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The Temperature Rise:: Lecture Nineteen - 2
The Temperature Rise:: Lecture Nineteen - 2
The Temperature Rise:: Lecture Nineteen - 2
Tool Wear:
Tool wear causes the tool to lose its original shape, so that in time the tool ceases to cut
efficiently or even fails completely.
Gradual wear occurs at two principal locations on a cutting tool: the top rake face and
the flank.
Accordingly, two main types of tool wear can be distinguished: crater wear, flank wear
& nose wear, as illustrated in Figure (5).
Figure 5: Diagram of worn cutting tool, showing the principal locations and types of wear that occur.
Crater wear:
It consists of a cavity in the rake face of the tool that forms and grows from the action of the
chip sliding against the surface. High stresses & temperatures characterize the tool–chip
contact interface, contributing to the wearing action.
Flank wear:
It occurs on the flank, or relief face, of the tool. It results from rubbing between the newly
generated work surface and the flank face adjacent to the cutting edge.
Nose radius wear:
This type occurs on the nose radius leading into the end cutting edge.
Tool Life:
Tool life may be defined as the effective cutting time between re-sharpening. When the wear
reaches a certain value the tool is not capable of further cutting unless it is re- sharpened.
The general relationship of tool wear versus cutting time is shown in Figure (6).
Three regions can usually be identified in the curve.
The first is the break-in period, in which the sharp cutting edge wears rapidly at the
beginning of its use within the first few minutes of cutting.
The second is a uniform rate of wear called the steady-state wear region. It is shown as
a linear function of time.
Finally, wear reaches a level at which the wear rate begins to accelerate. This marks
the beginning of the failure region, in which cutting temperatures are higher, and the
general efficiency of the machining process is reduced.
Q1: Tool life tests on a lathe have resulted in the following data: (1) at a cutting speed of (
160 m/min ), the tool life was ( 5 min ); (2) at a cutting speed of ( 100 m/min ), the tool life was
( 41 min. ). Determine the parameters ( n and C ) in the Taylor tool life equation.
Solution:
Using the Taylor tool life equation:
𝑽 . 𝑻𝒏 = 𝑪
With the following data, [ V = 160 m/min. and T = 5 min.], we can obtain the following
equation:
……. ( 1)
With the following data, [ V = 100 m/min. and T = 41 min.], we can obtain the following
equation:
..….. ( 2 )
Setting the left-hand sides of each equation ( 1 & 2 ) to be equal, we will get:
Solving the above equation for the parameter ( n ), then ( n ) will have the value of:
Substituting this value of ( n ) into either starting equation, we obtain the value of ( C ):
Or,
The Taylor tool life equation for the data of the above test is therefore:
𝑽 . 𝑻𝟎.𝟐𝟐𝟑 = 𝟐𝟐𝟗
Q2: The following equation for tool life was obtained for H. S. S. tool, which is:
𝑽 . 𝑻𝟎.𝟏𝟑 . 𝒇𝟎.𝟔 . 𝒅𝟎.𝟑 = 𝑪
A tool life of ( 60 min. ) was obtained by using the following cutting condition, which are:
V = 40 m/min., f = 0.25 mm., and d = 2 mm.
Calculate the effect on the tool life if the speed ( V ), feed ( f ) and the depth ( d ) are all
together increased by ( 25 % ), and calculate also the effect of tool life if each of the above
parameter ( V, f and d ) are individually increased by ( 25 % ).
Solution:
From the above given data, the constant ( C ) can be obtained to be:
𝑽 . 𝑻𝟎.𝟏𝟑 . 𝒇𝟎.𝟔 . 𝒅𝟎.𝟑 = 𝑪
𝑪 = 𝟒𝟎 ∗ 𝟔𝟎𝟎.𝟏𝟑 ∗ 𝟎. 𝟐𝟓𝟎.𝟔 ∗ 𝟐𝟎.𝟑 = 𝟑𝟔. 𝟒𝟐
In this problem, we have two cases:
Case ( 1 ):
the first case when each of following parameters are increased all together by ( 25 % ), that
means the cutting speed ( V ) is increased by ( 25 % ) to become:
𝑽𝟏 = 𝟒𝟎 ∗ 𝟏. 𝟐𝟓 = 𝟓𝟎 𝒎⁄𝒎𝒊𝒏.
