IAETSD JOURNAL FOR ADVANCED RESEARCH IN APPLIED SCIENCES ISSN NO: 2394-8442

A Review on Techniques to improve the life of cutting tools life

Ankit Raj 1, Israj khan2, Aadarsh kumara3, Abhishek yadav 4, Bhavesh Sharma5,
Amit Jain6
Student of mechanical engineering1, 2, 3, 4, 5, Assistant Professor6, ITM Group of Institute, Gwalior, India
jainamit085@gmail.com

Abstract

In any manufacturing industry the presence of precision in the cutting tool life is justified, hence it is essential to study the
amount of wear on the cutting tool. The number of times it can be reused for machining the components and the number
of tools to be present at any given time to avoid the stoppage of automated line in the manufacturing industry. To reduce
the machining cost, improve production rate and achieve world class efficiency it is essential to study the Tool failure
modes and optimize every possibility.

Keyword: - optimize, Tool life, automated flow line, insert, wear.

I. INTRODUCTION
To increase product need to boost productivity to machine more difficult materials and to improve quality in high volume
by the manufacturing industry has been the driving force behind the development of cutting tool materials. Numerous
cutting tools have been developed continuously since the first cutting tool material suitable for use in metal cutting, carbon
steel, was developed a century ago. Cemented carbides are the most popular and most common high production tool
materials available today. The productivity enhancement of manufacturing processes is the acceleration of improved
cutting tools with respect to the achievement of a superior tribological attainment and wear-resistance. This resulted in
developing hard coating for cutting tools these hard coatings are thin films of one layer to hundreds of layers

II. WEAR IN CUTTING TOOLS

2.1 Abrasive wear: Abrasive wear occurs whenever a hard rough surface or a surface containing hard particles slides on
top of a softer surface in tool wear, abrasive wear is the removal of tool material by hard abrasive phases in work material.
The abrasive phase with complex morphologies results in 2-body abrasion while the abrasive with simple morphologies
results in 3-body abrasion.

2.2 Diffusion wear: - Solid-state diffusion takes place from regions of high atomic concentration to regions of low
atomic concentration. The diffusion rate increases exponentially with temperature. Diffusion wear can occur in metal
cutting due to the intimate contact at high temperatures in a very narrow reaction zone between the tool and the chip as
shown in Fig 3. Diffusion wear mainly causes weakening of the surface structure of the tool

2.3 Dissolution wear:-The high temperature required for dissolution wear to occur, not only the machining condition
must be severe but also it occurs on rake face. In dissolution wear, the species from the tool material forms a solid solution
within the chip. As the chip passes, tool material is constantly removed from the rake face. Dissolution wear depends on
the chemical inertness of
III. TECHNIQUES TO IMPROVE LIFE
Praveen Kumar k , Gaurav K Lakshman, Jaya Krishna C, karthik M, Midhun [1]:- has introduced method of coating the
surfaces of cutting tools to increases their life. The hard coatings have been proven to increase the tool life by as much as
10 folds through slowing down the wear phenomenon of the cutting tools.

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IAETSD JOURNAL FOR ADVANCED RESEARCH IN APPLIED SCIENCES ISSN NO: 2394-8442

This increase in tool life allows for less frequent tool changes, therefore increasing the batch sizes that could be
manufactured and in turn not only reducing manufacturing cost but also reducing the setup time as well as the setup cost.
Hard coating deposited on cutting tools allows for improved and more consistent surface roughness of the machined work
piece. The surface roughness of the machined work piece changes as the geometry of the cutting tool due to wear and
slowing down the wear which leads more consistency and better surface finish. As by analysis and examine the coated
tools is done through Rapid I machines and result are very satisfying so, final result is Yellow bar represents the number
of parts produced in the usual cycle for the respective machines and the green bar represents the number of parts
produced after improvement for respective machines. As the result of life improvement 11350 components were
produced more than before.

Chandrashekar BH, Ashwin C Gowda, Udaykumar PA:- has describes different methods to reduces different types of
defects which is responsible to reduces the life of cutting tools such as

3.1 Chipping
Mechanical Chipping occurs when small particles of the cutting edge are broken away rather than being abraded away in
abrasive wear

This type of defects occurring n cutting tools surfaces is minimized by following:-

3.1.1 Tougher cutting tool material:

3.1.2 Cobalt enriched grades, higher cobalt Ti, & Ta, bearing grade
3.1.3 Stronger geometry
3.1.4 by using Negative rake rather than the positive rake
3.1.5 Increasing Tool Nose
3.1.6 Maximize rigidity
3.1.7 Reduced metal removal

3.2 Carter wear:

Cratering are Tool wear characterized by a concave depression in the rake face of the cutting tool. Cratering is also called
crater wear.

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IAETSD JOURNAL FOR ADVANCED RESEARCH IN APPLIED SCIENCES ISSN NO: 2394-8442

It is minimized and improving the surfaces of tools by following methods

By Reduce Cutting speed (by reduced spindle speed)

By using Higher Ti Content grade
By Lower cobalt grade
By Use of CVD coated grades - Al2O3&TiC

3.3 Thermal deformation:-

It is also called as plastic deformation and takes place as a result of combination of high temperature and high pressures
on the cutting edge.

It is overcome by following methods:-

By Use of grades with higher Ta content
By Use of grades with lower cobalt content
By Using CVD coated grades - Al2O3&TiC

3.4 Built-Up Edge

This occurs due to welding between the tool and chip (i.e work material is deposited on the rake and flank face of the tool)
at the asperities and the subsequent breakage of the welds. When weld breaks it plucks away material from the tool. It is
also called as Adhesion.

It is minimized and improve the life of cutting tools by following methods:-

PVD Coating by using materials like TiC, TiN , TiC and Tin have lesser affinity to steel to form built-up edge.
Moreover low wettability of these materials by ferrous material reduces built-up edge formation. The edges are
uniformly coated hence there is less chance of adherence property
Polished edges: Adherence property is weaker at polished surfaces.
Using Coolant: Coolant washes away built up material at earlier stages.
By using positive rake: Area of contact is minimum.
by Minimizing the flank wear
If above minimizing techniques is followed, we can achieve higher tool life as a result.

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IAETSD JOURNAL FOR ADVANCED RESEARCH IN APPLIED SCIENCES ISSN NO: 2394-8442

IV. CONCLUSIONS
This study evaluates that tool coatings were found to improve upon the wear resistance of the cutting tool. This was
shown by the decrease in wear on the flank face of the coated tools compared to that of the uncoated tool. The other
types of Mechanical failures occurs such as chipping, built up edges, thermal deformation , carter wear can effectively
minimized and increases the life of the cutting tools.

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