2. Submitted for partial fulfillment of award of BACHELOR OF
TECHNOLOGY Degree
In
MECHANICAL ENGINEERING
By
ANUJ KUMAR
ALOK SHARMA
DEVVRAT SINGH
S.M ARSHIL ZAIDI
VIVEKANAND INSTITUTE OFTECHNOLOGY AND
SCIENCE,GHAZIABAD
UTTAR PRADESH TECHNICAL UNIVERSITY,LUCKNOW
3. We hereby the declare the work being presented in
this report entitled ” STUDY OF CUTTINGTOOLS
AND JIG FIXTURE” is an authentic record of our own
work carried out under the supervision of
Mr. “SUBHANKAR KARMAKAR”
The matter embodies in this report has not been
submitted by us for the award of any other degree.
Name of students
ANUJ KUMAR
ALOK SHARMA
DEVVRAT SINGH
S.M ARSHILZAIDI
4. 1. INTRODUCTION
2. TOOL DESIGN METHOD
3. DESIRABLE PROPERTIES OFTOOLING MATERIAL
4. TOOLING MATERIAL AND HEATTREATMENT
5. SELECTION OFTOOLING MATERIAL
6. TOOL GEOMETRY
7. CHIPS FORMATION
8. TYPE OF CHIPS
9. TOOL FAILURE ANDTOOL CUTTING LIFE
10. EFFECT OF DIFFERENT PARAMETERS ONTOOL LIFE
11. IMPORTANCE OF JIG FIXTURE
12. MANUFACTURING OF HANDVICE
13. CONCLUSION
5. This project deals with “STUDY OF CUTTINGTOOLS AND JIGS
FIXTURE” with an aim of increasing the tool life.Various factors
play an important role in deciding the tool life such as Geometry of
tools, tool material, machining operations, types of coolant used
and cutting environment etc.
This project describes the tool design procedures, various tool
materials, selection of appropriate tool for machining operations
and explains the reasons for tool failure. It also describes the
factors for increasing the tool life.
This project also completely explains the various types of “JIGS
AND FIXTURES” how they are manufactured, principle of location,
their specifications & their importance.
The project also includes manufacturing of “HANDVICE”.
6. 1.Statement of the problem
Why the tool is needed?
What are the required capabilities of the tool
The type of machine the tool must be used on
The number of the part to be produced
Other pertinent information concerning the
part.
7. 2.The need analysis
Will the tool used by the skilled or unskilled
operators?
How many parts can be held on the tool?
What are the hole-location tolerances on the
part?
What provisions are to be made for coolant
Is the cutting force heavy or light?
Etc.
8. 3.Research and the ideation(sketches)
Dimension of the part to be held or produced
Kind of the material from which the part is
made
The tolerance of the part
Dimensions of the machine
Limitations of the machine
Amount of the tonnage to blank the part.
20. All machining processes involve formation of chips by deforming the work
material on the surface of the job with the help of the cutting tool.
21.
22. (a) tightly curled chip; (b) chip hits workpiece and breaks; (c)continuous chip
moving away from workpiece; and (d) chip hits tool shank and breaks off.
23. Continuous chips
During the cutting of ductile materials like low carbon steel, copper, brass
etc., a continuous ribbon type chip is produced.The pressure of the tool
makes the material ahead of the cutting edge deform plastically.
24. Continuous chips with built up edge
Continuous chips
with built up edge
The temperature is high at the interface between the chip and the tool
during the cutting. Also, the work material slides under heavy pressure on
the rake face before being transformed into a free chip. In these conditions,
some portion of the chip may stick to the rake face of the tool. Because of
such a close contact, it discharges its heat to the tool and attracts more of
the deforming work material and thus the size of “built up edge” goes on
increasing and breaks up after a critical stage.
25. Discontinuous chips
These chips are produced during the cutting of brittle material like cast
iron, and brasses. Even a slight plastic deformation produced by a small
advance of the cutting edge into the job leads to a crack formation in the
deforming zone.
28. SOME TOOL FAILURE;
1.Flank wear-VB=0.3mm; VBmax=0.6mm.
2. Fracture failure.
3.Temperature failure
4. Gradual wear
5. Crater wear- KT = 0.06 + 0.3f, where f is the feed per revolutions
6. Plastic Deformation
7. 2 Mechanical Breakage
29.
30. Taylor’s Empirical Equation:
VT n =C
Where,T = tool life time; usually in minutes
V = cutting velocity, m/min
C = constant; the cutting velocity for 1 minute of elapsed
time before reaching the wear limit of the tool
n = constant which is considered a characteristic of the tool
material, called tool life index.
TypicalTool Life
Exponential Graph
31. ModifiedTaylor’s Equation
This incorporates the feed rate and depth of cut having their own index X andY
where the indexes are obtained experimentally.Typically from machining
practices these values can be taken as:
n=0.15, x=0.15, and y=0.6 (typical values)
VTndxfy = C
The above equation may be rewritten for determining the time as
shown:
T=C1/nV-1/nD-x/nf-y/n
38. To hold theWork Piece
To guide the tool (jigs)
Protects the tool from accidental failure
Better productivity
Automates the machine tools
Ensures machining accuracy
Less skilled labor can be used
39. The manufacturing of hand
vice is done with an aim of
practically examining
all the factors involved in
various machining
operations, that we have
studied in our project. All the
factors were carefully
studied with an approach to
increase the tool life for e.g
tool geometry, tool
material, temperature,
cutting fluid, and proper use
of jigs & fixtures etc.
40. Parameter Influence and interrelationship
Cutting speed, depth of cut ,
feed Rate , cutting fluids.
Tool angles
Continuous chip
Built-up-edge chip
Discontinuous chip
Temperature rise.
Tool wear
Machinability
Forces power, temperature rise, tool life, type of chips,
surface finish.
influence on chip flow direction; resistance to tool chipping.
Good surface finish ; steady cutting forces ; undesirable in
automated machinery.
Poor surface finish , thin stable edge can product tool
surface.
Desirable for ease of chip disposal ; fluctuating cutting forces
; can affect surface finish and cause vibration and chatters.
Influences surface finish , dimensional accuracy,
temperature rise, forces and power.
Influences surface finish , dimensional accuracy ,
temperature rise , forces and power.
Related to tool life , surface finish , forces and power
41. Parameter Influence and interrelationship
Selection of machining
process
Selection of tool material
Cutting environment
Selection of proper jigs
and fixture
Accuracy of machine
Vibration in machine
Right machining process minimize the tool wear ,& gives
better tool life.
Selection of tooling material is most important factor. Tool
material always should have higher strength then the
material to be cut.
Tool life is also depend upon the right jigs/fixture is used.
They minimize the accidental tool failure & gives the
direction to tool.
Accurate machine have low tool wear rate.
Vibration in machine increase the tool wear.
42. Parameter Influence and interrelationship
Mechanical properties of tool
material
chemical properties of tool
material
Selection of cutting fluid
Proper heat treatment
Coating Material
Skill of workers
Tool life is directly depend upon the mechanical properties of
tool material
Oxidation decrease the tool life
A proper cutting fluid can increase the tool life uptu 20%
A heat treated tool can with stand higher temp.& have longer
tool life
A proper Coated material can increase the tool life uptu
300%
Skill worker have better knowledge of cutting process &
machine operation
44. Parameter Influence and interrelationship
Proper heat treatment
Coating Material
Skill of workers
A heat treated tool can with stand higher temp.& have longer
tool life
A proper Coated material can increase the tool life uptu
300%
Skill worker have better knowledge of cutting process &
machine operation
