advances in cutting tool technology

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A presentation on advances in cutting tool technology NANDU SONMANKAR TE PRODUCTION (S/W) EXAM SEAT NO. T140087656

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Page 1: Advances in cutting tool technology

A presentation on advances in cutting tool technology

NANDU SONMANKAR

TE PRODUCTION (S/W)EXAM SEAT NO. T140087656

Page 2: Advances in cutting tool technology

Introduction

Design

Construction

A general view of the tool world

New machining techniques

Page 3: Advances in cutting tool technology

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)

Page 4: Advances in cutting tool technology

2. Sintered Carbide (Hardmetal)

mixture of tungsten carbide micro grains with cobalt

Tantalum, titanium or vanadium carbides can be also mixed in small proportions.

Page 5: Advances in cutting tool technology

Hard-metal tools are manufactured in two forms:Integral toolsInserts

(a)Ball-endmill with inserts, (b) and integral bull- nose endmill

Page 6: Advances in cutting tool technology

CeramicsCeramic tools are based primarily on

alumina (Al2O3), silicon nitride (Si3N4)

(a) Ceramic inserts (b) matrix of a reinforced ceramic

Page 7: Advances in cutting tool technology

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

Page 8: Advances in cutting tool technology

Coatingsthickness ranging from 2 to 15 μm

improve the cutting-tool performance

applied after the tool is shaped

Page 9: Advances in cutting tool technology

Coatings provideA hard Tool

Chemically stable surface

Thermal protection to tools

Improving their performance during cutting.

Page 10: Advances in cutting tool technology

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

Page 11: Advances in cutting tool technology

Five-axis Ball-endmillingTwo additional orientation axes added.

Cannot be machined using three-axis machines.

Tool stiffness is higher.

Page 12: Advances in cutting tool technology

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.

Page 13: Advances in cutting tool technology

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

Page 14: Advances in cutting tool technology

High-feed MillingThis produces a minimam radial and a

maximum axial cutting force.

The Penta-edge insert for high-feed milling of Safety

Page 15: Advances in cutting tool technology

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

Page 16: Advances in cutting tool technology

Spinning ToolUses a specialized insertFull-radius insert

(a) Spinning tool, and (b) Kennametal

Page 17: Advances in cutting tool technology

Spinning ToolDesigned to distribute heat and wear more effectively.

increase productivity by up to500 % and tool life by up to 2,000 %.

Page 18: Advances in cutting tool technology

Trochoidal Millingcombination of a uniform circular

motion with a uniform linear motion.tool-path is a kinematics curve so-

called trochoid.

Page 19: Advances in cutting tool technology

Trochoidal MillingLarge axial depth of cut.

Drawback is that tool path length is much higher .

Recommended for slotted shapes.

Page 20: Advances in cutting tool technology

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.

Page 21: Advances in cutting tool technology

Drilling holes efficientlyDrill bit can penetrate flat, convex,

concave, inclined and irregular surfaces

Page 22: Advances in cutting tool technology

Tools for Multitask MachiningCombining turning and milling operations

in the same machine bed.The programming of these machines was

a real challenge.

Page 23: Advances in cutting tool technology

Multitasking machines include a spindle instead of a turret.

A reliable solution for the machining of complex parts.

Tools for Multitask Machining

Page 24: Advances in cutting tool technology

ConclusionLot of time, money and effort

invested.

Supply a much optimized tool, in all the related aspects discussed in this report.

The application guide.

Page 25: Advances in cutting tool technology

ConclusionThe economic impact increasing.

Reduction of the amount of material to be removed in each part.

Improvement of productivity.

Tool life and workpiece precision.

Page 26: Advances in cutting tool technology

Future Scope of ToolsMicro milling -with special attention to medical

devices. -Tool fabrication is another important

issue.

Page 27: Advances in cutting tool technology

Future Scope of Toolshigh silicon aluminium alloys.

carbon-fibre-reinforced plastic composites, and others.