All India Shri Shivaji Memorial Society’s

Polytechnic KennedyRoad, Near RTO,

Pune - 411001

MICRO PROJECT ON
Commonly Used Workpiece Materials and Recommended Cutting Tool
Grades

Name : Vinayak Balasheb Khade

Roll No: 2005

Enrolment No:

Program Name: Diploma in Mechanical Engineering

Program Code: M.E.5.I

Semester: Fifth

Course Title: Advanced Manufacturing Processes

Course Code : 22563

Name of Micro project Guide: Mr.

 All India Shri Shivaji Memorial Society’s Polytechnic, KennedyRoad near
RTO, Pune-411 001

CERTIFICATE

Certified that this micro project report titled ‘ Commonly Used Workpiece
Materials and Recommended Cutting Tool Grades.’ is the bonafide work of
Name: Vinayak Balasheb khade Rollno:2005, of Third year diploma in
Mechanical Engineering for the course : Advanced Manufacturing
Processes, Course code: 22563, during the academic year 2024- 2025, who
carried out the micro project work under my supervision.

Mr.
(Name & signature subject teacher)
 INDEX

Sr. content Page

No. No.
1. Micro Project Proposal 1.
2. Rationale 2.

3. Aims/Benefits of the Micro Project 4.

4. Course Outcome achieved 6.

5. Literature Review 6.

6. Actual Methodology Followed 6.

7. Actual Resources Used 7.

8. Output of the Micro Projects 8.

9. Skill Developed / Learning outcome of the 9.

MicroProject
10. Conclusion 10.
 Micro Project Proposal
1.0 Title of the Micro-project:
Commonly Used Workpiece Materials and Recommended Cutting Tool
Grades.

2.0 : Rationale
Mechanical technologists (diploma holders) have to work with men, machines
and materials. With the advancements, newer difficult to machine materials and
complex shapes with high surface finish is the demand of the manufacturing
sector. To machine these materials and also the complex geometries with very
high surface finish the student must have the knowledge of non-conventional
machining processes like EDM, ECM, LBM, PAM, WJM, EBM, WEDM and
also the conventional machining like milling processes, gear manufacturing,
grinding, surface finishing, Broaching, boring processes etc. This course is aimed
to make them achiever the various outcomes required for the given jobs
3.0 : Aims/Benefits of the micro project

The primary purpose of this micro project is to serve as a valuable

resource for professionals and enthusiasts in the machining and
manufacturing sectors.
It aims to address the following objectives:

 To provide a thorough understanding of commonly used workpiece

materials, their properties, and applications in manufacturing
processes.
 To explore the diverse landscape of cutting tool grades,
their compositions, and how they interact with different
workpiece materials.
 To offer practical recommendations and insights into the selection
of cutting tool grades based on specific workpiece materials.

 To equip readers with the knowledge and tools necessary to make

informed decisions when selecting cutting tool grades for machining
operations.
 To discuss emerging trends and advancements in cutting tool
materials that are shaping the future of the manufacturing
industry.
4.0: Course Outcome achieved

a. Maintain the non conventional machining process to produce complex

and hard tomachine components.
b. Produce components using milling machined.) Apply principles of safety
management in all activities.

5.0: Proposed Methodology

1. Finalize the topic
2. Find and Collect information
3. Arrange information
4. Proofread the information
5. Review from the teacher
6. Edit project report as per the suggestions of the teacher
7. Proofread and finalize the report
8. Submission of the report

6.0 : Actual Resources Used

Sr.
Name of resource material Specificions Quantity
no

1 PC windows 7 1

2 textbook Advanced manufacturing 1

1
3 MS WORD 2018

7.0 : Skill Developed / Learning outcome of the MicroProject

1) The objective of discussing emerging trends and advancements in cutting

tool materials that are shaping the future of the manufacturing industry. This
encourages readers to stay current with industry developments, fostering a
continuous learning mindset.
2) The practical tips for effective tool grade selection, the report helps
readers apply the knowledge gained to real machining scenarios. This
practical application of information is valuable for professionals in the
manufacturing industry.
 DAY TO DAY WORK OF MICRO PROJECT
NO
Date Remarks
OF Activity performed
DATE

