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Cast Iron …………………….. Aluminium alloys ………….. Titanium alloys …….. Where a switchover to carbide tool from HSS is impossible and totally uneconomical, use of these cobalt tools is one option available to process engineers to increase productivity for machining normal steels and other regular materials.

This option is also resorted to, when increased tool life for a given cutting speed is the need of the hour. Depending on the drill size and minimum order quantity, Cobalt drills can cost from 1.

A right compromise between increased tool life and increased productivity has to be arrived Small Wood Turning Lathe For Sale Quora at to effectively balance the increased cost of the tools. Such coatings considerably increase the wear resistance and lubricity at the cutting point and facilitate use higher speeds and feeds and improve tool life.

TiN coated tools can easily be identified by the characteristic golden color coating on HSS tools. It should be noted that regrinding of drill point is going to take away the coating at the cutting point. If the rake angle is retaining the coating even after regrinding, to that extent, the coating remains useful, though to a reduced extent. It must be noted here that the quality of coating plays a very vital role in the effectiveness of coating and it can vary considerably from supplier to supplier.

As a consequence, the benefits of coated HSS tools may also vary. So, we can conclude that HSS tools will continue to play their vital role in manufacturing for more years to come. Total replacement of HSS by carbide tools can only be a distant dream. It would be interesting to watch the future scenario in technology as to how HSS tools are going to improve further to meet the compelling demands on productivity.

In metal cutting, various cutting parameters like cutting speed, feed rate, depth of cut, tool material, work material etc are involved. This article series explores the influence of each on the other parameters.

Part:1 introduces the parameters in brief. Subsequent parts elaborate them one by one. What are Errors in Measuring Instruments. Measuring Instruments Errors. Page content. These additives strongly enhance the antiwelding properties of the product. The major advantage of straight oils is the excellent lubricity or "cushioning" effect they provide between the work piece and cutting tool. This is particularly useful for low speed, low clearance operations requiring high quality surface finishes.

Although their cost is high, they provide the longest tool life for a number of applications. They are also the fluid of choice for most honing operations due to their high lubricating qualities. Straight oils offer good rust protection, extended sump life, easy maintenance, and are less likely to cause problems if misused. They also resist rancidity, since bacteria cannot thrive unless water contaminates the oil.

Disadvantages of straight oils include poor heat dissipating properties and increased fire risk. They may also create a mist or smoke that results in an unsafe work environment for the machine operator, particularly when machines have inadequate shielding or when shops have poor ventilation systems.

The oily film left on the work piece makes cleaning more difficult, often requiring the use of cleaning solvents. Straight oil products of different viscosities are available for each duty class.

Highly viscous fluids tend to cling to the work piece and tool. This causes increased machine coolant loss by dragout and necessitates lengthier, more costly cleanup procedures.

A concentrate is mixed with water to form the metalworking fluid. They also cause the oils to cling to the work piece during machining. Emulsifier particles refract light, giving the fluid a milky, opaque appearance. Soluble oils offer improved cooling capabilities and good lubrication due to the blending of oil and water. They also tend to leave a protective oil film on moving components of machine tools and resist emulsification of greases and slideway oils.

Soluble oils are a general-purpose product suitable for light and medium duty operations involving a variety of ferrous and nonferrous applications. The presence of water makes soluble oils more susceptible to rust control problems, bacterial growth and rancidity, tramp oil contamination, and evaporation losses. Soluble oils are usually formulated with additives to provide additional corrosion protection and resistance to microbial degradation.

Maintenance costs to retain the desired characteristics of soluble oil are relatively high. Other disadvantages of soluble oils include the following:. When mixed with hard water , soluble oils tend to form precipitates on parts, machines and filters. Misting of soluble oils may produce a dirty and unsafe work environment, through slippery surfaces and inhalation hazards.

