1. CUTTING TOOLS & FLUIDS

2. Chan Yim Ling101674 Isaac Koh Ming Kuan101688 Lye Jin Hoon101703 Soon Vern Yee101719 Teo Pao Ter101725 Teoh Kheng Swee101726 Yip Zhang Rong101734

3. Introduction Cutting Tools Cutting Fluids Conclusion

4. What is cutting tool/fluid ? General properties ? Types ? STAY TUNED…..

5. Attached to machine → removal of unwanted part → machining is accomplished Modes of tool failure: a)Fracture – due to excessive force at cutting point b)Temperature – due to cutting temperature too high → tool point soften (plastic deformation) → loss of sharp edge c)Gradual wear – causes loss of tool shape & reduction in cutting efficiency Different cutting tools = Different performances

6. Hot Hardness Wear resistance Toughness Capability of material to absorb energy before failing High toughness is required Ability of material to retain its hardness at high temperature High hot hardness = high resistance to bulk deformation Ability of material to resist abrasion & erosion High hardness = high wear resistance (required)

7. Various Types High Speed Steel Plain Carbon Tool Steel Cast Cobalt Alloys Synthetic Diamonds Ceramics Carbides Group

8. Any liquid that is applied directly to the machining operation to improve cutting performance. Why cutting fluids? – To overcome: a)Heat generation at shear zone and friction zone b)Friction at tool–chip & tool–work

9. Coolant Role Reduction in temperature Retain tool hardness & reduce thermal distortion

10. Lubricant Role Reduce friction effect at tool-chip & tool-work Carry away chip

11. Types Straight Metal Working oil Semi- synthetic metal Working Fluids Emulsifiable Metal Working Oil Synthetic Metal Working Fluids

12. Discussions of Selected Cutting Tools Comparison of the Tools

13. Selected Cutting Tool Synthetic Diamond High Speed Steel Cermet, Cemented & Coated Carbides

14. General Info Strength & Weakness Applications

16. M- series: Molybdenum (95% of HSS) – Higher abrasion resistance – Less distortion during heat treatment – Inexpensive T- series: Tungsten It was developed to machine at higher speed than carbon steel

17. STRENGTH High toughness Inexpensive Good for interrupted cuts WEAKNESS Low cutting speeds compare to carbide tools Limited hardenability Limited wear resistance

18. Drills Reamers Taps Gear Cutters Saw blades

19. General Info Strength & Weakness Applications

20. Made of sintered polycrystalline diamond (SPD) Fabricated by sintering fine grained diamond crystal under high temperature and pressure. Crystal have random orientation. SYNTHETIC DIAMOND CUTTING TOOL

21. STRENGTH Hardest material (6000 HK) High toughness High strength (1000 MPa) WEAKNESS Not suitable for machining ferrous metals and nickel based alloy – Due to chemical affinity between metals & carbon

22. Widely used in high speed machining of non- ferrous metals and abrasive non-metal materials such as Fiberglass Graphite Wood

23. General Info Properties Applications

24. 1.Definition Ceramic-metal composites containing TiC, TiN, and certain other ceramics not including WC 2.General Info TiC, TiN, and TiCN, with Ni and/or Mo as binders. Some of the cermets are more complex

25. 3.Properties Higher speeds - better compared with steel-cutting carbide grades. Lower feeds - better surface finishing & no need for grinding. 4.Applications High-speed finishing and semi-finishing of steels, stainless steels, and cast irons.

26. 1.Definition Cermets based on WC–Co, including WC–TiC–TaC–Co 2.General Info Non-steel-cutting grades, consisting of only WC–Co Steel-cutting grades, with combinations of TiC and TaC added to the WC–Co.

27. 3.Properties High compressive strength but low-to-moderate tensile strength; High hardness (90 to 95 HRA); Good hot hardness; Good wear resistance; High thermal conductivity; High modulus of elasticity—E values up to around 600 x 10 3 MPa (90 x 10 6 lb/in 2 ); Toughness is lower than high-speed steel.

28. Non-steel Cutting Grade Suitable for machining Al, brass, Cu, Mg, titanium, and other nonferrous metals (gray cast iron) Steel cutting Grade Used for low carbon, stainless and other alloy steels 10 to 25wt% of the WC might be replaced by combinations of TiC and TaC 4. Applications

29. 1.Definition Very thin coating to a WC–Co substrate 2.General Info A cemented carbide insert coated with one or more thin layers of wear-resistant material, such as TiC, TiN, and/or Al 2 O 3. Thickness - 2.5 to 13 mm

30. 3.Properties Provides low dynamic force and thermal shock 4.Applications To machine cast irons and steels in turning and milling operations

31. CharacteristicSynthetic diamondCoated carbidesCemented carbideCermetHSS Toughness Hot hardness Wear resistance Cutting speed Material Sintered polycrystalline diamond WC-Co coated with thin film Cermet + WC-Co Or WC-Co TiC, TiN, TiCNMO (10%) Or T (12-18%) Strength (+) or weakness (-) Can’t use to machine ferrous & Ni alloy (-) Prevent crater wear (+) WC-Co type: Crater wear occur rapidly (-) Can’t cut ferrous alloy (-) Good surface finish (+) Complex single- piece tools possible (+) High rake- angle tools (+)

32. CharacteristicSynthetic diamondCoated carbidesCemented carbideCermetHSS Exact application of the tools Powder => grinding abrasive Drill bit Incorporated in angle grinder blade. High speed milling Rotary cutters for high-speed cutting of artificial fibres. Blades in boring machine Tool bits Blades in power saw

33. General Strength Types, Strength & Weakness Parameter of Cutting Fluids

34. Improve surface finish Increase tool life Improve cutting dimensional accuracy Lower energy consumption Cleaner cutting zone Better corrosion protection

35. TypesStrengthWeakness Straight metalworking oils Excellent lubrication Good corrosion protection Easy maintenance Poor heat removal Toxic mist High viscosity Flammable Expensive Emulsifiable metalworking oils Good lubrication Good cooling capacity Some corrosion protection Low cost Non-flammable Require other additives (anti-bacteria, maintenance) Toxic mist Susceptibility to form hard water Synthetic metalworking fluids Very good cooling capacity Good lubrication Stable Good corrosion protection Low mist Easy handling, cleaning and maintenance Some toxicity Easy contamination High cost Semi-synthetic metalworking fluids Combination of emulsifiable oils and synthetic fluids

36. Flow Rate Thermal Practical Directional of Fluid Fluid Pressure Fluid penetration Volume of liquid flow per unit time Chip-tool interface (Rake Face) Work piece-tool interface (Flank Face) Top surface of the chip

38. Parameters Control Cooling Rate Sticky Zone Hardness of Chip

39. Improve surface finish Increase tool life Improve cutting dimensional accuracy Lower energy consumption Cleaner cutting zone Better corrosion protection

40. Cutting tools required high wear resistance, high hardness and high hardness. Cutting fluid applications depend on type of fluid, fluid pressure, fluid flow rate and fluid direction. Combination of cutting tools with cutting fluid will improve the machining process.