18MEPK0 – METAL CUTTING
ENGINEERING
Course Outcomes
By the end of the course, student will be able to:
1. Explain the types and characteristics of tool materials,
cutting tools nomenclature and various tool angle
specification
2. Explain the Mechanics of the machining process
3. Examine the thermal aspects and cutting fluids
4. Examine the tool wear, tool life, machinability.
5. Determine the tool life and surface roughness of machined
surfaces
6. Optimize the machining cost by varying the cutting
parameters
18MEPK0 – METAL CUTTING
ENGINEERING
Chapter-4
Tool wear, Tool life and
Machinability
Prof. [Link], M.E
E-mail: mkmect@[Link]
2
Chapter-4
Tool wear, Tool life and
Machinability
4.1 Introduction – Tool wear mechanism - 1
4.2 Types of tool damages – wear and chipping characteristic
of different tool materials - 1
4.3 Tool wear equation – Failure criteria – Tool life equation– 2
4.4 Effect of process parameters on tool life – Tool life tests - 2
4.5
Machinability – Introduction – Machinability rating- 1
4.4.1 Effect of Process Parameters
The different wear mechanisms are influenced by the hardness
an strength of the different constituents of the work material, hot
hardness, toughness and resistance to abrasive wear of the tool
material, tool temperature and affinity between work and tool
materials.
a) Tool Material Properties
b) Coating of tool
c) Work Material
d) Speed, Feed and Depth of cut
e) Tool Geometry
f) Cutting Fluid
g) Vibration Behaviour of the machine and tool
h) Interruption in the cut
i) Build Up Edge
4.4.1 Effect of Process Parameters
a) Tool Material Properties
The Properties of the tool material, which enhance its life,
include the following:
a) High hot-hardness to resist deformation, adhesion and
abrasion at the relatively high cutting temp
b) Toughness to resist sudden loads interrupted cutting
c) Wear Resistance
d) Lack of chemical affinity
e) High thermal conductivity and specific hear to
minimize the thermal stress and thermal shock.
4.4.1 Effect of Process Parameters
b) Coating of Tool
Coating of tool is a well known fact that enhances the tool life
considerably.
a) HSS tools are coated with TiN
b) WC tools are coated with TiC, Al2O3, TiN – Single
Layer
c) WC tools with Double layer (TiC + TiN, TiC, Al2O3)
4.4.1 Effect of Process Parameters
b) Coating of Tool
4.4.1 Effect of Process Parameters
b) Coating of Tool
4.4.1 Effect of Process Parameters
b) Coating of Tool
4.4.1 Effect of Process Parameters
c) Work Material
The properties of the work material that tend to increase the
life of the tool include the following:
a) Low strength and hardness to reduce the cutting forces,
cutting temp and abrasive wear.
b) Absence of abrasive constituents such as surface scale,
sand and slag
c) Presence of additives like lead to act as boundary
lubricant and sulfur to reduce cutting force and temp.
d) Lack of work hardening tendency
e) Favourable microstructure.
4.4.1 Effect of Process Parameters
d) Speed, Feed and Depth of Cut
4.4.1 Effect of Process Parameters
d) Speed, Feed and Depth of Cut
4.4.1 Effect of Process Parameters
d) Speed, Feed and Depth of Cut
4.4.1 Effect of Process Parameters
d) Speed, Feed and Depth of Cut
4.4.1 Effect of Process Parameters
d) Speed, Feed and Depth of Cut
4.4.1 Effect of Process Parameters
e) Tool Geometry
Rake angles, cutting edge angles, relief angles and nose radius
are affect the tool life by varying degree.
4.4.1 Effect of Process Parameters
e) Tool Geometry
Rake angles, cutting edge angles, relief angles and nose radius
are affect the tool life by varying degree.
4.4.1 Effect of Process Parameters
e) Tool Geometry
Rake angles, cutting edge angles, relief angles and nose radius
are affect the tool life by varying degree.
4.4.1 Effect of Process Parameters
f) Cutting Fluid
The cutting fluid cools the chip and the workpiece and even
reduce the frictional force between tool and workpiece.
If the tool material has low value of hot hardness (MS, HSS)
there is appreciable increase in tool life.
However in the case of carbides and oxides which have high
value of hot hardness, cutting fluid has negligible effect on tool
life.
