Unit 3 - Multi Point Cutters

UNIT-3
MULTI POINT CUTTERS

Topics: Nomenclature, classification and selection, construction
methods, cutter setting, design and manufacture of drills, reamers,
milling cutters, broaches, hobs and gear shaper cutters. Grinding-
wheel specification and selection
Outcomes:
1. Be able to demonstrate the nomenclature and construction details of
various multi-point cutting tools
2. Design & calculate main elements of cutting tools & select machine tools
with correct capacity
3. Demonstrate the ability to select the right multipoint cutting tools based on
the cutting requirements
4. Demonstrate how to specify grinding wheels
15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 1

MULTI POINT CUTTERS
(PART-1)
Drilling & Reaming tools

MULTI POINT CUTTERS – NOMENCLATURE, CLASSIFICATION AND CONSTRUCTION
INTRODUCTION
CUTTINGS TOOLS ----- WITH MORE THAN ONE

CUTTING EDGE / POINT ARE CALLED MULTI
POINT CUTTERS
(UNLIKE THE TURNING / BORING / PLANING /

SLOTTING TOOLS)
 MOST COMMON MULTIPOINT CUTTER IS

“DRILLING TOOL” (or commonly known as
DRILL BIT)

 DRILL NOMENCLATURE:
 DRILL IS ROTARY END-CUTTING TOOL HAVING ONE OR

MORE CUTTING EDGES AND CORRESPONDING
FLUTES THAT CONTINUE THE LENGTH OF THE DRILL
BODY
 THE FLUTES WHICH CAN BE EITHER STRAIGHT OR HELICAL

PROVIDE PASSAGES FOR CHIPS AND CUTTING FLUID
 MOST DRILLS HAVE TWO FLUTES; BUT CERTAIN DRILLS

HAVE 3 OR 4 FLUTES AND ARE CALLED CORE DRILLS
(NOT USED TO START A HOLE BUT TO ENLARGE OR
FINISH DRILL A HOLE OR CORED HOLE IN A CI OR
STEEL CASTING)
 MOST COMMON DRILL IS A TWIST DRILL WHICH HAS TWO

FLUTES AND TWO CUTTING EDGES
DRILL NOMENCLATURE:
TOOL ELEMENTS & GEOMETRY:
CUTTING EDGE – LIPS; SHANK; BODY; NECK; FLUTES;
LAND (PERIPHERAL PORTION OF BODY BETWEEN ADJ FLUTES)
CHISEL EDGE; WEB; POINT ANGLE; LIP RELIEF ANGLE; HELIX ANGLE; WEB THICKNESS

TYPES OF DRILL POINTS
STANDARD LONG ANGLE FLAT
DOUBLE ANGLE
SPLIT
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MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW
DRILL POINT GEOMETRY -- (DESIGN & PERFORMANCE)
COMPOSED OF
1. HELIX ANGLE
2. POINT ANGLE
3. LIP CLEARANCE ANGLE
 ALTERATION OF ANY ONE OF THE ABOVE WILL AFFECT THE PERFORMANCE OF THE
DRILL
 HELIX ANGLE:  DECIDES THE RAKE ANGLE OF DRILLS

 HIGH SPEED STEEL DRILLS – 22° TO 33°
 SERVES TO REDUCE THE AXIAL THRUST AND TORQUE FORCES
 POINT ANGLE
 DECIDES THE EFFECTIVE RAKE ANGLE OF DRILLS
 INCREASING THE POINT ANGLE INCREASES THE EFFECTIVE RAKE ANGLE
 INCREASE SHOULD BE LIMITED TO A CERTAIN RANGE – STRENGTH POINT
 STD POINT ANGLE = 118° FOR STEEL, CI & ALLOY STEEL
 RANGE = 90° TO 140°
 LONG POINT = 60°TO 90° -- USED ON SOFT PLASTICS, WOOD, SOFT NON-
FERROUS MATERIAL
MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-
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MECH-SW
EFFECT OF DRILL POINT ANGLE ON PERFORMANCE OF DRILLING
Increasing point angle increases effective rake angle

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MECH-SW
DRILL POINT GEOMETRY
EFFECT OF DRILL POINT ANGLE ON PERFORMANCE OF DRILLING
SANDARD POINT ANGLE LONG POINT ANGLE

TABLE 4-26 Pg 382 in Donaldson GIVES RECOMMENDED DRILL POINT GEOMETRY
DRILL APPROACH ALLOWANCE & POINT ANGLE RELATIONSHIP
A = THE DISTANCE THE DRILL MUST FEED

INTO THE WORKPIECE BEFORE REACHING
A = APPROACH ALLOWANCE;
FULL DIA
Ɵ = DRILL POINT ANGLE
D = DRILL DIA
DESIGN OF DRILLS
DEPENDS ON CUTTING CONDITIONS:
CUTTING SPEED (V) (=πDN) (N is the spindle speed in rpm)

FEED (f) - mm/rev ( prop to drill dia)
FEED RATE = fr = N * f (mm/min)
APPROACH ALLOWANCE (A) = 0.5D tan(90-Ɵ/2)
DRILL DIAMETER = D; Ɵ = point angle
Machining time reqd to drill a hole = Tm = (t+A)/ (fr)

where t = depth of hole; fr = feed rate;
A = approach allowance;
Metal Removal Rate in drilling =
Power reqd for drilling = (uhp * Rmr) / efficiency

TYPES OF DRILLS
TWIST DRILLS: END CUTTING TOOL WITH ONE OR MORE CUTTING EDGES
HAVING HELICAL OR STRAIGHT FLUTES OR GROOVES FOR ADMISSION OF
COOLANT AND EJECTION OF CHIPS
STRAIGHT SHANK DRILLS:

(0.006” TO 2” SIZES)
 SHANK DIA = DRILL BODY DIA
DRILL LENGTH, HELIX ANGLE & WEB THICKNESS ARE IMPORTANT
TAPER SHANK DRILLS:

