = diameter of rotating object (in.)
N = rotation rate (RPM)N = rotation rate (RPM)
Feed and speedFeed and speed
Example: Assume a high-speed steel saw with 100 Example: Assume a high-speed steel saw with 100 teeth and a diameter of 6 inches is used to cut teeth and a diameter of 6 inches is used to cut aluminum. Determine the proper RPM and feed aluminum. Determine the proper RPM and feed rate.rate.
V (HSS, aluminum) = 550-1000 ft/min [in table]V (HSS, aluminum) = 550-1000 ft/min [in table]N = 12V/(N = 12V/(ππD) = 12(550-1000)/(D) = 12(550-1000)/(ππ6)6)= 350-637 RPM= 350-637 RPM
Feed (aluminum, saw) = .006-.01 in/tooth [in table]Feed (aluminum, saw) = .006-.01 in/tooth [in table](.006-.01)100 teeth = .6-1in(.006-.01)100 teeth = .6-1in(.6-1)350 RPM = 210-350 in/min(.6-1)350 RPM = 210-350 in/min
Start with the lowest values. They can be increased Start with the lowest values. They can be increased so long as the finish is acceptable.so long as the finish is acceptable.
Cutting PerformanceCutting Performance
How do we know if cutting How do we know if cutting parameters are optimal?parameters are optimal?
1.1. Surface finishSurface finish
2.2. Tool wearTool wear
3.3. Chip shapeChip shape
4.4. SoundSound
5.5. Cutting timeCutting time
6.6. HeatHeat
SummarySummary
Tools fail slowly with gradual wear or Tools fail slowly with gradual wear or suddenly with fracturesuddenly with fracture
Cutting fluids help reduce the effects of Cutting fluids help reduce the effects of wear and temperature failurewear and temperature failure
The materials of the tool and the workpiece The materials of the tool and the workpiece affect the tool shape and lifeaffect the tool shape and life
Higher cutting speeds increase the Higher cutting speeds increase the operating temperature and decrease tool operating temperature and decrease tool lifelife
It is necessary to calculate proper feed and It is necessary to calculate proper feed and speed to prevent excessive tool wearspeed to prevent excessive tool wear