CUTTING TOOLS

AND
FLUIDS
METAL CUTTING
CUTTING TOOLS
THE SIMILE OF AN AXE CUTTING WOOD WAS
OFTEN USED INCORRECTLY TO ILLUSTRATE
THE ACTION OF A CUTTING TOOL.




METAL-CUTTING TERMINOLOGY
A NUMBER OF TERMS RESULTED
FROM THE RESEARCH CONDUCTED
ON THE METAL CUTTIN, AND IT
MAY BE WISE TO CLEAR DEFINE
THIS TERMS
A BUILT-UP EDGE IS A LAYER OF
COMPRESSED METAL FROM THE
MATERIAL BEING CUT WHICH
ADHERES TO AND PILES UP ON THE
CUTTING TOOL EDGE DURING A
MACHINIG OPERATION.
THE CHIP-TOOL INTERFERENCE IS
THE PORTION OF THE FACE OF THE
CUTTING TOOL UPON WHICH THE
CHIP SLIDES AS IT IS CUT FROM
THE METAL.
PLASTIC DEFORMATION IS THE
DEFORMATION OF THE WORK
MATERIALS OCCURING IN THE
SHEAR ZONE DURING A CUTTING
ACTION.
PLASTIC FLOW IS THE FLOW OF
METAL OCCURING ON THE SHEAR
PLANE WHICH EXTENDS FROM THE
CUTTING TOOL EDGE.
A RUPTURE IS THE TEAR THAT OCCURS
WHEN BRITTLE MATERIAL, SUCH AS CAST
IRON, ARE CUT AND THE CHIP BREAKS
AWAY THE SURFACE. THIS GENERALLY
OCCURS WHEN DISCONTINUOUS OR
SEGMETED CHIPS ARE PRODUCED.
THE SHEAR ANGLE OR PLANE IS
THE ANGLE OF THE AREA OF THE
MATERIAL
Is the area where plastic deformation of the metal occurs. It is
along a plane from the cutting edge of the tool to its original
work surface.
Shear Zone
MACHINING OPERATION PERFORMED
ON LATHES, SHAPERS, MILLING
MACHINE, OR SIMILAR MACHINE
TOOLS PRODUCED CHIPS WHICH
FALL INTO THREE BASIC TYPES.

Type 1: discontinuous
(segmented) chips
-> are produced when brittle
metals, such as cast iron
and hard bronze, or some
ductile metals are cut under
poor cutting conditions.
Type 2: continuous chip
is a continuous ribbon
produced when the flow of
metal next to the tool face
is not greatly retarded by a
built-up edge at the chip
tool interface.
Type 3: continuous chip with
a built-up edge
-> Low-carbon machine steel,
when cut with a high sped
steel cutting tool without
the use of cutting fluids,
generally produces a
continuous-type chip with a
built-up edge.
DESCRIBES THE EASE OR
DIFFICULTY WITH WHICH A METAL
CAN BE MACHINED. SUCH
FACTORS AS CUTTING TOOL LIFE,
SURFACE FINISH PRODUCED, AND
POWER REQUIRED MUST BE
CONSIDER.
MACHINABILITY OF METALS
THE MACHINABILITY OF A METAL IS AFFECTED BY
ITS MICROSTRUCTURE AND WILL VARY IF THE
METAL HAS BEEN ANNEALED. CERTAIN
CHEMECAL NAD PHYSICAL MODIFICATION OF
STEEL WILL IMPROVE THERE MACHINABILIY .
FREE-MACHINING STEELS HAVE GENERELLY
BEEN MODIFIED IN THE FOLLOWING MANNER BY:

*THE ADDITION OF SULFUR
*THE ADDITION OF LEAD
*THE ADDITION OF SODIUM SULFITE
*COLD WORKING WHICH MODIFIES THE
DUCTILITY

GAIN STRUCTURE
BY MAKING THESE(FREE-MACHINIG) MODIFICATIONS TO THE STEEL, THREE
MAIN MACHINING CHARACTERISTICSBECOME EVIDENT:

*TOOL LIFE IS INCREASED




*A BETTER SURFACE
FINISH IS PRODUCED




*LOWER POWER CONSUMPTION
IS REQUIRED FOR MACHINING

THE MICROSTRUCTURE OF LOW-CARBON STEEL MAY HAVE LARGE
AREAS OF FERRITE ANTERPPERSED WITH SMALL AREAS OF
PEARLITE. FERIEIS SOFT WITH HIGH DUCTILITY AND LOW
STRENGTH, WHILE PEARLITE, A COMBINATION OF FERRITE AND
IRON CARBIDE, HAS LOW DUCTILITY AND HIGH STRENGHT.
LOW-CARBON(MACHINE) STEEL
A GREATER AMOUNT OF PEARLITE IS PRESENT IN HIGH CARBON
STEEL BECAUSE OF THE HIGHER AMOUNT OF CARBON CONTENT.
THE GREATER AMOUNT OF PEARLITE (LOW DUCTILITY AND HIGH
STRENGH) PRESENT IN THE STEEL, THE MORE DIFFICULT IT BECOMES
TO MACHINE THE STEEL EFFICIENTLY.






MICROSTRUCTURES DRILL BITS HEXAGON DIE
HIGH-CARBON(TOOL) STEEL
WHICH ARE ACOMBINATION OF TWO METALS ARE GENERALLY
LITTLE MORE DIFFICULT TO MACHINE THEN LOW OR HIGH-CARBON
STEELL. INORDER TO IMPROVE THEIR MACHINING QUALITES,
COMBINATIONS OF SULFUR AND LEAD OR SULFUR AND
MANGANESE IN PROPER PROPORTION ARE SOMETIMES ADDED
ALLOY STEEL.
ALLOY STEEL
CONSISTINGGENERALLY OF FERRITE, IRON CARBIDE, AND FREE
CARBON, FORM AN IMPORTANT GROUP OF MATERIALS USED BY
INDUSTRY. THE MICROSTRUCTURE OF CAST IRON CAN BE
CONTROLLED BY THE ADDITION OF ALLOYS, THE METHOD OF
CASTIG , THE RATE OF COOLING AND BY HEATING







WHITE CAST IRON


GREY CAST IRON
CAST IRON
Cutting Fluids

are essential in most metal-cutting operation. During a
machining process, considerable heat and friction are
created by the plastic deformation of metal occurring in
the shear zone when the chip slides along the chip-tool
interface. This heat and friction causes metal to adhere to
the cutting edge of the tool and the tool may break down,
result of poor finish and inaccurate work.
*REDUCTION OF TOOL COST. Cutting fluids reduced tool
ware
*INCREASED SPEED OF PRODUCTION. Because cutting
oils help reduce heat and friction, higher cutting speed can
be used in the operation
*REDUCTION OF POWER COST. Since friction is reduced by
a cutting fluid, less power is required for machining
operation and a corresponding saving in power cost is
possible.
*BETTER SURFACE FINISH. Since cutting fluids reduce
friction and prolong the keen edge of cutting tools, better
surface finishes and dimensional accuracy can be obtained.
Purposes and Advantages
GOOD COOLING CAPACITY
To reduce the cutting temperature, increase tool life and production, and improve
dimensional accuracy
GOOD LUBRICATING QUALITIES
to prevent metal from adhering to the cutting edge, forming a built-up edge, resulting
in a poor surface finish.
RUST RESISTANCE
which should eliminate stain, rust or corrosion to the work piece or machine.
Stability
both on storage or in use
RESISTANCE TO RANCIDITY
NONTOXICITY
so it will not cause skin irritation to the operator.
TRANSPARENCY
so that the operator can clearly see the work during machining
NONFLAMMABLE
so it will not burn easily and preferably be noncombustible, as well as not
smoke excessively, form gummy deposit which may cause machine slides to become
sticky

CHARACTERISTICS OF A GOOD CUTTING
FLUIDS
Cutting oils are classified under two types: active and inactive
cutting oils.
These terms relate to the oils chemical activity or ability to
react with the metal surface at elevated temperature to protect
it and improve the cutting action
CUTTING OILS
Which may be dark or transparent, fall into 3 general categories
SULFURIZED MINERAL OILS They are useful for cutting of
low-carbon steel and tough, ductile metals.

SULFOCHLORONATED MINERAL OIL These oil prevent
excessive built-up edges from forming and prolong the life of
the cutting tool. Also effective on low-carbon and chrome nickel
alloy steel

SULFOCHLORINATED FATTY OIL BLEND Contains more
sulfur than the other types and are effective cutting fluids for
heavy-duty machining.
Active Cutting Oils
Where the sulfur is so firmly attached to the oil that the every little is
released to react with the work surface during the cutting action, fall
into four general categories.
STRAIGHT MINERAL OILS They used for the nonferrous metals
such as aluminum and brass.
FATTY OILS They are generally used for severe cutting operation
on tough, nonferrous metals where a sulfurized oil might cause
discoloration.
FATTY AND MENIRAL OIL BLEND Are combinations of fatty and
mineral oil, resulting in better wetting and penetrating qualities than
straight mineral oils.
SULFURIZED FATTY-MINERALS OIL BLENDS they often used on
machine when ferrous and nonferrous metals are machined at the
same time
Inactive Cutting Tools
AN EFFECTIVE CUTTING FLUIDSHUOLD POSSES HIGH HEAT
CONDUCTIVITY, AND NIETHER MINERAL NOR FATTY OIL ARE VERY
EFFECTIVE AS COOLANTS. WATER IS THE BEST COOLING KNOWN;
HOWEVER USED CUTTING FLUID, WATER ALONE WOULD CAUSE RUST
AND HAVE LITTLE LUBRICATING VALUE. BY ADDING A CERTAIN
PERCENTAGE OF SOLUBLE OIL TO WATER, IT IS POSSIBLE TO ADD
RUST-RESISTANCE AND LUBRICATION QUALITIES TO THE EXCELLENT
COOLING CAPABILITIES OF WATER.
EMULSIFIABLE OILS
Sometimes called as synthetic fluids, have been widely accepted since they
were first introduced for machining purposes.
As a result of the chemical agents which are added to the cooling qualities of
water, synthetic fluids provide the following advantages:
Good rust control
Resistance for long period of time to becoming rancid
Excellent cooling quantities
longer durability than cutting or soluble oils
They are nonflammable
They are nontoxic
Easy separation from the work and chips, which makes them clean to
work with.
No clogging of the machine cooling system due to detergent action of
the fluid
CHEMICAL CUTTING FLUIDS
Cutting tool life and the machining
operation are greatly influenced by
the way that the cutting fluid is
applied.
Application of cutting fluids
The most effective method of applying cutting fluids
for these operation is to use oil feed drills and
hollow-shank reamers. Tools of this type transmit
the cutting edges and at the same time flush the
chip out of the hole
Drilling and Reaming
In slab milling, cutting fluid should be directed to
both sides of the cutter by fan-shaped nozzles
approximately three- forths the width of the cutter
Milling