STANDARD TAPER – MORSE TAPER
 1/8” TO 3-1/2” SIZES
EXTRA LENGTH DRILLS:

FOR REACHING INACCESSIBLE PLACES OR DEEP HOLE DRILLING
 6” TO 12” EXTENDED SHANK (USED IN AIRCRAFT EXTENSION DRILLS – WINGS,
COWLINGS)
TYPES OF DRILLS
HIGH HELIX DRILLS:

FOR DEEP HOLE DRILLING OF LOW TENSILE STRENGTH MATERIAL VIZ Al, Mg,
Cu, WOOD, PLASTIC & MARBLE
 FLUTES ARE WIDE AND POLISHED
 HELIX ANGLE IS LARGE
LOW HELIX DRILLS:

LOW HELIX ANGLE – THEREFORE LOW RAKE ANGLE – REDUCES GRAB DURING
HEAVY FEEDING
 DRILLING BRASS – SHALLOW DRILLING OF Al and Mg ALLOYS
MULTIPLE DIA DRILLS:

STEP DRILLING (2 OR MORE DIAs)
 MFD BY GRINDING AN ORDINARY DRILL TO OBTAIN REQUIRED REDUCTION IN
DIA FOR STEP APPLICATION

OPERATIONS RELATED TO DRILLING

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MECH-SW
REAMERS
REAMING PROCESS:
IS A FINISHING OPERATION & NOT INTENDED TO REMOVE A LARGE AMOUNT
OF MATL.
TYPES OF REAMING
 M/C REAMING –
 0.005” TO 0.015” --- ¼” HOLE
 0.010” TO 0.015” --- ½” HOLE
 0.11”5 TO 0.030” --- 1- 1/2” HOLE
 CUTS AT END BY CHAMFER = 45°
 LITTLE OR NO CUTTING DONE BY LONGITUDINAL CUTTING EDGE
HAND REAMING –
 0.001” TO 0.005” – DIFFICULTY IN FORCING THE REAMER
 CUTTING IS DONE ALONG LONGITUDINAL CUTTING EDGE
FINISH IS VERY ACCURATE WHEN DONE BY SKILLED OPERATOR

REAMERS
REAMING PROCESS:
SPEED:
2/3RD OF DRILLING SPEED
 REAMERS GET DAMAGED EASILY THAN DRILLS WHEN SUBJECTED TO CHATTER
 RESULTS ARE GOOD AT LOW CUTTING SPEEDS ( CLOSE TOL AND FINE FINISH)
FEEDS:
 MUCH HIGHER THAN DRILLING FEEDS – SINCE MORE TEETH
 VARIES FROM 0.0015” (0.0381mm) TO 0.005” (0.127mm) PER FLUTE / REV
 TOO LOW FEED CAUSES BURNISHING
 TOO HIGH FEED – REDUCES ACCURACY OF HOLE & FINISH QUALITY

REAMERS -
NOMENCLATURE
CHUCKING REAMER –
STRAIGHT & TAPER SHANK
HAND REAMER –
PILOT & GUIDE
ELEMENTS OF METAL CUTTING REAMERS

REAMERS - NOMENCLATURE
HAND REAMER; 0° RADIAL MACHINE REAMER: - POSITIVE RADIAL

RAKE ANGLE & RIGHT HAND RAKE ANGLE & RIGHT HAND ROTATION
ROTATION SHOWN SHOWN
ELEMENTS OF METAL CUTTING REAMERS

REAMERS - NOMENCLATURE
MACHINE REAMER IN ITS SIMPLEST FORM HAS

TEETH CHAMFERED ON THE END AND CUTS
ONLY ON THE END – LONGITUDINAL TEETH ARE
NOT RELIEVED AND FORM A CIRCULAR LAND
NEARLY AS WIDE AS THE FLUTES
ROSE REAMER – USED FOR HEAVY CUT – MADE
SLIGHTLY UNDER SIZE – FINISH REAMING
FOLLOWS FOR EXTREME ACCURACY

REAMERS – TYPES (HAND REAMERS & MACHINE REAMERS)
HAND REAMERS – SIMPLEST TYPE & MOST COMMONLY EMPLOYED ARE SOLID STRAIGHT-
FLUTE HAND REAMERS WITH A SQUARED SHANK (Fig d)
 MADE OF CARBON STEEL OR CHROMIUM STEEL – CAN’T REGRIND TO ORIGINAL SIZE AFTER
WEAR; CAN BE ELIMINATED BY USING BALL TYPE EXPANSION REAMER OR ADJUSTABLE
REAMER (BY SLIDING BLADES ALONG THE INCLINED SLOTS)

REAMERS - TYPES
SET OF TAPER REAMERS

a) Roughing
b) Intermediate
c) Finishing

REAMERS – TYPES (MACHINE REAMERS)
HAS SHORTER BODY & FEWER FLUTES

REAMERS - TYPES

MULTI POINT CUTTERS – Design
Exercise Problem:
(1) The power available on a drilling machine is 2.6 kW. For drilling a blind hole 24mm deep on
an alloy steel part as shown below in Fig-1, a feed of 0.6mm/rev was used at a drill chuck
speed of 1200 RPM; Calculate the drill diameter “D” and the drill point angle “Ɵ” if the
approach allowance was 10.0mm. Assume drilling machine efficiency of 85%. Unit power for
the given material is 0.8 W-sec/mm³.
FIG-1

MULTI POINT CUTTERS – Design
DESIGN OF DRILLS
DEPENDS ON CUTTING CONDITIONS:
CUTTING SPEED (V) (=πDN) (N is the spindle speed in rpm)

FEED (f) - mm/rev ( prop to drill dia)
FEED RATE = fr = N * f (mm/min)
APPROACH ALLOWANCE (A) = 0.5D tan(90-Ɵ/2)
DRILL DIAMETER = D; Ɵ = point angle
Machining time reqd to drill a hole = Tm = (t+A)/ (fr)

where t = depth of hole; fr = feed rate;
A = approach allowance;
Metal Removal Rate in drilling =
Power reqd for drilling = (uhp * Rmr) / efficiency

