MACHINE SHOP TECHNOLOGY-I

Cutting Tool Geometry

P Prasenjit Swain

Cutting Tool:
A cutting tool in metal working can be defined as “any tool that is used to
remove metal from the work piece by means of shear deformation”.
Frequently, it also refers as a tool bit.

In order to perform effective cutting operation, the cutting tool must be made
of a material harder than the work material to be cut. Also, the tool must be
able to withstand the heat generated during machining process.

The tool must have a specific geometry (known as tool geometry) for effective
cutting and smooth surface finish. According to the tool geometry, the cutting
tools can be classified into solid cutting tools and carbide tipped tools.

There are two surfaces adjacent to the cutting edge of the tool:
(a) Rake surface.

(b) Flank surface.

Rake Surface:

Rake surface directs the flow of newly

formed chip. It is oriented at a certain
angle is called the rake angle ‘α’. It is
measured relative to the plane perpendicular to the work surface. The rake
angle can be positive or negative.

Flank Surface:
The flank surface of the tool provides a clearance between the tool and the
newly formed work surface, thus protecting the surface from abrasion which
would degrade the finish. This angle between work surface and the flank
surface is called the relief or clearance angle.

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 MACHINE SHOP TECHNOLOGY-I
Cutting Tool Geometry
P Prasenjit Swain

Types of Cutting Tools:

Various cutting operations require various types of cutting tools. To achieve
good surface quality, proper cutting tool selection is very important.

Following are some important parameters to be considered while

selecting a cutting tool for particular machining operation:
i. Geometry.

ii. Material to be machined.

iii. Shape and Size of part.

iv. Type of operation required.

v. Machine tool quality.

vi. Surface finish required.

vii. Holding facility.

viii. Machining parameters such as feed speed and depth of cut selected.

The major classifications of cutting tools are following:

(i) According to Construction:
(a) Solid tool.

(b) Carbide tipped tool.

(ii) According to Number of Cutting Edges:

(a) Single point tool.

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Cutting Tool Geometry
P Prasenjit Swain

(b) Multipoint tool.

(c) Formed (Tailor designed) tool.

(iii) According to Shape:

(a) Square.

(b) Circular.

(c) Left hand.

(d) Right hand.

(e) Round nose.

(f) Straight nose.

(iv) According to Operations:

(a) Turning.

(b) Drilling.

(c) Threading.

(d) Knurling.

(e) Boring.

(f) Forming.

(g) Parting-off.

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Cutting Tool Geometry
P Prasenjit Swain

(h) Reaming etc.

(v) According to Type of Cutting Tool Material:

(a) H.S.S.

(b) Carbide.

(c) Ceramics.

(d) Diamond etc.

Cutting Tool Angles:

The face and the flank are pain surfaces, the cutting edge can be assumed to be
a line. These surfaces and the edges are inclined with respect to some
reference plan or line. The inclinations are called tool angles.

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 MACHINE SHOP TECHNOLOGY-I
Cutting Tool Geometry
P Prasenjit Swain

For efficient machining operation, the cutting tool must be provided with
necessary tool angles. A tool with proper geometry (cutting edge and tool
angles) cuts the metal effectively. Therefore reducing the chattering, breaking
of the tool with less heat generation.

Rake Angle (α):

(a) Black rake angle.

(b) Side rake angle.

Clearance or Relief Angle (γ):

(a) End clearance relief angle.

(b) Side clearance relief angle.

Cutting Edge Angle:

(a) End cutting edge angle.

(b) Side cutting edge angle.

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Cutting Tool Geometry
P Prasenjit Swain

(i) Back Rake Angle:

It is the angle between the face of the tool and plane parallel to its base. It is
also known as front rake angle or top rake angle.

(ii) Side Rake Angle:

It is the angle between the face of the tool and the shank of the tool.

(iii) End Clearance (Relief) Angle:

It is the angle between the front surface of the tool and a line normal to the
base of the tool. It is also known as front clearance angle.

(iv) Side Clearance (Relief) Angle:

It is the angle between the side surface of the tool and a line normal to the
base of the tool.

(v) End Cutting Edge Angle:

It is the angle between the end cutting edge of the tool and a line
perpendicular to its shank.

(vi) Side Cutting Edge Angle:

It is the angle between the side cutting edge of the tool and shank of the tool.

(vii) Nose Radius:

Nose radius is one which connects the side and end cutting edge. Now, we will
discuss the functions and effects of cutting tool angles on cutting process.

Functions of Nose Radius:

i. A sharp point at the end of tool is undesirable, because it is highly stressed,
short lived and leaves groove in the path of cut.

