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Tool Life Wear and Failure
Tool Life Wear and Failure
Tool
Wear
Tool wear adversely affects tool life, the quality of the machined surface and its
dimensional accuracy, and economics of cutting operations.
Wear is a gradual process (like wear on a pencil tip)
The rate of the tool wear depends on:
(1) tool and workpiece materials
(2) tool geometry
(3) process parameters
(4) cutting fluids
(5) characteristic of the machine tool
Tool Wear
Tool wear can be classified as:
- Flank wear
- Notching
- Gross fracture
-Crater wear
- Plastic deformation of the tool tip
- Nose wear
- Chipping
(a)
(d)
(b)
(e)
(c)
Flank Wear
Flank wear occurs on the relief (flank) face of the tool.
Flank wear is generally attributed to;
(a) Rubbing of the tool along the machined surface
causing adhesive and abrasive wear
(b) High temperatures, which adversely affect the toolmaterials properties.
Taylor tool life equation is established:
n
V T C
V is the cutting speed
T is the time (minutes)
n is the exponent that depends on tool and workpiece
materials and cutting conditions
C is a constant
Each combination of workpiece and tool materials and
each cutting condition have their own n and C values,
determined experimentally.
Flank Wear
Cutting speed is the most important process variable associated with tool life, followed
by depth of cut and feed, f. For turning, Taylor Equation can be modified to:
V T n d x f y C
Where,
d: the depth of cut
f: feed in mm/rev
x and y must be determined experimentally for each cutting condition.
Taking n=0.15, x = 0.15 and y = 0.6 as typical values encountered in machining practice.
T C1/ nV 1/ n d x / n f y / n
Using typical values;
T C 7V 7 d 1 f 4
NOTEs:
-tool life decreases rapidly as the
cutting speed increases
- the condition of the workpiece
material has a strong influence on
tool life
- differences in tool life for
different workpiece-material
microstructures.
Temperature increases, flank
wear rapidly increases.
Crater Wear
Crater wear occurs on the rake face of the tool
Crater wear changes the tool-chip interface contact geometry.
The most significant factors influencing crater wear are:
(a) The temperature at the tool-chip interface
(b) The chemical affinity between the tool and workpiece materials
Additionally, the factors influencing flank wear may affect crater wear.
Crater Wear
Crater wear
Crater wear generally attributed to a diffusion
mechanism, which is the movement of atoms across the
tool-chip interface.
Diffusion rate increases with increasing temperature,
crater wear increases as temperature increases.
Applying protective coatings to tools in an effective
means of slowing the diffusion process and thus
reducing crater wear.
Typical coatings are titanium nitride, titanium carbide,
titanium carbonitride, and aluminum oxide.
Rake
face
Crater
wear
Flank
face
chip