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Tool life and Tool Wear 1 Tool life and Tool Wear
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Tool life and Tool Wear 1/4/2013 Tool life and Tool Wear 1/4/2013
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•When softer metal slide over hard metal , parts of soft metal •Finally the built up edges will torn from the surface result uneven
adhere high spots on the metal due to: structure on the tool surface
9Friction
9High temperature
9Pressure
•The spots result irregular flow of chip over the face and build
up of more particles on the tool
Tool life and Tool Wear 1/4/2013 Tool life and Tool Wear 1/4/2013
Tool life and Tool Wear 1/4/2013 Tool life and Tool Wear 1/4/2013
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Oxidation is the result of reaction between tool face and oxygen •Will occur when two surfaces slides in contact with other under
Ex. When machining steel work piece with HSS or cemented high pressure
carbide tool , groove formation is greatly accelerated if the •Roughness of one surface interlocks with those of other.
cutting zone is subjected to a jet oxygen. •Due to friction , compressive force will be produced in one side
and
d ttensile
il on other
th side
id ,These
Th phenomenon
h cause surface
f crackk
Tool life and Tool Wear 1/4/2013 Tool life and Tool Wear 1/4/2013
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•Primary region
•It produces wear land on the sides and breakage of sharp cutting edges
end of a flank •Secondary zone
•Tool-work piece interface The predominant zone caused by abrasion
•Predominant at low speed •Tertiary zone
Very sensitive to temperature ,caused
by diffusion wear
Increment of MRR increases flank wear
Tool life and Tool Wear 1/4/2013 Tool life and Tool Wear 1/4/2013
form of pit called crater the lose of hardened atoms at the tool chip inter face is the major
•Tool-chip interface
Tool life and Tool Wear 1/4/2013 Tool life and Tool Wear 1/4/2013
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Tool life and Tool Wear 1/4/2013 Tool life and Tool Wear 1/4/2013
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Example
A steel bar of 40mm diameter is to be turned over a length of
200mm with a depth of cut 1.2mm and feed of 0.2mm/rev at
200rpm. If the tool life equation is given by
Ideal transverse roughness
Rmax = f 2 /8R
VT 0 .2
d 0 . 13 f 0 . 31
= 40 where R is the tool nose radius and f is the feed.
a b
Tool life and Tool Wear 1/4/2013
Surface produced on steel during cutting by SEM, a) turning and b) shaping
High temperature
a)) RRegion
i AB is i PPrimary
i shear
h zone-
• Reduces strength of the tool and formation of plastic deformation ( Ps )
create wear. b) Region BC is Secondary shear
• Shortens tool life zone friction ( Pf )
c) Region BD Between tool &
• Causes thermal distortion work piece plowing force (negligible)
• Caused dimensional change in work piece , Pm Power consumed
making of control dimensional accuracy difficult Pm = FcV
Fc Cutting force
Pm = Ps + Pf Pf = Ff V
Tool life and Tool Wear 1/4/2013 Tool life and Tool Wear 1/4/2013
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