PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar • Gill • Smid

Carbide Cutting Tools

Unit 31

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 31-2

Objectives
• Identify and state the purpose of the two
main types of carbide grades
• Select the proper grade of carbide for
various workpiece materials
• Select the proper speeds and feeds for
carbide tools
 31-3

Carbide Cutting Tools

• First used in Germany during WW II as
substitute for diamonds
• Various types of cemented (sintered)
carbides developed to suit different
materials and machining operations
– Good wear resistance
– Operate at speeds ranging 150 to 1200 sf/min
• Can machine metals at speeds that cause
cutting edge to become red hot without
loosing harness
 31-4

Manufacture of Cemented
Carbides
• Products of powder metallurgy process
– Tantalum, titanium, niobium
• Operations
– Blending
– Compaction
– Presintering
– Sintering
 31-5

Blending
• Five types of powders
– Tungsten carbide, titanium carbide, cobalt,
tantalum carbide, niobium carbide
• One or combination blended in different
proportions depending on grade desired
• Powder mixed in alcohol (24 to 190 h)
• Alcohol drained off
• Paraffin added to simplify pressing
operation
 31-6

Compaction
• Must be molded to shape and size
• Five different methods to
compact powder
– Extrusion process
– Hot press
– Isostatic press
– Ingot press
– Pill press
• Green (pressed) compacts soft, must be
presintered to dissolve paraffin
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 31-7

Presintering

• Green compacts heated to about 1500º F in

furnace under protective atmosphere of
hydrogen
• Carbide blanks have consistency of chalk
• May be machined to required shape
– 40% oversize to allow for shrinkage that occurs
during final sintering
 31-8

Sintering
• Last step in process
• Converts presintered machine blanks into
cemented carbide
• Carried out in either hydrogen atmosphere
or vacuum
– Temperatures between 2550º and 2730º F
• Binder (cobalt) unites and cements carbide
powders into dense structure of extremely
hard carbide crystals
 31-9

Cemented-Carbide Applications
• Used extensively in manufacture of metal-
cutting tools
– Extreme hardness and good wear-resistance
• First used in machining operations as lathe
cutting tools
• Majority are single-point cutting tools used
on lathes and milling machines
 31-10

Types of Carbide Lathe

Cutting Tools
• Blazed-tip type
– Cemented-carbide tips brazed to steel shanks
– Wide variety of styles and sizes
• Indexable insert type
– Throwaway inserts
– Wide variety of shapes: triangular, square,
diamond, and round
• Triangular: has three cutting edges
– Inserts held mechanically in special holder
 31-11

Reasons Indexable Inserts More

Popular than Brazed-Tip Tools
1. Less time required to change cutting edge
2. Amount of machine downtime reduced
considerable thus production increased
3. Time normally spent in regrinding
eliminated
4. Faster speeds and feeds can be used
5. Cost of diamond wheels eliminated
6. Indexable inserts cheaper than brazed-tip
 31-12

Cemented-Carbide Insert
Identification
• American Standards Association has
developed system by which indexable
inserts can be identified quickly and
accurately
• Adopted by manufacturers
• Table 31.1 in text
 31-13

Grades of Cemented Carbides

• Two main groups of carbides
– Straight tungsten carbide
• Contains only tungsten carbide and cobalt
• Strongest and most wear-resistant
• Used for machining cast iron and nonmetals
– Crater-resistant
• Contain titanium carbide and tantalum carbide in
addition to tungsten carbide and cobalt
• Used for machining most steels
 31-14

Qualities of Tungsten
Carbide Tools
• Determined by size of tungsten carbide
particles and percentage of cobalt
1. Finer the grain particles, lower the tool
toughness
2. Finer the grain particles, higher tool hardness
3. Higher the hardness, greater wear resistance
4. Lower cobalt content, lower tool toughness
5. Lower cobalt content, higher hardness
 31-15

Additive Characteristics
• Titanium carbide
– Addition provides resistance to tool cratering
– Content increased
• Toughness of tool decreased
• Abrasive wear resistance at cutting edge lowered
• Tantalum carbide
– Addition provides resistance to tool cratering
• Without affecting abrasive wear resistance
– Addition increases tool's resistance to
deformation
 31-16

General Rules for Selection of

Proper Cemented-Carbide Grade
1. Use grade with lowest cobalt content and finest
grain size
2. Use straight tungsten carbide grades to combat
abrasive wear
3. To combat cratering, seizing, welding, and
galling, use titanium carbide grades
4. For crater and abrasive wear resistance, use
tantalum carbide grades
5. Use tantalum carbide grades for heavy cuts in
steel, when heat and pressure might deform
cutting edge
 31-17

Coated Carbide Inserts

• Give longer tool life, greater productivity
and freer-flowing chips
• Coating acts as permanent lubricant
– Permits higher speed, reduced heat and stress
• Two or three materials in coating give tool
special qualities
– Innermost layer of titanium carbide
– Thick layer of aluminum oxide
– Third, very thin layer titanium nitride
 31-18

Coatings
• Titanium carbide
– High wear and abrasion resistance
(moderate speed)
– Used for roughing and finishing
• Titanium nitride
– Extremely hard, good crater resistance
– Excellent lubricating properties
• Aluminum oxide
– Provides chemical stability
– Maintains hardness at high temperatures
 31-19

