Manufacturing

Processes I
MECH1211
TEACHING AND LEARNING PLAN (TLP)
 UNIT 2 REVIEW
Lecture 01
▪ Fundamentals of Machining
▪ Mechanics of Cutting
▪ Mechanics of Chip Formation
▪ Cutting Ratio/Chip Thickness Ratio
▪ Velocities in the Cutting Zone
▪ Shear Plane, Angle, and Strain
Lecture 02
▪ Fundamentals of Machining
▪ Mechanics of Cutting
▪ Mechanics of Chip Formation
▪ Cutting Ratio/Chip Thickness Ratio
▪ Velocities in the Cutting Zone
▪ Shear Plane, Angle, and Strain
Lecture 03
▪ Cutting Temperatures
▪ Cutting Tool Geometry
▪ Tool Life
▪ Surface Finish and Integrity
 UNIT 3
Cutting Tool Materials
and Cutting Fluids
 LEARNING GOALS/TOPICS

▪ Cutting tools
▪ Inserts
▪ Coated tools
▪ Cutting fluids
 CUTTING TOOL MATERIALS
As noted in previous lectures, the cutting tool is subjected to:
▪ high temperatures
▪ high contact stresses
▪ friction along the tool-chip interface and along the machined surface

Consequently, the cutting-tool material must possess the following

characteristics:
▪ hot hardness
▪ toughness and impact strength
▪ thermal shock resistance
▪ wear resistance
▪ chemical stability and inertness

https://www.youtube.com/watch?v=DGlJs7YhVcw https://www.youtube.com/watch?v=VFBMJHdqjcs
 CUTTING TOOL MATERIALS
Hot Hardness
▪ maintains hardness, strength, and
wear resistance of the tool at the
temperatures encountered in
machining operations
▪ ensures that the tool does not
undergo any plastic deformation,
and thus retains its shape and
sharpness
▪ note how rapidly carbon tool steels
lose their hardness and how well
ceramics maintain their hardness
 CUTTING TOOL MATERIALS

Toughness and Impact Strength

▪ guards against chip or fracture of the tool due to impact forces

during interrupted cutting operations or forces due to vibration
and chatter
 CUTTING TOOL MATERIALS

Thermal Shock Resistance

▪ withstands the rapid temperature cycling encountered in

interrupted cutting
 CUTTING TOOL MATERIALS

Wear Resistance

▪ ensures that an acceptable tool life is obtained before

replacement is necessary
 CUTTING TOOL MATERIALS

Chemical Stability and Inertness

▪ This characteristic, with respect to the workpiece, avoids or

minimizes any adverse reactions, adhesion, and tool-chip
diffusion that would contribute to tool wear
 CUTTING TOOL MATERIALS
▪ A variety of cutting tool materials with a wide range of mechanical,
physical, and chemical properties have been developed.
▪ The following table lists several cutting materials.
▪ The properties listed in the first column of this table are useful in
determining desirable tool material characteristics for a particular
application.
▪ For example:
- hardness and strength are important with respect to mechanical
properties of the workpiece material to be machined
- impact strength is important in making interrupted cuts in machining
- melting temperature of the tool material is important, especially
compared to the temperature developed in the cutting zone
- thermal conductivity and coefficient of thermal expansion are important
in determining the resistance of the tool materials to thermal fatigue
and shock
CUTTING TOOL MATERIALS

General Properties of Tool Materials

 CUTTING TOOL MATERIALS

▪ Note that a particular tool material may not have all of the
desired properties for a particular operation
▪ The following table show specific trends.
▪ Note that:
- High speed steels are tough, but they have limited hot hardness
- Ceramics have high resistance to temperature and wear but they
are brittle and can easily chip
- note also that the cost of tools increases from HSS to diamond
CUTTING TOOL MATERIALS

General Characteristics of Cutting-Tool Materials

 CUTTING TOOL MATERIALS

▪ The operating characteristics of tool materials are shown on

following slide listed in the order in which they were developed
and implemented in industry
▪ Note that many of these materials are also used for dies and
molds in casting, forming, etc.
CUTTING TOOL MATERIALS

Operating Characteristics of Cutting-Tool Materials

INSERTS

https://www.youtube.com/watch?v=0QrynzJ_lZ4
 INSERTS
▪ As tools wear, tool repairing and replacing can be time consuming
▪ The need for a more effective method has led to development of inserts
▪ Inserts are individual cutting tools with several cutting points
▪ Inserts are usually clamped on the toolholder
▪ When one point of the insert is worn, it is indexed (rotated in its holder)
to make another cutting point available
 INSERTS
▪ Carbide inserts are available in a wide variety of shapes such as
square, triangle, diamond, and round
▪ The strength of the cutting edge depends on its shape.
▪ The smaller the included angle , the lower the strength of the
edge
 INSERTS
Chip Breakers Features on Inserts
▪ controls chip flow
▪ eliminates long chips
▪ reduces heat generated
▪ reduce tendency for vibration and chatter
COATED TOOLS

https://www.youtube.com/watch?v=nY6o04ODJ3U
 COATED TOOLS
▪ A large variety of new materials are generally abrasive and
chemically reactive with tool material
▪ Coated tools have been developed to address this resulting in
improved efficiencies and performance
▪ Compared with the tool materials, coatings have advantageous
properties such as:
- lower friction
- higher resistance to wear and cracking
- higher hot hardness and impact resistance
- acting as a diffusion barrier between the tool and the chip

Coated tools can last 10 times more than those uncoated, allowing for high
cutting speeds and reducing both the time required for machining
operations and production costs
 COATED TOOLS

