1. IMS ENGINEERING COLLEGE
PRESENTATION ON
CUTTING FLUID
TOOL MATERIAL
TOOL WEAR
TOOL LIFE
PRESENTED BY
ADITYA KUMAR
ME-1 3rd YEAR
IMS ENGINEERING COLLEGE
SUBMITTED TO
Mr. DEEPAK SHARMA

2. OBJECTIVE
To make you aware about the cutting fluids , tool material , tool wear and tool life in simple and easier way.

3. OVERVIEW Cutting Fluid Types of cutting fluid Cutting Fluid Effects
Cutting Fluid Selection Criteria
Tool Material
Tool Wear
Tool Life

4. Cutting Fluids
Cutting fluids are used in metal machining for a variety of reasons such as improving tool life, reducing work piece thermal deformation, improving surface finish and flushing away chips from the cutting zone. Practically all cutting fluids presently in use fall into one of four categories:
1.Straight oils
2.Soluble oils
3.Semi synthetic fluids
4.Synthetic fluids

5. Straight oils are non emulsifiable and are used in machining operations in an undiluted form. They are composed of a base mineral or petroleum oil and often contains polar lubricants such as fats, vegetable oils and esters as well as extreme pressure additives such as Chlorine, Sulphur and Phosphorus. Straight oils provide the best lubrication and the poorest cooling characteristics among cutting fluids. 
Synthetic Fluids contain no petroleum or mineral oil base and instead are formulated from alkaline inorganic and organic compounds along with additives for corrosion inhibition. They are generally used in a diluted form (usual concentration = 3 to 10%). Synthetic fluids often provide the best cooling performance among all cutting fluids. 
Soluble Oil Fluids form an emulsion when mixed with water. The concentrate consists of a base mineral oil and emulsifiers to help produce a stable emulsion. They are used in a diluted form (usual concentration = 3 to 10%) and provide good lubrication and heat transfer performance. They are widely used in industry and are the least expensive among all cutting fluids. 

6. Semi-synthetic fluids are essentially combination of synthetic and soluble oil fluids and have characteristics common to both types. The cost and heat transfer performance of semi-synthetic fluids lie between those of synthetic and soluble oil fluids. 

7. Cutting fluid effects
The primary functions of cutting fluids in machining are :
Lubricating the cutting process primarily at low cutting speeds
Cooling the work piece primarily at high cutting speeds
Flushing chips away from the cutting zone
Corrosion protection of the machined surface
Enabling part handling by cooling the hot surface
Longer Tool Life
Reduced Thermal Deformation of Work piece
Better Surface Finish (in some applications)
Ease of Chip handling 

8. Cutting Fluid Selection
Criteria
Process performance :
Heat transfer performance
Lubrication performance
Chip flushing
Fluid carry-off in chips
Corrosion inhibition
Fluid stability (for emulsions)
Cost Performance
Environmental Performance
Health Hazard Performance

9. Material
Milling
Drilling
Tapping
Turning
Aluminium
Soluble oil (96% water) or mineral oil
Soluble oil (70-90% water)
25% sulfur-based oil mixed with mineral oil
Mineral oil with 10% fat (or) soluble oil
Brass
Soluble oil (96% water)
Soluble oil
10-20% lard oil with mineral oil
Mineral oil with 10% fat
Bronze
30% lard with mineral oil
Alloy Steels
10% lard oil with 90% mineral oil
30% lard oil with 70% mineral oil
25% sulfur base oil with 75% mineral oil
Cast Iron
Dry
Dry or 25% lard oil with 80% mineral oil
Malleable Iron
Copper
Low Carbon and Tool Steels
25-40% lard oil with mineral oil
25% lard oil with 75% mineral oil

10. TOOL MATERIAL
Tool failure modes identify the important properties that a tool material should possess:
Toughness ‑ to avoid fracture failure
Hot hardness ‑ ability to retain hardness at high temperatures
Wear resistance ‑ hardness is the most important property to resist abrasive wear

11. Plain carbon steel shows a rapid loss of hardness as temperature increases.
High speed steel is substantially better, while cemented carbides and ceramics are significantly harder at elevated temperatures.

12. HIGH SPEED STEEL
Highly alloyed tool steel capable of maintaining hardness at elevated temperatures better than high carbon and low alloy steels
One of the most important cutting tool materials
Especially suited to applications involving complicated tool geometries, such as drills, taps, milling cutters, and broaches
Two basic types (AISI)
Tungsten‑ type, designated T‑ grades
Molybdenum‑ type, designated M‑ grades

13. HIGH SPEED STEEL COMPOSITION
Typical alloying ingredients:
Tungsten and/or Molybdenum
Chromium and Vanadium
Carbon, of course
Cobalt in some grades
Typical composition:
Grade T1: 18% W, 4% Cr, 1% V, and 0.9% C

14. CERAMICS
Primarily fine‑grained Al2O3, pressed and sintered at high pressures and temperatures into insert form with no binder.
Applications: high speed turning of cast iron and steel
Not recommended for heavy interrupted cuts (e.g. rough milling) due to low toughness
Al2O3 also widely used as an abrasive in grinding .

15. SYNTHETIC DIAMOND
Sintered polycrystalline diamond (SPD) - fabricated by sintering very fine‑grained diamond crystals under high temperatures and pressures into desired shape with little or no binder
Usually applied as coating (0.5 mm thick) on WC-Co insert
Applications: high speed machining of nonferrous metals and abrasive nonmetals such as fiberglass, graphite, and wood
Not for steel cutting

16. CUBIC BORON NITRIDE
Next to diamond, cubic boron nitride (cBN) is hardest material known
Fabrication into cutting tool inserts same as SPD: coatings on WC‑Co inserts
Even at high temp. C.B.N is chemically inert to ferrous metals and resist oxidation.
Applications: machining steel and nickel‑based alloys
SPD and cBN tools are expensive

17. TOOL WEAR Abrasion - dominant cause of flank wear
Adhesion – high pressure localized fusion and rupturing
Diffusion – Loss of hardening atoms at tool-chip boundary (contributes to crater wear)
Plastic deformation – contributes to flank wear

18. CRATER WEAR
FLANK WEAR

19. Taylor Tool Life Equation
This relationship is credited to F. W. Taylor (~1900)
where v = cutting speed; T = tool life; and n and C are parameters that depend on feed, depth of cut, work material, tooling material, and the tool life criterion used
n is the slope of the plot
C is the intercept on the speed axis

20. A more general form of the equation is

22. THANK YOU