Tool
Geometry
Terms adopted
by ASME

SIDE RELIEF
SIDE CLEARANCE

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 31-20

Cutting-Tool Terms

• Front, End, Relief

(Clearance)
– Allows end of cutting tool to
enter work
• Side Relief (Side)
– Permits side of tool to
advance into work

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 31-21

Cutting-Tool Terms
• Side Cutting Edge Angle
– Angle cutting edge meets work
• Positive
• Negative - protects point at start and end of cut
• Nose Radius
– Strengthens finishing point of tool
– Improves surface finish on work
– Should be twice amount of feed per revolution
• Too large – chatter; too small – weakens point
 31-22

Side Rake
• Large as possible to allow
chips to escape
• Amount determined
– Type and grade of cutting tool
– Type of material being cut
– Feed per revolution
• Angle of keenness
– Formed by side rake and side
clearance
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 31-23

Back Rake
• Angle formed between top face of tool and
top of tool shank
– Positive
• Top face slopes downward
away from point
– Negative
• Top face slopes upward
away from point
– Neutral
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 31-24

Cemented-Carbide Cutting-Tool
Angles and Clearances
• Vary greatly
• Depend on three factors
– Hardness of cutting tool
– Workpiece material
– Type of cutting operation
• May have to be altered slightly to suit
various conditions encountered
 31-25

Cutting Speeds and Feeds

• Important factors that influence speeds,
feeds, and depth of cut
– Type and hardness of work material
– Grade and shape of cutting tool
– Rigidity of cutting tool
– Rigidity of work and machine
– Power rating of machine
 31-26

Machining with Carbide Tools

• To obtain maximum efficiency
– Precautions in machine setup
• Rigid and free from vibrations
• Equipped with heat-treated gears
• Sufficient power to maintain constant cutting speed
– Cutting operation
• Cutting tool held as rigidly as possible to avoid
chatter
 31-27

Suggestions for Using

Cemented-Carbide Cutting Tools

• Work Setup
– Mount work in chuck or holding device to
prevent slipping and chattering
– Revolving center used in tailstock for turning
work between centers
– Tailstock spindle extended minimum distance
and locked securely
– Tailstock should be clamped firmly to lathe bed
 31-28

Suggestions for Using

Cemented-Carbide Cutting Tools
• Tool Selection
– Use cutting tool with proper rake and clearances
– Hone cutting edge
– Use side cutting edge angle
large enough tool can be
eased into work
– Use largest nose radius
operating conditions permit
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 31-29

Tool Setup
1. Hold carbide tool in turret-type holder
• Amount of tool overhang enough for chip clearance
2. Cutting tool set exactly on center
3. Designed to operate while bottom of tool shank
is in horizontal position
4. If rocker-type toolpost: remove rocker, invert
rocker base, shim tool to correct height, Use
special carbide toolholder (having no rake)
5. Always keep it from touching work and machine
parts to avoid damaging tool point
 31-30

Machine Setup
• Always make sure machine has adequate power
rating for machining operation and no slippage in
clutch and belts
• Set correct speed for material cut and operation
performed
– Too high cause rapid tool failure
– Too low result in inefficient cutting action
• Set machine feed for good metal-removal rate and
good surface finish
– Too light causes rubbing
– Too coarse slows down machine creates heat
 31-31

Cutting Operation
1. Never bring tool point against work that is
stationary
2. Always use heaviest depth of cut possible
for machine and size of cutting tool
3. Never stop machine while feed engaged
• Will break cutting edge
• Stop feed and allow tool to clear before
stopping machine
 31-32

4. Never continue to use dull cutting tool

5. Dull cutting tool recognized by
• Work produced oversize with glazed finish
• Rough and ragged finish
• Change in shape or color of chips
6. Apply cutting fluid only if
• Can be applied under pressure
• Can be directed at point of cutting and kept
there at all times
 31-33

Tool Selection and

Application Guide
• Table 31.7 in text lists points to follow to
obtain most efficient metal-removal rates
• Other factors affecting optimum life
– Horsepower available on machine tool
– Rigidity of machine tool and toolholders
– Shape of workpiece and setup
– Speed and feed rates used for machining
operation
 31-34

Grinding Wheels
1. 80-grit silicon carbide wheel used for
rough grinding carbides
2. 100-grit silicon carbide wheel used for
finish grinding carbides
3. Diamond grinding wheels (100-grit)
excellent for finish grinding; high finishes
use 220-grit diamond wheel
 31-35

Type of Grinder
• Heavy-duty grinder used for grinding
carbides
– Cutting pressures required to remove carbide
are 5 to 10 times as great as high-speed steel
tools
• Should be equipped with adjustable table
and protractor so necessary tool angles and
clearances may be ground accurately
 31-36

Tool Grinding
1. Regrind cutting tool to angles and clearances
recommend by manufacturer
2. Use silicon carbide wheels for rough grinding
• Use diamond wheels when high surface finishes
required
3. Move carbide tool back and forth over grinding
wheel face to keep amount of head generated to
minimum
4. Never quench carbide tools that become hot
during grinding – allow them to cool gradually
 31-37

Honing
• Remove fine, ragged edge left by grinding
wheel
– Fine, nicked edge fragile
• Suggestions for successful honing
– 320-grit silicon carbide or diamond hone
– 45º chamfer .002 to .004 in. wide honed
on cutting edge when cutting steel
– No chamfer if used for aluminum,
magnesium and plastics

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 31-38

Cemented-Carbide
Tool Problems
• Consult Table 31.8 in text for possible
causes and remedies
• Change only one thing at a time until
problem corrected