4.4.1 Effect of Process Parameters
g) Vibration behavior
The machine, tool and work constitute a vibratory system
having several significant modes of vibration.
The larger the stiffness of machine, tool and w/p, and large the
inherent/damping, then greater in dynamic rigidity of the system
are cause of vibration in a machine.
If the machine is not properly not designed.
If the w/p is long and thin
If the tool overhang.
4.4.1 Effect of Process Parameters
h) Interruption in the cut
Sometimes the job is such that cutting edge has to frequently
enter and exit from the cut as, for example, in turning a work
piece having longitudinal slots.
Each entrance and exit means an impact on the cutting edge
that can shorten the tool life, especially if the tool material is hard
or brittle.
4.4.1 Effect of Process Parameters
i) Build up Edge
Under favorable cutting conditions, a built-up edge is
sometimes formed in case of certain tool-work pairs.
The built-up edge sticks to the actual cutting edge of the tool
and being in a work-hardened condition itself starts acting as a
cutting edge.
The built-up edge increases the effective rake angle of the tool
and reduces the cutting force, tool temperature and tool wear.
However the built-up edge has a tendency to grow in size,
become unstable and finally breakup.
The net effect of the built-up edge is an increase in flank wear
and decrease in crater wear.
4.4.2 Tool Life Tests
Tool life data is of crucial practical importance in machining
due to the following reasons.
To arrive at economical cutting conditions
To obtain the optimum tool geometry
To assess the performance of tool material, cutting
fluid, work material and machine tool.
Tool life tests can be classified as three types
i. Conventional tool life test
ii. Accelerated (High speed Cutting)
iii. Based on Variable speed cutting.
4.4.2 Tool Life Tests
i) Conventional Tool life Test
Conventional tool life tests are performed under practical
cutting conditions.
Given work material, tool material, tool geometry and
cutting fluid tentatively selected with help of data book
The factors whose effects on tool life are investigated in tool
life testing are speed, feed and depth of cut.
Often one factor is varied over its full range while other
factors are kept constant.
4.4.2 Tool Life Tests
i) Conventional Tool life Test
The tool life exponents n, n1 and
ne for T, f and d in are found by
plotting the experimental data.
This procedure involves a fairly
long and expensive testing program
involving considerable amount of
material, labour and machine time.
In order to minimize the
experimentation, DOE, RA and RSM
techniques are used.
4.4.2 Tool Life Tests
i) Conventional Tool life Test
A complicating element in tool
life testing is the relatively large
scatter of experimental data.
Identification and elimination of
extreme values and assessment of tool
life variability values of constants are
important.
4.4.2 Tool Life Tests
ii) Accelerated Tool life Tests
The main types of quick and less costly tool life testing are
the following:
a) Extrapolation on the basis of steady wear rate:
The progress of the flank wear before the onset of rapid wear is
produced in figure
4.4.2 Tool Life Tests
ii) Accelerated Tool life Tests
b) High Speed tests:
In this method, the tool life tests are carried out at much higher
cutting speeds than those that are used in practice, thereby shortening the tool
life to only a few minutes.
It is assumed that the constants of the tool life equation determined from
these tests also apply to practical cutting speeds.
This assumption must always be verified because as noted earlier higher
speeds cause higher tool-chip interface temperatures that may change the very
character of wear from say predominantly flank wear to predominantly crater
wear.
4.4.2 Tool Life Tests
iii) Variable speed Tests
A conventional tool life test is performed at constant cutting conditions
including the cutting speed.
Theoretically for a turning tool it would require many constant diameter
work pieces on which a single cutting pass is performed, because the piece
remaining after the pass is not used.
The cost of work material may be decreased by taking multiple machining
passes on the same work piece. This is precisely the purpose of variable speed
tests.
There are the three types of variable cutting speed tests namely
a) Facing Tests
b) Multi Pass turning
c) Taper turning
4.4.2 Tool Life Tests
iii) Variable speed Tests
a) Facing Tests
4.4.2 Tool Life Tests
iii) Variable speed Tests
a) Facing Tests
4.4.2 Tool Life Tests
iii) Variable speed Tests
b) Multi pass turning
4.4.2 Tool Life Tests
iii) Variable speed Tests
b) Multi pass turning
4.4.2 Tool Life Tests
iii) Variable speed Tests
c) Taper turning
4.4.2 Tool Life Tests
iii) Variable speed Tests
c) Taper turning
