Re-sharpen and use it again. TOOL LIFE: • Useful life of a tool expressed in terms of time from start of a cut to termination point (defined by failure criterion). Sometimes also expressed in terms of no. Of the parts machined. • Tool failure criterion depends on • 1. The requirements of the component being produced. • 2. Type of Operation: • Roughing: force and power requirement. • Finishing : Surface finish & dimensional accuracy. TAYLOR’S TOOL LIFE EQUATION TAYLOR’S TOOL LIFE EQUATION VARIABLES AFFECTING TOOL LIFE Cutting Conditions (V, d, f) • Tool Geometry (all six angles, and nose radius) • Workpiece Material • Cutting fluid • Machine tool and Work piece region • Tool Material MACHINABILITY Mainly concerned with work piece material properties, not the tool properties. It depends on work piece material properties and good machinability means: 1. Low tool wear 2. 2. Good surface finish produced 3. 3. Low cutting forces Tool life Tool wear is a time dependent process. As cutting proceeds, the amount of tool wear increases gradually. But tool wear must not be allowed to go beyond a certain limit in order to avoid tool failure. The most important wear type from the process point of view is the flank wear, therefore the parameter which has to be controlled is the width of flank wear land, VB. This parameter must not exceed an initially set safe limit, which is about 0.4 mm for carbide cutting tools. The safe limit is referred to as allowable wear land (wear criterion), VBk . The cutting time required for the cutting tool to develop a flank wear land of width VBk is called tool life, T, a fundamental parameter in machining. The general relationship of VB versus cutting time is shown in the figure (so-called wear curve). Although the wear curve shown is for flank wear, a similar relationship occur for other wear types. The figure shows also how to define the tool life T for a given wear criterion VBk . • The slope of the wear curve (that is the intensity of tool wear) depends on the same parameters, which affect the cutting temperature as the wear of cutting tool materials is a process extremely temperature dependent. Parameters, which affect the rate of tool wear are v cutting conditions (cutting speed V, feed f, depth of cut d) v cutting tool geometry (tool orthogonal rake angle) v properties of work material From these parameters, cutting speed is the most important one. As cutting speed is increased, wear rate increases, so the same wear criterion is reached in less time, i.e., tool life decreases with cutting speed: • Tool wear describes the gradual failure of cutting tools due to regular operation. It is a term often associated with tipped tools, tool bits, or drill bits that are used with machine tools. • Types of wear include: • flank wear in which the portion of the tool in contact with the finished part erodes. Can be described using the Tool Life Expectancy equation. • crater wear in which contact with chips erodes the rake face. This is somewhat normal for tool wear, and does not seriously degrade the use of a tool until it becomes serious enough to cause a cutting edge failure. • Can be caused by spindle speed that is too low or a feed rate that is too high. In orthogonal cutting this typically occurs where the tool temperature is highest. Crater wear occurs approximately at a height equaling the cutting depth of the material. Crater wear depth ~ t0 t0= cutting depth • built-up edge in which material being machined builds up on the cutting edge. Some materials (notably aluminum and copper) have a tendency to anneal themselves to the cutting edge of a tool. It occurs most frequently on softer metals, with a lower melting point. It can be prevented by increasing cutting speeds and using lubricant. When drilling it can be noticed as alternating dark and shiny rings. • glazing occurs on grinding wheels, and occurs when the exposed abrasive becomes dulled. It is noticeable as a shine while the wheel is in motion. • edge wear, in drills, refers to wear to the outer edge of a drill bit around the cutting face caused by excessive cutting speed. It extends down the drill flutes, and requires a large volume of material to be removed from the drill bit before it can be corrected.