Design of Flat Form Tool

What is form tool?

Form tools are intended for producing the
desired contour on a work piece by means
of a turning operation.
The form tool is used for production work on
capstan and automatic lathes in order to ensure
• (a) High production rate.
• (b) Uniform cut shapes on all the parts,
• (c) Accuracy in work piece shape and
dimensions.
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 Form Tool Materials
Mostly form tools are made up of
high-speed steel, but now, carbide-forming
tools are also gaining popularity, owing to
productivity being raised by 30-40%.

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 Types of Form Tools
(a) Circular form tool (b) Flat form tool

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 Types of Form Tools continued..
(C) Dovetail form tool

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 Types of Form Tools continued..

(C) A Radially fed form tool

(d) A Tangentially fed form tool

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 Form Tool Geometry

• A form tool should have the

proper rake and relief angles so
that the metal is cut under
sufficiently advantageous
conditions.

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 Rake angles ()
are listed below for the form turning of various
materials.
Material Hardness (BHN) Rake angle (Deg.)
()
Mild steel Up to 150 25

Hard steel 235-290 12 - 20

Soft cast iron Upto 150 15

Hard cast iron 150-200 12

Aluminum, copper - 20 - 25

Bronze, leaded brass - 0-5

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Design of a Flat Form Tool (Using Graphical Method)

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The profile of the work
piece is drawn in two
views, i.e. the front
view and the top view.
The basic points of the
work piece profile with
dimensions L1 and L2
are projected on the
axis I-I drawn
perpendicular to the
work piece axis. The
projected points
are1’,2’,3’. From
point 01 as the center
draw circles
corresponding to work
piece radii r1, r2 and
r3.
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Apex of the cutting
tool ‘1’ should lie on
the work piece axis.
From point 1 (the
apex) draw the line
representing the tool
face (F) at the angle
=200 and the line of
the tool flank (K) at the
angle =120.

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From points 1, 2
and 3 draw lines
parallel to the
tool flank, (K).

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To construct the cross section of
the tool perpendicular to the
flank, K
(section N – N), draw line L L
(perpendicular to the flank, K.
From line L L lay off the
lengths since the dimensions of
the tool profile
measured along the work piece
are equal to the corresponding
axial dimensions of the work
piece. At lengths draw lines
parallel to L.L.
Denote by 2” and 3” the points
of intersection of these lines with
the lines drawn from points 2
and 3 parallel to the tool flank,
K.
Points 1” , 2” and 3” are the
points of the profile of the flat
form tool in section N – N.

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Design of Flat Form Tool
using Analytical Method
Draw
perpendi
cular
from
point 2
and 3 on
face K of
the tool
so as to
form right
angle
triangles
1A2 and
1B3

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It will be
sufficient to
determine
the
dimensions
denoted by
P2 and P3
in this
figure

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If the
dimensions
C2 and C3
are known
,dimensions
P2 and P3
can be
readily
determined
since they
are sides of
the right
angle
triangles.

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Following relations are used to solve right angle
triangles:



P2= C2.COS 

P3= C3.COS 

Dimensions P2 AND P3 should be calculated to an accuracy

within 0.001 mm.

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