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Fundamentals of Cutting

South Bend lathe Chip Formation Chip Breakers Feeds and Speeds Tool Materials. Tool Properties Tool Wear Surface Finishes Cutting Fluids CNC Lathes. Fundamentals of Cutting. South Bend Engine Lathe. Chip Formation. Discontinuous Continuous Built up edge. Chip Breakers.

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Fundamentals of Cutting

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  1. South Bend lathe Chip Formation Chip Breakers Feeds and Speeds Tool Materials Tool Properties Tool Wear Surface Finishes Cutting Fluids CNC Lathes Fundamentals of Cutting

  2. South Bend Engine Lathe

  3. Chip Formation Discontinuous Continuous Built up edge

  4. Chip Breakers • On the Cutting Tool • In the Material • Inclusions • Sulfur

  5. Speed, Feed, Depth of Cut

  6. Speeds, Depth of Cut • Depth of Cut • Speed

  7. Feed Rates or

  8. Cutting Time Considerations • Material removal rate • Time to Cut

  9. Tool Materials • High SpeedSteel (HSS) • CoatedCarbideInserts

  10. High Hardness Resist Abrasion Resist Chipping Hot Hardness Resist BulkDeformation (E) Chemical Stability Adequate Thermalproperties Consistent ToolLife Geometry Tool Properties

  11. Tool Wear • slow death mechanisms: gradual wear on flanks, or rake face of tool (crater) • abrasion, adhesion, diffusion, chemical • sudden death mechanisms: unpredictable, catastrophic failure • brittle fracture, chipping, plastic deformation

  12. Tool Life • Taylor's Equation: Surface Speed • Variation in material hardness • within piece and piece to piece • Variation in tool material and geometry • Vibrations • Changing surface characteristics of workpiece

  13. Tool Geometry

  14. Surface Finishes • Tool Geometry and Feed rate

  15. Surface Finishes • Surface Speed and Depth of Cut

  16. Cutting Fluids • Reduces Cutting Temperature • dimensional stability • reduces thermal tool wear • Acts as Lubricant • reduces forces and energy consumption

  17. Cutting Fluids • Flood Cooling • lowers temperature • reduces oxidation • Mist Cooling • Better Visibility • gets to inaccessible areas

  18. Effects of Coolants • On workpiece • cracking, staining, chemical attack • On machines • bearings and slideways • On environment • breathing apparatus, and disposal

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