CUTTING TOOLS

Prepared by : Submitted to :
Reena Nagar (362) Dr. Vandana J. Rao
Associate Prof.
ME II (Ind. Met)

Department of Metallurgical & Materials Engineering

Faculty of
Technology and Engineering
The Maharaja Sayajirao University of Baroda
CONTENT

Introduction

Cemented Carbide

Manufacturing of cemented carbide

Diamond cutting tool

References 2
Introduction:

Powder metallurgy is used for manufacturing

products or articles from powdered metals by
placing these powders in molds and are
compacting the same using heavy compressive
force. Typical examples of such article or
products are grinding wheels, filament wire,
magnets, welding rods, tungsten carbide cutting
tools, self-lubricating bearings electrical contacts
and turbines blades having high temperature
strength.. 3
 The manufacture of parts by powder metallurgy process
involves
 the manufacture of powders,

 blending,

 compacting,

 sintering and

 a number of secondary operations such as sizing, coining,

machining, impregnation, infiltration, plating, and heat
treatment

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 • Here we will discuss about Two Mostly utilized cutting
tool manufactured by Powder metallurgy

 1. CEMENTED CARBIDES
 2. DIAMOND TOOLS

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 CEMENTED CARBIDES
 Cemented carbides is a class of composite materials in
which a carbide, often tungsten carbide (WC), provides
hardness and wear resistance and a metal binder, almost
exclusively cobalt (Co), provides toughness .
 These materials have long been used in applications such
as cutting, grinding, drilling and wear-resistant mechanical
components.
 A wide range of material properties can be obtained by
changing the material composition. Although the most often
used carbide is the hexagonal WC, atlternatives are
available. With cubic carbides such as TiC, NbC and TaC
the high temperature properties are improved
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 CEMENTED CARBIDE :
 Manufacture of Cemented Carbides
 Products of powder metallurgy process Tantalum,
titanium, niobium, cobalt , Mo, Nickel

 Operations
 Powder Mixing
 Compaction
 Presintering
 shapig
 Sintering
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 POWDER MIXING

Five types of powders

• Tungsten carbide(carburizing1550), titanium
carbide(2200), cobalt, tantalum carbide(1050),
niobium carbide • One or combination blended in
different proportions depending on grade desired
• Powder mixed in alcohol (24 to 190 h)
• Alcohol drained off
• Paraffin added to simplify pressing operation

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 COMPACTION

 Must be molded to shape and

size
 Five different methods to • Extrusion process
compact
 • Green (pressed) compacts • Hot pressing

soft
• Isostatic pressig
must be pre sintered to
dissolve paraffin
• Ingot pressing

• Pill pressing

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 PRE SINTERING & SHAPING

 • Green compacts heated to about 1500º F

in furnace under protective atmosphere of
hydrogen

 Shaping is done with techniques such ad

milling, grinding, turning etc

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 SINTERING

• Converts presintered machine blanks

into cemented carbide

• Carried out in either hydrogen

atmosphere or vacuum • Temperatures
between 2550º and 2730º F

•Binder (cobalt) unites and cements

carbide powders into dense structure of
extremely hard carbide crystals 12
MICROGRAPH OBTAINED AFTER HEATING A WC-CO
MATERIAL TO 1280C AND COOLING. WC APPEARS
LIGHT GREY, CO DARK GREY AND PORES BLACK.

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 CEMENTED-CARBIDE APPLICATIONS

 Most impotant is tool for metal cutting and machining of

abrasive material
 70 % are used as cutting tools

 Wear parts used in section drawing,

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DIAMOND CUTTING TOOLS

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 WHY DIAMOND ?:
 • Hardest
known substance
 • Low friction, high wear resistance
 • Ability to maintain sharp cutting edge
 • Diamond is brittle , tool shape &
sharpened is important

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 MANUFACTURE OF
POLYCRYSTALLINE CUTTING TOOLS
 Two distinct types
 Polycrystalline cubic boron nitride
 Polycrystalline diamond

 Manufacture of blanks basically same

 Layer of polycrystalline diamond or cubic
boron nitride (.020 in. thick) fused on cemented-carbide substrate by
high temperature (3275ºF), high pressure (1 million psi)

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 POLYCRYSTALLINE MASS
 Created from substrate composed of tiny grains of tungsten
carbide cemented tightly together
 Cobalt binder
 High-heat, high-pressure conditions
 Cobalt liquefies, flows up and sweeps around diamond or cubic
boron nitride abrasive
Serves as catalyst that promotes intergrowth

