TOOL DESIGN

UNIT-2
SINGLE POINT TOOLS
PART-2

SINGLE POINT TOOLS

UNIT-2 - TOPICS
NOMENCLATURE
TYPES & STYLES
DESIGN AND MANUFACTURE OF HSS & CARBIDE INSERT TYPE
TOOLS
FOR
TURNING
BORING
SHAPING
PLANING
SLOTTING OPERATIONS
DESIGN & MANUFACTURE OF FORM TOOLS;
TOOLS & HOLDERS FOR CNC APPLICATIONS;
TOOLS FOR DRY MACHINING
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UNIT-2 SINGLE POINT TOOLS- VSC-SR.AP-MECH-SW

TOOLS FOR DRY MACHINING

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TOOLS FOR DRY MACHINING - VSC-SR.AP-MECH-SW

TOOLS FOR DRY MACHINING

DRY MACHINING WHAT IS IT??
THE USE OF CUTTING TOOLS TO REMOVE MATERIAL FROM
WORKPIECES WITHOUT THE USE OF COOLANTS
DRY MACHINING WHY IS IT REQUIRED??
THE NEED FOR LARGE VOLUME OF COOLANT / CUTTING FLUID DURING
MACHINING AT HIGH SPEEDS AND DISPOSAL OF THE SAME AFTER MACHINING
HAS POSED
GREAT PROBLEMS TO THE ENVIRONMENT POLLUTION
INCREASED COSTS OF PRODUCTION / MACHINING BY 7% TO 17%
HEALTH PROBLEM IN HANDLING / WORKING WITH CONVENTIONAL
COOLANTS
REMOVAL OF COOLANT ON PART AND CLEAN
TRYING TO REDUCE OR ELIMINATE USE OF COOLANTS MOVING TOWARDS
COMPLETE DRY MACHINING
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TOOLS FOR DRY MACHINING - VSC-SR.AP-MECH-SW

TOOLS FOR DRY MACHINING

DRY MACHINING HOW IS IT DONE?
BY USING CUTTING TOOLS WITH SPECIAL COATINGS TO WITHSTAND
VERY HIGH TEMPERATURES DURING HIGH SPEED / HIGH FEED
MACHINING
COATINGS THAT GIVE HIGH HOT HARDNESS TO TOOL
PVD COATINGS DONE UNDER HIGH VACUUM (6-10 TORR)
METAL VAPOR IS DEPOSITED ON ELECTRICALLY CONDUCTIVE MATL
AS A THIN PURE METAL OR ALLOY
METAL VAPOR IS COMBINED / REACTED WITH VARIOUS GASES TO
DEPOSIT OXIDES, NITRIDES, CARBIDES & CARBO-NITRIDE

USES CATHODIC ARC SOURCE

Eg.. Zirconium nitride hard gold yellow color high wear and
corrosion resistance
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TOOLS FOR DRY MACHINING - VSC-SR.AP-MECH-SW

TOOLS FOR DRY MACHINING

DRY MACHINING HOW IS IT DONE?
CVD COATING Vs PVD COATING
CVD USED TO PRODUCE HIGH PURITY, HIGH PERFORMANCE
SOLID MATERIALS
SEMI-CONDUCTOR INDUSTRY FOR THIN FILMS
SILICON WAFERS FOR ICs
CARBON NANO FIBRES, TUNGSTEN FILAMENTS PRODN.
SYNTHETIC DIAMOND PRODN.

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TOOLS FOR DRY MACHINING - VSC-SR.AP-MECH-SW

TOOLS FOR DRY MACHINING

Improved hot hardness after coating

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TOOLS FOR DRY MACHINING - VSC-SR.AP-MECH-SW

TOOLS FOR DRY MACHINING

DRY MACHINING WHERE / WHEN SHOULD WE USE??
SOME MATERIALS REACT WITH WATER IN COOLANT
MAGNESIUM ALWAYS DRY MACHINED SINCE IT REACTS WITH
WATER
CI, PHENOLICS, GLASS FILLED MATERIAL, GRAPHITE WHEN
MACHINED PRODUCE DUST/POWDER RATHER THAN CHIP
WHEN THEY MIX WITH COOLANT FORM SLUDGE MAKING
MACHINING EVEN MORE DIFFICULT
GENERALLY A TOOL WITH > Rc 42 CAN BE USED FOR DRY
MACHINING
WHAT IF BASE MATL > 42 Rc?
Eg.. FOR 50Rc SST A FLAT TOP INSERT OF AL-TITANIUM-NITRIDE
COATING W/O CHIP BREAKER IS USED
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TOOLS FOR DRY MACHINING - VSC-SR.AP-MECH-SW

TOOLS FOR DRY MACHINING

DRY MACHINING / NEAR DRY MACHINING
TECHNIQUE CALLED MQL (MINIMUM QUANTITY
LUBRICATION) IS USED
THE HEAT OF THE MACHINING BURNS OR EVAPORATES
MUCH OF THE OIL LEAVING A NEAR DRY PART
A NOZZLE / AEROSOL GENERATOR DISPERSES OIL AS FINE
DROPLETS IN AIR PRODUCING AN AEROSOL / MIST
NOZZLE HELD ON TOOL HOLDER
LOW FRICTION COATINGS ALSO USED ON TOOLS WHICH
CAN HELP IN NEAR DRY MACHINING

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TOOLS FOR DRY MACHINING - VSC-SR.AP-MECH-SW

TOOLS FOR DRY MACHINING

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TOOLS FOR DRY MACHINING

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TOOLS FOR DRY MACHINING

MULTILAYERED AlCrN-BASE COATING DESIGNED FOR DRILLING

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TOOLS FOR DRY MACHINING

CARBON BASED COATINGS, PROPERTIES, APPLICATIONS

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