Fundamentals of Cutting Fundamentals of Cutting &&

Cutting-Tool Materials Cutting-Tool Materials and Cutting Fluidsand Cutting Fluids

MANUFACTURING MANUFACTURING ENGINEERINGENGINEERING

AND TECHNOLOGYAND TECHNOLOGY

BY KALPAKJIANBY KALPAKJIANTHIRD EDITIONTHIRD EDITION

IntroductionIntroduction

Cast, formed and shaped products may need further machining operations.

Machining processes remove material from a workpiece.

• CUTTING:

• ABRASIVE:

• NONTRADITIONAL:

Fundamentals of CuttingFundamentals of Cutting

• Mechanics of Chip Formation.Mechanics of Chip Formation.– RAKE ANGLERAKE ANGLE

– RELIEF ANGLERELIEF ANGLE

– SHEAR ANGLESHEAR ANGLE

• Chip Type.Chip Type.– CONTINUOUSCONTINUOUS

– BUILT-UP EDGEBUILT-UP EDGE

– SERRATEDSERRATED

– DISCONTINUOUS.DISCONTINUOUS.

Fundamentals of CuttingFundamentals of Cutting

• Oblique Cutting.Oblique Cutting.– THREE DIMENTIONALTHREE DIMENTIONAL

– INCLINATION ANGLEINCLINATION ANGLE

• Cutting Forces and Power.Cutting Forces and Power.– MACHINE TOOL SELECTIONMACHINE TOOL SELECTION

– DYNAMOMETERDYNAMOMETER

– MANY VARIABLESMANY VARIABLES• FRICTIONFRICTION

• CUTTING FLUIDSCUTTING FLUIDS

• TOOL SHARPNESSTOOL SHARPNESS

• PROCESSPROCESS

Fundamentals of CuttingFundamentals of Cutting

• Temperatures in Cutting.Temperatures in Cutting.– TOOL PROPERTIESTOOL PROPERTIES

– DIMENSIONAL ACCURACYDIMENSIONAL ACCURACY

• Tool Life.Tool Life.– HIGH STRESSES & HIGH STRESSES &

TEMPERATURESTEMPERATURES

– GRADUAL WEARGRADUAL WEAR

– MANY VARIABLESMANY VARIABLES• MATERIALMATERIAL

• CUTTING FLUIDSCUTTING FLUIDS

• TOOL SHAPETOOL SHAPE

• SPEEDS & FEED RATESPEEDS & FEED RATE

– CHIPPINGCHIPPING

• Surface Finish and IntegritySurface Finish and Integrity– GEOMETRYGEOMETRY

– PROPERTIESPROPERTIES• FATIGUE LIFEFATIGUE LIFE

• CORROSION RESISTANCECORROSION RESISTANCE

• MachinabilityMachinability– RATINGS BASED ON TOOL LIFERATINGS BASED ON TOOL LIFE

– DECREASES AS HARDNESS INCREASESDECREASES AS HARDNESS INCREASES

– ALLOYING ELEMENTSALLOYING ELEMENTS

Fundamentals of CuttingFundamentals of Cutting

• Cutting Tool Cutting Tool MaterialsMaterials

• ARE SUBJECTED TO...ARE SUBJECTED TO...– HIGH TEMPERATURESHIGH TEMPERATURES– CONTACT STRESSESCONTACT STRESSES– ABRASIONABRASION

• MUST HAVE...MUST HAVE...– HARDNESSHARDNESS– TOUGHNESSTOUGHNESS– WEAR RESISTANCEWEAR RESISTANCE– CHEMICAL STABILITYCHEMICAL STABILITY

Cutting Tool Materials and Cutting Cutting Tool Materials and Cutting FluidsFluids

• Material Material Categories:Categories:

• CARBON AND MEDIUM CARBON AND MEDIUM ALLOY STEELSALLOY STEELS

• HIGH-SPEED STEELSHIGH-SPEED STEELS

• CAST-COLBALT ALLOYSCAST-COLBALT ALLOYS

• CARBIDESCARBIDES

• COATED TOOLSCOATED TOOLS

• ALUMINA-BASED ALUMINA-BASED CERAMICSCERAMICS

• CUBIC BORON NITRIDECUBIC BORON NITRIDE

• SILICON-NITRIDE-BASED SILICON-NITRIDE-BASED CERAMICSCERAMICS

• DIAMONDDIAMOND

• WHISKER-REINFORCED WHISKER-REINFORCED MATERIALSMATERIALS

• Cutting FluidsCutting Fluids– REDUCE FRICTION AND WEARREDUCE FRICTION AND WEAR

– REDUCE ENERGY CONSUMPTIONREDUCE ENERGY CONSUMPTION

– COOL THE CUTTING ZONECOOL THE CUTTING ZONE

– PROTECT MACHINED SURFACESPROTECT MACHINED SURFACES

• Fluid ActionFluid Action– CAPILLARY ACTIONCAPILLARY ACTION

– SMALL MOLECULAR SIZESMALL MOLECULAR SIZE

– PROPER WETTING CHARACTERISTICSPROPER WETTING CHARACTERISTICS

Cutting Tool Materials and Cutting Cutting Tool Materials and Cutting FluidsFluids

• Types of Cutting FluidsTypes of Cutting Fluids– OILSOILS

– EMULSIONSEMULSIONS

– SEMI-SYNTHESISSEMI-SYNTHESIS

– SYNTHETICSSYNTHETICS

• Methods of ApplicationMethods of Application– FLOOD COOLINGFLOOD COOLING

– MIST COOLINGMIST COOLING

– HIGH PRESSURE REFRIGERATED SYSTEMSHIGH PRESSURE REFRIGERATED SYSTEMS

Cutting Tool Materials and Cutting Cutting Tool Materials and Cutting FluidsFluids

• Effects of Cutting Fluids on…Effects of Cutting Fluids on…– WORKPIECE MATERIALSWORKPIECE MATERIALS

– MACHINE TOOLSMACHINE TOOLS

• Biological and Environmental EffectsBiological and Environmental Effects– OPERATOR CONTACTOPERATOR CONTACT

– EXTERNAL ENVIRONMENTEXTERNAL ENVIRONMENT

– DEGREDATION & CHEMICAL CHANGEDEGREDATION & CHEMICAL CHANGE

• Waste ManagementWaste Management– CLARIFICATIONCLARIFICATION

– RECYCLINGRECYCLING

– DISPOSALDISPOSAL

Cutting Tool Materials and Cutting Cutting Tool Materials and Cutting FluidsFluids