advances in cutting tool technology
TRANSCRIPT
A presentation on advances in cutting tool technology
NANDU SONMANKAR
TE PRODUCTION (S/W)EXAM SEAT NO. T140087656
Introduction
Design
Construction
A general view of the tool world
New machining techniques
Materials for Cutting-tool Manufacture
1. High-speed Steel
Max. working temperature of HSS is about 500 °C.
Currently, HSS produced by powder metallurgy (HSS-PM)
2. Sintered Carbide (Hardmetal)
mixture of tungsten carbide micro grains with cobalt
Tantalum, titanium or vanadium carbides can be also mixed in small proportions.
Hard-metal tools are manufactured in two forms:Integral toolsInserts
(a)Ball-endmill with inserts, (b) and integral bull- nose endmill
CeramicsCeramic tools are based primarily on
alumina (Al2O3), silicon nitride (Si3N4)
(a) Ceramic inserts (b) matrix of a reinforced ceramic
Extra-hard MaterialsDiamond and Polycrystalline Diamond
(PCD)
- available in various grain sizes- Mono-crystalline diamond (MCD) is
natural diamond
Polycrystalline Cubic Boron Nitride (PCBN)
- CBN is a polymorph boron-nitride-based material
- CBN is the second-hardest synthetic material
Coatingsthickness ranging from 2 to 15 μm
improve the cutting-tool performance
applied after the tool is shaped
Coatings provideA hard Tool
Chemically stable surface
Thermal protection to tools
Improving their performance during cutting.
Hard Machining for Mould and DiesBall-endmilling for Sculptured
Surfaces
A four-flute geometry with a full cutting edge to the centre of the ball
Five-axis Ball-endmillingTwo additional orientation axes added.
Cannot be machined using three-axis machines.
Tool stiffness is higher.
Toolholders and Tool Clamping Systems
Assembly and disassembly must be simple.
Allow automatic tool change (ATC) commanded from the CNC.
Maximum coaxial accuracy on the tool–tool holder–spindle assembly.
Maximum torque transmission from the spindle to the tool.
New Techniques for Hard MachiningThe main purpose of them is to avoid
machining vibrations
1. High-feed Milling
2. Plunge Milling
3. Turn Milling and Spinning Tool
4. Trochoidal Milling
High-feed MillingThis produces a minimam radial and a
maximum axial cutting force.
The Penta-edge insert for high-feed milling of Safety
Plunge MillingHigh-performance roughing technique.This technique is also referred to as milling in
the Z-axis.
(a) general procedure, (b) maximum radial width of cut
Spinning ToolUses a specialized insertFull-radius insert
(a) Spinning tool, and (b) Kennametal
Spinning ToolDesigned to distribute heat and wear more effectively.
increase productivity by up to500 % and tool life by up to 2,000 %.
Trochoidal Millingcombination of a uniform circular
motion with a uniform linear motion.tool-path is a kinematics curve so-
called trochoid.
Trochoidal MillingLarge axial depth of cut.
Drawback is that tool path length is much higher .
Recommended for slotted shapes.
Drilling holes efficientlyToday’s drills are several
generations ahead with very high capabilities as regards: -
1. Penetration rate.2. Finishing capability.3. Operational versatility.4. Power requirement.5. Reliability.
Drilling holes efficientlyDrill bit can penetrate flat, convex,
concave, inclined and irregular surfaces
Tools for Multitask MachiningCombining turning and milling operations
in the same machine bed.The programming of these machines was
a real challenge.
Multitasking machines include a spindle instead of a turret.
A reliable solution for the machining of complex parts.
Tools for Multitask Machining
ConclusionLot of time, money and effort
invested.
Supply a much optimized tool, in all the related aspects discussed in this report.
The application guide.
ConclusionThe economic impact increasing.
Reduction of the amount of material to be removed in each part.
Improvement of productivity.
Tool life and workpiece precision.
Future Scope of ToolsMicro milling -with special attention to medical
devices. -Tool fabrication is another important
issue.
Future Scope of Toolshigh silicon aluminium alloys.
carbon-fibre-reinforced plastic composites, and others.