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T. Y. B .

Tech (Production) Machining Science II

Name Of Course: - Machining Science-II/ Design


of Cutting Tools/ Single Point Tools:

Classification of cutting tools:

Depending upon the number of cutting edges, the cutting tools


used in metal cutting are classified as follows.

1. Single point tools - having only one cutting edge and.


2. Multiple points - having more than one cutting edge
e.g. milling, reamers, drills, broaches, grinding wheels etc.
The single point tools can be classified into various types, depending
on various criteria as under.

• According to construction - Solid Brazed tip and Throw away


Tip.
• According to type of operation - Turning, facing. Boring,
Knurling, Threading, parting, forming.
• According to Shape - Cranked, straight, circular, square,
• According to usage on machine tools - Lathe tools, Shaper
tools, Planner tools, boring tools.
• According to direction of cut - Left hand cut tool. Right hand
cut tools.

FIG SINGLE POINT


CUTTING TOOL

VJTI, Matunga, Mumbai-19 1 Prof. D.V. Shirbhate


T. Y. B .Tech (Production) Machining Science II

Cutting tool Nomenclature/Designation:


1) ASA System – American standards Association system or American National
standards Institute (ANSI)

VJTI, Matunga, Mumbai-19 2 Prof. D.V. Shirbhate


T. Y. B .Tech (Production) Machining Science II

American Standards Association (ASA) System


The American Standards Association (ASA) system specified the
tool face by defining its slope in two orthogonal planes: one
parallel to, the other perpendicular to, the axis of the cutting tool,
both planes being perpendicular to the base of the tool. The two
angles thus specified are known as the tool back rake and tool side
rake. (Similar to our conventional drawing method-first angle)

Orthogonal Rake System (ORS or DIN) German System


In this system the various angles (rake) clearance etc. are measured
in different planes than that used in ASA system.

VJTI, Matunga, Mumbai-19 3 Prof. D.V. Shirbhate


T. Y. B .Tech (Production) Machining Science II

ISO System (NRS):


In this system, the side rake angle is defined as the angle between
the base plane of the tool and the rake face of the tool measured in
a plane normal to the side cutting edge.

International System (ISO Normal Rake System)

British System (Maximum rake system or MRS OR BS):

Tool Signature: (for various systems):


The various angles are specified in a particular order viz. rake angle
(Back, side), Relief angle (end, side), and cutting edge (end, side) radius.
For various systems the tool angles may be specified in the following
sequence called as tool signature.
The shape of a tool may be specified in a special sequence as given
1. American system
γy - γx - αy -αx - φe- φs – r (ASA)
2. Orthogonal rake system
λ - γ0 - α0 -α'0 - φe - φ – r (ORS)
3. Normal rake system
λ - γn - αn -α'n - φe - φ – r (NRS)
4. Maximum rake system
φγ - γmax - αy - αx - φe - φ – r (MRS)

VJTI, Matunga, Mumbai-19 4 Prof. D.V. Shirbhate


T. Y. B .Tech (Production) Machining Science II

Significance of Various Tool Angles:

1. Rake Angle (back & side):

• Larger the rake angle- lower the cutting force & power.
However the strength of tool & heat dissipation capacity
reduces when rake angle is increased.

• In general rake angle is small for cutting hard materials &


large for cutting soft ductile materials.

2. Relief angles (SRA & ERA):

VJTI, Matunga, Mumbai-19 5 Prof. D.V. Shirbhate


T. Y. B .Tech (Production) Machining Science II

• These angles are provided so that the flank of the tool clears
the work piece surface & there is no rubbing action between
the two.
0 0
• Relief angles vary from 5 to 15 for general turning.
• Small relief angles are necessary to give strength to the
cutting edge while machining hard & strong materials.
• Tools with increased values of relief angles penetrate and cut
the work piece material more efficiently and this reduces the
cutting forces.
• Too large relief angles weaken the cutting edge & there is
less mass to absorb & conduct the heat away from cutting
edge.

3. Side cutting edge angle (SCEA) (150-300):

• The side cutting edge angle avoids formation of BUE,


controls direction of chip flow, and distributes the cutting
force and heat produced over larger cutting edge.
• As SCEA is increased effective cutting edge length for same
depth of cut increases (increasing tool life), thickness of chip
reduces, width of chip increase.
• On the other hand, the larger is the value of SCEA, the
greater is the component of force tending to separate work &
tool. This tends to promise chatter.
0 0
• For general machining SCEA 15 to 30 is recommended.
0
• To produce 90 shoulders, zero degree SCEA is needed.

VJTI, Matunga, Mumbai-19 6 Prof. D.V. Shirbhate


T. Y. B .Tech (Production) Machining Science II

• No SCEA is required for machining castings or forgings with


hard scaly skins, because the least amount of tool edge
should be exposed to destructive action of the skin.

4. End Cutting edge angle (ECEA) (80 – 150):

• It provides a clearance or relief to the trailing end of the


cutting edge to prevent rubbing or drag between machined
surfaces.

Nose Radius makes the finish of the cut smoother as it can


overlap the previous cut and eliminate the peaks and valleys that
a pointed tool produces. Having a radius also strengthens the
tip, a sharp point being quite fragile.

Design consideration in single point cutting tool:

1. Selection of tool material:

a) Steels

Originally, all tool bits were made of high carbon tool


steels with the appropriate hardening and tempering. Since
the introductions of high-speed steel (HSS) (early years of
the 20th century), sintered carbide (1930s), and ceramic
cutters, those materials have gradually replaced the earlier

VJTI, Matunga, Mumbai-19 7 Prof. D.V. Shirbhate


T. Y. B .Tech (Production) Machining Science II

kinds of tool steel in almost all cutting applications. Most


tool bits today are either HSS or carbide.

b) Carbides and ceramics


Carbide, ceramics (such as cubic boron nitride) and
diamond, having higher hardness than HSS, all allow faster
material removal than HSS in most cases. Because these
materials are more expensive and brittle than steel,
typically the body of the cutting tool is made of steel, and a
small cutting edge made of the harder material is attached.
The cutting edge is usually either screwed on (in this case it
is called an insert), or brazed on to a steel shank (this is
usually only done for carbide).

c) Inserts

Almost all high-performance cutting tools use indexable


inserts. There are several reasons for this. First of all, at the
very high cutting speeds and feeds supported by these
materials, the cutting tip can reach temperatures high
enough to melt the brazing material holding it to the shank.
Economics are also important; inserts are made
symmetrically so that when the first cutting edge is dull
they can be rotated, presenting a fresh cutting edge. Some

VJTI, Matunga, Mumbai-19 8 Prof. D.V. Shirbhate


T. Y. B .Tech (Production) Machining Science II

inserts are even made so that they can be flipped over,


giving as many as 16 cutting edges per insert.

A tipped tool or insert generally refers to any cutting tool


where the cutting edge consists of a separate piece of
material, either brazed or clamped on to a separate body.

They are used principally in the metalworking and


woodworking industries; however they may be found in
various forms in many cutting tools. Some examples are
milling cutters (end mills, fly cutters), turning tools, and
saw blades.

These tools provide the advantage of pre-ground cutting


edges and geometry on inserts that may be readily replaced
in a less expensive holder (or body).

VJTI, Matunga, Mumbai-19 9 Prof. D.V. Shirbhate

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