Cutting tool material

The influential parameter for selection of cutting fluid in machining processes is the cutting
tool material. Various cutting tool materials are commercially available for all kind of
machining processes. High speed steel cutting tools can be used with all type of cutting
fluids. However waterless cutting fluids are preferred when difficult-to-cut materials are
machined. In case of the tungsten carbide (WC) cutting tools application, more cooling
characteristics from cutting fluids are required. This is because of high generated heat in the
interface of cutting tool and work piece material. The negative effect of generated heat during
machining with WC cutting tools causes rapid tool wear. Hence tool life will be shorter and
surface finish quality falls. Ceramic and diamond cutting tools can also protect their
characteristics at high temperatures. They are generally used in finish machining operation. In
using ceramic cutting tools, air is sprayed into the cutting zone. The water based cutting
fluids must be used when diamond type cutting tool materials are used. [1]
Carbide tool
Nowadays Carbide tools have replaced instead of high-speed steels in most applications.
These carbide and coated carbide tools cut about 3 to 5 times faster than high-speed steels.
Ceramic cutting tools are harder and more heat-resistant than carbides, but more brittle.
The proper choice can double tool life or double the cutting speed of the same tool. Coated
tools should be considered for most machining applications because of their longer life and
faster machining.
Super hard tool
Super hard tool materials are divided into two categories: Cubic boron nitrate (CBN) and
polycrystalline diamonds (PCD) cutting tools have been found important place in machining
processes. However, these cutting tools are expensive and they can protect their
characteristics in high temperature machining conditions. They are generally used in finish
machining operation to obtain high dimensional accuracy and excellent surface finish quality.
The application of cutting fluids is not necessary when machining operations are carried out
with these cutting tool materials. Cubic boron nitride is used for machining very hard ferrous
materials such as steel dies, alloy steels and hard-facing materials.
All cutting tools are perishable, meaning they have a finite working life. A stronger carbide
grade, different edge preparation, or lead angle change may eliminate chipping. Built-up edge
is a deposit of work piece material adhering to the rake face of an insert. These deposits can
break off, pulling out pieces of carbide from the tool. [3]
Cutting tool coatings
The major categories of hard carbide include tungsten carbide, titanium carbide, tantalum
carbide, and niobium carbide. Each type of carbide affects the cutting tools characteristics
differently. A higher tungsten content increase wears resistance, but reduces tool strength. A
higher percentage of cobalt binder increases strength, but lowers the wear resistance. [2]
Work piece material
The main factor for selection of suitable cutting fluids in machining processes is the type of
work piece material. The application of cutting fluids should provide easy machining
operation in all materials. Cast iron cast group of material s are brittle during machining they
break into small size chips. The friction between cutting tool and chip is less due to small size
chip formation. It was proposed that using emulsion cutting fluids increases surface finish
quality and prevents dust formation during machining. The concentration of emulsion cutting
fluid should be kept around 12% 15% to decrease oxidation.

In steel machining operation, generally the high pressure containing and additive cutting
fluids are used. In stainless steel machining, high pressure cutting oils should be selected.
Work-hardening properties in some steels would cause some problems during machining
operation. However using sulphur added oils for this kind of steels machining leave stain
over machined surface. For machining of heat resistant and difficult-to-cut steel alloys, water
based cutting fluids are preferred, because temperature becomes higher in cutting area. The
mixture ration of water based cutting fluids changes between 1/20 1/40. In some machining
operations, using sulphur added mineral cutting oils is possible.

During machining of aluminium and aluminium alloys, high temperatures do not occur
Waterless cutting fluids prevent the formation of built up edge, however this type of cutting
fluids must be non-active (leaving no stain).

Machining of copper and copper alloys poses similar problems. The application of emulsion
cutting fluids or thin mineral oils should be selected for copper and copper based alloys
machining. High pressure additive cutting oils are preferred for brass machining.

In the machining of nickel and nickel alloys, the machining operation should be carried out as
dry or using cutting fluids. Higher cutting speeds and feed rates should be selected when
cutting fluids are used in the machining of these materials. Generally sulphured mineral oil as
cutting fluid is preferred. Water based cutting fluids are used in turning with high cutting
speed, milling and drilling operations. The applications of synthetic cutting fluids are possible
in drilling and broaching operations.

In machining of the difficult-to-cut materials such as titanium alloys, high temperature
becomes an influential factor for selection of cutting fluid. Therefore the application of
cutting fluid would eliminate the effect of generated heat during machining process. The
selected cutting fluid must have both cooling and lubricating characteristics. The cooling
factor of cutting fluid is more important in machining of titanium alloys due to high heat
generation during machining operation. This would also induce to use higher cutting speeds.
It is observed that lubrication properties of selected cutting fluids are preferred when low
cutting speeds are selected. Emulsion oil can be selected in the machining of titanium alloys
when cutting speeds are used; chlorine additive cutting oils are preferred when high cutting
speed is selected.

