amalan bengkal mekanikal 4.ppt 31-01-2010.ppt2.pptx 6

8/14/2019 Amalan Bengkal Mekanikal 4.Ppt 31-01-2010.Ppt2.Pptx 6

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MECHANICAL WORKSHOPECHANICAL WORKSHOPACTIVITY 4CTIVITY 4-J4102-4102-

NAME LECTURER: EN. SHUHAIRI BIN MOHDAME LECTURER: EN. SHUHAIRI BIN MOHDSAMSUDINAMSUDIN

PRESENTATION: GROUP 3

TOPIC: CARBIDE FUNDAMENTALS


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1:RAJA MUHAMMAD FADZRIL BIN RAJA JOHAR SHAH

2:MOHD AZIZI BIN BAHAROM

3:MIR HARRIS BIN AHMAD

4:MUHAMAD TAUFIQ BIN ZAKARIA

5:MEOR ASNAWI BIN MIOR SADON

TEAM OF GROUP- 3EAM OF GROUP- 3CARBIDE FUNDAMENTALSARBIDE FUNDAMENTALS


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A common cutting tool material developed by the combination of carbon with usuallychromium, tungsten, or titanium that is used in metal cutting tools for its hardnessand wear resistance.

For carbide cutting are made that a cutting bit made of hard carbide material that

has multiple cutting edges.

Once a cutting edge is excessively worn, it can be indexed to another edge, or theinsert can be replaced.

Describe how carbide insert are made.Describe how carbide insert are made.


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Cemented carbide, also called tungsten-carbide cobalt orhardmetal orwidia,

is a hard material used in machining tough materials such as carbon steel orstainless steel, as well as in situations where other tools would wear away, suchas high-quantity production runs.

Most of the time, carbide will leave a better finish on the part, and allow fastermachining. Carbide tools can also withstand higher temperatures than standardhigh speed steel tools.

State the two maintate the two maincharacteristics of carbide.haracteristics of carbide.
http://en.wikipedia.org/wiki/Carbon_steelhttp://en.wikipedia.org/wiki/Stainless_steelhttp://en.wikipedia.org/wiki/High_speed_steelhttp://en.wikipedia.org/wiki/High_speed_steelhttp://en.wikipedia.org/wiki/Stainless_steelhttp://en.wikipedia.org/wiki/Carbon_steel


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Carbide Grade Applications

(C-2 / K20) Uncoated grade used primarily in mild cuttingconditions. Used for milling steel, cast steel and other non-ferrous alloys.

(C-5 / P30) For roughing to semi-finishing of steel.

(TiN-55) Multi Layer CVD coating (TiN/TiC/TiCN/TiN)For milling and turning carbon and alloy steels, tool steels

Selection of carbide tool grade.election of carbide tool grade.


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To increase the life of carbide tools, they are sometimes coated. Four such coatingsare TiN (titanium nitride), TiC (titanium carbide), Ti(C)N (titanium carbide-nitride),and TiAlN (titanium aluminum nitride). (Newer coatings, known as DLC (DiamondLike Coating) are beginning to surface, enabling the cutting power of diamondwithout the unwanted chemical reaction between real diamond and iron.)

Most coatings generally increase a tool's hardness and/or lubricity. A coating allowsthe cutting edge of a tool to cleanly pass through the material without having the

material gall (stick) to it. The coating also helps to decrease the temperatureassociated with the cutting process and increase the life of the tool.

The coating is usually deposited via thermal CVD and, for certain applications, withthe mechanical PVD method. However if the deposition is performed at too hightemperature, an eta phase of a Co6W6C tertiary carbide forms at the interface

between the carbide and the cobalt phase, facilitating adhesion failure of the

coating.

Coatings for carbide insert.Coatings for carbide insert.
http://en.wikipedia.org/wiki/Titanium_nitridehttp://en.wikipedia.org/wiki/Titanium_carbidehttp://en.wikipedia.org/wiki/Titanium_carbide-nitridehttp://en.wikipedia.org/wiki/Titanium_aluminum_nitridehttp://en.wikipedia.org/wiki/Gallinghttp://en.wikipedia.org/wiki/Chemical_vapor_depositionhttp://en.wikipedia.org/wiki/Physical_vapor_depositionhttp://en.wikipedia.org/wiki/Physical_vapor_depositionhttp://en.wikipedia.org/wiki/Chemical_vapor_depositionhttp://en.wikipedia.org/wiki/Gallinghttp://en.wikipedia.org/wiki/Titanium_aluminum_nitridehttp://en.wikipedia.org/wiki/Titanium_carbide-nitridehttp://en.wikipedia.org/wiki/Titanium_carbidehttp://en.wikipedia.org/wiki/Titanium_nitride


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The nose radius, Figure 6-9, will affect tool strength and surface finish.

The larger the nose radius, the stronger the insert and the better the finish.

However, if tooling and setup are not rigid, a large nose radius can cause chatter.

The chart in Figure 6-10 indicates the smoothness of surface finish that should result from various combinations of nose radii and feed rates.

Tool-nose radiusTool-nose radius


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Different insert shapes accomplish specific types of machining operations on

various workpiece shapes.

See Figure 6-7. The strength of the insert also depends on the shape of theinsert.

For example, the round insert has the greatest strength and the most cuttingedges, while the 35 diamond insert has the lowest strength. The triangularinsert is very versatile for milling operations.

Insert shapeInsert shape


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Insert size is determined by the largest inscribed circle (IC) that will fit inside the insert or touch all edges of the insert, Figure 6-8.

