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Problems on Tool Life and
Machining Parameters |
Metals
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This article provides problems on tool life and
machining parameters of metals.

Problem 1:

Determine percentage change in cutting speed required
to give 50% reduction in tool life (i.e., to reduce tool life
to 1/5 of its previous value). Take n = 0.2.

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Solution:

Given:

Tool life in Ist case = 1

Tool life in IInd case = 1/5

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Exponent n = 0.2

To find:

Percentage change in cutting speed.

Formula used:

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Taylor’s tool life equation

VTn = C

where, V= Cutting speed (m/min)
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T= Tool life (min) Privacy - Terms

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C = Machining constant

Procedure:
Using the Taylor’s tool life equation

Result:

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The percentage increase in cutting speed is 38% by
doing half tool life.

Problem 2:

Compare the tool life of two catting tools (HSS and
carbide) at a speed of30 m/min. The tool life is 130 min.
The tool life equation for HSS tool is given by VT1/7 = C1
and for carbide VT1/5 = C2 at a cutting speed of 24
m/min.

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Solution:

Given:

Tool life T= 128 min

VT1/7 = C1 (for HSS) at 24 m/min

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VT1/5 = C2 (for carbide) at 24 m/min

To find:

(i) Tool life for HSS = T1 at V = 30 m/min

(ii) Tool life for carbide = T2 at V=30m/min

(iii) T1/T2.

Formula used:

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Taylor’s tool life equation VTn = C.

Procedure:

(i) Tool life for HSS = T1
(ii) Tool life for carbide = T2

Taylor’s equation for carbide,

(iii) Comparing tool life for HSS and carbide

T1/T2 = 27/42.5 = 0.63 Ans.

Results:

(i) Tool life for HSS at 30m/min is 27 minutes.

(ii) Tool life for carbide at 30m/min is 42.5 minutes.

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(iii) T1/T2 =0.63.

Problem 3:

Find the tool life equation if a tool life of 80 min is
obtained at a cutting speed of 30 m/min and 8 min at
60 m/min.

Solution:

Given:

Tool life T1 = 80 min, cutting speed V1 = 30 m/min

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Tool life T2 = 8 min, cutting speed V2 = 60 m/min.

To find:

Tool life equation
Formula used:

Taylor’s tool life equation

VTn = C

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Procedure:

Applying V1T1n = V2T2n

30(80f = 60 (8)n

=> n = 0.3

Hence, Tool life equation becomes VT0.3 = C.

Result:

Tool life equation VT0.3 = C.

Problem 4:

For machining medium carbon steel, the
conditions are:

Cost of operating machine = Rs 0.3 per min

Total cost of tool change = Rs 8.

The cutting speed = 40 m/min.

Tool life = 50min

Exponent index n = 0.2

Find optimum tool life and cutting speed at optimum
tool life i.e., optimum cutting speed.

Solution:

Given:

Cost of operating machine = C1 = Rs 0.3 per min.

Total cost of tool change = C2 = Rs 8.

Cutting speed = V = 40 m/min

Tool life = T = 50 min

Exponent index = n = 0.2
To find:

(i) Optimum tool life (TQpT)

(ii) Optimum cutting speed (VopT)

Formula Used:

Procedures:

(i) Finding optimum tool life TOPT

(ii) Finding optimum cutting speed (VOPT)

Results:

(i) Optimum Tool life, TOPT = 106 min.

(ii) Optimum cutting speed, VOPT = 34.41 m/min

Related Articles:
1. Cutting Speed, Feed and Depth of Cut | Metals
2. Cutting Process of Metals: 4 Parameters | Metallurgy

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 1. is there any advantage to having a built-up edge on a tool? Explain.

A built-up edge (BUE) is a thin layer of workpiece material that adheres to the tool edge during cutting.
In some cases, a BUE can provide benefits such as increased tool life, reduced cutting forces, and
improved surface finish. However, the advantages of a BUE are highly dependent on the specific
machining conditions, tool geometry, and workpiece material. In some cases, a BUE can also cause
problems such as poor surface finish, tool chatter, and premature tool failure.

2. What is the function of chip breakers? How do they function?

Chip breakers are features on cutting tools that are designed to break the chips into smaller pieces
during the cutting process. This helps to prevent chip jamming, reduce cutting forces, and improve
surface finish. Chip breakers work by interrupting the continuous chip flow, causing the chips to curl and
break into smaller pieces. The shape, size, and orientation of the chip breaker are important factors that
determine its effectiveness.