MULTI POINT CUTTING TOOLS
BROACHES
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MPC TOOLS-BROACH-GEARCUTTERS-VSC-AP-SG-MECH-SW
BROACHING TOOLS / GEAR CUTTING TOOLS
BROACHING PROCESS:
BROACHING IS PERFORMED USING A MULTIPLE-TEETH CUTTING TOOL BY

MOVING THE TOOL LINEARLY RELATIVE TO THE WORK IN THE
DIRECTION OF THE TOOL AXIS
 THE MACHINE IS CALLED BROACHING MACHINE & THE TOOL IS CALLED
BROACH
 USED FOR MACHINING THROUGH HOLES OF ANY CROSS-SECTIONAL
SHAPE
 STRAIGHT OR HELICAL SLOTS, EXTERNAL SURFACES OF VARIOUS SHAPES,
EXTERNAL AND INTERNAL TOOTHED GEARS
THE BROACHING OPERATION
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BROACHING PROCESS:
IN-FEED IS BUILT INTO THE CONSTRUCTION BY HAVING SUCCESSIVE

TOOTH HIGHER THAN PRECEDING ONE
 PRIMARY CUTTING MOTION IS TRANSLATIONAL
 BROACH SECURED WITH MAIN SLIDE OF THE BROACHING M/C &

TRAVELS WITH THE SLIDE
THE BROACHING OPERATION
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BROACHING PROCESS TYPES
 EXTERNAL BROACHING – PERFROMED ON THE OUTSIDE SURFACE OF
THE WORKPART
 INTERNAL BROACHING – ACCOMPLISHED ON THE INTERNAL SURFACE

OF A HOLE IN THE PART – THEREFORE A STARTING HOLE MUST BE
PRESENT IN THE PART SO AS TO INSERT THE BROACH AT THE
BEGINNING OF THE BROACHING STROKE
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BROACHING PROCESS TYPES
POSSIBLE SHAPES THAT CAN BE DONE BY EXTERNAL & INTERNAL BROACHING

IS SHOWN
 VERTICAL BROACHING OR HORIZONTAL BROACHING IS POSSIBLE BASED ON

THE MACHINE USED
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BROACHES - TYPES
 PULL BROACH – FORCE APPLIED TO THE SHANK – TENSILE FORCE

 BROACH IS PULLED PAST THE WORK
 PUSH BROACH – FORCE APPLIED TO THE REAR END OF THE BROACH –

COMPRESSIVE FORCE
 BROACH IS PUSHED THROUGH THE WORK ( ALSO CALLED

BROACHING PRESS)
 BODY IS IN COMPRESSION
 SHORTER TO AVOID BUCKLING
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BROACHES – TYPES
 CONTINUOUS BROACHING -
WORKPARTS FIXTURED TO AN ENDLESS BELT LOOP MOVING PAST A
STATIONARY BROACH – THIS M/C USED ONLY FOR SURFACE
BROACHING
 GENERALLY CUTTING SPEED IS LOW – 2 TO 15 M/MIN
 PRODUCTION CAPACITY IS HIGH BECAUSE TOTAL LENGTH OF CUTTING

EDGES IS LARGE
MATERIALS USED TO MANUFACTURE BROACHES

 HSS
 CHROMIUM VANADIUM STEEL
 CEMENTED CARBIDES (FOR CI MACHINING)
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BROACHES – TYPES
ROUND PULL BROACH
1- PULL END
2- NECK
3- FRONT TAPER
4- FRONT PILOT
5- CUTTING TEETH
6- SIZING TEETH
7- REAR PILOT
ROUND PUSH BROACH

- SHORTER THAN PULL
BROACH WITH LENGTH < 15D
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TOOL GEOMETRY
GEOMETRIC ELEMENTS OF BROACH TEETH

1. BACK OFF ANGLE (RELIEF ANGLE) – BASED ON THE TYPE OF BROACH (ROUND &
SPLINE, KEYWAY, EXTERNAL SURFACE(ADJUSTABLE OR NON-ADJUSTABLE)
 KIND OF TEETH (ROUGHING, SEMI-FINISH, SIZING)
2. FACE ANGLE (HOOK ANGLE OR RAKE ANGLE)

 DEPENDS ON WORK MATL HARDNESS (eg. AL ALLOY – 10° TO 12°, STEEL –
8 TO 15°, BRASS-2°, CI- 5 TO 8° & Zn 6°)
 BRITTLE –SMALL & DUCTILE – LARGE
3. WEAR LAND – ON SIZING AND FINISHING TEETH

 STRAIGHT NARROW (CYLINDRICAL)
 0.05 TO 0.2mm)
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TOOL GEOMETRY
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TYPES OF INTERNAL BROACHES
a) Solid round broach

b) Sectional round broach
c) Helical cut broach
d) Burnishing broach
e) Straight spline broach
f) Helical spline broach
g) Involute spline broach
h) Serrated spline broach
i) Combination broach
j) Square broach
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CUTTING FORCES & POWER REQUIRED IN BROACHING
Fz = F . Ʃb
Pull force or
Push force = force per unit cutting edge length X Total Cutting edge length
Where F = CUTTING FORCE PER mm OF CUTTING EDGE LENGTH – N/mm

and Ʃb = TOTAL LENGTH OF CUTTING EDGES OF ALL TEETH IN OPERATION
SIMULTANEOUSLY (mm)
FORCE F DEPENDS ON CUT PER TOOTH Sz AND WORK MATL.

