A Micro project

On
Tabulate various cutting tool materials with main elements, properties and application.

Submitted by

Mr. Prasad Kanti Patil (1815470063)

Mr. Rutik Manohar Dongare (1815470067)

Mr. Kunal Bhaskar Bodake (1815470064)

Mr. Yatish Dwarakanath Patil (1615470083)

Submitted as a requirement for Diploma in Mechanical Engineering

Subject of Advance manufacturing processes Under the Guidance of

Prof. Kokate sir

(Lecturer in Mechanical Engg. G. P. Vikramgad)

Department of Mechanical Engineering

Government Polytechnic Vikramgad,

Academic Year 2019-20

Introduction :

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There are many types of cutting process done in different conditions. In such conditions along
with the general requirements of the cutting tool, they need some unique properties. To
achieve this properties the cutting tools are made up of different material. The material chosen
for a particular application depends on the material to be machined, type of machining,
quantity and quality of production.

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According to the material used the tools are classified into

1. Carbon tool steel

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Carbon tool steel

Carbon tool steel is one of the inexpensive metal cutting tools used for the low-speed machining
operation. These plain carbon steel cutting tool have the composition of 0.6-1.5% carbon and
very small amount of (less than 0.5 %) Mn, Si. Other metal like Cr, V are added to change the
hardness and grain size. High carbon steels are abrasion resistant and have the ability to
maintain sharp cutting edge. Carbon tool steels possess good machinability. This material loses
their hardness rapidly at a temperature about 250°C. Therefore, it can’t use high-temperature
application. It does not prefer in a modern machining operation.

Carbon steel tool is used in twist drills, milling tools, turning and forming tools, used for soft
material such as brass, aluminum magnesium, etc.

Temperature - 450°C

Hardness – up to HRC 65

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High speed steel :

This is a high carbon steel with a significant amount of alloying element, such as tungsten,
molybdenum, chromium, etc. to improve hardenability, toughness and wear resistance. It gives
a higher metal removal rate. It loses its hardness at a moderate temperature about 650°C.
Therefore, a coolant should be used to increase tool life. It can use many times by re-
sharpening. Some surface treatment is done on the HSS to improve its property.

To find out the effect of alloying material in steel click here

Surface treatment used in the HSS

Super finishing - Reduce friction

Nitriding - Increase wear resistance

Chromium electroplating - Reduce friction

Oxidation - Reduce friction

High-speed steel tools are used in drills, milling cutters, single point lathe tools, broaches.

Cutting speed range - 30-50 m/min

Temperature - 650°C

Hardness – up to HRC 67

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T-Type - Tungsten predominant type

M-Type - Molybdenum dominant type

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Cemented carbide tool and cermet

The cemented carbide cutting tool is produced by powder metallurgy technique. It consists of
tungsten, tantalum and titanium carbide with cobalt as a binder (when the binder is nickel or
molybdenum, then it is called cermet). Cemented carbide tools are extremely hard; they can
withstand very high-speed cutting operation. Carbide tool does not lose their hardness up to
1000° C. A high cobalt tool is used for a rough cut while low cobalt tool used for finishing
operations.

Cutting speed range - 60-200m/min

Temperature - 1000°C

Hardness – up to HRC 90

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Ceramics

Most common ceramic materials are aluminum oxide and silicon nitride. Powder of ceramic
material Compacted in insert shape, then sintered at high temperature. Ceramic tools are
chemically inert and possess resistance to corrosion. They have high compressive strength. They
are stable up to temperature 1800°C. They are ten times faster than HSS. The friction between
the tool face and chip are very low and possess low heat conductivity, usually no coolant is
required. They provide the very excellent surface finish.

Cutting speed 300-600m/min

Temperature - 1200°C

Hardness – up to HRC 93

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Cubic boron nitride (CBN)

It is the second hardest material after diamond. They are generally used in hand machines. They
offer high resistance to abrasion and use as an abrasive in grinding wheels. Sharp edges are not
recommended.

Speed 600-800m/min

Hardness - higher than HRC 95

Diamond

It is the hardest material known and it is also expensive. It possesses very high thermal
conductivity and melting point. Diamond offers excellent abrasion resistance, low friction
coefficient and low thermal expansion. It is used in machining very hard material such as
carbides, nitrides, glass, etc. Diamond tools give a good surface finish and dimensional accuracy.
They are not recommended for machining steel.

Hot hardness of cutting tool material

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Properties of cutting tool material:

The various properties of cutting tool materials:

Hot Hardness:

The cutting tool is able to withstand high temperature during the machining without any losses
its cutting edge. So the tools or maintained it hardness at high temperature. The hardness of
tool must be higher than workpiece. The additional material added to tool for improve
hardness. The material of aluminium, tungsten, molybdenum and vanadium.

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Wear resistance:

It is the tool ability of resist the wearing. The friction due to contact between tools and work
materials during the machining operation. In this reason wear in the tool. If tool not having the
sufficient amount of wear resistance, so it will be fail quickly. That give poor surface finish of
work material. So the additional of Cobalt material added in the tool combination to increase
the wear resistance property.

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Toughness:

It is a combination properties of strength and ductility. The tool should be having sufficient
toughness withstand the shock and vibration. If the tool having sufficient amount of toughness,
the fine edge of cutting tool does not break down or chip formation. When the cutting tool
suddenly loaded together, this types of property limit with the hardness in the tool. The high
hardness of tool will be brittle and weak in tensile load. For adding additional of molybdenum
and Nickel in tool material to improve the toughness.

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Low friction:

For generally, the coefficient of friction between workpiece and tool must be a lower. So the
lower friction reduce the heating and wearing in the tool material.

Tool cost:

The tool material must be important for economical in mass of production. It should be easily
manufacture from the material combination. Above properties addition to the tool material to
get the following properties,

Thermal conductivity will be high

Easily to grind and sharping operation

Resistance to thermal shocking

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