The most common insert is a square. As the size of the insert increases, thedepth of cut can increase as well. A rule to follow is to set the depth of cut to no

more than 2/3 the cutting edge length.

Insert sizeInsert size


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The rake angle has a primary influence on cutting forces and consequently the

cutting torque and surface finish of the thread. Test results made with different rake angles are shown in the above diagram,

illustrating how cutting torque decreases with a larger rake angle.

There is, however, a limit. A large rake angle means lower strength of the cuttingedge.

Rake anglesRake angles


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Lead angles on a milling cutter have an effect on cutting force direction, chip

thickness, and tool life. Lead angles can be 0 degree, 15 degree , 20 degree, and45 degree . A 0 degree lead is used to produce a 90 degree shoulder. See Figure6-5.

For general milling applications where rigid conditions exist, 15 degree and 20degree leads are used.

A 45 degree lead angle allows higher feed rates to be used.

As the lead angle increases from 0 degree to 45 degree , the amount of entry shockminimizes.

Lead angleLead angle

Figure 6-5. An example of an insert with 0 degree leadangle, is used to create a 90 degree shoulder.


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A standardized letter and number system developed by ANSI, Figure 6-11, is used to identify and classify indexable carbide inserts. The

identification reference is a combination of nine letters and numbers. The

reference indicates the insert shape, clearance (relief angle), tolerance,

insert type, size, thickness, point (nose) radius or chamfer, cutting edge

condition, and (optional) manufacturers identifier.

Choohoose insert for variouse insert for variousapplicationspplications


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Carbide InsertCarbide Insert

Steel & Stainless (Toshiba)

Aluminum & Plastics (Vardex)

Tool Holders

Boring Bars
http://www.techtoolsys.com/thumbnail.asp?cid=13http://www.techtoolsys.com/thumbnail.asp?cid=14http://www.techtoolsys.com/thumbnail.asp?cid=15http://www.techtoolsys.com/thumbnail.asp?cid=16http://www.techtoolsys.com/thumbnail.asp?cid=16http://www.techtoolsys.com/thumbnail.asp?cid=15http://www.techtoolsys.com/thumbnail.asp?cid=14http://www.techtoolsys.com/thumbnail.asp?cid=14http://www.techtoolsys.com/thumbnail.asp?cid=14http://www.techtoolsys.com/thumbnail.asp?cid=13


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By confining the expensive hard cutting tip to the part doing the actual cutting, thecost of tooling is reduced. The supporting tool holder can then be made from atougher steel, which besides being cheaper is also usually better suited to the task,being less brittle than the cutting-edge materials.

The tool holders may also be designed to introduce additional properties to the cuttingaction, such as

Angular approach - direction of tool travel.

Spring loading - deflection of the tool bit awayfrom the material when excessive loadis applied.

Variable overhang - the tool bit may be extended or retracted as the job requires.

Rigidity - the tool holder can be sizedaccording to the work to be performed.

Direct cutting fluid or coolant to the work area.

Note that since stiffness (rather than strength) is usually the design driver of a toolholder, the steel used doesn't need to be particularly hard or strong as there isrelatively little difference between the stiffnesses of most steel alloys.

Describe how tool holders areescribe how tool holders areidentified.dentified.
http://en.wikipedia.org/wiki/Cutting_fluidhttp://en.wikipedia.org/wiki/Cutting_fluid


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DiagramDiagram

Diagram 1: In order to identify each of the manyvarieties of carbide inserts, part numbers areprinted directly on the inserts. (Seco Tools AB)


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THANKS FOR WACTHING.THANKS FOR WACTHING.

THE END.THE END.


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1.Carbon compounded with a non-metal (such as boron, calcium,or silicon) or metal (such as in cobalt, tantalum, titanium,tungsten, or vanadium).

2.Metal carbides are characterized by their extreme hardness andresistance to hightemperatures, and are used as abrasives,and in cutting, drilling, grinding, and polishing tools. See also

hard metal.3.

CARBIDE FUNDAMENTALSARBIDE FUNDAMENTALS
http://www.businessdictionary.com/definition/carbon.htmlhttp://www.businessdictionary.com/definition/metal.htmlhttp://www.businessdictionary.com/definition/titanium.htmlhttp://www.businessdictionary.com/definition/hardness.htmlhttp://www.investorwords.com/4214/resistance.htmlhttp://www.investorwords.com/2306/high.htmlhttp://www.businessdictionary.com/definition/temperature.htmlhttp://www.businessdictionary.com/definition/tool.htmlhttp://www.businessdictionary.com/definition/hard-metal.htmlhttp://www.businessdictionary.com/definition/hard-metal.htmlhttp://www.businessdictionary.com/definition/tool.htmlhttp://www.businessdictionary.com/definition/temperature.htmlhttp://www.investorwords.com/2306/high.htmlhttp://www.investorwords.com/4214/resistance.htmlhttp://www.businessdictionary.com/definition/hardness.htmlhttp://www.businessdictionary.com/definition/titanium.htmlhttp://www.businessdictionary.com/definition/metal.htmlhttp://www.businessdictionary.com/definition/carbon.html


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Carbide Grade Applications (C-2 / K20) Uncoated grade used primarily in

mild cutting conditions. Used for milling

steel, cast steel and other non-ferrousalloys. (C-5 / P30) For roughing to semi-finishing of

steel. (TiN-55) Multi Layer CVD coating

(TiN/TiC/TiCN/TiN)For milling and turning carbon and alloysteels, tool steels.

Carbide insertCarbide insert

amalan bengkal mekanikal 4.ppt 31-01-2010.ppt2.pptx 6

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