Single Point Tools Part1 Aug18 1

TOOL DESIGN (12M505)
UNIT-2
SINGLE POINT TOOLS
SINGLE POINT TOOLS
UNIT-2 - TOPICS
NOMENCLATURE
TYPES & STYLES
DESIGN AND MANUFACTURE OF HSS & CARBIDE INSERT TYPE
TOOLS
FOR
TURNING
BORING
SHAPING
PLANING
SLOTTING OPERATIONS
DESIGN & MANUFACTURE OF FORM TOOLS;
TOOLS & HOLDERS FOR CNC APPLICATIONS;
TOOLS FOR DRY MACHINING
8/24/2018 2
UNIT-2 SINGLE POINT TOOLS- VSC-SR.AP-MECH-SW
SINGLE POINT TOOLS
WHEN AND WHERE USED?
8/24/2018 3
SINGLE POINT TOOLS
NOMENCLATURE
8/24/2018 4
SINGLE POINT TOOLS
NOMENCLATURE
8/24/2018 5
SINGLE POINT TOOLS
TOOL ELEMENTS CONTD…
8/24/2018 6
SINGLE POINT TOOLS
NOMENCLATURE
TOOL ANGLES CONTD…
8/24/2018 UNIT-2 SINGLE POINT TOOLS- VSC-SR.AP-MECH-SW 7

SINGLE POINT TOOLS
TOOL ANGLES CONTD…
8/24/2018 8
SINGLE POINT TOOLS
TOOL SIGNATURE
8/24/2018 9
SINGLE POINT TOOLS
TYPES AND STYLES
(1) Solid type tools:

 Entirely made of same material – HSS & cast alloys
 purchased pre-ground or machined to required geometry
 material cost – less expensive
Refer : (Pg.284-286 – Donaldson) AND
Fundamentals of Modern Manufacturing
– Mikell P Groover
(2) Brazed tip type:
Tips are silver brazed to steel shank
 tungsten carbide
 torch, gas burner, induction heating / pocket machined & tip
brazed
8/24/2018 10
SINGLE POINT TOOLS
TYPES AND STYLES
(3) Long indexable insert type

Also called on-end or slug type tool
 Mech tool holder + indexable insert with top & bottom as
cutting edges  can be re-ground for correct geometry
 1-1/2” long  square, rect, diamond, round & triangular shapes
Refer : (Pg.284-286 – Donaldson) AND

Fundamentals of Modern Manufacturing
– Mikell P Groover – Pg570
8/24/2018 11
SINGLE POINT TOOLS Refer : (Pg.284-286 – Donaldson) AND
TYPES AND STYLES Fundamentals of Modern Manufacturing
(4) THROW AWAY INDEXABLE INSERT TYPE
– Mikell P Groover – Pg-570
MECHANICALLY HELD IN TOOL HOLDER
READY COTS ITEM
DEPENDING ON SHAPE , GEOMETRY – HAVE NO. OF CUTTING EDGES; CAN BE INDEXED
DISCARDED AFTER ALL CUTTING EDGES ARE USED
SQUARE, TRIANGLE, ROUND, DIAMOND & OTHER SHAPES
ALL EDGES OF SQUARE & TRIANGLE INSERTS CAN BE USED
Eg. - NEGATIVE RAKE INSERTS BOTH TOP & BOTTOM EDGES CAN BE USED
+VE RAKE INSERTS CAN BE INDEXED ON ONE SIDE ONLY
TOOL HODERS ARE DESIGNED FOR EXTREME RIGIDITY
- NEST OR POCKET ON THE SHANK IS A CRITICAL AREA TO SEAT INSERTS
SHOULD BE ACCURATE TO 1° AT CORNER ANGLES & MUST HAVE STRAIGHT SIDES
- TOOL LIMIT OF 0.0005” ( 12 TO 13 µ) ARE MAINTAINED IN THE POCKET GEOMETRY
TO ENSURE ACCURATE INDEXING
8/24/2018 12
SINGLE POINT TOOLS
TYPES AND STYLES
CLAMPING MECHANISMS FOR INSERTS
- -SCREW TYPE
-- BRIDGE TYPE
- SIMPLOK-PIN TYPE & CARB-O-LOCK PIN TYPE
BRIDGE TYPE CLAMP
8/24/2018 13
SINGLE POINT TOOLS
TYPES AND STYLES
- SCREW TYPE
- BRIDGE TYPE
8/24/2018 14
SINGLE POINT TOOLS
TYPES AND STYLES
- SCREW TYPE
- BRIDGE TYPE
8/24/2018 15
SINGLE POINT TOOLS
CHIP BREAKERS
A step is ground at an angle to the cutting edge (8-10 deg)

A step is ground parallel to the cutting edge – used for cuts
extending to a 90deg shoulder
General
8/24/2018 16
SINGLE POINT TOOLS
CHIP BREAKERS
Parallel type
Angular type
Groove type
8/24/2018 17
SINGLE POINT TOOLS
TOOL HOLDER COMPONENTS
8/24/2018 18
SINGLE POINT TOOLS
TOOL HOLDERS UTILIZING THE PRESSED-IN OR

