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    it is a pdf contaning metal cutting notes

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    it is a pdf contaning metal cutting notes

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    9 views44 pages

    New Doc 22-02-20

    Uploaded by

    Manish kumar
    it is a pdf contaning metal cutting notes

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 44
    2 | Geometry of Cutting Tools Learning Objectives The contents of this chapter would enable the readers to: Be familiar with the configuration and ometry (mainly the angles) of cutting tools, fone Oe ed ol angles i diferent systems of references: ASA, ORS, NRS, etc # Use designations of single-point tools in different systems Use the graphical and vector methods of converting the tool angles from one system. to the other systems. © Illustrate the shape and major geometrical features of HSS drills and milling cutters. Evaluate different geometrical angles of single- point tools, drills and milling cutters in any reference system from the given specification of those tools. Practice re-sharpening of curning tools and twist drills in different methods. _ 21 Introduction ‘mond and cubic boron nitrid tveand easy machining, the 48 pomible The cutting edges are And the two clearance su le today, revoluti main cut {cvcloped as the lines of intersection ofthe three major surfces ~ the rake surface faces, Thus, the total performance of any cutting tool depends on , The material of the tool, The sharpness of 1 Me Cu 3, ae sharpnes of the cutting edges, “orlentation angles of the planes that generate the ‘cutting edges Therefore, the overall p try of tha a Pettormance of cutting tools is governed almost equally by choice of the material mbes eficene tins tools and by cheie way oF application, Appropriate selection of rool geometry "g of any job. This requires thorough knowledge of cutting tool and economic machis 28 Machining and Machine Tools 2.2 Geometry of Single-Point Turning Tools 2.2.1 General Configuration of Cutting Edges of i Tools Used for Machining Both the mateial and the geometry of cutting tools play very important roles on of achieving efficiency and overall econom, Cutting vols may tt Pi umber of thi working cutting edges (points) 3 follows aiid their of machi turning tools, shapir 1. Single-poi 2. Double-point or two-point: drills, 3. Multipoint (more than two points): milling cutters, broaching tools, ho planing and slotting tools an planing i t00ls and boring too, obs, pear ete. Grinding wheels are also multipoint cutting tools. ‘Sear apg a so Hovwevet the bs principle of machining by gradual material removal inthe fo of ig rage 22 | SO same forall cutting tools, where the sharp wedge shaped cutting edge(s) is forcibly pushog Stee material a indicated in Fig 2.1 ce en cadaive ab A... Positive ral 2.2.1.1 Concept of Rake and Clearance Angles of Cutting Tools Ane ‘The phrase ‘tool geometry’ refers to some specific angles or slope of the salient faces and eg of emg Adearance ang] at their cuts oint. Rake angle and clearance angle are the most significant geometrical fetus amy 2.1 shows the general configuration of rake angle and clearance angle. and mut tools. Figur 1, Rake angle (7): It is the angle of inclination of the cutting tool’ rake surface fom them plane, that is, the plane perpendicular to the velocity vector, V. 2. Clearance angle (): It is the angle of inclination of the clearance or flank surface of heros 22,2 Syster the finished surface or the cutting plane, 7 Cutting oo! geon Rake angle is generally provided for ease of chip flow, and it may be positive, negative or even 203 C tdi! in Fig. 2.2. However, clearance angle must be greater alized as I yar : - Machin were i wedge angle, which shouldbe uffEATTOF mechani F 3 Took ref = : 40 oO 1 ~Rake ange J @— Clearance angle Aeteronce pane (x4) —al > Force oo Rae surlace Cutt too (chiset) ~ T tao Wedge angle, 5 Flank surface Flank surtace 7 Cuting Chip. velocity vector V, Figure 2.1 | Wedge, rake and clearance angles