Metal Cutting Training

Metal Cutting Technology
Metal cutting training was conducted by Sandvik coromant in pune.
Participants
1. Mr. Nalin
2. Mr. Siva Sankara Reddy
Training Topic
 Six material Group

 Cutting tool material
 Machinability
 Turning
 Parting & Grooving
 Threading
 Milling
 Drilling
 Boring
ISO – Standard Material Grouping & Suitable Insert :
Steel - Coated Carbide (CVD/PVD) & Cermet
Stainless Steel - Coated Carbide {CVD (1st priority) / PVD (Better size
control)}
Cast Iron - Coated Carbide (CVD) / Cermet / Ceramics / Cubic Carbon

Nitride (CBN) / Diamond
Aluminum - Uncoated Carbide / Non-Ferrous
Heat Resistant Alloy - Coated Carbide / Ceramics
Hardened Steel - Coated Carbide / Cubic Carbon Nitride (CBN)
Notes:
CVD – Chemical Vapor Deposition:
 Thick Powder Coating.

 Harder, Wear & Heat resistance.
PVD – Physical Vapor Deposition:
 Thin Powder Coating.

 Toughness is higher.
 Recommended for Drill bits.
Cutting Tool Material:
 High Heat & Wear resistance

 Increased Hardness Poly Crystalline Diamond
 High cost
 Higher finish
Cubic Carbon Nitride
Ceramics
Cermet
Coated Carbide
Uncoated Carbide
 Low speed & Low finish High Speed Steel

 Increased Toughness
 High feed
 Cost effective
Insert Production Process Layout:
RM powder mixed in %
Milling
Water & Ethanol
(8 – 55 Hrs))
Nitrogen use to
Spray Drying vaporize Water &
Ethanol
Cemented Carbide
Powder
Pressure Die
Sintered
(Shrinkage 50%)
1. Top & Bottom Grinding

Machining operation
2. Peripheral Grinding
(Grinding)
3. Profile Grinding
Heat Treatment
Quality Check
Dispatch
Chip Breakage
Chip formation various with depth of cut, entering (lead) angle, feed, material and insert
geometry. Chip breakage is very important in metal cutting because it decide power
consumption, insert wear and surface finish.
Reduces relative to the feed rate as the entering angle reduces (lead angle increases)
1. Continuous chip formation
2. Discontinuous or Segmental Chip formation
3. Continuous chip with built up edges formation
Continuous chips:
According to its name, continuous chips have a continuous segment. This chip is form
during cutting of ductile material like aluminum, mild steal, cooper etc. with a high cutting
speed. The friction between tool and material is minimum during this process. This is form
due to continuous plastic deformation of the material by application of tool. These chips
have equal thickness throughout the length. It generally gives good surface finish.
The most favorable conditions of forming continuous chips are
 Work piece should have ductile in nature.
 The rack angle should be large.
 Friction between work piece and tool should minimum.
 Cutting speed should high.
 Deft of cut should be small.
 Proper use of coolant and lubricant.
 Tool should have low coefficient of friction.
Continuous chips formation benefits.

 It gives high surface finish of machining ductile material.
 Continuous chips form when low friction which minimize friction loss.
 Due to low friction, tool life is high.
 Power consumption is low.
Discontinuous chips or segmental chips:

According to its name, this chips form in segment. It is form when machining of brittle
material like cast iron, brass etc. with slow cutting speed. Chips cut into small segment
during cutting. This is formed during slow cutting speed with small rack angle. This chips
form in ductile material when the friction between tool and work piece is high.
Discontinuous chips in ductile material give poor surface finish and slow machine. It is
suitable form of chips of machining brittle material.
The favorable conditions of forming this type of chip are
 The work piece should have brittle in nature.

 Slow speed of cutting
 Small rack angle of tool
 Depth of cut should large
Continuous Chips with built up edge:
This type of chip is same as the continuous chips except a built edge is form at the face of
tool. It is form during machining of ductile metal with excessive friction between tool and
work piece. This chip is not smooth as continuous chips. The built up edge form due to high
temperature between tool and work piece. This high temperature is due to high friction force
between tool and work piece.
The common factors promoting built up edge are
 Cutting of ductile metal.