MOLDED CHIP BREAKER (Courtesy: General
Electric Company)
8/24/2018 19
SINGLE POINT TOOLS
FORCES ACTING ON THE CUTTING TOOL & POWER
REQUIRED FOR TURNING OPERATION
8/24/2018 20
SINGLE POINT TOOLS
FORCES ACTING ON THE CUTTING TOOL & POWER
REQUIRED FOR TURNING OPERATION
(a) Forces acting on the chip

in orthogonal cutting
(b) Forces acting on the tool

that can be measured
8/24/2018 21
SINGLE POINT TOOLS
POWER REQUIRED FOR TURNING OPERATION
FORCES – TANGENTIAL, LONGITUDINAL & RADIAL
TANGENTIAL – TURNING CUT

LONGITUDINAL – FEED FORCE
RADIAL – DEPTH OF CUT
POWER REQD FOR EACH FORCE = FORCE X VELOCITY Nm/sec ( or watt)
Total power reqd = Ft * Vt + Fl * Vl + Fr * Vr ( DIVIDE BY 33000 for hp)
Normally the radial velocity (depth of cut – very small) is negligible or zero (i.e.
Vr=0)
Therefore Total power reqd for turning a workpiece = Ft * Vt + Fl * Vl
8/24/2018 22
SINGLE POINT TOOLS POWER REQUIRED FOR TURNING OPERATION
Ex Prob: The tangential, longitudinal and radial forces on a turning tool are 19000N,
5000N & 2000N respectively. Calculate the power required for turning at a cutting speed
of 100m/min. The feed rate & spindle speed are 0.8mm/rev and 2500rpm
Solution:
Total power reqd = Ft * Vt + Fl * Vl + Fr * Vr
= (19000 x 100/60) + (5000 x 0.8/1000 x 2500/60) + (2000 x 0) N-m/sec
### Sometimes the problem is to design a single point tool (calculate power reqd and
shank dimensions) - given the following:
Specific cutting force (or specific cutting resistance) – (if not given, picked up from data
book based on the material being machined)
Feed , Depth of cut, Tool overhang, material
Power required = (Vc x Fz) / (60 x ɳ) where

Fz (resultant cutting force) = Ks x d x f
ɳ = efficiency (depends on the type of machine used – range is 65% to 80%)

Ks = specific cutting force (or resistance)
8/24/2018 23
SINGLE POINT TOOLS
EX. Prob from semester exams
Solution:
Given S or σ = allowable stress = Ultimate shear strength / FOS (FOS depends on
work material)
UTS = 300MPa; d = 4mm; f = 0.2mm/rev overhang L = 50mm
Fz = Ks x d x f; M = Fz x L (take Ks from databook for Carbon steel)
M/I = σ/y = E/r (bending moment equation); shank cs = square b = h
M/I = σ/y; y = h/2; I = bh^3/12 deflection δ = (FL^3)/3EI
Substituting, we can find h and b (shank dimension)
8/24/2018 24
SINGLE POINT TOOLS
EX. Prob from semester exams
Solution:
Given S or σ = allowable stress = Ultimate shear strength / FOS (FOS depends on
work material)
300MPa; d = 4mm; f = 0.2mm/rev overhang L = 50mm
knowing shear angle – find rake angle by using cutting ratio & shear angle equation
Deflection = δ = (FL^3)/3EI; δ= (4 x Fz x L^3) / E x b x h^3)
8/24/2018 25

Single Point Tools Part1 Aug18 1

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Single Point Tools Part1 Aug18 1

Uploaded by

Copyright:

Available Formats

TOOL DESIGN (12M505)

8/24/2018 UNIT-2 SINGLE POINT TOOLS- VSC-SR.AP-MECH-SW 7

TYPES AND STYLES

(1) Solid type tools:

TYPES AND STYLES

(3) Long indexable insert type

Refer : (Pg.284-286 – Donaldson) AND

BRIDGE TYPE CLAMP

A step is ground at an angle to the cutting edge (8-10 deg)

TOOL HOLDERS UTILIZING THE PRESSED-IN OR

(a) Forces acting on the chip

(b) Forces acting on the tool

TANGENTIAL – TURNING CUT

POWER REQD FOR EACH FORCE = FORCE X VELOCITY Nm/sec ( or watt)

Total power reqd = Ft * Vt + Fl * Vl + Fr * Vr ( DIVIDE BY 33000 for hp)

Therefore Total power reqd for turning a workpiece = Ft * Vt + Fl * Vl

Power required = (Vc x Fz) / (60 x ɳ) where

ɳ = efficiency (depends on the type of machine used – range is 65% to 80%)

M/I = σ/y = E/r (bending moment equation); shank cs = square b = h

M/I = σ/y; y = h/2; I = bh^3/12 deflection δ = (FL^3)/3EI

Substituting, we can find h and b (shank dimension)

You might also like