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 POLYCRYSTALLINE CUBIC BORON
NITRIDE TOOLS
 Structure of cubic boron nitride feature nondirectional,
consistent properties
 Resistchipping and cracking
 Provide uniform hardness
 Abrasion resistance in all directions
 Qualities built into turning and milling butting-tool blanks
and inserts
 Can operate at higher cutting speeds, and take deeper cuts

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 MAIN PROPERTIES OF PCBN
 Hardness
 Impact resistance, high strength, hardness in all directions
(random orientation of tiny CBN crystals)
 Highest Hot Hardness of all tools
 Abrasion Resistance
 Maintain sharp cutting edges much longer
 Second only to Diamond
 Compressive Strength
 Maximum stress in compression material will take before
ruptures
 Thermal Conductivity
 Allow greater heat dissipation or transfer

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 ADVANTAGES OF
PCBN CUTTING TOOLS
 High Material-Removal Rates
 Cutting speeds (250 to 900 ft/min) and feed rates (.010 to .020 in.)
result in removal rates three time carbide tools with less tool wear
 Cutting Hard, Tough Materials
 Capable of machining all ferrous materials with Rockwell C hardness
of 45 and above
 Also used to machine cobalt-base and nickel-base high temperature
alloys (Rockwell c 35)

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POLYCRYSTALLINE DIAMOND TOOLS
 Polycrystalline diamond (PCD) layer fused to cemented-
carbide substrate
 .020 in. thick
 Highly efficient cutting tool
 Increased production when machining abrasive
nonmetallic, nonferrous materials

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TYPES AND SIZES OF PCD TOOLS
 Catalyst-bonded PCD available in three microstructure
series
 Coarse PCD blanks
 Medium-fine PCD blanks
 Fine PCD blanks

 Basic difference between types is size of diamond

particle used to manufacture blank

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 PROPERTIES OF PCD TOOLS

 Composite materials found in base provide mechanical

properties
 High thermal conductivity and low coefficient of thermal
expansion
 Diamond layer
 Hardness, abrasion resistance, compressive strength, and
thermal conductivity
 Compressive strength highest of any tool
 Thermal conductivity highest of any tool

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 TYPES OF MATERIAL CUT

1. Nonferrous metals
 Typically soft but have hard particles dispersed
 Silicon-aluminum alloys
 Copper alloys
2. Tungsten carbide
3. Advanced composites
4. Ceramics
5. Wood composites

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ELECTRO-PLATED DIAMOND TOOLS
• Polycrystalline Diamond coated with copper or nickel
metal
 • Copper or nickel mixture electroplated to a metallic
form
 • Electroplated form then dressed to remove a small
amount of metal to expose PCD within
 • Form tools can be de-plated and re-plated multiple
times

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PCD cutters designed for milling, composites and
light alloys.

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Fig. Natural (left) and synthetic diamond abrasives
produced by using cobalt-base (centre) and nickel-base
catalyst (right)

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 DIAMOND-COATED TOOLS (CVD)

 • Early 1980s brought new process of chemical vapor

deposition (CVD)
 • Produce diamond coating few microns thick

 • Process

 • Elemental hydrogen dissolved in hydrocarbon gas

around 1330º
 • Mixture contacts cooler metal, carbon precipitates in
pure crystalline form and coats metal with diamond film
(slow 1-5 microns/hr)

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METAL-BONDED DIAMOND TOOLS:
 The tools' bonding material is metal mixture powder. The
functional parts of the tool are usually diamond segments.
These tools include metal-bonded  diamond saw blades, 
diamond grinding cup wheels, diamond core drill bits, etc.
For metal-bonded diamond tools, the bond is one of the
prime factors when selecting which tool to use for cutting
or grinding a specific material, depending on how hard or
abrasive the material is. The bond used dictates the rate at
which the metallic powders wear down and expose new
diamond crystals at the surface, thereby maintaining an
abrasive cutting surface. Different bond strengths are
achieved by the alloy mix of metallic powders chosen and
how much heat and pressure are applied to the sintered 35
segment.
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DIAMOND MILLING HEADS WITH MCD
AND PCD INSERTS

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 REFERENCES
 1. Wolf-Dieter Schubert, Erik Lassner (Institute of Chemical Technologies
and Analytics – Vienna University of Technology) and Wolfgang Böhlke
(CERATIZIT Luxembourg SA)

 2. Cemented Carbide Sintering: Constitutive Relations and Microstructural

Evolution Anders Petersson Stockholm 2004 Doctoral Dissertation Royal
Institute
 3.www. Wikipedia.com

4. Metal-bonded diamond tools - production and applications Janusz

Konstanty

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THANK YOU

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