Cutting force increase Dimensional accuracy will decrease Work piece surface roughness Temperature increase in between the tool and the work piece Loss of production Machine will vibrate TYPES OF WEAR MECHANISM • Shearing at highest temperature • Diffusion wear • Adhesive wear • Abrasive wear • Fatigue wear • Electrochemical effect • Oxidation effect Tool Life Tool life is defined as the time elapsed between the two successive grinding of tool or The time for which a cutting edge of a cutting tool can be usefully employed without grinding TOOL FAILURE CRITERION • Complete wear • Flank wear • Finish failure • Size failure • Cutting force failure Wear zone • Crater wear • Corner wear • Flank wear TOOL LIFE EQUATION • Frederick W. Taylor derived an equation the find the tool life equation as 𝑉𝑇 𝑛 = 𝐶 Where V = Cutting speed in M/min T = Tool Life in min n = 0.2 to 0.25 for HSS 0.25 to 0.45 for Carbide tool n = tool life index 0.4 to 0.55 for ceramic tool C = Constant Effect of feed rate and depth of cut 𝑛 𝑛1 𝑛2 𝑉𝑇 𝑓 𝑑 = 𝐶1 V = Cutting speed in M/min 𝜋𝐷𝑁 = m/min 1000 T = Tool Life in min n = tool life index C = Constant f = Feed in mm/min t = Depth of cut in mm Factors affecting tool life The life of the cutting tool is affected by the following factors: Cutting speed. Feed and depth of cut. Tool geometry. Tool material. Cutting fluid. Work piece material. Rigidity of work, tool and machine. Machinability • Machinability is defined as “the ease with which a given work piece material can be machined wit a specified cutting tool. • Machinability can be tentatively defined as “ability of being machined” and more reasonably as “ease of machining”. Machinability rating (MR) SURFACE FINISH Generally, surface finish of any product depends on the following factors: Cutting speed. Better surface finish can be obtained at higher cutting speeds. Rough cutting takes place at lower cutting speeds Feed. Surface finish will not be good when coarse feed is applied. But better finish can be obtained in fine feeds. Depth of cut. Lighter cuts provide good surface finish to the work piece. If depth of cut increases during machining, the quality of surface finish will reduce. CUTTING FLUIDS The basic purposes of cutting fluid application are: Cooling of the job and the tool to reduce the detrimental effects of cutting temperature on the job and the tool. Lubrication at the chip Cleaning the machining zone by washing away the chip Protection of the nascent finished surface Methods of application of cutting fluid • Drop-by-drop under gravity. • Flood under gravity. • In the form of liquid jet(s). • Mist (atomized oil) with compressed air. Types of cutting fluids and their application Solid or semi-solid lubricant Paste, waxes, soaps, graphite, Moly- disulphide (MoS2) may also often be used, either applied directly to the work piece or as an impregnant in the tool to reduce friction and thus cutting forces, temperature and tool wear. Water For its good wetting and spreading properties and very high specific heat, water is considered as the best coolant and hence employed where cooling is most urgent. Soluble oil Water acts as the best coolant but does not lubricate. Besides, use of only water may impair the machine-fixture-tool-work system by rusting. So oil containing some emulsifying agent and additive together called cutting compound, is mixed with water in a suitable ratio ( 1 ~ 2 in 20 ~ 50). Chemical fluids These are occasionally used fluids which are water based where some organic and or inorganic materials are dissolved in water to enable desired cutting fluid action. There are two types of such cutting fluid: Inactive type - high cooling, anti-rusting and wetting but less lubricating. Active (surface) type - moderate cooling and lubricating. Types of additives present in cutting fluid S.No Additives Functions 1 Mineral oils and other Base oil hydrocarbon 2 Polyglycoether Emulsifier 3 Aliphatic amines Neutralized agent 4 Sulfonates Corrosion protection 5 Fatly acid amides Lubricity improvement 6 Sulphur / Phosphorous Pressure additives additives 7 Aldehyde Derivatives Biocides