[LAB #7]: TOOL LIFE EXPERIMENT

Purpose : To study tool wear and tool life measurements for machinability

Equipment & Materials :

1. Engine lathe
2. Tool maker's microscope
3. Cutting tool : Carbide insert and tool holder
4. Steel rule and caliper
5. Test workpiece (4140 steel alloy bars)

Procedure :

1. Be familiar with the test lathe for different settings and operations.
Calculate the cutting speed and verify the speed setting using a speed meter.
2. Cut the test workpiece at specified test condition (depth of cut : 0.030", feed:
0.003"/rev, speed: 500, 600, 650 ft/min). Stop the test at a certain time interval (1
or 2 min.) to measure flank wear using a tool maker's microscope. Read at least
more than three readings and record the average value.
Note: Choose the closest cutting speeds available on the machine
3. To stop cutting, first back off the tool, stop "feed" and stop the spindle. The
remove the insert for measurement.
4. Continue the test until the flank wear reaches a critical value (0.015").
5. After each pass of the test workpiece, measure diameter of the workpiece. Make
sure that the speed setting is correct at each different diameter.
6. For each different cutting condition, use a fresh edge of the test insert.

Test conditions :

1. Cutting Speeds: V1 = _____ fpm, V2 = ____ fpm, V3 = ____ fpm

2. Depth of cut : ______ in, Feed: _____ ipr.

Computation :

1. Generate plots for measured tool wear values vs. cutting time.
2. Generate a plot of tool life vs. speed on a log-log scale.
2. Determine tool-life equation: VTn=C

Evaluation :

1. Flankwear rates and tool life curves.

2. Effects of speed on tool wear and tool life.