This is ap resentation showing the developments of cutting tools materials used from early life to present. their materials, properties, advantages, etc.

1. TOOLS
MMW = NR(HE)
where,
MMW- men’s material welfare
NR- natural resources available
HE- Human Efforts
Chronological development of cutting
tool materials
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2. CHRONOLOGICAL
DEVELOPMENT OF
CUTTING TOOL
MATERIALS
Presented by:
Bilal Hasan Syed
syedbilalhasan@gmail.com
March, 2013
Chronological development of cutting
tool materials
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3. Basic Requirements of Tool
Material
•
•
•
•
Hardness: retaining hardness at elevated
temperatures
Toughness: to survive under intermittent
cutting operation
Wear resistance: attainment of acceptable
tool life before replacement
Thermal Conductivity, etc.
Chronological development of cutting
tool materials
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4. Chronicle of tool materials
Chronological development of cutting
tool materials
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5. Chronicle of tool materials
Chronological development of cutting
tool materials
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6. Ancient Tools
Stone

Use predominated over millions of years.

Used to make hand axes, knives and arrow heads.

limitation - inability to produce different shapes.
Copper and Bronze

Use started as early as between 5000-6000 b.c.

Copper used mostly for knives and chisel.

Use of bronze started between 3000-3500 b.c.

Bronze - axes and hatchets, knives, arrowheads, lance heads and
swords
Iron


Use dates back to 1200 b.c.
Early applications - swords, knives, chisels, axes, sickles and
arrow heads.
Chronological development of cutting
tool materials
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7. Stone Tools
Chronological development of cutting
tool materials
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8. HIGH CARBON STEEL

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(Industrial Rev.
Carbon percentage -0.8 toPeriod)
1.5%
Oldest known tool material
Low Hot Hardness
Maximum Cutting Speed – 5-7 m/min
Maximum Temperature Limit -250 ºC
Suitable for Low Cutting
Low Cost
Used for taps, dies, hacksaw blades, hand
drills, wood working tools etc.
Chronological development of cutting
tool materials
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9. Self Hardening Steel
(1868)
Robert Mushet
W
•
•
•
Cr
C
(6-10)%
•
Mn
(1.2-2)%
0.5%
(1.2-1.5)%
No need of water quenching
Speed for steel 7-10 m/min
Self hardening because of Mn and Cr
Increased temp limit because of W
Chronological development of cutting
tool materials
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10. (1906)
HIGH SPEED STEEL & White
Taylor
T-Series (Tungsten Type)
M-Series (Molybdenum type)
W
Cr
Va
C
W
M
Cr
Va
18
4
1
0.75
6
6
4
2


Cutting speed up to 30 m/min
Maximum Limiting Temperature (560650)ºC
 Less Costly
 Excellent toughness
 Widely used in industries as a solid Tool
like form tool, drill, milling cutters, endmill,
reamers, Broach, Single point cutting tool
etc.
Chronological development of cutting
tool materials
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11. CAST COBALT ALLOYS (1915)
Elwood Haynes
C
Co
W
48-53%


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
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Cr
30-33%
10-20%
1.5-2.0%
Manufacturing Process- Casting
Hot hardness- 760ºC
Cutting Speed -45 m/min
Higher tool life compare to H.S.S.
Hardness -58 to 64 HRC
Lower toughness/brittle
Limited strength
Used for form tool, Machining cast and
malleable iron.
Chronological development of cutting
tool materials
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12. CEMENTED CARBIDES (1920)
Tunsten Carbide
Henry Moisson
W
C
Co
94%
6%
3-12%
Manufactured by
Powder Metallurgy
Grain size – 1 micron to
8 micron

Many verity can be
produced by controlling
grain size and % of
cobalt.