Relative Time Required to Machine with Various Cutting-Tool Materials

 COATED TOOLS

Coatings should posses:

▪ high hardness at elevated temperatures (hot hardness)
▪ chemical stability / inertness to workpiece material
▪ low thermal conductivity
▪ compatibility and good bonding to substrate
▪ low porosity
CUTTING FLUIDS
 CUTTING FLUIDS

Cutting fluids are used extensively for

the following purposes:
▪ reduce friction and wear
▪ cooling the cutting zone
▪ reduces force and energy
consumption
▪ flush away chips
▪ protect surfaces from environmental
corrosion

https://www.youtube.com/watch?v=-o5luQ5Tw80
 CUTTING FLUIDS

Depending on the type of machining operation, the cutting fluid

needed may be:
▪ coolant
▪ lubricant
▪ both
 CUTTING FLUIDS
The necessity of cutting fluid depends on the severity of the
machining operation defined as:
▪ The temperature and forces encountered and the ability of the tool
materials to withstand them
▪ The tendency for built-up edge formation
▪ The ease with which chips produced can be removed from the cutting
zone
▪ How effectively the fluids can be supplied to the proper region at the
tool-chip interface
 CUTTING FLUIDS
Types of Cutting Fluids
▪ Oils (straight oils):
- include minerals, animal, vegetable, compounded, and synthetic oils
- typically used for low speed operations where temperature rise is not
significant
▪ Emulsions (soluble oils)
- mixture of oil and water, with additives
- generally used for high-speed operations where temperature rise is
significant
▪ Semi-synthetics
- chemical emulsions containing little mineral oil, diluted in water, and
additives that reduce oil particle size
▪ Synthetics
- chemicals with additives, diluted in water, and containing no oils
 CUTTING FLUIDS
Cutting Fluid Application
There are four basic methods of cutting fluid applications:
1. Flooding - most common method
2. Mist - supplies fluids to inaccessible areas
3. High Pressure Systems – high pressure refrigerated coolant
systems particularly effective for excessive heat removal
4. Through the Cutting Tool System – for more effective
applications, narrow passages can be produced in cutting tools,
as well as tool holders, through which cutting fluids can be
supplied under high pressure
 CUTTING FLUIDS
Effects of cutting fluid:
The selection of cutting fluid should include considerations such as its
effects on:
▪ workpiece material
▪ machine tool components
▪ biological considerations
▪ the environment

Much progress has been made in ensuring the safe use of cutting fluids
in manufacturing facilities, including reducing or eliminating their use by
considering the more recent trends in dry or near-dry machining
techniques as well as in the design of machine tools with enclosed
working areas
 CUTTING FLUIDS
Cutting fluids have been used for a very long time and with great
success but there are inherent problems, including:
▪ cost of buying, maintaining and disposing of cutting fluid, which is
estimated to account for 7 to 17 percent of the cost of machining.
▪ need to clean parts after machining and to remove as much fluid as
possible from chips before recycling
▪ health problems from handling or working around conventional
coolants include skin irritation or allergic reactions, asthma,
bronchitis and other respiratory difficulties. It’s possible that long-
term exposure to some coolant additives could lead to cancer.
 CUTTING FLUIDS
Competitive cost pressures and increasingly stringent environmental
and occupational health standards are inspiring some shops to seek
ways to minimize or eliminate their use of cutting fluids.

They are finding that dry, near-dry, and other techniques offer benefits
far beyond simply reducing their cutting fluid costs.

Advanced cutting tool materials, coatings and designs, along with a

variety of strategies for lubrication, cooling and chip removal, make it
possible to achieve the same or better results with dry or MQL
machining: shorter cycle times, better surface finish, longer tool life,
and higher recycling value for clean chips.
 CUTTING FLUIDS

Near-Dry Machining

The practice of “near-dry machining” (NDM) or “minimum-quantity

lubrication” (MQL)” has significant benefits such as:
▪ alleviating the environment; impact of using fluids, improving air quality
and reducing health hazards
▪ reducing the cost of machining operations, including the cost of
maintenance, recycling, and disposal of cutting fluid

https://www.youtube.com/watch?v=aP3glc4HoWg https://www.youtube.com/watch?v=uoqDMPzSyGU
 CUTTING FLUIDS
Dry Machining

Some materials have always been machined dry – magnesium, for

example, reacts with water, so common coolants are incompatible
with it.
Dry cutting has also long been used with materials such as cast
iron where what you create is a dust, not chips
Adding cutting fluids would create sludge and therefore dry cutting
is a better method
 CUTTING FLUIDS
With the right combination of work material and tool, cutting fluids
can be avoided and, in turn, increase the spindle speed and feed
rate. In fact, some materials can be cut faster dry than with cutting
fluid.
Companies and universities are conducting research to understand
dry machining, including the behavior of materials at the tool/work
interface, performance of the coatings, and the heat generated and
how it affects surface finish and tool life.
 RECAP/SUMMARY

▪ Cutting tools
▪ Inserts
▪ Coated tools
▪ Cutting fluids
 WEEK 3 CHECKLIST OF ACTIVITIES

ACTIVITIES DESCRIPTION CHECKBOX

Reading Assignment: Read Chapter 22: “Cutting Tool Materials and Cutting
Activity 1 Fluids” and answer questions as per the instructions

Activity 2 View lecture video(s) and review lecture presentation

Activity 3 Test 3 (covers Unit 3 content)

Activity 4 Unit 3 reading Assignment

3
9
NEXT STEPS