Fundamentals of Cutting

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Fundamentals of Cutting Cutting-Tool Materials
and Cutting Fluids
MANUFACTURING ENGINEERINGAND TECHNOLOGYBY
KALPAKJIANTHIRD EDITION
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Introduction

• Cast, formed and shaped products may need
  further machining operations.
• Machining processes remove material from a
  workpiece.
• CUTTING
• ABRASIVE
• NONTRADITIONAL

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Fundamentals of Cutting

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

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Fundamentals of Cutting

• Oblique Cutting.
• THREE DIMENTIONAL
• INCLINATION ANGLE
• Cutting Forces and Power.
• MACHINE TOOL SELECTION
• DYNAMOMETER
• MANY VARIABLES
• FRICTION
• CUTTING FLUIDS
• TOOL SHARPNESS
• PROCESS

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Fundamentals of Cutting

• Temperatures in Cutting.
• TOOL PROPERTIES
• DIMENSIONAL ACCURACY
• Tool Life.
• HIGH STRESSES TEMPERATURES
• GRADUAL WEAR
• MANY VARIABLES
• MATERIAL
• CUTTING FLUIDS
• TOOL SHAPE
• SPEEDS FEED RATE
• CHIPPING

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Fundamentals of Cutting

• Surface Finish and Integrity
• GEOMETRY
• PROPERTIES
• FATIGUE LIFE
• CORROSION RESISTANCE
• Machinability
• RATINGS BASED ON TOOL LIFE
• DECREASES AS HARDNESS INCREASES
• ALLOYING ELEMENTS

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Cutting Tool Materials and Cutting Fluids

• Cutting Tool Materials
• ARE SUBJECTED TO...
• HIGH TEMPERATURES
• CONTACT STRESSES
• ABRASION
• MUST HAVE...
• HARDNESS
• TOUGHNESS
• WEAR RESISTANCE
• CHEMICAL STABILITY

• Material Categories
• CARBON AND MEDIUM ALLOY STEELS
• HIGH-SPEED STEELS
• CAST-COLBALT ALLOYS
• CARBIDES
• COATED TOOLS
• ALUMINA-BASED CERAMICS
• CUBIC BORON NITRIDE
• SILICON-NITRIDE-BASED CERAMICS
• DIAMOND
• WHISKER-REINFORCED MATERIALS

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Cutting Tool Materials and Cutting Fluids

• Cutting Fluids
• REDUCE FRICTION AND WEAR
• REDUCE ENERGY CONSUMPTION
• COOL THE CUTTING ZONE
• PROTECT MACHINED SURFACES
• Fluid Action
• CAPILLARY ACTION
• SMALL MOLECULAR SIZE
• PROPER WETTING CHARACTERISTICS

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Cutting Tool Materials and Cutting Fluids

• Types of Cutting Fluids
• OILS
• EMULSIONS
• SEMI-SYNTHESIS
• SYNTHETICS
• Methods of Application
• FLOOD COOLING
• MIST COOLING
• HIGH PRESSURE REFRIGERATED SYSTEMS

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Cutting Tool Materials and Cutting Fluids

• Effects of Cutting Fluids on
• WORKPIECE MATERIALS
• MACHINE TOOLS
• Biological and Environmental Effects
• OPERATOR CONTACT
• EXTERNAL ENVIRONMENT
• DEGREDATION CHEMICAL CHANGE
• Waste Management
• CLARIFICATION
• RECYCLING
• DISPOSAL