ISSUES RELATED TO

MACHINING OF HARD
MATERIALS
ISSUES
SOLUTIONS
ALTERNATIVES
PRESENTED BY:
NIKUNJ RATHOD 15BME145D
ROHAN LODAYA 15BME146D
JAY TAWRAVALA 15BME147D
DARSHAN TRENTIYA 15BME148D
KISHAN SAVALIYA 15BME149D
 PRIMARY ISSUES
VIBRATIONS:-
• The tool pressure force in other than primary direction causes vibrations,
because this force is about twice the main cutting force.

PRESSURE FORCE:-
• Structural strength not enough to carry force during machining of hard
material.
• Affects work piece form and roughness.

ACCURACY:-
• Accuracy can’t be achieved due to hard machining.
• Rigidity of w/p required.

INCREASED HEAT:
• Increased heat in the w/p due to hot chips building up on the component,
so it would affects the metallurgical properties of the machine tool.
CONTINUED
CHIP FORMATION:-
• chip produced is different from traditional soft turned chip.
• In this case, very thin, ribbon like chip is produced.
• If the insert does not have a chip breaker, chip control can be
difficult.

TOOL MATERIAL:
• Costly tool material required for machining hard material and
not easily available.
• For materials like cubic boron nitride, boron carbon nitride and
other super-hard materials cannot be machined by normal tool,
other tool material like diamonds, carbide and ceramic
inserts(expensive alternative).
CONTINUED
MACHINING TIME:
• The time required for machining hard materials will be very
high and hence would affect the rate of production.
• Poor chip control can lead to poor surface finish due to chips
rubbing on the finished part surface.

TOOL LIFE:
• The tool life would be drastically reduced as the tool would be
getting worn out more rapidly.
• Selection of tool-material grade is one of the most challenging
task in hard turning in terms of obtaining efficient and stable
machining process.
• The insert shape and tool holders just add more complication.
 MODIFICATIONS IN CONVENTIONAL
TURNING
BY APPLYING A COATING to the inserts. coatings of a
protective layer on the tool, increasing tool life. which
allows higher spindle speed and little extra feed rate to be
used.
 Whenever you coat an insert you will get longer tool life.

Special cutting tools with MODIFIED TOOL GEOMETRY

are need with coating of alloying element for increasing the
tool strength.
CONTINUED
By applying HIGH PRESSURE COOLANT, we can get
two or three times faster and even at the same time
getting longer tool life.

hard turning requires a large range of speeds. COLLET

CHUCKS is offering maximum flexibility, are easy to
handle, provide excellent shock absorbing characteristics
and offer an excellent range of clamping diameters. These
are suitable of aggressive roughing and semi finishing of
hardened materials.
 FACTORS OF SUCCESS IN HARD
MATERIAL MACHINING
• M/c rigidity

• W/p clamping rigidity

• Good vibration damping characteristics

• Rigid c/tool

• Rigid tool location

 ALTERNATIVES TO CONVENTIONAL
TURNING
HARD TURNING
 Hard turning is a technology driven processes, dependent upon
 M/c technology
 Work holding technology
 Material & tooling technology
 Process technology

 HARD TURNING TECHNIQUES:-

 Feed speed
 M/c setup
 Positioning
 Coolant application
 The base construction and the individual components of the machine, such
as the spindle, and chucking system must be able to handle high cutting
force with a rigid base with good vibrations damping characteristics.
 MODIFICATIONS IN CONVENTIONAL
MILLING
Machine tool:
• The base construction and the individual components of the
machine, such as the drive train, spindle, and CNC system,
must be able to handle high cutting forces with a rigid base with
good vibration damping characteristics.

