Manufacturingtechnology

Chapter3 TOOLWEARANDTOOLLIFE

2/6/2013

ProfDrAdelM.AbdelmaboudManuf.TechnologyChapter3ToolwearandToolLife

References
1 Kalpakjian 1. Kalpakjian,S S.and andSchmidt Schmidt,S. S R R.,2002, 2002 ManufacturingProcessesforEngineering Materials,PrenticeHall, Hall UpperSaddleRiver, River NJ. 2 MPGroover, 2. Groover FundamentalsofModern Manufacturing 3/e2007JohnWiley&Sons, Inc. Inc

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TOOLWEARANDTOOLLIFE

Introduction
Thelifeofacuttingtoolcanbeterminatedby anumberofmeans.

Twomaincategories g oftoollife:
1. Gradualwearingofcertainregionsofthe faceandflankofthecuttingtool tool,and 2. Abrupttoolfailure.
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TOOLWEARANDTOOLLIFE

Case(1) Gradualwearingofcertain
regions i of fthe h f faceand dfl flank kof fthe h cuttingtool),
The life of a cutting tool is therefore determined by the amount of wear that has occurred on the h tool l profile fil and d which hi h reduces d the h efficiency of cutting to an unacceptable level, or eventually causes tool failure (Case2 ) { Abrupt tool failure.}
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TOOLWEARANDTOOLLIFE
Whenthetoolwearreachesaninitiallyaccepted amount,there h areTwo T options, ti 1. toresharpenthetoolonatoolgrinder,or 2. toreplacethetoolwithanewone.This secondpossibilityappliesinTwocases, (i) whentheresourcefortoolresharpeningis exhausted or exhausted. (ii) (ii)thetooldoesnotallowforresharpening
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Wearzones
Gradualwearoccursatthreeprincipallocation onacutting i tool. l Accordingly,threemaintypesoftoolwearcan bedistinguished, 1. craterwear 2. flankwear 3 cornerwear 3.

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ProfDrAdelM.AbdelmaboudManuf.TechnologyChapter3Toolwearand ToolLife

Craterwear
Crater wear: consists of a concave section on the tool l face f f formed d by b the h action i of f the h chip hi sliding lidi on the surface. Crater wear affects the mechanics of the process increasing the actual rake angle of the cutting tool and consequently, making g cutting g easier. At the same time, the crater wear weakens the tool wedge and increases the possibility for tool breakage. In general, crater wear is of a relatively small concern.
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Flankwear
Flankwear: occurs on the tool f flank as a result of ff friction between the machined surface of the workpiece and the tool flank. Flank wear appears in the form of socalled wear land and is measured by the width of this wear land, VB OR (FW), flank wear affects to the great extend the mechanics of cutting. Cutting forces increase significantly with flank wear. If the h amount of f flank fl k wear exceeds d some critical i i l value l (VB > 0.5~0.6 mm), the excessive cutting force may cause tool failure.
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Cornerwear
Cornerwear: occurs on the tool corner. Can be considered as a part of the wear land and respectively flank wear since there is no distinguished boundary between the corner wear and flank wear land. We consider corner wear as a separate wear type because of its importance for the precision of machining. Corner wear actually shortens the cutting tool thus increasing gradually the dimension of machined surface and introducing a significant dimensional error in machining, which can reach values of about 0.03~0.05 mm.

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1-Flank wear

Rapid flank wear causing poor surface finish or out of tolerance.

Solution 1. Reduce the cutting speed. Select a more wear resistant grade. grade 2. Select an Al2O3 coated grade. 3. For work-hardening materials, select a smaller entering angle or a more wear resistant grade.

Cause: Cutting speed too high or insufficient wear resistance.

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2-Notch wear

Notch wears causing poor surface finish and risk of edge breakage. breakage

Cause

a) Oxidation b) Attrition

S l i Solution

a) Select a cermet grade b) Reduce the cutting speed. (When machining heat resistant material with ceramics, increase cutting speed)

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3-Crater wear

Excessive crater wear causing a weakened edge. Cutting edge breakthrough on the trailing edge causes poor surface finish. Risk of insert breakdown. breakdown

Cause

Diffusion wear due to cutting temperatures that are too high on the rake face. Select an Al2O3 coated grade. Select positive insert geometry. First reduce the speed to obtain a lower temperature, First, temperature then reduce the feed
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Solution

4-Plastic deformation

Plastic deformation. Edge depression or flank impression. Leads to poor chip control and poor surface finish. Risk of excessive flank wear leading to insert breakage.

Cause

Cutting temperature is too high, high combined with a high pressure. pressure

Solution

Select a harder grade with better resistance to plastic deformation. g depression p reduce feed. Edge Flank impression reduce speed.
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5-Built-up

edge (B.U.E.)

Built-up edge causing poor surface finish and cutting edge frittering when the built-up edge is torn away.