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Cutting Tool Geometry
P Prasenjit Swain

ii. Therefore Nose Radius is favourable for long tool life and good surface
quality.

iii. It affects the tool life, radial force, and surface quality of work piece.

iv. If nose radius is too large chatter will occur.

v. There is an optimum value of the nose radius at which the tool life is
maximum.

vi. If the nose radius exceeds optimum value, the tool life decreases.

vii. Larger nose radius means larger area of contact between tool and work
piece. Resulting more frictional heat is generated. Also, cutting force increases
due to which the work part may start vibrating and chattering, if work part
holding is not very tight.

viii. The recommendations for use of more nose radius are.

R= 0.4 mm for delicate components.

R = 0.4 mm to 1.2 mm for disposable carbide inserts for common use.

R = 1.2 mm to 1.5 mm for heavy duty inserts.

R ≥ 1.5 mm for heavy depth of cut, interrupted cuts and heavy feeds.

Functions of Back Rake Angle:

(a) It helps to control the chip flow in a convenient direction.

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Cutting Tool Geometry
P Prasenjit Swain

(b) It reduces the cutting force required to shear the metal and consequently
helps to reduces power requirements and increase tool life.

(c) It also helps counteract the pressure against the cutting tool from the work
by pulling the tool into the work.

(d) It provides keenness to the cutting edge and improves the surface finish.

Functions of Side Rake angle:

(a) It performs similar functions as performed by back rake angle.

(b) Side rake angle along with back rake angle controls the chip flow direction.

(c) It partly counteracts the resistance of the work to the movement of the
cutter.

(d) For example, brass requires a back and side rake angle of almost 0°, while
aluminum uses a back rake of 35° and a side rake of 15°.

Significance of Rake Angle:

1. The rake angles may be positive, zero or negative.

2. An increased rake angle will reduce the strength of the cutting edge.

3. Rake angle affects the values of cutting angle and the shear angle.

4. Larger the rake angle, smaller the cutting angle (and larger the shear angle).

5. In general, the small rake angle is used for cutting hard metals and a larger
rake angle is used for cutting soft and ductile metals.

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Cutting Tool Geometry
P Prasenjit Swain

6. The use of negative rake angle started with the employment of carbide
cutting tools. When positive rake angle is used, the force on the tool is directed
towards the cutting edge, tending to chip or break it

7. Since the carbide material is brittle and lacks shock resistance, it will fail if
positive rake angles are used with it. Using negative rake angles, directs the
force back into the body of the tool away from the cutting edge, which protects
to the cutting edge

8. The use of negative rake angle increases the cutting force. This can
compensate by higher cutting speeds. Therefore, high cutting speeds are
always used with negative rake angles. High cutting speeds require high power
of the machine tool.

9. The use of index able inserts also need the use of negative rake angles.

10. A negative rake angle insert has twice life than an equivalent positive rake
angle insert.

11. Negative rake angle increases cutting edge strength, because the cutting
force acts on the middle of cutting edge.

12. Positive rake angle decreases cutting edge strength, because the cutting
force acts on the end or corner of the cutting edge.

13. Positive rake angle recommendations are:

(a) When machining low strength metals and alloys, such as aluminum and
copper alloys, mild steel, etc.

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Cutting Tool Geometry
P Prasenjit Swain

(b) Where cutting at low speeds.

(c) When set up has low strength and rigidity.

(d) When low power machines used.

(e) When tool materials are H.S.S. and cast alloys.

14. Negative rake angle recommendations are:

(a) When machining high strength metal and alloys, such as stainless steel,
alloy tool steel, titanium alloys, etc.

1. Negative 2. Neutral 3. Positive

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Cutting Tool Geometry
P Prasenjit Swain

Functions of End Clearance (relief) Angle:

(a) It allows the tool to cut freely without rubbing against the work surface.

(b) This angle varies from 0° to 15°, and usually 8°.

(c) Excessive relief angle reduces strength of the tool.

Functions of Side Clearance (relief) Angle:

i. It avoids the rubbing of flank against the work piece when the tool is fed
longitudinally.

ii. This angle is 6° to 10° for steel, 8° for aluminum.

iii. It maintains that no part of the tool besides the actual cutting edge can
touch the work.

Functions of End Cutting Edge Angle:

i. It avoids rubbing between the edge of the tool and workspace.

ii. It influences the direction of chip flow.

Functions of Side Cutting Edge Angle:

i. Increase in side cutting edge angle tends to widen and thin the chip.

ii. An excessive side cutting edge angle redirects feed forces in radial direction
which may cause chatter.

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