This document discusses different materials and techniques used in cutting tool manufacturing. It covers common materials like high-speed steel and hardmetals like tungsten carbide, as well as advanced materials like ceramics, diamond, and cubic boron nitride. Coatings are also discussed which provide benefits like hardness, thermal protection and improved performance. New machining techniques covered include high-feed milling, plunge milling, spinning tools and trochoidal milling which aim to reduce vibrations. The document concludes by discussing future areas like micro milling and machining of new materials.

1. NANDU SONMANKAR
TE PRODUCTION (S/W)
EXAM SEAT NO. T140087656

2. Introduction
 Design
 Construction
 A general view of the tool world
 New machining techniques

3. Materials for Cutting-tool
Manufacture
1. High-speed Steel
 Max. working temperature of HSS is about 500 °C.
 Currently, HSS produced by powder metallurgy (HSS-
PM)

4. 2. Sintered Carbide (Hardmetal)
mixture of tungsten carbide micro
grains with cobalt
Tantalum, titanium or vanadium
carbides can be also mixed in small
proportions.

5. Hard-metal tools are manufactured in two
forms:
 Integral tools
 Inserts
 (a)Ball-endmill with inserts, (b) and integral bull-
nose endmill

6. Ceramics
 Ceramic tools are based primarily on alumina
(Al2O3), silicon nitride (Si3N4)
 (a) Ceramic inserts (b) matrix of a reinforced ceramic

7. Extra-hard Materials
 Diamond and Polycrystalline Diamond (PCD)
- available in various grain sizes
- Mono-crystalline diamond (MCD) is natural
diamond
 Polycrystalline Cubic Boron Nitride (PCBN)
- CBN is a polymorph boron-nitride-based material
- CBN is the second-hardest synthetic material

8. Coatings
thickness ranging from 2 to 15 μm
improve the cutting-tool performance
applied after the tool is shaped

9. Coatings provide
 A hard Tool
 Chemically stable surface
 Thermal protection to tools
 Improving their performance during
cutting.

10. Hard Machining for Mould and
Dies
 Ball-endmilling for Sculptured Surfaces
A four-flute geometry with a full cutting edge to the
centre of the ball

11. Five-axis Ball-endmilling
Two additional orientation axes added.
Cannot be machined using three-axis
machines.
Tool stiffness is higher.

12. Toolholders and Tool Clamping
Systems
 Assembly and disassembly must be simple.
 Allow automatic tool change (ATC)
commanded from the CNC.
 Maximum coaxial accuracy on the tool–tool
holder–spindle assembly.
 Maximum torque transmission from the
spindle to the tool.

13. New Techniques for Hard
Machining
 The main purpose of them is to avoid machining
vibrations
1. High-feed Milling
2. Plunge Milling
3. Turn Milling and Spinning Tool
4. Trochoidal Milling

14. High-feed Milling
 This produces a minimam radial and a maximum axial
cutting force.
 The Penta-edge insert for high-feed milling of Safety

15. Plunge Milling
 High-performance roughing technique.
 This technique is also referred to as milling in the Z-
axis.
 (a) general procedure, (b) maximum radial width of
cut

16. Spinning Tool
 Uses a specialized insert
 Full-radius insert
 (a) Spinning tool, and (b) Kennametal

17. Spinning Tool
Designed to distribute heat and wear
more effectively.
 increase productivity by up to500 %
and tool life by up to 2,000 %.

18. Trochoidal Milling
 combination of a uniform circular motion
with a uniform linear motion.
 tool-path is a kinematics curve so-called
trochoid.

19. Trochoidal Milling
Large axial depth of cut.
Drawback is that tool path length is
much higher .
 Recommended for slotted shapes.

20. Drilling holes efficiently
 Today’s drills are several generations ahead
with very high capabilities as regards: -
1. Penetration rate.
2. Finishing capability.
3. Operational versatility.
4. Power requirement.
5. Reliability.

21. Drilling holes efficiently
 Drill bit can penetrate flat, convex, concave,
inclined and irregular surfaces

22. Tools for Multitask Machining
 Combining turning and milling operations in the
same machine bed.
 The programming of these machines was a real
challenge.

23. Multitasking machines include a
spindle instead of a turret.
A reliable solution for the machining of
complex parts.
Tools for Multitask Machining

24. Conclusion
 Lot of time, money and effort invested.
 Supply a much optimized tool, in all the
related aspects discussed in this report.
 The application guide.

25. Conclusion
The economic impact increasing.
Reduction of the amount of material to be
removed in each part.
Improvement of productivity.
Tool life and workpiece precision.

26. Future Scope of Tools
 Micro milling
-with special attention to medical devices.
-Tool fabrication is another important issue.

27. Future Scope of Tools
high silicon aluminium alloys.
carbon-fibre-reinforced plastic
composites, and others.