CuttingTools 1 Materials PDF

Cutting Tool Design
Tool Materials, Tool Geometry

Sources:
Fundamentals of Modern Manufacturing, Groover
Fundamentals of Tool Design, SME
http://www.feine-klingen.de/PDFs/verhoeven.pdf
Tool Design, 3331

Dr Simin Nasseri
Southern Polytechnic State University
Content
Tool material selection,

Tool failure,
Properties of tool materials,
Tool materials,
Tool geometry.
MET3331, Prof Simin Nasseri
Tool Materials
The number one error when selecting tooling is calculating monetary
savings based on lowest cost per tool, rather than on maximized
productivity and extended tool life. To effectively select tools for

machining, a machinist or engineer must have specific information about:
the starting and finished part shape
the workpiece hardness
the material's tensile strength
the material's abrasiveness
the type of chip generated
the workholding setup
the power and speed capacity of the machine tool
Cutting Tool Selection

Different machining applications require different cutting tool materials.
The ideal cutting tool material should have all of the following
characteristics:
harder than the work it is cutting
high temperature stability
resists wear and thermal shock
impact resistant
chemically inert to the work material and cutting fluid
Three Modes of Tool Failure

Fracture failure:
Cutting force becomes excessive and/or dynamic, leading to

brittle fracture
Temperature failure:
Cutting temperature is too high for the tool material
Gradual wear:
Gradual wearing of the cutting tool (leads to the longest

possible use of the tool )
Tool Materials
Tool failure
Tool
failure modes
modes identify
identify the
the important
important properties
properties
that a tool material should possess:
Toughness -- to
Toughness
to avoid
avoid fracture
fracture failure
failure
Hot hardness - ability to retain hardness at high

temperatures
Wear resistance - hardness is the most important
property to resist abrasive wear
Tool Materials- Most Important Ones

Tools are made of:
High Speed Steel (HSS)
Cemented carbides
Non-steel Cutting Carbide Grades
Steel Cutting Carbide Grades
Coated Carbides
Cermets
Ceramics
Synthetic Diamonds
Cubic Boron Nitride
One of the most important cutting tool materials
An alloyed steel with 14-22% tungsten, as well as cobalt,

molybdenum and chromium, vanadium.
The cobalt component gives the material a hot hardness

value much greater than Carbon Steels
Highly alloyed tool steel capable of maintaining hardness at

elevated temperatures (better than high carbon and low alloy
steels)
Two basic types (AISI or American Iron and Steel Institute)

Tungsten-type, designated T- grades
Molybdenum-type, designated M-grades
can cut materials with tensile strengths up to 75

tons/sq.in. at speeds of 50-60 fpm
Hardness is in the range of 63-65 C Rockwell
cuts 4 times faster than the carbon steels
Used in all type of cutters, single/multiple point

tools, and rotary tools; Especially suited to
applications involving complicated tool geometries,
such as drills, taps, milling cutters
Cemented Carbides
Class of hard tool material based on tungsten carbide using
powder metallurgy techniques with cobalt (Co) as the binder.
The carbide and coated carbide tools cut about 3 to 5 times

faster than high-speed steels (Speeds up to 300 fpm are
common on mild steels).
Two basic types:
Non-steel cutting grades (Used for nonferrous metals and

gray cast iron)
Steel cutting grades (Used for low carbon, stainless, and

other alloy steels)
Cemented Carbides General Properties
High compressive strength but low-to-moderate tensile strength
High hardness
Good hot hardness
Good wear resistance
High thermal conductivity
High elastic modulus - 600 x 103 MPa (90 x 106 lb/in2)
Toughness lower than high speed steel
Each type of carbide affects the cutting tools

characteristics differently.
A higher tungsten content increases wear

resistance, but reduces tool strength.
A higher percentage of cobalt binder increases

strength, but lowers the wear resistance.
Coated Carbides
Cemented carbide insert coated with one or more thin layers of

wear resistant materials, such as TiC, TiN, and/or Al2O3.
Coating applied by chemical vapor deposition or physical vapor

deposition.
Coating thickness = 2.5 - 13 m (0.0001 to 0.0005 in).
Applications: cast irons and steels in turning and milling

operations.
Usage of Carbide Cutting Tools

Carbide is used in solid round tools or in the form of
replaceable inserts.
Shock-resistant types are used for interrupted

cutting.
Harder, chemically-stable types are required for

high speed finishing of steel.
More heat-resistant tools are needed for machining
the superalloys, like Inconel and Hastelloy.
Coated Carbide Tool
Photomicrograph
of cross section
of multiple
coatings on
cemented
carbide tool
(photo courtesy of
Kennametal Inc.)
Cermets
Bonded material containing ceramics and metals, widely used in jet

engines and nuclear reactors. Cermets behave much like metals but
have the great heat resistance of ceramics.
Tungsten carbide, titanium carbide, zirconium bromide, and aluminum