(GIVEN IN HANDBOOKS SIMILAR TO SPECIFIC CUTTING RESISTANCE)
Ʃb = (πd) . Zi / Zg (FOR CYLINDRICAL HOLES)
Ʃb = (bw .n ). Zi / Zg (FOR SPLINED HOLES & KEYWAYS)

Where d = max dia of teeth (mm)
Zg = no. of teeth in a group
Zi = no. of teeth in operation simultaneously
bw = width of broached surface on work piece ( mm)
n = no. of splines or keyways
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CUTTING FORCES & POWER REQUIRED IN BROACHING
POWER = P = (Fz . V) / 60
WHERE Fz = CUTTING FORCE - N
V = CUTTING SPEED - m/min
V – DEPENDS ON CUTTING CONDITIONS

MATL (STEEL GRADE 35 – BHN=197 – 269)
ACCURACY (2ND CLASS)
SURFACE FINISH ( 3 TRIANGLES / 4 TRIANGLES OR Ra / Rz √ VALUE)
DATA AVLBL IN HANDBOOKS
POWER OF MOTOR REQD = Pm = P/ɳ
PULLING CAPACITY OF BROACHING M/C = Q = (60 x Pm x ɳ) / V N

Also = Fz
NOTE: (PULLING CAPACITY SHOULD BE EQUAL TO OR GREATER THAN Fz)
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BROACHING TOOLS
To determine the permissible length of cut, the following
formula is often used:

Problem 1:
Calculate the length of broach for roughing and finishing operation for machining a
slot 10 mm in depth and 20 mm in width for 400 mm long steel piece having specific
cutting energy of 2000 N/mm2. Cutting speed is 5 m/min and chip space number 8.
Take roughing feed as 0.08 mm/tooth and finishing feed as 0.02 mm/tooth. Calculate the power
required for the rough cut and finish cut
Solution:
For Roughing:
Out of 10 mm depth, let 8 mm be removed in roughing cut and 2 mm in finishing cut
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Problem 2:
Calculate the power required for broaching (rough cut and finish cut) a keyway of 10
mm depth and 18mm in width for a 200mm long Aluminium alloy part. The no. of
cutting teeth in operation simultaneously is 4 and the specific cutting resistance is
given as 3000 N/mm2. Cutting speed of the broach is 3 m/min and chip space
number 8. Take roughing feed as 0.1mm/tooth and finishing feed 0.04mm/tooth.
Also calculate the length of broach for roughing and finishing operation.

Part-2 - MILLING CUTTERS
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MPC TOOLS-MILNG-CUTTERS-VSC-AP-SG-MECH-SW
MILLING CUTTERS
MILLING PROCESS:
IS A PROCESS WHERE A WORKPART IS FED PAST A ROTATING CYLINDRICAL
TOOL WITH MULTIPLE CUTTING EDGES
THE AXIS OF ROTATION OF THE TOOL IS PERPENDICULAR TO THE DIRECTION

OF FEED
 THIS IS THE FEATURE THAT DISTINGUISHES MILLING FROM DRILLING

(WHERE FEED IS PARALLEL TO AXIS OF ROTATION)
 TOOL IN MILLING IS CALLED MILLING CUTTER & CUTTING EDGES ARE CALLED
TEETH
(a) Peripheral or plain

milling; (b) face milling
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MILLING CUTTERS
MILLING PROCESS:
MILLING IS AN INTERRUPTED CUTTING OPERATION – THE TEETH OF THE

CUTTER ENTER AND EXIT THE WORK DURING EACH REVOLUTION 
LEADS TO CYCLE OF IMPACT FORCE & THERMAL SHOCK ON EVERY
ROTATION
 HENCE THE TOOL MATL & CUTTER GEOMETRY MUST BE DESIGNED TO

WITHSTAND THESE CUTTING CONDITIONS
(a) Peripheral or plain

milling; (b) face milling
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MILLING CUTTERS
PERIPHERAL MILLING :
THE AXIS OF THE TOOL IS PARALLEL TO THE SURFACE BEING MACHINED

 OPERATION IS PERFORMED BY CUTTING EDGES ON THE OUTER PERIPHERY OF THE
CUTTER
 SEVERAL TYPES OF PERIPHERAL MILLING ARE SHOWN IN FIG
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MILLING CUTTERS
PERIPHERAL MILLING :
THE DIRECTION OF CUTTER ROTATION DISTINGUISHES TWO FORMS OF PERIPHERAL

MILLING
 UP MILLING (ALSO CALLED CONVENTIONAL MILLING)
 DIRECTION OF CUTTER MOTION IS OPPOSITE TO FEED DIRECTION i.e. MILLING
AGAINST THE FEED
 DOWN MILLING (ALSO CALLED CLIMB MILLING)

 DIRECTION OF CUTTER MOTION IS SAME AS THE FEED DIRECTION – i.e. MILLING
ALONG WITH THE FEED
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MILLING CUTTERS
FACE MILLING :
THE AXIS OF THE CUTTER IS PERPENDICULAR TO SURFACE BEING MILLED

 MACHINING IS PERFORMED BY CUTTING EDGES ON BOTH, THE END AND OUTSIDE
PERIPHERY OF THE CUTTER
 VARIOUS TYPES OF FACE MILLING IS SHOWN
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MILLING CUTTERS
CUTTING CONDITIONS IN MILLING
FOR PERIPHERAL MILLING
CUTTING SPEED V (AT THE OUTSIDE

DIAMETER OF THE CUTTER)
 RELATED TO SPINDLE SPEED (N=RPM) Metal removal rate = Rmr= w*d*fr
V = πDN
(where w=width of workpart; d= depth to
 FEED IS GIVEN AS FEED PER CUTTER which material is removed & fr = feed rate
TOOTH “f” (CALLED CHIP LOAD)
 Machining time = Tm = (L +A) / fr
FEED RATE fr = N * nt * f where L=length of workpiece;
Where nt = no. of teeth on cutter; A=approach distance;

N=spindle RPM; f=chip load
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MILLING CUTTERS
CUTTING CONDITIONS IN MILLING
FOR FACE MILLING (Axis of rotation is perpendicular to surface being machined)
TWO CONDITIONS ARE POSSIBLE

