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INTRODUCTION:
C[1] thus can be used at higher
Over the years the economic competition in the cutting speed and at elevated temperature. Ceramics
field of manufacturing industries has increased a lot aids in increasing the production and lowering cost.
and metal cutting forms the basis of industrial Ceramics provide good surface finish .However
engineering as a result lot of researchers are owing to brittleness and lack of strength their
motivated in the field of metal cutting. A wedge application was limited .UCON a new material
shaped tool is constrained to move relative to the consisting of Tungsten ,Columbium and Titanium
work piece and metal is removed in the form of chips. was introduced. It was developed by Union Carbide
Properties of cutting tool material and tool geometry ,USA. UCON cuts very cool. It has excellent thermal
have considerable influence on the tool wear, which shock resistance, high hardness and toughness.
causes a tool to lose its original shape and has adverse UCON is primarly recommended for roughing and
effect in production. Also for assessing the finishing cuts in turning, facing and boring. Next to
UCON, Diamond of various forms comes which
because of exponentially high hardness, inertness and
modulus of elasticity found to be ideal material for and tools. There are two groups of carbides available
obtaining fine surface finish and accuracy. But for machining tungsten carbide and titanium carbide.
Diamond is extremely brittle also it starts to oxide at Titanium carbide have higher wear resistance but
a temp C[1] .Further to improve lacks in toughness. For machining steels, cast irons
shock and to increase strength polycrystalline and abrasive non-ferrous materials mostly uses
diamond has been introduced. Problem of oxidation tungsten carbide. It is used for machining at higher
has been overcome with the introduction of Cubic speed as compared to tungsten carbide.
Boron Nitride. It was successfully used for grinding
wheel on High Speed Steel which provides better 5. Cermets: Cermets contain 30% Titanium and 70%
surface finish and higher output. Aluminum oxide. [2]
CUTTING TOOL MATERIAL 6. Ceramics : Ceramics are hard and have high
degree of compressive strength till a temperature of
The tool is a wedge shape material. The main 1400°C and their strength is becomes uniform at
requirement of tool is hardness .It must be hard to 1200°C. Ceramics are highly reactive on the work
resist forces during cutting, applied to the work piece. piece. Ceramics are used in the applications where
Hot hardness, thermal conductivity, toughness, wear good surface finish is a requirement .Ceramics
resistance and specific heat, coefficient of friction are permits higher cutting speed than Carbide.
the other requirement of a tool material. The different
materials for cutting tool are (a) Alumina : There are two classes available for
cutting tools: Fine grained Aluminium oxide of high
1. Carbonsteels: Carbon generally varies from 0.6 % purity and Silicon nitride , these are pressed into tip.
to 1.5 %[1] and hardened to about 62Rc.[2]Properties These tips have high abrasion resistance, hot hardness
varies with the change in carbon percentage. At low and more chemical resistance as compared to HSS,
carbon content, tools are tough and shock resistant but low in toughness. Cutting speed varies from 150-
whereas at high carbon content they are abrasive 650m/min.
resistant. But carbon steel start to soften at a
temperature of 180°C.[2] Therefore such tools are (b) Silicon Nitride : Silicon Nitride have affinity for
operated at low cutting speed and take only light iron and it is not suitable for machining steels.
loads. They are widely used for woodworking.
7. Cubic Boron Nitride: Boron has a hexagonal
2. High Speed Steel: They were developed to cut at structure but on heating in the presence of catalyst it
higher speed as compared to carbon steel which is get converted into cubic structure, which is very hard
about 28-30 m/min. and are most highly alloyed tool and it is the second hardest material after diamond. It
steel tools. It contain 12-18 % Tungsten, 4% is chemically inert. CBN is used in the form of solid
Chromium and 1-5 % Vanadium. Most of grade tips or as a thick layer of polycrystalline boron nitride
contain 0.5% Molybdenum and some other contain 4- which is sintered carbide substrate under pressure.