As a result of these disadvantages, soluble oils have been replaced in most operations with chemical machine coolants. Chemical Machine Coolants. Chemical machine coolants, called synthetic or semi synthetic fluids, have been widely accepted since they were first introduced in about They are stable, preformed emulsions, which contain very little oil and mix easily with water. Chemical machine coolants rely on chemical agents for lubrication and friction reduction.

These additives also improve wettability. At temperatures above approximately OF C , these additives become ineffective and EP lubricant additives chlorine, phosphorus and sulfur compounds are utilized. Fluids containing EP lubricants significantly reduce the heat generated during cutting and grinding operations.

Synthetics - No Petroleum Oils. Synthetic fluids contain no petroleum or mineral oil. They were introduced in the late 's and generally consist of chemical lubricants and rust inhibitors dissolved in water.

Like soluble oils, synthetics are provided as a concentrate, which is mixed with water to form the metalworking fluid. These fluids are designed for high cooling capacity, lubricity, corrosion prevention, and easy maintenance. They are also desirable when clarity or low foam characteristics are required. Synthetic fluids can be further classified as simple, complex or emulsifiable synthetics based on their composition.

Simple synthetic concentrates also referred to as true solutions are primarily used for light duty grinding operations. Complex synthetics contain synthetic lubricants and may be used for moderate to heavy duty machining operations. Machining may also be performed at higher speeds and feeds when using complex synthetics.

Both simple and complex synthetics form transparent solutions when mixed in a coolant sump, allowing machine operators to see the work piece. The appearance of emulsifiable synthetic fluids ranges from translucent to opaque. Synthetics provide excellent microbial control and resistance to rancidity. They are largely nonflammable and nonsmoking with good corrosion control and superior cooling Lathe Chisels For Sale France qualities.

Synthetics have greater stability when mixed with hard water. In addition they reduce misting problems and foaming problems. Synthetics are easily separated from the work piece and chips, allowing for easy cleaning and handling of these materials. Overall, synthetics are easier to maintain due to their cleanliness, they offer long service life if properly maintained and can be used for a variety of machining operations.

A number of health and safety concerns , such as misting and dermatitis, also remain with the use of synthetics in the shop. Synthetic fluids are easily contaminated by other machine fluids such as lubricating oils and need to be monitored and maintained to be used effectively.

The remaining portion of a semi synthetic concentrate consists mainly of emulsifiers and water. Wetting agents, corrosion inhibitors and biocide additives are also present.

Semi synthetics are often referred to as chemical emulsions or preformed chemical emulsions since the concentrate already contains water and the emulsification of oil and water occurs during its production. The high emulsifier content of semi synthetics tends to keep suspended oil globules small in size, decreasing the amount of light refracted by the fluid.

Semi synthetics are normally translucent but can vary from almost transparent having only a slight haze to opaque. Most semi synthetics are also heat sensitive. Oil molecules in semi synthetics tend to gather around the cutting tool and provide more lubricity. As the solution cools, the molecules redisperse. Like synthetics, semi synthetics are suitable for use in a wide range of machining applications and are substantially easier to maintain than soluble oils.

They provide good lubricity for moderate to heavy-duty applications. They also have better cooling and wetting properties than soluble oils, allowing users to cut at higher speeds and faster feed rates. Their viscosity is also less than that of a soluble oil, providing better settling and cleaning properties. Semi synthetics provide better control over rancidity and bacterial growth, generate less smoke and oil mist because they contain less oil than straight or soluble oils , have greater longevity, and good corrosion protection.

Water hardness affects the stability of semi synthetics and may result in the formation of hard water scum deposits. Semi synthetics also foam easily because of their cleaning additives and generally offer less lubrication than soluble oils. Machine Coolant Types Advantages vs. Straight Oils. Excellent lubricity. Poor heat dissipation.

Good rust protection. Increased risk of fire. Good sump life. Increased risk of smoking. Easy maintenance. Increased risk of misting. Rancid resistant. Oil film on work piece. Limited to low-speed, severe cutting operations.

Soluble Oils. Good lubrication. More susceptible to rust problems. Improved cooling capabilities.

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