1
Various topics of micro project were discussed

Group formation- group was formed by the project

2 guide/subject teacher and the topic was selected

3
Detailed list prepared for the project topics

4
Collected data of topics from various industry

5
Collected data is cross checked by the project guide

6
Data is collected from internet of different materials

Roughly noted in a book all the necessary details and notes

7 are prepared

8
Typing and data sequence formed and set as per project

14 Rough copy is prepared and if any corrections are needed

9 to the related project

Finalized the report and gave for printing and Hard copy is
10 prepared and attached to the file
 ( PART – B)
Title of the Micro-project:
Commonly Used Workpiece Materials and Recommended Cutting Tool Grades.

1. Introduction :
In the field of machining and manufacturing, the selection of cutting tools and their
appropriate grades plays a pivotal role in determining the efficiency, precision, and quality
of the machining process. The interaction between cutting tool materials and workpiece
materials is a complex science that significantly impacts the success of machining
operations. The choice of the right cutting tool grade for a specific workpiece material can
lead to increased productivity, reduced costs, and improved product quality. Conversely,
improper tool grade selection can result in tool wear, reduced tool life, and subpar
machining outcomes.
The critical relationship between commonly used workpiece materials and the
recommended cutting tool grades. It aims to provide a comprehensive guide for
professionals in the manufacturing industry, including machinists, engineers, and
manufacturers, by offering insights into the selection process, factors influencing decisions,
and practical recommendations for achieving optimal machining results. By understanding
the significance of this relationship, individuals and organizations can enhance their
machining capabilities, reduce downtime, and ultimately boost competitiveness in the
market.

CUTTING TOOL MATERIAL

1. Introduction to Cutting Tool Materials

Cutting tools are essential components in machining processes, and their performance
directly impacts the quality and efficiency of machining operations. The choice of cutting
tool materials is a critical decision that manufacturers and machinists must make to achieve
desired outcomes. In this section, we'll explore the fundamental aspects of cutting tool
materials, including their types, properties, and applicatio

2. Types of Cutting Tool Materials:

 High-Speed Steel (HSS):

HSS is a traditional cutting tool material known for its versatility and ability to handle a wide
range of materials and cutting conditions. It is primarily composed of steel with additives
like tungsten, molybdenum, and chromium to enhance its hardness and wear resistance.

 Carbide (Tungsten Carbide):

Carbide cutting tools are renowned for their exceptional hardness and heat resistance.
Tungsten carbide is the primary component, often combined with cobalt as a binder. Carbide
tools are suitable for high-speed machining of hard materials like steel and titanium.

 Ceramics:
Ceramic cutting tools are known for their high-temperature resistance and wear resistance.
They are commonly used for machining high-temperature alloys and hardened steels.

 Cubic Boron Nitride (CBN):

CBN is an abrasive cutting tool material that excels in machining hard materials like
hardened steels and cast iron. It offers high cutting speeds and extended tool life.

 Diamond:
Diamond cutting tools are the hardest and offer exceptional performance in machining non-
ferrous materials, composites, and ceramics. They are often used in precision machining.
 3. Properties of Cutting Tool

Materials: Hardness:
The hardness of a cutting tool material determines its ability to resist wear and deformation
during machining.

Toughness:
Toughness is the ability of a cutting tool to absorb shock and resist fracture under high stress
conditions.

Heat Resistance:
Cutting tools must withstand high temperatures generated during machining without losing
their hardness.

Wear Resistance:
Good wear resistance ensures prolonged tool life and consistent machining performance.

Chemical Stability:
The cutting tool should be chemically stable to avoid chemical reactions with workpiece
materials.

Thermal Conductivity: Thermal conductivity helps in dissipating heat away from the
cutting edge.

4. Factors Influencing Cutting Tool Selection:

Selecting the right cutting tool for a machining operation depends on various factors,
including:

 Workpiece Material: The type of material being machined (e.g., steel,

aluminum, titanium) greatly influences tool selection.

 Cutting Speed and Feed Rate: The desired cutting speed and feed rate impact
tool performance and tool life.

