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    Cutting Tool Materials: Chapter

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    Mahmoud Elsamanty
    Introduction „ Carbon and medium alloy steels „ High speed steels „ Cast-cobalt alloys „ Carbides „ Coated tools „ Alumina-based ceramics „ Cubic Boron Nitride „ Silicon Nitride based ceramics „ Diamond „ Whisker-reinforced tool materials

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Cutting Tool Materials: Chapter

    Uploaded by

    Mahmoud Elsamanty
    43 views34 pages
    Introduction „ Carbon and medium alloy steels „ High speed steels „ Cast-cobalt alloys „ Carbides „ Coated tools „ Alumina-based ceramics „ Cubic Boron Nitride „ Silicon Nitride based ceramics „ Diamond „ Whisker-reinforced tool materials

    Original Title

    Tool Materials

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    Introduction „ Carbon and medium alloy steels „ High speed steels „ Cast-cobalt alloys „ Carbides „ Coated tools „ Alumina-based ceramics „ Cubic Boron Nitride „ Silicon Nitride based ceramics „ Diamond „ Whisker-reinforced tool materials

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    43 views34 pages

    Cutting Tool Materials: Chapter

    Uploaded by

    Mahmoud Elsamanty
    Introduction „ Carbon and medium alloy steels „ High speed steels „ Cast-cobalt alloys „ Carbides „ Coated tools „ Alumina-based ceramics „ Cubic Boron Nitride „ Silicon Nitride based ceramics „ Diamond „ Whisker-reinforced tool materials

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 34

    Chapter (1)

    CUTTING TOOL MATERIALS

    TOPICS :

    Introduction
    Carbon and medium
    alloy steels
    High speed steels
    Cast-cobalt alloys
    Carbides
    Coated tools
    Alumina-based
    ceramics

    Cubic Boron Nitride


    Silicon Nitride
    based ceramics
    Diamond
    Whisker-reinforced
    tool materials

    Introduction:
    Characteristics of cutting tool :
    Hardness (resistance to wear)
    Hot hardness (capacity to retain hardness at high
    temperatures
    Toughness (resistance to impact forces on tool in
    interrupted operations)
    Chemical stability or inertness (to avoid adverse
    reactions)

    Cutting tool materials

    Carbon & medium alloy steels


    High speed steels
    Cast-cobalt alloys
    Carbides
    Coated tools
    Alumina-based ceramics
    Cubic boron nitride
    Silicon-nitride-base ceramics
    Diamond
    Whisker-reinforced materials

    Carbon and Medium alloy steels :

    Oldest of tool materials


    Used for drills taps, broaches, reamers
    Inexpensive, easily shaped, sharpened
    No sufficient wear resistance
    Limited to hand tools and low cutting speed
    operation. (Red hardness temp.: 200 C)

    High speed steels (HSS)

    Hardened to various depths


    Good wear resistance

    Suitable for high positive rake angle tools

    Two basic types of HSS

    Molybdenum (M-series)

    Tungsten (T-series)
    M-series (6-6-4-2): Contains 6% molybdenum, 6% tungsten,
    4% chromium, 2% vanadium & cobalt

    Higher, abrasion resistance

    H.S.S. are majorly made of M-series


    T-series (18-4-1): Contains 18 % tungsten, 4% chromium, 1%
    vanadium & cobalt

    undergoes less distortion during heat treating

    H.S.S.

    available in wrought, cast & sintered


    (Powder metallurgy)
    Coated for better performance
    Subjected to surface treatments such as casehardening for improved hardness and wear
    resistance or steam treatment at elevated
    temperatures
    High speed steels (Red hardness temp.: 650 C)

    Cast-Cobalt alloys

    Commonly known as stellite tools


    Composition ranges 38% - 53 % cobalt
    30%- 33% chromium
    10%-20%tungsten
    Good wear resistance ( higher hardness)
    Less tough than high-speed steels and sensitive to impact
    forces
    Less suitable than high-speed steels for interrupted cutting
    operations
    Continuous roughing cuts relatively high g=feeds &
    speeds
    Finishing cuts are at lower feed and depth of cut

    Carbides :
    (Hot hardness temp.: 1000 C)

    These carbides are also known as cemented or


    sintered carbides
    High elastic modulus, thermal conductivity
    Low thermal expansion

