Advance Manufacturing Processes (IM-307)

Course Teacher: Zaid Khan (Lecturer).

Class room Passwords: p7u6r2l, f6jiahu, f7i35pa
Topics:
• Mechanics of Orthogonal Metal Cutting.
• Tool Life and Tool Wear.
Reference Books:
• Fundamentals of Modern Mfg., By Mikell P. Groover (3rd
Edition).
• Materials and Processes in Mfg., By De Garmo (10TH
Edition).
TOPICS: TOOL LIFE AND TOOL WEAR

Forms of wear in metal cutting, Tool life criteria, Variables

affecting tool life, Taylor's tool life equation, Generalized tool life
equation, Methods of tool life testing data. Economics of Metal
Cutting: Application of minimum cost per piece, maximum
production rate, and maximum profit rate criteria in turning
operations.

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MEANING OF TOOL LIFE

Tool life generally indicates, the amount of satisfactory

performance or service rendered by a fresh tool or a cutting
point till it is declared failed

The tool life can be defined in following different ways:

• The time elapsed between two successive grindings.
• The period during which a tool cuts satisfactory.
• The total time accumulated before tool failure occurs.
• Tool life is expressed in minutes.

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Methods for Tool Life Measurements:
The most commonly used methods for tool life measurements
are following:
(i) Machining Time:
• Elapsed time of operation of machine tool.
(ii) Actual Cutting Time:
• The time during which the tool actually cuts.
(iii) A fixed size of Wear Land on Flank Surface:
• On carbide and ceramic tools where crater wear is almost
absent.
(iv) Volume of metal removed.
(v) Number of pieces machined.

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The tool life between re-conditioning and replacement can be
defined in a number of ways, such as:
(a) Actual cutting time taken to failure.
(b) Volume of metal removed to failure.
(c) Number of parts produced to failure.
(d) Cutting speed for a given time to failure.
(e) Length of work machined to failure.
FORMS OF WEAR IN METAL CUTTING
Tool wear is common phenomenon is metal cutting, The cutting
tools fail due to following three conditions.
• Breakage of tool due to excessive shock and force.
• Tool wears due to plastic deformation or change in chemical
or physical condition of tool.
• Gradual wear like flank wear, crater wear etc.

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TOOL WEAR MECHANISM:
1. Abrasive wear:
This wear is depends upon work hardening of work piece. When
the tool cut the work piece, some small chips are forms which
act as hard particle. These hard particle acts as small cutting
edge like grinding wheel, which cause tool wear.
2. Adhesion wear:
This tool wear is due to sliding of chips over the tool. The chips
forms by metal cutting are hard and have high temperature. This
wear is due to rubbing of these chips over the tool. This wear
cause due to high friction and high temperature of chips flowing
over tool face.
3. Diffusion:
Diffusion means diffuse of hard metal into soft metal due to high
temperature of contact surface between hard material and soft
material. In tool wear chips act as hard material and tool act as
soft material.
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TOOL WEAR MECHANISM:
4. Oxidation:
Oxidation mean diffuse of oxygen particle on tool face. It is also
depend surface temperature of tool and tool material.
5. Chemical decomposing:
Due to high temperature and pressure there is change in
chemical composition of tool which reduces its life.

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TYPE OF TOOL WEAR:
1. Flank wear:
Flank wear is due to abrasive action of discontinuities like debris
from built up edge etc. It wears out side and end flank of the
tool. It is occur at tool work-piece interface. This wear
predominates at low speed.
2. Crater wear:
Crater wear generally occur in machining ductile material due to
abrasion and diffusion of metal at face of tool. It is occur at face
at a short distance from cutting edge. This wear predominates at
high speed.
3. Nose wear:
Nose wear are consider as separate part of wear. It wears out the
tool corner. It is considered as separate wear because the tool
corners are very important for proper cutting of work-piece

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CONTROLLING MECHANISM

Tool wear can be reduce by:

• Proper cooling and lubricate because the major cause of tool
wear is friction and temperature rise due to friction. Lubricate
reduce friction between chips and tool which reduce tool wear
tool. It can also be reduced by using high hardness and
abrasion resistance tool and high resistance to adhesion and
diffusion.
• By protective coating.

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TOOL LIFE CRITERIA
Every device or tool has its functional life. At the expiry of which
it may function, but not efficiently. So it is also true with a
cutting tool. During use, the tool losses its material, i.e., it gets
worn out. As the wear increases, the tool losses its efficiency. So
its life has to be defined and on expiry of its life, it should be
reground for fresh use. Criteria for tool life is as follows:
• Change of quality of machined surface.
• Change in the magnitude of cutting force.
• Change in the cutting temperature.

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TOOL LIFE CRITERIA
TOOL LIFE EXPECTANCY (TAYLOR’S TOOL LIFE EQUATION):
• In 1907, F. W. Taylor developed relation between tool life and
cutting speed, temperature, by keeping feed as constant
VTn = C
• A more general form of the equation considering depth of cut
and feed rate is
VTnDxFy = C
• Where, KC = Cutting speed (m/min)
• T = Tool life (min)
• D = Depth of cut (mm)
• F = Feed rate (mm/rev)
• x, y = Exponents, that are determined experimentally for each
cutting conditions.

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n = Exponent, that depends on tool materials.
Value of n = 0.1 to 0.2; for H.S.S. tools
0.2 to 0.4; for Carbide tools
0.4 to 0.6; for Ceramic tools
C = Machining constant, found by experimentation or published
data-book. It depends on properties of tool material, workpiece
and feed rate.
OBSERVATIONS FROM THE TOOL LIFE EQUATION:

i. Tool life decreases with increase in cutting speed.

ii. Tool life also depends to a great extent on the depth of cut (D)
and feed rate (F).
iii. Decrease of tool life with increased speed is twice as great
(exponentially) as the decrease of life with increased feed.
iv. The greatest variation of tools life is with the cutting speed
and tool temperature which is closely related to cutting speed.

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FACTORS AFFECTING TOOL LIFE

The following factors play an important role in tool life:

(i) Cutting speed.
(ii) Feed rate and Depth of cut.
(iii) Hardness of workpiece.
(iv) Microstructure of workpiece.
(v) Tool material.
(vi) Tool geometry.
(vii) Type of cutting fluid and its method of application.
(viii) Nature of cutting.
(ix) Grain size of workpiece.
(x) Rigidity of workpiece machine-tool system.

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METHODS OF TOOL LIFE TESTING DATA

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Conventional

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ECONOMICS OF METAL CUTTING
As with most engineering problems we want to get the highest
return, with the minimum investment. In this case we want to
minimize costs, while increasing cutting speeds.
Cost is a primarily affected by:
- Tool life
- Power consumed

The production throughput is primarily affected by:

- Accuracy including dimensions and surface finish
- MRR (metal removal rate)

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ECONOMICS OF METAL CUTTING

The factors that can be modified to optimize the process are:

- cutting velocity (biggest effect)
- feed and depth
- work material
- tool material
- tool shape
- cutting fluid

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ECONOMICS OF METAL CUTTING

There are two basic conditions to trade off:

- Low cost - exemplified by low speeds, low mrr, longer tool life
- High production rates - exemplified by high speeds, short tool
life, high mrr

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