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    Tool Life Important

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    Serajul Haque
    Tool wear and tool life are affected by many factors during single point cutting operations. Flank wear, crater wear, and nose wear are the main types of tool wear that occur. Flank wear increases cutting forces and temperatures over time. Crater wear increases the rake angle and weakens the tool. Nose wear shortens the tool and reduces machining accuracy. Factors like cutting speed, feed rate, depth of cut, tool geometry, tool and work materials influence the tool wear rate and tool life. Proper selection of these factors can maximize tool life during machining operations.

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    Tool Life Important

    Uploaded by

    Serajul Haque
    42 views31 pages
    Tool wear and tool life are affected by many factors during single point cutting operations. Flank wear, crater wear, and nose wear are the main types of tool wear that occur. Flank wear increases cutting forces and temperatures over time. Crater wear increases the rake angle and weakens the tool. Nose wear shortens the tool and reduces machining accuracy. Factors like cutting speed, feed rate, depth of cut, tool geometry, tool and work materials influence the tool wear rate and tool life. Proper selection of these factors can maximize tool life during machining operations.

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    Tool wear and tool life are affected by many factors during single point cutting operations. Flank wear, crater wear, and nose wear are the main types of tool wear that occur. Flank wear increases cutting forces and temperatures over time. Crater wear increases the rake angle and weakens the tool. Nose wear shortens the tool and reduces machining accuracy. Factors like cutting speed, feed rate, depth of cut, tool geometry, tool and work materials influence the tool wear rate and tool life. Proper selection of these factors can maximize tool life during machining operations.

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    © All Rights Reserved
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    42 views31 pages

    Tool Life Important

    Uploaded by

    Serajul Haque
    Tool wear and tool life are affected by many factors during single point cutting operations. Flank wear, crater wear, and nose wear are the main types of tool wear that occur. Flank wear increases cutting forces and temperatures over time. Crater wear increases the rake angle and weakens the tool. Nose wear shortens the tool and reduces machining accuracy. Factors like cutting speed, feed rate, depth of cut, tool geometry, tool and work materials influence the tool wear rate and tool life. Proper selection of these factors can maximize tool life during machining operations.

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    Tool Wear And Tool Life Of Single Point

    Cutting Tool

    Presented by-
    Sudhanshu Anand (12BME001)
    Akshay Arvind (12BME002)
    Ayan Bairoliya (12BME003)
    Dhruv Baranda (12BME004)
    Deepanshu Chanda (12BME005)
    Tool wear
    Wear is loss of material on an asperity or
    micro-contact, or smaller scale, down to
    molecular or atomic removal mechanisms. It
    usually progresses continuously. Tool wear
    describes the gradual failure of cutting tools
    due to regular operation. It is a term often
    associated with tipped tools, tool bits, or drill
    bit that are used with machine tools.
    Types of tool wear
    • Flank wear
    • Crater wear
    • Nose wear
    Flank wear
    Flank wear occurs on the tool flank as a result of
    friction between the machined surface of the
    workpiece and the tool flank. Flank wear appears
    in the form of so-called wear land and is
    measured by the width of this wear land, VB,
    Flank wear affects to the great extend the
    mechanics of cutting. Cutting forces increase
    significantly with flank wear. If the amount of
    flank wear exceeds some critical value (VB >
    0.5~0.6 mm), the excessive cutting force may
    cause tool failure.
    Crater wear
    Crater wear consists of a concave section on the tool
    face formed by the action of the chip sliding on
    the surface. Crater wear affects the mechanics of
    the process increasing the actual rake angle of the
    cutting tool and consequently, making cutting
    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.
    Nose wear
    Nose wear 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 nose wear as a
    separate wear type because of its importance for
    the precision of machining. Nose 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.
    Effects of Tool Wear

    Some General effects of tool wear include:


    • Increased cutting forces
    • Increased cutting temperatures
    • Poor surface finish
    • Decreased accuracy of finished part
    • May lead to tool breakage
    • Causes change in tool geometry
    Wear Control
    The rate of tool wear strongly depends on the cutting
    temperature, therefore , any measures which could be
    applied to reduce the cutting temperature would reduce the
    tool wear as well. The figure shows the process parameters
    that influence the rate of tool wear:
    Reduction in tool wear can be accomplished by using
    lubricants and coolants while machining. These
    reduce friction and temperature, thus reducing the
    tool wear.

    Additional measures to reduce the tool wear include


    the application of advanced cutting tool materials,
    such as coated carbides, ceramics, etc.
    Tool Life Of Single Point Cutting Tool
    Definition
    (a) In R & D : Actual machining time (period) by which a fresh
    cutting tool (or point) satisfactorily works after which it needs
    replacement or reconditioning. The modern tools hardly fail
    prematurely or abruptly by mechanical breakage or rapid
    plastic deformation. Those fail mostly by wearing process
    which systematically grows slowly with machining time. In
    that case, tool life means the span of actual machining time by
    which a fresh tool can work before attaining the specified limit
    of tool wear. Mostly tool life is decided by the machining time
    till flank wear, VB reaches 0.3 mm or crater wear, KT reaches
    0.15 mm.
    (b) In industries or shop floor : The length of time of
    satisfactory service or amount of acceptable output provided
    by a fresh tool prior to it is required to replace or recondition.
    Assessment of tool life
    There are three ways of assessment of tool life
    1. No. of pieces of work machined – This is
    used commonly when the tool operates
    continuously .
    2. Total volume of material removed –This is
    used commonly when the tool is used for high
    stock removal.
    3. Total length of cut
    Modes Of Failure Of Tool
    1-Premature Failure
    (a)Fracture failure - Cutting force becomes
    excessive and/or dynamic, leading to brittle
    fracture.
    (b)Thermal failure - Cutting temperature is too
    high for the tool material.
    2-Gradual Wear-Gradual failure
    Factors Affecting Tool Life
    Cutting speed
    Feed and depth of cut
    Tool geometry
    Tool material
    Work material
    Nature of cutting
    Rigidity of machine tool and work
    Use of cutting fluids
    Cutting Speed
    Depth of cut
    Too small
    • Loss of chip control
    • Vibration
    • Excessive heat
    • Uneconomical
    Too deep
    • High power consumption
    • Insert breakage
    • Increased cutting force
    Feed Rate
    Too light
    • Stringers
    • Rapid flank wear
    • Build-up edge
    • Uneconomical
    Too heavy
    • Loss of chip control
    • Poor surface finish
    • Crater wear/plastic deformation
    • High power consumption
    Tool Geometry
    Rake angle-If it is increased in positive direction , the cutting
    force and amount of heat generated are reduced. This increases
    the life of the tool. But if it is increased too much , cutting
    edge is weakened and capacity to conduct heat also decreases.
    Relief angle-These are provided on the cutting tool to prevent
    rubbing of tool flank with machined work surface. Thus it
    reduces the amount of heat generated and increases tool life.
    Cutting edge angles- these angles affect tool wear. Up to a
    certain value of these angles , higher speed without an adverse
    affect on tool life can be used.
    Tool material
    Hardness
    Cutting tool material must be 1 to 1/2 times harder than
    the material it is being used to machine.
    Wear Resistance
    • Able to maintain sharpened edge throughout the
    cutting operation
    • Same as abrasive resistance
    Shock Resistance
    • Able to take the cutting loads and forces
    Shape and Configuration
    • Must be available for use in different sizes and shapes.
    Thank You

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