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Technology of Machine Tools

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130 views25 pages

Technology of Machine Tools

Uploaded by

Anibal Daza
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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PowerPoint to accompany

Technology of Machine Tools


6th Edition

Krar • Gill • Smid

Polycrystalline
Cutting Tools
Unit 33

Copyright © The McGraw-Hill Companies, Inc.


Permission required for reproduction or display.
33-2

Objectives

• Explain the manufacture and properties of


polycrystalline tools
• Select the proper type and size of
polycrystalline cutting tools
• Set up a tool and machine for cutting with
polycrystalline tools
33-3

History
• Bessemer invented commercial method of
making steel in 1860 (carbon steel)
• Late 1800 saw high-speed steel cutting tools
• Then came more productive cemented-
carbide and coated carbide cutting tools
• General Electric Company produced
manufactured diamond in 1954
– Today, polycrystalline layer composed of small
diamond nitride particles fused to base
33-4

Manufacture of Polycrystalline
Cutting Tools
• Two distinct types
– Polycrystalline cubic boron nitride
– Polycrystalline diamond
• Manufacture of blanks basically same
– Layer of polycrystalline diamond or cubic
boron nitride (.020 in. thick) fused on cemented-
carbide substrate by high temperature (3275ºF),
high pressure (1 million psi)
33-5

Polycrystalline Mass
• Created from substrate composed of tiny
grains of tungsten carbide cemented tightly
together
– Cobalt binder
• High-heat, high-pressure conditions
– Cobalt liquefies, flows up and sweeps around
diamond or cubic boron nitride abrasive
– Serves as catalyst that promotes intergrowth
33-6

Polycrystalline Cubic Boron


Nitride Tools
• Structure of cubic boron nitride feature
nondirectional, consistent properties
– Resist chipping and cracking
– Provide uniform hardness
– Abrasion resistance in all directions
• Qualities built into turning and milling
butting-tool blanks and inserts
– Can operate at higher cutting speeds, and take
deeper cuts
33-7

Types and Sizes of PCBN Tool


Blank Insert Shapes Available

Copyright © The McGraw-Hill Companies, Inc.


Permission required for reproduction or display.
33-8

Four Main Properties of PCBN


1. Hardness
• Impact resistance, high strength, hardness in all
directions (random orientation of tiny CBN crystals)
2. Abrasion Resistance
• Maintain sharp cutting edges much longer
3. Compressive Strength
• Maximum stress in compression material will take
before ruptures
4. Thermal Conductivity
• Allow greater heat dissipation or transfer
33-9

Types of PCBN Tools


• Tipped inserts
– Available in most carbide insert shapes
– Usually most economical
– Only one cutting edge (can be reground)
• Full-faced inserts
– Layer of PCBN bonded to cemented-carbide
– Available as triangles, squares and rounds
– Can downsize repeatedly
• Brazed-shank tools
– Made by machining pocket in proper-style of
tool shank and brazing PCBN blank in place

Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
33-10

Four General Types of


Metal Cut
1. Hardened ferrous metals ( >45 Rc)
• Hardened steels
• Cast irons
2. Abrasive ferrous metals (180-240 Brinell)
• Pearlistic gray cast iron and Ni-Resist
3. Heat-resistant alloys
4. Superalloys (jet engine parts)
33-11

Advantages of
PCBN Cutting Tools
• High Material-Removal Rates
– Cutting speeds (250 to 900 ft/min) and feed
rates (.010 to .020 in.) result in removal rates
three time carbide tools with less tool wear
• Cutting Hard, Tough Materials
– Capable of machining all ferrous materials with
Rockwell C hardness of 45 and above
– Also used to machine cobalt-base and nickel-
base high temperature alloys (Rockwell c 35)
33-12

More Advantages
• High Quality Products
– Wear very slowly
• Uniform Surface finish
– Surface finishes in range of 20 to 30 µin.
possible during roughing operations
– Finishing surfaces in single-digit micro-inches
• Lower Cost per Piece
• Reduced Machine Downtime
• Increased Productivity
33-13

Polycrystalline Diamond Tools


• Polycrystalline diamond (PCD) layer fused
to cemented-carbide substrate
– .020 in. thick
• Highly efficient cutting tool
• Increased production when machining
abrasive nonmetallic, nonferrous materials
33-14

Types and Sizes of PCD Tools


• Catalyst-bonded PCD available in three
microstructure series
– Coarse PCD blanks
– Medium-fine PCD blanks
– Fine PCD blanks
• Basic difference between types is size of
diamond particle used to manufacture blank
33-15

Coarse PCD Blanks


• Made of coarse diamond crystals
• Designed to cut wide variety of abrasive
nonferrous, nonmetallic materials
• Highly recommended for machining cast
aluminum alloys
– Especially those containing more than 16%
silicon
• More durable than other types
33-16

Medium-Fine PCD Blanks

• Composed of fine to medium-fine crystals


• Greater size distribution than coarse blanks
• Used for machining highly abrasive
nonferrous and nonmetallic materials
– Short cutting edges acceptable
33-17

Fine PCD Blanks


• Made from fine diamond crystals
– Fairly uniform in size
• Have extremely sharp cutting edges
• High finishes on rake and flank sides
• Recommended for very fine surface finishes
and long cutting edges
33-18

Properties of PCD Tools


• Composite materials found in base provide
mechanical properties
– High thermal conductivity and low coefficient
of thermal expansion
• Diamond layer
– Hardness, abrasion resistance, compressive
strength, and thermal conductivity
– Compressive strength highest of any tool
– Thermal conductivity highest of any tool
33-19

Advantages of PCD Tools


Offset their higher initial cost
1. Long tool life
2. Cuts tough, abrasive material
3. High quality parts
4. Fine surface finishes
5. Reduced machine downtime
6. Increased productivity
33-20

Types of Material Cut


• Five general categories
1. Nonferrous metals
– Typically soft but have hard particles dispersed
– Silicon-aluminum alloys
– Copper alloys
2. Tungsten carbide
3. Advanced composites
4. Ceramics
5. Wood composites
33-21

Diamond-Coated Tools
• Early 1980s brought new process of
chemical vapor deposition (CVD)
– Produce diamond coating few microns thick
• Process
– Elemental hydrogen dissolved in hydrocarbon
gas around 1330º
– Mixture contacts cooler metal, carbon
precipitates in pure crystalline form and coats
metal with diamond film (slow 1-5 microns/hr)
33-22

QQC
• Process developed by Pravin Mistry in mid
1990s
• Eliminated problems of adhesion, adjusting
to various substrates, coating thickness and
cost
• Process creates diamond film through use of
laser energy and carbon dioxide as source
of carbon
33-23

QQC Process
• Laser energy directed at substrate to mobilize,
vaporize and reate with primary element (carbone)
to change crystalline structure of substrate
• Conversion zone created
beneath substrate surface
– Changes metallurgically
to composition of
diamond coating on
surface
• Diffusion bonding of
diamond coating to substrate

Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
33-24

Major Advantage of the


QQC Process
• Superior bonding and reduced stress form
metallurgical bond between diamond and
substrate
• Diamond-coating process can be carried
out in atmosphere (no vacuum needed)
• Parts do not require pretreatment or
preheating to be coated
33-25

More Advantages
• Only carbon dioxide primary or secondary
source for carbon; nitrogen acts as shield
• Diamond deposition rates exceed 1 micron
per second
• Process can be used for wide variety of
materials
• Tool life up to 60 times better than tungsten
carbide and 240 times better than high-speed
steel

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