High speed steel
⚫ These steels are used for cutting metals at a much higher
cutting speed than ordinary carbon tool steels.
⚫ The high speed steels have the valuable property of
retaining their hardness even when heated to red heat.
⚫ Most of the high speed steels contain tungsten as the chief
alloying element, but other elements like cobalt,
chromium, vanadium, etc. may be present in some
proportion.
Contd…
⚫ With time the effectiveness and efficiency of HSS (tools)
and their application range were gradually enhanced by
improving its properties and surface condition through -
⚫ Refinement of microstructure
⚫ Addition of large amount of cobalt and Vanadium to
increase hot hardness and wear resistance respectively
⚫ Manufacture by powder metallurgical process
⚫ Surface coating with heat and wear resistive materials
like TiC , TiN , etc.
18-4-1 High speed steel
⚫ This steel contains 18 per cent tungsten, 4 per cent
chromium and 1 per cent vanadium.
⚫ It is considered to be one of the best of all purpose tool
steels.
⚫ It is widely used for drills, lathe, planer and shaper tools,
milling cutters, reamers, broaches, threading dies,
punches, etc.
Molybdenum high speed steel
⚫ This steel contains 6 per cent tungsten, 6 per cent
molybdenum, 4 per cent chromium and 2 per cent
vanadium.
⚫ It has excellent toughness and cutting ability.
⚫ The molybdenum high speed steels are better and cheaper
than other types of steels.
⚫ It is particularly used for drilling and tapping operations.
Super high speed steel
⚫ This steel is also called cobalt high speed steel because
cobalt is added from 2 to 15 per cent, in order to increase
the cutting efficiency especially at high temperatures.
⚫ This steel contains 20 per cent tungsten, 4 per cent
chromium, 2 per cent vanadium and 12 per cent cobalt.
MATERIALS
1.STELLITE
⚫ STELLITE is a non ferrous alloy with range of elements
Cobalt 40-48 %,Cr-30-35 %,Tungsten-12-19 %.In addition to one
or more carbide forming elements , carbon is added in amount of 1.8
to 2.5 %.
⚫ They can not be forged to shape but may be deposited directly on
the tool shank in an oxy accetylene flame.
⚫ Stellites preserve hardness upto 1000 °C and can be operated on
steel at cutting speed twice that for HSS.
⚫ These materials are not widely used for metal cutting since
they are very brittle, however they are used extensively in
some non metal cutting application such as rubber ,plastics
where loads are gradually applied and the support is firm and
where wear and abrasion are problems
Contd.
⚫ Stellites are currently being phased out for cutting-tool
applications because of increasing costs, shortages of strategic
raw materials (Co, W, and Cr), and the development of other,
superior tool materials at lower cost.
2.Cemented Carbide
⚫ Carbides, which are nonferrous alloys, are also called, sintered
(or cemented) carbides because they are manufactured by
powder metallurgy techniques.
⚫ The most important property of cemented carbide are very high
heat and wear resistance and they are very brittle also.
⚫ They can withstand cutting speed 6 times higher than HSS tool.
⚫ They can machine metals even when their cutting elements are
heated to 1000 °C
⚫ Cemented carbide is the hardest manufactured material and has
extremely high compressive stregth.It has low resistance to
shock and must be very rigidly supported to prevent cracking.
Types of cemented carbides
⚫ a)Tungsten(W) cemented carbide
⚫ b)Titanium tungsten cemented carbide
⚫ a)Tungsten(W) cemented carbide-They are less brittle
than Ti-W type. They contain 92 to 98 % tugsten carbide
and 2 to 8 % Co. These cemented carbides are
designed chiefly for machining brittle metals such as
cast iron, bronze but they may also be used for non
ferrous metals and alloy steels etc.
b)Titanium tungsten cemented carbide
⚫ They are more wear resistant. They contain
66 to 85 % tungsten carbide,5 to 30% titanium carbide
and 4 to 10 % cobalt . These cemented carbide are
designed for machining tougher materials chiefly for
various steels.
Coated Carbide Tools
⚫ Coated tools are becoming the norm in the metalworking
industry because coating , can consistently improve, tool
life 200 or 300% or more.