    2-groups of carbides used for machining operations


    tungsten carbide
    titanium carbide

    Tungsten Carbide

    Composite material consisting of tungsten-carbide particles


    bonded together

    Alternate name is cemented carbides

    Manufactured with powder metallurgy techniques

    Particles 1-5 m in size are pressed & sintered to desired


    shape in a H2 atmosphere furnace at 1550C
    Amount of cobalt present affects properties of carbide tools
    As cobalt content increases strength, hardness & wear
    resistance increases

    Titanium carbide

    Titanium carbide has higher wear resistance


    than tungsten carbide
    Nickel-Molybdenum alloy as matrix Tic
    suitable for machining hard materials
    Steels & cast irons
    Speeds
    carbide

    higher

    than

    those

    for

    tungsten

    Cutting tool materials HSS alloying


    Element

    Properties

    Tungsten

    Increases hot hardness


    Hard carbides formed, improving abrasion resistance

    Molybdenum

    Increases hot hardness


    Hard carbides formed, improving abrasion resistance

    Chromium

    Depth hardenability during heat treat


    Hard carbides formed, improving abrasion resistance
    Some corrosion resistance

    Vanadium

    Combines with carbon for wear resistance


    Retards grain growth for better toughness

    Cobalt

    Increases hot hardness, toughness

    Carbon

    Hardening element
    Forms carbides

    Inserts

    Inserts

    Individual cutting tool with severed cutting points


    Clamped on tool shanks with locking mechanisms
    Inserts also brazed to the tools
    Clamping is preferred method for securing an insert
    Carbide Inserts available in various shapes-Square,
    Triangle, Diamond and round
    Strength depends on the shape
    Inserts honed, chamfered or produced with negative
    land to improve edge strength

    Insert Attachment

    Fig : Methods of
    attaching inserts to
    toolholders : (a)
    Clamping and (b)
    Wing lockpins. (c)
    Examples of inserts
    attached to
    toolholders with
    threadless lockpins,
    which are secured
    with side screws.

    Edge Strength
    Fig : Relative edge
    strength and
    tendency for chipping
    and breaking of
    inserts with various
    shapes. Strength
    refers to the cutting
    edge shown by the
    included angles.

    Fig : edge preparation of


    inserts to improve edge
    strength.

    Chip breakers:
    Purpose :
    Eliminating long chips
    Controlling chip flow during machining
    Reducing vibration & heat generated
    Selection depends on feed and depth
    of cut, work piece material and type
    of chip produced during cutting

    Coated tools :
    -

    High strength and toughness but generally


    abrasive and chemically reactive with tool
    materials
    (Hot hardness temp.: 1100 C)

    Unique Properties :
    Lower Friction
    High resistance to cracks and wear
    High Cutting speeds and low time & costs
    Longer tool life

    Coating materials
    Titanium nitride (TiN)

    Titanium carbide (Tic)

    Titanium Carbonitride (TicN)

    Aluminum oxide (Al2O3)

    Diamond coating
    Thickness range: 2-15 m (80-600 in)

    Techniques used :

    Chemical vapor deposition (CVD)


    Plasma assisted CVD

    Physical-vapor deposition(PVD)

    Medium temperature chemical- vapor


    deposition(MTCVD)

    Properties for Group of Materials

    Fig : Ranges of properties


    for various groups of
    tool materials.

    Cutting tool Characteristics for coating :

    High hardness
    Chemical stability
    Low thermal conductivity
    Good bonding
    Little or no Porosity

    Titanium nitride (TiN) coating :

    Low friction coefficients


    High hardness
    Resistance to high temperatures
    Good adhesion to substrate
    High life of high speed-steel tools

    Titanium carbide (TiC) coating:

    Titanium carbide coatings on tungsten-carbide inserts have high flank


    wear resistance.

    Ceramics :

    Low thermal conductivity ,resistance ,high temperature


    Resistance to flank wear and crater wear
    Ceramics are suitable materials for tools
    Al2O3 (most commonly used)

    Multi Phase Coatings :

    First layer Should bond well with substrate


    Outer layer Resist wear and have low thermal
    conductivity
    Intermediate layer Bond well & compatible with both
    layers
    Coatings of alternating multipurpose layers are also
    formed.

