MFG Tooling - 04 Cutting Tool Design

Tool Design Cutting Tool Design
Nageswara Rao Posinasetti
Guidelines for Cutting tool Design

Rigidity Strength Weak links Force limitations Speed, feed and size Related force components Chip disposal Uneven motions Chatter
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Basic tool angles (Tool Signature)

Back rake angle Side rake angle End relief angle Side relief angle End cutting edge angle Side cutting edge angle Nose radius
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Selecting carbide Tools

Establish the operating conditions Select the
Cemented carbide grade Nose radius Insert shape Insert size Insert thickness Tool style Rake angle Shank size Chip breaker
Establish the operating conditions

Feed, speed and depth of cut greatly influence the machining performance. Also lead angle affects the performance
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FIGURE F-27 The difference in style A and style D holders for depth of cut and cutting edge engagement length (copyright General Electric Company).
Richard R. Kibbe, John E. Neely,31, January Roland O. Meyer, and Warren T. White
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Machine Tool Practices, 7e
Copyright 2002 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.
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FIGURE F-28 Large, well-formed chips were produced by this tool with built-in chip breaker (Kennametal, Inc., Latrobe, PA).
Large depth of cut
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To reduce cutting edge chipping

Increase the speed Decrease the feed and/or depth of cut Change to a tougher grade carbide insert Use a negative rake Hone the cutting edge before use Check the rigidity and tool overhang
Select the cemented carbide grade

Straight carbides Tungsten carbide (WC) and cobalt binder Cast iron, nonferrous and nonmetallic materials Resistance to edge wear
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Select the cemented carbide grade

Straight carbides Tungsten carbide (WC) and cobalt binder WC + Titanium carbide + Tantalum carbide with cobalt binder Coated carbides
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Cast iron, nonferrous and nonmetallic materials Steels
Resistance to edge wear
Resistance to cratering
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Select the nose radius

Based on surface finish
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FIGURE F-34 Surface finish versus nose radius (copyright General Electric Company).
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Select the insert shape

Round strong and large radius, good for higher feed rates Square medium stronger Traingular least stronger, less number of cutting edges, but more versatile in use
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FIGURE F-35 Insert shapes for various applications (Kennametal, Inc., Latrobe, PA)
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FIGURE F-36 A 38-degree triangular insert used for a tracing operation (copyright General Electric Company).
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Select the insert size

Smallest size based on the depth of cut used Cutting edge should be 1.5 times that of the length of cutting edge engagement.
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Select the insert thickness

Gives the strength of the tool
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FIGURE F-37 Insert thickness as determined by length of cutting edge engagement and feed rate (copyright General Electric Company).
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Select the tool style

Based on the geometry of the operation to be performed.
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FIGURE F-38 Several of the many tool styles available (Kennametal, Inc., Latrobe, PA).
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Select the rake angle
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FIGURE F-39
Side view of back rake angles.
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Select the shank size
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FIGURE F-40 Determining shank size according to depth of cut, feed rate, and tool overhang (copyright General Electric Company).
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FIGURE F-41 A boring bar with various interchangeable adjustable heads (Kennametal, Inc., Latrobe, PA).
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Select the chip breaker
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FIGURE F-42 Chip breakers used are the adjustable chip deflator (center) with a straight insert and the type with the built-in chip control groove.
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FIGURE F-43(b, c) (a) Negative rake two-sided Kenloc inserts; *Maximum D.O.C. and feed rates (ipr) are limited by the insert thickness and cutting edge length. Application ranges are for AISI 1045 steel at 180 to 220 BHN (Kennametal, Inc., Latrobe, PA.)
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Tool Holder Identification
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FIGURE F-44 ASA tool identification system (Tool Application Handbook; data courtesy of Kennametal, Inc., Latrobe, PA, 1973.)
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Carbide Insert Identification
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FIGURE F-45 ASA carbide insert identification (Tool Application Handbook; data courtesy of Kennametal, Inc., Latrobe, PA, 1973.)
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Multiple-Point Cutting Tools

Drilling Reaming Milling Gear cutting
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Power requirement for Drilling

Torque, M = 25,200 f 0.8 d 1.8
Thrust , T = 57,500 f 0.8 d 0.8 + 625 d 2
d = drill diameter, in f = feed in/rev
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Power requirement for Reaming

M = 23,300 k f 0.8 d 1.8
2 d 1 1 d 0.2 d1 1 + d
T = 42,600 k f 0.8 d 0.8
d 1 1 d 0.2 d 1 + 1 d
d1 = reamer diameter, in. f = feed in/rev

Power
Power in HP
Pc =
M N 63,025
M = tool torque, in-lb N = speed, rpm Power in Watts = Hp * 746
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Milling Cutters
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Machining Power
Depends on the material removal rate Uses empirical equations developed based on experiments See Machinerys Handbook
pp 1046 1055 (26th Edition)
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Pc = power at the cutting tool Pm = power at the motor Kp = power constant (see tab 24, 25 and 30) Q = metal removal rate (tab 29)
fm = feed rate, in/min or mm/min f = feed rate for turning, in/rev or mm/rev
Drilling
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T = Thrust; lb or N M = Torque; in-lb or N.m N = Spindle rpm January 31, 2008

Nageswara Rao Posinasetti 93
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Tool Design Cutting Tool Design

Nageswara Rao Posinasetti

Guidelines for Cutting tool Design

Basic tool angles (Tool Signature)

January 31, 2008

Nageswara Rao Posinasetti

January 31, 2008

Nageswara Rao Posinasetti

January 31, 2008

Nageswara Rao Posinasetti

January 31, 2008

Nageswara Rao Posinasetti

January 31, 2008

Nageswara Rao Posinasetti

January 31, 2008

Nageswara Rao Posinasetti

Selecting carbide Tools

Establish the operating conditions

January 31, 2008

Nageswara Rao Posinasetti

Nageswara Rao Posinasetti

Machine Tool Practices, 7e

Large depth of cut

Nageswara Rao Posinasetti

Machine Tool Practices, 7e

To reduce cutting edge chipping

Select the cemented carbide grade

January 31, 2008

Nageswara Rao Posinasetti

Select the cemented carbide grade

Cast iron, nonferrous and nonmetallic materials Steels

Resistance to edge wear

Nageswara Rao Posinasetti

January 31, 2008

Nageswara Rao Posinasetti

January 31, 2008

Nageswara Rao Posinasetti

January 31, 2008

Nageswara Rao Posinasetti

Select the nose radius

January 31, 2008

Nageswara Rao Posinasetti

Nageswara Rao Posinasetti

Machine Tool Practices, 7e

Select the insert shape

January 31, 2008

Nageswara Rao Posinasetti

Nageswara Rao Posinasetti

Machine Tool Practices, 7e

January 31, 2008

Nageswara Rao Posinasetti

January 31, 2008

Nageswara Rao Posinasetti

Nageswara Rao Posinasetti

Machine Tool Practices, 7e

Select the insert size

January 31, 2008

Nageswara Rao Posinasetti

Select the insert thickness

January 31, 2008

Nageswara Rao Posinasetti

Nageswara Rao Posinasetti

Machine Tool Practices, 7e