of cutting 10 ‘ / > Botte, & gute 22 | Sign convention of tooi rake angles. (a) Positive rake, (b) zero rake, (c) negative rake. Ne ory he We ‘The waive advantages of different types of rake angles are: Az. Positive rake: It helps reduce cutting force, thus cutting power requirement. AZ, Negative rake: It increases strength and life of the cutting edge. ‘Tero rake: lt simplifies design and manufacture (of form tools, etc.) . ‘ovis Adearance angle is essentially provided to avoid rubbing of the tool (flank) against the machined surface > Cutting snd thas 10 reduce loss of energy and damages to the tool and the job surface. Hence, clearance angle must ‘>: ae a, 26% = 1 A= IM” p= 15°, = 30" and nose ads reg (ing Here, % = 10°, yao a n of Tool Geometry in the Orthogonal Rak — old system. The planes of reference and wien the co-ording 2 E22? 2 Designatio' mo" dX,- ¥,- and ¥,~ Zp respectively, which, a is abe known as 15 ange | in ORS are a~ 5s indiated 9 Fi cael perpen Principal al ct pve + Ais the cutting ph the orthogonal pla Plan Hg action of 304 Ke vis pimps ie normal to both X, ind, lity, oe v the velocity Vector co designate £0 geometry in ORS are shown in Fig definitions "© arin ofthe ake sure fom 1. angles: (@ ‘Orchogonal rake To" Ie is the angle of inci mesure on theo hoger plane, Zo” (b) ise eA tis the angle oF ne om ofthe prin caries the cutti ae Fe 2, Clearance angles: @) Orthos sonal clearance of the principal sank a: ROO angle of ition flank fom es measure red on My (b) ‘Auxiliary 0" zonal ¢l clearance i: Ie is the angle of inclination of the aun plane ‘measured 7 the gy othogon plane #5 asst berweer™ and ihe diet susiliary angle es curring ©48° angle 9%, is th _, meas zeured on Te 0 Geometry of Cutting Tools _ 33 Auxiliary curting edge angle ¢,: Ie is f : . ° on Tp. 8 edge angle 4 Iris the angle between 2,’ (Figs. 2.7 and 2.8) and 7, measured 44, Nose radius r (mm): Nose radius ris the radius of curvature of the tool tip (mm) ‘egsumery of single-point curning tools is designated in ORS by 7% OS» Oy Or (mm) Section C- ¢ Fi ‘gure 2.8 | Auxiliary orthogonal clearance «’ (ORS) yg AN w= Machining — tion of Tool An gles in Normal Rake System (Na s) u* Wao - new ee THE ASA SE A 3 aha cageously used for analysis and research in mach? hy tare of the tool geometry when the eyrn 8% TING ed ss 2 Besides, ifthe tool is sharpened ot res ew angles have 0 be done using ORS, ly ‘overcome by using NRS for designation of : re the fact that in ORS, rake and clearance 2.2.23 Design@' js also known as ‘ e ae ut ORS is advan! However itd al the true pl However. 1 ¢ the reference PI additional calc These two limi fference beeween C Joes not Fe’ Jane, that iss ations for correct rations of ORS JRS and NR’ whereas in NR 100 geome, § those angles are visualized in another plane ae tei led the dit tthogonal plane Ky Ta ethogonal plane A i simply oval and respective of hein rn bar m, (and for the auiliary curting cage, 4) is always normal to the curing 2 hown in Fig, 2.9. meee ORS and NRS are st ed the coordinates used in NRS ate yy ~My and Ky, We rence plane (che X,~ ¥, plane), is the normal plan hey eae ing edge and Zi the normal coX,and ¥. isweee Ve WandZ, Wis tobe ag beeween The planes of refe where Rg is the normal cutting edge), X, + = 0, NRS and ORS become same, that is, % = 7» The definition of tool angles in NRS is as follows: 1. Rake angles: fa) Normal rake 7 Ie isthe angle of inclination of the rake surface from alin normal plane 2. Clearance angles: (a) Normal clearance ay: Iris the angle of inclination of the lank from 7 andis sts a ee : ; ) Asi normal clearance a; It is the angle of inclination of the auxlay S\* xiliary cutting plane (7%.) and is measured on the auxiliary normal plane #° perpendicular to the auxiliary cutting edge). Figure 2. 