    Multiphase Coatings

    Fig : Multiphase coatings on a


    tungsten-carbide
    substrate. Three
    alternating layers of
    aluminum oxide are
    separated by very thin
    layers of titanium nitride.
    Inserts with as many as
    thirteen layers of
    coatings have been
    made. Coating thick
    nesses are typically in
    the range of 2 to 10 m.

    Diamond Coated tools :

    Use of Polycrystalline diamond as a coating


    Difficult to adhere diamond film to substrate
    Thin-film diamond coated inserts now
    commercially available
    Thin films deposited on substrate with PVD & CVD
    techniques
    Thick films obtained by growing large sheet of
    pure diamond
    Diamond coated tools particularly effective in
    machining non-ferrous and abrasive materials

    New Coating materials :

    Titanium carbo nitride (TiCN)


    Titanium Aluminum Nitride(TiAlN)
    Chromium Based coatings
    Chromium carbide
    Zirconium Nitride (ZrN)
    Hafnium nitride (HfN)
    Recent developments gives nano coating & composite coating

    Ion Implementation :

    Ions placed into the surface of cutting tool


    No change in the dimensions of tool
    Nitrogen-ion Implanted carbide tools used for alloy steels & stainless
    steels
    Xeon ion implantation of tools as under development

    Alumina-Based ceramics:

    Cold-Pressed Into insert shapes under high pressure and


    sintered at high temperature
    High Abrasion resistance and hot hardness (1200C)
    Chemically stable than high speed steels & carbides
    So less tendency to adhere to metals
    Good surface finish obtained in cutting cast iron and steels
    Negative rake-angle preferred to avoid chipping due to poor
    tensile strength

    Cermets, Black or Hot- Pressed :

    70% aluminum oxide & 30 % titanium carbide


    cermets(ceramics & metal)
    Cermets contain molybdenum carbide, niobium carbide and
    tantalum carbide.

    Cubic boron Nitride ( CBN ) :

    Made by bonding (0.5-1.0 mm) Layer of poly crystalline cubic


    boron nitride to a carbide substrate by sintering under
    pressure
    While carbide provides shock resistance CBN layer provides
    high resistance and cutting edge strength
    Cubic boron nitride tools are made in small sizes without
    substrate

    Fig : (a) Construction of a polycrystalline cubic boron nitride or a diamond layer on a tungsten-carbide insert.
    (b) Inserts with polycrystalline cubic boron nitride tips (top row) and solid polycrystalline CBN inserts
    (bottom row).

    Silicon-Nitride based ceramics (SiN)

    They consists various addition of Aluminum Oxide ythrium oxide,


    titanium carbide
    SiN have toughness, hot hardened & good thermal shock
    resistance

    SiN base material is Silicon

    High thermal & shock resistance

    Recommended for machining cast iron and nickel based super


    alloys at intermediate cutting speeds

    Diamond :

    Hardest known substance


    Low friction, high wear resistance
    Ability to maintain sharp cutting edge
    Single crystal diamond of various carats used
    for special applications
    Machining copperfront precision optical
    mirrors for (SDI)
    Diamond is brittle, tool shape & sharpened is
    important
    Low rake angle used for string cutting edge

    Polycrystalline-Diamond ( PCD ) Tools:

    Used for wire drawing of fine wires


    Small synthesis crystal fused by high pressure and
    temperature
    Bonded to a carbide substrate
    Diamond tools can be used fir any speed
    Suitable for light un-interrupted finishing cuts
    To avoid tool fracture single crystal diamond is to
    be re-sharpened as it becomes dull
    Also used as an abrasive in grinding and polishing
    operations

    Whisker reinforced & Nanocrystalline


    tool materials
    New tool materials with enhanced properties :

    High fracture toughness


    Resistance to thermal shock
    Cutting edge strength
    Hot hardness

    Whiskers used as reinforcing fibers :

    Examples: Silicon-nitride base tools reinforced


    with silicon-carbide (SiC)
    Aluminum oxide based tools reinforced with
    silicon-carbide with ferrous metals makes SiCreinforced tools
    Progress in nanomaterial
    development of cutting tools

    has

    lead

    to

    the

    Made of fine grained structures as (micro grain)


    carbides

    Cutting-Tool Reconditioning

    When tools get worned, they are reconditioned for further


    use
    Reconditioning also involves recoating used tools with
    titanium nitride

    Web site:
    http://www.staff.zu.edu.eg/awafa/

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