TOOL DESIGN (12M505)

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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TOOLS FOR DRY MACHINING - VSC-AP-SG-MECH-SW
TOOLS FOR DRY MACHINING
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
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 NITRIDES, OXIDES, 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
CVD PROCESS Vs PVD COATING PROCESS

CVD - CHEMICAL VAPOR DEPOSITION

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.

Advantages typically cited for CVD include (1) capability to deposit refractory
materials at temperatures below their melting or sintering temperatures; (2) control
of grain size is possible; (3) the process is carried out at atmospheric pressure—it
does not require vacuum equipment; and (4) good bonding of coating to substrate
surface [1].
Disadvantages include (1) corrosive and/or toxic nature of chemicals generally
necessitates a closed chamber as well as special pumping and disposal equipment;
(2) certain reaction ingredients are relatively expensive; and (3) material utilization
is low
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TOOLS FOR DRY MACHINING
Improved hot hardness after coating

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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
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

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TOOLS FOR DRY MACHINING

TOOLS FOR DRY MACHINING - VSC-AP-SG-

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MECH-SW
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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