3. Identify the forces involved in a cutting operation. Which of these forces contributes to the
power required?

The primary forces involved in a cutting operation are cutting force, feed force, and radial force. Cutting
force is the force exerted on the tool by the workpiece during cutting and is the primary force that
contributes to the power required for machining. Feed force is the force required to move the tool
through the workpiece, and radial force is the force exerted on the tool perpendicular to the cutting
direction.

4. Explain the characteristics of different types of tool wear.

There are three main types of tool wear: flank wear, crater wear, and edge wear. Flank wear is the wear
that occurs on the flank of the tool, which is the portion of the tool that is in contact with the workpiece.
Crater wear is the wear that occurs on the rake face of the tool, which is the surface that is exposed to
the chip flow. Edge wear is the wear that occurs on the cutting edge of the tool. The characteristics of
tool wear depend on the specific machining conditions, tool material, and workpiece material.
Generally, tool wear results in increased cutting forces, poor surface finish, and reduced tool life.

5. List the factors that contribute to poor surface finish in cutting.

There are several factors that can contribute to poor surface finish in cutting, including improper tool
geometry, incorrect cutting parameters, insufficient coolant, workpiece material properties, and
vibrations or chatter during cutting. Poor tool geometry can result in excessive tool wear, which can lead
to poor surface finish. Incorrect cutting parameters, such as cutting speed, feed rate, and depth of cut,
can also cause poor surface finish. Insufficient coolant can cause heat buildup, which can lead to thermal
damage and poor surface finish. Workpiece material properties, such as hardness and toughness, can
also affect surface finish. Vibrations or chatter during cutting can cause uneven cuts and poor surface
finish.
 6. Explain what is meant by the term machinability and what it involves. Why does titanium have
poor machinability?

Machinability refers to the ease with which a material can be machined using various cutting tools and
techniques. It involves factors such as cutting forces, tool wear, surface finish, and chip formation.
Materials with good machinability can be machined efficiently with minimal tool wear and good surface
finish. Titanium has poor machinability due to its high strength, low thermal conductivity, and tendency
to work harden during machining. These properties make it difficult to remove material efficiently
without excessive tool wear and poor surface finish. Titanium also has a low thermal conductivity, which
can cause heat buildup and thermal damage during machining. Specialized cutting tools and techniques
are often required to

7. Let n = 0.5 and C = 90 in the Taylor equation for tool wear. What is the percent increase
in tool life if the cutting speed is reduced by (a) 50% and (b) 75%?
ANSWER:
A) reducing the cutting speed by 50% increases the tool life by 41.4%.
B) reducing the cutting speed by 75% increases the tool life by 114.1%.

Tool life can be almost infinite at low cutting speeds. Would you then
recommend that all machining be done at low speeds? Explain.
21.19. Explain the consequences of allowing temperatures to rise to high levels in
cutting.
21.20. The cutting force increases with the depth of cut and decreasing rake
angle. Explain why.
21.21. Why is it not always advisable to increase the cutting speed in order to
increase the production rate?
.22. What are the consequences if a cutting tool chips?
21.23. What are the effects of performing a cutting operation with a dull tool? A
very sharp tool?

While tool life can be extended at low cutting speeds, machining at low speeds may not
always be the most efficient option. Machining at low speeds may result in lower
production rates, increased machining time, and higher costs. Additionally, some
materials may not be suitable for machining at low speeds due to their unique
properties, such as their hardness or heat sensitivity.

Allowing temperatures to rise to high levels in cutting can have negative consequences,
including excessive tool wear and damage, decreased tool life, and poor surface finish.
High temperatures can also lead to the distortion or warping of the workpiece or tool,
which can result in dimensional inaccuracies.
The cutting force increases with the depth of cut and decreasing rake angle because a
larger chip thickness is generated, which requires more force to remove. Decreasing the
rake angle also increases the contact area between the tool and the workpiece, resulting
in higher frictional forces and cutting forces.

Increasing the cutting speed to increase production rates may not always be advisable,
as it can result in higher temperatures, increased tool wear, and decreased tool life.
Additionally, some materials may not be able to withstand high cutting speeds due to
their properties, such as their hardness or heat sensitivity.

If a cutting tool chips, it can result in a loss of dimensional accuracy, poor surface finish,
and the need for tool replacement or repair. Additionally, the chips generated from the
chipped tool can damage the workpiece or other parts of the machining setup.

Performing a cutting operation with a dull tool can result in increased cutting forces,
higher temperatures, and decreased tool life. The surface finish may also be poor due to
the inability of the dull tool to cut cleanly. On the other hand, using a very sharp tool
can result in improved surface finish and decreased cutting forces, but it can also lead to
increased tool wear and the need for more frequent tool sharpening or replacement.