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

Fundamentals of Cutting Oblique Cutting.Oblique Cutting. –THREE DIMENTIONAL –INCLINATION ANGLE Cutting Forces and Power.Cutting Forces and Power. –MACHINE TOOL SELECTION –DYNAMOMETER –MANY VARIABLES FRICTIONFRICTION CUTTING FLUIDSCUTTING FLUIDS TOOL SHARPNESSTOOL SHARPNESS PROCESSPROCESS

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

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

Cutting Tool MaterialsCutting Tool Materials ARE SUBJECTED TO...ARE SUBJECTED TO... –HIGH TEMPERATURES –CONTACT STRESSES –ABRASION MUST HAVE...MUST HAVE... –HARDNESS –TOUGHNESS –WEAR RESISTANCE –CHEMICAL STABILITY Cutting Tool Materials and Cutting Fluids Material Categories:Material Categories: CARBON AND MEDIUM ALLOY STEELSCARBON AND MEDIUM ALLOY STEELS HIGH-SPEED STEELSHIGH-SPEED STEELS CAST-COLBALT ALLOYSCAST-COLBALT ALLOYS CARBIDESCARBIDES COATED TOOLSCOATED TOOLS ALUMINA-BASED CERAMICSALUMINA-BASED CERAMICS CUBIC BORON NITRIDECUBIC BORON NITRIDE SILICON-NITRIDE-BASED CERAMICSSILICON-NITRIDE-BASED CERAMICS DIAMONDDIAMOND WHISKER-REINFORCED MATERIALSWHISKER-REINFORCED MATERIALS

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

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

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