Assignment

TOOL WEAR & TOOL LIFE

Submitted by:
Devansh Agrawal (14109042)
Avinash Jakkar (14109043)
Contents:

TOOL WEAR MECHANISM ........................................................................................................ 2

1. Abrasive wear ...................................................................................................................... 2

2. Adhesive Wear ..................................................................................................................... 2

3. Diffusion ............................................................................................................................... 3

4. Oxidation .............................................................................................................................. 3

5. Fatigue Wear ........................................................................................................................ 4

TYPES OF WEAR ......................................................................................................................... 5

1. Flank Wear ........................................................................................................................... 5

2. Crater wear .......................................................................................................................... 6

3. Chipping (premature wear) ................................................................................................. 6

TOOL LIFE .................................................................................................................................... 7

Tool Life Prediction...................................................................................................................... 7

Temperature in Metal cutting ..................................................................................................... 7

Temperature distribution in metal cutting ................................................................................. 8

Cutting temperature control ....................................................................................................... 8

Cutting temperature as a function of cutting parameters ......................................................... 8

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 TOOL WEAR MECHANISM
Major wear mechanisms-
1. Abrasive wear
2. Adhesion wear
3. Diffusion
4. Oxidation
5. Fatigue
6. Chemical decomposing

1. Abrasive wear
Softer material sliding over the face of hard material may contain appreciable concentration
of hard particles
Hard particles act as small cutting edge like grinding wheel
Hard particles result worn out of tool material
Particles of hard material are intermittently turn out from the surface and dragged along
the surface.

2. Adhesive Wear
When softer metal slide over hard metal, parts of soft metal adhere high spots on the metal
due to:
1. Friction
2. High temperature
3. Pressure
The spots result irregular flow of chip over the face and build up of more particles on the
tool

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 Finally, the built up edges will torn from the surface result uneven structure on the tool
surface

3. Diffusion
When a metal is in sliding contact with another metal the temperature at the interface is
high
The high temperature allows the atoms of hard material to diffuse into softer material
matrix
Hence the strength and abrasiveness of the softer material Increase
Atoms of the softer metal may also diffuse into harder medium, thus weakening the surface
of harder material, thus weakening the surface of harder material.

Diffusion phenomenon is strongly dependent on temperature.

4. Oxidation
Oxidation is the result of reaction between tool face and oxygen Ex. When machining steel
work piece with HSS or cemented carbide tool , groove formation is greatly accelerated if
the cutting zone is subjected to a jet oxygen.

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5. Fatigue Wear
Will occur when two surfaces slides in contact with other under high pressure
Roughness of one surface interlocks with those of other.
Due to friction, compressive force will be produced in one side and tensile on the other
side, These phenomenon course surface crack.
The cracks ultimately combine with one another and lead surface crumble.

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 TYPES OF WEAR
1. Flank wear (wear land)
2. Crater wear
3. Chipping

1. Flank Wear
It produces wear land on the sides and end of a flank
Tool-work piece interface
Predominant at low speed

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Primary region
breakage of sharp cutting edges
Secondary zone
The predominant zone caused by abrasion
Tertiary zone
Very sensitive to temperature, caused by diffusion wear
Increment of MRR increases flank wear

2. Crater wear
It occurs on the rake face of the tool in the form of pit called
crater
Predominant at high speed
Tool-chip interface
Diffusion, the loss of hardened atoms at the tool chip inter
face is the major cause of creator wear

3. Chipping (premature wear)

It refers the breaking y p g away of small chips from the cutting edge of tool or an insert on
account of impact or excessive plastic deformation.
Large chipping can be caused by interrupted cutting and sudden shock.

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 TOOL LIFE
Criteria for tool life-
Change of quality of machined surface
Change in magnitude of cutting force
Change in cutting temperature

Tool Life Prediction

Taylors tool life equation

where V is the cutting speed, T is the tool life, n is Taylor exponent.

n and C are constants depends on work material, feed, depth of
cut and cutting speed.

Modified Taylors tool life equation

where V is the cutting speed,

f is the feed
d is depth of cut
T is the tool life,
n, n1 and n2 are Taylor exponent.
n, n1 and n2 and C are constants depends on work material, feed, depth of cut and
cutting speed.

Example
A steel bar of 40mm diameter is to be turned over a length of 200mm with a depth of cut
1.2mm and feed of 0.2mm/rev at 200rpm. If the tool life equation is given by

VT 0.2d 0.13 f 0.31 = 40

Determine the number of components that may be turned before regrinding the tool.

Temperature in Metal cutting

High temperature
Reduces strength of the tool and formation of create wear.
Shortens tool life
Causes thermal distortion

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 Caused dimensional change in work piece, making of control dimensional accuracy difficult.

Temperature distribution in metal cutting

Cutting temperature control

Temperature in metal cutting can be controlled by

Application of cutting fluid(coolant)

Changing the cutting condition by reduction of cutting speed and/or feed.
Selection of proper cutting Geometry ex Positive tool orthogonal rake angle

Cutting temperature as a function of cutting parameters