 Tool Geometry: Tool geometry, including rake angle, clearance angle, and
cutting edge design, should match the machining process.
  Cutting Conditions: Factors like depth of cut, width of cut, and coolant usage
affect tool performance.

 Tool Coatings: Coatings can enhance tool life and performance by reducing
friction and heat generation.

5. Importance of Matching Tool Grades to Workpiece Materials

Matching the right cutting tool grade to the workpiece material is essential for several
reasons:

 Tool Life: Proper tool selection prolongs tool life, reducing the frequency of
tool changes and downtime.

 Surface Finish: The right tool grade ensures a smooth surface finish on
machined parts.

 Productivity: Optimized tool grades improve machining efficiency and

reduce production costs.

 Quality: Accurate tool selection results in precise machining and high-quality parts.

 Cost Savings: Using the right tool grade reduces tool wear and the need for
frequent replacements, leading to cost savings.

6. Recommended Cutting Tool Grades for Specific Workpiece Materials

In this section, we will provide recommendations for cutting tool grades tailored to specific
workpiece materials commonly encountered in machining operations.

 Steel and its Alloys:

Recommended Cutting Tool Grade: High-speed steel (HSS) tools are suitable for low- to
medium-carbon steels. For high-carbon and alloy steels, carbide tools offer better
performance and longer tool life.

 Aluminum and its Alloys:

Recommended Cutting Tool Grade: Carbide cutting tools with polished or coated surfaces
are ideal for machining aluminum and its alloys due to their excellent heat resistance and
wear characteristics.

 Titanium and Titanium Alloys:

Recommended Cutting Tool Grade: Carbide cutting tools with specialized coatings (e.g.,
titanium nitride TiN or titanium carbonitride TiCN) are preferred for machining titanium and
its alloys. These coatings enhance tool life and reduce friction and built-up edge formation.
  Stainless Steel:
Recommended Cutting Tool Grade: For austenitic stainless steels, use carbide cutting tools
with TiN or TiCN coatings. For martensitic or precipitation-hardened stainless steels,
consider advanced carbide grades or ceramic tools.

 Cast Iron:
Recommended Cutting Tool Grade: For gray cast iron, carbide inserts with a CVD or
PVD coating provide excellent performance. For ductile cast iron, uncoated carbide inserts
work well. For compacted graphite iron (CGI), consider CBN or ceramic tools.

 Non-Ferrous Metals:
Recommended Cutting Tool Grade: For copper, brass, and bronze, use carbide or HSS tools.
For magnesium and its alloys, carbide tools are suitable. For high-temperature alloys like
Inconel, use carbide tools with specialized coatings.

 Plastics and Composite Materials:

Recommended Cutting Tool Grade: Polycrystalline diamond (PCD) or carbide tools with
polished surfaces are excellent choices for machining plastics and composite materials due to
their sharpness and wear resistance.

7. Factors Influencing Tool Grade Selection:

When selecting cutting tool grades, several factors come into play to ensure optimal
machining results.

 Cutting Speed and Feed Rate:

Higher cutting speeds often require cutting tools with better heat resistance, such as carbide
or ceramic grades. Appropriate feed rates should also be considered for efficient material
removal.

 Workpiece Hardness and Toughness:

Softer materials may require less durable tool grades, while harder materials demand harder
tool materials like carbide or CBN. Toughness becomes critical when machining materials
with unpredictable hardness variations.

 Temperature and Heat Resistance:

Materials that generate significant heat during machining, such as superalloys, require
cutting tool grades with excellent heat resistance. Coatings like TiN or TiAlN can further
enhance heat resistance.

 Tool Wear and Tool Life:

Consider the desired tool life and the point at which tool wear becomes unacceptable. Longer
tool life may necessitate the use of more wear-resistant tool grades.
  Surface Finish and Precision Requirements:
For applications demanding a high-quality surface finish and tight tolerances, choose cutting
tool grades that minimize chatter and provide precise machining.

8. Advances in Cutting Tool Materials:

The field of cutting tool materials is continuously evolving, with advancements driven by the
need for improved performance, efficiency, and sustainability. This section explores
emerging technologies and materials in the cutting tool industry, as well as future trends that
are shaping the landscape of machining
Emerging Technologies and Materials

 Nanomaterials: Nanotechnology is being applied to create cutting tools

with enhanced hardness, wear resistance, and thermal stability at the
nanoscale.