Drawback is its
Affinity with
steel
Chronological development of cutting
tool materials
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13. Tungsten-Titanium-Tantalum Carbide Bonded
With Cobalt ({WC+ TiC + TaC} -Co)
W
TaC
15%

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TiC
Co
10%
High hardness and wear resistance
Maximum limiting Temperature -1200 ºC
Various Shapes Of Inserts
Cutting Speed -100 m/min
High Tool life
High compressive strength
High production rate
Better surface finish
Chronological development of cutting
tool materials
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14. Coated Carbides


Coating of micro thin layer insets made of tungsten carbide
Most commonly used coating materials are:

Titanium Nitride (TiN)

Titanium Carbide (TiC)

Titanium CarboNitiride (TiCN)
 Aluminium Oxide (Al2O3)

Zicronium Nitride (ZrN)

Titanium Aluminium Nitride (TiAlN)

Methods of Coatings
 Chemical Vapor Deposition (CVD)
 Physical Vapor Deposition (PVD)

Advantages:




High hot hardness
Chemically stable
High cutting speed -150 to 250 m/min
High Tool life (2 to 3 times higher than carbide)
Chronological development of cutting
tool materials
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15. SUPER COATED CARBIDES
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WC- Higher interior Hardness and toughness
Triple layer coating
Inner layer –FCCN (Fibrous Crystalline
Carbon Titanium )
Balance between wear resistance and
fracture resistance
Outer coating –Al2O3 (Fine Grain)
outer most layer – Special laminated Titanium
Alloys
Superior high temperature strength.
Chronological development of cutting
tool materials
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16. Alumina Tools (Ceramics)(1960s)
Al2O3 + MgO
90%

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Cr2O3, SiC, TiO, TiC
10%
High abrasive of wear
Resistance
Less tendency to weld to
metal
Very high compressive
strength
Very high hot hardness
High refractoriness – 1800
ºC
High Cutting Speed -200 to
400 m/min
Longer tool life
Limitation
 Poor Toughness
 Unreliable (Sudden
fail)
 High rigidity of set
up
Chronological development of cutting
tool materials
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17. Cermets
70% aluminum oxide & 30 %
titanium carbide
 Cermets contain molybdenum
carbide, niobium carbide and
tantalum carbide.

Chronological development of cutting
tool materials
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18. SIALON
•
•
•
•
•
•
•
(1976)
Silicon Nitride based alloy with Aluminium &
Oxygen addition
Low Coefficient of thermal expansion
Increased resistance of thermal shocks & thermal
fatigue
Used with Negative rake
Speed for C.I. is 600 m/min
Speed for steel is 60m/min
Hot pressing and sintering of mixture of Al2O3
and Si3N4 powder
Chronological development of cutting
tool materials
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19. CUBIC BORON NITRIDE


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Sanitized artificially made under high pressure
and high temperature.
Stable up to 10000C temperature.
Manufactures under ultra high pressure and high
temperature.
Excellent in chemical and thermal stability.
Hardness next to natural diamond.
Applications:



Permits high feeds and speeds.
Available in large variety of shapes and sizes in
insert form.
Use to turn bore, face, groove and mill difficult to
machine materials.
Chronological development of cutting
tool materials
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20. DIAMOND
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Hardest substance BHN 7000
High heat conductivity (Twice then steel)
High hot hardness 1650 ºC
High wear resistance
Very low co-efficient of friction
High compressive strength
High cutting speed (300 to 1000 m/min)
High tool life
Used for cutting hard material like glass,
plastic Ceramics and cemented carbides.
 Used for turning and dressing wheel of
grinding wheel
 Used for machining non-metallic and nonferrous alloy
Chronological development of cutting
tool materials
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21. Polycrystalline Diamond ( PCD )

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Synthetic having diamond matrix structure.
Sintered under extremely high temperature
and pressure.
High in uniform hardness and abrasive
resistance in all direction.
Very high tool life compare to carbide tool (50
times).
Shock resistance is more than natural
diamond.
Consistency in wear resistance.
Available in large verity of shapes and sizes.
Discs as large as 58 mm in diameter.
Better thermal conductivity then natural
diamond.
Lower cost then natural diamond.
Used for machining milling, turning, grooving,
Chronological development of cutting
facing and boring.
tool materials
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22. Diamond coated carbide tools



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Use of Polycrystalline diamond as a
coating
Difficult to adhere diamond film to
substrate
Thin-film diamond coated inserts now
commercially available
Thin films deposited on substrate with
PVD & CVD techniques
Thick films obtained by growing large
sheet of pure diamond
Diamond coated tools particularly
effective in machining non-ferrous and
abrasive materials
Chronological development of cutting
tool materials
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23. FUTURE…
Few possible concepts –
• Thermo mechanical treatment to produce
textural or orientation hardening
• Application of splat cooling technique to
produce material of very fine grain size
approaching an amorphous structure
• Continued and composite concepts
Chronological development of cutting
tool materials
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