Cutting of Soft Gummy Metals

CUTTING OF SOFT 'GUMMY' MET
ALS.
:- Manoj Dhage.
ABSTRACT :-
This presentation briefs about the cutting of soft

gummy metals and the methodologies used to cut the
gummy metals also it briefs about the various type of
tools used also fluids and the different machining
process with different kind of materials and the
precision.
INTRODUCTION :
Permanent markers, glue sticks and packing tape may offer a
surprisingly low-tech solution to a long-standing nuisance in
manufacturing: Making soft and ductile, i.e., "gummy" metals easier
to cut.The application of a permanent marker, glue or tape makes
gummy metals such as aluminum, stainless steels, copper and
tantalum much easier to cut for industrial applications.What makes
inks and adhesives effective isn't their chemical content, but their
stickiness to the surface of any gummy metal such as nickel,
aluminum, stainless steels or copper. That’s according to researchers
at Purdue University and the University of West Florida , who recently
published their findings in Physical Review Applied .
These adhesives help achieve a smoother, cleaner and faster cut than
current machining processes, impacting products ranging from
orthopedic implants and surgical instruments to aerospace
components.
A significant improvement in the "machinability" of gummy metals or
alloys could potentially lower the cost of products, improve their
performance or enable new and improved designs.Gummy metals
characteristically deform in a very wiggly manner,.This wiggly flow
involves significant energy consumption, which means that these
metals require more force to machine than even some hard metals.
We needed to find a way to suppress this wiggly flow."
Getting rid of the wiggles means that the metal now tends to act more
like a brittle ceramic or glass in the spot where it needs to be cut.
LITERATURE SURVEY :-
One well-known way to make the gummy metal brittle is by coating it
with a suitable liquid metal, such as gallium in the case of aluminum.
Liquid metals like these, however, tend to work too well; diffusing
through the surface and causing the whole metal to crumble into a
powder. Other attempts which met with limited success tended to be
either toxic or result in tears and cracks on the machined surface. This
led the researchers to explore benign chemical media that would cut
cleaner.
Marking with ink or attaching any adhesive on the metal's surface
dramatically reduced the force of cutting without the whole metal
falling apart, leaving a clean cut in seconds. The quality of the
machined surface also greatly improved.
Stickiness didn't initially stand out as a solution that permanent
markers, glue sticks and tape have in common.
"We looked at the chemical ingredients of the permanent ink,
isolated each of those on the metal's surface, and there was no
noticeable effect," said Anirudh Udupa, lead author on the study
and a postdoctoral researcher in Purdue's School of Industrial
Engineering. "So we realized that it's not a particular chemical but
the ink itself sticking to the metal through a physical adsorption
mechanism."
The Sharpie and adhesives also appeared to work on many gummy
metals, regardless of the cutting tool.
Purdue researchers have discovered a simple solution for
cutting soft gummy metals just as cleanly and easily as hard
metals .In hindsight, we can tell you why certain things weren't
successful in previous work. It all comes back to the existence of
this wiggly flow," said Koushik Viswanathan, Purdue
postdoctoral researcher in industrial engineering. "Some people
might have been trying to cut copper, for example, that was in
the hard state rather than in the soft state."
To the researchers' knowledge, using permanent markers, glues
or tape to make gummy metals easier to machine does not pose
any environmental hazards.
Metal cutting
Metal cutting or Machining operation is to produce a desired shape, size and
finish of a component by removing excess material in the form of chips.
Chips may constitute more than 50% of initial work piece.
Machining processes are performed on metal cutting
machines, using various types of cutting tools
Metal cutting process in general should be carried out at high speeds and
feeds with least cutting effort at minimum cost.
Factors affecting metal cutting
1. Properties of Work material

2. Properties & geometry of cutting tool
3. Interaction between tool and work
turning facing grooving forming threading
External
Internal
Mechanics of Metal Cutting
A cutting tool exerts compressive force on the workpiece which stresses the work
material beyond the yield point and therefore metal deform plastically and shears off.
Plastic flow takes place in a localized region
called the shear plane.
Sheared material begins to flow along the

cutting tool face in the form of chips.
Flowing chips cause tool wear.
Applied compressive force which leads to

formation of chips is called cutting force.
Heat produced during shearing action raises the temperature of the workpeice, cutting
tool and chips.
Temperature rise in cutting tool softens and causes loss of keenness in cutting edge.
Cutting force, heat and abrasive wear are important features in metal cutting.
Types of Cutting Tools
Cutting tools performs the main machining operation.
It is a body having teeth or cutting edges on it.
They comprise of single point cutting tool or multipoint cutting

tools.
Types of Metal Cutting Process
Orthogonal cutting is also known as two dimensional metal cutting in which the cutting edge is
normal to the work piece. (angle = 90deg)
Oblique cutting is also known as three dimensional cutting in which the cutting action is
inclined with the job by a certain angle called the inclination angle. (angle ≠ 90deg)
Single point cutting tool : This type of tool has a effective cutting edge and
removes excess material from the work piece along the cutting edge.
These tools may be left-handed or right-handed.