 Additive Manufacturing: 3D printing and additive manufacturing techniques are

enabling the creation of complex tool geometries and the incorporation of
advanced materials.

 Smart Tooling: Tools with embedded sensors and data collection capabilities
are emerging, allowing for real-time monitoring of tool condition and
performance.

9. Future Trends in Cutting Tool Development:

 Sustainable Materials: The industry is moving toward more sustainable

tool materials and coatings, with an emphasis on reducing environmental
impact.

 Digitalization: The integration of digital technologies, such as artificial

intelligence (AI) and machine learning, is expected to enhance tool design and
performance prediction.

 Customization: Tailoring cutting tools to specific applications and workpiece

materials is a growing trend, allowing for optimized machining processes.

 Rapid Prototyping: Faster development and prototyping of cutting tools are

anticipated, enabling quicker adaptation to evolving manufacturing needs.

10. Case Studies :

In this section, we present real-world case studies that highlight the importance of
informed tool grade selection and the tangible outcomes and improvements achieved
in machining operations.
  Case Study 1: Enhancing Stainless Steel Machining

 Background:
A manufacturer specializing in precision components needed to improve the efficiency
and tool life of their machining processes for austenitic stainless steel components.

 Tool Grade Selection:

The manufacturer decided to switch from conventional high-speed steel (HSS) tools to
carbide tools with specialized coatings designed for stainless steel machining.

 Outcomes and Improvements:

 Improved Tool Life: The carbide tools exhibited significantly longer tool
life, reducing the frequency of tool changes and associated downtime.

 Increased Productivity: Faster machining speeds were achieved due to

reduced tool wear, resulting in a 20% increase in production output.

 Superior Surface Finish: The use of carbide tools led to a smoother

surface finish, reducing the need for secondary finishing processes.

 Cost Savings: Despite the higher initial tooling cost, the longer tool life
and increased productivity resulted in substantial cost savings over time.

 Case Study 2: Machining Aerospace Titanium Components

 Background:
An aerospace manufacturer faced challenges when machining titanium components,
including high tool wear rates and frequent tool replacements.

 Tool Grade Selection:

After careful analysis, the manufacturer opted for carbide cutting tools with advanced
titanium nitride (TiN) coatings specifically designed for high-temperature alloys like
titanium.

 Outcomes and Improvements:

 Extended Tool Life: The TiN-coated carbide tools exhibited exceptional

wear resistance, leading to a four-fold increase in tool life.

 Reduced Downtime: Less frequent tool changes reduced machine

downtime and increased operational efficiency.

 Consistent Precision: Improved tool wear consistency resulted in

tighter tolerances and reduced part rejections.
  Competitive Advantage: Enhanced machining capabilities allowed
the manufacturer to secure additional aerospace contracts.

11. Conclusion
In conclusion, this report has delved into the critical relationship between workpiece
materials and cutting tool grades, offering valuable insights and recommendations for
professionals in the manufacturing industry. Here are the key takeaways:

 Understanding the properties and characteristics of workpiece materials

is fundamental for informed tool grade selection.

 Different workpiece materials, such as steel, aluminum, titanium, stainless

steel, cast iron, non-ferrous metals, plastics, and composites, require specific
cutting tool grades and coatings for optimal machining results.

 Factors like cutting speed, feed rate, workpiece hardness, temperature

resistance, tool wear, and surface finish influence tool grade selection.

 Informed tool grade selection can lead to improved tool life,

increased productivity, cost savings, and superior surface finish.

 References

This section provides a comprehensive list of citations and sources used

throughout the report. It serves as a reference for readers who wish to explore
specific topics in more detail. Additionally, additional reading materials are
suggested for those interested in further expanding their knowledge of cutting
tool materials, machining processes, and related subjects.

The report's goal is to empower professionals in the manufacturing industry with

the knowledge and tools necessary to make informed decisions when selecting
cutting tool grades. It emphasizes the importance of this decision in achieving
optimal machining outcomes, productivity, and cost efficiency.