In the machining operations of composites that used commonly nowadays, using cutting
fluids is recommended. In particular the using cutting fluid has positive influence on the
surface roughness quality. [1]

Effect on work piece material properties

Some research found that when alloys were subjected to cryogenic cooling, the hardness
increased retaining most of their mechanical properties, making them a very good choice as
cutting material. However, some other researchers have noted little difference when the same
cryogenic treatment is applied on high-speed steels and other cutters. Some researchers
agreed that different treatment attempted by different researchers has contributed to the
difference in the results of material properties being reported. Further recommended that the
best approach is by having simultaneous cooling of both work piece and cutting tools would
be an ideal effective cryogenic cooling strategy. [4]
Die and mould material
Our research focus is on the Die and mould manufacturing industries. Die and mold makers
deal with steel in wide ranges of hardness, from low (HB 200 and less) to high (HRC 63).In
line with the main field of application there are six general and two special-purpose classes of
tool steels, from which the following are the most popular in the die and mold industry:
Cold- work tool steels including A series (air-hardening medium-alloy), D series (high-
carbon high-chromium) and O series (oil hardening)
Hot-work H series
Water hardening W series
Plastic mold P series
Shock resistant S series
Special-purpose L series (low-alloy).
In die and mold design, the main properties of tool steels are strength, wear resistance,
corrosion resistance, etc. However, while for a die and tool maker dealing with the material,
which has already been specified by designers, more important properties are: hardness,
machinability, polish ability and dimensional stability. Consequently, in die and mold
making process, hardness of tool steel (even the Same grade) can vary within a wide range
from HB 200 and less (soft steel) to HRC 63 (hard steel). Therefore, steels can be divided
into the following conditional groups depending on their hardness.
Soft annealed to hardness to HB 250
Pre-hardened of two grades:-HRC 30-37 HRC 38-44
Hardened of three grades: - HRC 45-49 HRC 50-55 HRC 56-63 and more


Hard to cut metals
Machining performance on hard to cut metals should be done with properly designed hard
tools and this would cost much higher than soft metal machining. Materials especially
tailored for extreme conditions and environments, which are resistant to very high or very
low temperatures are becoming increasingly important in a variety of industrial fields. Such
materials are difficult to cut.
Moreover difficult to cut materials such as special cast iron (ADI), Aerospace Titanium- or
Sandwich materials, Inconel alloys, hard AISI 440 C stainless steel and hard SCM 440 alloy
steels and organic matrix composites (OMC) are more extensive used in different mechanical
industrial fields. These require a greater use of specialized fluids and tools; both of which
incur a high cost to the final product and also a series of environmental and health problems.
[5]
Hard martensitic stainless steel is found that from the research it produced saw tooth chips in
all operating parameters which increased the cutting forces. There was a research conducted
study on cutting AISI 420 steel using PCBN tool. In this research, two work materials are
used and they are hard AISI 440 C martensitic stainless steel and SCM 440 alloy steel. AISI
410, 420 and 440 A, B, C is all considered as martensitic stainless steel and can be hardened
like other alloy steels. AISI 440 C is widely used in aerospace industries for bearings, steam
and water valves, pumps, turbines, compressor components, shafting, cutlery, surgical tools,
plastic moulds, nuclear applications etc. which demand high strength and high resistance to
wear and corrosion. It has high viscosity, poor thermal conductivity, low corrosion, high
work hardening rate and tendency to form built up edge (BUE) at tool edge. AIST 440 C has
high chromium and high carbon content and possesses high mechanical strength. The SCM
440 material is best known as Cr-Mo alloy steel. This grade steel is used in high tensile
applications where wear resistance is of prime importance.