1. CUTTER IS CENTERED OVER WORKPIECE
2. CUTTER IS OFFSET TO ONE SIDE OVER THE WORKPIECE
MACHINING TIME = Tm = (L +A) / fr where L=length of workpiece;

A=approach distance – given below for both conditions
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MILLING CUTTERS
EX Problem:
#1. Calculate the machining time required to mill the block of length 100mm
as shown in fig-1. Assume a feed rate of 0.05m/min, cutter diameter of
60mm, metal to be removed to a width of 10mm.
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MILLING CUTTERS
TOOL GEOMETRY
REFER DONALDSON – PAGE

355 TO 358 FOR FULL
GEOMETRY ELEMENTS &
PSG TECH DESIGN DATA
BOOK
Axial rake angle

and
Radial rake angle
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MILLING CUTTERS
CLASSIFICATION OF MILLING CUTTERS
1. PROFILE RELIEF CUTTERS

2. FORM RELIEF CUTTERS PROFILE RELIEF
3. END MILLS CUTTERS
FORM RELIEF
CUTTERS
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MILLING CUTTERS
CLASSIFICATION OF MILLING CUTTERS
1. PROFILE RELIEF CUTTERS

2. FORM RELIEF CUTTERS
3. END MILLS
END MILLS
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MILLING CUTTERS
SELECTION OF MILLING CUTTERS (Parameters to be considered)
MAJOR ELEMENTS TO CONSIDER FOR MILLING CUTTER SELECTION ARE
1. SIZE
 FACE WIDTH SHOULD BE WIDE ENOUGH TO PROVIDE ADEQUATE SUPPORT
BEHIND CUTTING EDGE;
 DIA SHOULD BE KEPT SMALLER AS POSSIBLE SINCE IT REQUIRES LESS
TORQUE & DEFLECTS LESS
 CUTTER DIA TO HOLE DIA SHOULD BE 3:1
 LARGE DIA CUTTERS USED WHEN ARBOR STEP (SUPPORT) INTERFERES
WITH WORKPIECE
2. TEETH
 NO OF TEETH IS A COMPROMISE DEPENDING ON MATL, TYPE OF MILLING
CUTTER & SURFACE FINISH REQD
 NOT TOO LITTLE – FOR CONTINUOUS CONTACT WITH WORK MATL
 NOT TOO MANY – TO PROVIDE FOR ADEQUATE CHIP SPACE
 THUMB RULE – MIN ONE TOOTH IS ALWAYS DOING THE CUT; ONE TOOTH
WILL NOT LEAVE THE WORK BEFORE NEXT TOOTH ENTERS; THIS
PROMOTES A SMOOTH CUTTING OPERATION
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MILLING CUTTERS
SELECTION OF MILLING CUTTERS
3. FLUTES
 STRAIGHT – CUTTING ACTION IS INTERMITTENT – FORCES HIGH ; SHOCK LOAD
HIGH – LEADS TO CHATTER – SLITTING SAWS
 HELICAL –MOST WIDELY USED FOR PERIPHERAL MILLING- REDUCES CHATTER –

LEFT OR RIGHT HELIX
 RIGHT HELIX - GOOD FOR SLOTS & SHOULDER MILLIING

 LEFT HELIX – END MILLS – GOOD FOR PROFILE OPERATION
 ANGULAR FLUTE – IN BETWEEN STRAIGHT AND HELICAL

 SUITED FOR SYMMETRIC FORMS AND NARROW FACE WIDTHS
 FACE OF CUTTER IS AT AN ANGLE TO THE AXIS OF CUTTER
 RADIAL RAKE VARIES FROM ONE SIDE TO OTHER SIDE OF CUTTER
 NOT RECOMMENDED FOR WIDE CUTTERS

MILLING CUTTERS
SELECTION OF MILLING CUTTERS
4. RELIEF
 FORM RELIEF AND PROFILE RELIEF

 ENSURES MAX HEAT DISSIPATION & MAX STRENGTH AT CUTTING EDGE
 HIGH RELIEF ANGLE LEADS TO CHATTER DURING HEAVY MILLING
 RELIEF ANGLES TO BE MINIMUM TO AVOID HEEL DRAG
5. MATERIAL
 HARDNESS SHOULD BE OPTIMUM – EFFECTS CORRECT RELIEF ANGLE
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MILLING CUTTERS
Concave & convex
VARIOUS TYPES OF
MILLING CUTTERS Double angle
Woodruff key
plain Side Staggered tooth side Metal-slitting saw
interlocking
Screw-slotting
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Milling Cutter, Single, Double, Angle, HSS,
HSCO, Carbide ID 946

MILLING CUTTERS
Exercise Problem:
(1) Justify whether a 2.0 kW capacity milling machine is sufficient to mill the
Aluminium block of length 30mm as shown in fig-1. Assume a feed rate of
0.08m/min, total depth of cut of 1.5mm, cutter diameter of 50mm, block width of
25mm. The specific energy for the given work material is 0.8 Wsec/mm³
Metal removal rate = Rmr= w*d*fr
(where w=width of workpart; d= depth to

which material is removed & fr = feed rate
 Machining time = Tm = (L +A) / fr

where L=length of workpiece;
A=approach distance;
FIG-1
30-09-2020 19
MILLING CUTTERS
High speed machining with milling cutters:
Video clipping
30-09-2020 20
GEAR HOBS, GEAR SHAPERS &
GRINDING TOOLS
06-10-2020 MPC TOOLS-GEAR CUTTERS-VSC-AP-SG-MECH-SW 1

