THE SELECTION OF CUTTING TOOL MATERIAL AND GEOMETRY FOLLOWEDBY THE SELECTION OF CUTTING CONDITIONS FOR AGIVEN APPLICATION

N DEPENDS ON MANY VARIABLES. Cutting tool is any tool that is used to remove material from the work piece by means of shear deformation. Cutting tools must be made of a material harder than the material which is to be cut, and the tool must be able to withstand the heat generated in the metal-cutting process. High-speed steels and cemented carbides are currently the most extensive used tool materials. High-speed steels retain its cutting ability at temperatures up to 1100F, and can operate at about double the cutting speed. Cast cobalt alloys are hard as cast and cannot be softened. Carbides, these tool materials are much harder and chemically stable; they have better hot hardness, high stiffness and lower friction and they operate at higher cutting speeds. Ceramics resist cratering, usually require no coolants. Diamond is the hardest material known. They have high hardness, good thermal conductivity, the ability to form a sharp edge of a cleavage, very low friction, no adherence to most materials, the ability to maintain sharp edge for a long period of time and good wear resistance. Cubic boron nitride retains its hardness at elevated temperatures and has low chemical reactivity at the pool or chip interface. When selecting cutting tools for a given application, the following cutting condition should be considered; temperature and high local stresses. The cutting tool must have the below characteristics; 1. High hardness 2. High hardness temperature, hot hardness 3. Resistance to abrasion, wear due to sliding friction 4. Chipping of the cutting edges 5. High toughness (impact strength) 6. Strength to resist bulk deformation 7. Good chemical stability (inertness or negligible affinity with the work material) 8. Adequate thermal properties 9. High elastic modulus (stiffness) 10. Correct geometry and surface finish. Also, the tool must have a specific geometry, with clearance angles designed so that the cutting edge can contact work piece without the rest of the tool dragging on the work piece for cutting tools, geometry depends mainly on the properties of the tool material and the work material. The most important angles are 1. Back rake angle The back rake angle affects the ability of the tool to shear the work material and form the chip. When machining hard work materials, the back rake angle must be small. If the back rake angle is too large, the strength of the tool is reduced as well as its capacity to reduce heat.

2. Relief angles These mainly affect the tool life and the surface quality of the work piece. To reduce the deflections of the tool and the work piece and to provide good surface quality, larger relief values are required for high speed steel, relief angles in the range of 5-10 degrees are normal. For carbides they are lower to give added strength to the tool.

CUTTING CONDITIONS

CUTTING SPEED The cutting speed (v) is the speed at which the cutting edge travels relative to the machined surface of the work piece It depends on material composition and geometry of the tools. These can have independent impact on cutting speed. Below are the geometrical and material factors of cutting tools; 1. Material Hardness (depends on the amount of carbon and iron) of a cutting tool is directly proportion to the cutting speed. For instance, High stainless steel its hard, thus has double cutting speed. 2. Geometry The most important angle to consider when selecting a cutting tool is the rake angle and side relief angle. If the back rake angle is too large, the strength of the tool is reduced as well as its capacity to reduce heat, hence low speed. As for side

FEED RATE The feed rate is the distance advanced by the cutting tool relative to the machined surface in a direction which is usually normal to the cutting speed (how fast a lathe tool should move through the material being cut). Its units can be mm/cycle depending on the type of the machining operation and the tool used. Feed rates will decrease with dull (geometry factor) tools a lack of coolant or deeper cuts. The feed rate will also depend on the material of the cutting tool such that the cutting tool made from weaker material has to have a slower feed rate. DEPTH OF CUT The depth of cut (t) is the normal distance from the original surface before machining to the machined surface. The depth of chip taken by cutting tool and one-half total removed from work piece in one cut

Only one roughing and one finishing cut.

TOOL MATERIALS Tool materials should possess the following properties. Retain its hardness at elevated temperatures. High near resistance. High resistance to withstand vibrations and stocks due to intermittent cutting. Low coefficient of friction in order to avoid excessive temperature rise due to friction at the tool chip interface. High thermal conductivity in order to absorb the heat generated during cutting.

VARIABLES TO BE CONSIDERED WHEN SELECTING CUTTING TOOLS Work material Type of cut: roughing vs. finishing. Lot size: small batch vs. mass production. Machinability data i.e. tool life. Quality capability needed. Part geometry and size.

Lot size- the number of parts created during the use of a particular tooling setup. The smaller your lot size, the more flexible you can be when it comes managing your trades. The quantity of the job will determine how much cutting speed, feed rate should be applied, and how long should the cuts be made through the working. The more the job to be produced the higher the cutting speed, feed rate and the long the depth of cuts. Since the cutting tool will be subjected to high temperature, local stresses, the cutting tool material should have high hardness and resistance to abrasion. The geometrical structure of the tool should be very sharp so that as the depth of cut increases the cutting tool should be flexible during the operation. Machinability The principal definitions of a term are entirely different, the first based on material properties, the second based on tool life and Tool life

The tool cannot cut effectively for an unlimited following are the factors influencing tool life. 1. Cutting speed When the cutting speed increases, the cutting temperature increases. Due to this, hardness of the tool increase. 2. Feed and depth of cut The tool life depends upon the amount of material removed by the tool per minute. For a given cutting speed, if the feed or depth of cut is increased, tool life will be reduced. 3. Tool geometry Large rake reduces the tool cross-section. Area of the tool which will absorb heat is reduced so the tool will become weak. Type of cut When selecting a cutting tool depending on a type of cut as a variable, tools of different geometry have to be selected. Orthogonal cutting is that type of cutting where the straight cutting edge of the Wedge-shaped cutting tool is at right angle to the direction of cutting. Oblique cutting is that type of cutting where the straight cutting edge of the wedgeshaped cutting tool is not at right angle to the direction of cutting. When you want to make a deep cut then the tool selected should be able to increase its feed rate and cutting speed. Work material When the work material is hard the selected cutting tool should be harder than the material and should have angles which work on those materials. If the material is hard the cutting speed should be low as well as feed rate and the depth of cut should

REFERENCE
JT. Black, Materials & Process in Manufacturing, 10th edition, 2008. www.kassel.de/upress/online A textbook of manufacturing technology: (manufacturing processes) by R.K Rajput. Metal forming processes by Dr Pulak M pandey.

FACULTY OF EDUCATION AND MEDIA STUDIES

DEPARTMENT OF TECHNICAL EDUCATION

COURSE COURSE CODE TITLE SUBMITTED BY

: PRODUCTION TECHNOLOGY : PRD-231 : METAL LATHE : STEVEN CHINKHUKU (013), DICKSON M.MPINGANJIRA (054),JOANA MBEWE(046), JUDITH PHIRI (063), CAROLYN LUMBALU (34), TUMBIKANI GADAMA(019), MPHATSO MKANDIRA (028), ROBIN SAMSON (064), BRIGHT CHIDZUMENI (009) : MR R.K MGAWI : 18TH OCTOBER, 2012

SUBMITTED TO DUE DATE