8 | Tool angles in ORS and normal rake syste” (nr) pagre 215 | Axes and planes o Silent reference systems used frei geometry 2.3.2.1 Cutting Angles (9) Br comparing diling with earning in a lathe, it appears (Fig. 2.18) that =p (sameall along the cutting edge) (2.5) where @ isthe cutting angle of the principal cutting edge in the static reference system and is half of the point angle ofthe dil Since pand hence @, are independent of the velocity vector, @, remains constant throughout the cut- ting edges. But the values of @,, (dynamic cutting angle in the X, ~ Yp plane) and @y (work custing agle nthe Ay ~ Yq plane) differ (though slightly) from thac of @, and they continuously vary along the custing edge due to variation of the direction of the velocity vector along the cutting edges (as shown Fg. 2.14), pe 2.19 ini how 4, hy ad ay oi i corresponding to a radial distance y, are inter- It can lished using Fig, 2.19 where OC, AB and KD ate taken parallel wo X,, (the drill axis and Z,,. respectively, that ' » (he dil axis) and Machine Tools ] 42_ Machining a. a Figure 2.16 | Axes and planes of different systems of reference at any point ‘’ on a cutting edge: a twist dil tan dp; = tan Os/cos B, and tan Gy, = tan Op\/cos H, where B= sin (Jr) Bis the web angle and r, the chisel edge radius tan Hy, = (VV e,) = 5 N2IyN = 5/207, qure2i7 | Axes and planes of different reference systems to designate geometry of a drill at its chisel PAN Figure 2.18 | Simulation of drilling with turning to determine cutting angle, ¢,. 2 Inclination Angles (4) be inclination angle Ain any cutting tool refers to the angle of inclination of the main cutting edge from reference plane ,, measured on the cutting plane (the plane perpendicular to 4, and containing the sing edge). In a drill, the value of the inclination angle continuously changes along the cutting edge due ‘change in orientation of the reference plane for orientation of velocity vector V,,. Inclination angle of any tating edge i visualized in the cutting plane as indicated in Fig. 2.20. It is derived from the drill geometry town in Fig, 2.20 that sin f= (rJr) Figure 2.19 | inter-relationships among the cutting angles (of a dril) taken in a#*= - sin Ap and hin p drill is always negative. Therefore, in dil According to convention, A, is zero asin dls the cuting edge sited angle dp, and work inclination angle dy, can be derived using Figs 2-2 Zp, and Zyy, then According to sign convention, 2 Ao yOA)= _ sin(~Ay,) = ABIOA = (ABIAC)-(AC Geometry Cutting To's _ 45 (AE+FG) _ ABcosu, | BE sin(~Ay,) = oa 0A * 0A sin(—Ayq) = “sin, sin pcos, + cos psin 4) 9) 2.3.2.3 Rake Angles (7) ial ake 7, ofthe main cutting edge ata radial distance , in various reference systems is shown in Fig. 2.22. “The dynamic axial ake Zp, ata radial distance r, is evaluated from the simple relation ol fan Yopy = (gir)tan8 2.10) ) rent refer yen eo a Figure 2.20 | Web angie (8,) and inclination angle (2) of a twist dri Figure 2.24 | Inclination angle 4 Of a drill in dynamic and Work reference ge 1a Yogi = CaN Jy; c05 B, yam axial rake 7 88° Figure 2.21 reveals that the work axial rake Yo is telated co dynamic axa Yaw = Yaoi ty where “1, oan) “(Vey) = an, 02 P H, = tan"; a an the Itis also to be not by 44, as cer th is becomes lesser ed that the work axial clearance, y, beet a Oy = yy, bt k Goometry of Cutting Tools _47 \ Figure 2.22 | Axial rake angles of drill in different reference systems. Section A~ A (ys) Therefore, in any cutting tool, the value of dy.) should be large enough so that Oy does not become zero x negative under any circumstances. ‘This is very important in the case of drills as 4, becomes mote and more significant wich che decrease in V, towards the drill axis, Figure 2.23 visualizes orthogonal rake 7. and ormal rake 7. as well as orthogonal clearance a, and normal clearance @,, in the dynamic reference tymtem. 7, and @., are visualized and taken in any orthogonal plane 7,., which is perpendicular to both qo, and ,, whereas 7. and a, are obtained in the normal plane, %,, which is perpendicular to the ‘concerned cutting edge. 2.4 Conversion of Tool Angles 2.4.1 Conversion of Tool Geometry of Single-Point Tools 1k is regularly required to convert the angle of cutting tools from one reference system of tool geometry

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