oxide are among the ceramics used; iron, cobalt, nickel, and chromium
are among the metals.
Properties:
Higher speeds and lower feeds than steel-cutting carbide grades.
Better finish achieved, often eliminating need for grinding.
Applications: high speed finishing and semifinishing of steels, stainless

steels, and cast irons
Ceramics
Primarily fine-grained Al2O3, pressed and sintered at high pressures

and temperatures into insert form with no binder.
Ceramic cutting tools are harder and more heat-resistant than

carbides, but more brittle.
Applications: high speed turning of cast iron and steel (Mild steels can
be cut at speeds up to 1500 fpm).
Two types of ceramic cutting tools are available:
the alumina-based and the silicon nitride-based

ceramics.
The alumina-based ceramics are used for high
speed semi- and final-finishing of ferrous and
some non-ferrous materials.
The silicon nitride-based ceramics are generally
used for rougher and heavier machining of
cast iron and the superalloys.
Synthetic Diamonds
Sintered polycrystalline diamond (SPD) - fabricated by

sintering very fine-grained diamond crystals under high
temperatures and pressures into desired shape with little or
no binder.
Polycrystalline diamond cutting tools can outlast regular

carbide by a factor of 100!
Applications: high speed machining of nonferrous metals and

abrasive nonmetals such as fiberglass, graphite, and some
plastics.
Not for steel cutting.
Cubic Boron Nitride
Next to diamond, cubic boron nitride (cBN) is hardest material

known.
Fabrication into cutting tool inserts same as SPD, or used as

coatings.
Applications: machining very hard ferrous materials like steel and

also nickel-based alloys
SPD and cBN tools are expensive (Their cost can be 30 times
that of a carbide insert).
Other Materials
Tool Materials
Carbon Steels
Limited tool life. Therefore, not suited to mass production
Can be formed into complex shapes for small production runs
low cost
suited to hand tools, and wood working
Carbon content about 0.9 to 1.35% with a hardness about 62
HRC Rockwell
Maximum cutting speeds about 26 ft/min. dry
The hot hardness value is low. This is the major factor in tool
life.
Tool Materials
Stellite
a family of alloys made of cobalt, chromium, tungsten and
carbon
The material is formed using electric furnaces, and casting
technique, and it cannot be rolled, or worked.
The material has a hardness of 60-62C Rockwell without heat
treating, and the material has good hot hardness properties
Cutting speed of up to 80-100 fpm can be used on mild steels
The tools that use this method either use inserts in special
holders, or tips brazed to carbon steel shanks
Tool Materials
Cemented Oxides
Produced using powder metallurgy techniques
Suited to high speed finishing
Cutting speeds from 300 to 7500 fpm
Coolants are not required
High resistance to abrasive wear and cratering
Classes of Tool Steel
W. Water hardening tool steels
O: Oil hardening tool steels
A: Air hardening die steels
D: High carbon, high chromium die steels
S: Shock-resisting tool steels
H: Hot-work die steels
T and M: Tungsten and Molybdenum high speed steels
L: Low alloy tool steels
F: Finishing steels
http://www.feine-klingen.de/PDFs/verhoeven.pdf

In the discussion of steel selection, the major properties of the
steels are considered to be:
1. Wear resistance,
2. Toughness
3. Hot hardness.
In the following table a rating of 1 to 10 is used with 10 being the
best possible value.
High values of these 3 properties indicate:
High wear resistance:
More carbides
High toughness:
Low %C in the steel
High hot hardness:
More alloy carbides
W- Steel: The W stands for water hardening. These steels are

similar to the plain carbon 1095 steel and have very low
hardenability. Therefore the toughness of the steel is improved
significantly if the steel shallow hardened. This means the steel
is quenched at a rate that produces martensite only near the
surface and allows the core to remain unhardened and therefore
tougher.
L Steel: The L stands for low alloy (composition similar to the AISI
alloy steels, (eg L6 is similar to AISI 4340 steel, just the C% is a
bit higher).
S Steel: The S stands for shock resisting. The high toughness

needed for shock load resistance is obtained by reducing the %C
in these steel to low levels (which also results in the low wear
resistance and hot hardness of the S steels).
O Steel: The O steel for oil hardening. The key alloying elements
are mainly Mn and V. These are responsible for its improved
hardenability over the W steels allowing them to generally be oil
quenched to through hardness.
A Steel: The A stands for air hardening. Hardenability of these is

improved to the point that they may be air hardened. The key
elements are Cr and Mo.
D Steel: These steels are sometimes called High-Carbon, High