GEAR CUTTING TOOLS
GEAR CUTTING PROCESS

→FORM MILLING
→ GEAR HOBBING
→ GEAR SHAPING

GEAR CUTTING TOOLS
GEAR CUTTING PROCESS (FORM MILLING):
→IN THIS PROCESS THE TEETH ON A GEAR

BLANK ARE MACHINED INDIVIDUALLY BY A
FORM MILLING CUTTER WHOSE CUTTING
EDGES HAVE THE SHAPE OF THE SPACES
BETWEEN THE TEETH ON THE GEAR
→ TERMED FORMING BECAUSE THE SHAPE

OF THE CUTTER DETERMINES THE
GEOMETRY OF THE GEAR TEETH
→ DISADV - PRODN RATES ARE LOW SINCE

EACH TOOTH SPACE IS CREATED ONE AT A
TIME & GEAR BLANK HAS TO BE INDEXED
BETWEEN EACH PASS TO ESTABLISH THE
CORRECT SIZE OF GEAR TOOTH – TIME
CONSUMING
→ADV – LESS EXPENSIVE COMPARED TO

GEAR HOBBING – HENCE SUITED FOR LOW
PRODUCTION QUANTITIES.
FORM MILLING OF GEAR TEETH ON STARTING BLANK

GEAR CUTTING TOOLS
GEAR CUTTING PROCESS (GEAR HOBBING):
→ CUTTER IS CALLED A GEAR HOB – GEOMETRY IS MORE COMPLEX & HENCE MORE EXPENSIVE
THAN FORM CUTTER
→SPECIAL MACHINES (HOBBING M/C) ARE
REQUIRED TO ACCOMPLISH RELATIVE SPEED
BETWEEN CUTTER AND BLANK
→ THE HOB HAS A SLIGHT HELIX – ITS ROTATION IS

COORDINATED WITH THE MUCH SLOWER
ROTATION OF THE GEAR BLANK
→ FOR A SPUR GEAR THE AXIS OF ROTN OF HOB IS

OFFSET BY 90° LESS THAN THE HELIX ANGLE
RELATIVE TO THE AXIS OF THE GEAR BLANK
→ IN ADDITION TO THESE ROTARY MOTIONS OF

HOB AND WORKPIECE, A STRAIGHT LINE MOTION
IS REQUIRED TO FEED THE HOB RELATIVE TO THE
GEAR BLANK THROUGHOUT ITS THICKNESS
→ SEVERAL TEETH ARE CUT SIMULTANEOUSLY –

ALLOWS FOR HIGHER PRODN RATE
→ WIDELY USED FOR MEDIUM & HIGH GEAR HOBBING
PRODUCTION QUANTITIES.
GEAR CUTTING TOOLS
GEAR CUTTING PROCESS (GEAR SHAPING):
→A RECIPROCATING CUTTER MOTION IS USED
RATHER THAN A ROTARY MOTION
→ TWO DIFF TYPES USED – FIRST TYPE A SINGLE

POINT TOOL MAKES MULTIPLE PASSES TO
GRADUALLY SHAPE EACH TOOTH PROFILE
USING COMPUTERIZED CONTROLS OR
TEMPLATE – GEAR BLANK IS SLOWLY INDEXED
WITH SAME PROFILE BEING IMPARTED TO EACH
TOOTH – SLOW PROCESS & SUITED FOR FABN
OF VERY LARGE GEARS (TANKS)
→ 2ND TYPE – CUTTER HAS THE GENERATED

SHAPE OF A GEAR WITH CUTTING TEETH ON
ONE SIDE – THE AXIS OF CUTTER AND BLANK GEAR SHAPING
ARE PARALLEL (FIG) & ACTION IS SIMILAR TO A
PAIR OF CONJUGATE GEARS EXCEPT THAT THE
RECIPROCATION OF THE CUTTER IS GRADUALLY
CREATING THE FORM OF THE MATCHING TEETH
IN ITS MATING COMPONENT
→ THE 2ND METHOD IS WIDELY USED IN

INDUSTRY – MACHINES CALLED GEAR SHAPERS
ARE USED FOR THIS PROCESS.
GEAR CUTTING TOOLS
EXERCISE PROBLEMS
#1. Design a shell type class A gear hob for 1.75 module, 20 pressure
angle, work material C45.
Find a) Diameter (Arbor and Major diameter) b) No of teeth
c) Height of tooth d) Helix angle of hob e) Length of hob
f) Pitch of hob (Axial and normal section) g) Normal tooth
thickness h) Rake and relief angle i) Circular pitch.
Module Precision Solid Hobs
D mm d mm z
1.5-1.75 80 40 16

GEAR CUTTING TOOLS
EXERCISE PROBLEMS

GEAR CUTTING TOOLS
EXERCISE PROBLEMS

GRINDING TOOLS
GRINDING PROCESS:
→EMPLOYS AN ABRASIVE TOOL WHOSE
CUTTING ELEMENTS ARE GRAINS
OF ABRASIVE MATERIALS
→ GRAINS – HAVE HIGH HARDNESS & HIGH
HEAT RESISTANCE
→ SHARP EDGES HELD TOGETHER BY
BONDING MATL FORMED INTO
DEFINITE SHAPES CALLED
ABRASIVE TOOLS
→ PROJECTING GRAINS OF THE ABRASIVE
MATL, FIRMLY SECURED IN THE
GRINDING WHEEL BY THE BOND,
CUT (ABRADE) A LAYER OF METAL
FROM THE WORKPIECE IN THE
FORM OF VERY MINUTE CHIPS AS
THE WHEEL ROTATES AT HIGH SPEED
→ FINISHING OPERATION 95% OF THE
TIME & 5% ROUGHING OPERATION
(FETTLING OF CASTINGS)
→ CHIP REMOVED IN 0.0001 TO 0.0005 SEC
9
06-10-2020 MPC TOOLS-GEAR CUTTERS-VSC-AP-SG-MECH-SW
GRINDING TOOLS
WHEEL SELECTION / TOOL SHAPES
→SHAPES INCLUDE WHEELS, SEGMENTS, MOUNTED POINTS, STICKS & COATED
ABRASIVES
→ ALSO EMPLOYED AS PASTES & POWDERS
→ WHEEL ROTATES AT HIGH SPEED → 75m/sec (Vwh)
→ SMALL C.S. OF CHIPS

