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Module 3

This document discusses failure of cutting tools and tool life. It covers the following key points: (i) Cutting tools generally fail through mechanical breakage, plastic deformation, or gradual wear. Gradual wear is inevitable but can be slowed to enhance tool life. (ii) The main mechanisms of tool wear are mechanical, thermochemical, chemical, and galvanic wear. Wear patterns depend on factors like cutting temperature and work material properties. (iii) Essential properties for cutting tool materials include high strength, toughness, hardness, hot hardness, chemical stability, and thermal conductivity to resist failure mechanisms and prolong tool life.

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44 views4 pages

Module 3

This document discusses failure of cutting tools and tool life. It covers the following key points: (i) Cutting tools generally fail through mechanical breakage, plastic deformation, or gradual wear. Gradual wear is inevitable but can be slowed to enhance tool life. (ii) The main mechanisms of tool wear are mechanical, thermochemical, chemical, and galvanic wear. Wear patterns depend on factors like cutting temperature and work material properties. (iii) Essential properties for cutting tool materials include high strength, toughness, hardness, hot hardness, chemical stability, and thermal conductivity to resist failure mechanisms and prolong tool life.

Uploaded by

rahul231023
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Module3

Machinability
Version 2 ME IIT, Kharagpur

Lesson
14
Failure of cutting tools
and tool life
Version 2 ME IIT, Kharagpur
Instructional objectives
At the end of this lesson, the students will be able to
(i)
State how the cutting tools fail
(ii)
Illustrate the mechanisms and pattern of tool wear
(iii)
Ascertain the essential properties of cutting tool materials
(iv)
Define and assess tool life
(v)
Develop and use tool life equation.
(i) Failure of cutting tools
Smooth, safe and economic machining necessitate
• prevention of premature and catastrophic failure of the cutting tools
• reduction of rate of wear of tool to prolong its life
To accomplish the aforesaid objectives one should first know why and how the
cutting tools fail.
Cutting tools generally fail by :

i) Mechanical breakage due to excessive forces and shocks. Such kind of tool failure is random and
catastrophic in nature and hence are extremely detrimental.

ii) Quick dulling by plastic deformation due to intensive stresses and temperature. This type of failure also
occurs rapidly and are quite detrimental and unwanted.

iii) Gradual wear of the cutting tool at its flanks and rake surface.
The first two modes of tool failure are very harmful not only for the tool but also for the job and the
machine tool. Hence these kinds of tool failure need to be prevented by using suitable tool materials and
geometry depending upon the work material and cutting condition.

But failure by gradual wear, which is inevitable, cannot be prevented but can be
slowed down only to enhance the service life of the tool.

The cutting tool is withdrawn immediately after it fails or, if possible, just before it totally fails. For that
one must understand that the tool has failed or is going to fail shortly.

It is understood or considered that the tool has failed or about to fail by one or more
of the following conditions :
(a) In R&D laboratories

• total breakage of the tool or tool tip(s)


• massive fracture at the cutting edge(s)
• excessive increase in cutting forces and/or vibration
• average wear (flank or crater) reaches its specified limit(s)

(b) In machining industries

• excessive (beyond limit) current or power consumption


• excessive vibration and/or abnormal sound (chatter)
• total breakage of the tool
• dimensional deviation beyond tolerance
• rapid worsening of surface finish
• adverse chip formation.

Version 2 ME IIT, Kharagpur


(ii) Mechanisms and pattern (geometry) of cutting tool wear
For the purpose of controlling tool wear one must understand the various
mechanisms of wear, that the cutting tool undergoes under different conditions.
The common mechanisms of cutting tool wear are :
i) Mechanical wear
• thermally insensitive type; like abrasion, chipping and delamination
• thermally sensitive type; like adhesion, fracturing, flaking etc.
ii) Thermochemical wear
• macro-diffusion by mass dissolution
• micro-diffusion by atomic migration
iii) Chemical wear
iv) Galvanic wear

In diffusion wear the material from the tool at its rubbing surfaces, particularly at the rake surface
gradually diffuses into the flowing chips either in bulk or atom by atom when the tool material has
chemical affinity or solid solubility towards the work material. The rate of such tool wear increases with
the increase in temperature at the cutting zone.

Diffusion wear becomes predominant when the cutting temperature becomes very
high due to high cutting velocity and high strength of the work material.

Chemical wear, leading to damages like grooving wear may occur if the tool material is not enough
chemically stable against the work material and/or the atmospheric gases.

Galvanic wear, based on electrochemical dissolution, seldom occurs when both the work tool materials
are electrically conductive, cutting zone temperature is high and the cutting fluid acts as an electrolyte.

The usual pattern or geometry of wear of turning and face milling inserts are typically
shown in Fig. 3.2.1 (a and b) and Fig. 3.2.2 respectively.
KT
Fig. 3.2.1 (a) Geometry and major features of wear of turning tools
Version 2 ME IIT, Kharagpur
(iii) Essential properties for cutting tool materials

The cutting tools need to be capable to meet the growing demands for higher productivity and economy
as well as to machine the exotic materials which are coming up with the rapid progress in science and
technology.

The cutting tool material of the day and future essentially require the following
properties to resist or retard the phenomena leading to random or early tool failure :
i)

high mechanical strength; compressive, tensile, and TRA


ii) fracture toughness – high or at least adequate
iii) high hardness for abrasion resistance

iv) high hot hardness to resist plastic deformation and reduce wear rate at
elevated temperature
v) chemical stability or inertness against work material, atmospheric gases
and cutting fluids
vi) resistance to adhesion and diffusion
vii) thermal conductivity – low at the surface to resist incoming of heat and

high at the core to quickly dissipate the heat entered


viii) high heat resistance and stiffness
ix) manufacturability, availability and low cost.

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