Chromium steels and the D symbol has no obvious meaning,
although usually correlated with the term direct hardening. The
steels may be air hardened. They have excellent wear resistance,
moderately good hot hardness, but poor toughness.
H Steel: The H stands for hot hardness. These are usually the
steels of choice for the die steels of extrusions that are done hot.
Here, the combination of low carbon and moderate to high alloy
content gives good toughness and hot hardness but only fair
wear resistance.
M and T Steels: The M and T stand for molybdenum and tungsten

additions in these high speed tool steels. The carbides of these 2
elements are stable to quite high temperatures. Therefore, the
high level of these alloying elements produces large carbide
volume fractions which give good wear resistance and hot
hardness, but poor toughness.
Tool Geometry
Tool Geometry
Two categories:
Single point tools:
One dominant cutting edge
Used for turning, boring, shaping.
Multiple cutting edge tools:
More than one cutting edge
Used for drilling, reaming, tapping, milling,

broaching, and sawing.
Single-Point Tool Geometry

(a) Seven elements of
single-point tool geometry;
and (b) the tool signature
convention that defines the
seven elements.
Holding the Tool
Three ways of holding and presenting the cutting edge for a

single-point tool: (a) solid tool, typical of HSS; (b) brazed insert, one
way of holding a cemented carbide insert; and (c) mechanically
clamped insert, used for cemented carbides, ceramics, and other
very hard tool materials.
Common Insert Shapes
Common insert shapes: (a) round, (b) square, (c) rhombus with two 80
point angles, (d) hexagon with three 80 point angles, (e) triangle
(equilateral), (f) rhombus with two 55 point angles, (g) rhombus with two
35 point angles. Also shown are typical features of the geometry.
Carbide is used in solid

round tools or in the form of
replaceable inserts.
A collection of metal cutting
inserts made of various
materials (photo courtesy of
Kennametal Inc.).
Test yourself!
1. High-speed steel cuts faster than carbon steel by a factor of:
a. 2
b. 4
c. 8
d. 10
2. High tungsten content in a carbide tool will:
a. increase strength, but decrease wear-resistance
b. increase wear-resistance, but decrease strength
c. allow increased feed speeds while improving heat-resistance
d. improve the chemical-resistance of the tool
3. Inconel and Hastelloy require cutting tools that are:
a. tough
b. wear-resistant
c. heat-resistant
d. shock-resistant
Test yourself!
4. Ceramic cutting tools are very:
a. porous for cutting fluid retention
b. shock-resistant
c. resistant to wear
d. brittle
5. Polycrystalline diamond cutting tools can outlast regular
carbide by a factor of:
a. 10
b. 20
c. 50
d. 100
6. For machining purposes, cast iron is considered:
a. abrasive
b. hard
c. brittle
d. soft
Test yourself!
7. Synthetic diamond tools are suitable for cutting steels:
True
False
8. More carbides in tool steels indicate:
High wear resistance
High toughness
High hot hardness

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Cutting Tool Design

Tool Materials, Tool Geometry

Fundamentals of Modern Manufacturing, Groover

Fundamentals of Tool Design, SME

Tool Design, 3331

Tool material selection,

MET3331, Prof Simin Nasseri

Southern Polytechnic State University

productivity and extended tool life. To effectively select tools for

the starting and finished part shape

the workpiece hardness

the material's tensile strength

the material's abrasiveness

the type of chip generated

the workholding setup

the power and speed capacity of the machine tool

MET3331, Prof Simin Nasseri

Southern Polytechnic State University

Cutting Tool Selection

harder than the work it is cutting

high temperature stability

resists wear and thermal shock

chemically inert to the work material and cutting fluid

MET3331, Prof Simin Nasseri

Southern Polytechnic State University

Three Modes of Tool Failure

Cutting force becomes excessive and/or dynamic, leading to

Cutting temperature is too high for the tool material

Gradual wearing of the cutting tool (leads to the longest

MET3331, Prof Simin Nasseri

Southern Polytechnic State University

Hot hardness - ability to retain hardness at high

Wear resistance - hardness is the most important

property to resist abrasive wear

MET3331, Prof Simin Nasseri

Southern Polytechnic State University

Tool Materials- Most Important Ones

High Speed Steel (HSS)

Non-steel Cutting Carbide Grades

Steel Cutting Carbide Grades

Cubic Boron Nitride

MET3331, Prof Simin Nasseri

Southern Polytechnic State University

High Speed Steel (HSS)

One of the most important cutting tool materials

An alloyed steel with 14-22% tungsten, as well as cobalt,

The cobalt component gives the material a hot hardness

Highly alloyed tool steel capable of maintaining hardness at

Two basic types (AISI or American Iron and Steel Institute)

MET3331, Prof Simin Nasseri

Southern Polytechnic State University

High Speed Steel (HSS)

can cut materials with tensile strengths up to 75

Hardness is in the range of 63-65 C Rockwell

cuts 4 times faster than the carbon steels

Used in all type of cutters, single/multiple point

MET3331, Prof Simin Nasseri

Southern Polytechnic State University

Class of hard tool material based on tungsten carbide using

powder metallurgy techniques with cobalt (Co) as the binder.

The carbide and coated carbide tools cut about 3 to 5 times

Two basic types: