Fundamentals of Cutting CuttingTool Materials and Cutting Fluids

Fundamentals of Cutting & Cutting-Tool Materials and Cutting Fluids MANUFACTURING ENGINEERING AND TECHNOLOGY BY KALPAKJIAN THIRD EDITION

Introduction Cast, formed and shaped products may need further machining operations. Machining processes remove material from a workpiece. • CUTTING: • ABRASIVE: • NONTRADITIONAL:

Fundamentals of Cutting • Mechanics of Chip Formation. – RAKE ANGLE – RELIEF ANGLE – SHEAR ANGLE • Chip Type. – CONTINUOUS – BUILT-UP EDGE – SERRATED – DISCONTINUOUS.

Fundamentals of Cutting • Oblique Cutting. – THREE DIMENTIONAL – INCLINATION ANGLE • Cutting Forces and Power. – MACHINE TOOL SELECTION – DYNAMOMETER – MANY VARIABLES • • FRICTION CUTTING FLUIDS • TOOL SHARPNESS • PROCESS

Fundamentals of Cutting • Temperatures in Cutting. – TOOL PROPERTIES – DIMENSIONAL ACCURACY • Tool Life. – HIGH STRESSES & TEMPERATURES – GRADUAL WEAR – MANY VARIABLES • • MATERIAL CUTTING FLUIDS • TOOL SHAPE • SPEEDS & FEED RATE – CHIPPING

Fundamentals of Cutting • Surface Finish and Integrity – GEOMETRY – PROPERTIES • FATIGUE LIFE • CORROSION RESISTANCE • Machinability – RATINGS BASED ON TOOL LIFE – DECREASES AS HARDNESS INCREASES – ALLOYING ELEMENTS

Cutting Tool Materials and Cutting Fluids • Cutting Tool Materials • ARE SUBJECTED TO. . . – HIGH TEMPERATURES – CONTACT STRESSES – ABRASION • MUST HAVE. . . – – HARDNESS TOUGHNESS WEAR RESISTANCE CHEMICAL STABILITY • Material Categories: • CARBON AND MEDIUM ALLOY STEELS • HIGH-SPEED STEELS • CAST-COLBALT ALLOYS • CARBIDES • COATED TOOLS • ALUMINA-BASED CERAMICS • CUBIC BORON NITRIDE • SILICON-NITRIDE-BASED CERAMICS • DIAMOND • WHISKER-REINFORCED MATERIALS

Cutting Tool Materials and Cutting Fluids • Cutting Fluids – REDUCE FRICTION AND WEAR – REDUCE ENERGY CONSUMPTION – COOL THE CUTTING ZONE – PROTECT MACHINED SURFACES • Fluid Action – CAPILLARY ACTION – SMALL MOLECULAR SIZE – PROPER WETTING CHARACTERISTICS

Cutting Tool Materials and Cutting Fluids • Types of Cutting Fluids – OILS – EMULSIONS – SEMI-SYNTHESIS – SYNTHETICS • Methods of Application – FLOOD COOLING – MIST COOLING – HIGH PRESSURE REFRIGERATED SYSTEMS

Cutting Tool Materials and Cutting Fluids • Effects of Cutting Fluids on… – WORKPIECE MATERIALS – MACHINE TOOLS • Biological and Environmental Effects – OPERATOR CONTACT – EXTERNAL ENVIRONMENT – DEGREDATION & CHEMICAL CHANGE • Waste Management – CLARIFICATION – RECYCLING – DISPOSAL