4. BASIC REQUIREMENT OF A TOOL MATERIALS
HOT HARDNESS
WEAR RESISTANCE
TOUGHNESS AND STRENGTH
THERMAL CONDUCTIVITY
CO-EFFICIENT OF FRICTION
CO-EFFICIENT OF THERMAL EXPANSION
MACHINIBILITY AND GRINDABILITY
7. TYPES OF CUTTING TOOL MATERIALS
ADVANCE CUTTING TOOL MATERIALS
Coated Carbides
CBN
PCD
UCON
Multi Coated
Super Coated Alloy
8. CUTTING TOOL MATERIALS
HIGH CARBON STEEL
Carbon percentage -0.8 to 1.5%
Oldest known tool material
Low Hot Hardness
Maximum Cutting Speed – 10 m/min
Maximum Temperature Limit -250 ºC
Suitable for Low Cutting
Low Cost
Used for taps, dies, hacksaw blades, hand drills, wood working
tools etc.
9. CUTTING TOOL MATERIALS
HIGH SPEED STEEL (H.S.S)
T-Series M-Series
(Tungsten Type) (Molybdenum Type)
18 - 4 - 1- 0.75 6 – 6 – 4 - 2
W Cr Va C W M Cr Va
Cutting speed up to 30 m/min
Maximum Limiting Temperature 560ºC
Less Costly
Excellent toughness
Widely used in industries as a solid Tool like form tool, drill, milling
cutters, endmill, reamers, Broach, Single point cutting tool etc.
10. CUTTING TOOL MATERIALS
CAST COBALT ALLOYS (STALLITE):
48-53% 30-33% 10-20% 1.5-2.0%
Co Cr W C
Manufacturing Process- Casting
Hot hardness- 760ºC
Cutting Speed -45 m/min
Higher tool life compare to H.S.S.
Hardness -58 to 64 HRC
Lower toughness/brittle
Limited strength
Used for from tool, Machining cast and malleable iron.
11. CUTTING TOOL MATERIALS
CERAMICS:
Al2O3 + MgO, Cr2O3, SiC, TiO, TiC
90% ________10%____________
High abrasive of wear Resistance
Less tendency to weld to metal
Very high compressive strength
Very high hot hardness
High refractoriness – 1800 ºC
High Cutting Speed -200 to 400 m/min
Longer tool life
Used for cutting steel and HSS
Used for high speed machining
Limitation:
Poor Toughness
Unreliable (Sudden
fail)
High rigidity of set up
12. CUTTING TOOL MATERIALS
CEMENTED CARBIDES (TUNGUSTAN CARBIDE):
Plain Tungsten Carbide
W C Co
94% 6% BINDER
Manufactured by Powder Metallurgy
Grain size – 1 micron to 8 micron
% of Co -3 to 12%
Many verity can be produced by controlling
grain size and % of cobalt.
Machining of non-ferrous, non-metallic and C.I
Drawback is its
Affinity with steel
13. CUTTING TOOL MATERIALS
CEMENTED CARBIDES (TUNGUSTAN CARBIDE):
Steel Grade (Triple) Tungsten Carbide
W TiC TaC Co
15% 10%
High hardness and wear resistance
Maximum limiting Temperature -1200 ºC
Various Shapes Of Inserts
Cutting Speed -100 m/min
High Tool life
High compressive strength
High production rate
Better surface finish
Drawback is its
Affinity with
steel
VARIOUS SHAPES OF INSERTS
14. CUTTING TOOL MATERIALS
DIMOND:
Hardest substance BHN 7000
High heat conductivity (Twice then steel)
High hot hardness 1650 ºC
High wear resistance
Very low co-efficient of friction
High compressive strength
High cutting speed (300 to 1000 m/min)
High tool life
Used for cutting hard material like glass, plastic
Ceramics and cemented carbides.
Used for turning and dressing wheel of grinding wheel
Used for machining non-metallic and non-ferrous alloy
Limitation:
• High rigidity of setup is
required.
• Poor shock and impact
resistance
• Not suitable for ferrous
materials
15. CUTTING TOOL MATERIALS
COATED CARBIDES:
Coating of micro thin layer insets made of tungsten carbide
Most commonly used coating materials are:
Titanium Nitride (TiN)
Titanium Carbide (TiC)
Titanium CarboNitiride (TiCN)
Aluminium Oxide (Al2O3)
Zicronium Nitride (ZrN)
Titanium Aluminium Nitride (TiAlN)
Methods of Coatings
- Chemical Vapor Depositio (CVD)
- Physical Vapor Deposition (PVD)
16. CUTTING TOOL MATERIALS
SUPER COATED CARBIDES :
UE6020 for steel turning } Development by Mitsubishi Material
UE5015 for C.I Turning } Corporation, Japan in 2000
WC- Higher interior Hardness and toughness
Triple layer coating
Inner layer –FCCN (Fibrous Crystalline Carbon Titanium )
Balance between wear resistance and fracture resistance
Outer coating –Al2O3 (Fine Grain)
outer most layer – Special laminated Titanium Alloys
Superior high temperature strength.
17. COATED CARBIDES:
Advantages:
High hot hardness
Chemically stable
High cutting speed -150 to 250 m/min
High Tool life (2 to 3 times higher than carbide)
Applications:
Widely used for high speed machining
Production of turning and milling of steels and C.I
Machining of very hard materials
Used as inserts
18. CUTTING TOOL MATERIALS
MULTI PHASE COTING
Outer most layer specially laminated by titanium alloy
Smooth surface structure and high chemical stability
Two of three layers of various coating materials to get
desired Properties
High speed, continues cutting –Tic/ Al2O3
Heavy duty, continues cutting –TiC/Al2O3 / Tin
Light interrupted cutting – TiC / TiC + TiN
TiN - Low friction
Al2O3 – High thermal stability
TiCN – Resistance to flank and crater wear
19. UCON
Nitrided refectory metal alloy developed by Union Carbide, USA.
Composition :50% columbium, 30%titanium and 20%tungsten and
contain no carbides.
Hardness 2500-3000 vickers.
Manufacture by cast into ingots and rolled into sheets and then cut
into strips.
Withstand very high temperature.
Used as through away inserts.
Excellent thermal shock resistance, High hardness and toughness.
Excellent resistance proof to diffusion and adhesion wear.
3-5 times more tool life then conventional carbide.
Cutting speed range of 250-500 M/Min on steels of 200 BHN
20. Application
Recommend for roughing, semi roughing and finishing cuts in
turning, facing and boring.
Use for steel machining grade.
21. CUTTING TOOL MATERIALS
CUBIC BORON NITRIDE:
Sanitized artificially made under high pressure and high
temperature.
Stable up to 10000C temperature.
Manufactures under ultra high pressure and high temperature.
Excellent in chemical and thermal stability.
Hardness next to natural dimond.
Applications:
Permits high feeds and speeds.
Available in large varity of shapes and sizes in insert form.
Use to turn bore, face, groove and mill difficult to machine
materials.
22. CUTTING TOOL MATERIALS
CUBIC BORON NITRIDE :
Material Recommended for cutting with CBN
Alloy Steel (45-68 Rc)
Carbon Tool Steel (45-68 Rc)
Die Steel S (45-68 Rc)
High Speed Steel (45-68 Rc)
23. CUTTING TOOL MATERIALS
PCD:
Synthetic having diamond matrix structure.
Sintered under extremely high temperature and pressure.
High in uniform hardness and abrasive resistance in all
direction.
Very high tool life compare to carbide tool (50 times).
Shock resistance is more than natural dimond.
Consistency in wear resistance.
Available in large verity of shapes and sizes.
Discs as large as 58 mm in diameter.
Better thermal conductivity then natural dimond.
Lower cost then natural diamond.
Used for machining milling, turning, grooving, facing and
boring.
26. CUTTING TOOL MATERIALS
REFERANCES:
production Technology- HMT
Theory and Application of Metal Cutting by Thomas Child
Production Technology- Kalpak Jain
Production Technology – P.C.Sharma
Production Engineering and Sciences – By Pandey and Singh
Metal Cutting – Milton Saw
27. Regression Analysis :
Farewell Corporation manufactures Integrated Circuit boards(I.C board) for
electronics devices. The planning department knows that the sales of their
client goods depends on how much they spend on advertising, on account of
which they receive in advance of expenditure. The planning department wish
to find out the relationship between their clients advertising and sales, so as
to find demand for I.C board.
The money spend by the client on advertising and sales (in dollar) is given for
different periods in following table :
Period(t)
Advertising
(Xt)
$(1,00,000)
Sales (Dt)
$(1,000.000)
Dt
2
Xt
2 XtDt
1 20 6 36 400 120
2 25 8 64 625 200
3 15 7 49 225 105
4 18 7 49 324 126
5 22 8 64 484 176
6 25 9 81 625 225
7 27 10 100 729 270
8 23 7 49 529 161
9 16 6 36 256 96
10 20 8 64 400 120
211 76 592 4597 1599
