[CSIT DURG] MACHINE TOOL TECHNOLOGY

Lecture 2

Unit 1
Cutting Tool, Geometry of Single Point Cutting Tool, Mechanics of Metal Cutting

Cutting tool
A cutting tool is a piece of metal having a single or a number of hard (hardened) cutting
edges, suitably shaped."
OR
Machine tools are kind of machines on which metal cutting or metal forming processes are
carried out.
Material removal is essentially done on machine tools, which may be Lathe, Milling,
Drilling, Shaping, Planning, Broaching and Grinding machines
The functions of machine tools are:
holding the workpiece
holding the tool
moving the tool or the work piece or both relative to each other,
supply energy required to cause metal cutting.
Every machine tool has a primary cutting tool for metal removal.
Toolings

It refers to hardware necessary to produce a particular component. The common classification

of the types of toolings is
Cutting tools Milling bit and Drill bit (Example CNC Tools)
Press tools
Dies for die casting
Jig and fixture
Gauges

Cutting tools (Thirupati Reddy Page 1.4-1.6)

It is piece of metal having a single or number of hard cutting edges. The types of cutting tools
used depend upon the shape of the work surface and to some extent quantity of work. The
general classification of cutting tools is given

<1> According to number of cutting edges:

(a) Single point tool: This type of tool has an effective cutting edge and removes
excess material from the work piece along the cutting edge. Example :- lathe, shaper
tools, and planer tools etc.

PREPARED BY- RITURAJ CHANDRAKER 1

 [CSIT DURG] MACHINE TOOL TECHNOLOGY

Types:
a). Ground type
b). Forged type
c). Tipped type
d). Bit type

(b) Multiple (more than one): They have more than one effective cutting edge to
remove excess material from work piece.

Examples: Milling cutters, drills, and reamers broaches and grinding wheels etc.

<2> According to application:

<a> Form cutting toolstools for cutting grooves, tapers.
<b> Thread cutting tools - dies, taps etc.
<c> straight cutting tool - broach, hand saw, power saw etc.

The exact mechanism of cutting is that cutting tool exerts a compressive

force on the work at predetermined position to be machined. The work material is stressed
beyond its yield point causing the material to deform plastically and shear off, and begins to
PREPARED BY- RITURAJ CHANDRAKER 2
 [CSIT DURG] MACHINE TOOL TECHNOLOGY

flow along tool face in the form of chips. Owing to the generation of frictional heat the
cutting tool point tends to soften, loosing hardness resulting to wear and ultimately failure of
cutting tool.

The cutting must be designated and operated in such a way so that it has
adequate strength, enough volume at cutting tip to dissipate the heat generated and adequate
wear resistance. These points are called for adequate tool geometry, its cross section and
material. The important characteristics of cutting tool material are,

<1> Toughness: To avoid fracture failure, the tool material must possess high toughness.
"Toughness is the capacity of material to absorb energy without failing." It is usually
characterised by a combination of strength and ductility in the material.[1]
<2> Hot hardness: Hot hardness is ability of a material to retain its hardness at high
temp." It is ability of the cutting tool to withstand at high temp. without losing its cutting
edge. Hot hardness temp. should be high.
<3> Wear resistance: Hardness is the single most important property needed to resist
abrasive wear during machining .
All cutting tool material must be hard.
<4> Mechanical and thermal shock resistance.
<5> Coefficient of friction between tool and work part should be low in order to have low
tool wear and better surface finish in work part(s).
<6>Ability to maintain above properties at temperature occurring during cutting
operation.
<7> Ease of fabrication.
<8> It should be in range of favorable cost. ( Ref- fliiby.com Internet Source)

Cutting tool material

The selection of cutting tool material is made on the basis of various factors such as speed,
type of cut and wear takes place. Generally the effect of cutting speed on cutting tool
temperature is largest as evidence by an empirical formula[18]

Where

T cutting tool temperature

S, f, d Cutting speed, feed and depth of cut

K constant depending upon work tool material, cutting process and tool
geometry

Effect of alloying material (Ref- Handbook of Manufacturing Engineering and Technology,

2015)

carbon
o As the percentage of carbon increases hardness increases (used to manufacture
punches and dies wrenches and hammers.)

PREPARED BY- RITURAJ CHANDRAKER 3

 [CSIT DURG] MACHINE TOOL TECHNOLOGY

(For advance study Refer Research paper-

www.journalamme.org/papers_vol55_2/58259.pdf)

manganese
o It increases ductility, hardenability. It is having high strain hardening capacity,
strength and excellent wear resistance[4] (Uses - Cell Phone batteries)
sulphur
o If carefully proportioned it can increase machinability without imparting
embrittlement. ( Use- Matches, Fireworks)
www.chem4kids.com/files/elements/016_speak.html

Nickel
o It increases toughness and impact resistance. It shows good properties at low
temperature with other alloy. It imparts excellent corrosion resistance and
increases strength with little loss of ductility. ( Uses- Coins)
www.chem4kids.com/files/elements/028_speak.html
Chromium
o If added in large amount it imparts corrosion resistance and heat resistance and
hardenability.
Molybdenum
o It improves hardenability and increases strength primarily under dynamic and
high temperature conditions. It helps to retain fine grain size which provides
strength and creep resistance at elevated temperatures. Molybdenum carbides
are used in hot work tool steel and for forging dies to impart hardness even at
red hot temperatures. (Ref- www.mechlook.com)
Vanadium
o Like molybdenum it forms strong carbide at elevated temperature and also
limits grain size. (Uses spring)
www.chem4kids.com/files/elements/023_speak.html

Tungsten
o It is used in tool steel to maintain their hardness at elevated temperature.
Copper
o It increases corrosion resistance which is to be controlled otherwise tool will
lose surface quality and hot working behavior.
Silicon
o It increases strength without limiting grain size.
Boron
o It is very important hardenability agent, it also improves machinability and
cold formability
Phosphorous
o It improves machinability, hardenability and it is strong ferrite former.
Titanium
o It increases hardness and tensile strength.

