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Carbon, alloy steel, nitriding steel, tool steel, cast steels, cast iron, aluminium, magnesium, copper, brass and plastics Cast iron, steel, stainless steel, brass and plastic (high corrosion resistant) Medium alloy steel, steels, grey cast iron, abrasive non-ferrous materials and high temperature alloys (selection will very much depends on the grade) Annealed carbon, low alloy steel, cast iron high-temperature alloys and high-hardness alloy steel
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Titanium Carbides (coated also)
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Aluminum (affinity between tool and workpiece) (Contd)
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Precision Engineering
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Table 210 (Contd) Tool material Suitable Ceramic (Al2O3) Cast iron, hard steel (less cratering than tungsten carbide), molybdenum TZM alloys, tungsten and Rene 41, 4340 steel (no chemical interaction) Work material Unsuitable Aluminium, titanium alloy (high affinity for oxygen causing rapid tool wear), B-120 VCA titanium alloy and D6 AC steel (slight chemical interaction Molybdenum TZM alloys, 4340 steel, B-120 VCA titanium alloy (slight chemical interaction) and aluminium silicon alloy Carbon steel (chemical incompatibility) Iron, ferrous materials below 42 Rc and titanium super alloys (react chemically)
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Hard cast iron and hard steel Tungsten, Rene 41, D6 AC steel (no chemical interaction), cast iron, nickelbased alloys and hard steel
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Nickel-based super alloys and grey cast iron Nickel-based alloys (Inconel, Waspoloy and Hastelloy), cast iron and steels, low to medium alloy steels, heat treated alloy steel, die steel, hard iron (Rc between 45 and 65) and hard ferrous materials
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Whisker Reinforced Ceramic (WG-300)
Diamond (Single Non-ferrous metals, aluminium, Babbitt, crystal, Polycrystalline, white metal, brass, copper, bronze, gold, CVD coated) silver, platinum, non-metallic materials, epoxies and fibreglass-filled resins Cubic Boron Nitride (only available in polycrystalline form) High-speed steels, tool steels, die steels, bearing steel, alloys steels, casehardened steels, white cast irons and alloy cast irons (hardness values considered are in the range of HRC 50-70)
Plain-carbon steels, titanium, nickel and cobalt-based alloy (strong chemical affinity)
The future for machining as a manufacturing process remains bright Machining has all the attributes for making almost any product The cutting tools needed for this are discussed in this chapter and they have exhibited a good performance and have met the exacting requirements of precision engineering If single-crystal CBN tools could be developed, they could be used successfully
Tool Materials for Precision Machining
for ultra-precision turning Likewise, if CBN coatings, like diamond coatings, could be deposited on carbide substrates, then the applications for machining of steel would be useful This would make the expectations in the relevance tree in Figure 21 more meaningful
27 REFERENCES
1 Boothroyd, G, Fundamentals of Machining and Machine Tools, Marcel Dekker, 1989 2 Kalpakjian, S, and Schmid, SR, Manufacturing Processes for Engineering Materials, Prentice Hall, 2003 3 Venkatesh, VC and Chandrasekaran, Experimental Techniques in Metal Cutting, Prentice Hall of India, 1987 4 Basha, M and Venkatesh, VC, Metal cutting performance of sandwich carbide tools, Proc 4th AIMTDR Conference, Madras, 1970, 181 193 5 Venkatesh, VC, Radhakrishnan, V and Chandramowli, J, Wear propagation in cutting tools, Annals of CIRP, Vol XVII, 317 323 6 Raju, AS, Vaidyanathan, S and Venkatesh, VC, Comparative performance of coated sandwich and conventional carbide tools, Proc Int Conf on Hard Material Tool Technology, Pittsburgh, 1976, 144 156 7 Horlin, NA, TiC coated cemented carbides their introduction and impact on metal cutting, The Production Engineer, London, 1971, 153 8 Cook, NH, Enhancement of Cemented Tungsten Carbide Tool Properties, NSF Report (GK 29379), MIT, 1972, 1 50 9 Noordin, MY, PhD Thesis, Universiti Teknologi Malaysia, 2003 10 Santhanam, AT, Personal Communications, June 2004 11 Carson, WW, et al, Enhancement of Cemented Tungsten Carbide Tool Properties, NSF Report (GK 29379), MIT, 1973, 269 347 12 Venkatesh, VC and Sampath, WS, Joint patent proposal with Widia (India) submitted on January 4, 1980, Patent No 74/M2S/80 dated April 11, 1980 13 Venkatesh, VC, On the Role of Titanium Carbide in Cutting Tool Materials, SME MR 80-217, Society of Manufacturing Engineers, March 1980 14 Venkatesh, VC, Sachithanandam, M and Sampath, WS, Studies on TiC coated solid TiC, Proc VIII Int Conf on Chemical Vapour Deposition, Paris, September 1981 15 Venkatesh, VC, Sachithanandam, M and Sampath, W S, Studies on a new tool TiC coated cemented titanium carbide, Proc 9th AIMTDR Conf, IIT, Kanpur, December 1980, 188 192 16 Ranganath, BJ, Study of Tool Materials Containing Titanium Carbide, PhD Thesis, IIT Madras, April 1981 17 Ranganath, BJ, and Venkatesh, VC, A study of wear of cemented titanium carbide tools, Proc IX NAMRI Conf, Pennsylvania, May 1981 18 Venkatesh, VC, Wear studies in TiC coated cemented titanium carbide tools, Trans of ASME, January 1984, Vol 106, 84 87 19 Bauer, CE, Inspektor, A and Oles, E J, A comparative machining study of diamond coated tools made by plasma torch, microwave and hot filament, Sadhana, Indian Academy of Sciences, 2003, Vol X 20 Stephenson, DA and Agapiou, JS, Metal Cutting Theory and Practice, Marcel Dekker, Inc, New York, 158 159
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