Again single point cutting tools classified as
A. solid type
B. tipped tool.
C. Brazed tools
are generally known as tool bits and are used in tool holders.
The tipped type of tool is made from a good shank steel on which is mounted a
tip of cutting tool material.
Tip may be made of high speed steel or cemented carbide.
Different types of carbide tips are generally used on tipped tool.
 Two types of HSS i.e, is T-type and M-Type
 Vanadium increases abrasion resistance but higher percentage will decreases
grindability.
 Chromium increases hardenability
 Cobalt is added to HSS to increase red hardness.
3. Cast Cobalt Base Alloys:
 It is a combination of W, Cr, carbon and Cobalt which form an alloy with red hardness,
wear resistance and toughness. It is prepare by casting.
 Used for machining Cast iron, alloy steels, non-ferrous metals and super alloys
4. Cemented Carbides:
 These are carbides of W, Titanium and tantalum with small amount of cobalt produced
by means of powder metallurgy route.
 Two types i.e, Straight Tungsten Carbide Cobalt Grade and Alloyed Tungsten Carbide
Grade
Straight Tungsten Carbide Cobalt Grade : Cast iron, non ferrous alloys, plastics, wood,
glass etc.
Alloyed Tungsten Carbide Grade: All grades of steel at 3 to 4 times more speeds than HSS
5. Ceramic Tools:
 Aluminium Oxide, Silicon Carbide, Boron Carbide, Titanium Carbide, Titanium Boride
 High speed, longer tool life, superior surface finish, No coolant is required.
6. Diamond Tools:
 More abrasion resistance
 Used for turning grinding wheels
 Used to produce mirror surface finish.
 Diamond abrassive belts are used to produce TV screens
 Poly crystalline diamond inserts are brazed into cutting edges of circular saws for cutting
construction materials like concrete, refractories, stone etc.
Tool Life
Properly designed cutting tool is expected to perform the metal cutting operation in an
effective an smooth manner
If a tool is not giving satisfactory performance it is an indicative of tool failure.
Following are the adverse effects observed during operation;
Extremely poor surface finish on the workpiece

Higher consumption of power
Work dimensions are not produced as specified
Overheating of cutting tool
Appearance of burnishing band on the work surface
During operation cutting tool may fail due to following;
Thermal cracking and softening
Mechanical Chipping
Gradual wear
Machinability
The major factor involved in metal cutting are,
Forces and power absorbed
Tool wear and tool life
Surface finish
Dimensional accuracy
Machining cost
This factor depend upon a large variables, such as

Property of work material
Tool geometry
Cutting condition
Machine tool rigidity
The machinability may be evaluated as given below
• Long tool life at a given cutting speed

• Low power consumption per unit volume of materia
l removed.
• Maximum metal removal per tool re sharpening
• High quality of surface finish
• Good and uniform dimensional accuracy of successiv
e parts
• Easy disposable chips.
What is Cutting Fluid ?
Cutting fluid
is a type of coolant and lubricant designed specifically for metalw
orking
and machining processes.
There are various kinds of cutting fluids, which include oils, oil-
water emulsions, pastes, gels and other gases.
 They may be made from petroleum distillates, animal fats,

plant oils, water and other raw ingredients.
Depending on context, type of cutting fluid is being considered,

it may be referred to as cutting fluid, cutting oil, cutting
compound, coolant, or lubricant.
Characteristics of a Good Cutting Fluid
Good cooling capacity

Good lubricating qualities
Relatively low viscosity
Stability (long life)
Rust resistance
Nontoxic
Transparent
Nonflammable
SOFT GUMMY METALS
Aluminum
• Pure aluminum generally more difficult to machine th
an aluminum alloys
• Produces long stringy chips and harder on cutting tool
• Aluminum alloys
• Cut at high speeds, yield good surface finish
• Hardened and tempered alloys easier to machine
• Silicon in alloy makes it difficult to machine
• Chips tear from work (poor surface)
22
Copper
• Heavy, soft, reddish-colored metal refined from copper ore
(copper sulfide)
• High electrical and thermal conductivity
• Good corrosion resistance and strength
• Easily welded, brazed or soldered
• Very ductile
• Does not machine well: long chips clog flutes of cutting tool
• Coolant should be used to minimize heat
23
Copper-Based Alloys: Brass
• Alloy of copper and zinc with good corrosion resistanc
e, easily formed, machines, and cast.
• Several forms of brass.
• Alpha brasses: up to 36% zinc, suitable for cold working.
• Alpha 1 beta brasses: Contain 54%-62% copper and used in
hot working.
• Small amounts of tin or antimony added to minimize pi
tting effect of salt water.
• Used for water and gas line fittings, tubings, tanks, radi
ator cores, and rivets.
24
Copper-Based Alloys: Bronze
• Alloys of copper and tin which contain up to 12% of pr
incipal alloying element
• Exception: copper-zinc alloys
• Phosphor-bronze
• 90% copper, 10% tin, and very small amount of phosphorus
• High strength, toughness, corrosion resistance
• Used for lock washers, cotter pins, springs and clutch discs
25
Copper-Based Alloys: Bronze
• Aluminum-bronze (copper-aluminum alloy)
• Contains between 4% and 11% aluminum
• Other elements added
 Iron and nickel (both up to 5%) increases strength
 Silicon (up to 2%) improves machinability
 Manganese promotes soundness in casting
• Good corrosion resistance and strength
• Used for condenser tubes, pressure vessels, nuts and bolts
26

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CUTTING OF SOFT 'GUMMY' MET

This presentation briefs about the cutting of soft

Factors affecting metal cutting

1. Properties of Work material

Sheared material begins to flow along the

Flowing chips cause tool wear.

Applied compressive force which leads to

Cutting tools performs the main machining operation.

It is a body having teeth or cutting edges on it.

They comprise of single point cutting tool or multipoint cutting

These tools may be left-handed or right-handed.

If a tool is not giving satisfactory performance it is an indicative of tool failure.

Following are the adverse effects observed during operation;

Extremely poor surface finish on the workpiece

This factor depend upon a large variables, such as

• Long tool life at a given cutting speed

 They may be made from petroleum distillates, animal fats,

Depending on context, type of cutting fluid is being considered,

Good cooling capacity

• Good corrosion resistance and strength

• Easily welded, brazed or soldered

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