MACHINING PROCESSES AND

METROLOGY

Dr. A.S.Sheytrabalan (Asso.Prof)

SMEC
 Module- 1
Mechanics of metal cutting
• Tool geometry and cutting tool materials
• temperature
• wear
• tool life considerations,
• chip formation
• surface finish
• Machinability and optimization.

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 Metal Cutting

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 Tool geometry and cutting tool materials

• Both material and geometry of the cutting tools play very

important roles on their performances in achieving

• effectiveness,

• efficiency and

• overall economy of machining

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 Cutting –Tool materials
• Cutting tools are subjected to

severe conditions with regard to

temperature, contact stresses,

and rubbing against the

workpiece surface as well as the

chip’s contact with the tool face.

• Proper selection of cutting

material is important.

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 Cutting –Tool materials
• Hot hardness- hardness, strength, and wear resistance of the tool are
maintained at the higher and the tool does not undergo any plastic
deformation and it should retains its shape and sharpness.

• Toughness and impact strength-forces due to vibration and chatter

during machining do not chip or fracture the tool.

• Thermal shock resistance- to withstand the rapid temperature cycling

encountered in interrupted cutting.

• Wear resistance- ability to resist abrasion

• Chemical stability and inertness – any adverse reactions, adhesion, and

tool-chip diffusion that would contribute to tool wear
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 Cutting –Tool materials

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Characteristics of Different cutting material

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 Cutting Tools
19th Century
• Plain carbon steels (low hot
hardness)
• Poor cutting properties
• begin to lose strength 200-300oC
• used in taps, cheap drills
1850’s
• Discovery of Fe3C (cementite)
• Hardening of steel
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1900: Development of high-speed
steel by Taylor, et al.
• add W, Mo, Cr, V to steel
• not much harder
• stable at high temperatures
• can be used at twice the speed of
tool steels
1923: – WC + Co
• Co wets WC and binds together
• Cemented 1-3 μm carbide structure
• Twice the speed of WC
• Not as tough as HSS
• fine grain structure helps
9
 Insert cutting tool

3-Aug-16 MEE307 CAD-CAM VIT VELLORE 10

 Cutting Tools-inserts
1960’s: Increased cutting speeds
• Powder metallurgy
• production of carbide inserts
• disposable inserts, no
resharpening
coatings feasible:
• TiC, TiN, Al2O3
• ≈ 5 μm layer to minimize strain
• higher wear resistant
• 50-70% of tool life expended
before coating penetrated.

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 Cutting Tool material-Ceramics
Diamond (C)
Aluminum oxide (Al2O3)
• wear resistant, but low strength • Higher hardness
Al2O3 + 30% TiC: hot-pressed • soluble in steel
(Cermets) • good for aluminum
• increased strength 15-30% • good for Si-Al alloys
• higher speeds - 3-5x of carbides • 10-40 μm particles are sintered
Si3N4 • onto a WC substrate ⇒
• – high toughness in bulk form polycrystalline tool
• – low thermal expansion
• – not for steel, dissolves - fast wear
Al2O3 + Si3N4 (SiAlON)
• – cuts Ni superalloys and steels

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 Cubic Boron Nitride (CBN)

• more stable with respect to steel

and Ni

• cuts very hard steels (10x carbide)

• cuts Ni-based super alloys (10x

carbide)

• wears quickly at low speeds, only

• good at high speeds

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Characteristics of cutting tool material

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