PREPARED BY- RITURAJ CHANDRAKER 4

 [CSIT DURG] MACHINE TOOL TECHNOLOGY

(For advance study Refer Research paper-

ijsetr.org/wp-content/uploads/.../IJSETR-VOL-2-ISSUE-4-814-817.pdf )

For More details Refer Following Notes.

New Microsoft Office Word Document.docx

References

1. Machine tool technology by Thirupati Reddy Scitech Publication Page no. (1.4 1.6)
2. fliiby.com Internet Source
3. www.mechlook.com
4. Handbook of Manufacturing Engineering and Technology, 2015.

Suggested Books
1. Manufacturing engineering and technology Serope Kalpakjain And Steven R. Schmiding
page no (164- 165)
2. Manufacturing technology metal cutting and machine tools P. N. Rao (page no -5).

Objective Questions

1. A 25-degree back rake angle on a high speed single point tool used on a lathe suggests
that the material being machined is
a) copper
b) cast iron
c) high carbon steel
d) aluminium or magnesium alloy

2. . The cutting speed in turning operation would be least in case of

a. aluminium alloys
b. medium carbon steel
c. mild steel
d. stainless steel
3. The straight grades of cemended carbide cutting tool materials contain
a. tungsten carbide only
b. tungsten carbide and titanium carbide
c. tungsten carbide and-cobalt
d. tungsten carbide and cobalt carbide

4. Ceramic cutting tools are fixed to the tool body by

(a) clamping (b) welding (c) soldering (d) brazing
5. The most commonly used tool material for all purposes is the 18-4-1 high speed steel.
It contains
a. 18% tungsten, 4% chromium and 1 % vanadium
b. 18 % chromium, 4 % tungsten and 1 %cobalt
(c) 18% tungsten, 4% cobalt and 1 % molybdenum
(c) 18% molybdenum, 4% chromium and 1 % tungsten
6. Which one of the following tool materials has the highest temperature value upto
which it retains its hardness?

PREPARED BY- RITURAJ CHANDRAKER 5

 [CSIT DURG] MACHINE TOOL TECHNOLOGY

a. high speed steel. (b) ceramics

(c) carbon steels (d) stelIite
7. The most important requisite of a cutting tool material is
a. carbon percentage (b) percentage of alloying elements
(c) red (hot) hardness (d) easy fabrication
8. Which of the following processes can be used for production thin, hard, heat resistant
coating at TiN, on HSS? (IAS- 1997)
1. Physical vapour deposition.
2. Sintering under reducing atmosphere.
3. Chemical vapour deposition with post treatment
4. Plasma spraying.
Select the correct answer using the codes given below:
Codes:
a. 1 and 3 (b) 2 and 3
b. 2 and 4 (d) 1 and 4
9. Cutting tools made of high carbon steel have shorter tool life. Reason(R): During
machining, the tip of the cutting tool is heated to 600/700C which cause the teal tip
to lose its hardness. (IAS- 1997)

a. Both A and R are individually true and R is the correct explanation of A

(b) Both A and R are individually true but R is not the correct explanation of A
(d) A is true but R is false
(e) A is false but R is true
Ans. (a)
10. The correct sequence of elements of 1841 HSS tool is IES2003
a. W, Cr, V
b. Mo, Cr, V
c. Cr, Ni, C
d. Cu, Zn, Sn
Ans. (a)
11. Cutting tool material 1841 HSS has which one of the following compositions?
(IAS 2007)
a. 18% W, 4% Cr, 1% V (b) 18% Cr, 4% W, 1% V
b. 18% W, 4% Ni, 4 1% V (d) 18% Cr, 4% Ni, 1% V
Ans. (a)
12. The compositions of some of the alloy steels are as under:
1. 18 W 4 Cr 1 V
2. 12 Mo 1 W 4 Cr 1 V
3. 6 Mo 6 W 4 Cr 1 V
4. 18 W 8 Cr 1 V
The compositions of commonly used high speed would include steels (IES 1995
a. 1 and 2 (b) 2 and 3
b. 1 and 4 (d) 1 and 3
Ans. (d)
13. Percentage of various alloying elements present in different steel materials are given
below: (IES 2000)
1. 18% W; 4% Cr; 1% V; 5% Co; 0.7% C
2. 8% Mo; 4% Cr; 2% V; 6% W; 0.7% C
3. 27% Cr; 3% Ni; 5% Mo; 0.25% C
4. 18% Cr; 8% Ni; 0.15% C

PREPARED BY- RITURAJ CHANDRAKER 6

 [CSIT DURG] MACHINE TOOL TECHNOLOGY

Which of these relate to that of high speed steel?

a. 1 and 3 (b) 1 and 2
b. 2 and 3 (d) 2 and 4
Ans. (b)
14. Stellite is a nonferrous cast alloy composed of: (IAS 2011)
a. Cobalt, chromium and tungsten
b. Tungsten, vanadium and chromium
c. Molybdenum, tungsten and chromium
(d)Tungsten, molybdenum, chromium and vanadium
Ans. (a)

PREPARED BY- RITURAJ CHANDRAKER 7