12% Cobalt.[2] Later it was found that Molybdenum CBN coated tools are widely used for machining
can be used as a substitute for Tungsten, which stainless steel and high speed steel.
results in better abrasion resistance. There cutting
edge can withstand at a temperature of 600°C. 8. Diamond: It is the hardest substance known, its
HSS tools are tough and therefore is much suitable hardness value is about 7500HV and cutting speed is
for interrupted cutting. HSS are used to manufacture nearly 1000m/min. A single diamond crystal is brittle
drills, reamers, taps, dies and gear cutters. and it needs to be mounted at correct crystal
orientation. Single crystal diamond tool is replaced by
3. Cast Cobalt alloys: It contain about 40-55 % of polycrystalline diamond in which small synthetic
Cobalt, 30% Chromium and 10-20 % Tungsten.[2] crystal is fused at high temperature and pressure to a
Addition of Cobalt with Tungsten and Chromium thickness of between 0.5-1 mm[2] and bounded to a
forms an alloy which has properties of higher wear carbide substrate. It is mostly used for finishing at
resistance, red hardness, toughness. Maximum any speed mainly at high for machining of aluminum-
hardness values varies from 55 to 64Rc. Cast Cobalt silicon, composites and other metallic materials.
alloys has better wear resistance but lacks in
toughness. 9. UCON: UCON is developed by Union carbide,
USA and it is a material. It has a composition of 50%
4. Carbides: Carbides are known as cemented or Columbium, 30% Titanium.[1] UCON has excellent
sintered carbides. Maximum cutting speed is high hardness, toughness and possess high thermal
150m/min. For such type of tool carbide chip is made shock resistance. Cutting range varies from 250 to
by powder metallurgy and then it is fixed over the 500m/ min. Its edge life is 3-5 times than that of
tool by brazing. They have high hardness and high Carbides.
thermal conductivity and hence used for making dies
Base :
Face :
Flank :
Cutting Edge :
10. Coatings: Coatings are applied to carbide tool tips
to enable higher cutting speed. Some mostly used Cutting edge separates chip from the work piece. The
materials for coating are nitride and carbide of cutting edge consists of side cutting edge , the nose
titanium and oxide of aluminium and thickness varies and the cutting edge.
from 2-15 micro-m .
In a study, six different model of cutting tool have
taken having edge radii (0.01,0.05,0.1,0.15,0.2 and
0.25)mm and the effect on cutting forces , stress
PRINCIPLE OF METAL CUTTING distribution were studied at rake face and tool chip
contact length was summarized. The optimum edge
The chip formation process in the cutting of brittle radius which was found is 0.05 mm because for this
and elastic-plastic work piece material is considered radius the value for stress is minimum .Also it is
as a result of the dynamic interaction of the system observed during analysis if the cutting edge is 0.01
components. The system consideration reveals that: mm , the tangential and feed force is minimum [3].
Tool geometry takes its approach with the basic tool Neck :
angle. A single point cutting tool has only one cutting
edge and is most widely used in machining operation Neck is small cross section behind the point.
and there are two forms of such tool , in one form it is
solid tool and in other form it is tipped tool. TOOL ANGLES:
Size is determined by height , width and overall It is also called lead angle or principal angle. Side
length of tool. cutting edge angle is the angle between side of
cutting of cutting edge and tool shank.
Shank :
End cutting edge :
It is the main body of tool on which the cutting edge
is formed and it is generally analyzed for strength and It is the angle between the cutting edge on the side of
rigidity. tool and shank, it should be kept as sharp as possible.
It provides major cutting action.