 High friction force at the face of tool.
 High temperature between tool and work piece.
 Lack of coolant and lubricant.
Depth of
Chip Type Material type Rack angle cut Cutting speed
Large /
Continuous Chips Ductile High Small medium
Brittle, Ductile
Discontinuous Chips but hard Medium High Low
Continuous chips Low /

with built edge Ductile Medium Medium Medium
Turning, Parting & Grooving
There are three main methods in turning
1. Rough machining
2. Medium machining
3. Finish machining
Roughing:
Maximum metal removal rate and/or severe conditions
Large cutting depth and feed rate combinations
High cutting forces
Medium machining:
 Most applications – general purpose
 Medium operations to light roughing
 Wide range of cutting depth and feed rate combinations.
Finishing:
 Small cutting depths and low feed rates
 Low cutting forces.
The Working area of Insert Geometry:

 Cutting depth (ap) and feed (fn) must be adapted to the chip breaking area of the
geometry to get acceptable chip control.
 Chip breaking which is too hard can lead to insert breakage.
 Chips which are too long can lead to disturbances in the machining process and bad
surface finish.
The chip breaking diagram for insert geometry is defined by acceptable chip breaking for
feed and depth of cut.
Types:
Longitudinal Turning (Axial tool movement)
Facing (Radial tool movement)
Profiling (Axial and Radial tool movement)
Terms of Turning
Terminology Notation Units Formulae
Machined diameter Dm mm -
Feed per revolution (Cutting fn mm/rev -

Feed)
Depth of cut ap mm -
Cutting Speed Vc m/min = (π x Dm x n) / 1000
Spindle speed n rpm = (1000 x Vc) / (π x D)
Power Pc kW = (Vc x ap x fn x Kc) / (60 x 103)
Circumference C mm = π x Dm
Metal removal rate cm3/min Q = Vc x ap x fn
Average chip thickness hm mm = fn x sin KAPR
Maximum chip thickness hex mm = fn x
Machining time, (Period of Tc min = lm / (fn x n)

engagement)
Machined length lm mm -
Specific Cutting force Kc N/mm2 = Kc1 x(1/hm)mc x(1-( γ0/100))
Entering angle KAPR Deg -
Effective rake angle γ0 Deg -

Internal turning
Parting & Grooving:
Chip evacuation is a critical factor in parting operations. There is little opportunity to break
chips in the confined space as the tool moves deeper. The cutting edge is designed largely to
form the chip so it can be evacuated smoothly. Consequences of poor chip evacuation are
chip obstruction, which leads to poor surface quality, and chip jamming, leading to tool
breakdown.
External parting & Grooving:
1. Parting-off solid bars and tubes
2. Turning and recessing
3. Undercutting
4. Shallow to deep grooving
5. Face grooving
6. Profiling
Internal Grooving:
1. Grooving and pre-parting
2. Face grooving
3. Profiling
Three types of insert with different entering angles:
 Right hand (R)
 Neutral (N)
 Left hand (L).
The image is the illustration of the right hand parting insert operation. But, However the pip
mark in small amount will always available in the product.
Grooving Method:
There are two type of grooving methods

 Small Groove width.
 Long Groove width.
Small Groove Width:
This kind of groove can take by multiple or single passes based on the available depth.
Long Groove Width:
This Grooving is done by below following process.
Internal Grooving Method:
Threading
The prime functions of a thread are:
- to form a mechanical coupling
- to transmit motion by converting rotational movement into linear and vice-versa
- to obtain a mechanical advantage; using a small force to create a larger one
Types of threads:
 Molding
 Metal cutting
 Rolling
 Thread turning
 Thread tapping
 Thread milling
 Thread whirling
 Grinding

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Metal Cutting Technology

Metal cutting training was conducted by Sandvik coromant in pune.

 Six material Group

Steel - Coated Carbide (CVD/PVD) & Cermet

Cast Iron - Coated Carbide (CVD) / Cermet / Ceramics / Cubic Carbon

Aluminum - Uncoated Carbide / Non-Ferrous

Heat Resistant Alloy - Coated Carbide / Ceramics

Hardened Steel - Coated Carbide / Cubic Carbon Nitride (CBN)

CVD – Chemical Vapor Deposition:

 Thick Powder Coating.

PVD – Physical Vapor Deposition:

 Thin Powder Coating.

 High Heat & Wear resistance

Cubic Carbon Nitride

 Low speed & Low finish High Speed Steel

1. Top & Bottom Grinding

Continuous chips formation benefits.

Discontinuous chips or segmental chips:

The favorable conditions of forming this type of chip are

 The work piece should have brittle in nature.

 Cutting of ductile metal.

Continuous chips Low /

The Working area of Insert Geometry:

Feed per revolution (Cutting fn mm/rev -

Cutting Speed Vc m/min = (π x Dm x n) / 1000

Spindle speed n rpm = (1000 x Vc) / (π x D)

Power Pc kW = (Vc x ap x fn x Kc) / (60 x 103)

Metal removal rate cm3/min Q = Vc x ap x fn

Average chip thickness hm mm = fn x sin KAPR

Maximum chip thickness hex mm = fn x

Machining time, (Period of Tc min = lm / (fn x n)

Specific Cutting force Kc N/mm2 = Kc1 x(1/hm)mc x(1-( γ0/100))

Entering angle KAPR Deg -

Effective rake angle γ0 Deg -

Parting & Grooving:

There are two type of grooving methods

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