The feeding ( f ) is increased by ( 25 % ), to become:
𝒇𝟏 = 𝟎. 𝟐𝟓 ∗ 𝟏. 𝟐𝟓 = 𝟎. 𝟑𝟏𝟐𝟓 𝒎𝒎
And the depth of cutting ( d ) is also become:
𝒅𝟏 = 𝟐 ∗ 𝟏. 𝟐𝟓 = 𝟐. 𝟓 𝒎𝒎
Substituting, the above values in the tool life equation to obtain:
𝑽 . 𝑻𝟎.𝟏𝟑 . 𝒇𝟎.𝟔 . 𝒅𝟎.𝟑 = 𝑪
𝟓𝟎 ∗ 𝑻𝟎.𝟏𝟑 ∗ 𝟎. 𝟑𝟏𝟐𝟓𝟎.𝟔 ∗ 𝟐. 𝟓𝟎.𝟑 = 𝟑𝟔. 𝟒𝟐
𝟑𝟔. 𝟒𝟐
𝑻𝟎.𝟏𝟑 = = 𝟏. 𝟏𝟎𝟔
𝟑𝟐. 𝟗
𝑻 = 𝟐. 𝟏𝟕 𝒎𝒊𝒏.
Case ( 2 ):
In this case, each of the above parameters are increased individually by ( 25 % ), that means
we have here three tests where is done separately as follows:
a) When the cutting speed is increased lonely by ( 25 % ) to become ( 50 m/min. ), and the
other parameters, the feed ( f ) and the depth ( d ) are kept the same ( 0.25 mm and 2
mm ) respectively:
𝑽 . 𝑻𝟎.𝟏𝟑 . 𝒇𝟎.𝟔 . 𝒅𝟎.𝟑 = 𝑪
𝟎.𝟏𝟑
𝟓𝟎 ∗ 𝑻 ∗ 𝟎. 𝟐𝟓𝟎.𝟔 ∗ 𝟐𝟎.𝟑 = 𝟑𝟔. 𝟒𝟐
𝟑𝟔. 𝟒𝟐
𝑻𝟎.𝟏𝟑 = = 𝟏. 𝟑𝟒
𝟓𝟎 ∗ 𝟎. 𝟒𝟑𝟓 ∗ 𝟏. 𝟐𝟑
𝑻 = 𝟗. 𝟕𝟑 𝒎𝒊𝒏.
b) When the feed ( f ) is increased lonely by ( 25 % ) to become ( 0.3125 mm ), and the
other parameters, the cutting speed ( V ) and the depth ( d ) are kept the same ( 40
m/min. and 2 mm ) respectively:
𝑽 . 𝑻𝟎.𝟏𝟑 . 𝒇𝟎.𝟔 . 𝒅𝟎.𝟑 = 𝑪
𝟒𝟎 ∗ 𝑻𝟎.𝟏𝟑 ∗ 𝟎. 𝟑𝟏𝟐𝟓𝟎.𝟔 ∗ 𝟐𝟎.𝟑 = 𝟑𝟔. 𝟒𝟐
𝟑𝟔. 𝟒𝟐
𝑻𝟎.𝟏𝟑 = = 𝟏. 𝟓𝟏𝟕
𝟒𝟎 ∗ 𝟎. 𝟓 ∗ 𝟏. 𝟐𝟑
𝑻 = 𝟐𝟒. 𝟖 𝒎𝒊𝒏.
c) When the depth ( d ) is increased lonely by ( 25 % ) to become ( 2.5 mm ), and the other
parameters, the cutting speed ( V ) and the depth ( f ) are kept the same ( 40 m/min.
and 0.25 mm ) respectively:
𝑽 . 𝑻𝟎.𝟏𝟑 . 𝒇𝟎.𝟔 . 𝒅𝟎.𝟑 = 𝑪
𝟒𝟎 ∗ 𝑻𝟎.𝟏𝟑 ∗ 𝟎. 𝟐𝟓𝟎.𝟔 ∗ 𝟐. 𝟓𝟎.𝟑 = 𝟑𝟔. 𝟒𝟐
𝟑𝟔. 𝟒𝟐
𝑻𝟎.𝟏𝟑 = = 𝟏. 𝟔𝟏
𝟒𝟎 ∗ 𝟎. 𝟒𝟑𝟓 ∗ 𝟏. 𝟑
𝑻 = 𝟑𝟗. 𝟏𝟓 𝒎𝒊𝒏.
It appears that the significant effect on the tool life when all of these parameters together are
increased by ( 25 % ) to reduce the tool life to ( 2.17 min. ).
But, when each of these parameters are increased individually, the most significant effect is
utilized when the cutting speed is increased by ( 25 % ) to reduce the tool life to ( 9.73 min.),
the lowest effect is obtained when the depth ( d ) is increased by ( 25 % ) to reduce the tool life
to ( 39.15 min. ).
Assistant professor Sahib M.Mahdi
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