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Tool Wear and Tool Life
1.New tool has sharp cutting edges and smooth flank
*Forces concentrated over a small contact area
*High temperature and stress concentration-Wear
2.Because of wear-frequent tool change – machining time
lost – productivity
3.Tool life is important to save time and productivity and
also knowledge of tool wear is important.
Common wear mechanism
1.Abrasion
2.Adhesion
3.Diffusion
4.Fatigue
5.Electrochemical
6.Oxidation
7.Chemical Decomposition
Fatigue Wear
1. During machining, interlocking of asperities occur by which compressive stresses are
generated on one side and tensile stresses on other side.
2. If asperites pair up, stresses cancel out and relieved
3. But new asperities form ,cycle repeats ….cyclic stresses
4. Formation of crack and crumbling of hard material
Electrochemical Wear
1. Due to high temperature emf is setup in a closed circuit
-Flow of current
-Wear occurred
Oxidation Wear
• Surfaces reacted with atmospheric oxygen and form abrasive oxide (flank wear)
Chemical Decomposition
1. Localised chemical reaction weakens the tool
2. Because of formation of weak compound and dissolution of bond between binder and hard
constitutes
3. weaker surface easily torn away.
 Buildup Edge
Tool Geometry vs Tool Life
Tool life test in turning yield the following data (1)
v=100m/min, T=10min (2) v=75m/min, T=30 min
(a) Determin the n and C values in the taylor tool life
equation .Based on this question compute (b) the tool life for
a speed of 90 m/min and (c) the speed corresponding to a
tool life of 20 min
Numerical
Turning tests have results in 1 min tool life for a cutting
speed of v=4m/s and a 20 min tool life at a speed v= 2.0
m/s.(a) find the n and c values in the taylor tool life equation
(b) Project how long the tool would last at a speed v=1.0m/s.
Numerical
Thermal Aspect of Machining
Average Shear plane Temperature
Machinability
Ease of machining or ease with which a given work material can be machined under a given set
of cutting conditions
Economically important for production engineer to know in advance of machinability of work
material so that he can planned efficiently.
Machinability Criteria
Ease of machining of different material can be compared in terms of
• Tool Life
• Cutting forces
• Surface finish
• Cutting Temperature
• Chip Disposal
• Operator safety

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Tool Wear and Thermal Aspects of machining

  • 1. Tool Wear and Tool Life 1.New tool has sharp cutting edges and smooth flank *Forces concentrated over a small contact area *High temperature and stress concentration-Wear 2.Because of wear-frequent tool change – machining time lost – productivity 3.Tool life is important to save time and productivity and also knowledge of tool wear is important.
  • 3.
  • 4. Fatigue Wear 1. During machining, interlocking of asperities occur by which compressive stresses are generated on one side and tensile stresses on other side. 2. If asperites pair up, stresses cancel out and relieved 3. But new asperities form ,cycle repeats ….cyclic stresses 4. Formation of crack and crumbling of hard material Electrochemical Wear 1. Due to high temperature emf is setup in a closed circuit -Flow of current -Wear occurred
  • 5. Oxidation Wear • Surfaces reacted with atmospheric oxygen and form abrasive oxide (flank wear) Chemical Decomposition 1. Localised chemical reaction weakens the tool 2. Because of formation of weak compound and dissolution of bond between binder and hard constitutes 3. weaker surface easily torn away.
  • 6.
  • 7.
  • 8.
  • 9.
  • 11.
  • 12.
  • 13.
  • 14. Tool Geometry vs Tool Life
  • 15.
  • 16.
  • 17. Tool life test in turning yield the following data (1) v=100m/min, T=10min (2) v=75m/min, T=30 min (a) Determin the n and C values in the taylor tool life equation .Based on this question compute (b) the tool life for a speed of 90 m/min and (c) the speed corresponding to a tool life of 20 min Numerical
  • 18.
  • 19. Turning tests have results in 1 min tool life for a cutting speed of v=4m/s and a 20 min tool life at a speed v= 2.0 m/s.(a) find the n and c values in the taylor tool life equation (b) Project how long the tool would last at a speed v=1.0m/s. Numerical
  • 20.
  • 21. Thermal Aspect of Machining
  • 22. Average Shear plane Temperature
  • 23. Machinability Ease of machining or ease with which a given work material can be machined under a given set of cutting conditions Economically important for production engineer to know in advance of machinability of work material so that he can planned efficiently. Machinability Criteria Ease of machining of different material can be compared in terms of • Tool Life • Cutting forces • Surface finish • Cutting Temperature • Chip Disposal • Operator safety