⚫ In cutting tools, material requirements at the surface of the
tool need to be abrasion resistant, hard, and chemically
inert to prevent the tool and the work material from
interacting chemically with each other during cutting.
⚫ A thin, chemically stable, hard refractory coating of TiC,
TiN, or accomplishes this objective.
⚫ The bulk of the tool is a tough, shock‐resistant carbide that
can withstand high‐temperature plastic deformation and
high resist breakage.
⚫ The coatings must be fine grained, & free of binders
and porosity.
⚫ Naturally, the coatings must be metallurgically bonded
to the substrate.
⚫ Interface coatings are graded to match the properties
of the coating and the substrate.
⚫ The coatings must be thick enough to prolong tool life
but thin enough to prevent brittleness.
⚫ Coatings should have a low coefficient of friction so
that the chips do not adhere to the rake face.
⚫ Multiple coatings are used, with each layer imparting
its own characteristic to the tool. Con56td…
⚫ The most successful combinations are
TiN/TiC/TiCN/TiN and TiN/TiC/ .
⚫ Chemical vapour deposition (CVD) is the technique
used to coat carbides.
3.Cermets
⚫ These sintered hard inserts are made by combining ‘cer’ from
ceramics like TiC, TiN or TiCN and ‘met’ from metal (binder) like
Ni, Ni-Co, Fe etc.
⚫ Harder, more chemically stable and hence more wear resistant
⚫ More brittle and less thermal shock resistant
⚫ Wt% of binder metal varies from 10 to 20%.
⚫ Cutting edge sharpness is retained unlike in coated carbide inserts
⚫ Can machine steels at higher cutting velocity than that used for
tungsten carbide, even coated carbides in case of light cuts.
⚫ Modern cermets with rounded cutting edges are suitable for
finishing and semi-finishing of steels at higher speeds, stainless
steels but are not suitable for jerky interrupted machining and
machining of aluminium and similar materials.
4.Diamonds
⚫ Diamond is the hardest of all the cutting tool materials.
⚫ Diamond has the following properties:
⚫ extreme hardness,
⚫ low thermal expansion,
⚫ high heat conductivity, and
⚫ a very low co-efficient of friction.
⚫ This is used when good surface finish and dimensional accuracy are
desired.
⚫ The work-materials on which diamonds are successfully employed are
the non-ferrous one, such as copper, brass, zinc, aluminium and
magnesium alloys.
⚫ On ferrous materials, diamonds are not suitable because of the
diffusion of carbon atoms from diamond to the work-piece material.
Contd…
⚫ Diamond tools have the applications in single point turning and
boring tools, milling cutters, reamers, grinding wheels, honing tools,
lapping powder and for grinding wheel dressing.
⚫ Due to their brittle nature, the diamond tools have poor resistance to
shock and so, should be loaded lightly.
⚫ Diamond tools offer dramatic performance improvements over
carbides. Tool life is often greatly improved, as is control over part
size, finish, and surface integrity.
⚫ Positive rake tooling is recommended for the vast majority of
diamond tooling applications.
⚫ If BUE is a problem, increasing cutting speed and the use of more
positive rake angles may eliminate it.
Contd…
Cubic boron nitride/Borazon
⚫ Next to diamond, cubic boron nitride is the hardest
material presently available.
⚫ It is made by bonding a 0.5 – 1 mm layer of
polycrystalline cubic boron nitride to cobalt based
carbide substrate at very high temperature and
pressure.
⚫ It remains inert and retains high hardness and fracture
toughness at elevated machining speeds.
⚫ It shows excellent performance in grinding any
material of high hardness and strength.
⚫ The only limitation of it is its high cost.
⚫ CBN is less reactive with such materials as hardened
steels, hard‐chill cast iron, and nickel‐ and
cobaltbased,superalloys.
⚫ CBN can be used efficiently and economically to
machine these difficult‐to‐machine materials at higher
speeds (fivefold) and with a higher removal rate
(fivefold) than cemented carbide, and with superior
accuracy, finish, and surface integrity.