Tool-holders:
• Hard milling requires a large range of speeds. Collet chucks in
addition to offering maximum flexibility, are easy to handle,
provide excellent shock absorbing characteristics and offer an
excellent range of clamping diameters.
• These are suitable for aggressive roughing and semi finishing
of hardened materials.
CONTINUED
Cutting tools:
• For roughing hardened materials, four-flute end mills or higher
are recommended.
• The selection of cutting tools should be short with short flute
lengths along with a helix angle of approximately thirty degrees
which has proven to be optimal for chip flow and dispersal of
heat.
• Hard milling creates a great amount of stress on the tool from
high heat and abrasive wear.
• To help overcome these stresses, coatings of a protective layer
on the tool, substantially increasing its life.
• The most common coatings are titanium nitride (TiN), titanium
carbon nitride (TiCN), titanium aluminum nitride (TiAlN) and
titanium aluminum carbon nitride (TiAlCN)
ALTERNATIVES TO CONVENTIONAL
MILLING
METAL LASER MELTING
 The innovative process has a number of
clear benefits, ranging from the ability to
manufacture complex geometries and
manipulate materials that are difficult to
machine,
 to the creation of components without the
use of tools in very short periods of time
and with extremely minimal waste of
material.
ELECTRON-BEAM MACHINING
It is a process where high-velocity electrons concentrated
into a narrow beam are directed toward the work piece,
creating heat and vaporizing the material.
EBM can be used for very accurate cutting or boring of a
wide variety of hard materials.
ELECTRICAL DISCHARGE MACHINING
Material is removed from the work piece by a series of
rapidly recurring current discharges between
two electrodes, separated by a dielectric liquid and
subject to an electric voltage
 MODIFICATIONS IN CONVENTIONAL
DRILLING
Because the amount of heat generated is high, a
COATED TOOL is the correct choice.
Tools having a PVD [physical vapor deposition] titanium
aluminum coating, which acts as a barrier between the
carbide and the material being cut, essentially acting as a
shield so the heat doesn’t get into the tool.
“If you can control heat, you can control tool life.”
THE ICM EXCHANGEABLE DRILL HEAD was developed
for cutting stainless steel, but works well with hard
materials because it has a T-land on the cutting edge.
 DRY MACHINING
It does not involve the use of wet cutting fluids that are
hazardous to environment and also cost sufficiently high.
 DRY MACHINING
It does not involve the use of wet cutting fluids that are
hazardous to environment and also cost sufficiently high.
1. Tool material
Multilayer coated Carbides
Cubic Boron Nitride
Tungsten Carbide

2. Tool coating
Titanium Nitrate
Titanium Aluminum Nitrate
Laser-cut 964

3. Chip removal using spindle air

Cold Air Guns can be successfully employed in place of liquid cutting
fluids.
Cold Air Guns use filtered compressed air (80-100 PSI) and vortex
tube technology to produce sub-zero air for industrial spot cooling.
 DISADVANTAGES
• In dry machining there might be chances of carrying away
of chips which might cause harm to operators.
• For avoiding this Telescoping covers, enclosures, seals,
and dust collectors are also required to protect the
operator from any dust that might get in the air. This
causes in increased cost.
• Friction and adhesion between chip and tool tend to be
higher, which causes
Higher temperatures
Higher wear rates
Shorter tool lives
Affect form and dimensional accuracy and subsurface
structure
 WET MACHINING
• Cutting fluids have been introduced into the cutting
process with the purpose to improve the characteristics of
the tribological processes which are always present on
the contact surfaces between the tool and the work piece.

ADVANTAGES:
 Better part quality
 Less tool wear.
 Hard material at high speeds can be machined
 Less heat generation
 Facilitates chip disposal
 FUNCTIONS OF CUTTING
LUBRICANTS
Reduce heat generation by reducing friction
To dissipate the heat generated due to plastic deformation
of the metal during machining
To cool the tool for increasing the tool life
To cool the work for preventing thermal distortion of the
work
To lubricate and reduce friction
Also have an important transport function for the removal
of the chips
CONTINUED
• Thus efficient lubrication systems enable to high
performance operations in practice.
 Increases the tool life,
 Contributes to a more economical cutting speed
 Improves the efficiency of the production systems when taken as a
whole.

DISADVANTAGES:
 Economic reasons
 Environmental reasons
Minimum Quantity Lubrication(MQL)
MQL Serves as an alternative to
flood cooling by reducing the
volume of cutting fluid used in the
machining process but not
without significant Health
Concerns.
Flood cooling is Primarily used to
cool and lubricant the cutting tool
and work piece interface during
Machining Process.
MQL Concentration varies
between 0.2 and 500ml/hr.
Quality Lubricants are required in
MQL.
 Advantages of MQL
Reduced Fluid Consumption

Safer Fluids

Reduced Health Hazards

Faster Machining

Long tool Life

Lower disposal Costs

Cleaner Shop Environment

Reduced Maintenance
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Date:29/04/2017
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http://www.hembrug.com/hard-
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