CONCLUSION:
6. Mr. Yash R. Bhoyar1, Prof. P. D. Kamble2. "Finite element
analysis on temperature distribution." International Journal of
A review of history of cutting tool reveals that a new Modern Engineering Research (IJMER) Issue.1, Jan-Feb.
tool material seldom fully replaces the old one . The 2013.
performance of a cutting in any machining operation 7. Lalitha Babu1, M. Kumara Swamy, "Finite element analysis of a
is mainly determined by wear resistance, hot hardness plane; milling cutter" International Journal of Modern
Engineering Research (IJMER) :Vol. 2, Issue. 6, Nov-Dec.
and toughness. A material which permits high cutting 2012.
speed will produce better surface finish, thus the 8. Vivek Varia, and Prof. Jegadeeshwarwn. "Finite element
order would be carbon steel , HSS, Cast alloy analysis of deformation of single point cutting tool "
Sintered Carbide tool. Diamond produced best International journal on Innovation in engineering and
Technology Dec 25-26 2013.
surface finish due to smaller built up edge as a result 9. P.C.Sharma, “Production Engineering”, S.Chand publisher, New
low friction of material on the face of diamond. Tool Delhi, pp 149-155. [12] P.N.Rao,
life and surface finish are are influence by tool 10. Manufacturing technology-Metal Cutting and Manufacturing
geometry. The important tool characteristic Tools, Tata McGraw-Hill Publishing Company Limited, New
Delhi
considered are the nose radius , rake angle and tool 11. Production Technology R. K. Jain ,Khanna publishers .
edge geometry. Surface finish is improved by 12. NBV Lakshmi Kumari, S. Irfan Sadaq G. Prasana Kumar
increasing nose radius. Machining is significantly ''Analysis of Single Point Cutting Tool of a Lathe Machine
influence by heat generation . It escalates tool wear Using FEA ''International Journal of Engineering Trends and
Technology (IJETT) – Volume 20 Number 5 – Feb 2015
and reduces tool life, Also the failure mechanism 13. Olugboji Oluwafemi Ayodeji1, Matthew Sunday Abolarin,Jiya
developing during cutting are influence by Jonathan Yisa, Popoola Solomon Olaoluwa, Ajani Clement
temperature. It is observed that the maximum Kehinde ''Effect of Cutting Speed and Feed Rate on Tool
interface temperature exist in the first part of tool - Wear Rate and Surface Roughness in Lathe Turning Process
''International Journal of Engineering Trends and Technology
chip contact and at higher cutting speed surface (IJETT) – Volume22 Number 4- April 2015
temperature is decreased . Cutting forces has been 14. Mr.MangesR.Phate,Dr.V.H.Tatwawadi''Modeling of Power
found to be an important variable in generating Consumption in Turning of Ferrous and Nonferrous Materials
surface temperature . So, to prevent wear and failure using Artificial Neural Network ''International Journal of
Engineering Trends and Technology- Volume4Issue3- 2013
characteristic of a tool , it is necessary to quantify the
temperature limit .
ACKNOWLEDGEMENT:
I extend my courtesy to all authors and publishers of
the journal from where I have collected my
information. I am deeply privileged to be a part of
SHRI GOVINDRAM SEKSARIA INSTITUTE OF
TECHNOLOGY AND SCIENCE for the course of
my work on this paper. I am highly thankful to Prof.
Dr. Smita ManePatil, Professor and Head Of the
Department, Mechanical Department, for her expert
advice, technical suggestions and moral support
during in this work.
In addition, I would like to thank my friends for
sharing their experience in CATIA, ANSYS. Finally,
I would like to thank my family for their support and
putting up with me for these past few months moral
and financial support during my studies.
REFERENCES:
1. Production Technology, Tata McGraw- Hill Publishing
Company Ltd.; New Delhi.
2. Dr David J Grieve, Manufacture and Materials -2.7 Materials
for Cutting Tools 23-03-2009.
3. Dr. Maan Aabid Tawfiq and Suha Kareem Shahab "Analysis of
single point cutting tool using different tool edge
geometry."Eng. & Technology, Vol.25, No.4, 2007.
4. Deepak Bhardwaj, B. Kumar "Study and analysis of single point
cutting tool under variable rake angle" International Journal
of Scientific and Innovative Research 2014.
5. Maheshwari, N Patil Shreepad Sarange, Dr. D. Y. Patil
"Analysis of von mises stress and deformation at the tip of
cutting tool." International Journal of Innovative Research in
Advanced Engineering (IJIRAE) Volume 1 Issue 1 (April
2014.