Scribd
Upload
72 views21 pages

4.5 Machinability and Rating Class Notes

The document discusses tool wear, tool life, and machinability, explaining factors that affect machinability like material properties and tool characteristics. It also covers tool wear mechanisms and equations, machinability ratings based on tool life, cutting power, and surface finish, and the machinability of various ferrous and nonferrous metals. The machinability of different metals depends on properties like hardness, thermal conductivity, tendency to work harden, and chemical composition.

Uploaded by

TAMILARASAN M
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
72 views21 pages

4.5 Machinability and Rating Class Notes

The document discusses tool wear, tool life, and machinability, explaining factors that affect machinability like material properties and tool characteristics. It also covers tool wear mechanisms and equations, machinability ratings based on tool life, cutting power, and surface finish, and the machinability of various ferrous and nonferrous metals. The machinability of different metals depends on properties like hardness, thermal conductivity, tendency to work harden, and chemical composition.

Uploaded by

TAMILARASAN M
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 21

18MEPK0 – METAL CUTTING

ENGINEERING
Course Outcomes
By the end of the course, student will be able to:
1. Explain the types and characteristics of tool materials,
cutting tools nomenclature and various tool angle
specification
2. Explain the Mechanics of the machining process
3. Examine the thermal aspects and cutting fluids
4. Examine the tool wear, tool life, machinability.
5. Determine the tool life and surface roughness of machined
surfaces
6. Optimize the machining cost by varying the cutting
parameters
18MEPK0 – METAL CUTTING
ENGINEERING

Chapter-4
Tool wear, Tool life and
Machinability

Prof. M.Karthic, M.E


E-mail: [email protected]

2
Chapter-4
Tool wear, Tool life and
Machinability

4.1 Introduction – Tool wear mechanism - 1

4.2 Types of tool damages – wear and chipping characteristic


of different tool materials - 1
4.3 Tool wear equation – Failure criteria – Tool life equation– 2
4.4 Effect of process parameters on tool life – Tool life tests - 2
4.5
Machinability – Introduction – Machinability rating- 1
4.5.1 Machinability
Machinability is defined in terms of:
1. Surface finish and surface integrity of machined part
2. Tool life
3. Force and power required
4. The level of difficulty in chip control
Good machinability indicates
– good surface finish and surface integrity
– a long tool life
– and low force and power requirements
Note: continuous chips should be avoided for good
machinability.
Machinability ratings (indexes) are available for each type of
material and its condition
4.5.1 Machinability
Factors affecting machinability of metals
1. Material of w/p- hardness, tensile properties, strain
hardenability
2. Tool material.
3. Size and shape of the tool.
4. Type of machining operation.
5. Size, shape and velocity of cut.
6. Type and quality of machine used
7. Quality of lubricant used in machining
8. Friction b/w chip & tool
9. Shearing strength of w/p material
4.5.1 Machinability
Grain structure
• Machinability of metal affected by its microstructure.
• Ductility and shear strength modified greatly
by
Operation such as annealing, normalizing and stress
relieving.
Certain chemical and physical modifications of steel
improve Machinability.
– Addition of sulfur, lead, or sodium sulfate

– Cold working, which modifies ductility


4.5.1 Machinability
Evaluation of machinability
 Machinability decreases with increase in tensile strength
and hardness
 Machinability of a material is assessed by any of the
following.
 Tool life
 Cutting force
 Surface finish
 Other factors
 Chip shape
 Physical properties
4.5.2 Machinability Index/Ratings
i) Tool life criterion
 This is the most important criterion from the point of

view of machining economics.


 A convenient machinability criterion based on tool life is

the so called specific cutting speed.


 It may be defined as the cutting speed corresponding to a

predetermined tool life.


4.5.2 Machinability Index/Ratings
i) Tool life criterion
 Machinability index= Vt/Vs x100
 Vt – cutting speed of metal for 1 min tool life
 Vs – cutting speed of standard free cutting steel for 1 min
tool life.
4.5.2 Machinability Index/Ratings
i) Tool life criterion
4.5.2 Machinability Index/Ratings
i) Tool life criterion
4.5.2 Machinability Index/Ratings
ii) Cutting power criterion

 This criterion may be used where it is necessary to limit

cutting forces.
 The specific cutting power are often considered as an

index of machinability of a given work material. (If


power of the drive motor or rigidity of the machine tool
structure is not high)
4.5.2 Machinability Index/Ratings
ii) Cutting power criterion
4.5.2 Machinability Index/Ratings
iii) Surface finish criterion

 A material according to this criterion, would be, more

easily machinable than another (better finish)


 This criterion may be used in a situation where poor

surface finish is the cause of rejection of machined parts.


 In such cases tool life, cutting power criteria not be

helpful because satisfactory finish may not be achieved.


4.5.2 Machinability Index/Ratings
iv) Other criterion

 Several other criteria have been put forward to assess

machinability of different work materials.


a) Temperature developed at tool-chip
b) Depth of the hole cut / depth of cut in hacksaw
c) Physical properties ( different combinations)
4.5.2 Machinability Index/Ratings
iv) Other criterion
4.5.1 Machinability
Machinability of Ferrous Metals
Steels:
 If a carbon steel is too ductile, chip formation can produce built-up
edge, leading to poor surface finish

 If too hard, it can cause abrasive wear of the tool because of the
presence of carbides in the steel

 In leaded steels, a high percentage of lead solidifies at the tips of


manganese sulfide inclusions

 Calcium-deoxidized steels contain oxide flakes of calcium silicates


(CaSO) that reduce the strength of the secondary shear zone and
decrease tool–chip interface friction and wear
4.5.1 Machinability
Machinability of Ferrous Metals
Effects of Various Elements in Steels:

 Presence of aluminum and silicon is harmful, as it combine with

oxygen to form aluminum oxide and silicates, which are hard and
abrasive

 Thus tool wear increases and machinability reduce

Stainless Steels:

 Austenitic (300 series) steels are difficult to machine

 Ferritic stainless steels (also 300 series) have good machinability

 Martensitic (400 series) steels are abrasive.


4.5.1 Machinability
Machinability of Nonferrous Metals
 Aluminum is very easy to machine

 Beryllium requires machining in a controlled environment

 Cobalt-based alloys require sharp, abrasion-resistant tool materials


and low feeds and speeds

 Copper can be difficult to machine because of builtup edge formation

 Magnesium is very easy to machine, with good surface finish and


prolonged tool life

 Titanium and its alloys have very poor thermal conductivity

 Tungsten is brittle, strong, and very abrasive


4.5.1 Machinability
Machinability of Nonferrous Metals
• Aluminum
– very easy to machine
– but softer grades: form BUE ⇒ poor surface finish
– ⇒ recommend high cutting speeds, high rake and relief angles
• Beryllium
– requires machining in a controlled environment
– this is due to toxicity of fine particles produced in machining
• Cobalt-based alloys
– abrasive and work hardening
– require sharp, abrasion-resistant tool materials, and low feeds and
speeds
• Copper
– can be difficult to machine because of BUE formation
4.5.1 Machinability
Machinability of Nonferrous Metals
• Magnesium
– very easy to machine, good surface finish, prolonged tool life
– Caution: high rate of oxidation and fire danger
• Titanium and its alloys
– have very poor thermal conductivity
– ⇒ high temp. rise and BUE ⇒ difficult to machine
• Tungsten
– brittle, strong, and very abrasive
– ⇒ machinability is low
• Zirconium
– Good machinability
– Requires cooling cutting fluid (danger of explosion, fire)

You might also like