ARE REMOVED BY SEVERAL
GRAINS AT HIGH SPEED –
HENCE ACCURACY AND
SURFACE FINISH IS HIGH (7Δ
TO 12Δ - NOW GIVEN AS Ra
OR Rz)
06-10-2020 10
MPC TOOLS-GEAR CUTTERS-VSC-AP-SG-MECH-SW
GRINDING TOOLS
→MANY CUTTING GRAINS → PRODUCES LARGE NO. OF CHIPS – EACH AT
HIGH TEMP (1000° C -1500° C) → HIGH TEMP ARE REACHED
BECAUSE OF THE DIVERSE IRREGULAR GEOMETRY OF THE CUTTING
ELEMENTS OF THE GRAINS (NEGATIVE RAKE) AND HIGH CUTTING SPEED
06-10-2020 11
GRINDING TOOLS
→GRINDING TEMP RISES WITH
INCREASED WEAR OF THE
GRAINS – WHICH MAY LEAD TO
DISTORTION OF WORKPIECE,
BURNS, STRUCTURAL CHANGES
AND CRACK FORMATION IN THE Employed for internal grinding & to clean up hard-to-reach
spots in making moulds & dies when grinding wheels are
GROUND SURFACE unsuitable. Do not have thro holes, cemented onto a
special stem. Size ranges from 3 to 40 mm in dia
→ HENCE ABUNDANT FLOW OF
COOLANT (10 TO 60 LPM) IS
COMMONLY USED IN GRINDING
Segments have length from 125 to 300mm; used in

surface grinding; many segments are attached to wheel-
modular & can be replaced with new segment

GRINDING TOOLS
→COMMON CUTTING FLUIDS USED IN

GRINDING STEEL ARE SODA ASH
+ SODIUM NITRATE; AQUEOUS
SOLUTION OF POWDERED
SOAP; AQUEOUS SOLUTION OF
PASTE TYPE EMULSION;
AQUEOUS SOLUTION OF PASTE
TYPE EMULSION + OLEINIC ACID
Sticks are used for hand fitting operations and
→ AL – KEROSENE WITH OR W/O ADDN honing and superfinishing of workpieces by
OF MINERAL OIL attaching them to special heads.
→ CI & CU – GROUND DRY (NEEDS DUST

EXHAUSTING FACILITY)

GRINDING TOOLS
GRAIN SIZE OF ABRASIVE MATERIALS
→SIZE VARIES FROM 3.5 TO 2500 MICRONS

→ DESIGNATED WITH NOS. 200, 160, 125, 100, 80, 63, 50, 40, 32, 25, 20, 16, 12, 10, 8, 6,
5, 4, 3 & THEN M40 TO M5 (Russian GOST standards)
→ 200 TO 16 ARE GRINDING GRAINS
→ 12 TO 3 ARE CALLED GRINDING POWDERS
→ GRAIN SIZES ARE GIVEN USING SCREEN MESH SIEVES EXPRESSED AS 1/100 OF a mm
06-10-2020 14
GRINDING TOOLS
GRAIN SIZE OF ABRASIVE MATERIALS (ANSI standards)
06-10-2020 15
GRINDING TOOLS
WHEEL SELECTION - (GRADE AND HARDNESS)
→GRADE IS IMPORTANT FOR SURFACE FINISH
→ IS DETERMINED AND CHECKED BY
→SAND BLASTING (DEPTH OBTAINED BY A JET OF QUARTZ SAND)
→MEASURING INDENTATION DEPTH BY A STEEL BALL
→SOMETIMES DESIGNATED BY GRAIN STRUCTURE – NUMERICAL RATIO & RELATIVE
ARRANGEMENT OF GRAINS, BOND, VOIDS IN UNIT VOL OF TOOL
→ FROM 0 TO 12 → 13 STRUCTURES DIVIDED INTO 3 GROUPS
→ (0-3) – DENSE; (4-6) –MEDIUM DENSE; (7-12) – OPEN
→ STRUCTURE NO. DETERMINES THE SPACING OF GRAINS IN THE TOOL – LARGER
THE NO. WIDER THE SPACING
WHEEL GRADE GRADE DESIGNATION
→HARD WHEELS M – SOFT M1, M2, M3
RECOMMENDED FOR (→ HARDNESS INCREASES)
SOFT MATL & CM – MEDIUM SOFT CM1, CM2
→ SOFT WHEELS
RECOMMENDED FOR C – MEDIUM C1, C2
HARD MATERIALS CT – MEDIUM HARD CT1, CT2, CT3
T – HARD T1, T2
BT – VERY HARD BT1, BT2
Цt – EXTREMELY HARD Цt1, цT2
GRINDING TOOLS
MATERIALS (ABRASIVE AND BONDING)
→ABRASIVES
→NATURAL – MINERALS –QUARTZ, DIAMOND, CORUNDUM, EMERY (ALUMINA Al

OXIDE), GARNET
→MANUFACTURED – Al OXIDE, SILICON CARBIDE, CUBIC BORON NITRIDE, ELBOR,

SYNTHETIC DIAMOND (GRAPHITE SUBJECTED TO HIGH PR &
TEMP), ZIRCONIUM OXIDE

GRINDING TOOLS
→BONDING MATERAL
→BINDERS WHICH HOLD ABRASIVE PARTICLES IN PLACE
→ FIRMNESS (STRENGTH OF WHEEL) DEPENDS ON THE BOND
→ORGANIC BONDS –
→ RUBBER (R) – RUBBER AND SULPHUR
→RESINOID (B) – BAKELITE + SYNTHETIC RESIN (CARBOLIC ACID) + FORMALDEHYDE
→ SOMTEIMES IMPREGNATED WITH PARAFFIN TO AVOID REACTION WITH
COOLANTS; SOMETIMES GRAPHITE FILLER IS USED TO IMPROVE SURFACE FINISH
→ SHELLAC (E) – SHELLAC MIXED WITH ABRASIVE GRAINS