Chemical Properties of materials Operating parameters
Alloying elements AISI 440C SCM 440
Carbon 0.95-1.20 0.35-0.43 Cutting velocity - 100,125,150,175,200
m/min
Manganese 1.00 0.75-1.00 Feed rate - mm/rev 0.10, 0.20 and 0.30
Chromium 16-18 0.75-0.80 Depth of cut 1.00
Molybdenum 0.75 0.15-0.25
[6]
Chemical properties of materials and Operating parameters
Hard to cut metals have been selected
AISI D2
AISI D2 is a high-carbon, high-chromium tool steel alloyed with molybdenum and vanadium
characterized by:
High wear resistance
High compressive strength
Good through-hardening properties
High stability in hardening
Good resistance to tempering-back.
Typical
analysis
C
1.55
Si
0.3
Mn
0.4
Cr
11.8
Mo
0.8
V
0.8
Standard
Specification
AISI D2 W-Nr 1.2379
Delivery
Condition
Soft annealed to approx. 210 HB
Color code Yellow / White


Applications
AISI D2 is recommended for tools requiring very high wear resistance, combined with
moderate toughness (shock-resistance). AISI D2 can be supplied in various finishes,
including the hot-rolled, pre-machined and fine machined condition.
Properties
Physical Data
Temperature
68 F
(20C)
390F
(200C)
750F
(400C)
Density
lbs/in^3 0.277 0.276 0.275
kg/m^3 7700 7650 7600
Coefficient of thermal
expansion
low tempering
Per F from 68F 6.8*10^-6
Per C from 20C 11.2*10^-6
high temperature tempering
per F from 68 F 6.2*10^-6 6.7*10^-6
per C from 20C 11.2*10^-6 12810^-6
Thermal conductivity
Btu in/ft^2hF 139 146 159
W/m F 20 21 23
Modulus of elasticity
ksi 30 450 29 000 26 100
Mpa 210 000 200 000 180 000
Specific heat
Btu/lbF 0.11
J/kgC 460
Properties of hard to cut materials
AISI P20
Mechanical properties:
As normally delivered in the hardened and tempered state, hardness is normally 32HRC. No
hardening risks, no heat treatment, no distortion to tools. Can be further nitride or flame
hardened, locally. Heavier sections can be supplied pre machined saving on weight and less
machining.


Physical Properties:
Density 0.284 lb/in
3
(7861 kg/m
3
)
Specific Gravity 7.86
Modulus of
Elasticity
30 x 10
6
psi (207 GPa)
Thermal
conductivity
24 Btu/ft/hr/F 41.5 W/m/K
Machinability 60-65% of a 1% carbon steel

Coefficient Of Thermal Expansion
Temperature F in/in F x10
6
Temperature C mm/mm Cx10
6

70-200 6.7 21-93 12.0
70-500 7.2 21-260 12.9
70-1000 7.6 21-538 13.7

Tempering:
Temperature P20 tool steel
F C HRC
400 204 48 49
600 316 46 47
800 427 43 44
1000 538 39 40
1100 593 33 34
1150 621 30 31

P20 is chrome - moly tool steel made specifically to fill the requirements for the machined
cavities and forces used in zinc die casting and plastic molding. It is delivered fully quenched
and tempered to approximately Brinell 300. Other hardness levels may be obtained through
additional heat treatment. P20 is the standard mold steel for machine - cut plastic molds and
zinc die casting dies. P20 is usually supplied in the pre hardened condition, about 300 Brinell,
for injection molds and zinc die casting dies. While in the pre hardened condition, P20 can be
nitride for greater wear resistance. It can also be textured in the pre hardened state. P20 is
also available at an annealed hardness of about 200 Brinell. It can be hardened or carburized
up to a higher hardness of 50/60 RC when used for compression or transfer work. Pre
hardened P20 is used in cavities and cores of zinc die -casting dies, in plastic - molding dies,
and in other mold parts which do not require high surface hardness or high temperature
operation. When carburized, P20 is used for compression, transfer, and other types of molds
requiring high surface hardness.
Machinability - In the pre hardened condition, P20 has a machinability rating of 65 as
compared with a rating of 100 for a 1 percent carbon tool steel. Dimensional Stability -When
quenched in oil from a hardening temperature of 1550 F, this grade normally expands 0.003
in./in. However, as with all liquid quenching analyses, dimensional changes during heat
treatment are greatly influenced by the size and shape of the piece. Strict observance of good
heat treating practice is essential for minimum distortion.


References

[1] A. Yardimeden, T. Ozben, E. Kilickap O. akr*, "Jornal of Achievements in Materials,"
Selection of cutting fluids in machining process, vol. 25, p. 4, December 2007.
[2] Dr. Neil Canter, "The possibilities and limitations of dry machining".
[3] www.sme.org.
[4] Zahari Taha1 and Indra Putra Almanar2 Aznijar Ahmad-Yazid1*, "A review of cryogenic
cooling in high speed machining," January 2010.
[5] Italy) ,TECOS Celje (Slovenia),Gazela d.o.o. (Slovenia) Wolframcarb SpA (Piedmont.
(2007) www.manunet.net.
[6] S.Thamizhmanii and Sulaiman Hasan, "Machinability Study using Chip Thickness Ratio
on Difficult to Cut," p. 6, Feb 2012.