Cause

Workpiece material is welded to the insert due to: a) ) Cutting C tti th that ti is too t low. l b) Negative cutting geometry. c) Adhesive workpiece material.

Solution

a) Increase the cutting speed or cool heavily. b) Select a positive geometry. Reduce feed at the beginning of the cut. c) Select a thin coated PVD grade and a positive geometry.
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6-Chip hammering

The part of the cutting edge not in cut is damaged through chip hammering hammering. Both the top side and the support for the insert can be damaged.

Cause

The chips are deflected against the cutting edge. edge

Solution

Change the feed. Select alternate insert geometry or change to a tougher grade
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7-Frittering

Small S ll cutting i edge d fractures f (frittering) (f i i ) causing i poor surface f finish fi i h and excessive flank wear.

Cause

a) Grade is too brittle b) Insert geometry is too weak c) Built-up edge

Solution

a) ) Select tougher g g grade. b) Select an insert with a stronger geometry (bigger chamfer for ceramic inserts). c) Increase the cutting speed or select a positive geometry. Decrease the cutting g speed p and coolant. Reduce feed at the beginning of the cut.
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8-Thermal cracks

Small cracks perpendicular to the cutting edge causing frittering and poor surface finish. finish

Cause

Thermal cracks due to temperature variations caused by: ) Intermittent machining g a) b) Varying coolant supply

Solution

a) Select a tougher grade with better resistance to crack propagation ti b) Coolant should be applied copiously, or not at all
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9-Insert breakage

Insert breakage that damages not only the insert but also the shim and workpiece.

Cause

a) Grade is too brittle b) Excessive load on the insert c) Insert geometry is too weak d) Insert size is too small

Sol tion Solution

a) Select a tougher grade. b) Reduce the feed and/or the depth of cut. c) Select a stronger geometry, geometry preferably a single-sided insert. insert d) Select a thicker/larger insert
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10-Slice fracture - ceramics

Cause

Excessive tool pressure

Solution

Reduce the feed Select a tougher grade Select an insert with a smaller chamfer, or use another geometry to change cutting force direction
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Toollife
ThreeModesofToolFailure
1. Cutting gforceisexcessiveand/or / dynamic,leadingtoBrittleFracture. 2. Cuttingtemperatureistoohighforthe toolmaterialleadingThermalFailure. 3. GradualWearingofthecuttingtool

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GradualWearMode
GradualWearMode Gradualwearoccursattwolocationsonatool:

1. Craterwearoccursontoprake k f face 2. Flankwearoccursonflank(sideoftool)

Craterwear

flankwearonacemented carbidetool, Diagramofworncuttingtool tool,showingtheprincipallocationsandtypesof wearthatoccur

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ToolWearMechanisms
1. Adhesion wear: Fragments g of f the workp piece g get welded to the tool surface at high temperatures; eventually, they break off, tearing small parts of the tool with them. 2. Abrasion: Hard particles, microscopic variations on the bottom surface of the chips rub against the tool surface and break away a fraction of tool with them. 3 Diffusion wear: At high temperatures, 3. temperatures atoms from tool diffuse across to the chip; the rate of diffusion increases exponentially with temperature; this reduces the fracture strength of the crystals
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ToolLife
ToolLife Toolwearisatimedependentprocess process.As cuttingproceeds,theamountoftoolwear increasesgradually gradually. Toolwearmustnotbeallowedtogobeyonda certainlimitinordertoavoidtoolfailure. failure Toollifeisdefinedasthetimeintervalforwhich toolworkssatisfactorilybetweentwosuccessive grindingorresharpeningofthetool.
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ToolLife

Toolwearasafunctionofcuttingtime Flankwear(FW)isusedhereasthemeasureoftoolwear Craterwearfollowsasimilargrowthcurve

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TaylorToolLifeEquation
TaylorToolLifeEquation where: n v =cuttingspeed,m/min; VT = C T =toollife,min;and n andC areparametersthatdependon feed,depthofcut,workmaterial,and toolingmaterial,butmostlyonmaterial (workandtool).

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TaylorToolLifeEquation
TypicalValuesofnandC Toolmaterialn C (m/min) 1Highspeedsteel: Nonsteel work 0.125 120 Steel work 0.125 70 2Cementedcarbide N steel Non t lwork k0.25 0 25900 Steelwork0.25500 3Ceramic Steelwork0.63000

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Effectofcutting gspeed p ontoolflankwear

Effectofcuttingspeedontoolflankwear(FW)forthreecutting speeds,usingatoollifecriterionof0.50mmflankwear
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Effectofcuttingspeedontoolflankwear

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ToolNearEndofLife
Changesinsoundemittedfromoperation Chipsbecomeribbonlike,stringy,anddifficultto disposeof Degradationofsurfacefinish Increasedpowerrequiredtocut Visualinspectionofthecuttingedgewith magnifyingopticscandetermineiftoolshouldbe replaced.
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