GRINDING TOOLS
→BONDING MATERIALS
→IN-ORGANIC BONDS
1. VITRIFIED (V) – REFRACTORY CLAY + FELDSPAR + QUARTZ + TALC + CHALK + SILICATE
OF SODA
→ HIGH PRODUCTION CAPACITY
→ DISADV – BRITTLE – CAN’T TAKE HEAVY IMPACT LOADS
2. MAGNESIUM OXYCHLORIDE (O)
→ MAGNESITE + Mg CHLORIDE
3. SILICATE BOND (S)
→ CLAY + FLINT DUST + SILICATE OF SODA ASH
ABRASIVE TOOLS MADE OF THESE BONDS ARE SOFT AND USED TO A LIMITED EXTENT –
LOW PRODUCTION CAPACITY)
06-10-2020 19
GRINDING TOOLS
GRINDING WHEEL DESIGNATION AND NOMENCLATURE
EG. 32-C-100-P-11-B & 47-A-24-E-14-R
06-10-2020 20
GRINDING TOOLS
METHODS OF SUPPORTING WORK BETWEEN

CENTERS & CENTERLESS TYPE OF CYLINDRICAL
GRINDING
TYPES OF SURFACE GRINDING

MACHINES

GRINDING TOOLS
CUTTING FORCES IN CYLINDRICAL GRINDING
CUTTING FORCES Fx, Fy & Fz ARE LARGE IN

VALUE; THE GREATEST OF THEM IS THE
RADIAL FORCE Fy WHICH TENDS TO PUSH
THE WHEEL AWAY FROM THE WORK
GENERALLY Fy = (1.3 TO 3) Fz
Fz IS DEPENDENT ON Vw, s , t and (Vwh /
Vw = 60 to 100)
Where Vwh = wheel velocity
Vw = work velocity
POWER REQD FOR CUTTING

(POWER TO DRIVE THE GRINDING
WHEEL) =
THE REQD (DESIGN)

POWER RATING OF
ELECTRIC MOTOR =

GRINDING TOOLS
REPRESENTATION OF VARIOUS
TERMS IN THE EQUATION
UNDER DIFFERENT
SITUATIONS IN GRINDING

GRINDING TOOLS
Machining time
required =

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Unit 3 - Multi Point Cutters

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Unit 3 - Multi Point Cutters

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UNIT-3

MULTI POINT CUTTERS

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 1

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 2

CUTTINGS TOOLS ----- WITH MORE THAN ONE

(UNLIKE THE TURNING / BORING / PLANING /

 MOST COMMON MULTIPOINT CUTTER IS

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 3

 DRILL IS ROTARY END-CUTTING TOOL HAVING ONE OR

 THE FLUTES WHICH CAN BE EITHER STRAIGHT OR HELICAL

 MOST DRILLS HAVE TWO FLUTES; BUT CERTAIN DRILLS

 MOST COMMON DRILL IS A TWIST DRILL WHICH HAS TWO

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 5

TYPES OF DRILL POINTS

STANDARD LONG ANGLE FLAT

 HELIX ANGLE:  DECIDES THE RAKE ANGLE OF DRILLS

Increasing point angle increases effective rake angle

MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-

SANDARD POINT ANGLE LONG POINT ANGLE

A = THE DISTANCE THE DRILL MUST FEED

CUTTING SPEED (V) (=πDN) (N is the spindle speed in rpm)

Machining time reqd to drill a hole = Tm = (t+A)/ (fr)

Metal Removal Rate in drilling =

Power reqd for drilling = (uhp * Rmr) / efficiency

STRAIGHT SHANK DRILLS:

TAPER SHANK DRILLS:

EXTRA LENGTH DRILLS:

HIGH HELIX DRILLS:

LOW HELIX DRILLS:

MULTIPLE DIA DRILLS:

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 13

MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 15

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 16

ELEMENTS OF METAL CUTTING REAMERS

HAND REAMER; 0° RADIAL MACHINE REAMER: - POSITIVE RADIAL

ELEMENTS OF METAL CUTTING REAMERS

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 18

MACHINE REAMER IN ITS SIMPLEST FORM HAS

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 19

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 20

SET OF TAPER REAMERS

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 21

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 22

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 23

15-09-2020 MUTLIPOINT CUTTING TOOLS - VSC-AP-SG-MECH-SW 24

CUTTING SPEED (V) (=πDN) (N is the spindle speed in rpm)

Machining time reqd to drill a hole = Tm = (t+A)/ (fr)

Metal Removal Rate in drilling =

Power reqd for drilling = (uhp * Rmr) / efficiency

BROACHING IS PERFORMED USING A MULTIPLE-TEETH CUTTING TOOL BY

THE BROACHING OPERATION

IN-FEED IS BUILT INTO THE CONSTRUCTION BY HAVING SUCCESSIVE

 PRIMARY CUTTING MOTION IS TRANSLATIONAL

 BROACH SECURED WITH MAIN SLIDE OF THE BROACHING M/C &

THE BROACHING OPERATION

 INTERNAL BROACHING – ACCOMPLISHED ON THE INTERNAL SURFACE

POSSIBLE SHAPES THAT CAN BE DONE BY EXTERNAL & INTERNAL BROACHING

 VERTICAL BROACHING OR HORIZONTAL BROACHING IS POSSIBLE BASED ON

 PULL BROACH – FORCE APPLIED TO THE SHANK – TENSILE FORCE

 PUSH BROACH – FORCE APPLIED TO THE REAR END OF THE BROACH –

 BROACH IS PUSHED THROUGH THE WORK ( ALSO CALLED

Metal removal rate = Rmr= wdfr