K.J.Institute of Technology, Savli Guided by:- Sandeep Dave sir Made by : Gaekwad Jahnvi S (130640119028) Gandhi Jaimil H (130640119127) Tiwary Nishant S (130640119121) 1

Cutting tool geometry & Tool signature

Machining Process Cast, formed and shaped products may need further machining operations to give them the desired final shape, after removal of extra material in the form of chips. Machining processes remove material from a work piece by CUTTING ( As in case of machine tools like lathe, shaper etc) ABRASIVE ( As in case of a grinding wheel) NON TRADITIONAL ( Processes such as EDM, ECM Etc.)

Metal Cutting Processes

Turning High proportion of work machined in shop turned on lathe Turning tool set to given depth of cut, fed parallel to axis of work (reduces diameter of work) Chip forms and slides along cutting tool's upper surface created by side rake

Planing or Shaping Workpiece moved back and forth under cutting tool Fed sideways a set amount at end of each table reversal

Plain Milling Multi-tooth tool having several equally spaced cutting edges around periphery Each tooth considered single-point cutting tool (must have proper rake and clearance angles) Workpiece held in vise or fastened to table Fed into horizontal revolving cutter Each tooth makes successive cuts Produces smooth, flat, or profiled surface depending on shape of cutter

Inserted Blade Face Mill Consists of body that holds several equally spaced inserts Cutting action occurs at lower corner of insert Corners chamfered to give strength

End Milling Multi-fluted cutters held vertically in vertical milling machine spindle or attachment Used primarily for cutting slots or grooves Workpiece held in vise and fed into revolving cutter End milling Cutting done by periphery of teeth

Drilling Multi-edge cutting tool that cuts on the point Drill's cutting edges (lips) provided with lip clearance to permit point to penetrate work piece as drill revolves

What is a Cutting Tool A cutting tool is any tool that is used to remove metal from the work piece by means of shear deformation. It is one of most important components in machining process It must be made of a material harder than the material which is to be cut, and the tool must be able to withstand the heat generated in the metal cutting process. Two basic types Single point Multiple point

Single Point Cutting Tool

Multi Point Cutting Tool

Cutting-Tool Materials Cutting tool bits generally made High-speed steel Cast alloys Cemented carbides Ceramics Cermets Cubic Boron Nitride Polycrystalline Diamond

Cutting Tool Properties Hardness Cutting tool material must be 1 1/2 times harder than the material it is being used to machine. Capable of maintaining a red hardness during machining operation Red hardness: ability of cutting tool to maintain sharp cutting edge at elevated temp. It is also sometimes referred to as hot hardness or hot strength

Cutting Tool Properties Wear Resistance Able to maintain sharpened edge throughout the cutting operation Same as abrasive resistance Shock Resistance Able to take the cutting loads and forces Shape and Configuration Must be available for use in different sizes and shapes.

High-Speed Steel May contain combinations of tungsten, chromium, vanadium, molybdenum, cobalt Can take heavy cuts, withstand shock and maintain sharp cutting edge under red heat Generally two types (general purpose) Molybdenum-base (Group M) Tungsten-base (Group T) Cobalt added if more red hardness desired

Cast Alloy Usually contain 25% to 35% chromium, 4% to 25% tungsten and 1% to 3% carbon Remainder cobalt Qualities High hardness High resistance to wear Excellent red-hardness Operate 2 ½ times speed of high-speed steel Weaker and more brittle than high-speed steel

Carbide Cutting Tools First used in Germany during WW II as substitute for diamonds Various types of cemented (sintered) carbides developed to suit different materials and machining operations Good wear resistance Operate at speeds ranging 150 to 1200 sf/min Can machine metals at speeds that cause cutting edge to become red hot without loosing harness

Single Point Cutting Tool

Single Point Cutting Tool

Know the Single Point Cutting Tool Shank: Main body of tool, it is part of tool which is gripped in tool holder Face: Top surface of tool b/w shank and point of tool. Chips flow along this surface Flank: Portion tool which faces the work. It is surface adjacent to & below the cutting edge when tool lies in a horizontal position. Point: Wedge shaped portion where face & flank of tool meet. Base: Bearing surface of tool on which it is held in a tool holder. Nose radius: Cutting tip, which carries a sharp cutting point. Nose provided with radius to enable greater strength, increase tool life & surface life. Typical Value : 0.4 mm – 1.6 mm

SPC Tool Geometry SIDE RELIEF SIDE CLEARANCE AA Tool Geometry The geometry of cutting tools refers to the various angles and clearances machined or ground on the tool faces. Although the terms and definitions relating to single-point cutting tools vary greatly, those adopted by the American Society of Mechanical Engineers (ASME) and currently in general use are illustrated in Fig. 31-6. SIDE RELIEF SIDE CLEARANCE

Nomenclature of Single Point Lathe Tool The most significant terms in the geometry of a cutting tool angles are: Relief or clearance angle Side relief End relief Rake angle Back Rake angle Side Rake angle Cutting edge angle Side Cutting edge angle End Cutting edge angl Nose Radius

Cutting-Tool Terms Relief or Clearance angle: Ground on the end and side faces of a tool to prevent it from rubbing on the work piece. To enable only the cutting edge to touch the work piece. Side Relief angle: Angle ground directly below the cutting edge on the flank of the tool End Relief angle: Angle ground from the nose of the tool

Cutting-Tool Terms Cutting edge angle End Cutting edge angle Ground on a tool so that it can be mounted in the correct position for various machining operations. Side Cutting edge angle Allows flank of the tool to approach the work piece first Spreads the material over a greater distance on the cutting edge, thereby thinning out the chip. Approximately 150 End Cutting edge angle Allows the cutting tool to machine close to the work piece during turning operations Usually 20 – 300

Cutting-Tool Terms Rake angle: Back Rake angle Side Rake angle Ground on a tool to provide a smooth flow of the chip over the tool so as to move it away from the work piece Back Rake angle Ground on the face of the tool Influences the angle at which chip leaves the nose of the tool Generally 8 - 100 Side Rake angle Ground on the tool face away from the cutting edge Influences the angle at which the chip leaves the work piece A lathe tool has 140 side rake.

Side Rake Large as possible to allow chips to escape Amount determined Type and grade of cutting tool Type of material being cut Feed per revolution Angle of keenness Formed by side rake and side clearance

Back Rake Angle formed between top face of tool and top of tool shank Positive Top face slopes downward away from point Negative Top face slopes upward away from point Neutral

Rake Angles Small to medium rake angles cause: high compression high tool forces high friction result = Thick—highly deformed—hot chips

Negative Rake Tools Typical tool materials which utilize negative rakes are: Carbide Diamonds Ceramics These materials tend to be much more brittle than HSS but they hold superior hardness at high temperatures. The negative rake angles transfer the cutting forces to the tool which help to provide added support to the cutting edge.

Cutting-Tool Terms Nose Radius: Rounded tip on the point of the tool Functions: Strengthens finishing point of tool Improves surface finish on work Should be twice amount of feed per revolution Too large – chatter; too small – weakens point

Tool Angle Application Factors to consider for tool angles The hardness of the metal Type of cutting operation Material and shape of the cutting tool The strength of the cutting edge